Rexroth IndraMotion MLC 03VRS

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1 Electric Drives Linear Motion and Hydraulics Assembly Technologies Pneumatics Service Rexroth IndraMotion MLC 03VRS R Edition 01 Functional Description

2 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description Title Type of Documentation Document Typecode Internal File Reference Purpose of Documentation Record of Revision Rexroth IndraMotion MLC 03VRS Functional Description DOK-IM*MLC-SYSTEM**V03-FK01-EN-P RS-643eadb7c4ceee9b0a6846a000e3a242-1-en-US-6 The documentation describes wizards, context menus, dialogs, frequently required sequences and additional components (function modules) of the IndraMotion MLC03VRS. It is the basis for the online help of the system. Edition Release Date Notes B321-01/EN VRS Copyright Validity Published by Note Bosch Rexroth AG, 2007 Copying this document, and giving it to others and the use or communication of the contents thereof without express authority are forbidden. Damages will be payable in case of contravention. 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) This document has been printed on chlorine-free bleached paper.

3 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Table of Contents Bosch Rexroth AG I/VII Table of Contents 1 Important Instructions on Use Intended Use Introduction Fields of Use and Application Misuse 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 IndraMotion MLC - System Overview IndraMotion MLC - Components IndraMotion MLC - Further Documentations IndraMotion MLC - Hardware Commissioning and Basic Sequences in Offline Mode IndraMotion MLC - Basic Sequences, General IndraMotion MLC - Hardware Commissioning Installation and Start of IndraWorks MLC Creation of a Project Modes for Project Processing Creation of an IndraMotion MLC L40 Control Creation of Onboard - I/Os Creation of Inline - I/Os Creation of Profibus I/Os Creation of Axes in the "Motion" Folder of the MLC Control Creation of a Real Axis on the Basis of IndraDrive Creation of a Real Axis on the Basis of HNC Devices Modes for Operating a Real Axis on the Basis of IndraDrive or HNC Disabled Axis Parking Axis... 50

4 II/VII Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description Table of Contents Page Notes on the Use of Disabled and Parking Axes Creation of a Virtual Axis (Virtual Master Axis) Creation of an Encoder Axis (Real Master Axis) Creation of an Axis in the Project Explorer Configuration of the Measuring Encoder Creation of a Link Axis Creation of a Function Module IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization Structure of an IndraMotion MLC Project MLC Control - Context Menu MLC Control - Menu Items of the Context Menu MLC Control - Context Menu, Device Status MLC Control - Context Menu, Communication MLC Control - Context Menu, Communication, Drive Bus Configuration MLC Control - Context Menu, Communication, IP Settings MLC Control - Context Menu, Cam Explorer MLC Control - Context Menu, Parameter Handling MLC Control - Context Menu, Diagnostic MLC Control - Context Menu, Diagnostic, Device Status MLC Control - Context Menu, Diagnostic, Extended MLC Properties MLC Control - Context Menu, Diagnostic, Clear Errors MLC Control - Context Menu, Diagnostic, Error/Diagnostic Memory MLC Control - Context Menu, Diagnostic, Invalid Parameters MLC Control - Context Menu, Diagnostic, Cycle Times MLC Control - Context Menu, Archiving Data On the MLC MLC Control - Context Menu, Get Data from MLC MLC Control - Context Menu, Print Preview MLC Control - Context Menu, Printing MLC Control - Folders MLC Control - Overview of Folders MLC Control - Logic Folder MLC Control - Logic Folder, Context Menu MLC Control - Logic Folder, Sub-Folder MLC Control - Logic Folder, Overall Task System MLC Control - Motion Folder MLC Control - Robot Folder Creation of a RoCo Project Details on the Project "RoCoTestV03" MLC Control - Onboard I/Os Folder MLC Control - Inline I/Os Folder MLC Control - Profibus/M Folder MLC Control - CrossCom Folder (CF01.1-Q2) MLC Control - SERCOS Folder Real Axis (IndraDrive) - Context Menu

5 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG III/VII Table of Contents Page Real Axis (IndraDrive) - Menu Items of the Context Menus Real Axis (IndraDrive) - Context Menu, Initial Commissioning Real Axis (IndraDrive) - Context Menu, Exchange Drive/Firmware Real Axis (IndraDrive) - Context Menu, Parameter Handling Real Axis (IndraDrive) - Context Menu, Parameter Handling, Load Basic Parameters Real Axis (IndraDrive) - Context Menu, Parameter Handling, Drive Password - Change Password Real Axis (IndraDrive) - Context Menu, Parameter Handling, Save Mode Real Axis (IndraDrive) - Conetxt Menu, Parameter Handling, Save Parameter in Drive Real Axis (IndraDrive) - Context Menu, Communication Real Axis (IndraDrive) - Context Menu, Communication, Cyclic SERCOS Data Channel Real Axis (IndraDrive) - Context Menu, Communication, Signal Status Word Real Axis (IndraDrive) - Context Menu, Communication, Signal Control Word Real Axis (IndraDrive) - Context Menu, Diagnostic Real Axis (IndraDrive) - Context Menu, Diagnostic, Status Real Axis (IndraDrive) - Context Menu, Diagnostic, Clear Errors Real Axis (IndraDrive) - Context Menu, Diagnostic, Error/Diagnostic Memory Real Axis (IndraDrive) - Context Menu, Diagnostic, Average Value Filter Display Real Axis (IndraDrive) - Dialogs Real Axis (IndraDrive) - Overview of Dialogs Real Axis (IndraDrive) - Dialog, Motor Real Axis (IndraDrive) - Dialog, Motor Temperature / Brake Real Axis (IndraDrive) - Dialog, Measuring Systems Real Axis (IndraDrive) - Dialog, Measuring Systems - Motor Encoder Real Axis (IndraDrive) - Dialog, Measuring Systems - Optional Encoder Real Axis (IndraDrive) - Dialog, Scaling/Measuring Units Settings Real Axis (IndraDrive) - Dialog, Extended Scaling / Measuring Units Real Axis (IndraDrive) - Dialog, Mechanical Gear Real Axis (IndraDrive) - Dialog, Regulation Real Axis (IndraDrive) - Dialog, Status Messages Settings Real Axis (IndraDrive) - Dialog, Drive Halt Real Axis (IndraDrive) - Dialog, Establish Measurement Reference Real Axis (IndraDrive) - Dialog, Measurement Reference Motor Encoder Real Axis (IndraDrive) - Dialog, Measurement Reference Optional Encoder Real Axis (IndraDrive) - Dialog, Error Reaction Drive Error Reaction Error Reaction Power Unit Real Axis (IndraDrive) - Dialog, E-Stop Functions Real Axis (IndraDrive) - Dialog, Motion Limit Values Real Axis (IndraDrive) - Dialog, Initial Values Real Axis (IndraDrive) - Dialog, Compensation Functions / Corrections Real Axis (IndraDrive) - Dialog, Compensation Functions / Corrections, Encoder Correction Real Axis (IndraDrive) - Dialog, Compensation Functions / Corrections, Reversal Error Correction Real Axis (IndraDrive) - Dialog, Drive-Integrated Setpoint Generator Real Axis (IndraDrive) - Dialog, Cam

6 IV/VII Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description Table of Contents Page Real Axis (IndraDrive) - Dialog, Cam, General Real Axis (IndraDrive) - Dialog, Cam, Master Axis Position Offset Real Axis (IndraDrive) - Dialog, Cam, Gear Settings Real Axis (IndraDrive) - Dialog, Cam, Angle Offset Begin of Table Real Axis (IndraDrive) - Dialog, Cam, Dynamic Angle Offset Real Axis (IndraDrive) - Dialog, Cam, Cam Table Selection Real Axis (IndraDrive) - Dialog, Cam, Dynamic Synchronization Real Axis (IndraDrive) - Dialog, Electronic Motion Profile Real Axis (IndraDrive) - Dialog, Electronic Motion Profile, General Real Axis (IndraDrive) - Dialog, Electronic Motion Profile, Master Axis Position Offset Real Axis (IndraDrive) - Dialog, Electronic Motion Profile, Gear Settings Real Axis (IndraDrive) - Dialog, Electronic Motion Profile, Angle Offset Begin of Table Real Axis (IndraDrive) - Dialog, Electronic Motion Profile, Dynamic Angle Offset Real Axis (IndraDrive) - Dialog, Electronic Motion Profile, Cam Table Selection Real Axis (IndraDrive) - Dialog, Electronic Motion Profile, Dynamic Synchronization Real Axis (IndraDrive) - dialog, gear with velocity synchronization Real Axis (IndraDrive) - Dialog, Gear with Velocity Synchronization - General Real Axis (IndraDrive) - Dialog, Gear with Velocity Synchronization - Master Axis Position Offset Real Axis (IndraDrive) - Dialog, Gear with Velocity Synchronization - Fine Adjustment Real Axis (IndraDrive) - Dialog, Gear with Velocity Synchronization - Dynamic Synchronization Real Axis (IndraDrive) - Dialog, Gear with Angle Synchronization Real Axis (IndraDrive) - Dialog, Gear with Angle Synchronization - General Real Axis (IndraDrive) - Dialog, Gear with Angle Synchronization - Master Axis Position Offset Real Axis (IndraDrive) - Dialog, Gear with Angle Synchronization - Fine Adjustment Real Axis (IndraDrive) - Dialog, Gear with Angle Synchronization - Dynamic Synchronization Real Axis (IndraDrive) - Dialog, Position Switch Point Real Axis (IndraDrive) - Dialog, Measuring Probe Virtual Axis - Context Menu Virtual Axis - Menu Items of the Context Menu Virtual Axis - Context Menu, Initial Commissioning Virtual Axis - Context Menu, Parameter Handling, Load Basic Parameters Virtual Axis - Context Menu, Diagnosis, Status Virtual Axis- Context Menu, Diagnostic, Clear Errors Virtual Axis - Dialogs Virtual Axis - Overview of Dialogs Virtual Axis - Dialog, Scaling/Measuring Units Settings Virtual Axis - Dialog, Extended Scaling/Measuring Units Virtual Axis - Dialog, Status Messages Settings Virtual Axis - Dialog, Motion Limits Virtual Axis - Dialog, Initial Values Virtual Axis - Dialog, Electronic Motion Profile Virtual Axis - Dialog, Electronic Motion Profile, General Virtual Axis - Dialog, Electronic Motion Profile, Master Axis Position Offset

7 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG V/VII Table of Contents Page Virtual Axis - Dialog, Electronic Motion Profile, Gear Settings Virtual Axis - Dialog, Electronic Motion Profile, Angle Offset Begin of Table Virtual Axis - Dialog, Electronic Motion Profile, Dynamic Angle Offset Virtual Axis - Dialog, Electronic Motion Profile, Cam Table Selection Virtual Axis - Dialog, Electronic Motion Profile, Dynamic Synchronization Virtual Axis - Dialog, Gear with Velocity Synchronization Virtual Axis - Dialog, Gear with Angle Synchronization Encoder Axis - Context Menu Encoder Axis - Menu Items of the Context Menu Encoder Axis - context menu, initial commissioning Encoder Axis - Context Menu, Parameter Handling, Load Basic Parameters Encoder Axis - Context Menu, Diagnostic, Status Encoder Axis - Context Menu, Diagnostic, Clear Errors Encoder Axis - Dialogs Encoder Axis - Overview of Dialogs Encoder Axis - Dialog, Scaling/Measuring Units Settings Encoder Axis - Dialog, Extended Scaling/Measuring Units Encoder Axis - Dialog, Axis Configuration Link Axis - Context Menu Link Axis - Menu Items of the Context Menu Link Axis - Context Menu, Initial Commissioning Link Axis - Context Menu, Parameter Handling, Load Basic Parameters Link Axis - Context Menu, Diagnostic, Status Link Axis - Context Menu, Diagnostic, Clear Errors Link Axis - Dialogs Link Axis - Overview of Dialogs Link Axis - Dialog, Scaling/Measuring Units Settings Link Axis - Dialog, Extended Scaling/Measuring Units Link Axis - Dialog, Axis Configuration Function Modules (Additional Components) General 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

8 VI/VII Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description Table of Contents Page SERCOS III C2C (CFL01.1-R3), MLC Cross-Communication, SERCOS III SERCOS III C2C Function Module (CFL01.1-R3) Project Planning of MLC Network, SERCOS III (CFL01.1-R3), in the MLC Project 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) - Redundancy and Error Tolerance MLC Network, SERCOS III C2C (CFL01.1-R3) - Configuration Examples CrossComm (CFL01.1-Q2), MLC Cross-Communication, SERCOS II CrossComm Function Module (CFL01.1-Q2) Project Planning of the MLC Network, CrossComm (CFL01.1-Q2), in the MLC Project 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) - Redundancy and Error Tolerance MLC Network, CrossComm (CFL01.1-Q2) - Configuration Examples 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

9 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG VII/VII Table of Contents Page 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 Insertion of DeviceNet Slaves Configuration of DeviceNet Slaves 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 IndraMotion MLC - Tools and Frequently Required Sequences MLC Icon Bar Parameter Handling - Exporting Parameter Handling - Importing Parameter Editor Parameter Group Frequently Required Sequences MLC - Clear Memory MLC - Setting of the IP Address MLC - Firmware Exchange MLC - Hardware Exchange Drive/Drive Firmware Exchange Service and Support Helpdesk Service Hotline Internet Helpful Information Index

10 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description

11 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 1/333 Important Instructions on Use 1 Important Instructions on Use 1.1 Intended Use Introduction Bosch Rexroth products are developed and manufactured according to the. Before delivery, they are checked for operational safety. WARNING Risk of personal injury and damage to equipment due to misuse of products! The products are designed for the usage within the industrial environment and may only be used according to their intended purpose. If they are not used as intended, situations may arise resulting in personal injury or material damage Fields of Use and Application Bosch Rexroth, as the manufacturer of the products, will not assume any warranty, liability or payment of damages in case of damage resulting from a misuse of the products. If the user fails to use the products as intended, they will be solely responsible for any risks resulting therefrom. Before Bosch Rexroth products can be used, the following prerequisites must be fulfilled to ensure that the products be used as intended: Anyone using our products in any way whatsoever must read and understand the corresponding safety instructions and the notes on the intended use of the product. To the extent that the products are hardware items, they must be kept in their original state, i.e. no structural modifications must be made. Software products must not be decompiled; their source codes must not be modified. Damaged or defective products must not be installed or put into operation. It must be ensured that the products are installed according to the regulations specified in the documentation. The IndraControl and its function modules offered by Rexroth Indramat are suitable for motion / logic applications. The IndraControl and its function modules must only be used with the accessories and attachment parts indicated in the present documentation. Components that are not specifically indicated must neither be attached nor connected. The same is true for cables and lines. The operation must only be carried out in configurations and component combinations expressly indicated as well as with the respective functional description and the software and firmware specified. The IndraControl and its function modules were developed for the use in singleaxis and multiple-axis drive and control applications. For the application-specific use of machine operating and visualization terminals, device types with different equipments and different interfaces are available.

12 2/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description Important Instructions on Use Among the typical fields of application for the IndraControl and its function modules are: [Handling and installation systems] [Packing and food-processing machines] [Printing and paper-converting machines] [Machine tools] IndraControl as well as its function modules must only be operated under the mounting and installation conditions, in the position of use and under the environmental circumstances (temperature, degree of protection, humidity, EMC etc.) described in this documentation. 1.2 Misuse The use of the IndraControl and its function modules beyond the fields of application listed above and under different operating conditions and with different technical data than described and indicated in the documentation is considered as "misuse". IndraControl and its function modules must not be used, if they are exposed to operating conditions that do not comply with the ambient conditions prescribed. It is not allowed to use them e.g. under water, under extreme temperature fluctuations or extreme maximum temperatures etc. the intended applications were not expressly authorized by Rexroth. Please observe the data given in the general safety notes!

13 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 3/333 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.

14 4/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS 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:

15 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 5/333 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!

16 6/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS 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.

17 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 7/333 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"

18 8/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS 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.

19 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 9/333 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.

20 10/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS 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.

21 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 11/333 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.

22 12/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS 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.

23 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 13/333 IndraMotion MLC - System Overview 3 IndraMotion MLC - System Overview 3.1 IndraMotion MLC - Components Hardware Software The IndraMotion MLC control contains the following components: IndraControl L40.2 for MLC applications (with onboard I/O, onboard Profibus master or slave, onboard SERCOS interface connection and Ethernet/IP slave) with Firmware IndraMotion MLC on 128 MB Compact Flash Card Male connector set for IndraMotion MLC Inline IO modules (possible IO extensions on the right side of the control) Function Modules (possible extensions on the left side of the control): Cross-Communication function module (CFL01.1-Q2) for establishing an MLC cross link via SERCOS fiber optic cable rings (single or double ring) DeviceNet master function module (CFL01.1-V1) Profibus master function module (CFL01.1-P1), multimaster-enabled, (can be combined with onboard Profibus slave) SERCOS-III function module (CFL01.1-R3) Control of IndraDrive, SERCOS III (CFL01.1-R3) and CrossCommunication, SERCOS III C2C (CFL01.1-R3) high-performance camshaft gear PLS (CFL01.1-N1) with a scan rate of 125 μs and 16 outputs Fast I/O function module (CFL01.1-E2): 8 inputs, 8 outputs, 8 freely programmable I/O SRAM memory function module (CFL01.1-Y1) 8 MByte, battery-buffered, for RoCo projects Thus the IndraControl L40.2 is a modular and scalable control. In combination with the firmware IndraMotion MLC, it can be used as a universal hardware platform for motion applications. The software "IndraWorks Engineering" serves for commissioning and project planning purposes. The software consists of the following components: IndraWorks: project planning, configuration IndraLogic: PLC programming IndraWorks HMI: visualization and operating interface IndraWorks WinStudio: project planning tool for the creation of user masks for IndraWorks HMI IL-Target_MLC_L40-TSP: target system files (Target Support Package) are installed which are required for the processing of IndraWorks MLC with IndraWorks and IndraLogic. Target Manager: administration of TSP data, e. g. with update of control functions (can be accessed via Start Program Files Rexroth IndraWorks Target Manager). Please do not use the program Start Program Files Rexroth IndraLogic InstallTargets any longer. All components are automatically installed. IndraWorks WinStudio is installed as a demo version.

24 14/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description IndraMotion MLC - System Overview In addition to the standard IndraLogic libraries, libraries with PLCopen function blocks and technology functions are available: PLCopen function blocks Technology function blocks (Tech-FB) extend the basic functionality of the target systems (like e.g. MLD / MLC) and provide application-specific functionalities like e.g. Flying Shear, Cross Cutter, Register Controller etc. (internal library: ML_Technology0x.lib) Common technology function blocks (Common-Tech-FB) extend the basic functionality of the target system IndraMotion MLC and provide application-specific functionalities like e.g. Cam Blocks, Camshaft Gear, PID Controller and Safe Key Transmission (external library: ML_TechnologyCommon0x.lib) Additional licenses for the following elements are offered: IndraWorks CamBuilder for creating and processing cams IndraWorks WinStudio 3.2 IndraMotion MLC - Further Documentations No. Title Designation /1/ Rexroth IndraControl L40, project planning DOK-CONTRL-IC*L40*****-PR03-EN-P /2/ PLC programming with Rexroth IndraLogic 1.2; operating and programming guide DOK-CONTRL-IL**PRO*V02-AW..-EN-P /3/ Rexroth Inline PROFIBUS DP; application description DOK-CONTRL-R-IL*PBSSYS-AW..-EN-P /4/ Rexroth Inline PROFIBUS DP terminal and module supply; Functional Description DOK-CONTRL-R-IL*PB*-BK-FK..-EN-P /5/ Rexroth IndraWorks Engineering; operating and programming guide DOK-IWORKS-ENGINEE*V..-AW..-EN-P /6/ Rexroth WinStudio; brief and functional description DOK-CONTRL-WIS*PC**V06-KB01-EN-P /7/ Rexroth IndraMotion MLC Cam Builder; functional description DOK-IM*MLC-CAM*B***V01-FK01-EN-P /10/ Rexroth IndraDrive; firmware for drive units MPH-03, MPB-03, MPD-03, functional description /11/ Rexroth IndraDrive; firmware for drive units MPH-04, MPB-04, MPD-04, functional description /12/ Rexroth IndraDrive, drive units, MPx-02; MPx-03; MPx-04, parameter description /13/ Rexroth IndraDrive, firmware for drive units, notes on troubleshooting (MPx02, MPx03, MPx04 and HMV) DOK-INDRV*-MP*-03VRS**-FK01-EN-P DOK-INDRV*-MP*-04VRS**-FK01-EN-P DOK-INDRV*-GEN-**VRS**-PA03-EN-P DOK-INDRV*-GEN-**VRS-WA03-EN-P /20/ Rexroth IndraMotion MLC03VRS; functional description DOK-IM*MLC-SYSTEM**V03-FK01-EN-P /21/ Rexroth IndraMotion MLC02VRS; axis, control and kinematics parameters DOK-IM*MLC-A*C*PAR*V03-PA01-EN-P /22/ Rexroth IndraMotion MLC03VRS; diagnostics DOK-IM*MLC-DIAGN***V03-WA01-EN-P /23/ Rexroth IndraMotion MLC03VRS, PLCopen function blocks and data types DOK-IM*MLC-PLCOPEN*V03-FK01-EN-P /24/ Rexroth IndraMotion MLC03VRS; function modules DOK-IM*MLC-FM******V03-FK01-EN-P /25/ Rexroth IndraMotion MLC03VRS, the first steps DOK-IM*MLC-F*STEP**V03-KB01-EN-P

25 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 15/333 IndraMotion MLC - System Overview No. Title Designation /30/ Rexroth IndraMotion MLC, technological function blocks of the ML_TechnologyCommon library /31/ Rexroth IndraMotion MLC, technological function blocks of the ML_Technology library 32/ Rexroth IndraMotion MLC03VRS motion control RCL programming guide DOK-IM*MLC-TECHCOM*V02-AW01-EN-P DOK-IM*MLC-TECHFB**V02-AW01-EN-P DOK-IM*MLC-RCL*BEF*V03-FK01-EN-P 33/ Rexroth IndraMotion MLC axis interface 01VRS DOK-IM*MLC-TF*AX*IFV03-FK01-EN-P Fig.3-1: Further documentations

26 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description

27 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 17/333 IndraMotion MLC - Hardware Commissioning and Basic Sequences in Offline Mode 4 IndraMotion MLC - Hardware Commissioning and Basic Sequences in Offline Mode 4.1 IndraMotion MLC - Basic Sequences, General The work with IndraWorks MLC assumes a functioning hardware with firmware components suited for each other. For this reason, the following steps are recommended: Hardware Commissioning Run-Up of the Control, page 17, Clearing Memory of the Control, page 18, if required, IP Address - Initial Setting, page 18, Switch-On of the Error-Free SERCOS Ring, page 18. Then, the IndraWorks' user interface is prepared for work and the steps of the project creation are processed in the offline mode. At first, the offline activities: Installation and Start of IndraWorks MLC, page 19, Creation of a Project, page 21, Creation of an IndraMotion MLC L40 Control, page 25, Creation of Onboard - I/Os, page 31, Creation of Inline - I/Os, page 32, Creation of Profibus I/Os, page 36, Creation of Axes in the Motion Folder of the MLC Control, page 40, MLC Control - Robot Folder, page 92, If separate points are not necessary in the specific case, these can be omitted. Now, the transition to the online mode in IndraWorks with subsequent drive parameterization or to the offfline parameterization with subseqent online adjustment is carried out. 4.2 IndraMotion MLC - Hardware Commissioning Run-Up of the Control The purpose of this section is to describe how a control is to be prepared for work on the network without operating user interface and without connection to the Ethernet.

28 18/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description IndraMotion MLC - Hardware Commissioning and Basic Sequences in Offline Mode Clearing Memory of the Control IP Address - Initial Setting Delivery State Fig.4-1: Terminals for the SERCOS bus Compact Flash Card Power supply IndraControl L40 for MLC applications Requirements for the First Run-Up are: bridging of the SERCOS input and output (X7S1 and X7S2) with a fiber optic cable (elimination of possible errors in the SERCOS ring); insertion of the Compact Flash Card with the MLC firmware; provision of the supply voltage. After the switch-on of the supply voltage, the control runs up to the diagnostics display BB STOP. The control may contain, from a previous use, old program components, parameterizations and PLC data which are removed in this step through clearing the memory (for details, see MLC - Clear Memory, page 317). With brand-new controls, this step can be omitted. Before the MLC is coupled to the programming device (e.g. notebook) via Ethernet, it must possess an IP address admissible for the network. In the delivery state, the following addresses are adjusted on the control: Address Initial value Get IP address Subnet mask Standard gateway Fig.4-2: Initial values The IP and subnet mask of a control is set via the four keys of the control display. Afterwards, the control can be connected with the PC via the firm network or via cross-over cable. The cross-over connection requires no address change on the control; only the programming device side must be adjusted (for details, see MLC - Setting of the IP Address, page 318). If the control is connected to the firm network, the instructions of the network administrator must be complied with. Switch-On of the Error-Free SER COS Ring The terminal suggested in section Run-Up of the Control, page17,, which was used instead of the SERCOS bus, is now replaced by the bus itself. For this, it is necessary that

29 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives every single drive in the ring has the same current firmware (MPH/MPB, function package "Synchronous operation" or HNC3x, function package "Servo package"); each address was only allocated once and the wiring was correctly executed. The separate drives are automatically synchronized to the baud rate of the master (of the control). After the switch-off and subsequent switch-on of the control, it should be possible to reach BB Stop for the control and - without power connection - bb for the drives again. Notes on the project planning and commissioning of the SERCOS bus are given in "Rexroth IndraLogic MLC, project planning", /1/, IndraMotion MLC - Further Documentations, page 14,. 4.3 Installation and Start of IndraWorks MLC Installation of "IndraWorks Engineering" Before the first use, the programming system IndraWorks MLC of the Indra Works Engineering Suite must be installed. In order to ensure the operability, the following conditions must be met: PC Pentium 4, 512 MB RAM, 1.5 GB hard disk capacity WindowsXP with SP 1 or Windows2000 with SP 4 Bosch Rexroth AG 19/333 IndraMotion MLC - Hardware Commissioning and Basic Sequences in Offline Mode The installation CD or - in case of an installation from the network - the installation guide contains notes on service packages. IndraWorks - Startup Picture After the first start of IndraWorks Engineering (or after View Show Startup Picture), the following screen appears:

30 20/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description IndraMotion MLC - Hardware Commissioning and Basic Sequences in Offline Mode Fig.4-3: Engineering Suite - startup picture after the first start In the figure, the menu 1 of the Engineering Suite can be recognized. The menu items are supplemented or changed during the work in the Suite, if required. Menus that cannot be used are grayed out. The icon bars 2 below the menu can be displayed/hidden (menu item "View") as well as configured by the user. The library 3 contains the elements which can be used for the configuration in the Suite. Its elements are filed in the folders Drive and Control: IndraDrive, HNC, IndraMotion MLC L40, SercosDrive, EcoDrive Cs Visualization: BVT-/Vxx Devices, VCP and VEH-/VPP Devices Periphery: Inline I/Os, Profibus and Sercos III Devices Simulation: 3D Visualization, Virtual Operating Panel, Virtual Control (is currently not supported by MLC) FM: Function Modules (help per right mouse button on the element). The current library element is described in more detail 4 in the information given. Area 5 is reserved for the project navigator. In the project navigator, the library elements are arranged according to the preference of the user. The work with the project navigator is described in the following chapters. The project file 6 serves to summarize several single projects.

31 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives 4.4 Creation of a Project The status line 7 contains information about the current project (online / offline). As an alternative to the startup figure, the central area 8 offers the space for the parameterization and configuration dialogs opened by the user. The creation of a new project is carried out via IndraWorks - Startup Picture, page 19, or via menu item File New Project. Alternatively, a project file can be created via File New Project File and be sorted with the right mouse button into a new or an already existing project. Via the following dialog window, the user can determine the name of the project, the filing directory and the project language. With the help of these windows, it is also possible to specify the fonts for the project. Default settings: Proportional font: Arial Non-proportional font: Courier New Bosch Rexroth AG 21/333 IndraMotion MLC - Hardware Commissioning and Basic Sequences in Offline Mode Fig.4-4: Creation of a new project - assignment of the name Upon the assignment of the project name, the name of the file folder will also be assigned. The proposed default name can be replaced by the user.

32 22/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description IndraMotion MLC - Hardware Commissioning and Basic Sequences in Offline Mode Context Menu for the Project Fig.4-5: Context menu for a project The context menu is opened through a click with the right mouse button on the project (or on the project: <Shift>+<F10>). The project context menu contains: Save - the current status of the project is stored manually Save as - the current status of the project is stored manually with the same content, but under a different name and in a different folder Archive - the current status of the project is stored in the file system or on the device as a password-protected data record Print Preview - delivers a preview of the project and device data to print Print - printing of project and device data Print Settings - selection of the type font and the font size for the print job Search for Devices - searching for connected drives at the different interfaces (serial RS232, Ethernet, Profibus, serial RS485, PCI). Further information can be found in the online help. Delete - removes the project node and all of its sub-nodes Rename - allows the renaming of the project name Add - allows the addition of a new folder, a new file or a new element (simulation) to the project Properties - shows the name and path of the project The saving of the changes is effected automatically and Suite-controlled. However, the user can trigger the saving process themselves at this place. Operating Strategy If the user owns a license for using the "CamBuilder", each project brings along the "Cam Pool" folder for storing cam data (see also /7/, IndraMotion MLC - Further Documentations, page 14). There are two fundamental ways to operate the Engineering Suite: Dragging elements from the library and placing them in the project navigator at the desired position. (This possibility is applied with physically existing elements, e.g. control, real axis, inline I/O module, see also Creation of an IndraMotion MLC L40 Control, page 25).

33 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 23/333 IndraMotion MLC - Hardware Commissioning and Basic Sequences in Offline Mode 4.5 Modes for Project Processing Offline Mode Online Mode Offline Parameterization Defining elements in the project navigator at the desired position by means of the right mouse button (this possibility is used for logical elements, e.g. virtual axis, see alsocreation of a Virtual Axis (Virtual Master Axis), page 51). In the offline mode, configuration data are developed for the project, data are prepared for the PLC component of the IndraMotion MLC for the transfer to IndraLogic and, in general, all activities which require no data exchange with the control and / or a drive are carried out. Any firmware exchange that might be required is also carried out in the offline mode. In the online mode, data are developed which assume a communication between the user interface (programming device) and the control (and / or the drives). These data are stored at least partly in the control (and/or the drives) or are read from them and are, therefore, available only with existing communication. The transferability of data between user interface/control/drive is influenced by the P0/P2-Parameterization mode/bb-operating mode device status for the motion component and by the STOP/RUN device status for the PLC component. The following rules apply in the Online Mode: 1. If no axes are enabled, the PLC can be stopped and restarted in the IndraLogic. 2. If axes are enabled, a stop of the PLC leads, in IndraLogic, to a forced halt (F5 error), even if the icon bar in IndraWorks is used. 3. If no axes are enabled, the user can switch between the operating mode and the parameterization mode in IndraWorks. 4. If axes are enabled, the control is in the operating mode; a switch-over to the parameterization mode is blocked in IndraWorks. The parameters possess different properties according to the field of application (only readable / writable and here in the "Operating ModeBB" with enabled drives or in the "Parameterization Mode P2" with disabled drives (see also "Attributes of the Parameters")). In addition to the known states "Online" and "Offline", the status "Offline Parameterization" is introduced for the "MLC" device. In the "Offline Parameterization" status, the MLC user interface is - by analogy with the "Online" status - connected to a control, with the difference, however, that it is not about a real device, but about the parameterization of an emulated control. The drive devices are also emulated and communicate with the emulated control. The emulation allows thus the parameterization of the control and drives without control and drive hardware being required. The emulation of the MLC control is realized on the same PC, on which the associated MLC user interface runs. Dialogs, handling and behavior of the user interface are analogous to the "Online" status. A parameter export or import is possible at any time.

