Bosch Rexroth IndraMotion MLD Series Instructions for use

The Drive & Control Company
Rexroth IndraDrive
Rexroth IndraMotion MLD (2G)
as of MPx-18
Edition 02
Application Manual
R911338914
LSA Control S.L. www.lsa-control.com [email protected] ([phone]

Rexroth IndraDrive
Rexroth IndraMotion MLD (2G)
as of MPx-18
Application Manual
DOK-INDRV*-MLD3-**VRS*-AP02-EN-P
RS-77461bce0f8a914b0a6846a501d9a219-2-en-US-3
This documentation describes the specific functionalities of Rexroth
IndraMotion MLD as of the MPx-18 firmware.
Starting with this firmware version, IndraLogic 2G is supported; therefore, this
documentation additionally explains how to convert IndraLogic 1.x projects to
IndraLogic 2G projects.
Edition Release Date Notes
DOK-INDRV*-MLD3-**VRS*-APRS-EN-P 2014-08 See chapter "About this
documentation", margin‐
al note "Editions of this
documentation"
Copyright © Bosch Rexroth AG 2014
This document, as well as the data, specifications and other information set
forth in it, are the exclusive property of Bosch Rexroth AG. It may not be re‐
produced or given to third parties without its consent.
Liability The specified data is intended for product description purposes only and shall
not be deemed to be a guaranteed characteristic unless expressly stipulated
in the contract. All rights are reserved with respect to the content of this docu‐
mentation and the availability of the product.
Editorial Department Dept. DC-IA/EDY1
Title
Type of Documentation
Document Typecode
Internal File Reference
Purpose of Documentation
Record of Revision
Bosch Rexroth AG DOK-INDRV*-MLD3-**VRS*-AP02-EN-P
Rexroth IndraDrive Rexroth IndraMotion MLD (2G) as of MPx-18
LSA Control S.L. www.lsa-control.com [email protected] ([phone]

Table of Contents
Page
1 Introduction.................................................................................................................... 5
1.1 About this documentation....................................................................................................................... 5
1.2 Structure of the documentation............................................................................................................... 8
1.3 Documentations...................................................................................................................................... 8
1.3.1 Overview.............................................................................................................................................. 8
1.3.2 Drive systems, system components.................................................................................................... 9
1.3.3 Motors.................................................................................................................................................. 9
1.3.4 Cables............................................................................................................................................... 10
1.3.5 Firmware............................................................................................................................................ 10
1.4 Reference documentations................................................................................................................... 11
1.5 Product presentation............................................................................................................................. 11
1.5.1 Introduction and overview.................................................................................................................. 11
1.5.2 Brief description................................................................................................................................. 12
1.5.3 IndraMotion MLD-S........................................................................................................................... 13
1.5.4 IndraMotion MLD-M........................................................................................................................... 14
1.5.5 Digital and analog I/O extensions...................................................................................................... 15
1.5.6 Terms, basic principles...................................................................................................................... 17
1.5.7 Function overview and system properties......................................................................................... 18
2 Important directions for use ........................................................................................ 29
2.1 Appropriate use ................................................................................................................................... 29
2.1.1 Introduction........................................................................................................................................ 29
2.1.2 Areas of use and application............................................................................................................. 29
2.2 Inappropriate use.................................................................................................................................. 30
3 Safety instructions for electric drives and controls....................................................... 31
3.1 Definitions of terms............................................................................................................................... 31
3.2 General information.............................................................................................................................. 32
3.2.1 Using the Safety instructions and passing them on to others............................................................ 32
3.2.2 Requirements for safe use................................................................................................................ 32
3.2.3 Hazards by improper use.................................................................................................................. 33
3.3 Instructions with regard to specific dangers.......................................................................................... 34
3.3.1 Protection against contact with electrical parts and housings........................................................... 34
3.3.2 Protective extra-low voltage as protection against electric shock .................................................... 35
3.3.3 Protection against dangerous movements........................................................................................ 36
3.3.4 Protection against electromagnetic and magnetic fields during operation and mounting.................. 37
3.3.5 Protection against contact with hot parts........................................................................................... 38
3.3.6 Protection during handling and mounting.......................................................................................... 38
3.3.7 Battery safety..................................................................................................................................... 38
3.3.8 Protection against pressurized systems............................................................................................ 39
3.4 Explanation of signal words and the Safety alert symbol..................................................................... 40
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Page
4 Basic functions of Rexroth IndraMotion MLD............................................................... 41
4.1 Overview............................................................................................................................................... 41
4.2 Definition of terms................................................................................................................................. 41
4.3 Device control....................................................................................................................................... 42
4.3.1 General information........................................................................................................................... 42
4.3.2 Master communication...................................................................................................................... 42
4.3.3 Axis control........................................................................................................................................ 43