34 24/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description IndraMotion MLC - Hardware Commissioning and Basic Sequences in Offline Mode The Switch-over from the "Offline" status to the "Offline Parameterization" status and back is carried out via a context menu command of the MLC device. The backing up of the required data takes place in binary files without the user having to do anything. Upon the switch-over from the Offline Parameterization status to the Online status, an automatic adjustment of the real A/C/S/P/K parameters with the preset values is effected. Transitions Between the Modes It is possible to switch over between the three modes, as shown in the following figure: Fig.4-6: Transitions between the modes The Online/Offline switch-over is realized via the icon bar or the MLC context menu item "Device Status". Start/Stop Offline Parameterization is realized via the MLC context menu item of the same name and the Online switch-over from the Offline Parameterization again via the icon bar or the MLC context menu item "Device status". In addition to this, it is possible to save - in the Online mode - the current status of the parameters in the devices, in a parameter record, via "Update Online Parameterization". The switch-over from Online to Offline Parameterization allows the overwriting of parameters in the axes/drives. A selection window enables the user to decide which axis/drive is changed.

35 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 25/333 IndraMotion MLC - Hardware Commissioning and Basic Sequences in Offline Mode Fig.4-7: Selection of axes for adjustment For this purpose, the "Parameterization Mode P2" is switched over to. The differences between the parameter assignment in the axes/drives and the emulation are indicated. The user can choose between: inclusive of all device data (online) project data (offline) inclusive of all project data (offline) device data (online) individual adjustment. 4.6 Creation of an IndraMotion MLC L40 Control The creation of an MLC control within a project is realized through the dragging of the "IndraMotion MLC L40" library element from the "Drive and Control" library folder into the project folder. The properties of this element are given in the informational window.

36 26/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description IndraMotion MLC - Hardware Commissioning and Basic Sequences in Offline Mode Fig.4-8: Creation of the control - dragging it from the library Fig.4-9: Creation of a control - dropping it on the project navigator

37 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 27/333 IndraMotion MLC - Hardware Commissioning and Basic Sequences in Offline Mode Dialogs for the Creation of the Control Instead of "Drag&Drop", the control can also be transferred through "Copy and Paste". The creation of a control is supported by a wizard with three dialog windows. Fig.4-10: Creation of a control - general settings In the "General Settings" step, the device name, a comment on this device and the author are entered. You can either accept the preset values (a comment is optional) or change them. The author name is derived from your Login. Fig.4-11: Creation of a control - configuration In the configuration step, the IP address of the desired IndraMotion MLC L40 must be adjusted; otherwise, it is not possible to communicate with the control. The address corresponds to the value adjusted in section IP Address - Initial Setting, page 18,. The connection test checks whether a control with this IP address exists (ping) and answers with the device name of the control and the name of the current

38 28/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description IndraMotion MLC - Hardware Commissioning and Basic Sequences in Offline Mode user (author). Both can differ from the device name and author adjusted in the previous figure. In the lower part of the dialog window, you have the possibility to select a different PLC programming language for your future programs than the suggested one. In the third dialog of the wizard, the desired function modules must be preset in the real order and the use of the onboard interfaces DP and EtherNetIP slave has to be defined. Fig.4-12: Creation of a control - connection of the function modules, here: Cross Com (CFL01.01) Click then on Finish. A function module can also entered, if it is not yet connected to the control. However, when you go online, the absence is confirmed by an error message. A module that is connected later is recognized upon the next control's run-up. In the following waiting time, the PLC program belonging to the IndraMotion project is automatically created in the background. The "Mlc1" device of the "IndraMotion MLC L40" type is thus added to the current IndraMotion project:

39 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 29/333 IndraMotion MLC - Hardware Commissioning and Basic Sequences in Offline Mode Overview in the Project Navigator Context Menu Fig.4-13: Creation of a control - overview in the project navigator Below the folder of the control, there are - subject to the logical structure - a "Logic" folder with the transition to the tasks and programs predefined for IndraLogic and the "Motion" folder with four different axis types which can be configured (see also Creation of Axes in the Motion Folder of the MLC Control, page40) as well as the "Robot" folder which allows the creation of a kinematics (see also MLC Control - Robot Folder, page 92). According to the device structure of the control used, the folders onboard I/O, i.e. the 1-byte inputs and outputs of the control (see also /5, I/O configuration/, IndraMotion MLC - Further Documentations, page 14.) inline I/O, i.e. the inline modules which can be attached additionally to the local I/O by the user (see also /5/) Profibus/M; this bus allows the connection of I/O modules as well as the connection of visualization devices and drives (see also /5/) Function modules, here: CrossCom (CFL01.1.Q2), and SERCOS; via this bus, the drives and devices with SERCOS interface are connected are designed. If the context menu on the control's folder is opened by means of the right mouse button, the following screen appears:

40 30/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description IndraMotion MLC - Hardware Commissioning and Basic Sequences in Offline Mode Fig.4-14: Creation of a control - context menu Since, at this point in time, no connection with the control exists yet (offline mode), a number of commands is enabled, i.e. grayed out (for the complete description, see MLC Control - Menu Items of the Context Menu, page 61). Among the enabled commands are: Start Offline Parameterization, see also Modes for Project Processing, page 23, Firmware Management, i.e. the possibility to transfer a new / a different firmware to the control with the entered IP address (see also MLC - Firmware Exchange, page 320, Archive data on / Get data from the MLC: here, any files can be selected and filed on the Compact Flash Card of the MLC or be taken from there. Print Preview, delivers a preview of project and device data Print, allows the printing of the current project and device data Delete; this menu item deletes - after a safety prompt - the device and all of its sub-folders Rename; the name of the device can be changed Properties; data entered in the first both dialogs "General Settings" and "Communication" during the creation of the device can be determined and changed, if required Following the creation of the control, it is possible to switch over to the "Online Mode" or "Offline Parameterization".

41 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 31/333 IndraMotion MLC - Hardware Commissioning and Basic Sequences in Offline Mode 4.7 Creation of Onboard - I/Os The "IndraMotion MLC L40.2" provides the user with 1 byte (fast) inputs and outputs. The connections can be used byte- or bit-wise. During the configuration process, it is possible to assign names and comments in each case (see also /5, I/O-Configuration/, IndraMotion MLC - Further Documentations, page 14.) The average value determined for the response time of the bus - writing output to reading changed input value - is 2 ms for the control CML40.2 (SERCOS cylce time: 2 ms). The window opens after a double click on the "Onboard I/O" folder in the project navigator. Fig.4-15: Creation of local I/O - declaration of the inputs and outputs The start addresses for the input byte and the output byte are allocated automatically and can be changed after the switch-over from I/O addresses to I/O settings:

42 32/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description IndraMotion MLC - Hardware Commissioning and Basic Sequences in Offline Mode Fig.4-16: Possibility of changing the basic I/O addresses Keep the start addresses %IB0 or %QB0 for onboard I/Os. The start addresses of the inline I/O could then be set to %IB2 or %QB2 and for Profibus I/O e.g. to %IB500 or %QB Creation of Inline - I/Os The declared variables are indicated in IndraLogic under Ressources Control Configuration <R> and can be used globally. In addition to the 1 byte fast onboard inputs and outputs, the user may connect other inline modules to the "IndraMotion MLC L40.2" (for details, see also /5, I/ O configuration/, IndraMotion MLC - Further Documentations, page 14). The average value determined for the response time of the bus - writing output to reading changed input value - amounts to 8 ms for the control CML40.2, R-IB IL 24 DI 16, R-IB IL 24 DO 16, (onboard I/Os: 2 ms), SERCOS cycle time: 2 ms. Addressing of the Entire Inline I/O Block A double click on the "Inline I/O" folder in the project navigator opens the following dialog: Fig.4-17: Inline IO Bus basic dialog

43 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 33/333 IndraMotion MLC - Hardware Commissioning and Basic Sequences in Offline Mode The dialog allows the input of basic addresses for all modules of the inline bus. On the basis of these addresses, a closely packed automatic address assignment is carried out. Please check that there are no address overlaps, for example between onboard I/Os and inline I/Os. Keep the start addresses %IB0 or %QB0 for onboard I/Os. The start addresses of the inline I/O could then be set to %IB2 or %QB2 and for Profibus I/O e.g. to %IB500 or %QB500. Creation of Inline IO Modules The inline modules are to be selected from the stock of the library under Periphery Inline Rexroth-Inline by means of Drag&Drop or by means of the context menu / right mouse button Inline IO Add module.

44 34/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description IndraMotion MLC - Hardware Commissioning and Basic Sequences in Offline Mode Fig.4-18: Creation of inline I/O - selection and dragging of the module from the library The respective inline module is dragged on the MLC to the project navigator and dropped there on the "Inline I/O" folder. The order of the assembly is to be taken into account for the creation process!

45 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 35/333 IndraMotion MLC - Hardware Commissioning and Basic Sequences in Offline Mode Fig.4-19: - or - Creation of inline I/O - dropping it in the project navigator Fig.4-20: Creation of inline I/O - selection via context menu Subject to the respective module, the required module settings are to be carried out.

46 36/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description IndraMotion MLC - Hardware Commissioning and Basic Sequences in Offline Mode Fig.4-21: Creation of inline I/O - declaration of the inputs and outputs The start addresses for input bytes or output bytes of the respective modules are allocated automatically and can be changed beyond the basic setting after the switch-over from I/O addresses to I/O settings: Fig.4-22: Possibility of changing the basic I/O addresses The configuration process is thus completed. The declared variables are indicated in IndraLogic under Ressources Control Configuration <R> and can be used globally. Context Menu of the Inline Module Via its context menu/the right mouse button, the respective module can be opened or deleted. 4.9 Creation of Profibus I/Os In addition to onboard I/Os and inline I/Os, the field busses supported by the IndraMotion MLC L40.2 offer other possibilities to configure and control I/Os. The field bus port can be realized onboard or as a function module extension

47 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 37/333 IndraMotion MLC - Hardware Commissioning and Basic Sequences in Offline Mode (a detailed description of the function module and its project planning are given in chapter Profibus-DP Master Function Module CFL01.1-P1, page 285). Onboard, the Profibus/M interface offers the possibility to configure I/Os according of the elements existing in the device library under Library Periphery ProfibusDP I_O R-IL PB BK. (for detailed descriptions, see/5, I/O configuration/, IndraMotion MLC - Further Documentations, page 14). The average value determined for the response time of the bus - writing output to reading changed input value - is 10 ms for the control CML40.2, R-IL PB BK, R-IB IL 24 DI 16, R-IB IL 24 DO 2-2A (onboard I/Os: 2 ms), SERCOS cycle time: 2 ms. Setting the Bus Parameters - Profibus/M, Onboard Interface The preset values of the Profibus interface can be displayed via the context menu of the Profibus. Fig.4-23: Creation of Profibus I/O - basic bus settings These preset values are chosen so as to make sure that they are only changed by the user in justified cases (see also /5, I/O configuration/).

48 38/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description IndraMotion MLC - Hardware Commissioning and Basic Sequences in Offline Mode Creation of the Profibus/M Device (Bus Coupler) For the configuration process, the same strategy is realized that is also used for the inline I/O (selection from the library according to the order of the assembly on the bus, Drag&Drop on the Profibus folder). The configuration of the Profibus begins with the dragging of a bus coupler, followed by the desired participants. Fig.4-24: Creation of Profibus I/O - selection and dragging of the module from the library The dropping is effected on the "Profibus/M" folder.

49 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 39/333 IndraMotion MLC - Hardware Commissioning and Basic Sequences in Offline Mode Module Settings Fig.4-25: Creation of Profibus I/O - dropping it in the project navigator Subject to the selected module, the required module settings (context menu of the bus coupler) are to be made. Fig.4-26: Dialog for parameterization of the selected bus coupler R-IL PB BK, bus address 2 For the bus coupler, these are: the bus address of the participant, the enabling / disabling and Fig.4-27: a comment, if required. Disabled bus coupler The IO addresses of the modules are distributed automatically. The enabling/disabling of the bus coupler (and its I/O modules) can be achieved via the above dialog or by moving the mouse pointer across the bus coupler icon. Keep the start addresses %IB0 or %QB0 for onboard I/Os. The start addresses of the inline I/O could then be set to %IB2 or %QB2 and for Profibus I/O e.g. to %IB500 or %QB500. The modules which are to be assigned to the bus coupler can

50 40/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description IndraMotion MLC - Hardware Commissioning and Basic Sequences in Offline Mode be dragged per Drag&Drop from the device library and dropped on the coupler (not the Profibus/M node) or be selected from the context menu of the coupler by means of "Add module" Context Menu of the Profibus/M Module Via its context menu/the right mouse button, the respective module can be opened or deleted Creation of Axes in the "Motion" Folder of the MLC Control The motion component of the "IndraMotion MLC" control - as of the version 03VRS - is able to administrate the following axis types ( 32 axes): Real Axes on the basis of IndraDrive (function package: "Synchronous Package") with the following firmware 1. FWA-INDRV*-MPH-03VRS-D5-1-SNC-NN 2. FWA-INDRV*-MPD-03VRS-D5-1-SNC-NN 3. FWA-INDRV*-MPB-03VRS-D5-1-SNC-NN 4. FWA-INDRV*-MPH-04VRS-D5-1-SNC-NN (MP-03 operating modes) 5. FWA-INDRV*-MPD-04VRS-D5-1-SNC-NN (MP-03 operating modes) 6. FWA-INDRV*-MPB-04VRS-D5-1-SNC-NN (MP-03 operating modes) 7. FWA-INDRV*-MPH-05VRS-D5-1-SNC-NN (MP-03 operating modes) 8. FWA-INDRV*-MPD-05VRS-D5-1-SNC-NN (MP-03 operating modes) 9. FWA-INDRV*-MPB-05VRS-D5-1-SNC-NN (MP-03 operating modes) How to create a real axis (IndraDrive) is described in section Creation of a Real Axis on the Basis of IndraDrive, page 41,. or HNC Axes HNC3x-Compact with SERCOS interface (function package: "Servo Package") with the following firmware FWA-HNC3X*-HDH-04VRS-D5 How to create a real axis (HNC) is described in section Creation of a Real Axis on the Basis of HNC Devices, page 45,. The real axis can be used as a master or as a slave axis. Virtual axes The virtual axis can also be used as a master axis. It emulates the behavior of a real axis in a mathematically ideal way. How to create a virtual axis is described in section Creation of a Virtual Axis (Virtual Master Axis), page 51,. Encoder axes The encoder axis can be used as a real master axis. The data of a real master axis are calculated on the basis of the encoder's measuring results. How to create an encoder axis is described in section Creation of an Encoder Axis (Real Master Axis), page 53,. Link axes

51 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 41/333 IndraMotion MLC - Hardware Commissioning and Basic Sequences in Offline Mode Link axes serve to exchange data between several controls. For this, each control can define up to two axes (real, virtual, or encoder axes) as globally usable - i.e. usable on the other controls - master axis. The synchronously exchanged data are assigned to a link axis on each of the controls. How to create a link axis is described in section Project Planning of the MLC Network, CrossComm (CFL01.1-Q2), in the MLC Project, page 218, Creation of a Real Axis on the Basis of IndraDrive Axes can only be created in the offline mode! The creation of a real axis is carried out according to the Drag&Drop principle, for which the desired "IndraDrive" device is dragged from the library and Fig.4-28: Creation of a real axis - dragging it from the library dropped on the desired bus, here SERCOS. Dialogs for the Creation of a Real Axis (IndraDrive) Fig.4-29: Creation of a real axis - dropping it on the project navigator Instead of "Drag and Drop", the real axis can also be transferred by means of "Copy and Paste" (in the example Mlc1 Motion Real Axes). The creation of a real axis is supported by a wizard with two dialog windows.

52 42/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description IndraMotion MLC - Hardware Commissioning and Basic Sequences in Offline Mode Fig.4-30: Creation of a real axis (IndraDrive) - general settings In the "General Settings" step, the device name, a comment on this device and the author are entered. You can either accept the preset values or change them. Configuration Through Offline Parameterization Fig.4-31: Creation of a real axis (IndraDrive) - configuration The system offers the switch-over item (red arrow in the figure) to the "Offline Wizard" in order to enable the user to configure a not yet existing drive already offline.

53 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 43/333 IndraMotion MLC - Hardware Commissioning and Basic Sequences in Offline Mode Configuration of the Real Axis Since the default values are kept, the initial entry can only be changed by way of reparameterization. In the configuration step, the address of the drive in the SERCOS ring must be adjusted (address in the drive configuration, here also 1); otherwise, it is not possible to communicate with the drive. The "Firmware" setting allows to select between different software states for the IndraDrive, here MPH-03. The "Interpolation in the Drive" control box is available for IndraDrive and HNC drives only. If a check mark is set, the IndraDrive or HNC drive automatically calculates the set position values for the respective operating mode selected, e.g. synchronization or cam. If the check mark is not set, the control feeds the drive with set position values. This is a standard feature of Sercos and EcoDrives. This setting cannot be changed later! Software States and Function Packages: Real axes on the basis of IndraDrive, "Synchronous operation" function package, are available with the following firmware: 1. FWA-INDRV*-MPH-03VRS-D5-1-SNC-NN 2. FWA-INDRV*-MPD-03VRS-D5-1-SNC-NN 3. FWA-INDRV*-MPB-03VRS-D5-1-SNC-NN 4. FWA-INDRV*-MPH-04VRS-D5-1-SNC-NN (MP-03 operating modes) 5. FWA-INDRV*-MPD-04VRS-D5-1-SNC-NN (MP-03 operating modes) 6. FWA-INDRV*-MPB-04VRS-D5-1-SNC-NN (MP-03 operating modes) 7. FWA-INDRV*-MPH-05VRS-D5-1-SNC-NN (MP-03 operating modes) 8. FWA-INDRV*-MPD-05VRS-D5-1-SNC-NN (MP-03 operating modes) 9. FWA-INDRV*-MPB-05VRS-D5-1-SNC-NN (MP-03 operating modes) The type of the drive cannot be changed later! Axis Assignment For addressing the axis, the PLC uses the axis number and axis name (here "2"or "RA1").

54 44/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description IndraMotion MLC - Hardware Commissioning and Basic Sequences in Offline Mode Overview in the Project Navigator Context Menu Fig.4-32: Creation of a real axis - overview in the project navigator The real axis (IndraDrive) appears twice in the project navigator: 1. Motion Real Axes RA1, the axis dialogs are enabled in the online mode or the offline parameterization and are described in Real Axis (IndraDrive) - Overview of Dialogs, page 114,. The values of the A parameters, which are entered here, are passed on dominantly to the S or P parameters of the IndraDrive. S and P parameters achieve the target directly. The values, which are indicated in A parameters, are derived from the respective S and P parameters, if required. 2. SERCOS RA1, here additional drive dialogs are enabled in the online mode or in the offline parameterization. S and P parameters achieve the target directly or are displayed directly. If the context menu is opened on the folder Motion Real axes RA1 by means of the right mouse button, the following screen appears:

55 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 45/333 IndraMotion MLC - Hardware Commissioning and Basic Sequences in Offline Mode Fig.4-33: Creation of a real axis - context menu The enabled commands are Delete, Rename and View of the Properties (see figure). Since, at this point in time, no connection with the control exists yet (offline mode), a number of commands is disabled, i.e. grayed out (for the complete description, seereal Axis (IndraDrive) - Menu Items of the Context Menus, page 104). The possibility to park or disable the axis is described in section Modes for Operating a Real Axis on the Basis of IndraDrive or HNC, page 49, Creation of a Real Axis on the Basis of HNC Devices Axes can only be created in the offline mode! The creation of a real axis is carried out according to the Drag&Drop principle, for which the desired "HNC100-3X" device is dragged from the library and

56 46/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description IndraMotion MLC - Hardware Commissioning and Basic Sequences in Offline Mode Fig.4-34: Creation of an HNC axis - dragging it from the library dropped on the desired bus, here SERCOS. Dialogs for the Creation of a Real Axis (HNC) Fig.4-35: Creation of an HNC axis - dropping it in the project navigator Instead of "Drag and Drop", the real axis can also be transferred by means of "Copy and Paste" (in the example Mlc1 Motion Real Axes). The creation of an HNC axis is supported by a wizard with two dialog windows.

57 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 47/333 IndraMotion MLC - Hardware Commissioning and Basic Sequences in Offline Mode Fig.4-36: Creation of a real axis (HNC) - general settings In the "General Settings" step, the device name, a comment on this device and the author are entered. You can either accept the preset values or change them. Configuration of the Real Axis (HNC) Fig.4-37: Creation of a real axis (HNC) - configuration In the configuration step, the address of the HNC axis must be adjusted in the SERCOS ring (address in the drive configuration, here 6); otherwise, it is not possible to communicate with the drive. The "Project Firmware" setting allows to select different software states for the HNC axis, here HNC3X*-HDH-04VRS.

58 48/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description IndraMotion MLC - Hardware Commissioning and Basic Sequences in Offline Mode If a check mark is set, the HNC drive automatically calculates the set position values for the respective operating mode selected, e.g. synchronization or cam. If the check mark is not set, the control feeds the drive with set position values. This is a standard feature of Sercos and EcoDrives. The function package used must be of the "Servo Package" type. The type of the drive cannot be changed later! Axis Assignment Overview in the Project Navigator For addressing the axis, the PLC uses the axis number and axis name (here "6" or "HNC1"). Fig.4-38: Creation of a real axis (HNC) - overview in the project navigator The real axis (HNC) appears twice in the project navigator: 1. Motion Real Axes HNC1, the axis dialogs are enabled in the online mode. The values of the A parameters, which are entered here, are passed on dominantly to the S or P parameters of HNC devices. S and P parameters achieve the target directly. The values, which are indicated in A parameters, are derived from the respective S and P parameters, if required. 2. SERCOS HNC1, here additional drive dialogs are enabled in the online mode. S and P parameters achieve the target directly or are displayed directly. Until now, it is not possible to parameterize HNC devices offline. The respective axis is automatically disabled! Context Menu If the context menu is opened on the folder Motion Real Axes HNC1 by means of the right mouse button, the following screen appears:

59 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 49/333 IndraMotion MLC - Hardware Commissioning and Basic Sequences in Offline Mode Fig.4-39: Creation of a real axis - context menu The enabled commands are Delete, Rename and View of the Properties (see figure). Since, at this point in time, no connection with the control exists yet (offline mode), a number of commands is disabled, i.e. grayed out. The possibility to park or disable the axis is described in section Modes for Operating a Real Axis on the Basis of IndraDrive or HNC, page 49, Modes for Operating a Real Axis on the Basis of IndraDrive or HNC Disabled Axis Disconnecting Point: Properties Application Examples: between MLC and drive electronics The real axis is created in IndraMotion MLC. It can be assigned the "disabled" status via the context menu and is then marked in the user interface with in the project navigator. Its A parameters can be accessed. The drive must not exist physically. The drive is always in P0, even if the Sercos ring is in P4 Virtual axes and encoder axes cannot be "disabled". If the drive electronics is taken away from the encoder axis through the "disabling" of a real axis, it is also marked as "disabled". During the commissioning phase, only certain drives should be moved. Certainly, the other drives are configured and also pre-programmed in the PLC program, but they do not yet exist physically or are under construction, respectively.

60 50/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description IndraMotion MLC - Hardware Commissioning and Basic Sequences in Offline Mode Parking Axis Disconnecting Point: Properties Application Examples: Master project: A machines manufacturer builds a scalable device series with different stages of development. In order to allow an effective software production for the separate specific devices, the manufacturer creates a master project with the maximum state of development ( 32 axes). On devices with a lower stage of development, the non-existing axes are configured, but not activated. This means that the subsequent upgrading of the device is possible without software modifications being required. between drive electronics and motor The real axis is created in IndraMotion MLC. It can be assigned the "Parking" status via its context menu and is then marked in the user interface with the project navigator. The axis is active and has the property "Parking". The drive must exist physically; the motor need not exist. The drive command "Parking Axis" is used. The A/S and P parameters can be accessed. The drive follows the Sercos phase; no error messages are generated by the drive. Virtual axes and encoder axes cannot be "parked". It will prevent that a drive controller brings about an error with P4 switching without connected motor The S and P parameters remain achievable (e.g. writing in P2 out of the PLC program) Notes on the Use of Disabled and Parking Axes The parking and disabling can only be realized in P2: For the parking of axes, no phase change to P0 is required During the disabling of axes, a phase change to P0 is required (is automatically executed by the firmware) With the enabled axes being in P0, the PLC program can temporarily not access the S and P parameters! All axes, whether enabled, parking or disabled, are characterized by the facts that they have an axis number and SERCOS address assigned to them have a global axis version in the PLC referencing the respective axis number in Axis Moveable Access to A parameters Access to S/ P parameters Phase switching Commands enabled FB reaction in case of call in the PLC program Parameter check in the drive Active Yes Yes Yes Follows SERCOS Yes Normally without error, done at reached setpoint Enabled Parking No Yes Yes Follows SERCOS Partly Error message Disabled Disabled No Yes No Always in P0 No Error message Always in P0 Fig.4-40: Properties

61 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 51/333 IndraMotion MLC - Hardware Commissioning and Basic Sequences in Offline Mode 4.14 Creation of a Virtual Axis (Virtual Master Axis) Creation of the Virtual Axis In case of a virtual master axis, the master axis position is generated in accordance with the preset velocity setpoint. For this, the following restrictions are taken into account: A , Positive velocity limit A , Negative velocity limit A , Bipolar acceleration limit A , Bipolar jerk limit A , Emergency stop deceleration Axes can only be created in the offline mode! A virtual axis is created in the project navigator, in the Motion -> Virtual Axes folder of the control. For that purpose, the context menu must be enabled (right mouse button or <Shift>+<F10>). Dialogs for the Creation of a Virtual Axis Fig.4-41: Creation of a virtual axis - context menu, motion -> virtual axis The creation of a virtual axis is supported by a wizard with two dialog windows.

62 52/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description IndraMotion MLC - Hardware Commissioning and Basic Sequences in Offline Mode Fig.4-42: Creation of a virtual axis - general settings In the "General Settings" step, the device name, a comment on this device and the author are entered. You can either accept the preset values or change them. Fig.4-43: Creation of a virtual axis - configuration In the "Configuration" step, no entries are required.

63 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 53/333 IndraMotion MLC - Hardware Commissioning and Basic Sequences in Offline Mode Axis Assignment Context Menu For addressing the axis, the PLC uses the axis number and axis name (here "3" or "VA1"). The virtual axis appears only once in the project navigator: If the context menu is opened on the folder Motion -> Virtual Axis -> VA1 by means of the right mouse button, the following screen appears: Fig.4-44: Creation of a virtual axis - context menu The enabled commands are Delete, Rename and View of the Properties (see figure). Since, at this point in time, no connection with the control exists yet (offline mode), a number of commands is disabled, i.e. grayed out (for the complete description, seevirtual Axis - Menu Items of the Context Menu, page 149, or Virtual Axis - Overview of Dialogs, page 152) Creation of an Encoder Axis (Real Master Axis) Creation of an Axis in the Project Explorer Creation of the Real Axis for the Connection of the Encoder of the Encoder Axis For a real master axis, the master axis position is derived from the signals of a master axis encoder. The encoder uses the drive control electronics of a predefined real axis, e.g. RA2, for the supply of the data required, i.e. before defining an encoder axis, the real axis RA2 must be created first (see also Creation of a Real Axis on the Basis of IndraDrive, page 41,) and then the procedure described below is to be followed. In the example, the axis RA2 has the drive address 2 and the axis number 3. Axes can only be created in the offline mode! An encoder axis is created in the project navigator, in the Motion -> Encoder Axes folder of the control. For that purpose, the context menu must be enabled (right mouse button or <Shift>+<F10>).

64 54/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description IndraMotion MLC - Hardware Commissioning and Basic Sequences in Offline Mode Dialogs for the Creation of an Encoder Axis Fig.4-45: Creation of an encoder axis - context menu, Motion -> Encoder axis The creation of an encoder axis is supported by a wizard with two dialog windows. Fig.4-46: Creation of an encoder axis - general settings In the "General Settings" step, the device name, a comment on this device and the author are entered. You can either accept the preset values or change them.

65 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 55/333 IndraMotion MLC - Hardware Commissioning and Basic Sequences in Offline Mode Fig.4-47: Creation of an encoder axis - configuration In the "Configuration" step, the selection of the drive must be made (scroll window drive assignment: RA1, RA2 or HNC1). RA2 and thus its drive address 2 are selected. The disabling of the real axis RA2, its drive, its electronics, results in the disabling of the real encoder axis EA1 the encoder of which is connected to this electronics (see also Modes for Operating a Real Axis on the Basis of IndraDrive or HNC, page 49). Axis Assignment Context Menu For addressing the axis, the PLC uses the axis number and axis name (here "4" or "EA1"). The encoder axis appears only once in the project navigator: If the context menu is opened on the folder Motion -> Encoder Axes -> EA1 by means of the right mouse button, the following screen appears:

66 56/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description IndraMotion MLC - Hardware Commissioning and Basic Sequences in Offline Mode Fig.4-48: Encoder axis - context menu The enabled commands are Delete, Rename and View of the Properties (see figure). Since, at this point in time, no connection with the control exists yet (offline mode), a number of commands is disabled, i.e. grayed out (for the complete description, see Encoder Axis - Menu Items of the Context Menu, page 162, or Encoder Axis - Overview of Dialogs, page 165,) Configuration of the Measuring Encoder The configuration of the measuring encoder has to be carried out below the Sercos node in the real axis, the controller electronics of which uses the encoder. The selection of the encoder and the activation of the right mouse button opens the configuration dialog. Fig.4-49: Encoder, connected to the real axis RA1 The configuration of an encoder axis requires a referenced measuring encoder. The dialog differs subject to the type of the measuring encoder. The left side of the dialog serves to preset the encoder data. On the right side, the data for the referencing process are preset. A push on the <Set Absolute Value for Measuring Encoder> button triggers the processing of the complete referencing.

67 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 57/333 IndraMotion MLC - Hardware Commissioning and Basic Sequences in Offline Mode "Measuring Encoder Referenced" is the precondition for any further work with the encoder axis. Fig.4-50: 4.16 Creation of a Link Axis Configuration of the measuring encoder The following parameters are used: P , Encoder type 3 (measuring encoder) P , Assignment measuring encoder ->optional slot P , Encoder resolution of measuring encoder P , Type of position encoder for measuring encoder P , Measuring gear - output revolutions P , Measuring gear - input revolutions P , Absolute encoder monitoring window for measuring encoder P , Modulo factor measuring encoder P , Multiplication of measuring encoder P , Smoothing of actual position value 3 of measuring encoder P , Actual position value of measuring encoder P , Actual position value offset P , Absolute encoder range of measuring encoder P , Control word, measuring encoder P , Status of measuring encoder P , C300 command "Set Absolute Value" For details, see Rexroth IndraDrive Functional Description MPx03, Measuring Encoder Extended Package Synchronization. The creation of a link axis with the help of a CrossComm module is described in chapter Project Planning of the MLC Network, CrossComm (CFL01.1-Q2), in the MLC Project, page 218,

68 58/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description IndraMotion MLC - Hardware Commissioning and Basic Sequences in Offline Mode 4.17 Creation of a Function Module Indication of Function Module During MLC Configuration In order to extend the MLC functionality, up to four function modules can be connected to the function module bus (FB) on the MLC's left side. A function module can already be indicated during the MLC configuration (see figure), even if it is not yet connected to the control. The module is then already integrated in the right position in the Project Explorer. However, when you go online, the absence is confirmed by an error message. Insertion of a Module From the Device Library via Drag&Drop Fig.4-51: Indication of a function module during the MLC configuration, here CrossCom (CFL01.01) Function modules that are to be connected later must be selected from the library per Drag&Drop and stored on the MLC in the Project Explorer. Fig.4-52: Dragging a module from the library...and "let it drop" on the MLC.

69 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 59/333 IndraMotion MLC - Hardware Commissioning and Basic Sequences in Offline Mode Fig.4-53: Insertion of a module A module that is connected later is recognized upon the next control's run-up. Configuration of the Module Every module (with the exception of the SRAM module) must then be configured via corresponding dialogs. The function modules currently available for the MLC as well as their functionality and project planning are described in Function Modules (Additional Components), page 177,.

70 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description

71 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 61/333 IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization 5 IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization 5.1 Structure of an IndraMotion MLC Project An IndraMotion MLC project is characterized by an MLC control instance (Mlc1). The control instance possesses its own context menu and several folders: a "Motion", a "Logic" and a " Robot" folder; furthermore, onboard I/Os, inline I/Os as well as a "Profibus/M" and a "SERCOS" folder are available. The control can be completed with function module folders (e.g. CrossComm for the cross communication). The "Logic" folder comprises the sub-folders "POUs", "Tasks" and "Global Variables", via which the access to the PLC component (IndraLogic) is guaranteed. The "Motion" folder comprises the sub-folders "Real Axes", "Virtual Axes", "Encoder Axes" and "Link Axes", in which the several axis instances are created. The context menu and folders differ subject to the operating status (Offline or Online / Offline Parameterization). The offline status was already described in section IndraMotion MLC - Hardware Commissioning and Basic Sequences in Offline Mode, page 17,. Fig.5-1: Tree structure of an IndraMotion MLC project 5.2 MLC Control - Context Menu MLC Control - Menu Items of the Context Menu The context menu of the control contains the following menu items:

72 62/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization Fig.5-2: Context menu of a control in the online mode enabling of the Offline Parameterization (not for HNC devices), see Modes for Project Processing, page 23 MLC Control - Context Menu, Device Status, page 63 - phase switching between parameterization mode P2 and operating mode BB of the control communication: MLC Control - Context Menu, Communication, Drive Bus Configuration, page 64, and MLC Control - Context Menu, Communication, IP Settings, page 65 cam disc explorer: MLC Control - Context Menu, Cam Explorer, page 66 MLC Control - Context Menu, Parameter Handling, page 70 - the tools Parameter Handling - Exporting, page 305 and Parameter Handling - Importing, page 312 are used to read out and store the desired parameter as a file as well as to load the file and to write the parameters to their target positions in the control or drives diagnostic - contains the sub-points MLC Control - Context Menu, Diagnostic, Device Status, page 71 MLC Control - Context Menu, Diagnostic, Extended MLC Properties, page 73 MLC Control - Context Menu, Diagnostic, Clear Errors, page 73 - allows the deleting of all control and drive errors MLC Control - Context Menu, Diagnostic, Error/Diagnostic Memory, page 74 - gives an overview of the current diagnostic status of the control and its drives

73 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 63/333 IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization MLC Control - Context Menu, Diagnostic, Invalid Parameters, page 76 - displays the "Diagnostic (C )" parameters and lists the invalid parameters MLC Control - Context Menu, Diagnostic, Cycle Times, page 78 - displays the time history of the motion kernel, PLC and communication tasks Parameter Editor, page display and modification of an individual A, C, S, or P parameter Parameter Group, page display and change of a list of A, C, S, and P-Parameters arranged by the user firmware management - loading and updating of the MLC firmware, see also MLC - Firmware Exchange, page 320 The MLC itself can become the filing place for the user's own, passwordprotected project and any other data: MLC Control - Context Menu, Archiving Data On the MLC, page 79, or MLC Control - Context Menu, Get Data from MLC, page 81 For the acceptance of the project from the control, the project in the dialog must be selected by means of a double click on the project! Print Preview - delivers a preview of the project and device data. Via a dialog, the data to be indicated can be selected. Within the screen, data can be printed Print - allows the printing of the current project and device data. Via a dialog, the data to be printed can be selected Delete - allows the deletion of the control and its subfolders. Only available offline Rename - allows the renaming of the control. Only available offline Properties - display and modification of the control properties MLC Control - Context Menu, Device Status In the online / offline parameterization mode, the menu item indicates the control's status "Parameterization Mode P2" or "Operating Mode BB", and in the online mode, the menu item allows the phase switching between "Parameterization Mode P2" and "Operating Mode BB" of the control. The MLC icon bar situated above it in the figure is an alternative. Fig.5-3: Possibilities of changing the operating mode

74 64/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization In the figure, the operating mode is enabled (yellow field). It is possible to make a switch-over via the "Parameterization Mode" button. More powerful and always in view - the icon bar. Here, BB indicates the operating mode. A mouse click on P2 triggers the switch-over to the parameterization mode. In case of an offline parameterization P2, the parameterization mode is always preset. Switching over to BB is not possible MLC Control - Context Menu, Communication The switching over from P2 to BB can be prevented, if the parameters set are faulty. Example: During the cross-check of the C parameters, an invalid combination / an invalid min/max value or similar occurred. Cause: Possible causes e.g.: min/max values have been under- or over-run, invalid parameter combinations were detected. Remedy: Call parameter C and check the parameters noted therein. MLC Control - Context Menu, Communication, Drive Bus Configuration The dialog window displays the current data of the drive bus' control communication. Presently, this is always a SERCOS bus. The dialog allows to change the baud rate (= transmission rate: 1 Mbaud = 1 Mbit/s) and the FOC lengths of the individual connections in the drive SERCOS ring. Fig.5-4: Drive bus configuration The setting of the baud rate is only possible in SERCOS phase 0. Since, in this status, it is not possible to manually switch over, the changing of the baud rate temporarily leads to a switch-over to phase 0 and then back again to the parameterization mode. The setting of the SERCOS baud rate plays an important role for the number of drives which can be handled in the preset MC cycle time. If the baud rate is set too low, an attempt to switch over to the operating mode may fail and be acknowledged with the error message "MC cycle time too low". In this case, there are two possibilities to correct the error:

75 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 65/333 IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization increasing the MC cycle time (in dialog, page 78) or increasing the SERCOS baud rate The setting of the FOC lengths is made separately for each section. For this, the cable length at the transmitter output "TX" of the particular device is set. The specification of the FOC length determines the transmitting power at the TX output. The higher the value to which the SERCOS baud rate was set, the more exactly must the FOC length be adjusted to ensure a functioning SER COS ring. Parameters Involved Only the FOC lengths of drives that have been configured can be adjusted. Drives that were not configured are also listed; however, it is not possible to display or change their FOC length. C , Control name C , List of the drives found C , Control communication - configuration C , Control communication - baud rate C , Control communication - FOC length In the Drive List, Other Parameters are Used for Each Configured Drive: A , Axis name P , Transmission length - SERCOS Interface If a drive which belongs not to the project is located in the SERCOS ring, it is marked as a "non-configured" drive / axis and appears in the "C , List of the non-linked drives". MLC Control - Context Menu, Communication, IP Settings The dialog window displays the settings of the Ethernet connection between PC and control. Some values can be adjusted. Fig.5-5: IP settings The Help key in the IP Address line opens the help for setting the IP address at the control Package's time-to-live: Setting of the number of connecting nodes after the passing of which the package is discarded.

76 66/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization Response time-out: Period of time after which a response must have arrived for a query. Max. Number of Connections: Number of simultaneous connections a control can hold. Parameters Involved C , IP address C , Subnet mask C , Standard gateway C , MAC address C , TCP time-to-live C , TCP port for acyclic channels C , Transmitter time-out C , TCP - maximum number of connections MLC Control - Context Menu, Cam Explorer The "Cam Explorer" dialog offers access to all "Cams" and "Electronic Motion Profiles" (EMP) that can be stored in the MLC and the configured axes. Cams and electronic motion profiles of the MLC can either be stored in parameters or on the Compact Flash Card of the MLC as file. The dialog does not offer access to the cams and electronic motion profiles of the drives. This is possible either in the context menu of the CamPool entries or in the corresponding drive dialogs.

77 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 67/333 IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization Fig.5-6: Cam Explorer dialog: After the "Cam Pool" folder in the Project Explorer is opened, the stock of cams in the CamPool is shown on the left side of the dialog. For this, cams and electronic motion profiles are indicated in a mixed way. The Icon in every line shows the type.

78 68/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization Cams and electronic motion profiles are generated in an almost identical way with the help of the CamBuilder. Principally, every cam is also an electronic motion profile, i.e. it consists of segments having certain mathematical properties (= profile). If, for the creation of a cam, the "Electronic Motion Profile" version is used, the quantity of segment types is only limited. During the transfer of a cam into the control or the drive, a point table with the desired number of control points is generated on the basis of the segment description. The respective parameters are list parameters that only contain the points. On the basis of an electronic motion profile, it is also possible to calculate a point table and to load it into a cam parameter. The reloading of a point table from one parameter always leads to a new cam file that only contains control points and that does no longer indicate any segments or their mathematical description. Electronic Motion Profiles are stored in the control as the description of individual segments and can usually be reloaded in the same way. An electronic motion profile usually requires less memory space, but more computing power for the execution. Due to the kept segmentation, it is also possible to carry out modifications concerning existing segments during run-time (e.g. program-controlled fine adjustment). For the modification of cams, the complete point table must be transferred. In the dialog on the right top, all cam and electronic motion profile files are indicated which are stored on the Compact Flash Card. Here, too, cams and electronic motion profiles are indicated through the icons in each line. For cams, the number of points of the point tables is indicated in the "Control Points" column; for motion profiles, the file size is indicated in byte. In the dialog on the right bottom, all cams and electronic motion profiles are indicated which are stored in the MLC or axes parameters. In this regard, the following is applicable: Cams can only be stored in the MLC parameters C to C ; Electronic Motion Profiles can only be stored in the A parameters of the axes concerned. For cam parameters, the number of points of the point tables is indicated in the "Control Points " column; for motion profiles, the number of used segments is indicated. Electronic motion profiles exist in axes, the interpolation of which takes place in the MLC. The is always true for virtual axes, EcoDrive CS and SERCOS axes, as well as for IndraDrive, to the extent that the check mark before "Interpolation in the Drive" was deactivated during creation. Cams and electronic motion profiles can be copied from each of the three partial windows into a different one (exception: electronic motion profiles can currently not be copied from MLC to the Compact Flash Card). There are three possibilities for this: Arrow keys between the partial windows Send command in the context menu Drag & Drop

79 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 69/333 IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization If the arrow keys are used, it is necessary to at least select the element to be copied (simple click with the mouse); if the elements are copied into parameters, the copy target must also be selected. It might be that some copy processes cannot be realized (e.g. copying of cam into a motion profile parameter of one axis). Usually, this is indicated by a corresponding message. If a cam is copied from the left side ("Cams of the CamBuilder") to the right side, a conversion into a point table is realized. For this reason, a dialog is shown which prompts the user to enter the number of points as well as the precise storage space - parameter or file name -: Fig.5-7: Settings for the copying of a cam into a parameter During the copying between the windows on the right side, the number of points can no longer be modified. The entry field for the control points is then deactivated. Cams that are copied to the Compact Flash Card are stored so that they can be copied into cam parameters without having to be converted. Here, too, no mathematical segment description, but a point table, is stored on the Compact Flash Card. In the PLC program, appropriate FBs can be used to access stored files. The point tables contained can be copied into the corresponding parameters of the MLC or of the drives. Electronic motion profiles are also stored on the Compact Flash Card so as to guarantee that they can be copied into the parameters involved with reasonable efforts. Cams and motion profiles stored on the Compact Flash Card have the file extension ".cam" or ".cpf", respectively. Electronic motion profiles can also contain point tables in individual segments. During the copying of these motion profiles into an axis parameter, the storage space of the point tables contained must be queried. The following window is opened for the selection:

80 70/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization Fig.5-8: Selection of the cam parameter during the download of an electronic motion profile into an axis When an electronic motion profile is copied to the Compact Flash Card, the point table is stored in a separate file, the name of which is generated automatically according to the following example: <Name of the motion profile>[<segment number>]. In figure chapter "MLC Control - Context Menu, Cam Explorer" on page 66, the motion profile "CamProfile2" is converted into a cam file "CamProfile2 [0]". The motion profile itself is stored under the file name "CamProfile2". Parameters Involved C , Cams of the MLC And for Each Axis Indicated (A : Set 1, A : Set 2): A /A , Number of motion steps A /A , Master axis velocity A /A , List of master axes' initial positions A /A , List of motion step modes A /A , List of strokes A /A , List of slave axis velocities MLC Control - Context Menu, Parameter Handling By means of the tools Parameter Handling - Exporting, page 305, and Parameter Handling - Importing, page 312, it is possible to read out the parameters and to save them into a file or to load the parameters and write them into a file, respectively. The menu item is active in the online mode; here it refers to the real parameters of the control or axes / drives the offline parameterization mode; here it refers to the parameters of the emulated control or emulated axes / drives

81 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 71/333 IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization MLC Control - Context Menu, Diagnostic MLC Control - Context Menu, Diagnostic, Device Status The dialog window gives an overview of the essential properties of the current control. Fig.5-9: Device status dialog With the button "Clear error", all present errors of the control can be deleted. The current status is displayed in the "System Diagnostic" field. The display is realized according to priority, i.e. if several events are present, the event with the highest priority is displayed. For this, the following rule applies (descending priority): Error class Error class 0 Warnings Messages If one clicks twice on the display field of the current system diagnostic, the dialog MLC Control - Context Menu, Diagnostic, Error/Diagnostic Memory, page 74 is opened The button "More details" opens the window "Extended MLC Properties" (MLC Control - Context Menu, Diagnostic, Extended MLC Properties, page 73) The button "PC Control" transfers the system time of the PC into the control. The list of all defined axes gives an overview of some important properties of these axes. In the "Axis No." column, some other states are indicated by certain icons: Icon Explanation An error is applicable to this axis (display in the "Diagnostic" column). A warning is applicable to this axis (display in the "Diagnostic" column). There are neither errors nor warnings for this axis which is moving. The axis is in the "Drive is Ready" status (only for real axes). The axis is in the "Power is Available" status (only for real axes). The axis is in the "Drive is Torque-afflicted" status (only for real axes).

82 72/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization Icon Explanation Fig.5-10: Icons in the device status dialog The axis is in the "Drive is Parked" status (only for real axes). The axis is disabled (Disabled Axis, page 49). The "Addr" column indicates the address of the drive set in the drive ring (e.g. SERCOS). In the "Status Bit" column, the most important feedbacks of the axis are indicated in a compressed form. The letters have the following meaning: S - at standstill P - in position V - in velocity R - in reference, homed Y - synchronized If the mouse pointer is moved across several lines and columns of the axis list, tool tips are indicated to give further explanations concerning several cells. With the help of the right mouse button, a context menu with additional functions can be opened in the axis list: Fig.5-11: The bold entry corresponds to the double click on the axis. By means of the +/- icons in the upper area of the dialog, the marked areas can be minimized. The window thus reduced can be used as a permanent overview window. Parameters Involved: C , Hardware version C , Firmware version C , MLC system configuration C , Control name C , Control address C , System time C , User name C , System diagnostic In the Axis List, Further Parameters are Used for Each Configured Axis: A , Axis name A , Axis diagnostic message A , Axis status

83 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 73/333 IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization A , Extended axis status A , Actual position value S , Drive diagnostic (only for real and encoder axes) S , Diagnostic number (only for real and encoder axes) MLC Control - Context Menu, Diagnostic, Extended MLC Properties The "Extended MLC Properties" dialog contains additional details on the hardware and firmware of the control. These data are particularly required for the support: Fig.5-12: "Extended MLC properties" dialog In the "Current Values" container, some additional status values of the control are displayed. The temperature warning is switched on, when 60 C are reached, and switched off again, if the temperature is lower than 55 C. The "Max Temperature" value refers to the measuring period since the last reset, or the last switch-on of the control. Parameters Involved C , Hardware version C , LC firmware version C , Firmware version C , BSP version C , Technology functions C , Extended technology functions C , Hardware details C , MLC system status C , Serial number of the control C , Operating hour meter MLC Control - Context Menu, Diagnostic, Clear Errors The command "C , Clear all control errors" is executed. Said command also deletes all errors in the drives. Currently, warnings of the control are also deleted, if this command is executed. Clear Error can be called from different places:

84 74/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization in the context menu of the MLC: Clear Diagnostic/Error, in Device status dialog, page 71 in the MLC Control - Context Menu, Diagnostic, Error/Diagnostic Memory dialog, page 74, and in the MLC Icon Bar, page 305 MLC Control - Context Menu, Diagnostic, Error/Diagnostic Memory The "Error/Diagnostic memory" dialog box gives an overview of the error states of the control and its drives. For that purpose, it analyzes the logbook of the control. The access is carried out via the parameters described below. Error memory / logbook are organized as a stack. The current status is indicated at the top; it has the highest index (topmost line, see figure "Run-up, Error-free"). A total of 1,000 status messages can be filed in the control. (They are automatically saved in the NVRAM and in the Flash). Due to the great number, the display is limited by default: 10/20/50/all. One differentiates between errors, warnings and messages. In case of errors and warnings, the arrival and the departure is stored; messages are contained only once in the logbook. For reasons of storage space, the status messages which follow e.g. on an error deletion are not always indicated / registered completely, if the erasing procedure to BB RUN is carried out according to the plan. Categories Comment Status information of message type Error arrives, the error reaction is triggered, the error is active, Error passive, the error cause still exists, but the error was reset Fig.5-13: Error goes, the error cause doesn't exist any longer and the error was reset Warning arrives, the warning reaction is triggered, the warning is active Warning passive, the warning cause still exists, the warning was reset Warning goes, the warning cause doesn't exist any longer and the warning was reset Status information In addition to the category, the time of the log on/off, the source - whether it is an information received from the control or from an axis -, the status code and its explanatory text are also indicated. The status code and the text are documented in the "Notes on Troubleshooting" or the online help. Error-Free Run-Up The work with the diagnostic / error memory and the interpretation of its display are to be considered first for an error-free run-up:

85 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 75/333 IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization Diagnostic in Case of an Error Fig.5-14: Run-up, error-free The run-up is documented, starting with the bottom-most line: "Message BOOT END, booting of the application completed". The control runs automatically up to BB STOP (5th line from the bottom). Then, the user switches the control from offline to online. The control runs up to P2 STOP (7th line from the bottom). After a boot procedure, parameterizations are often realized. However, this is not necessary for us and so we proceed in the run-up from P2 to BB. Now the control runs to BB STOP. "F4034, E-Stop of the Drive of Axis 2" is considered to be an error. In the "E-Stop Function" dialog, the "Evaluation via Digital Input" must be activated and the "Interpretation as an Error Message F4034" must be chosen. The drive offers a function with which it is possible to monitor an E-Stop input (connection of an external hardware switch). The axis is set to a standstill as described in P , Optimum standstill procedure. Fig.5-15: Error F4034 arrives If the source of the warning or the error is located in a drive / its supply, its original error (warning) is indicated in the text. The status code consists of the original number, supplemented by the group information "Drive": F4034 -> F In the icon bar, an active error is indicated. The axis reporting the error is marked in the project navigator. If the error concerns a drive directly, the latter can - subject to the severity of the error - be set to a standstill according to the chosen strategy. A double click on the white cross on red ground activates the diagnostic and error memory window for the case that it is not opened in the foreground. Now the drive indicates on its display: 2 F4034,

86 76/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization Acknowledgment of the Error Sercos address 2, error F4034. Its electronics signals that the E-Stop input has responded. The control indicates on its display: F , axis 2. For the control, this is an axis error of the severity "F2" which leads to the disabling of the axis concerned. The diagnostic and error memory window combines both information, see above. Remove the failure which has led to the triggering of the E-Stop and delete the error (reset key or "Clear Error" command). Afterwards, switch on the power supply again and clarify the cause that triggered the E-Stop. Fig.5-16: Acknowledgement of the error after removal of the cause The acknowledgment of an error on the drive triggers the first 3 diagnostic lines. The diagnostic messages up to BB RUN are not required, if the procedure runs normally. Parameters Involved: C , Diagnostic memory index C , Indexed diagnostic message C , Amount of messages in the diagnostic memory C , Last reset message C , Absolute indexes C , Display message C , Command: Clear all Control Errors The specified parameters should not be used directly; they are developed specially for the handshake with this dialog. Use instead the following "public" parameters if necessary: C , Diagnostic C , Diagnostic number MLC Control - Context Menu, Diagnostic, Invalid Parameters The dialog window displays the current system diagnostic of the control and lists all invalid parameters: for the control the parameters included in "C , List of all invalid C parameters" for each axis the parameters included in "A , List of all invalid A parameters", or "A , List of non-transferable A parameters"

87 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 77/333 IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization for real and encoder axes, the parameters included in "S , IDN list of invalid operating data for phase 2" and "S , IDN list of invalid operating data for phase 3" are also evaluated How this dialog is used, can be explained with an example: The user wants to increase the "Positive velocity limit". For this, they exceed the maximum admissible entry value. The user is in the operating mode BB. The input is immediately transferred to the drive, which acknowledges it with an error message. Fig.5-17: Incorrect input, figure outside the range If, however, the change is made in the parameterization mode P2, the transfer does not take place until the switch-over from P2 to BB. Since it might be that several incorrect entries have been made, it is advisable to list all these errors. For this, the "Invalid Parameters" window is automatically opened.

88 78/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization Fig.5-18: Invalid parameters during switch-over from P2 to BB. Now the user is urged to make the appropriate correction(s) -here in the A parameters line - and to repeat the attempt of a switch-over from P2 to BB. Parameters Involved Frequently, lines are listed which - at first glance - seem identical. This is due to the fact that the S and P parameters determined as invalid are often overwritten with A parameters. If this is the case, it is necessary to write the corresponding A parameter. A writing on the S or P parameter would have no effect. Therefore, the parameters to be changed are highlighted in red. In the comment column, these facts are described for each case. C , List of all invalid C parameters C , Diagnostic And the Parameters Required for Each Axis A , List of all invalid A parameters A , List of non-transferred A parameters And the Parameters Required for Each Real and Encoder Axis S , IDN list of invalid operating data for phase 2 S , IDN list of invalid operating data for phase 3 S , Diagnostic number MLC Control - Context Menu, Diagnostic, Cycle Times In order to support the task management (see also MLC Control - Logic Folder, Overall Task System, page 89), the current load values of the individual tasks are indicated in this dialog. In addition to the current values, the minima and maxima of also collected from reset to reset (button Reset Minimum / Maximum). Under the boundary conditions Online (icon bar (1), Motion in the parameterization mode (2) and PLC in STOP (3)), the SERCOS cycle time (MC cycle time (Tcyc) setpoint) and the relative PLC time slot at the SERCOS time can be adjusted here. The default values are 2 ms (= 2,000 µs) and 50 %.

89 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 79/333 IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization Fig.5-19: Graphical evaluation of the time history of the task system The "MC Cycle Time" indicates in which intervals the motion control provides new setpoints for the connected drives. The MC cycle time is thus identical with the SERCOS cycle time in the drive ring. The "Time Slot of the Integrated PLC" determines how much time (sum) remains for the processing of the PLC motion task ("MotionTask", externally event-triggered by SERCOS) and the permanently cyclic PLC task ("PlcTask", less priority than the MotionTask). Parameters Involved If many axes are used, it can come to appropriate error messages when one tries to switch over from the parameterization mode (P2) to the operating mode (BB). The reason for this is the fact that the motion kernel is not able to provide so many axes in so short a time with setpoints via the SERCOS ring. In this case, the cycle time must be gradually increased (2 ms, 4 ms, 8 ms ms). Another reason for the increase of this value can be watchdog errors of the PLC, i.e. the PLC cannot process the time-controlled tasks in the available period of time. These errors can be activated separately for each task. C , MC cycle time (Tcyc) - setpoint C , Time slot of the integrated PLC from the MC cycle time C , MC cycle time (Tcyc) actual value C , List of current time slot values C , List of maximum time slot values C , List of minimum time slot values C , Command: Reset the Lists C and C MLC Control - Context Menu, Archiving Data On the MLC This menu item prepares the archiving of data / files in the OEM area on the Compact Flash Card of the MLC. The procedure is supported by a wizard consisting of two dialogs:

90 80/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization Fig.5-20: Select file group (step 1) The user has the possibility to select between the following file groups: user files, no system files system file archives complete archives The second dialog allows to determine the source path for the selected files. Fig.5-21: Select directory, here specifically user files The card has a capacity of 128 MBytes, 58 MBytes of which are reserved as OEM area!

91 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 81/333 IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization MLC Control - Context Menu, Get Data from MLC This menu item prepares the getting of data / files from the Compact Flash Card of the MLC. The procedure is supported by a wizard consisting of two dialogs: Fig.5-22: Select file group (step 1) The user has the possibility to select between the following file groups: user files, no system files system file archives complete archives The second dialog allows to determine the target path for the selected files.

92 82/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization Fig.5-23: Select files on the Flash and in the target directory, here specifically user files MLC Control - Context Menu, Print Preview If the Flash Card has to be cleared, the user can delete old archives within this menu item (right mouse button, Delete). This menu points allows to display the print preview of the: MLC properties MLC configuration MLC parameters of an MLC. In the first dialog box, the MLC as well as the data for the print preview can be selected.

93 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 83/333 IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization Fig.5-24: MLC properties Selection of the MLC and the data for the print preview Contains data on the project, such as project name, creation date, device names, general data, firmware versions and communication settings. MLC configuration Contains data on the project, such as project name, creation date, device names, function modules and axis configurations. MLC parameters Lists all parameters as well as the project name, the creation date and the device name. In the following dialog box, the settings selected before can be checked again and print settings (printer selection, layout, paper size and page setup) can be made.

94 84/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization Fig.5-25: Verification of print preview settings MLC Control - Context Menu, Printing The print preview can be realized both in the parameterization mode as well as in the operating mode. Its loading can, particularly in the second case, take one or even several minutes. Within the print preview, data can also be printed through the selection of the printer icon (top left). This menu points allows the unformatted documentation of the: MLC properties MLC configuration MLC parameters of an MLC. In the first dialog box, the MLC as well as the data to be printed can be selected.

95 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 85/333 IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization Fig.5-26: MLC properties Selection of MLC and the data to be printed Contains data on the project, such as project name, creation date, device names, general data, firmware versions and communication settings. MLC configuration Contains data on the project, such as project name, creation date, device names, function modules and axis configurations. MLC parameters Lists all parameters as well as the project name, the creation date and the device name. Controls file C parameters; real/virtual/encoder/link axes file A parameters and IndraDrive/HNC drives file S and P parameters. If an axis / a drive is disabled, only the A parameters which are duplicated on the control can be printed. In the following dialog box, the settings selected before can be checked again and print settings (printer selection, layout, paper size and page setup) can be made.

96 86/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization Fig.5-27: 5.3 MLC Control - Folders Verification of print settings MLC Control - Overview of Folders The print process can be realized both in the parameterization mode as well as in the operating mode. Its loading can, particularly in the second case, take one or even several minutes. The folders of the "Control MLC1" node result from the configuration of the control:

97 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 87/333 IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization Fig.5-28: MLC Control - Logic Folder MLC Control - Logic Folder, Context Menu Folders of the MLC control MLC Control - Logic Folder, page 87, switch-over to the PLC programming MLC Control - Motion Folder, page 91, basic principle of the motion programming MLC Control - Robot Folder, page 92, creation of a kinematics Possibility to connect and configure the input / output periphery MLC Control - Onboard I/Os Folder, page 103, each with 1 byte fast inputs and outputs, standard, MLC Control - Inline I/Os Folder, page 103, configurable inline modules, MLC Control - Profibus/M Folder, page 103, field bus for the connection of inline modules, HMI devices etc. function modules, here: CrossCom module (CFL01.1-Q2), see MLC Control - CrossCom Folder (CF01.1-Q2), page 103, MLC Control - SERCOS Folder, page 103, field bus for operation of the standard drives. The context menu of the "Logic" folder contains the following menu items:

98 88/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization Fig.5-29: MLC Control - Logic Folder, Sub-Folder Context menu of the Logic folder Open - the "IndraLogic" component is launched to create or modify the PLC program Save - the project is saved (manual saving in addition to the automatic saving, e.g. when IndraWorks is quit) Save PLC Project File As - the IndraLogic project can be saved under a different name Print Project - prints the project components contained in IndraLogic Note: This will lead to large paper volumes! Import PLC Project File - allows the importing of a project file already stored on the PC. The project objects to be imported can be selected before the import Update - the data record to be transferred to IndraLogic is updated (additional manual update) Start PLC - (e.g. switch-over from "BB Stop" to "BB Run") Stop PLC - (e.g. switch-over from "BB Run" to "BB Stop") Note: In case of enabled axes, a warning is output as to their emergency stop! The Logic node establishes the visible switch-over point to the PLC programming system "IndraLogic". Fig.5-30: "Logic" folder and its sub-folders

99 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 89/333 IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization After the MLC control was transferred into the project navigator, two program files are automatically created below the "POUs" folder and assigned to the two configured tasks (see MLC Control - Logic Folder, Overall Task System, page 89): "MotionProg" assigned to "MotionTask" task (SERCOS-controlled task of high priority), "PlcProg" assigned to "PlcTask" task (freely running or time-controlled task of a lower priority). Both programs contain only one dummy network each to ensure that the PLC project can be transmitted. The networks can be deleted later. The differences in the use of the programs are due to their task assignment. The "GlobalVariables" folder also allows the transfer to "IndraLogic", the respective file being opened: Global_Variables, general GlobalMLCVariables; here, the AXIS_REF declarations and the direct variables declarations are contained for each configured axis. Variable_Configuration. MLC Control - Logic Folder, Overall Task System The two preconfigured tasks are integrated in the overall task system of the control: Fig.5-31: Overall task system of the IndraMotion MLC The procedure begins SERCOS-synchronous (IR1) with the high-priority processing of the motion kernel MK1 and thus with the reception and the evaluation of the Drive Telegram in the MLC's motion component. After the shared memory (input variables) was processed, it is updated. Then, the PLC is allowed to process its tasks. Here, the two preconfigured PLC tasks "MotionTask" and "PlcTask" (and other tasks stipulated by the customer) are integrated according to their priority. As regards additional customer tasks, approx. 100 µs are required for each task.