4.3.4 Axis.................................................................................................................................................... 43
4.3.5 PLC runtime....................................................................................................................................... 43
4.3.6 MLD options for influencing axis control............................................................................................ 44
4.4 Commanding axes................................................................................................................................ 46
4.4.1 Basics on axis control........................................................................................................................ 46
4.4.2 Implementing motion commanding in the axis.................................................................................. 50
4.4.3 Basic functional principle of motion function blocks in conformity with PLCopen.............................. 51
4.4.4 Axis addressing................................................................................................................................. 53
4.4.5 Notes on application and programming............................................................................................. 57
4.5 Task system.......................................................................................................................................... 59
4.5.1 Definition of terms.............................................................................................................................. 59
4.5.2 Brief description................................................................................................................................. 59
4.5.3 Task properties.................................................................................................................................. 61
4.5.4 Motion task ....................................................................................................................................... 61
4.5.5 Task monitoring (watchdog).............................................................................................................. 64
4.5.6 Runtime measurements.................................................................................................................... 65
4.5.7 Task configuration............................................................................................................................. 69
4.5.8 Task cycle times and timing.............................................................................................................. 69
4.6 IndraMotion MLD error handling........................................................................................................... 70
4.6.1 IndraMotion MLD operating behavior................................................................................................ 70
4.6.2 General (for MLD-S and MLD-M)...................................................................................................... 71
4.6.3 Configuring the error reaction in MLD-S............................................................................................ 76
4.6.4 MLD-M error handling and reaction................................................................................................... 77
5 MLD communication interfaces and data channels..................................................... 83
5.1 Introduction and overview..................................................................................................................... 83
5.2 IndraMotion MLD data channels........................................................................................................... 85
5.2.1 Cyclic data channels.......................................................................................................................... 85
5.2.2 Acyclic data channels / interfaces................................................................................................... 103
5.2.3 Configuring the inputs and outputs (I/O configuration of MLD)....................................................... 116
5.2.4 Cyclic data in MLD-M system mode................................................................................................ 125
5.3 sercos I/O........................................................................................................................................... 130
6 Visualization and engineering interfaces................................................................... 133
6.1 Overview............................................................................................................................................. 133
6.2 Interfaces for connecting communication partners............................................................................. 135
6.2.1 Ethernet interface (TCP/IP)............................................................................................................. 135
6.2.2 Master communication interface...................................................................................................... 137
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Page
6.3 Connecting IndraControl (VCP/VE*)................................................................................................... 138
6.3.1 Introduction and overview................................................................................................................ 138
6.3.2 Configuring the symbols for variable/parameter access.................................................................. 140
6.3.3 Notes on utilization for IndraControl VCP........................................................................................ 143
6.3.4 Handling/diagnostics and service functions..................................................................................... 160
7 Notes on commissioning and application................................................................... 165
7.1 Requirements for using Rexroth IndraMotion MLD............................................................................ 165
7.1.1 Firmware and hardware requirements............................................................................................. 165
7.1.2 Software requirements.................................................................................................................... 165
7.1.3 Requirements for communication ................................................................................................... 165
7.2 Programming in IndraWorks MLD...................................................................................................... 166
7.3 Applications for Rexroth IndraMotion MLD......................................................................................... 167
7.3.1 Overview.......................................................................................................................................... 167
7.3.2 Using technology functions.............................................................................................................. 167
7.3.3 Free programming of Rexroth IndraMotion MLD............................................................................. 170
7.3.4 PLC project structure....................................................................................................................... 182
7.3.5 Programming and commissioning steps.......................................................................................... 187
7.4 Comparing the "IndraDrive Cs" range with the "IndraDrive C"/"IndraDrive M" range......................... 208
7.4.1 Introduction...................................................................................................................................... 208
7.4.2 Physical interfaces........................................................................................................................... 208
7.4.3 Byte order........................................................................................................................................ 208
7.4.4 MLD performance comparison........................................................................................................ 212
8 Programming information........................................................................................... 213