100 90/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization IR2 completes the authorization for the PLC work and starts the high-priority processing of the motion kernel MK2 and thus the creation and sending of the MasterDataTelegram. Furthermore, the processing of MK2 also includes the writing of the output range of the shared memory. The remaining time until IR1 is used for communication purposes. If (t MotionTask + t PlcTask > t PLC ), the "MotionTask" will process its program part completely in each cycle. The "PlcTask" is interrupted while being processed and can continue its work only in the subsequent cycle(s). The data in the shared memory can already have changed in the subsequent cycle! Setting of the SERCOS Cycle Time Alias MC Cycle Time If the time required for the "MotionTask" is longer than t Plc, the processing is interrupted with a system error SysError. The default value of the SERCOS cycle time = MC cycle time is 2 ms. Other setting possibilities are 4 ms, 8 ms, 16 ms. The PLC proportion of the overall duration is set to 50 % and should only be modified after consultation. On the basis of the SERCOS baud rate and the number of axes, the firmware determines the minimum SERCOS cycle time and generates an error message, if the processing is not possible. The user can manually increase the SERCOS cycle time via a parameterization dialog. t Cyc - adjustable via "C MC cycle time (Tcyc) - setpoint" t PLC - it is possible to adjust the PLC part in the overall duration t Cyc via "C Time slot of the integrated PLC from the MC cycle time". The time required for the PLC tasks can be controlled with the help of the IndraLogic tool under "Task Configuration". MotionTask PlcTask Watchdog (Extract from the Indra Logic Help) There are other possibilities to indicate information about the time behavior in the dialog window [control name] Diagnostic Cycle Times. The following setting was preconfigured: Priority: 1 externally triggered by the "OP_MODE_SERCOS_CYCLE" event Watchdog: not activated The following setting was preconfigured: Priority: 2 cyclic, 10 ms Watchdog: not activated The interval time has no influence on the triggering of the watchdog. If a task is not completed within the adjusted interval time with the watchdog being switched off, the task is not called in this cycle. The scheduler does not activate the task again, if it is already running. However, immediately after the task cycle was finished and the next schedule tick is started, the task is activated. Then, the 10 ms task which runs 15 ms is activated directly at 16 ms; it is then run as quickly as possible. In "IndraLogic", the following settings can be made in order to configure the watchdog:

101 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Watchdog on/off Watchdog time and Watchdog sensitivity Bosch Rexroth AG 91/333 IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization These settings have the following meaning; they apply to both time- as well as event-controlled tasks. If the watchdog is not activated, the elapsed time of a task is not monitored. The watchdog time determines after which period of time the watchdog becomes active. The watchdog sensitivity determines after how many consecutive cycles with a watchdog time-out the watchdog is triggered. In case of a watchdog sensitivity of 1, the watchdog is immediately triggered, if the watchdog time is exceeded. With a watchdog sensitivity of 2, the watchdog is not triggered until the watchdog time was exceeded in two consecutive cycles. This means that, if the watchdog time was exceeded in one cycle but complied with in the next one, the watchdog is not triggered. A repeated time-out also does not lead to the triggering of a watchdog, to the extent that it did not occur in the second consecutive cycle. The watchdog sensitivity can be used, if a task was allowed - e.g. during its initialization - to exceed the cycle time to a certain extent. Furthermore, the watchdog is triggered, if the elapsed time of the task exceeds the product of the watchdog time multiplied by the watchdog sensitivity in one cycle. Example: MLC Control - Motion Folder For a task, a watchdog time of 10 ms and a watchdog sensitivity of 5 was entered. If the task is not yet finished after 10 ms * 5 = 50 ms, the watchdog is triggered. This criterion serves to identify endless loops. If the check mark "Watchdog" is activated, but no explicit time specification was made, meaning that the field "Time" field remains empty, 0 (zero) (and not 10 ms!!) is loaded into the control! Below the "Motion" folder, four different types of axes can be created in the offline mode: real axes, on the basis of IndraDrive or HNC devices virtual axis (can be used as virtual master axes) encoder axes (real master axis); the encoder uses the plug-in card in the drive electronics of the drive of a real axis link axes; the axis information is transferred via a CrossComm (CFL01.1- Q2) cross-communication. For each type of axis,a folder is provided in which the respective axis instances can be configured. At first, the folders are empty. A real axis is generated by means of Drag&Drop or Copy&Paste of the respective library element (see also Creation of a Real Axis on the Basis of IndraDrive, page 41). A virtual axis is generated with the help of the context menu item "Add" (see also Creation of a Virtual Axis (Virtual Master Axis), page 51). An encoder axis is generated by means of the context menu item "Add" (see also Creation of an Encoder Axis (Real Master Axis), page 53).

102 92/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization A link axis is also generated with the help of the context menu item "Add" (see also Project Planning of the MLC Network, CrossComm (CFL01.1-Q2), in the MLC Project, page 218). Each axis builds up its own environment: Context menus Real Axis (IndraDrive) - Menu Items of the Context Menus, page 104, Virtual Axis - Menu Items of the Context Menu, page 149, Encoder Axis - Menu Items of the Context Menu, page 162, Link Axis - Menu Items of the Context Menu, page 169, Dialog windows MLC Control - Robot Folder Creation of a RoCo Project Real Axis (IndraDrive) - Overview of Dialogs, page 114, Virtual Axis - Overview of Dialogs, page 152, Encoder Axis - Overview of Dialogs, page 165, Link Axis - Overview of Dialogs, page 172. The context menus and dialogs are used to access the individual software tools. By selecting the "Robot" folder and pushing the right mouse button, one can add a kinematics to the project. It is possible to create 1 kinematics with 4 axes + auxiliary axes (bands). The use of the RoCo functionality (Robot Control) is based upon the use of a SRAM function module (CFL01.1-Y1) for the permanent data back-up (restitution of the RoCo program). This can be created in the "Configuration Dialog" of the MLC L40 (alternatively, this can be made via "Drag" from the Device Library FM and "Drop" to the control in the Project Explorer). See Creating the Function Module SRAM (CFL01.1-Y1), page 244. With the help of an easy example, we want to explain the basic procedure for the creation of a Robot Control project with the MLC. Before we go into the creation of a project up to the generation and loading of the RoCo source code as well as the generation of the PLC program, we want to give some hints on the configuration required in IndraWorks. For the "RoCoTestV03" example project, it is assumed that only virtual drives are available. However, we want to describe briefly what is to do, if real drives are available. For this, the virtual drives in the project are replaced by real drives. In this respect, it has to be made sure that 1. the real drive have always the same axis designation Axis1, Axis2 and Axis3 and 2. the axis numbers 1, 2 and 3 have been attributed in the same order It is thus guaranteed that the PLC program is operational without any adaptation being required.

103 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 93/333 IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization Procedure: The user can thus either load the example project; it contains the parameter export file the RCL program the PLC program and the visualization data If the user, however, wants to program the entire project, the attachment with the detailed data can be used. 1. Creation of a project, see Creation of a Project, page Creation and configuration of a MLC control, see Creation of an IndraMotion MLC L40 Control, page Creation and configuration of 3 virtual axes or real axes with the designations Axis1... Axis3, see Creation of a Virtual Axis (Virtual Master Axis), page 51 or Creation of a Real Axis on the Basis of IndraDrive, page Addition and configuration of a kinematics Fig.5-32: Creation of a kinematics Assignment of the kinematics name "KIN01".

104 94/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization Fig.5-33: Assignment of kinematics names Selection of the kinematics type. In this example, the cartesian kinematics type is used. Fig.5-34: Selection of the kinematics type

105 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 95/333 IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization Allocation of axes to the kinematics. All (real or virtual) axes physically belonging to the kinematics must be allocated here. Fig.5-35: Allocation of axes belonging to the kinematics Definition of the axis length and axis coupling. Here, the axis couplings and axis lengths that are typical for robots are entered. For the example discussed here, this, however, is not required.

106 96/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization Fig.5-36: Definition of axis lengths and axis couplings Definition of coordinate names. The coordinate names kx, ky and kz defined here are applied in the subsequent RoCo programming. Fig.5-37: Definition of coordinate names

107 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 97/333 IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization 5. go online The control is switched to P2 and the settings made until here are transferred to the control. 6. Importing of parameters For the example project, parameter sets - that can be imported - are available for both scenarios (RoCoVirtuell.par / RoCoReal.par). For the example project, the C, A and K parameters can be imported here. After a successful parameter import, it should be possible to switch the control to BB (P4). 7. Creation of a RoCo motion program for the kinematics For this, click on the "+" symbol left to the "Robot" folder and then on the "+" symbol left to the "KIN01" sub-folder. For the creation of a motion program, highlight the "Programs" sub-item and push the right mouse button. Select "Add" and apply the name "Prog1" for the new program. Alternatively, it can be imported from the RoCoTestV03 mlc208 _Emb_Prog1.qll Prog1.qll project with Prog1.QLL Prog1.PFT Prog1.IRD Prog1.SYM. Fig.5-38: Creation of a RoCo motion program 8. Editing and translating the following RoCo motion program For the translation, press the right mouse button within the editor window and select "Translate". The objective was to keep the program simple in order to have an operational program as quickly as possible. Our intention was to demonstrate the general operational readiness without going into the complexity of other functions.

108 98/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization More detailed information about the RoCo programming are given in the Manual "Rexroth IndraMotion MLC03VRS Motion Control RCL Programming Guide". Fig.5-39: Edition and translation of the RoCo motion program The translator sends a status message to an output window (in this case "No Errors"). Any program error would be listed here with indication of the error and the respective line number. Fig.5-40: 9. Editing a point file Output window of the translator After the translation process, a point file is created automatically, if the declaration "DEF POINT" was used in the program.

109 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 99/333 IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization Fig.5-41: Point file created after the translation process In this table, for each defined point (P0...P6), the corresponding coordinate values (kx, ky, kz) must be entered. When the window is closed, a query appears as to whether the values entered in the file are to be saved. Alternatively, the saving of the file values can be started at any given point in time with a push on the right mouse button within the window. 10. Loading of the motion program, the point file etc. into the MLC Fig.5-42: Loading of the motion program, the point file etc. into the MLC 11. RoCo in the PLC program If no SRAM function module is available, this step must be repeated after each switch-on and switch-off of the control, since the data are in the volatile memory of the control. Here, we confine ourselves to the minimum PLC code required for the execution of the RoCo program. For the control of the PLC part, there is a small operating panel (visualization) in the sample projet. Thus, all operating actions required, from the switch-on of the power supply for real drives up to the launch of the RoCo programm, as well as the state of the kinematics can be read off.

110 100/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization Fig.5-43: RoCo in the SPS program Brief Description of the PLC Functionality in the Programmed Sequence. 1. Switching on the Power Supply Please execute this command for real drives only. In case of virtual axes, this bit is always set. If it is possible to switch on the power supply for an axis can be derived from the "AxisData[n].Axis_Power" bit. 2. Execution of the Homing Procedure The homing mode is only required for real drives without absolute encoder evaluation. The status, if an axis is referenced, can be derived from the "AxisData [n].axis_homed" bit. 3. Allocation of Axes to the Kinematics In this step, all axes belonging to the defined kinematics are grouped. Axes that are grouped can no longer be displaced with the normal PLC motion modules, but receive their move commands directly from the RoCo motion program. This is only possible, after all axes belonging to the kinematics were grouped. If all required axis have been grouped can be derived from the status "KinData[n].dwKinExtStatus_i.3=FALSE" (incomplete). 4. Release of Axes from the Kinematics This is necessary in order to be able to displace individual axes out of the RoCo motion program 5. Selecting a RoCo Motion Program In order for a RoCo motion program to be executed, it has to be selected. This is to be repeated after each program end and after each program stop. 6. Launching a RoCo Motion Program This command launches the program selected

111 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 101/333 IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization 7. Stopping a RoCo Motion Program Thus, all axis movements are stopped and the selected program is reset. In Case of an Error Details on the Project "RoCoTestV03" 1. Resetting the Kinematics Group Reset the kinematics group. Thus, all kinematics errors are deleted 2. Clear MLC Control and Drive Errors Deletes all drive errors starting from the PLC Parameter Settings (minimum changes) C parameters: The configuration of C parameters is made automatically upon the acceptance of the MLC into the project navigator and creation of virtual axes. For the axes, the subsequent modifications in the IndraWorks dialogs "Scaling/ Measuring Units", "Status Messages Settings" and "Motion Limit Values" are reasonable: A , Scaling type for acceleration data: translatory A , Scaling type for velocity data: translatory A , Scaling type for position data: translatory, absolute According limit and range values. C , Kinematics configuration list and all K parameters can be derived from the kinematics configuration. RoCo programme listing Program: ;;COMPILER = RCL3 ;;INT = PTP ;;KINEMATICS: ( 1 = Kin01) ;;Kin01.JC_NAMES = Axis1,Axis2,Axis3 ;;Kin01.WC_NAMES = kx,ky,kz ; ***************************************************************************** ; This programme was created by: ; Author: rudokohl ; Department: esc3 ; Date: ; ; Programme description:... ; ***************************************************************************** PROGRAM Prog1 ; declarations Def Point: P0, P1, P2, P3, P4, P5, P6 BEGIN ; program Kin01.V_PTP = 0.4 Kin01.A = 1000 Kin01.V = 1200 ; velocity for point to point movement ; acceleration ; velocity ;LOOP: ;JUMP LOOP MOVE TO P0 Kin01.V = 400 WAIT 3 REPEAT 4 TIMES ; move to P0 ; velocity ; wait for 3 seconds

112 102/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization MOVE TO P1 ; move to P1 MOVE TO P2 ; move to P2 MOVE TO P3 ; move to P3 MOVE VIA P4, P5 TO P6 ; move via to P6 WAIT 3 ; wait for 3 seconds REPEAT_END PROGRAM_END PLC programme listing (kinematics) PROGRAM kinematics VAR fbpower bpower fbhome bhome fbaddtogroup baddto fbremfromgroup bremove fbgroupreset bgroupreset fbprgselect bprgselect fbprgstart bprgstart fbprgstop bprgstop strprog END_VAR Program: (* example program for kinematics *) : ARRAY[1..3] OF MC_Power; : ARRAY[1..3] OF BOOL; : ARRAY[1..3] OF MB_Home; : ARRAY[1..3] OF BOOL; : ARRAY[1..3] OF MC_AddAxisToGroup; : ARRAY[1..3] OF BOOL; : ARRAY[1..3] OF MC_RemAxisFromGroup; : ARRAY[1..3] OF BOOL; : MC_GroupReset; : BOOL; : MB_IRDProgSelect; : BOOL; : MB_IRDProgStart; : BOOL; : MB_IRDProgStop; : BOOL; : STRING(8) := 'Prog1'; (* set power for all real kinematics axes *) fbpower[1]( Enable := bpower[1], Axis := Axis1 ); fbpower[2]( Enable := bpower[2], Axis := Axis2 ); fbpower[3]( Enable := bpower[3], Axis := Axis3 ); (* homing for all real kinematics axes *) fbhome[1]( Execute := bhome[1], Axis := Axis1 ); fbhome[2]( Execute := bhome[2], Axis := Axis2 ); fbhome[3]( Execute := bhome[3], Axis := Axis3 ); (* add all axes to group *) fbaddtogroup[1]( Execute := baddto[1], Axis := Axis1, AxisGroup := Kin01 ); fbaddtogroup[2]( Execute := baddto[2], Axis := Axis2, AxisGroup := Kin01 ); fbaddtogroup[3]( Execute := baddto[3], Axis := Axis3, AxisGroup := Kin01 ); (* remove all axes from group *) fbremfromgroup[1]( Execute := bremove[1], Axis := Axis1, AxisGroup := Kin01 ); fbremfromgroup[2]( Execute := bremove[2], Axis := Axis2, AxisGroup := Kin01 ); fbremfromgroup[3]( Execute := bremove[3], Axis := Axis3, AxisGroup := Kin01 ); (* select program *) fbprgselect( Execute := bprgselect, IRDProgName := strprog, AxisGroup := Kin01 ); (* start program *) fbprgstart( Execute := bprgstart, AxisGroup := Kin01 ); (* stop program *) fbprgstop( Execute := bprgstop, AxisGroup := Kin01 ); (* reset group *) fbgroupreset( Execute := bgroupreset, AxisGroup:= Kin01 ); END_PROGRAM PLC programme listing (PlcPrg) for error deletion

113 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Program: Bosch Rexroth AG 103/333 IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization PROGRAM PlcPrg VAR fbreset berrclear END_VAR : MB_WriteParameter; : BOOL; (* error clear MLC *) fbreset( Execute := berrclear, ParameterNumber := FP_C_0_1030, Value := 3, Axis := Axis1, Done=>, Active=>, Error=>, ErrorID=>, ErrorIdent=> ); END_PROGRAM MLC Control - Onboard I/Os Folder MLC Control - Inline I/Os Folder MLC Control - Profibus/M Folder The configuration of the input / output environment of the control can be carried out with the help of the following possibilities: onboard - inputs/outputs (see also Creation of Onboard - I/Os, page 31) inline modules (see also Creation of Inline - I/Os, page 32) The individual possibilities are described in detail in /5, IO-Configuration/. The configuration of the input / output environment of the control can be carried out with the help of the following possibilities: onboard - inputs/outputs (see also Creation of Onboard - I/Os, page 31) inline modules (see also Creation of Inline - I/Os, page 32) The individual possibilities are described in detail in /5, IO-Configuration/. The individual possibilities are described in detail in /5, IO-Configuration/ MLC Control - CrossCom Folder (CF01.1-Q2) MLC Control - SERCOS Folder The individual function modules and their configurations are described in more detail in Function Modules (Additional Components), page 177. The SERCOS node of the control serves to integrate all participants who run physically on the SERCOS bus. For that purpose, the participants are transferred from the library to the node by means of Drag&Drop or Copy&Paste (for example, see Creation of a Real Axis on the Basis of IndraDrive, page 41). The addressing of the participants is preset by their SERCOS address. Technically speaking, the user has thus fulfilled all prerequisites for the configuration (order in the project navigator). If a participant (real axis) was dragged on the SERCOS node, it appears twice in the project navigator:

114 104/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization Fig.5-44: Creation of a real axis RA1 - overview in the project navigator 5.4 Real Axis (IndraDrive) - Context Menu Please use the upper dialogs under Motion->Real Axes-> <axis name> for the configuration of the respective participant. The dialogs under SERCOS-> <axis name> are special drive dialogs which only access S and P parameters. Important note: the user-defined settings in the drive dialogs are partly overwritten with the A parameter settings of the upper dialogs without a warning being output. (see section on parameterizing and programming, A and C parameters overlap S and P parameters) Real Axis (IndraDrive) - Menu Items of the Context Menus The context menu of a real axis (IndraDrive) contains the following menu items:

115 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 105/333 IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization Fig.5-45: Context menu of a real axis (IndraDrive) Possibility to switch between the drive's operating modes "Enabled Axis"/ "Disabled Axis" and "Parked Axis" with use of the possibilities of the IndraDrive (see also Modes for Operating a Real Axis on the Basis of IndraDrive or HNC, page 49). Real Axis (IndraDrive) - Context Menu, Initial Commissioning, page commissioning cycle of the real axis (IndraDrive), Real Axis (IndraDrive) - Context Menu, Exchange Drive/Firmware, page 106 Real Axis (IndraDrive) - Context Menu, Parameter Handling, page 106, Real Axis (IndraDrive) - Context Menu, Communication, page 108, Real Axis (IndraDrive) - Context Menu, Diagnostic, page 112, Parameter Editor, page 314, Parameter Group, page 316, Delete - this menu item activates the deletion of the complete axis and all of its sub-folders. Rename - this menu point is only available in the offline mode. It activates the renaming of the axis. In addition to the axis name, the data transferred to the PLC are also changing. In this way, the PLC project may be destroyed. Disabling of an Axis - Real Axis (IndraDrive) Properties - the dialog window shows the properties of the control which were entered during its configuration (see Creation of a Real Axis on the Basis of IndraDrive, page 41). The disabling of a real axis, its drive, its electronics, results in the disabling of the encoder axis the encoder of which is connected to this electronics.

116 106/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization Real Axis (IndraDrive) - Context Menu, Initial Commissioning For the initial commissioning of a real axis on the basis of IndraDrive, the following dialog windows are processed by a wizard: Real Axis (IndraDrive) - Context Menu, Parameter Handling, Load Basic Parameters, page 106, Real Axis (IndraDrive) - Dialog, Measuring Systems - Motor Encoder, page 117, Real Axis (IndraDrive) - Dialog, Measuring Systems - Optional Encoder, page 118, Real Axis (IndraDrive) - Dialog, Scaling/Measuring Units Settings, page 120, Real Axis (IndraDrive) - Dialog, Mechanical Gear, page 122, Real Axis (IndraDrive) - Dialog, Motor Temperature / Brake, page 117, Real Axis (IndraDrive) - Dialog, Motion Limit Values, page 127, Real Axis (IndraDrive) - Dialog, Initial Values, page 129, Real Axis (IndraDrive) - Dialog, E-Stop Functions, page 127, Real Axis (IndraDrive) - Context Menu, Communication, Signal Status Word, page 109, Real Axis (IndraDrive) - Context Menu, Communication, Signal Control Word, page 111, Real Axis (IndraDrive) - Dialog, Status Messages Settings, page 122, Real Axis (IndraDrive) - Context Menu, Communication, Cyclic SERCOS Data Channel, page 108. Dates changed during the processing in the dialog window are directly transferred to the control / drive, irrespective of the fact whether a subsequent date is still changed or whether the dialog window is quit with <Next> or <Cancel> Real Axis (IndraDrive) - Context Menu, Exchange Drive/Firmware For the exchange of a drive or its firmware, a wizard is available which supports said exchange via corresponding dialogs. After this procedure is terminated, the new drive is configured and available in the project. See Drive/Drive Firmware Exchange, page 322, Real Axis (IndraDrive) - Context Menu, Parameter Handling Real Axis (IndraDrive) - Context Menu, Parameter Handling, Load Basic Parameters Creation of a New Axis: To load the basic parameters is the last way out to restore a drive's basic functions. Practically, the axis is removed and newly created. All parameters which lie directly in the axes (stored in the S and P parameters of the drive) are assigned default values and all other A parameters in the control are set to default values. When a user creates a new axis, they should note that both the drive as well as the control have a history, i.e. certain presettings exist. 1. Creation of a new axis, complete restart drag the drive onto the project navigator go online

117 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives initial commissioning "Load Basic Parameters" or via parameter handling A , Command: loading the basic parameters of the axis: sets the required A parameters for the drive to default values. Triggering: 0x11, parameter is reset automatically. P , Configuration of default values, S , C07_x Command "Initial Loading" Triggering: P x1, S x11; P x0, S x00 2. Creation of a new axis with the drive already being optimized drag the drive onto the project navigator go online Parameter Handling A , Command: loading the basic parameters of the axis: sets the required A parameters for the drive to default values, not the S and P parameters. Triggering: 0x11, parameter is reset automatically. 3. Creation of a new axis,!!! Chaotic operating mode, not recommended!!! drag the drive onto the project navigator go online The old parameter allocations are accepted with the full risk. Real Axis (IndraDrive) - Context Menu, Parameter Handling, Drive Password - Change Password IndraDrive control devices offer the possibility to protect parameter values from unintentional or non-authorized changing by way of a password. On the basis of a default or known password, this menu item allows to enter a new changed customer password and to confirm it with the repeated entry. Concerning the write protection, there are 3 groups of writable parameters: The parameters which are always write-protected such as motor parameters, hardware identification parameters, encoder parameters, error memory, etc. ("Administration Parameters"). The values of these parameters ensure the correct functioning and performance of the drive. Parameters which can be grouped for a customer and be protected with a so-called customer password. It is thus possible to protect parameter values which serve to adapt the drive to the axis after they have been defined. All remaining writable parameters which are not included in one of the aforementioned groups. They have no write-protection. Password types: Bosch Rexroth AG 107/333 IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization The drive firmware makes it possible to activate or deactivate the write protection for parameter values through three hierarchically different passwords: Customer password: the values of the parameters of a customer parameter group can be protected. Control password: parameters protected by a customer password are writable; "Administration parameters" remain write-protected. Master password: all writable parameters, including "Administration parameters" and parameters protected by customer password, can be changed.

118 108/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization Real Axis (IndraDrive) - Context Menu, Parameter Handling, Save Mode IndraDrive drives allow different save modes after a parameter value was changed. The dialog for the menu item allows the presetting of the mode, including the loading, saving and selective backing up of the working memory, as well as the composition of lists for special treatments. The basic principles of "Loading, Saving and Backing up of Parameters" are described for individual products in IndraMotion MLC - Further Documentations, page 14, /10/, /11/ "Loading, Storing and Backing up of Parameters". The user is supported by the implemented online help. Real Axis (IndraDrive) - Conetxt Menu, Parameter Handling, Save Parameter in Drive With the help of this menu point, it is possible to trigger at any given point in time the saving of the content (parameter values) of the volatile working memory in the non-volatile Flash memory of the drive. The basic principles of "Loading, Saving and Backing up of Parameters" are described for individual products in IndraMotion MLC - Further Documentations, page 14, /10/, /11/ "Loading, Storing and Backing up of Parameters" Real Axis (IndraDrive) - Context Menu, Communication Real Axis (IndraDrive) - Context Menu, Communication, Cyclic SERCOS Data Channel All drives in the SERCOS ring communicate with the control in each SERCOS cycle. The most important components are the "Master Data Telegram" (MDT) and the "Drive Telegram" (AT). MDT is the control telegram. Here, setpoints are given. AT is the response telegram. Here, actual values are received. Both telegrams have a fixed number of places for parameters. The majority of these places is covered by the MLC firmware for controlling the drives. However, four places each can be freely configured by the user. The term "Cyclic SERCOS Data Channel" is thus to be understood as a possibility to influence the content of MDT and AT to a certain extent, i.e. to be able to transfer selected parameters into the SERCOS cycle. These parameters are reachable in the PLC program via the "Functional Variables" of each axis. Fig.5-46: Cyclic SERCOS data channel In the selection lists of the dialog window, a parameter each can be chosen for the four available places. For this, only parameters are offered which are reasonable. Only restriction: The user themselves has to make sure sure that they do not allocate one and the same parameter more than once.

119 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 109/333 IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization If a parameter is chosen, its value and - if applicable - its unit are indicated to the right of it. Settings in this dialog window can only be made in the parameterization mode. If settings are changed, the switch-over to the parameterization mode is offered, if necessary. Example: Access to the Parameter Data in the PLC Program In the PLC program, the parameters can be read- and write-accessed (in case of MDT) via the functional variables indicated. In the following example, the value of the Feedrate Override (S ) parameter is increased by 5 for the axis "RA1" with axis number "1": The variables can be called up as index in an array under the respective axis number. The data record itself is a structure of the "ML_AXISDATA_SM" type. Example: AxisData[1].dwUserCmdDataB_q.INT means axis 1, MDT data container B, interpreted as an INT. Fig.5-47: Use of the cyclic SERCOS data channel for writing For the data exchange, the following parameters A , Configuration of user-defined setpoint A A , Configuration of user-defined setpoint B A , Configuration of user-defined setpoint C A , Configuration of user-defined setpoint D are used for the write access and the following parameters A , Configuration of user-defined actual value A A , Configuration of user-defined actual value B A , Configuration of user-defined actual value C A , Configuration of user-defined actual value D are used for the read access. Please use the documented access via AxisData[n] for the axis with the axis number "n". The access via the direct variable <axis name>_dat.dwusercmddatab_q requires approx. the tenfold access time (15 µs) and is therefore to be avoided! Real Axis (IndraDrive) - Context Menu, Communication, Signal Status Word The "Signal Status Word" dialog is part of the control communication. It is possible to define up to four bit queries which are read in each SERCOS cycle. The bit values can be read-accessed in the PLC program via "Functional Variable" of the axis. In order to define a bit query, it is usually necessary to determine a parameter and a bit from its value.

120 110/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization In order to make sure that the settings of this window can be transferred to the control in a consistent manner, the values are exceptionally not immediately transferred after their editing, but only upon the explicit command to accept them with the button "Apply". All settings changed, but not yet transferred, are highlighted in blue. Fig.5-48: Signal status word In addition to the four bit queries freely configurable by the user, this dialog also indicates the other bit queries preconfigured by the control firmware. (Incorrect) multiple-axis definitions of the same bit queries can thus be avoided. For the selection of the bit number, a selection is always offered. However, according to the parameter, it is possible that the real bit width only amounts to No test concerning an admissible bit number is carried out. Example: In the PLC program, the bit values can be read-accessed reading via the functional variables indicated. In the following example, it is determined whether the value "S , Target position reached (Bit 0)" is set. The bit values can be accessed in the PLC program via the Functional Variable of the axis The variables can be called up as index in an array under the respective axis number. The data record itself is a structure of the "ML_AXISDATA_SM" type. Example: AxisData[1].wUserActualDataBitA_i means axis 1, data container A, WORD. In order to receive a Boolean value, the functional (WORD) variable must be masked with 0x0001: Fig.5-49: Use of the signal status word for reading

121 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 111/333 IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization Job Container A Container B Container C Container D defines the parameter of the drive A A A A definies the bit in the parameter of the drive A A A A contains the value which was read from the bit of the parameter A A A A Fig.5-50: Parameters used for reading a signal status word Please use the documented access via AxisData[n] for the axis with the axis number "n". The access via the direct variable <achsname>_dat.wuseractualdatabita_i requires approx. the tenfold access time (15 µs) and is therefore to be avoided! Real Axis (IndraDrive) - Context Menu, Communication, Signal Control Word The "Signal Control Word" dialog is part of the control communication. It is possible to define up to four bit positions in parameters, which are written on in each SERCOS cycle. In the PLC program, the bit values can be read- and write-accessed via the "Functional Variable" of the axis. In order to define such a cyclically written bit value, it is necessary to determine a parameter and a bit in its value. In order to make sure that the settings of this window can be transferred to the control in a consistent manner, the values are exceptionally not immediately transferred after their editing, but only upon the explicit command to accept them with the button "Apply". All settings changed, but not yet transferred, are highlighted in blue. Fig.5-51: Signal control word In addition to the four bit values freely configurable by the user, this dialog also indicates the other bit values preconfigured by the control firmware. (Incorrect) multiple definitions of the same bit values can thus be avoided.