8.1 Industrial standards for programming ................................................................................................ 213
8.1.1 General information......................................................................................................................... 213
8.1.2 IEC 61131........................................................................................................................................ 213
8.1.3 PLCopen.......................................................................................................................................... 213
8.2 Libraries for Rexroth IndraMotion MLD............................................................................................... 214
8.2.1 General properties of the libraries................................................................................................... 214
8.2.2 Libraries........................................................................................................................................... 215
8.3 Accessing files on the optional memory card..................................................................................... 217
8.4 Start behavior and boot project........................................................................................................... 219
8.4.1 General information......................................................................................................................... 219
8.4.2 Brief description............................................................................................................................... 219
8.4.3 Notes on usage and programming.................................................................................................. 220
8.5 Guidelines for programming with IndraLogic...................................................................................... 220
8.5.1 Overview.......................................................................................................................................... 220
8.5.2 Structuring PLC projects.................................................................................................................. 221
8.5.3 Programming languages................................................................................................................. 222
8.5.4 Global data...................................................................................................................................... 223
8.5.5 Program header............................................................................................................................... 223
8.5.6 History............................................................................................................................................. 224
8.5.7 Type identifiers................................................................................................................................ 224
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Page
8.5.8 Instance identifiers........................................................................................................................... 226
8.5.9 Definition of standard interfaces in function blocks......................................................................... 228
8.5.10 Error handling.................................................................................................................................. 232
8.5.11 Versioning libraries.......................................................................................................................... 232
8.5.12 Code optimization............................................................................................................................ 234
9 Diagnostic and service functions............................................................................... 237
9.1 Overview and introduction.................................................................................................................. 237
9.2 Device Editor...................................................................................................................................... 237
9.2.1 Device Editor, General Information................................................................................................. 237
9.2.2 Status.............................................................................................................................................. 237
9.2.3 Files................................................................................................................................................. 237
9.2.4 Log................................................................................................................................................... 238
9.2.5 PLC Settings.................................................................................................................................... 239
9.2.6 PLC Shell......................................................................................................................................... 240
9.2.7 Information....................................................................................................................................... 240
9.3 Diagnostic functions............................................................................................................................ 241
9.3.1 Standard drive diagnostic functions................................................................................................. 241
9.3.2 MLD diagnostic functions................................................................................................................ 242
9.4 Service functions................................................................................................................................ 245
9.4.1 Service functions of the PLC (IndraMotion MLD)............................................................................ 245
9.4.2 Changing firmware.......................................................................................................................... 246
9.4.3 Firmware version upgrade............................................................................................................... 248
9.4.4 Replacing the Controller.................................................................................................................. 250
10 Converting projects.................................................................................................... 255
10.1 Introduction......................................................................................................................................... 255
10.2 Requirements in MLD-1G................................................................................................................... 255
10.3 Adding to MLD-2G.............................................................................................................................. 256
10.3.1 Adding a project............................................................................................................................... 256
10.3.2 Compiling errors after converting projects....................................................................................... 257
10.3.3 Adjustments in MLD-2G.................................................................................................................. 258
11 Service and support................................................................................................... 261
Index.......................................................................................................................... 263
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1 Introduction
1.1 About this documentation
Editions of this documentation
Edition Release date Notes
DOK-INDRV*-MLD2-2G*VRS-AP01-EN-P 2014-01 First edition
DOK-INDRV*-MLD2-2G*VRS-AP02-EN-P 2014-08
● Corrections
– Information on available memory
● Amendments:
– WinStudio configuration required
when connecting an HMI
(IndraControl VE*) via Ethernet
– Description of context menu for
"Application"
– Information: "Advanced" perform‐
ance level cannot be configured
when "MLD-M" system mode has
been configured for MPC
Tab. 1-1: Record of revisions
Means of representation in this
documentation
To make it easier to read this documentation, the table below contains the
means of representation and notations of recurring terms.
What? How? For example...
Important facts that should
be highlighted in the body
text
Boldface "IndraDrive Cs" provides an analog input. There is no analog
output.
Parameter names, diagnostic
message names, function
designations
Quotation marks In the I/O configuration (IndraWorks), the inputs were linked
to parameter "P-0-1390, PLC input WORD0".
Tab. 1-2: Conventions of notation
Helpful information and tips are highlighted in the text. A symbol tells you
what kind of information is used in the text:
This box contains important information that should be taken into
consideration.
This symbol indicates useful tips and tricks.
Signal words in accordance with ANSI Z535.6-2011 draw the reader's atten‐
tion to hazards (see "Explanation of signal words and the safety alert sym‐
bol").
Your feedback Your experiences are important to our efforts in improving products and doc‐
umentation.
If you discover errors in this documentation or would like to suggest changes,
you can send your feedback to the following e-mail address:
[email protected]
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Introduction
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Please include the following information so we can process your feedback:
● The number indicated on the back of the front page under "Internal File
Reference"
● The page number
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Introduction
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1.2 Structure of the documentation
This documentation is structured for various audiences to make navigation as
quick and easy as possible. It is divided into the following main chapters,
each of which are tailored to a defined audience or use:
●chapter 1.5 "Product presentation" on page 11
Provides an overview of the main features and intended use of
"IndraMotion MLD"
●chapter 7 "Notes on commissioning and application" on page 165
Notes on the commissioning and use of "IndraMotion MLD"
●chapter 9 "Diagnostic and service functions" on page 237
This chapter explains troubleshooting options if a problem occurs in
conjunction with "IndraMotion MLD"
●chapter 10 "Converting projects" on page 255
This chapter describes how to convert IndraLogic 1.x projects (MLD-1G)
to IndraLogic 2G projects (MLD-2G)
1.3 Documentations
1.3.1 Overview
The following chart illustrates the relationships between the individual docu‐
ments for Rexroth IndraDrive as of MPx-18:
Fig. 1-1: Overview of documentations for Rexroth IndraDrive as of MPx-18
The description of the functionality of "IndraMotion MLD" is divided as fol‐
lows:
●Application Manual for Rexroth IndraMotion MLD-2G (this documenta‐
tion)
Describes the specific functionalities of "IndraMotion MLD", explains
how the PLC is integrated into the drive, and the technical options and
functions
●Getting Started with Rexroth IndraMotion MLD-2G
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Explains how to get started when using Rexroth IndraMotion MLD for
the first time (preparation and setup, commissioning, programming)
●Library for Rexroth IndraMotion MLD-2G
– Describes the functions and function blocks specially programmed
for "IndraMotion MLD" and compiled into a special library
– Contains references to the system libraries used by several sys‐
tems
– Contains references to the basic libraries used by several systems
You can easily access the descriptions for the system and basic
libraries via the online help feature in IndraWorks.