122 112/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization For the selection of the bit number, a selection is always offered. However, according to the parameter, it is possible that the real bit width only amounts to No test concerning an admissible bit number is carried out. Example: In the PLC program, the parameters can be read- and write-accessed via the indicated "Functional Variables". The variables can be called up as index in an array under the respective axis number. The data record itself is a structure of the "ML_AXISDATA_SM" type. Example: AxisData[1].wUserCmdDataBitA_q means axis 1, data container A, WORD. In the following example, the oscilloscope recording is launched in a programcontrolled way (bit 0 of P is set to 1): Fig.5-52: Use of the signal control word for writing Job Container A Container B Container C Container D defines the parameter of the drive A A A A definies the bit in the parameter of the drive A A A A contains the value which is to be written on the bit of the parameter A A A A Fig.5-53: Parameters used for reading a signal status word Please use the documented access via AxisData[n] for the axis with the axis number "n". The access via the direct variable <achsname>_dat.wuseractualdatabita_i requires approx. the tenfold access time (15 µs) and is therefore to be avoided! Real Axis (IndraDrive) - Context Menu, Diagnostic Real Axis (IndraDrive) - Context Menu, Diagnostic, Status With the dialog window, the status information concerning the respective axis are graphically prepared and displayed. In the given example, it is a real axis in an endless movement. The window is split, the upper half containing general information, whereas the lower half contains detailed additions. As regards the marking of the axis: A , Logical axis number A , Axis designation, the name of the axis A , Drive address, here: the SERCOS address of the drive A , Axis type Bit 3 - real axis, IndraDrive or HNC device Bit 4 - virtual axis Bit 5 - encoder axis

123 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 113/333 IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization Bit 6 - link axis A , Axis diagnostic message A , Command: Clear all axis errors, deletes the axis errors in the drive and in the control Current values of the axis: A , Actual position value A , Actual velocity value A , Actual acceleration value A , Actual torque/force value The "Drive Status" button triggers the status display for the drive belonging to the axis (see online help there). Fig.5-54: Axis status of a real axis The detailed information is encoded as bit bars in the parameters A , Axis status and A , Extended axis status Real Axis (IndraDrive) - Context Menu, Diagnostic, Clear Errors The "Axis status" dialog can also be opened through a double click on the desired axis in the "Device status" of the control. The enabling of this context menu item triggers the "A , Command: Clear all axis erros" and deletes the axis errors in the drive and in the control. Real Axis (IndraDrive) - Context Menu, Diagnostic, Error/Diagnostic Memory The dialog displays the operating hour meter and the error/diagnostic memory of the drive belonging to the axis. A double click on the respective error line / diagnostic line opens the help for the error / warning or message.

124 114/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization Real Axis (IndraDrive) - Context Menu, Diagnostic, Average Value Filter Display In the dialog, it is possible to make a selection for two signals of the drive from the parameter "P , Average value filter display: signal selection list: Signal selection list" for the parameter "P , Average value filter display: signal selection ". The function is disabled, if "S " is selected as signal. The filters are not interconnected and can therefore be separately enabled or disabled. The parameter is of the Ident number list type and possesses exactly 2 values (ident numbers) for both filters. Important note! For the oscilloscope etc., the sequences of the parameterization must be complied with! If the signal for the average value filter display is preset first and if then the same signal is selected as measuring signal in the oscilloscope, the filtered value is recorded in the oscilloscope. If the sequence is reversed, the value not filtered is recorded. If the signal for the average value filter display is changed or deleted, there is no automatic switch-over for the oscilloscope function. The signal must be selected again as a measuring signal. The basic principles are described for individual products in IndraMotion MLC - Further Documentations, page 14, /10/, /11/ "Velocity controller (with appropriate filters)". The user is supported by the implemented online help. 5.5 Real Axis (IndraDrive) - Dialogs Real Axis (IndraDrive) - Overview of Dialogs When the folder of a real axis is opened, the individual dialogs - display and adjustment possibilities for parameters of the axis / IndraDrive - are offered. First of all, it can be assumed that the presettings cover a wide range of applications and that a modification is only required in exceptional cases.

125 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 115/333 IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization Fig.5-55: Folder of a real axis If Indradrive drive devices without a check mark before "Interpolation in the Drive", EcoDrive CS, and SercosDrive are selected, the drive control is realized via the PackProfile. Since the Indradrive and EcoDrive CS devices are drive devices specified in more details, here - contrary to the SercosDrive - device-specific dialogs are offered for the commissioning. Real Axis (IndraDrive) - Dialog, Motor, page 116, Real Axis (IndraDrive) - Dialog, Motor Temperature / Brake, page 117, Real Axis (IndraDrive) - Dialog, Measuring Systems, page 117, Real Axis (IndraDrive) - Dialog, Scaling/Measuring Units Settings, page 120, Real Axis (IndraDrive) - Dialog, Extended Scaling / Measuring Units, page 120, Real Axis (IndraDrive) - Dialog, Mechanical Gear, page 122, Real Axis (IndraDrive) - Dialog, Regulation, page 122, (reference to the drive documentation),

126 116/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization Real Axis (IndraDrive) - Dialog, Status Messages Settings, page 122, Real Axis (IndraDrive) - Dialog, Drive Halt, page 123, Real Axis (IndraDrive) - Dialog, Establish Measurement Reference, page 124, Real Axis (IndraDrive) - Dialog, Error Reaction, page 126, Real Axis (IndraDrive) - Dialog, E-Stop Functions, page 127, Real Axis (IndraDrive) - Dialog, Motion Limit Values, page 127, Real Axis (IndraDrive) - Dialog, Initial Values, page 129, Real Axis (IndraDrive) - Dialog, Compensation Functions / Corrections, page 130, (reference to the drive documentation), Real Axis (IndraDrive) - Dialog, Drive-Integrated Setpoint Generator, page 131, (reference to the drive documentation), Real Axis (IndraDrive) - Dialog, Electronic Motion Profile, page 136, Real Axis (IndraDrive) - Dialog, Cam, page 131, Real Axis (IndraDrive) - Dialog, Motor Real Axis (IndraDrive) - dialog, gear with velocity synchronization, page 141, Real Axis (IndraDrive) - Dialog, Gear with Angle Synchronization, page 143, Real Axis (IndraDrive) - Dialog, Position Switch Point, page 146, Real Axis (IndraDrive) - Dialog, Measuring Probe, page 147, The values in the dialogs are partly calculated from multiple parameters. If a clear assignment exists, this is indicated. Dialogs that exclusively refer to internal drive data are only described by a reference to the mostly product-dependent orignal documentations. Fig.5-56: Motor dialog The dialog shows the essential data of the motor and allows the setting of the cooling method realized. The data of this window are filed in the following S and P parameters: S , Motor type P , Motor frame size P , Cooling type For details, see IndraMotion MLC - Further Documentations, page 14, /10/, / 11/; section: Motor, Axis Mechanics, Measuring Systems.

127 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 117/333 IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization Real Axis (IndraDrive) - Dialog, Motor Temperature / Brake Fig.5-57: Motor Temperature / Brake dialog The dialog serves to set the sensor type for the monitoring of the motor temperature and the transfer of information about the type and version of the brake to the control device. Furthermore, it informs about the thermal data of the motor. The data are filed in the following S and P parameters: P , Temperature sensor S , Motor warning temperature S , Motor switch-off temperature P , Thermal time constant of winding P , Thermal time constant of motor P , Thermal short-term overload of winding P , Holding brake, control word For details, see IndraMotion MLC - Further Documentations, page 14, /10/, / 11/; section: General notes on the operation of motors with IndraDrive Real Axis (IndraDrive) - Dialog, Measuring Systems Real Axis (IndraDrive) - Dialog, Measuring Systems - Motor Encoder IndraDrive supports three types of encoders: Motor encoder; the encoder is situated on the motor shaft, Real Axis (IndraDrive) - Dialog, Measuring Systems - Optional Encoder, page 118; the encoder is situated on the load side to compensate e.g. for disturbance variables of the gear, Configuration of the Measuring Encoder, page 56; the encoder has the largest degree of tolerance as regards its application; it only uses the drive electronics for the data communication and can e.g. realize a metering wheel or be used as a real master axis. (A measuring encoder is always configured with its encoder axis).

128 118/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization Fig.5-58: Motor Encoder dialog The following parameters are evaluated: S , Position encoder type 1 S , Encoder 1 resolution S , Maximum travel range S , Multiplication 1 (motor encoder) P , Internal position data format P , Gear 1 motor side (motor encoder) P , Gear 1 encoder side (motor encoder) The transmission ratio is derived from: T = (P ) / (P ) The remaining data come from "S , Position encoder type 1". For details, see IndraMotion MLC - Further Documentations, page 14, /10/, / 11/; section: Motor, Axis Mechanics, Measuring Systems Real Axis (IndraDrive) - Dialog, Measuring Systems - Optional Encoder IndraDrive supports three types of encoders: Real Axis (IndraDrive) - Dialog, Measuring Systems - Motor Encoder, page 117; the encoder is situated on the motor shaft, optional encoder; the encoder is situated on the load side to compensate e.g. for disturbance variables of the gear, Configuration of the Measuring Encoder, page 56; the encoder has the largest degree of tolerance as regards its application; it only uses the drive electronics for the data communication and can e.g. realize a metering wheel or be used as a real master axis. (A measuring encoder is always configured with its encoder axis).

129 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 119/333 IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization Fig.5-59: Optional encoder dialog The following parameters are evaluated: P , Assignment optional encoder ->optional slot S , Maximum travel range S , Encoder 2 resolution P , Internal position data format S , Multiplication 2 (optional encoder) P , Internal position data format P , Gear 2 load side (optional encoder) P , Gear 2 encoder side (optional encoder) S , Monitoring window, encoder 2 The transmission ratio is derived from: T = (P ) / (P ) The remaining data come from "S , Position encoder type 2 " or "P , Control word encoder 2 (optional encoder)". For details, see IndraMotion MLC - Further Documentations, page 14, /10/, / 11/; section: Motor, Axis Mechanics, Measuring Systems

130 120/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization Real Axis (IndraDrive) - Dialog, Scaling/Measuring Units Settings Fig.5-60: Scaling/measuring units settings dialog The "Scaling/Measuring Units Settings" dialog box derives the presettings for position, speed and torque / force data according to the same sample. The Scaling Type of the data determines in which format and which reference the data between the drive and the control or user interface are exchanged. With the Scaling Factor and the Scaling Exponent, the scaling factor and the decimal places are stipulated with parameterized scaling. In case of a preference scaling, these two units are set automatically. Scaling type Scaling factor Scaling exponent Position A A A Velocity A A A Torque / force A A A Fig.5-61: Overview of the scaling parameters In the scaling type, one can choose between rotatory and translatory scaling (A , A , A bit 1..0); for the format of the position data, absolute or modulo values are available (A , bit 7). A "A , Modulo value" is required for the modulo format. Alternatively, the "A , Slave drive feed travel" is evaluated for translatory movements. The scaling refers to the load or to the motor side (A , A , A bit 6 each). A negation of the position, velocity and torque/force data could be demanded "A , Position polarity (Bit 0)". Detailed data can be entered in Real Axis (IndraDrive) - Dialog, Extended Scaling / Measuring Units, page 120, Real Axis (IndraDrive) - Dialog, Extended Scaling / Measuring Units The dialog window supplements data to Encoder Axis - Dialog, Scaling/Measuring Units Settings, page 166, in more detail.

131 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 121/333 IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization Fig.5-62: Extended scaling/measuring units dialog The following parameters are evaluated: A , Scaling type for position data A , Scaling type for velocity data A , Scaling type for acceleration data A , Modulo value A , Slave drive feed travel The data of this window are calculated for the position data on the basis of the parameters "A , Scaling type for position data", "A , Scaling factor for position data", "A , Scaling exponent for position data", or "A , Rotational position resolution", as well as "A , Position polarity", the velocity data on the basis of the parameters "A , Scaling type for velocity data", "A , Scaling factor for velocity data", "A , Scaling exponent for velocity data", as well as "S , Velocity polarity", the acceleration data on the basis of the parameters "A , Scaling type for acceleration data", "A , Scaling factor for acceleration data", "A , Scaling exponent for acceleration data", the torque/force data on the basis of the parameters "A , Scaling type for torque/force data", "A , Scaling factor for torque/force data", "A , Scaling exponent for torque/force data", "S , Torque/force polarities" and the temperature data on the basis of "A , Scaling type for temperature data". A "A , Modulo value" is required for the modulo format.

132 122/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization The scaling refers to the load or to the motor side (A , A , A bit 6 each) Real Axis (IndraDrive) - Dialog, Mechanical Gear Fig.5-63: Mechanical gear dialog The data of this window are filed in the folllowing S and P parameters: S , Maximum travel range S , Load gear - input revolutions S , Load gear - output revolutions The (integer) number of motor revolutions (gear input) is indicated which causes an integer number of gear output revolutions. The transmission ratio is derived from: T = (S ) / (S ) S , Feed constant This parameter is only relevant with linear axes which are driven by a rotatory motor. The feed constant is the distance which is covered by the axis, when the gear output shaft or motor shaft does one rotation. Determination of the feed constant with different mechanical transmission elements: (For ball bearing screws, the default value amounts to: feed constant = spindle lead typ. value mm/ rotation.) For details, see IndraMotion MLC - Further Documentations, page 14, /10/, / 11/; section: Motor, Axis Mechanics, Measuring Systems Real Axis (IndraDrive) - Dialog, Regulation The basic principles of the regulation dialogs are described for the different products in IndraMotion MLC - Further Documentations, page 14, /10/, /11/ "Overview of Drive Regulation". The user is supported by the implemented online help Real Axis (IndraDrive) - Dialog, Status Messages Settings The dialog window evaluates the status of the axis (A ). The messages "A , Standstill (Bit 5)"

133 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 123/333 IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization "A , Actual velocity = velocity setpoint (Bit 4)" "A , In Position (Bit 6)" "A , Position synchronous (Bit 7)" and "A , Velocity synchronous" likewise (Bit 7) are dependent on whether the respective value is within its range. A , Standstill Range A , Velocity Data Range A , Position Data Range A , Position Synchronization Window A , Velocity Synchronization Window Fig.5-64: Status messages settings dialog The values themselves are filed in the following parameters: For the velocity setpoint zero, "A , Actual velocity value" is within the range defined by the "A , Standstill range". -> (A , Bit 5). For any velocity setpoint, "A , Actual velocity value" is in the range defined by the "A , Velocity data range". -> (A , Bit 4). For any position setpoint, "A , Actual position value" is within the range defined by "A , Position data range". -> (A , Bit 6). If, for the "Synchronized Motion" blocks with subordinate position regulation (MC_GearInPos, MC_CamIn), the difference between the position setpoint and the actual position value is smaller than the "A , Position synchronization window", bit 7 in parameter "A , Axis status" is set. If, for the "Synchronized Motion" blocks (MC_GearIn), the difference between the velocity setpoint and the actual velocity value is smaller than the "A , Velocity synchronization window", bit 7 in parameter "A , Axis status" is set Real Axis (IndraDrive) - Dialog, Drive Halt The dialog window unites the most important preset values of the drive (emergency) halt.

134 124/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization Fig.5-65: Drive halt dialog The individual parameters are preadjusted in different dialogs: A , Bipolar jerk limit - Real Axis (IndraDrive) - Dialog, Motion Limit Values, page 127, A , Emergency halt deceleration - Real Axis (IndraDrive) - Dialog, Initial Values, page 129, A , Standstill range - Real Axis (IndraDrive) - Dialog, Status Messages Settings, page 122, For the drive halt, the acknowledgement bit is also shown, "A , Axis status (Bit 15)" Real Axis (IndraDrive) - Dialog, Establish Measurement Reference Real Axis (IndraDrive) - Dialog, Measurement Reference Motor Encoder The dialog window is intended for the setting of the measurement reference for the motor encoder. P , Absolute Encoder Monitoring Window for Motor Encoder Fig.5-66: Measuring reference motor encoder dialog Upon the switch-on of a drive with absolute motor encoder, it is checked whether the current position value deviates from the actual position value at the point in time of the last switch-off.

135 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 125/333 IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization S , Reference Value S , Actual Position Value Encoder 1 If the deviation exceeds the value specified in this parameter, the error message "F2074 Actual position value 1 outside the absolute encoder range" is output. Upon the switch-off of the drive, the current encoder data of the absolute motor encoder are stored in "P , Absolute encoder buffer 1 (motor encoder)". In this parameter, the desired actual position value is inserted with regard to a certain axis position (reference position). With the command "P , C0300 command "Set Absolute Value"", the value inserted in parameter S becomes effective at the reference position as the actual position value. This way, a certain position reference system can be established for an axis or an existing reference system can be replaced by a new one (switch-over). The actual position value encoder 1 displays the current position of the motor encoder. After the drive is switched on, the communication phases are run through and the actual position value is initialized with the command "S , C0200 Preparation of switch-over to phase 4", i.e. it is set to its initial value. Furthermore, the following parameters are involved S , Actual position value status S , Homing parameter Real Axis (IndraDrive) - Dialog, Measurement Reference Optional Encoder The dialog window is intended for the setting of the measurement reference for an optional encoder. P , Absolute Encoder Monitoring Window for Optional Encoder S , Reference Value 2 Fig.5-67: Measurement reference optional encoder dialog When a drive with absolute optional encoder is switched on, it is checked whether the current position value deviates from the actual position value at the point in time of the last switch-off. If the deviation exceeds the value specified in this parameter, the error message "F2075 Actual position value 2 outside the absolute encoder range" is output. Upon the switch-off of the drive, the current encoder data of the absolute optional encoder are stored in "P , Absolute buffer (optional encoder)". In this parameter, the desired actual position value is inserted with regard to a certain axis position (reference position). With the command "P , C0300 command "Set Absolute Value"" the value inserted in parameter S becomes effective at the reference position as the actual position value. This way, a certain position reference system can be established for an axis or an existing reference system can be replaced by a new one (switch-over).

136 126/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization S , Actual Position Value Encoder 2 The actual position value encoder 2 displays the current position of the optional encoder. After the drive is switched on, the communication phases are run through and the actual position value is initialized with the command "S , C0200 Preparation of switch-over to phase 4", i.e. it is set to its initial value. Furthermore, the following parameters are involved S , Actual position value status S , Homing parameter Real Axis (IndraDrive) - Dialog, Error Reaction Drive Error Reaction This dialog allows to configure the reaction in case of a fault in the drive. Error Reaction Power Unit Fig.5-68: Drive error reaction dialog For each error case, the type of the "Optimum standstill procedure" as well as the maximum braking time can be indicated. This dialog allows to configure the reaction in case of a fault in the power unit. Fig.5-69: Power unit error reaction dialog The following parameters are displayed:

137 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 127/333 IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization P , Module Network, Control Word P , Module Network, Status Word P , Power Supply, Configuration In this parameter, the information is displayed which is sent by a device (WR or UR) to the module bus. Due to the hierarchical structure of the module bus, only the information with the highest priority becomes effective (read only)! In this parameter, the currently active information of the module bus is displayed. In this parameter, the settings regarding error messages and error reactions for drives are made, which are connected with each other via the DC intermediate circuit and the module bus (drive package). Furthermore, the handling of the DC intermediate circuit undervoltage is determined. The DC intermediate circuit voltage (power bus) is not switched off in case of slight errors when the "Drive package" is in operation! Real Axis (IndraDrive) - Dialog, E-Stop Functions The activation of the E-Stop function and the determination of the drive reaction is carried out via the parameter "P , Activation of E-Stop function". Fig.5-70: E-Stop functionality Through the activation of "P , E-Stop input (Bit 0 = 1)" and the allocation of the bit 0 condition of "P , E-Stop input" to a digital input, the drive is initiated to execute the reaction to shut down the drive defined via P , if the E-Stop input has a 0 V level. "P , E-Stop input" must be assigned via parameters "P , Digital I/Os, allocation list" and "P , Digital I/Os, bit numbers" to a digital input. The definition of the input can be influenced with the help of the dialog window which is behind the "Digital I/O X31/X32" link (for details, see IndraMotion MLC - Further Documentations, page 14,, /10/ and /11/, E-Stop function or online help. The input is always "0-active"! Real Axis (IndraDrive) - Dialog, Motion Limit Values The dialog window gives an overview of preset limit values for the real axis.

138 128/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization Monitoring of Travel Range Exceeding Fig.5-71: Motion limits The following parameters are evaluated: A , Positive position limit A , Negative position limit A , Positive velocity limit A , Negative velocity limit A , Bipolar acceleration limit A , Bipolar jerk limit A , Bipolar torque/force limit as well as the bit bars: A , Position polarities (Bit 4) P , Travel range limit switch parameter The value of "A , Position polarities (Bit 4)" decides whether the position limit monitoring of the axis is active (Bit 4 = TRUE) or not. If the position limit monitoring is active, "Actual position (A )" indicates the position of the axis and the adjustable "A , Positive position limit", "A , Negative position limit" show the admissible movement limits. Now the user can decide, whether a "Serious Warning" is released with subsequent shutdown of the drive or whether an "Error" is triggered according to the error reaction preset in "P , Optimum standstill procedure". Actual position value smaller than negative position limit higher than positive position limit Warning E Error F F Monitoring of Limits Fig.5-72: Diagnoses as a reaction to the exceeding of the position limits Irrespective of the activation of the position limit monitoring, the other limits can either be accepted with their default setting or be changed user-specifically. Bipolar Limit means that the same value is effective in the positive as well as in the negative direction. If said limits are exceeded in either direction, a warning is output (see following table).

139 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 129/333 IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization Actual value smaller than negative limit higher than positive limit Velocity Acceleration E E Fig.5-73: Warnings as a reaction to the execeeding of the limits The jerk and torque/force limits do neither trigger a warning nor an error message, but they limit the respective actual values (for detailed information, see parameter description (A ) and (A )) Real Axis (IndraDrive) - Dialog, Initial Values The dialog window displays the initial values that are used for the PLCopen blocks. Starting point is the status after a reboot: Fig.5-74: Initial values after a reboot The following parameters are evaluated: A , Position setpoint A , Target position A , Velocity setpoint A , Acceleration setpoint A , Emergency stop deceleration A , Jerk A , Direction of travel The values of the parameters given in the parameter monitor come from their initialization during run-up. They are actually of no relevance, since no movement was made yet. The jerk value comes from "A , Bipolar jerk limit". It can be changed in the dialog. The values displayed are overwritten by the values which the respectively active PLCopen block brings along.

140 130/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization Fig.5-75: Active PLCopen block: MC_MoveVelocity Fig.5-76: Setpoints on the basis of the block's initial values The velocity (120 min -1 ), acceleration (20 rad s -2 ) and deceleration (20 rad s -2 ) values have been accepted by the block. The previous position and distance values were kept. They would change e.g. with an active MC_MoveRelative Real Axis (IndraDrive) - Dialog, Compensation Functions / Corrections Real Axis (IndraDrive) - Dialog, Compensation Functions / Corrections, Encoder Correction The quality of the processing and the accuracy with which an axis can follow a preset path is affected by several factors. One of the influencing factors is the accuracy with which a measuring system can identify the position of an axis or a shaft. IndraDrive control devices offer the possibility to improve system-dependent inaccuracies of position-measuring systems with sinusoidal signals. The way in which a drive or an axis, respectively, follow the position and velocity setpoints can thus be improved. Frequently, the bandwidth of the control circuits can also be improved through a higher adjustable control circuit amplification. The basic principles of the "Compensation functions, encoder correction" are described for individual products in IndraMotion MLC - Further Documentations, page 14, /10/, /11/ "Encoder correction". The user is supported by the implemented online help.

141 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 131/333 IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization Real Axis (IndraDrive) - Dialog, Compensation Functions / Corrections, Reversal Error Correction By means of the reversal error correction, a clearance can be easily corrected in the axis mechanics. Fig.5-77: Parameters used: Reversal error correction dialog P , AxisCorr. Control word S , Actual position value encoder 1 P , AxisCorr., active correction value S , Backlash S , Standstill range S , Velocity setpoint Further information on the parameters to be used are given in the IndraDrive firmware description Real Axis (IndraDrive) - Dialog, Drive-Integrated Setpoint Generator The basic principles of the "Drive-Integrated Setpoint Generator" are described for individual products in IndraMotion MLC - Further Documentations, page 14, /10/, /11/ "Drive-Integrated Setpoint Generator". The user is supported by the implemented online help Real Axis (IndraDrive) - Dialog, Cam Real Axis (IndraDrive) - Dialog, Cam, General This dialog is only available, if the option "Interpolation in the Drive" was activated during the creation of the real axis. If a real axis operates as a slave on the MC_CamIn motion function block, the drive runs in the operating mode "Electronic cam with real/virtual master axis". In this operating mode, a given master axis position and a slave are firmly linked to each other. Master axes (masters) can be virtual, or encoder axes.

142 132/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization On the basis of the virtual master axis position (actual position value, master), the effective master axis position (actual position value in the actual value cycle) is generated with "Master Axis Position Offset", "Gear" and "Dynamic Synchronization". Gear Switching Stroke Switching Master Axis Position Offset - Cam Fig.5-78: Parameters used: Cam dialog P , Control word for synchronous operating modes A , Master axis, additive position setpoint A , Angle offset begin of table P , Dynamic angle offset P , Cam stroke switch angle P , Cam switch angle A , Cam stroke A , Slave axis, additive position setpoint A , Cam preselection A , Master, actual position value A , Master, actual velocity value P , Actual position value in the actual value cycle A , ELS position setpoint, CAM A , Gear reduction The cam dialog serves to display the master axis parameters, when the drive is in the operating mode "Electronic cam with real/virtual master axis". The parameters can be influenced by the settings made in the PLC program for the MC_CamIn motion function block. Definition of the gear switching either "immediately" or "like stroke switching" (P ). Definition of the stroke switching "immediately" or definition of the cam switch angle or the stroke switch angle (P ). Determination of the resulting master axis position on the basis of "A , Actual position value - master" and "A , Master axis, additive position

143 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 133/333 IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization Gear Settings Angle Offset Begin of Table Dynamic Angle Offset Cam - Download Dynamic Synchronization - Angle Synchronization setpoint" as well as "A , Additive master axis position, process controller". Definition of the gear transmission ratio of the master axis gear with "A , Input revolutions" and "A , Output revolutions" as well as gear fine adjustment and determination of "A , Effective master axis velocity". Definition of the angle offset with "A , Angle offset begin of table" and "A , Angle offset change rate" as well as "A , Angle offset begin of table, process controller". This functionality is currently not supported by the MLC. Selection and download of a cam created by means of the CamBuilder to a cam table of the drive. Definition of the "A , Synchronization mode", the "A , Synchronization velocity", the "A , Synchronization acceleration" as well as the "A , Synchronization direction", the "A , Slave axis, additive velocity setpoint" and the "A , Additive velocity setpoint, process controller". Real Axis (IndraDrive) - Dialog, Cam, Master Axis Position Offset Determination of the resulting master axis position on the basis of "A , Actual position value - master" and "A , Master axis, additive position setpoint" as well as "A , Additive master axis position, process controller". With the help of "P , Master axis revolutions per master axis cycle", the modulo range of the master axis position is specified. Fig.5-79: Parameters used: Master axis position offset dialog in the cam dialog A , Master, actual position value A , Master axis, additive position setpoint A , Additive master axis position, process controller A , Filter time constant, additive master axis position, process controller P , Master axis revolutions per master axis cycle A , Resulting master axis position Real Axis (IndraDrive) - Dialog, Cam, Gear Settings Definition of the gear transmission ratio of the master axis gear with "A , Input revolutions" and "A , Output revolutions" as well as gear fine adjustment and determination of "A , Effective master axis velocity".

144 134/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization Fig.5-80: Parameters used: Gear settings dialog in the cam dialog A , Resulting master axis position A , Master axis gear - output revolutions A , Master axis gear - input revolutions A , Gear transmission ratio fine adjustment A , Gear transmission ratio fine adjustment, process controller A , Polarity master axis position A , Effective master axis position A , Effective master axis position Real Axis (IndraDrive) - Dialog, Cam, Angle Offset Begin of Table Definition of the angle offset with "A , Angle offset begin of table" and "A , Angle offset change rate" as well as "A , Angle offset begin of table, process controller". Fig.5-81: Parameters used: Cam - angle offset dialog in the cam dialog A , Angle offset begin of table A , Angle offset change rate A , Angle offset begin of table, process controller A , Filter time constant, angle offset table, process controller Real Axis (IndraDrive) - Dialog, Cam, Dynamic Angle Offset This functionality is currently not supported by the MLC. Real Axis (IndraDrive) - Dialog, Cam, Cam Table Selection Selection and download of a cam created by means of the CamBuilder to a cam table of the drive. It is possible to load a different cam in any of the four cam tables. The selection of the cam to be processed is carried out on the MC_Ca

145 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 135/333 IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization min motion function block. Furthermore, it is possible to choose for each cam between linear and cubic spline interpolation. Fig.5-82: Cam download dialog in the cam dialog Real Axis (IndraDrive) - Dialog, Cam, Dynamic Synchronization Definition of the "A , Synchronization mode", the "A , Synchronization velocity", the "A , Synchronization acceleration" as well as the "A , Synchronization direction", of the "A , Additive velocity setpoint" and the "A , Additive velocity setpoint, process controller". Fig.5-83: Parameters used: Dynamic synchronization dialog in the cam dialog P , Synchronization mode (IndraDrive with interpolation on the MLC) A , Synchronization mode (SercosDrive and virtual axes) A , Synchronization velocity A , Synchronization acceleration A , Synchronization direction A , Scaling type for position data A , Modulo value P , Setpoint cycle

146 136/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization P , Load revolutions per actual value cycle (slave axis) A , Slave axis, additive position setpoint A , Additive position setpoint, process controller A , Filter time constant, additive position setpoint Real Axis (IndraDrive) - Dialog, Electronic Motion Profile Real Axis (IndraDrive) - Dialog, Electronic Motion Profile, General This dialog is only available, if the checkmark before the option "Interpolation in Drive" was removed during the creation of the real axis. If a real axis (IndraDrive) operates as a slave in the MB_MotionProfile motion function block, the drive runs in the operating mode "Electronic motion profile with real/virtual master axis". In this operating mode, a given master axis position and a slave are firmly linked to each other. Master axes (masters) can be real, virtual, or encoder axes. On the basis of the virtual master axis position (actual position value, master), the effective master axis position (actual position value in the actual value cycle) is generated with "Master Axis Position Offset", "Gear" and "Dynamic Synchronization". Fig.5-84: Electronic motion profile dialog Parameters used: A , Axis status A , Master axis, axis number A , Master axis, additive position setpoint A , Angle offset begin of table A , Slave axis, additive position setpoint A , Synchronous position setpoint A , Synchronous velocity A , ELS position setpoint, CAM A , Master, actual position value A , Master, actual velocity value

147 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 137/333 IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization Master Axis Position Offset - Electronic Motion Profile Gear Settings Angle Offset Begin of Table Dynamic Angle Offset Electronic Motion Profile - Download Dynamic Synchronization - Angle Synchronization A , Motion profile - basic configuration The Electronic Motion Profile dialog serves to display the master axis parameters, when the control is in the operating mode "Electronic motion profile with real/virtual master axis". The parameters can be influenced by the settings made in the PLC program for the MB_MotionProfile motion function block. Determination of the resulting master axis position on the basis of "A , Actual position value - master" and "A , Master axis, additive position setpoint" as well as "A , Additive master axis position, process controller". Definition of the gear transmission ratio of the master axis gear with "A , Input revolutions" and "A , Output revolutions" as well as gear fine adjustment and determination of "A , Effective master axis velocity". Definition of the angle offset with "A , Angle offset begin of table" and "A , Angle offset change rate" as well as "A , Angle offset begin of table, process controller". This functionality is currently not supported by the MLC. Selection and download of an Electronic Motion Profile created by means of the CamBuilder on the real axis. Definition of the "A , Synchronization mode", the "A , Synchronization velocity", the "A , Synchronization acceleration" as well as the "A , Synchronization direction", the "A , Slave axis, additive position setpoint" and the "A , Additive position setpoint, process controller". Real Axis (IndraDrive) - Dialog, Electronic Motion Profile, Master Axis Position Offset Determination of the resulting master axis position on the basis of "A , Actual position value - master" and "A , Master axis, additive position setpoint" as well as "A , Additive master axis position, process controller". With the help of "P , Master axis revolutions per master axis cycle", the modulo range of the master axis position is specified. Fig.5-85: Parameters used: Master axis position offset dialog in the electronic motion profile dialog A , Master, actual position value A , Master axis, additive position setpoint A , Additive master axis position, process controller A , Filter time constant, additive master axis position, process controller

148 138/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization P , Master axis revolutions per master axis cycle A , Resulting master axis position Real Axis (IndraDrive) - Dialog, Electronic Motion Profile, Gear Settings Definition of the gear transmission ratio of the master axis gear with "A , Input revolutions" and "A , Output revolutions" as well as gear fine adjustment and determination of "A , Effective master axis velocity". Fig.5-86: Parameters used: Gear settings dialog in the electronic motion profile dialog A , Resulting master axis position A , Master axis gear - output revolutions A , Master axis gear - input revolutions A , Gear transmission ratio fine adjustment A , Gear transmission ratio fine adjustment, process controller A , Polarity master axis position A , Effective master axis position A , Effective master axis position Real Axis (IndraDrive) - Dialog, Electronic Motion Profile, Angle Offset Begin of Table Definition of the angle offset with "A , Angle offset begin of table" and "A , Angle offset change rate" as well as "A , Angle offset begin of table, process controller" and "A , Filter time constant, angle offset table, process controller". Fig.5-87: Cam - angle offset dialog in the electronic motion profile dialog Parameters used: A , Angle offset begin of table A , Angle offset change rate A , Angle offset begin of table, process controller

149 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 139/333 IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization A , Filter time constant, angle offset table, process controller Real Axis (IndraDrive) - Dialog, Electronic Motion Profile, Dynamic Angle Offset This functionality is currently not supported by the MLC. Real Axis (IndraDrive) - Dialog, Electronic Motion Profile, Cam Table Selection Selection and download of a motion profile created by means of the CamBuilder into the axis. For each axis, a maximum of two motion profiles can be stored. With the help of the dialog, it is also possible to get back electronic motion profiles into the CamBuilder that have alredy been stored on the axis. The selection of the motion profile to be processed is carried out on the MB_Motion Profile motion function block. Fig.5-88: Cam - download dialog in the electronic motion profile dialog Parameters used: A , Motion profile, master axis switch position A , Motion step 1, slave axes' initial position A , Motion profile, control word A , Motion profile, status word The axis parameters describing the motion profile 0: A , Number of motion steps, motion profile 0 A , Master axis velocity, motion profile 0 A , List of master axes' initial positions, motion profile 0 A , List of motion step modes, motion profile 0

150 140/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization A , List of strokes, motion profile 0 A , List of slave axes' velocities, motion profile 0 The axis parameters describing the motion profile 1: A , Number of motion steps, motion profile 1 A , Master axis velocity, motion profile 1 A , List of master axes' initial positions, motion profile 1 A , List of motion step modes, motion profile 1 A , List of strokes, motion profile 1 A , List of slave axes' velocities, motion profile 1 Real Axis (IndraDrive) - Dialog, Electronic Motion Profile, Dynamic Synchronization Definition of the "A , Synchronization mode", the "A , Synchronization velocity", the "A , Synchronization acceleration" as well as the "A , Synchronization direction", the "A , Additive position setpoint, slave axis" and the "A , Additive position setpoint, process controller". Fig.5-89: Parameters used: Dynamic synchronization dialog in the electronic motion profile dialog P , Synchronization mode (IndraDrive, SercosDrive with interpolation on the MLC) A , Synchronization mode (IndraDrive, SercosDrive and virtual axes) A , Synchronization velocity A , Synchronization acceleration A , Synchronization direction A , Modulo value P , Setpoint cycle P , Load revolutions per actual value cycle (slave axis) A , Slave axis, additive position setpoint A , Additive position setpoint, process controller

151 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 141/333 IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization A , Filter time constant, additive position setpoint Real Axis (IndraDrive) - dialog, gear with velocity synchronization Real Axis (IndraDrive) - Dialog, Gear with Velocity Synchronization - General If a real axis operates as a slave in the MC_GearIn Motion-Function block, the drive runs in the operating mode "Velocity synchronization with real/virtual master axis". In this operating mode, the drive follows a given master axis velocity in a velocity-synchronous manner. Master axes (masters) can be virtual, or encoder axes. On the basis of the virtual master axis velocity "A , Master, actual velocity value", the effective master axis velocity "A , Effective velocity setpoint" is generated for the real axis with "Master Axis Position Offset", "Gear" and "Dynamic Synchronization". Master Axis Position Offset - Velocity Synchronization Gear with Fine Adjustment - Velocity Synchronization Dynamic Synchronization - Velocity Synchronization Application Fig.5-90: Parameters used: Gear dialog with velocity synchronization A , Master axis, additive position setpoint A , Master, actual position value A , Master, actual velocity value A , Modulo value A , Effective velocity setpoint The Gear with Velocity Synchronization dialog serves to display the master axis parameters, when the drive is in the operating mode "Velocity synchronization with real/virtual master axis". The parameters can be influenced by the settings made in the PLC program for the MB_GearIn motion function block. Determination of the resulting master axis position on the basis of "A , Actual position value - master" and "A , Master axis, additive position setpoint" as well as "A , Additive master axis position, process controller". Definition of the gear transmission ratio of the master axis gear with "A , Input revolutions" and "A , Output revolutions" as well as gear fine adjustment and determination of "A , Effective master axis velocity". Definition of the "A , Synchronization acceleration", the "A , Slave axis, additive velocity setpoint" and the "A , Additive velocity setpoint, process controller" The velocity synchronization is used, e.g. with simple feed rolls of printing machines. The drive runs in synchronism with the master axis velocity. The path velocity at the perimeter of the feed roll or of a winding support, respectively, is

152 142/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization preadjusted by means of the electric gear. A defined tension can be set in the framework of the gear fine adjustment. Real Axis (IndraDrive) - Dialog, Gear with Velocity Synchronization - Master Axis Position Offset Determination of the resulting master axis position on the basis of "A , Master, actual position value" and "A , Master axis, additive position setpoint" as well as "A , Additive master axis position, process controller". Fig.5-91: Parameters used: Master axis position subdialog in the gear with velocity synchronization dialog A , Master axis, additive position setpoint A , Master, actual position value A , Additive master axis position, process controller A , Filter time constant, additive master axis position, process controller P , Master axis revolutions per master axis cycle A , Resulting master axis position Real Axis (IndraDrive) - Dialog, Gear with Velocity Synchronization - Fine Adjustment Definition of the gear transmission ratio of the master axis gear with "A , Input revolutions" and "A , Output revolutions" as well as "A , Gear fine adjustment" and determination of the "A , Effective master axis velocity". Fig.5-92: Parameters used: Gear with fine adjustment dialog in the gear with velocity synchronization dialog A , Resulting master axis position A , Master axis gear - output revolutions

153 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 143/333 IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization A , Master axis gear - input revolutions A , Gear transmission ratio fine adjustment A , Gear transmission ratio fine adjustment, process controller A , Polarity master axis position A , Effective master axis position A , Effective master axis position Real Axis (IndraDrive) - Dialog, Gear with Velocity Synchronization - Dynamic Synchronization Definition of the "A , Synchronization acceleration", the "A , Slave axis, additive velocity setpoint" and the "A , Additive velocity setpoint, process controller" Fig.5-93: Parameters used: Dynamic synchronization dialog in the gear with velocity synchronization dialog P , Synchronization mode A , Synchronization mode A , Synchronization acceleration A , Slave axis, additive velocity setpoint A , Additive velocity setpoint, process controller Real Axis (IndraDrive) - Dialog, Gear with Angle Synchronization Real Axis (IndraDrive) - Dialog, Gear with Angle Synchronization - General If a real axis operates as a slave in the MC_GearInPos motion function block, the drive runs in the operating mode "Angle synchronization with real/virtual master axis". In this operating mode, the drive follows a given master axis position in an absolutely or relatively angle-synchronously way. Master axes (masters) can be virtual, or encoder axes. On the basis of the virtual master axis position "A , Master, Actual position value", the effective master axis position "A , ELS position setpoint, CAM " is generated for the real axis with "Master Axis Position Offset", "Gear" and "Dynamic synchronization".

154 144/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization Master Axis Position Offset Gear Dynamic Synchronization Fig.5-94: Parameters used: Gear with angle synchronization dialog A , Master axis, additive position setpoint A , Master, actual position value A , Master, actual velocity value A , Modulo value A , Slave axis, additive position setpoint A , ELS position setpoint, CAM The Gear with Angle Synchronization dialog serves to display the master axis parameters, when the drive is in the operating mode "Angle synchronization with real/virtual master axis". The parameters can be influenced by the settings made in the PLC program for the MC_GearInPos motion function block. Determination of the resulting master axis position on the basis of "A , Master, actual position value" and "A , Master axis, additive position setpoint" as well as "A , Additive master axis position, process controller". Definition of the gear transmission ratio of the master axis gear with "A , Input revolutions" and "A , Output revolutions" as well as "A , Gear fine adjustment" and determination of the "A , Effective master axis velocity". Definition of the "A , Synchronization mode", the "A , Synchronization velocity", the "A , Synchronization acceleration" as well as the "A , Synchronization direction", the "A , Slave axis, additive velocity setpoint" and the "A , Additive velocity value, process controller". Real Axis (IndraDrive) - Dialog, Gear with Angle Synchronization - Master Axis Position Offset Determination of the resulting master axis position on the basis of "A , Master, actual position value" and "A , Master axis, additive position setpoint" as well as "A , Additive master axis position, process controller". With the help of "P , Master axis revolutions per master axis cycle", the modulo range of the master axis position is specified.

155 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 145/333 IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization Fig.5-95: Parameters used: Master axis position offset dialog in gear with angle synchronization dialog A , Master axis, additive position setpoint A , Master, actual position value A , Additive master axis position, process controller A , Filter time constant, additive master axis position, process controller P , Master axis revolutions per master axis cycle A , Resulting master axis position Real Axis (IndraDrive) - Dialog, Gear with Angle Synchronization - Fine Adjustment Definition of the gear transmission ratio of the master axis gear with "A , Master axis gear - input revolutions" and "A , Master axis gear - output revolutions" as well as gear fine adjustment and determination of "A , Effective master axis velocity". Fig.5-96: Parameters used: Gear with fine adjustment dialog in the gear with angle synchronization dialog A , Resulting master axis position A , Master axis gear - output revolutions A , Master axis gear - input revolutions A , Gear transmission ratio fine adjustment A , Gear transmission ratio fine adjustment, process controller A , Polarity master axis position A , Effective master axis position A , Effective master axis position

156 146/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization Real Axis (IndraDrive) - Dialog, Gear with Angle Synchronization - Dynamic Synchronization Definition of the "A , Synchronization mode", the "A , Synchronization velocity", the "A , Synchronization acceleration" as well as the "A , Synchronization direction", the "A , Slave axis, additive position setpoint" and the "A , Additive position setpoint, process controller". Fig.5-97: Parameters used: Dynamic synchronization dialog in the gear with velocity synchronization dialog P , Synchronization mode A , Synchronization mode A , Synchronization velocity A , Synchronization acceleration A , Synchronization direction A , Scaling type for position data A , Modulo value P , Setpoint cycle P , Load revolutions per actual value cycle (slave axis) A , Slave axis, additive position setpoint A , Additive position setpoint, process controller A , Filter time constant, additive position setpoint Real Axis (IndraDrive) - Dialog, Position Switch Point The dialog allows to configure a virtual position-dependent switch.

157 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 147/333 IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization Fig.5-98: Position switch point The following parameters are evaluated: S , Position switch point 1 "On" S , Position switch point 1 "Off" S , Position switch point parameter (Bit 0) The switch positions for the drive are preset in "S , Position switch point 1 "On"", "S , Position switch point 1 "Off"". Between these both positions, the virtual switch is in status "1"; outside the two positions, the virtual switch is in status "0". The value can be read off in the parameter "S , Position switch point parameter". The basic principles of the "Position switch points" / the "Dynamic camshaft gear" are described for individual products in IndraMotion MLC - Further Documentations, page 14, /10/, /11/ "Dynamic camshaft gear". The user is supported by the implemented online help Real Axis (IndraDrive) - Dialog, Measuring Probe Measuring probes serve to measure absolute actual position values as well as actual position value differences and to record time intervals between measuring signals. Subject to the hardware version of the controller unit, up to two measuring probe inputs can be defined per axis. Measuring signals can either be actual position values of motor encoders, external encoders and measuring encoders or master axis position values or cam table values. A measurement can be triggered by positive and/or negative measuring probe signal edges. It is possible to make individual measurements or continuous measurements as well as to count the measuring events during continuous measurement. Furthermore, a position value range ("Range of Expected Values") can be defined for each measuring probe, in which measurements can be realized, incl. the activation of a "Failure counter" for the running through the range of expected values without measuring event. The scan time for measuring probe signals amounts to approx ms (for sufficient noise immunity, a signal edge change must continue at least 4.0 ms in order to be detected!).

158 148/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization The function is only active in the operating mode (BB). Fig.5-99: Measuring probe The following parameters are evaluated: S , Signal selection - measuring probe 1 P , Measuring probe, extended control word S , Signal selection - measuring probe 2 S , Measuring probe control parameter P , Start position measuring probe function 1 enabled P , End position measuring probe function 1 enabled P , Start position measuring probe function 2 enabled P , End position measuring probe function 2 enabled S , Command "Measuring Probe Cycle" S , Measuring probe 1 enabling S , Measuring probe 2 enabling The work in the dialog window begins and ends with the enabling or disabling, respectively, of the measuring probe evaluation. For the enabling, the parameter "S , Command "Measuring Probe Cycle"" is used to set the command in the drive and, at the same time, the command execution is enabled. During the disabling process, the command in the drive is deleted and, at the same time, the command execution is interrupted (Fig. Measuring probe, right bottom). Only if the measuring probe evaluation is activated are the remaining areas of the dialog active. Selection of the Signal Sources Basic Settings The selection of the signal sources is effected via a selection window, the sources selected being determined in the parameters "S , Signal selection measuring probe 1" or "S , Signal selection measuring probe 2". The remaining basic settings, Individual measurement / Continuous measurement, positive and / or negative edge, are filed in the parameters "S ,

159 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 149/333 IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization Activation of the Measuring Probe Evaluation Measuring probe control parameter" and "P , Measuring probe, extended control word" for both sources. If the measuring probe evaluation (S ) is activated, the measuring probes 1 and 2 can be enabled/disabled separately: "S , Measuring probe 1 Enabling" or "S , Measuring probe 2 Enabling". The settings can be extended for one or the other measuring probe: Activation of a Range of Expected Values: The Range of Expected Values limits the position range of an axis or a shaft and indicates the range in which measuring probe signal edges trigger a measurement. For this, the start and end position of the respectively selected measuring probe are filed in the parameters "P , Start position measuring probe function 1 enabled" / "P , End position measuring probe function 1 enabled" or "P , Start position measuring probe function 2 enabled" / "P , End position measuring probe function 2 enabled". Marker error monitoring: Recording of marker failures with the Range of Expected Values being activated: If the actual position value is outside the range of expected values, measuring probe signal edges do not trigger a measurement! If no "marker" was detected after a complete run (exceeding of both position limits) which triggered a measurement, this status can be stored in the parameter "P , Measuring probe, number of marker failures" and be indicated. In the case of reccurence, the value of (P ) is incremented. Upon the registration of a measurement trigger within the "Range of Expected Values", the value in the parameter (P ) is deleted. 5.6 Virtual Axis - Context Menu : The "Range of Expected Values" cannot be used with the "Time measurement"! Further basic principles of the "Measuring Probe Function" are described for individual products in IndraMotion MLC - Further Documentations, page 14, / 10/, /11/ "Measuring Probe Function". The user is supported by the implemented online help Virtual Axis - Menu Items of the Context Menu The context menu of a virtual axis contains the following menu items:

160 150/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization Fig.5-100: Context menu of a virtual axis Virtual Axis - Context Menu, Initial Commissioning, page initial commissioning cycle Virtual Axis - Context Menu, Parameter Handling, Load Basic Parameters, page 151, Virtual Axis - Context Menu, Diagnosis, Status, page 151, Virtual Axis- Context Menu, Diagnostic, Clear Errors, page 152, Parameter Editor, page 314, Parameter Group, page 316, Delete - this menu item activates the deletion of the complete axis and all of its sub-folders. Rename - this menu point is only available in the offline mode. It activates the renaming of the axis. In addition to the axis name, the data transferred to the PLC are also changing. In this way, the PLC project may be destroyed. Properties - the dialog window displays the properties of the control which were entered at the point in time of its configuration (see Creation of a Virtual Axis (Virtual Master Axis), page 51) Virtual Axis - Context Menu, Initial Commissioning For the initial commissioning, the following dialog windows are processed. Dates changed during the processing in the dialog window are directly transferred to the control / drive, irrespective of the fact whether a subsequent date is still changed or whether the dialog window is quit with <Next> or <Cancel>. Virtual Axis - Context Menu, Parameter Handling, Load Basic Parameters, page 151, Virtual Axis - Dialog, Scaling/Measuring Units Settings, page 152, Virtual Axis - Dialog, Motion Limits, page 154, Virtual Axis - Dialog, Initial Values, page 155, Virtual Axis - Dialog, Status Messages Settings, page 154,

161 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 151/333 IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization Virtual Axis - Context Menu, Parameter Handling, Load Basic Parameters To load the basic parameters is the last way out to restore a drive's basic functions. Practically, the axis is removed and newly created. All A parameters in the control are set to their default values Virtual Axis - Context Menu, Diagnosis, Status In this dialog window, the status information concerning the respective axis are graphically prepared and displayed. In the given example, it is a virtual (master) axis which is followed by a real axis. The window is split, the upper half containing general information, whereas the lower half contains detailed additions. As regards the marking of the axis: "A , Logical axis number" "A , Axis designation", the name of the axis "A , Axis type" Bit 3 - real axis Bit 4 - virtual axis Bit 5 - encoder axis Bit 6 - link axis (external axis) "A , Axis diagnostic message" "A , Command: Clear all axis errors", deletes the axis errors (in the drive and) in the control Current values of the axis: "A , Actual position value" "A , Actual velocity value" "A , Actual acceleration value" Fig.5-101: Status of a virtual axis The detailed information is encoded as bit bars in the parameters

162 152/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization A , Axis status and A , Extended axis status The "Axis status" dialog can also be opened through a double click on the desired axis in the "Device status" of the control Virtual Axis- Context Menu, Diagnostic, Clear Errors 5.7 Virtual Axis - Dialogs The activation of this context menu item releases the "A , Command: Clear all axis erros" Virtual Axis - Overview of Dialogs and deletes the axis errors in the drive and in the control. When the folder of the virtual axis is opened, the individual dialogs of the axis - display of axis data and adjustment possibilities for parameters - are offered. First of all, it can be assumed that the presettings cover a wide range of applications and that a modification is only required in exceptional cases. Fig.5-102: Folder of a virtual axis The values in the dialogs are partly calculated from multiple parameters. If a clear assignment exists, this is indicated Virtual Axis - Dialog, Scaling/Measuring Units Settings The "Scaling/Measuring Unit Settings" dialog window derives the presettings for position and velocity data according to the same sample. Fig.5-103: Scaling/measuring units settings dialog The following parameters are evaluated:

163 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 153/333 IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization A , Scaling type for position data A , Scaling type for velocity data A , Scaling type for acceleration data A , Modulo value A , Slave drive feed travel The Scaling Type of the data determines in which format and which reference the data between the drive and the control or user interface are exchanged. Since the preference scaling for virtual axes is prescribed, the Scaling Factor and Scaling Exponent cannot be accessed. In the scaling type, one can choose between rotatory and translatory scaling (A , A , A bit 1..0); for the format of the position data, absolute or modulo values are available (A , bit 7). For the modulo format, a degree value is to be indicated "A , Modulo value". The scaling refers to the load side (A , A , A bit 6 each = TRUE). Detailed data are given in Virtual Axis - Dialog, Extended Scaling/ Measuring Units, page 153, Virtual Axis - Dialog, Extended Scaling/Measuring Units The dialog window supplements data to Virtual Axis - Dialog, Scaling/Measuring Units Settings, page 152, in more detail. Fig.5-104: Extended scaling/measuring units dialog The following parameters are evaluated: A , Scaling type for position data A , Scaling type for velocity data A , Scaling type for acceleration data A , Modulo value A , Slave drive feed travel Subject to the rule that the preference scaling has to be used, the data of the window are calculated for the position data on the basis the parameter "A , Scaling type for position data"

164 154/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization for the velocity data on the basis of the parameter "A , Scaling type for velocity data" for the acceleration data on the basis of the parameter "A , Scaling type for acceleration data" In case of the Modulo format, the values must be indicated in degrees "A , Modulo value". The scaling refers to the load side (A , A , A bit 6 each = TRUE) Virtual Axis - Dialog, Status Messages Settings The status messages for virtual axes are identical with those of the real axes. The dialog window evaluates the status of the axis (A ). The messages "A , Standstill (Bit 5)" "A , Actual velocity = velocity setpoint (Bit 4)" "A , In Position (Bit 6)" are dependent on whether the respective value is within its range. "A , Standstill Range" "A , Velocity Data Range" "A , Position Data Range" Fig.5-105: Virtual Axis - Dialog, Motion Limits Status messages settings dialog For the velocity setpoint zero, "A , Actual velocity value" is within the range defined by the "A , Standstill range". -> (A , Bit 5). For any velocity setpoint, "A , Actual velocity value" is in the range defined by the "A , Velocity data range". -> (A , Bit 4) For any position setpoint, "A , Actual position value" is within the range defined by "A , Position data range". -> (A , Bit 6) The dialog window gives an overview of preset limit values for the virtual axis.

165 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 155/333 IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization Fig.5-106: Motion limits The following parameters are evaluated: A , Position polarities (Bit 4) A , Positive position limit, A , Negative position limit A , Positive velocity limit, A , Negative velocity limit A , Bipolar acceleration limit A , Bipolar jerk limit The bit value of "A , Position polarities (Bit 4)" decides whether the position limit monitoring of the axis is active (bit 4 = TRUE) or not. If the position limit monitoring is active, "A , Actual position value" indicates the position of the axis and the adjustable "A , Positive position limit", "A , Negative position limit" show the admissible movement limits. Irrespective of the activation of the position limit monitoring, the other limits (A , A , A ) can either be accepted with their default setting or be changed user-specifically. Bipolar Limit means that the same value is effective in the positive as well as in the negative direction. If said limits are exceeded in either direction, a warning is output, see following table. < negative limit > positive limit Actual value E E Velocity Acceleration Fig.5-107: Virtual Axis - Dialog, Initial Values Warnings as a reaction to the execeeding of the limits The jerk limit does neither trigger a warning nor an error message, but it limits the respective actual values (for detailed information, see parameter description (A )). The dialog window displays the initial values that are used for the PLCopen blocks. Starting point is the status after a reboot:

166 156/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization Fig.5-108: Initial values after a reboot The following parameters are evaluated: A , Position setpoint A , Target position A , Velocity setpoint A , Acceleration setpoint A , Emergency stop deceleration A , Jerk A , Direction of travel The values of the parameters given in the parameter monitor come from their initialization during run-up. They are actually of no relevance, since no movement was made yet. The jerk value comes from "A , Bipolar jerk limit". It can be changed in the dialog. The values displayed are overwritten by the values which the respectively active PLCopen block brings along. Fig.5-109: Active PLCopen block: MC_MoveVelocity

167 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 157/333 IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization Fig.5-110: Setpoints on the basis of the block's initial values The velocity (500 min -1 ), acceleration (25 rad s -2 ) and deceleration (25 rad s -2 ) values have been accepted by the block. The previous position and distance values were kept. They would change e.g. with an active MC_MoveRelative Virtual Axis - Dialog, Electronic Motion Profile Virtual Axis - Dialog, Electronic Motion Profile, General If a virtual axis operates as a slave in the Motion Function block MB_Motion Profile, the drive runs in the operating mode "Electronic motion profile with real/ virtual master axis". In this operating mode, a given master axis position and a slave are firmly linked to each other. Master axes (masters) can be real, virtual, or encoder axes. On the basis of the virtual master axis position (actual position value, master), the effective master axis position (actual position value in the actual value cycle) is generated with "Master Axis Position Offset", "Gear" and "Dynamic Synchronization". Fig.5-111: Electronic motion profile dialog

168 158/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization Master Axis Position Offset - Electronic Motion Profile Gear Settings Angle Offset Begin of Table Dynamic Angle Offset Electronic Motion Profile - Download Dynamic Synchronization - Angle Synchronization Parameters used: A , Axis status A , Master axis, axis number A , Master axis, additive position setpoint A , Angle offset begin of table A , Slave axis, additive position setpoint A , Synchronous position setpoint A , Synchronous velocity A , ELS position setpoint, CAM A , Master, actual position value A , Master, actual velocity value A , Motion profile - basic configuration The Electronic Motion Profile dialog serves to display the master axis parameters, when the control is in the operating mode "Electronic motion profile with real/virtual master axis". The parameters can be influenced by the settings made in the PLC program for the MB_MotionProfile motion function block. Determination of the resulting master axis position on the basis of "A , Actual position value - master" and "A , Master axis, additive position setpoint" as well as "A , Additive master axis position, process controller". Definition of the gear transmission ratio of the master axis gear with "A , Input revolutions" and "A , Output revolutions" as well as gear fine adjustment and determination of "A , Effective master axis velocity". Definition of the angle offset with "A , Angle offset begin of table" and "A , Angle offset change rate" as well as "A , Angle offset begin of table, process controller". This functionality is currently not supported by the MLC. Selection and download of an Electronic Motion Profile created by means of the CamBuilder on the real axis. Definition of the "A , Synchronization mode", the "A , Synchronization velocity", the "A , Synchronization acceleration" as well as the "A , Synchronization direction", the "A , Slave axis, additive position setpoint" and the "A , Additive position setpoint, process controller". Virtual Axis - Dialog, Electronic Motion Profile, Master Axis Position Offset Determination of the resulting master axis position on the basis of "A , Actual position value - master" and "A , Master axis, additive position setpoint" as well as "A , Additive master axis position, process controller".

169 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 159/333 IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization Fig.5-112: Parameters used: Master axis position offset dialog in the electronic motion profile dialog A , Master, actual position value A , Master axis, additive position setpoint A , Additive master axis position, process controller A , Filter time constant, additive master axis position, process controller A , Resulting master axis position Virtual Axis - Dialog, Electronic Motion Profile, Gear Settings Definition of the gear transmission ratio of the master axis gear with "A , Input revolutions" and "A , Output revolutions" as well as gear fine adjustment and determination of "A , Effective master axis velocity". Fig.5-113: Gear settings dialog in the electronic motion profile dialog Parameters used: A , Resulting master axis position A , Master axis gear - output revolutions A , Master axis gear - input revolutions A , Gear transmission ratio fine adjustment A , Gear transmission ratio fine adjustment, process controller A , Polarity master axis position A , Effective master axis position A , Effective master axis position

170 160/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization Virtual Axis - Dialog, Electronic Motion Profile, Angle Offset Begin of Table Definition of the angle offset with "A , Angle offset begin of table" and "A , Angle offset change rate" as well as "A , Angle offset begin of table, process controller" and "A , Filter time constant, angle offset table, process controller". Fig.5-114: Parameters used: Cam - angle offset dialog in the electronic motion profile dialog A , Angle offset begin of table A , Angle offset change rate A , Angle offset begin of table, process controller A , Filter time constant, angle offset table, process controller Virtual Axis - Dialog, Electronic Motion Profile, Dynamic Angle Offset This functionality is currently not supported by the MLC. Virtual Axis - Dialog, Electronic Motion Profile, Cam Table Selection Selection and download of a motion profile created by means of the CamBuilder into the axis. For each axis, a maximum of two motion profiles can be stored. With the help of the dialog, it is also possible to get back electronic motion profiles into the CamBuilder that have alredy been stored on the axis. The selection of the motion profile to be processed is carried out on the MB_Motion Profile motion function block.