●Operating and Programming Guide for IndraLogic 2G
This documentation specifically describes the programming environ‐
ment, as well as the programming and creation of PLC programs
●Reference Book of parameters for Rexroth IndraDrive
Apart from the PLC-specific parameters, all other drive parameters are
documented in the Reference Book of parameters
●Reference Book of diagnostic messages for Rexroth IndraDrive
Apart from the PLC-specific diagnostic messages, all other drive diag‐
nostic messages are documented in the Reference Book of diagnostic
messages
1.3.2 Drive systems, system components
Title Kind of documentation Document typecode1) Material number
R911…
Automation Terminals
Of The Rexroth Inline
Product Range
Application Manual DOK-CONTRL-ILSYSINS***-
AWxx-EN-P
317021
1) In the document typecodes, "xx" is a placeholder for the current
edition of the documentation (e.g., AW01 is the first edition of
an Application Manual)
Tab. 1-3: Documentations – overview
1.3.3 Motors
Title
Rexroth IndraDyn …
Kind of documentation Document typecode1)
DOK-MOTOR*-…
Material number
R911…
A Asynchronous Motors MAD / MAF Project Planning Manual MAD/MAF****-PRxx-EN-P 295781
H Synchronous Kit Spindle Motors Project Planning Manual MBS-H******-PRxx-EN-P 297895
L Synchronous Linear Motors Project Planning Manual MLF********-PRxx-EN-P 293635
L Ironless Linear Motors MCL Project Planning Manual MCL********-PRxx-EN-P 330592
S Synchronous Motors MKE Project Planning Manual MKE*GEN2***-PRxx-EN-P 297663
S Synchronous Motors MSK Project Planning Manual MSK********-PRxx-EN-P 296289
S Synchronous Motors MSM Data Sheet MSM********-DAxx-EN-P 329338
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Title
Rexroth IndraDyn …
Kind of documentation Document typecode1)
DOK-MOTOR*-…
Material number
R911…
S Synchronous Motors QSK Project Planning Manual QSK********-PRxx-EN-P 330321
T Synchronous Torque Motors Project Planning Manual MBT********-PRxx-EN-P 298798
1) In the document typecodes, "xx" is a wild card for the current
edition of the documentation (example: PR01 is the first edition
of a Project Planning Manual)
Tab. 1-4: Documentations – Motors
1.3.4 Cables
Title Kind of documentation Document typecode1)
DOK-CONNEC-…
Material number
R911…
Rexroth Connection Cables
IndraDrive and IndraDyn
Selection Data CABLE*INDRV-CAxx-EN-P 322949
1) In the document typecodes, "xx" is a wild card for the current
edition of the documentation (example: CA02 is the second ed‐
ition of the documentation "Selection Data")
Tab. 1-5: Documentations – Cables
1.3.5 Firmware
Title Kind of documentation Document typecode1) Material number
Rexroth IndraDrive
MPx-18
Functions
Application Manual DOK-INDRV*-MP*-18VRS**-APxx-EN-P R911338673
Rexroth IndraDrive
MPx-18
Version Notes
Release Notes DOK-INDRV*-MP*-18VRS**-RNxx-EN-P R911338658
Rexroth IndraDrive
MPx-16 to MPx-18
Parameters
Reference Book DOK-INDRV*-GEN1-PARA**-RExx-EN-P R911328651
Rexroth IndraDrive
MPx-16 to MPx-18
Diagnostic Messages
Reference Book DOK-INDRV*-GEN1-DIAG**-RExx-EN-P R911326738
Integrated Safety Technology
"Safe Torque Off" (as of MPx-16)
Application Manual DOK-INDRV*-SI3-**VRS**-APxx-EN-P R911332634
Integrated Safety Technology
"Safe Motion" (as of MPx-18)
Application Manual DOK-INDRV*-SI3*SMO-VRS-APxx-EN-P R911338920
Rexroth IndraDrive
Rexroth IndraMotion MLD (2G)
Libraries as of MPx-18
Reference Book DOK-INDRV*-MLD-SYSLIB3-RExx-EN-P R911338916
Rexroth IndraDrive
Rexroth IndraMotion MLD (2G)
as of MPx-18
Application Manual DOK-INDRV*-MLD3-**VRS*-APxx-EN-P R911338914
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Introduction
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Title Kind of documentation Document typecode1) Material number
Rexroth IndraDrive
Rexroth IndraMotion MLD (2G)
as of MPx-18
Commissioning Manual DOK-INDRV*-MLD3-F*STEP-COxx-EN-P R911341708
Rexroth IndraMotion
MLD 13VRS
Service Tool
Reference Book DOK-IM*MLD-IMST****V13-RExx-EN-P R911341347
1) In the document typecodes, "xx" is a wild card for the current
edition of the documentation (example: RE02 is the second ed‐
ition of a Reference Book)
Tab. 1-6: Documentations – Firmware
1.4 Reference documentations
Title
Rexroth IndraWorks 13VRS...
Kind of documentation Document typecode1) Material number
R911…
IndraLogic 2G
Basic Libraries
Library Description DOK-IL*2G*-BASLIB**V13-LIxx-
EN-P
336285
IndraLogic 2G
PLC Programming System
Application Manual DOK-IWORKS-IL2GPRO*V13-
APxx-EN-P
336876
1) In the document typecodes, "xx" is a placeholder for the current
edition of the documentation (e.g., RE02 is the second edition
of a Reference Book)
Tab. 1-7: Reference documentations
1.5 Product presentation
1.5.1 Introduction and overview
"IndraMotion MLD" (Motion Logic Drive-based) is a PLC integrated in the
drive provided as a functional firmware package for the "Rexroth IndraDrive"
range.
"IndraMotion MLD" combines motion and PLC functions in a modern, open
automation platform for modular machine designs. The decentralized control
architecture forms a compact Motion Logic system based on the scalable
IndraDrive platform, eliminating the need for higher-level control units.
● Electronic synchronization of up to 10 servo axes
● Up to 4 sercos III I/O nodes are supported
● Visualization via "IndraControl Vxx"
● Applications: belt conveyors, roll feeds, feed straightening machines,
unwinders, straightening machines
"IndraMotion MLD" is available in the characteristics MLD-S (single-axis
"Motion Logic Control") and MLD-M (multi-axis "Motion Logic Control").
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IndraMotion MLD (drive-integrated PLC)
IndraMotion MLD-S:
Single-axis "Motion Logic Control"
IndraMotion MLD-M:
Multi-axis "Motion Logic Control" ("MPC" firmware only)
"IndraDrive C" /
"IndraDrive M" (with
Cxx02 control sec‐
tions)
X X
"IndraDrive Cs" X X
"IndraDrive Mi" X -
This document describes the functionality and use of the
"IndraMotion MLD" drive-integrated PLC with "IndraDrive Cs" de‐
vices.
1.5.2 Brief description
"IndraMotion MLD" is a variant of the "IndraMotion" range that is embedded
in the drive controllers of the "Rexroth IndraDrive" drive range. It does not re‐
quire any additional hardware option, just the licensing of a functional firm‐
ware package ("ML" or "MA").
See also Functional Description of firmware "Functional packages"
Other characteristics of the "IndraMotion" range:
● IndraMotion MLC
● IndraMotion MTX
All IndraMotion variants are configured and operated with the
"IndraWorks MLD" engineering tool and programmed with the
embedded "IndraLogic" programming tool. This makes the pro‐
grams created with "IndraLogic" portable as long as the general
requirements are met (see "Programming information").
Main features of "IndraMotion
MLD"
These are the main features of "IndraMotion MLD":
● "IndraMotion MLD" is perfect for efficiently executing motion and logic
tasks with drive firmware functions (no additional hardware required)
● "Open drive", i.e., direct and transparent access to all drive functions
and parameters
● Programming functional extensions or custom motion solutions in ac‐
cordance with IEC 61131-3 based on comprehensive standard libraries
and additional libraries ("technology libraries")
● Flexible communication extension via on-board interfaces
"IndraMotion MLD" is available with the following characteristics:
● IndraMotion MLD-S (single-axis solution; "MPB" and "MPC" firmware)
– As an intelligent servo axis (drive functionality extension)
– As a stand-alone single-axis "Motion Logic Control"
● IndraMotion MLD-M (multi-axis solution; "MPC" firmware only)
– As a stand-alone multi-axis "Motion Logic Control" using CCD
(Cross Communication Drives) based on sercos III
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1.5.3 IndraMotion MLD-S
Connection Please refer to the appropriate Project Planning Manual for the
interfaces used to interconnect the components
Fig. 1-2: "IndraMotion MLD-S" basic system structure
Features of "IndraMotion MLD-S" "IndraMotion MLD-S" comes with the following main features:
● "Intelligent servo axis" (drive functionality extension) or "stand-alone sin‐
gle-axis "Motion Logic Control""
● Commanding local axis with direct access to the drive's device control
● Direct access to all drive parameters using system-wide PLC variables,
functions, function blocks or a configurable synchronous channel
● Direct access to the drive's digital inputs/outputs and analog input (local
axis)
● Connection of other inputs/outputs ("Rexroth Inline Block IO" / "Rexroth
Inline Modular IO") using the MLD-M system mode
Also included in the "stand-alone single-axis "Motion Logic Control"" charac‐
teristic:
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● Motion Control functionality for 1 axis by commanding the local axis with
a corresponding PLCopen-based Motion Control library
1.5.4 IndraMotion MLD-M
"IndraMotion MLD-M" not only controls the local axis but also remote axes
(so-called "CCD slaves").