171 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 161/333 IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization Fig.5-115: Cam - download dialog in the electronic motion profile dialog Parameters used: A , Motion profile, master axis switch position A , Motion step 1, slave axes' initial position A , Motion profile, control word A , Motion profile, status word The axis parameters describing the motion profile 0: A , Number of motion steps, motion profile 0 A , Master axis velocity, motion profile 0 A , List of master axes' initial positions, motion profile 0 A , List of motion step modes, motion profile 0 A , List of strokes, motion profile 0 A , List of slave axes' velocities, motion profile 0 The axis parameters describing the motion profile 1: A , Number of motion steps, motion profile 1 A , Master axis velocity, motion profile 1 A , List of master axes' initial positions, motion profile 1 A , List of motion step modes, motion profile 1 A , List of strokes, motion profile 1 A , List of slave axes' velocities, motion profile 1

172 162/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization Virtual Axis - Dialog, Electronic Motion Profile, Dynamic Synchronization Definition of the "A , Synchronization mode", the "A , Synchronization velocity", the "A , Synchronization acceleration" as well as the "A , Synchronization direction", the "A , Additive position setpoint, slave axis" and the "A , Additive position setpoint, process controller". Fig.5-116: Parameters used: Dynamic synchronization dialog in the electronic motion profile dialog A , Synchronization mode A , Synchronization velocity A , Synchronization acceleration A , Synchronization direction A , Slave axis, additive position setpoint A , Additive position setpoint, process controller A , Filter time constant, additive position setpoint Virtual Axis - Dialog, Gear with Velocity Synchronization The parameterization of the gear with velocity synchronization is carried out by analogy with the real axis, see Real Axis (IndraDrive) - Dialog, Gear with Velocity Synchronization - General, page Virtual Axis - Dialog, Gear with Angle Synchronization 5.8 Encoder Axis - Context Menu The parameterization of the gear with angle synchronization is carried out by analogy with the real axis, see Real Axis (IndraDrive) - Dialog, Gear with Angle Synchronization - General, page Encoder Axis - Menu Items of the Context Menu The context menu of an encoder axis - in this example: EA1- contains the following menu items:

173 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 163/333 IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization Fig.5-117: Context menu of an encoder axis Encoder Axis - context menu, initial commissioning, page commissioning cycle of the encoder axis, Encoder Axis - Context Menu, Parameter Handling, Load Basic Parameters, page 164, Encoder Axis - Context Menu, Diagnostic, Status, page 164, Encoder Axis - Context Menu, Diagnostic, Clear Errors, page 165, Parameter Editor, page 314, Parameter Group, page 316, Delete - this menu item activates the deletion of the complete axis and all of its sub-folders. Rename - this menu point is only available in the offline mode. It activates the renaming of the axis. In addition to the axis name, the data transferred to the PLC are also changing. In this way, the PLC project may be destroyed. Disabling of an axis - encoder axis Properties - the dialog window shows the properties of the control which were entered at the point in time of its configuration (see Creation of an Encoder Axis (Real Master Axis), page 53). The disabling of the real axis, its drive, its electronics, results in the disabling of a real encoder axis, the encoder of which is connected to this electronics. The parameter allocations of the axes to be deactivated are offered for an export Encoder Axis - context menu, initial commissioning For the initial commissioning of an encoder axis, the following dialog windows are processed by a wizard: Encoder Axis - Context Menu, Parameter Handling, Load Basic Parameters, page 164, Configuration of the Measuring Encoder, page 56, Encoder Axis - Dialog, Axis Configuration, page 167, (encoder configuration).

174 164/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization Dates changed during the processing in the dialog window are directly transferred to the control / drive, irrespective of the fact whether a subsequent date is still changed or whether the dialog window is quit with <Next> or <Cancel> Encoder Axis - Context Menu, Parameter Handling, Load Basic Parameters To load the basic parameters is the last way out to restore a drive's / an axis' basic functions. Practically, the axis is removed and newly created. All parameters which lie directly in the axes (stored in the S and P parameters of the drive) are assigned default values and all other A parameters in the control are set to default values Encoder Axis - Context Menu, Diagnostic, Status With the dialog window, the status information concerning the respective axis are graphically prepared and displayed. In the given example, it is a real master axis (encoder axis) which is followed by a real axis. The window is split, the upper half containing general information, whereas the lower half contains detailed additions. As regards the marking of the axis: "A , Logical axis number" "A , Axis designation", the name of the axis "A , Axis type" Bit 3 - real axis Bit 4 - virtual axis Bit 5 - encoder axis Bit 6 - link axis (external axis) "A , Drive address", drive electronics, to which the encoder is connected. The "Drive status" button allows the switch-over to a window with data relevant for the drive electronics "A , Axis diagnostic message" "A , Command: Clear all axis errors", deletes the axis errors in the drive and in the control Current values of the axis: "A , Actual position value" "A , Actual velocity value"

175 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 165/333 IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization Fig.5-118: Axis status of an encoder axis The detailed information is encoded as bit bars in the parameters "A , Axis status" and "A , Extended axis status" The "Axis status" dialog can also be opened through a double click on the desired axis in the "Device status" of the control Encoder Axis - Context Menu, Diagnostic, Clear Errors 5.9 Encoder Axis - Dialogs The activation of this context menu item releases the "A , Command: Clear all axis erros" and deletes the axis errors in the drive and in the control Encoder Axis - Overview of Dialogs When the folder of the encoder axis is opened, the individual dialogs of the axis - display of axis data and adjustment possibilities for parameters - are offered. First of all, it can be assumed that the presettings cover a wide range of applications and that a modification is only required in exceptional cases. Fig.5-119: Folder of an encoder axis The values in the dialogs are partly calculated from multiple parameters. If a clear assignment exists, this is indicated.

176 166/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization Encoder Axis - Dialog, Scaling/Measuring Units Settings The "Scaling/Measuring Units Settings" dialog window derives the presettings for position, velocity and torque/force data according to the same sample. Fig.5-120: Scaling/measuring units settings dialog The following parameters are evaluated: A , Scaling type for position data A , Scaling type for velocity data A , Scaling type for acceleration data A , Modulo value A , Slave drive feed travel The Scaling type of the data determines in which format and which reference the data between the drive and the control or user interface are exchanged. Since the preference scaling for encoder axes is prescribed, the Scaling Factor and Scaling Exponent cannot be accessed. Furthermore, the rotatory scaling type (A , A , A bit 1..0 each ) is prescribed, as is the format of the modulo position data (A , Bit 7), 360 degrees, "A , Modulo value". The scaling refers to the load side (A , A , A bit 6 each = TRUE). Detailed data are given in Encoder Axis - Dialog, Extended Scaling/ Measuring Units, page 166, Encoder Axis - Dialog, Extended Scaling/Measuring Units The dialog window supplements data to Encoder Axis - Dialog, Scaling/Measuring Units Settings, page 166, in more detail.

177 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 167/333 IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization Fig.5-121: Extended scaling/measuring units dialog The following parameters are evaluated: A , Scaling type for position data A , Scaling type for velocity data A , Scaling type for acceleration data A , Modulo value A , Slave drive feed travel Subject to the rule that the preference scaling has to be used, the data of the window are calculated for the position data on the basis the parameter "A , Scaling type for position data" for the velocity data on the basis of the parameter "A , Scaling type for velocity data" for the acceleration data on the basis of the parameter "A , Scaling type for acceleration data" Moreover, the modulo format, 360 degrees, is defined "A , Modulo value". The scaling refers to the load side (A , A , A bit 6 each = TRUE) Encoder Axis - Dialog, Axis Configuration The configuration of the encoder axis is based upon the referenced encoder "P , Status of measuring encoder (Bit 0= 1)" (lower illustration, left corner):

178 168/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization Fig.5-122: Configuration of an encoder axis The following parameters are evaluated: A , Master axis encoder configuration A , Master axis encoder status A , Master axis encoder - input revolutions A , Master axis encoder - output revolutions A , Master axis encoder - filter type A , Master axis encoder - filter cutoff frequency A , Master axis encoder - reference position A , Command "Set Absolute Value" A , Master axis encoder - position offset P , Actual position value P , Actual velocity value of measuring encoder A , Actual position value A , Actual velocity value The parameters (P ) and (P ) display the essential data of the encoder. Then, the electronic measuring gear is set. Its transmission ratio results from the proportion of the "A , Master axis encoder - output revolutions" in comparison with "A , Master axis encoder - input revolutions", i.e. RatioNumerator / RatioDenominator. The adjustment range is between 65,535 : 1 and 1 : The position value after the measuring gear is increased by the "A , Master axis encoder - position offset" value. A filter appears, in which the user can select and configure data. Via "A , Master axis encoder - filter type", the following selection can be made: Value Filter type 0 Filter deactivated 1 40 ms average value filter

179 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 169/333 IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization Value Filter type 2 1st order lowpass filter 3 2nd order lowpass filter 4 2nd order Butterworth 5 2nd order lowpass filter with velocity pilot control (dead time compensation) 6 3rd order lowpass filter 7 3rd order lowpass filter with velocity and acceleration pilot control (dead time compensation) 8 3rd order Butterworth Fig.5-123: Filter type specification The "A , Master axis encoder - filter cutoff frequency" parameter for filing the filter cutoff frequency completes the component. It is also possible to integrate a dead time compensation. It is preset between 0 and 4 cycles in parameter "A , Master axis encoder configuration (Bit )". (Default value is two cycles.) In the end, the position value can be set to the reference position by means of the reference command ("A , Master axis encoder - reference position", "A , Command: Set Absolute Value", "A , Master axis encoder status"). The fact that the referencing was successful is indicated in "A , Master axis encoder status (Bit 0 = 1)". Like with the two other axis types (real and virtual axis), the actual values for the encoder axis can also be taken from the following parameters: "A , Actual position value" "A , Actual velocity value" 5.10 Link Axis - Context Menu Link Axis - Menu Items of the Context Menu The context menu of a link axis contains the following menu items: Fig.5-124: Context menu of a link axis Link Axis - Context Menu, Initial Commissioning, page commissioning cycle of a link axis, Link Axis - Context Menu, Parameter Handling, Load Basic Parameters, page 170, Link Axis - Context Menu, Diagnostic, Status, page 170, Link Axis - Context Menu, Diagnostic, Clear Errors, page 171,

180 170/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization Parameter Editor, page 314, Parameter Group, page 316, Delete - this menu item activates the deletion of the complete axis and all of its sub-folders. Rename - this menu point is only available in the offline mode. It activates the renaming of the axis. In addition to the axis name, the data transferred to the PLC are also changing. In this way, the PLC project may be destroyed. Properties - the dialog window shows the properties of the control which were entered at the point in time of its configuration (see Project Planning of the MLC Network, CrossComm (CFL01.1-Q2), in the MLC Project, page 218) Link Axis - Context Menu, Initial Commissioning For the initial commissioning of a link axis, the following dialog windows are processed by a wizard: Link Axis - Context Menu, Parameter Handling, Load Basic Parameters, page 170, Link Axis - Dialog, Scaling/Measuring Units Settings, page 172, Link Axis - Dialog, Extended Scaling/Measuring Units, page 173, Dates changed during the processing in the dialog window are directly transferred to the control / drive, irrespective of the fact whether a subsequent date is still changed or whether the dialog window is quit with <Next> or <Cancel> Link Axis - Context Menu, Parameter Handling, Load Basic Parameters To load the basic parameters is the last way out to restore a drive's / an axis' basic functions. Practically, the axis is removed and newly created. All parameters which lie directly in the axes (stored in the S and P parameters of the drive) as well as any other A parameters in the control are set to default values Link Axis - Context Menu, Diagnostic, Status In case of a link axis, this procedure refers only to the "dummy" axes of the individual control. The originals on the other link controls are not affected! In this dialog window, the status information concerning the respective axis are graphically prepared and displayed. In the given example, it is a link axis. The window is split, the upper half containing general information, whereas the lower half contains detailed additions.

181 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 171/333 IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization Fig.5-125: Axis status of a link axis As regards the marking of the axis: "A , Logical axis number" "A , Axis designation", the name of the axis "A , Axis type" Bit 3 - real axis (IndraDrive or HNC device) Bit 4 - virtual axis Bit 5 - encoder axis Bit 6 - link axis (external axis) "A , Link axis - master axis selection" indicates, for the current "dummy" axis, the number of the MLC and the axis (A/B) designated for the transfer "A , Axis diagnostic message" "A , Command: Clear all axis errors", deletes the axis errors in the drive and in the control Current values of the axis: "A , Actual position value" "A , Actual velocity value" The detailed information is encoded as bit bars in the parameters "A , Axis status" and "A , Extended axis status" The "Axis status" dialog can also be opened through a double click on the desired axis in the "Device status" of the control Link Axis - Context Menu, Diagnostic, Clear Errors The activation of this context menu item releases the "A , Command: Clear all axis erros" and deletes the axis errors in the drive and in the control.

182 172/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization 5.11 Link Axis - Dialogs Link Axis - Overview of Dialogs When the folder of the link axis is opened, the individual dialogs of the axis - display of axis data and adjustment possibilities for parameters - are offered. First of all, it can be assumed that the presettings cover a wide range of applications and that a modification is only required in exceptional cases. Fig.5-126: Folder of a link axis The values in the dialogs are partly calculated from multiple parameters. If a clear assignment exists, this is indicated Link Axis - Dialog, Scaling/Measuring Units Settings The "Scaling/Measuring Units Settings" dialog window derives the presettings for position, velocity and torque/force data according to the same sample. Fig.5-127: Scaling/measuring units settings dialog The following parameters are evaluated: A , Scaling type for position data A , Scaling type for velocity data A , Scaling type for acceleration data A , Modulo value A , Slave drive feed travel The Scaling type of the data determines in which format and which reference the data between the drive and the control or user interface are exchanged. Since the preference scaling for link axes is prescribed, the Scaling Factor and Scaling Exponent cannot be accessed. Furthermore, the rotatory scaling type (A , A , A bit 1..0 each ) is prescribed, as is the format of the modulo position data (A , Bit 7), 360 degrees, "A , Modulo value". The scaling refers to the load side (A , A , A bit 6 each = TRUE). Detailed data are given in Link Axis - Dialog, Extended Scaling/Measuring Units, page 173,.

183 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 173/333 IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization Link Axis - Dialog, Extended Scaling/Measuring Units The dialog window supplements data to Link Axis - Dialog, Scaling/Measuring Units Settings, page 172, in more detail. Fig.5-128: Extended scaling/measuring units dialog The following parameters are evaluated: A , Scaling type for position data A , Scaling type for velocity data A , Scaling type for acceleration data A , Modulo value A , Slave drive feed travel Link Axis - Dialog, Axis Configuration Subject to the rule that the preference scaling has to be used, the data of the window are calculated for the position data on the basis the parameter "A , Scaling type for position data" for the velocity data on the basis of the parameter "A , Scaling type for velocity data" for the acceleration data on the basis of the parameter "A , Scaling type for acceleration data" Moreover, the modulo format, 360 degrees, is defined "A , Modulo value". The scaling refers to the load side (A , A , A bit 6 each = TRUE). The configuration of the link axis is realized via the following dialog.

184 174/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization Fig.5-129: Configuration of a link axis The following parameters are evaluated: A , Master axis encoder status A , Master axis encoder - input revolutions A , Master axis encoder - output revolutions A , Master axis encoder - filter type A , Master axis encoder - filter cutoff frequency A , Master axis encoder - reference position A , Command "Set Absolute Value" A , Master axis encoder - position offset A , Actual position value A , Actual velocity value The gear transmission ratio of the electronic measuring gear results from the proportion "A , Master axis encoder - output revolutions" in comparison to "A , Master axis encoder - input revolutions", i.e. RatioNumerator / RatioDenominator. The adjustment range is between 65,535 : 1 and 1 : The position value after the measuring gear is increased by the "A , Master axis encoder - position offset" value. A filter appears, in which the user can select and configure data. Via "A , Master axis encoder - filter type", the following selection can be made: Value Filter type 0 Filter deactivated 1 40 ms average value filter 2 1st order lowpass filter 3 2nd order lowpass filter 4 2nd order Butterworth 5 2nd order lowpass filter with velocity pilot control (dead time compensation)

185 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 175/333 IndraMotion MLC - Context Menus and Dialogs in the Online Mode and for the Offline Parameterization Value Filter type 6 3rd order lowpass filter 7 3rd order lowpass filter with velocity and acceleration pilot control (dead time compensation) 8 3rd order Butterworth Fig.5-130: Filter type specification The "A , Master axis encoder - filter cutoff frequency" parameter for filing the filter cutoff frequency completes the component. In the end, the position value can be set to the reference position by means of the reference command ("A , Master axis encoder - reference position", "A , Command: Set Absolute Value", "A , Master axis encoder status"). The fact that the referencing was successful is indicated in "A , Master axis encoder status (Bit 0 = 1)". Like with the other axis types (encoder axis, real axis and virtual axis), the actual values for the link axis can also be taken from the following parameters: "A , Actual position value" "A , Actual velocity value"

186 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description

187 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives 6 Function Modules (Additional Components) 6.1 General In order to extend the MLC functionality, up to four function modules can be connected to the function module bus (FB) on the MLC's left side. The function modules currently available for the MLC as well as their function and project planning are described hereinafter. 6.2 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.6-1: For Details, See Use of function modules SERCOS III (CFL01.1-R3), Control Communication, page 178, SERCOS II (CFL01.1-Q2), Control Communication, page 181, SERCOS III C2C (CFL01.1-R3), MLC Cross-Communication, SERCOS III, page 188, CrossComm (CFL01.1-Q2), MLC Cross-Communication, SERCOS II, page 213, The following configurations are available: Bosch Rexroth AG 177/333 Function Modules (Additional Components) 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.

188 178/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description Function Modules (Additional Components) L65 As of MLC 04VR S Control comm. Cross-comm. Fig.6-2: 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 6.3 SERCOS III (CFL01.1-R3), Control Communication 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.

189 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 179/333 Function Modules (Additional Components) Options of Configuration Fig.6-3: 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: L40 L65 with MLC 04VRS MC CC Fig.6-4: 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).

190 180/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description Function Modules (Additional Components) Fig.6-5: 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 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: 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.6-6: 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...

191 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 181/333 Function Modules (Additional Components) Fig.6-7: Dragging of the module...and "let it drop" between Profibus and SERCOS. Fig.6-8: Insertion of the module These settings can only be made in the offline mode. The SERCOS III function module is thus integrated in the MLC project. Fig.6-9: 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. 6.4 SERCOS II (CFL01.1-Q2), Control Communication 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.

192 182/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description Function Modules (Additional Components) Ring 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. The SERCOS II drives are to be connected to the primary ring of the function module via fiber optic cables 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.6-10: 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: 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

193 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 183/333 Function Modules (Additional Components) L65 with MLC 04VRS MC CC Fig.6-11: 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.6-12: 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) 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.

194 184/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description Function Modules (Additional Components) Fig.6-13: 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.6-14: Dragging of the module...and "let it drop" on the MLC. Fig.6-15: 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.

195 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 185/333 Function Modules (Additional Components) Fig.6-16: SERCOS II function module prepared for configuration A SERCOS II drive is to be dragged onto the SERCOS folder and to be dropped there. 6.5 SERCOS III C2C (CFL01.1-R3) and CrossComm (CFL01.1- Q2), MLC Cross-Communication 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 185, 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 213 Page 188 Project planning in IW Page 218 Page 193 Parameter Page 229 Page 202 Diagnostics Page 229 Page 203 PLC support Page 230 Page 205 Redundancy and error tolerance Page 235 Page 209 Configuration examples Page 239 Page 210 Fig.6-17: MLC-Link - Structuring Examples Several Master Axes Guide for both forms of realization 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: 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.

196 186/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description Function Modules (Additional Components) Fig.6-18: Print machine with 2 master axes for the production - section-oriented topology Fig.6-19: Print machine with 7 master axes and 2 production master axes - section-oriented topology

197 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 187/333 Function Modules (Additional Components) Modular Configuration Fig.6-20: 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.6-21: 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.

198 188/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description Function Modules (Additional Components) Fig.6-22: Example for the configuration at high system load 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:

199 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 189/333 Function Modules (Additional Components) Fig.6-23: 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.6-24: 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.

200 190/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description Function Modules (Additional Components) 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. Front View 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) 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.6-25: 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:

201 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 191/333 Function Modules (Additional Components) L40 L65 with MLC 04VRS MC CC Fig.6-26: 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.6-27: Addressing of function modules on an IndraControl Identification of the Hardware by the Firmware Connection Displays Line 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. In case of a line,, the MLCs involved are to be interconnected. The direction can bei top-top or bottom-bottom or top-bottom...

202 192/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description Function Modules (Additional Components) Ring Fig.6-28: Line, wiring example The line shown above can be converted into a ring, if the missing connection is added. Fig.6-29: Ring, wiring example

203 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 193/333 Function Modules (Additional Components) 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.6-30: 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.6-31: Dragging of the module...and "let it drop" between Profibus and SERCOS.

204 194/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description Function Modules (Additional Components) Fig.6-32: 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.6-33: 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.

205 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 195/333 Function Modules (Additional Components) Fig.6-34: 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.

206 196/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description Function Modules (Additional Components) 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:

207 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 197/333 Function Modules (Additional Components) Ring cycle time Admissible control addresses Maximum number of network slaves 2 ms ms ms Fig.6-35: 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.6-36: 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.

208 198/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description Function Modules (Additional Components) 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 195,, 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.6-37: 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.

209 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 199/333 Function Modules (Additional Components) 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.6-38: 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.6-39: Adding a link axis to the project

210 200/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description Function Modules (Additional Components) Fig.6-40: Selection of an external MLC's axis as link axis 1 Fig.6-41: 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:

211 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 201/333 Function Modules (Additional Components) 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.6-42: 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 194, and Configuration of the Link Axes, SERCOS III (CFL01.1- R3), page 197,. 3. Online Determination of Slave Settings For the configuration of the network slaves, the button is used. A new dialog is opened:

212 202/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description Function Modules (Additional Components) Fig.6-43: 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 195) 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

213 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 203/333 Function Modules (Additional Components) 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.6-44: 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 206) 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 F , C2C error command S , preparation for switch-over to P3

214 204/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description Function Modules (Additional Components) Diagnostic 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 F , C2C parameter S-0-xxxx not writable

215 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 205/333 Function Modules (Additional Components) Diagnostic 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.6-45: 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.6-46: 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 208). 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.

216 206/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description Function Modules (Additional Components) 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, 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 arlinksyncbits_i[3].wsync_i.isyncbit0 Status Network SYNC1 input, participant 3 arlinksyncbits_i[3].wsync_i.isyncbit0 Status Network SYNC2 input, participant 3

217 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 207/333 Function Modules (Additional Components) 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 Port 1 Error Port 2 Network Redundancy Loss Fig.6-47: 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 208). Access to the binary states in the MLC network

218 208/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description Function Modules (Additional Components) ControlData Dialog MLC Network - Status - SERCOS III C2C (CFL01.1-R3) 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.6-48: 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.6-49: 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:

219 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 209/333 Function Modules (Additional Components) 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.6-50: 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, 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.

220 210/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description Function Modules (Additional Components) 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 206. 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). Fig.6-51: Configuration example for a modular construction

221 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 211/333 Function Modules (Additional Components) Line Configuration Configuration of the Network Participants 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) Network master (MLC 2) Network slave 1 (MLC 1) Network slave 2 (MLC 3) Master Axis Allocation Rotatory Printing with Web Guide Roller 1 Fig.6-52: 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) 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. Fig.6-53: Configuration example for the master axis network production 1

222 212/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description Function Modules (Additional Components) Ring Configuration Configuration of the Network Participants 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 Folder B Fig.6-54: 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. 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.

223 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 213/333 Function Modules (Additional Components) Configuration of the Network Participants Master Axis Allocation Fig.6-55: 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" 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

224 214/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description Function Modules (Additional Components) 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.6-56: 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 Front View The MLC network can be closed either with a single or with a double fiber optic cable ring. The double ring offers 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) On the basis of the front view of the CrossCom function module, the configuration of a single ring and a double ring is indicated.

225 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 215/333 Function Modules (Additional Components) Options of Configuration Fig.6-57: 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 L65 with MLC 04VRS MC CC Fig.6-58: 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).

226 216/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description Function Modules (Additional Components) Fig.6-59: 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 Connection Displays Distortion Displays FOC Ports Single Ring: Primary Ring 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). 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.

227 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 217/333 Function Modules (Additional Components) Primary Ring, Secondary Ring Fig.6-60: FOC ports in the single ring Normally, the primary ring is used for the communication. The secondary ring serves to transmit redundancy signals. Fig.6-61: FOC ports in the double ring

228 218/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description Function Modules (Additional Components) The secondary ring must be connected in the opposite direction - as shown above. Optical Adjustment of the Ring(s), CrossComm (CFL01.1-Q2) According to the length of an fiber optic cable in the network, it might be necessary to adapt the optical transmitting power. Optical Transmitting Power - Single Ring Optical Transmitting Power - Double Ring Fig.6-62: 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 2. 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.

229 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 219/333 Function Modules (Additional Components) Fig.6-63: 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.6-64: Dragging of the module

230 220/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description Function Modules (Additional Components)...and "let it drop" between Profibus and SERCOS. Fig.6-65: 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.6-66: 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.

231 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 221/333 Function Modules (Additional Components) This procedure is used accordingly for further network participants. Participation in the MLC Network Identifier of the Network Control Address Fig.6-67: 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

232 222/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description Function Modules (Additional Components) 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.6-68: 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.

233 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 223/333 Function Modules (Additional Components) 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.6-69: 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 221,, 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.

234 224/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description Function Modules (Additional Components) Fig.6-70: 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.6-71: Dead time compensation in dependence upon the cascading depth

235 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 225/333 Function Modules (Additional Components) 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.6-72: Adding a link axis to the project

236 226/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description Function Modules (Additional Components) Fig.6-73: Selection of an external MLC's axis as link axis 1 Fig.6-74: Selection of an external MLC's axis as a link axis 2

237 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 227/333 Function Modules (Additional Components) 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.6-75: 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.

238 228/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description Function Modules (Additional Components) 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 220, and Configuration of the Link Axes, CrossComm (CFL01.1-Q2), page 223,. 3. Online Determination of Slave Settings For the configuration of the network slaves, the button is used. A new dialog is opened: Fig.6-76: 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 221) 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)

239 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 229/333 Function Modules (Additional Components) link axes on the consumer's side (local link axes) 5. Acceptance of Settings Parameters for the MLC Network, CrossComm (CFL01.1-Q2) The MLC is switched from the parameterization to the operating mode. Only thus do the configured network settings become effective in the MLC. 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.6-77: 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 231) 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

240 230/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description Function Modules (Additional Components) Diagnostic F , Network ring - master axis position incorrect MDT F , Network ring - master axis position incorrect AT Fig.6-78: 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 215). 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.6-79: 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 234). 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.

241 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 231/333 Function Modules (Additional Components) 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

242 232/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description Function Modules (Additional Components) 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.6-80: 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 234).

243 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 233/333 Function Modules (Additional Components) 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.6-81: 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"):

244 234/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description Function Modules (Additional Components) Fig.6-82: 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:

245 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 235/333 Function Modules (Additional Components) 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.6-83: 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 Error-Free Case MLC Network, CrossComm (CFL01.1-Q2), Double Ring, Error-Free 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.

246 236/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description Function Modules (Additional Components) Fig.6-84: 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 236, MLC Network, CrossComm (CFL01.1-Q2), FOC Break in Secondary Ring (Single Error), page 237, MLC Network, CrossComm (CFL01.1-Q2), FOC Break in Primary and Secondary Ring Between Two Neighbored Network Participants (Double Error), page 238, 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:

247 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 237/333 Function Modules (Additional Components) Reconfiguration Diagnostic Fig.6-85: 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.6-86: 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

248 238/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description Function Modules (Additional Components) Diagnostic ring. The secondary ring is disconnected and is omitted as a redundant system. The data are continued to be transferred via the primary ring. 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.6-87: 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.

249 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 239/333 Function Modules (Additional Components) The dynamic reconfiguration is released via the PLC through setting the binary input in the bit string ControlData.wLinkSyncBits_q (bit LINK_REBUILD_RING). 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 Fig.6-88: 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 ".

250 240/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description Function Modules (Additional Components) Configuration of the Network Participants 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: single ring) Network master (MLC 2) Network slave 1 (MLC 1) Network slave 2 (MLC 3) Master Axis Allocation Rotatory Printing with Web Guide Roller 1 Fig.6-89: 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) 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 Fig.6-90: 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".

251 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 241/333 Function Modules (Additional Components) Configuration of the Network Participants 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: 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.6-91: 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.

252 242/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description Function Modules (Additional Components) Configuration of the Network Participants Master Axis Allocation Fig.6-92: 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". 6.6 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

253 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 243/333 Function Modules (Additional Components) 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.6-93: 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. Fig.6-94: Addressing of function modules on an IndraControl

254 244/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description Function Modules (Additional Components) 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.6-95: 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... Fig.6-96: Drag the module...and "drop" it between Profibus and SERCOS or on the MLC self. Fig.6-97: Insertion of the module

255 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 245/333 Function Modules (Additional Components) 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 Battery Battery Buffering Battery Monitoring Battery Exchange Fig.6-98: 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. 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. 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". 6.7 PLS (CFL01.1-N1) - Camshaft Gear PLS (CFL01.1-N1) Function Module - General To avoid data loss with the exchange of the battery, the device must be switched on. 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

256 246/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description Function Modules (Additional Components) Fig.6-99: 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 Fig.6-100: 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.

257 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 247/333 Function Modules (Additional Components) Operating Principle of the Hardware-Based PLS Axis // Cam Disk // Output Cam Disk's Operating Modes 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 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).

258 248/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description Function Modules (Additional Components) Fig.6-101: 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). 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.

259 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 249/333 Function Modules (Additional Components) Register Force Source Output Fig.6-102: 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 Addressing of the PLS Function Module (CFL01.1-N1) Front View In the following, the front view of the function module is shown. Connection of the Function Module to the MLC Fig.6-103: 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

260 250/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description Function Modules (Additional Components) PLS Addressing of the Function Modules 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.6-104: Example for address assignment Fig.6-105: Addressing of function modules on an IndraControl Identification of the Hardware by the Firmware External Power Supply 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, provided it was configured. Every PLS function module must also be supplied via its X1S connector 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 252, (properties of the cam disks including the axis assignment for all cam disks), Configuration of a Camshaft Gear (Detail View Dialog), page 254, (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 254 overview of reference axes, cannot be edited,

261 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 251/333 Function Modules (Additional Components) 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 255, 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: 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.6-106: 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.6-107: Dragging of the module...and "let it drop" between Profibus and SERCOS or on the MLC itself.

262 252/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description Function Modules (Additional Components) Fig.6-108: 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. Deletion of a PLS Module Fig.6-109: 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.6-110: Overall overview of the PLS camshaft gear

263 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 253/333 Function Modules (Additional Components) 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. 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.6-111: PLS parameters

264 254/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description Function Modules (Additional Components) Configuration of a Camshaft Gear (Detail View Dialog) Parameters Used Fig.6-112: 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 253, 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.6-113: 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.

265 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 255/333 Function Modules (Additional Components) 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.6-114: 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.