Connection Please refer to the appropriate Project Planning Manual for the
interfaces used to interconnect the components
Fig. 1-3: "IndraMotion MLD-M" basic system structure
Features of "IndraMotion MLD-M" "IndraMotion MLD-M" comes with the following additional main features:
● Only available with "MPC" firmware
● Motion Control functionality for up to 10 axes by corresponding
PLCopen-based Motion Control library
● CCD cross communication interface to "remote axes" based on
sercos III
– For commanding local and remote axis motion
– For connecting additional inputs/outputs ("Rexroth Inline" or option‐
al modules in the remote axes)
● Direct access to the drives' digital and analog inputs/outputs (local and
remote axes)
● All drive parameters (local and remote axes) can be accessed
● sercos III interface to slave axes:
–Number of axes and cycle time
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Max. 9 slaves (T=500 µs with 1 slave, T=1000 μs with 2 slaves up
to T=4000 μs with 9 slaves)
– Cyclic data channel (MDT, AT) with maximum 48 bytes and 16 pa‐
rameters each
– Parameter or service channel (4-byte info container)
1.5.5 Digital and analog I/O extensions
Introduction
The "Rexroth Inline" range provides digital and analog I/O extensions in two
variants:
● Modular IOs: I/O modules that can be added modularly ("Rexroth Inline
Modular IO")
● Block IOs: compact remote I/O modules ("Rexroth Inline Block IO")
The "Rexroth Inline Block IO" and "Rexroth Modular IO" I/O modules can be
used in mixed mode. A total number of 4 block and modular I/O modules (bus
couplers) cannot be exceeded.
The I/O modules can only be operated under the following conditions:
● The I/O modules can only be operated in conjunction with an MLD-M
system (Advanced device with MPC firmware).
● A functional firmware package for "IndraMotion MLD" has to be enabled
for operation.
● The I/O modules have to be configured correctly in the project.
● The MLD project has been loaded to the control unit, i.e., the I/O config‐
uration is included in the MLD project.
● The sercos ring is in phase 4. (IOs can only be updated in sercos phase
4.)
In MLD-2G, the parameters of the I/O modules can be read via
the service channel for diagnostics; however, it is not possible to
apply the process data of the I/O modules to the cyclic communi‐
cation of the master communication. In cyclic mode, the I/O mod‐
ules can only be read/written via the MLD.
The signals applied to the "Inline Block I/O digital fast" I/O mod‐
ules are typically read/written via a CCD-synchronous task, which
requires the MLD-M system mode to be configured (P-0-1800.0.1,
CCD: Configuration).
"Rexroth Inline Block IO" in conjunction with "IndraMotion MLD"
"Rexroth Inline Block IO" is the ideal solution for applications with limited I/O
extent and low complexity. With its compact design, it is the perfect solution
for installing in flat control boxes.
A maximum of four "Rexroth Inline Block IO" devices can be operated at one
drive controller.
A latch-on inline connector is used for wiring. No additional terminal levels
are required thanks to its multi-conductor connection technology.