266 256/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description Function Modules (Additional Components) Parameterization Enabling / Disabling 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 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 --- *) Output_0_i : BYTE; (* physical output 'X201' *)

267 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 257/333 Function Modules (Additional Components) 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.). 6.8 Fast I/O Function Module CFL01.1-E Hardware Description Connection of the Function Module to the MLC The following applies: 1. module (nearest to the MLC): address 1; 2nd module: address 2 etc. (DIP switch S1 on the module). Fig.6-115: Addressing of function modules on an IndraControl The MLC must be disconnected from the power supply, before a function module can be attached.

268 258/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description Function Modules (Additional Components) Properties A B C D E F G Fig.6-116: 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)

269 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 259/333 Function Modules (Additional Components) 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.6-117: Input and output plugs X2I1, X2D2 and X2O1 Feed plug X1S port 24 V (+) S (sensor supply) GND ( ) FE Fig.6-118: 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.6-119: 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

270 260/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description Function Modules (Additional Components) Fig.6-120: Wiring the assembly

271 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 261/333 Function Modules (Additional Components) 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.6-121: 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

272 262/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description Function Modules (Additional Components) 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.6-122: 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.

273 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 263/333 Function Modules (Additional Components) 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.6-123: 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 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.

274 264/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description Function Modules (Additional Components) Fig.6-124: 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)...

275 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 265/333 Function Modules (Additional Components) Fig.6-125: Dragging of the module...and "let it drop" on the MLC.

276 266/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description Function Modules (Additional Components) Fig.6-126: Insertion of a Fast I/O module The Fast I/O function module is thus integrated in the MLC project. Fig.6-127: Fast I/O function module integrated in the MLC project These settings can only be made in the offline mode. Configuration of Fast IO 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.

277 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 267/333 Function Modules (Additional Components) Fig.6-128: 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. 6.9 DeviceNet Master Function Module CFL01.1-V Hardware Description Connection of the Function Module to the MLC The following applies: 1. module (nearest to the MLC): address 1; 2nd module: address 2 etc. (DIP switch S1 on the module). Fig.6-129: Addressing of function modules on an IndraControl

278 268/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description Function Modules (Additional Components) The MLC must be disconnected from the power supply, before a function module can be attached. A B C D E Fig.6-130: S1, Switch for slot number Stat, Function module status indication MNS, Module/Network status X7D, DeviceNet plug Mounting rail locking DeviceNet master module

279 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 269/333 Function Modules (Additional Components) X7D DeviceNet Interface Pin Meaning 1 V 2 CAN_L 3 Shield 4 CAN_H 5 V + Fig.6-131: 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.6-132: Meaning of light-emitting diodes on the DeviceNet master function module

280 270/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description Function Modules (Additional Components) 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.6-133: 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)...

281 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 271/333 Function Modules (Additional Components) Fig.6-134: Dragging of the module...and "let it drop" on the MLC.

282 272/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description Function Modules (Additional Components) Fig.6-135: Insertion of DeviceNet master module The DeviceNet master function module is thus integrated in the MLC project. Fig.6-136: DeviceNet master 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 "DeviceNet/M" object in the Project Explorer. Thus, a window opens in the working area.

283 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 273/333 Function Modules (Additional Components) CAUTION Master Settings "Parameter" Register Fig.6-137: "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: , ,

284 274/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description Function Modules (Additional Components) 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 274. 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.6-138: 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.

285 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 275/333 Function Modules (Additional Components) Configuration of DeviceNet Slaves General 1 2 Fig.6-139: 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.

286 276/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description Function Modules (Additional Components) "Slave Settings" Fig.6-140: 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 275. 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).

287 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 277/333 Function Modules (Additional Components) "I/O Settings" Register "Parameter" Register 1 2 Fig.6-141: 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.

288 278/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description Function Modules (Additional Components) Fig.6-142: 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 278. 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.

289 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 279/333 Function Modules (Additional Components) 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.6-143: 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.6-144: 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 280.

290 280/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description Function Modules (Additional Components) Fig.6-145: 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.6-146: 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).

291 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 281/333 Function Modules (Additional Components) 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.6-147: 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.6-148: 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.

292 282/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description Function Modules (Additional Components) General Data "I/O Addresses" Register Fig.6-149: 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.

293 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 283/333 Function Modules (Additional Components) "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 283 to fig ""I/O Connection Configuration" register for the I/O connection type "Bit Strobe"" on page 285. 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.6-150: "I/O Connection Configuration" register for the I/O connection type "Poll"

294 284/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description Function Modules (Additional Components) Fig.6-151: "I/O Connection Configuration" register for the I/O connection type "Change of State" Fig.6-152: "I/O Connection Configuration" register for the I/O connection type "Cyclic"

295 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 285/333 Function Modules (Additional Components) Fig.6-153: "I/O Connection Configuration" register for the I/O connection type "Bit Strobe" 6.10 Profibus-DP Master Function Module CFL01.1-P Hardware Description Connection of the Function Module to the MLC The following applies: 1. module (nearest to the MLC): address 1; 2nd module: address 2 etc. (DIP switch S1 on the module). Fig.6-154: Addressing of function modules on an IndraControl The MLC must be disconnected from the power supply, before a function module can be attached.

296 286/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description Function Modules (Additional Components) Fig.6-155: 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.

297 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 287/333 Function Modules (Additional Components) 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.6-156: 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.6-157: Meaning of light-emitting diodes on the DP-Master function module

298 288/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description Function Modules (Additional Components) 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.6-158: Error message, if a Profibus master module is created from the library, although the onboard interface was configured as master (default) 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.

299 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 289/333 Function Modules (Additional Components) Fig.6-159: 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)...

300 290/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description Function Modules (Additional Components) Fig.6-160: Dragging of the module...and "let it drop" on the MLC.

301 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 291/333 Function Modules (Additional Components) Fig.6-161: Insertion of a Profibus/M module The Profibus/M function module is thus integrated in the MLC project. Fig.6-162: Profibus/M 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 "Profibus/M" object in the Project Explorer. Thus, a window opens in the working area.

302 292/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description Function Modules (Additional Components) Master Settings Fig.6-163: "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!

303 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 293/333 Function Modules (Additional Components) "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.

304 294/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description Function Modules (Additional Components) Fig.6-164: "Profibus/M" window, "Groups" register In order to allocate slaves to a certain group, see "Group Allocation Register" on page 300. "Parameter" Register Insertion of Profibus DP Slaves 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. Display and processing of any available, manufacturer-specific bus master parameters. 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.

305 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 295/333 Function Modules (Additional Components) Fig.6-165: Configuration of Profibus DP Slaves Inserting a Profibus DP slave via the context menu of the "Profibus/M (COM-DPM)" object 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 "Insertion of Modules in Profibus DP Slave " on page 301.

306 296/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description Function Modules (Additional Components) Fig.6-166: 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):

307 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 297/333 Function Modules (Additional Components) "Slave Settings" Fig.6-167: 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).

308 298/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description Function Modules (Additional Components) "I/O Settings" Register 1 2 Fig.6-168: 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 296. "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:

309 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 299/333 Function Modules (Additional Components) 1 2 Fig.6-169: 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:

310 300/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description Function Modules (Additional Components) "Group Allocation " Register Fig.6-170: 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 294. 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.

311 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 301/333 Function Modules (Additional Components) Fig.6-171: Group allocation of a Profibus DP slave (example) Insertion of Modules in Profibus DP Slave Modules can only be inserted in case of modularly structured Profibus DP slaves, see chapter "Configuration of Profibus DP Slaves " on page 295. 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 302. Here, the new module is inserted as last module below the slave.

312 302/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description Function Modules (Additional Components) Fig.6-172: Adding a module Configuration of Modules of a Profibus DP Slave Fig.6-173: 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.

313 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 303/333 Function Modules (Additional Components) "Module Information" "I/O Addresses" Register Fig.6-174: 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.

314 304/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description Function Modules (Additional Components) "I/O Settings" Register "Manufacturer-specific Data" Register 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. "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. Display and processing of available, manufacturer-specific module parameters. If in the GSD file, "Manufacturer-specific Data" exist for the module, these are indicated. Further information on "Manufacturer-specific Data" are given in section "Manufacturer-Specific Data Register" on page 298.

315 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 305/333 IndraMotion MLC - Tools and Frequently Required Sequences 7 IndraMotion MLC - Tools and Frequently Required Sequences 7.1 MLC Icon Bar The MLC icon bar is tailored to the needs of the MLC user. It contains all essential information for a control. Fig.7-1: MLC icon bar (1) IP address of the control (2a) / (2b) switch-over of the motion control between "P2 -Parameterization mode"and"bb - Operating mode" (here: operating mode is active). (3a) / (3b) switch-over of the PLC between RUN - Green and STOP - Red (here: RUN is active). Red (3b) is also sensitive in the offline mode. It sets the PLC into the Stop status without opening IndraLogic. If axes are enabled, a warning is output concerning their forced halt! (4) at least one axis is active. A double click on the icon opens the window "Device status" (MLC Control - Context Menu, Diagnostic, Device Status, page 71). Here, the list with all available axes is given. (5) at least one active warning exists. A double click on the icon opens the window "Error/Diagnostic Memory" (MLC Control - Context Menu, Diagnostic, Error/Diagnostic Memory, page 74). Here, the extract of the control's logbook including the last diagnostics can be consulted. (6) at least one active error exists. A double click on the icon opens the window "Error/Diagnostic Memory" (MLC Control - Context Menu, Diagnostic, Error/Diagnostic Memory, page 74). Here, the extract of the control's logbook including the last diagnostics can be consulted. (7) Clear Error, pressing this button releases the "C , Command: Clear all Control Errors". The "Adapt" dialog offers the possibility to change the menu and icon bars according to your wishes. You can access it via Extras Adapt. 7.2 Parameter Handling - Exporting The user has the possibility to change the preset values via the the dialog windows of the control, the axes and, if required, the drives. Therefore, it is necessary to file these changed values as a file (export) and to read them in again from the file into the control or the drives, respectively, after a firmware was updated (Parameter Handling - Importing, page 312). In the "Offline Parameterization" mode, the parameters of the selected offline server (MLC, drives) - i.e. the offline parameters of the project - are transferred to the xxx.par file.

316 306/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description IndraMotion MLC - Tools and Frequently Required Sequences In the "Online" mode, the parameters of the selected real devices (MLC, drives) are transferred to the xxx.par file. The target of the xxx.par files can be freely chosen. If the project directory is chosen, the xxx.par file is automatically included in the archives. Parameters for the MLC (C parameters), every axis (A parameters) and every drive (S and P parameters) can be selected in groups (see figure). Fig.7-2: Parameter export, selection of parameters Quick Store means that only the name and the value of the parameter as well as a place holder for the min/max value and the measuring unit are filed. "Parameters required for Restitution" saves the parameters which can be written on the appropriate object again. "Save all Parameters" files the complete data record of the object, including the parameters which cannot be written again, e.g. actual values. Controls file C parameters, real/virtual/encoder/link axes file A parameters and IndraDrive and HNC drives file S and P parameters. If an axis / drive is disabled, only the A parameters duplicated on the control can be exported (see Fig., Hnc1). The export process can, particularly in the second case, take about one or several minutes. For this, the result is collected parameter by parameter and filed as a readable (editable) file (xxx.par). The following A parameters are determined in accordance with the axis type: Ident. No. Parameter name IDR HNC VA EA LA A Axis identifier x x x x x A A A A Axis configuration IDN list of the A checksum parameters Travel range limit switch Position polarities x x x x x x x x x x x x x

317 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 307/333 IndraMotion MLC - Tools and Frequently Required Sequences Ident. No. A A A A A Parameter name Positive position limit Negative position limit Positive velocity limit Negative velocity limit Bipolar acceleration limit IDR HNC VA EA LA x x x x x x x x x x x x x x x A Bipolar jerk limit x x x A Bipolar torque/ force limit x x A Modulo value x x x x A A A A A A A A A A A A Slave drive feed travel Scaling type for torque/force data Scaling factor for torque/force data Scaling exponent for torque/ force data Scaling type for acceleration data Scaling factor for acceleration data Scaling exponent for acceleration data Scaling type for velocity data Scaling factor for velocity data Scaling exponent for velocity data Scaling type for position data Scaling factor for translatory position data x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x

318 308/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description IndraMotion MLC - Tools and Frequently Required Sequences Ident. No. A A A A A Parameter name Scaling exponent for translatory position data Rotational position resolution Scaling type for temperature data Master axis' default address Direction of travel IDR HNC VA EA LA x x x x x x x x x x A Jerk x x x A Positioning window for shortest way x x A Standstill range x x x x x A A A A A A A A A A Velocity data range Emergency halt deceleration Configuration of user-defined setpoint A Configuration of user-defined setpoint B Configuration of user-defined setpoint C Configuration of user-defined setpoint D Configuration of user-defined actual value A Configuration of user-defined actual value B Configuration of user-defined actual value C Configuration of user-defined actual value D x x x x x x x x x x x x x x x x x x x x x x

319 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 309/333 IndraMotion MLC - Tools and Frequently Required Sequences Ident. No. A A A A A A A A A A A A A Parameter name Configuration of user-defined setpoint bit A Configuration of user-defined setpoint bit number A Configuration of user-defined setpoint bit B Configuration of user defined setpoint bit number B Configuration of user-defined setpoint bit C Configuration of user-defined setpoint bit number C Configuration of user-defined setpoint bit D Configuration of user-defined setpoint bit number D Configuration of user-defined actual value bit A Configuration of user-defined actual value bit number A Configuration of user-defined actual value bit B Configuration of user-defined actual value bit number B Configuration of user-defined actual value bit C IDR HNC VA EA LA x x x x x x x x x x x x x x x x x x x x x x x x x x

320 310/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description IndraMotion MLC - Tools and Frequently Required Sequences Ident. No. A A A A A A A A A A A A A Parameter name Configuration of user-defined actual value bit number C Configuration of user-defined actual value bit D Configuration of user-defined actual value bit number D Position synchronization window Velocity synchronization window Master, additive position setpoint Synchronization window for modulo format Positioning window Master axis encoder configuration Master axis encoder - input revolutions Master axis encoder - output revolutions Master axis encoder - filter type Master axis encoder - filter cutoff frequency IDR HNC VA EA LA x x x x x x x x x x x x x x x x x x x x x x x x x

321 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 311/333 IndraMotion MLC - Tools and Frequently Required Sequences Ident. No. A A Ident. No. C C C C Parameter name Master axis encoder - reference position Master axis encoder - position offset Parameter name Language selection Control name Control address Switch-on delay IDR HNC VA EA LA x x x x IDR IndraDrive HNC HNC device VA virtual axis EA encoder axis LA link axis Fig.7-3: Parameters to be exported subejct to the axis type ( ) C C C C C C C C C C C C C C C C C C IDN list of C checksum parameters User name TCP time-to-live UDP ports Transmitter time-out TCP max. number of connections MC cycle time (Tcyc) - setpoint Time slot of the integrated PLC from the MC cycle time Run-up cycle time Run-up motion target mode Axis configuration list Control communication configuration MLC network, cycle time (Tcyc) - setpoint MLC network functional modes configuration MLC network, FOC length configuration MLC network - master axis configuration MLC network - binary input setpoints MLC network, fine adjustment, dead time compensation Fig.7-4: C parameters to be saved ( ) The S and P parameters come from the "S , IDN list of operating data to back up".

322 312/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description IndraMotion MLC - Tools and Frequently Required Sequences 7.3 Parameter Handling - Importing The user has the possibility to change the preset values via the the dialog windows of the control, the axes and, if required, the drives. Therefore, it is necessary to file these changed values as a file (Parameter Handling - Exporting, page 305,) and to read them in again (import) from the file into the control or the drives, respectively, after a firmware was updated. In the "Offline Parameterization" mode, the parameters are transferred to the selected offline server (MLC, drives) - i.e. the offline parameters of the project. In the "Online" mode, the parameters are transferred into the selected real devices (MLC, drives). The allocation Parameter -> Device can be freely chosen for A, S and P parameters (see figure). The xxx.par file can be freely chosen (even outside the project directory). Parameters for the MLC (C parameters), every axis (A parameters) and every drive (S and P parameters) can be selected in groups (see figure). At first, the parameter file to be imported is selected for the import via the Windows dialog "Open". Then, the following options are adjustable: Importing Parameter Sets in Case of Concordance Between Address and Type Import No Names Source - Target Fig.7-5: Import presetting Option is the trivial setting, e.g. for reading in again a restituted parameter allocation in the same installation. Means that the names of the individual objects are not overwritten, e.g. in case of identical installation components which are contained several times in a system. The "Source" table gives the names of the objects the parameters of which were exported.

323 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 313/333 IndraMotion MLC - Tools and Frequently Required Sequences Import List In the "Target" table, the names of the objects included in the current project are indicated. An object is to be preselected in the "Source" table and one or several target objects are to be assigned to it. The import list is thus filled up. An import procedure is also possible for axes of different types (e.g. from real to virtual). For this, only parameters existing for both types are read in. In case of disabled axes, only the A parameters, not the S and P parameter, can be accessed! Point in Time of Writing The "Importing" releases the processing of the import list. A parameter must only be written an the point in time which is indicated in the online help for the respective parameter: What is typical for writable parameters is the fact that this takes place in the parameterization mode. However, several parameters be be still changed in the operating mode. For this reason, the user can decide in which mode the import is to start. (The user could thus read in a list of parameters edited by hand, which can be changed in the operating mode.) In case of an import in the operating mode, the parameters which cannot be changed lead to the switch-over request and even to an error message. Parameters, which are Writable in the Operating Mode A , Axis name A , Travel range limit switch A , Positive position limit A , Negative position limit A , Positive velocity limit A , Negative velocity limit A , Bipolar acceleration limit A , Bipolar jerk limit A , Bipolar torque/force limit A , Scaling type for temperature data A , Master axis's default address A , Direction of travel A , Jerk A , Positioning window for shortest way A , Standstill range A , Velocity data range A , Emergency stop deceleration A , User-defined setpoint bit number A A , User-defined setpoint bit number B A , User-defined setpoint bit number C A , User-defined setpoint bit number D A , Position synchronization window A , Velocity synchronization window A , Command: Clear all Axis Errors

324 314/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description IndraMotion MLC - Tools and Frequently Required Sequences 7.4 Parameter Editor A , Master, additive position setpoint A , Synchronization window for modulo format A , Positioning window A , Master axis encoder - reference position A , Command "Set Absolute Value" A , Master axis encoder - position offset C , Language selection C , Control name C , Project identification number C , Client access locking number C , Network ring identification number C , System time C , Switch-on delay C , Scaling type for temperature data - control C , User-defined decimal number C , User defined text C , IP address C , Subnet mask C , Standard gateway C , User name C , CPU load, threshold value for warning C , Run-up motion target mode C , Motion target mode C , Diagnostic memory index C , Last reset message C , MLC network - binary input setpoints C , Command: Store Motion Control Parameters in FW Module C , Command: Export Parameters C , Command: Clear all Control Errors C , Command: Reset the Lists C and C C , Command: Reset Parameters C and C The parameter editor allows to display and change an individual parameter. Its call is context-sensitive, i.e. it offers the C parameters in the area of the control and the A, S, and P parameters of the related axis for every axis or the K parameters of a kinematics or the S and P parameters for drives. The parameter editor can be called in the context menu of the control, the axes and the drives by means of the right mouse button on a parameter in any dialog box:

325 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 315/333 IndraMotion MLC - Tools and Frequently Required Sequences Name Status Min Max Value Fig.7-6: name of the parameter status of the query (transmission) possible minimum value of the parameter possible maximum value of the parameter value or lists of values Call of parameter editor The entry of a specific parameter is made with consideration of the source: In the figure above, the number of the control "C000", local control is prefixed. The overall designation for the parameter "C , Axis configuration list" is thus "C000:C ". For an axis, A, S and P parameters can be called up. The parameter name is to be extended with the axis number (A001...A016): A001:A for the "A , Axis designation" of axis "1". If the access is made from the local axis, the axis number can be omitted. If the parameter is writable in the current mode, the value can be changed and be transferred by <ENTER>. Tool Bar of the Parameter Editor Via the tool bar above the tabular display of the parameters, the following functionalities can be accessed: Icon Meaning opens the Parameter Selection List, page 316, opens the parameter group, transports the parameter into the parameter group, reads again, updates the display, gives help on the parameter, opens the chm-help file copies the value set of the parameter to the clipboard, inserts a list element with list parameters to the desired position (list is not immediately updated),

326 316/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description IndraMotion MLC - Tools and Frequently Required Sequences Icon Meaning deletes a list element with list parameters at the desired position (list is not immediately updated), transfers the changed list, if the operating status allows this. Parameter Selection List Fig.7-7: Tool bar of the parameter editor The parameter selection list gives a complete overview of the currently available parameters and allows to select the desired parameter for the display and processing in the parameter editor as well as in the parameter group (according to place of the call). Fig.7-8: Call of the parameter selection list from the parameter editor 7.5 Parameter Group On the basis of the individual parameter, illustrated in Parameter Editor, page 314, the user can prepare a list of parameters the values of which they can evaluate and change. Tool Bar of the Parameter Group Fig.7-9: Parameter group Via the tool bar above the tabular display of the parameters, the following functionalities can be accessed:

327 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 317/333 IndraMotion MLC - Tools and Frequently Required Sequences Icon Meaning inserts a new line for the parameter input (selection dialog), deletes the current line, loads the list of the parameters, stores the list of the parameters, copies the content as a text into the clipboard, prints the parameter group, displays the source of the parameters, opens the Parameter Editor, page 314, selects a parameter (selection dialog), see also Parameter Selection List, page 316, parameter description, opens the help file, shifts the line up / down. Fig.7-10: Tool bar of the parameter group 7.6 Frequently Required Sequences MLC - Clear Memory The control may contain, from a previous use, old program components, parameterizations and PLC data which are removed in this step by clearing the memory. With brand-new controls, this step can be omitted. Fig.7-11: Reboot of the control 1. After the control was switched on, the two outer keys <ESC> and <Enter> are to be pushed, when BOOT 1.01 appears. The display BOOTSTOP appears. 2. Now the two inner keys are to be pressed. REBOOT appears and the keys can be released again.

328 318/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description IndraMotion MLC - Tools and Frequently Required Sequences MLC - Setting of the IP Address IP Address - Initial Setting Delivery State 3. Now, the control runs up to BB STOP, the memory is cleared, the motion component is operational and the PLC component is stopped in its processing. Before the MLC is coupled to the programming device (e.g. notebook) via Ethernet, it must possess an IP address admissible for the network. In the delivery state, the following addresses are adjusted on the control: Address Initial value Get IP address Subnet mask Standard gateway Fig.7-12: Initial values The IP and subnet mask of a control is set via the four keys of the control display (for details, see). Afterwards, the control can be connected with the PC via the firm network or via cross-over cable. The cross-over connection requires no address change in the control; only the programming device side must be adapted If the control is connected to the firm network, the instructions of the network administrator must be complied with. In the "BB STOP" status, the reading and setting of the IP address and subnet address as well as the determination of the current firmware status can be realized. Esc Enter Fig.7-13: one level back, discarding a change navigation down in menus or decrement value navigation up in menus or increment value call of the next menu level or input confirmation Display with four operating keys (standard display) On the basis of the default display, the following figure shows the operating menu of the display:

329 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 319/333 IndraMotion MLC - Tools and Frequently Required Sequences Fig.7-14: Default display Fig.7-15: Sandard menu overview for the operation of display and keyboard 1. In the BB STOP default display, <Enter> can be used in order to access the ETHERNET display. 2. Upon the second activation of the <Enter> key, the IP Address is shown. 3. The preset address can be changed block for block, after the <ENTER> key was pushed again. (modification of the numerical values by pressing <DOWN> and <UP> and switching forward with <Enter>).

330 320/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description IndraMotion MLC - Tools and Frequently Required Sequences 4. After the fourth block, pressing <Enter> leads to the display ETHER NET. 5. The subnet mask and, if required, the gateway address can be changed accordingly. The modification of an address will only become effective, after the supply voltage was switched off and on again (booting). According to the menu overview, the MAC address and the firmware version of the MLC can still be determined. After the settings made, the IP address and the subnet mask ought to correspond to the requirements of the future use. Cross-Over Connection A special possibility for the coupling of am MLC and a PC is offered by a crossover cable. In this case, the IP address of the PC and its subnet mask must be adapted according to the operating system of the PC (e.g. for Windows XP: Start Setting Panel Network Connections LAN Connection Properties TCP/IP Internet Protocol General). With similar subnet mask, an (adjacent) IP address must be set on the PC: Address Control Notebook (XP) before Notebook adjusted Get IP address Get IP address Subnet mask automatically Standard gateway Not relevant. Not adjusted Fig.7-16: MLC - Firmware Exchange Objective Procedure Setting with connection via cross-over The MLC firmware in the control is to be exchanged without data loss. As a starting point, it is supposed that the control runs in BB RUN with active axes. Please read at first the release notes concerning the new firmware. We try as much as possible to keep stable the parameter spectrum within a version, so that you can work without deleting the NVRAM. It is recommended to follow the following procedure: 1. IndraLogic: disable the axes, stop the PLC, log out, close IndraLogic. Inconsistent data which are caused by the PLC can be excluded. 2. IndraWorks: phase switching BB -> P2. Any NVRAM data not yet saved are thus stored on the Compact Flash Card. 3. IndraWorks: close all dialog boxes in order to terminate the IndraWorks activities. 4. IndraWorks: phase switching P2 -> BB -> P2. Any NVRAM data that were still saved are thus stored on the Compact Flash Card 5. Switch MLC offline

331 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 321/333 IndraMotion MLC - Tools and Frequently Required Sequences 6. Realisation of the firmware download via the context menu item "Firmware Management" of the MLC control. Fig.7-17: MLC - Hardware Exchange Objective Procedure Firmware management dialog The window can be activated in the context menu of the respective control. On its left side, the available firmware versions are listed to choose from. The desired version is to be selected; then the download is to be activated. The versions that can be selected are given under: Drive:\Program Files\Rexroth\IndraMotion MLC\Firmware. The new firmware can only become effective after a restart of the control. 7. The reboot of the control is carried out automatically. After a restart, the control runs up to P2 Stop or BB Stop, depending on the setting "C , Run-up motion target mode". The MLC hardware is to be exchanged. The project data and firmware are to be transferred from one control hardware to a different control hardware via Compact Flash. As a starting point, it is supposed that the control runs in BB RUN with active axes. The following steps are required: 1. IndraLogic: disable the axes, stop the PLC, log out, close IndraLogic. Inconsistent data which are caused by the PLC can be excluded. 2. IndraWorks: phase switching BB -> P2. NVRAM data not yet saved are stored on the Compact Flash Card.

332 322/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description IndraMotion MLC - Tools and Frequently Required Sequences Drive/Drive Firmware Exchange Introduction 3. IndraWorks: close all dialog boxes in order to terminate the IndraWorks activities. 4. IndraWorks: phase switching P2 -> BB -> P2. Any NVRAM data that were still saved are thus stored on the Compact Flash Card. 5. Switch off the control, replace it and wire the new control. 6. The Compact Flash Card is inserted into another control hardware. The control hardware detects the new Compact Flash Card, after it was switched on. The control displays "E00C0001 Parameter inconsistent, restitution via C ". 7. The control runs up to P2 Stop or BB Stop, depending on the setting "C , Run-up motion target mode". And then up to the desired final status. Since it might be necessary to exchange a drive or the drive firmware, a semiautomatic sequence is available for this process. The reasons for such an exchange are diverse, e.g.: upgrade to a more recent firmware version exchange of the drive for a different drive type replacement of a defective device Subject to the status of the control and drive (online/offline), three different measures can be taken: 1. The MLC as well as the drive to be exchanged are available online. The parameters to be saved are stored online by the drive and the MLC control into a parameter file. After the exchange was successful, the control goes back to the online status. The procedure is described below. 2. The configuration of the drive ring is available; the connection to the MLC is switched offline. 3. No configuration of the drive ring is available (no drive exists); the connection to the MLC control is switched offline or the control was not found. Selection of the Drive to be Exchanged Principally, the sequence consists of three working steps: 1. Back-up of existing settings and parameters 2. Exchange of the drive or the drive firmware (physically and in the MLC project) 3. Rewriting of the secured settings and parameters In the context menu of the desired real axis, choose the entry "Exchange Drive/ Firmware...". A wizard is opened which leads through the exchange process. The description below corresponds to the first measure described above. It might be that, for the two other ways, less setting possibilities and less dialogs are offered.

333 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 323/333 IndraMotion MLC - Tools and Frequently Required Sequences Settings for Parameter Back-Up Fig.7-18: Selection of the drive to be exchanged In the first step, the parameters are stored. Subject to the availability of parameter data, this can be done on the basis of online or offline data. These settings can be made separately for the axis data (A parameters) in the MLC and the S and P parameters in the drive. In the further course, the parameters are stored internally. Furthermore, they can be backed up for a later use in a general parameter file (*.par). Parameter Back-Up Fig.7-19: Setting for parameter back-up The A, S, and P drive parameters are stored in a back-up file on the PC. Preparation for the Exchange of the Drive / the Drive Firmware Fig.7-20: Parameter back-up A push of the confirmation button sets the control into a safe state and disables the drive.

334 324/333 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 03VRS Functional Description IndraMotion MLC - Tools and Frequently Required Sequences Back Up Drive Parameters in Non- Volatile Memory Fig.7-21: Preparation for the exchange of the drive / the drive firmware Some drives store their current parameters (optionally) only in the volatile memory. For the going-offline, it is therefore recommended to back up these parameters in a non-volatile memory of the drive. Exchange of the Drive / Drive Firmware Fig.7-22: Back up drive parameters in non-volatile memory Now, the drive or drive firmware can be exchanged. Fig.7-23: Exchange of the drive / drive firmware The mechanism used for the exchange of the drive firmware depends on the type of the drive and cannot be carried out here. It is necessary to use the commissioning tool of the drive. Definition of New Drive This dialog is used to determine online and enter offline, respectivley, the new drive. If an online connection exists, all drives that were found in the SERCOS ring of the MLC and that were not yet configured in the current project, are offered for the selection. In the "Enter Offline" mode, the new drive can be freely determined. Adaptations in the Project Fig.7-24: Selection of the new drive The project settings are now adjusted. Only now are actual changes made to the project! An interruption in the preceding steps leaves the project unchanged.

335 Functional Description Rexroth IndraMotion MLC 03VRS Electric Drives Bosch Rexroth AG 325/333 IndraMotion MLC - Tools and Frequently Required Sequences Parameter - Restitution Fig.7-25: Settings in the project are adjusted Now, the parameters backed up are imported again. If the firmware version or the drive type were changed, it is "normal" that the parameters backed up do not completely match the currently available parameters. It might then be that several parameters are not written into the drive, i.e. if you try to do that, a SERCOS error message is output. All parameters concered are output together with the error message in a list in the lower area of the dialog. Fig.7-26: Parameter - restitution With the end of the parameters restitution, the Wizard is finished. Instead of the "Cancel" button, the "Finish" button appears. Any parameter file created in the course of the first two steps is maintained after the end of the wizard.

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