A number of variants of the "Rexroth Inline Block IO" are available for
sercos III connection:
● Inline Block IO with 16 digital inputs and 16 configurable digital inputs or
outputs (R-ILB S3 24 DI16 DIO16)
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Documentation: "Rexroth Inline Block IO for sercos III With Digital Inputs
and Outputs", DOK-CONTRL-S3DI16DIO16-KB, R911170500
● Inline Block IO with 4 analog inputs and 2 analog outputs
(R-ILB S3 24 AI4 AO2)
Documentation: "Rexroth Inline Block IO for sercos III With Analog
Inputs and Outputs", DOK-CONTRL-S3AI4AO2***-KB, R911170558
● Inline Block IO with 16 digital high-speed inputs and 16 digital high-
speed inputs or outputs, timestamp and oversampling
(R-ILB S3 24 DI16 DIO16/F)
Documentation: In preparation
● Inline Block IO with 6 analog high-speed inputs and 4 analog high-
speed outputs, oversampling (R-ILB S3 AI6 AO4/F)
Documentation: In preparation
"R-ILB S3 24 DI16 DIO16" / "R-
ILB S3 24 DI16 DIO16/F"
The Inline Block IO "R-ILB S3 24 DI16 DIO16" has been designed for use
within sercos III. It is used to register digital input signals and put out digital
signals. "R-ILB S3 24 DI16 DIO16" features 16 digital inputs and 16 freely
configurable digital inputs or outputs.
"R-ILB S3 24 DI16 DIO16/F" also features 16 digital inputs and 16 freely con‐
figurable digital inputs or outputs. With its quick signal processing, it is suita‐
ble for use in time-critical applications.
"R-ILB S3 24 AI4 AO2" / "R-
ILB S3 24 AI6 AO4/F"
The Inline Block IO "R-ILB S3 24 AI4 AO2" has been designed for use within
sercos III. It can be used to register current or voltage signals as well as tem‐
perature sensors. It also provides the option of outputting analog current and
voltage signals. "R-ILB S3 24 AI4 AO2" features 4 analog inputs and 2 ana‐
log outputs.
"R-ILB S3 24 AI6 AO4/F" features 6 analog inputs and 2 analog outputs. With
its quick signal processing, it is suitable for use in time-critical applications.
"R-ILB S3 24 AI6 AO4/F" is scheduled for release in the 4th quarter of 2014.
For general information on the "Rexroth Inline" product range, re‐
fer to the documentation "Automation Terminals Of The Rexroth
Inline Product Range", document typecode "DOK-CONTRL-ILSY‐
SINS***-AWxx-EN-P".
"Rexroth Inline Modular IO" in conjunction with "IndraMotion MLD"
A maximum of 4 bus couplers for sercos III with a maximum of 16 modules
(nodes) each can be evaluated at a CCD master.
All modules that can be operated as simple digital or analog I/Os are suppor‐
ted.
The following devices ("Rexroth Inline" product range) are available:
● Bus coupler for sercos III with digital inputs and outputs (R-
IB IL S3 BK DI8 DO4-PAC)
● Modules with analog inputs (R-IB IL AI xx) or analog outputs (R-
IB IL AO xx)
● Modules with digital inputs (R-IB IL 24 DI xx) or digital outputs (R-
IB IL 24 DO xx)
For general information on the "Rexroth Inline" product range, re‐
fer to the documentation "Automation Terminals Of The Rexroth
Inline Product Range", document typecode "DOK-CONTRL-ILSY‐
SINS***-AWxx-EN-P".
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Introduction
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1.5.6 Terms, basic principles
General information
● A technology function or technology package is a self-contained, com‐
prehensive functionality (e.g., preventive diagnostic system).
● Based on technology function blocks and packages, Bosch Rexroth also
provides ready-made, application-specific complete solutions (so-called
"turnkey solutions"), such as "IndraMotion for Metalforming" and
"IndraMotion for Handling".
A technology function/technology package or a turnkey solution
consists of the following components:
● Ready-made PLC project loaded to the drive, e.g., as a pa‐
rameter file
● Function documentation (incl. involved parameters) that,
e.g., can be called using the DriveTop commissioning soft‐
ware
● If necessary, a separate dialog (e.g., for IndraWorks MLD)
for commissioning and operating the function
PLC programming
The paragraph below contains definitions of some basic terms used in PLC
programming:
●Resources are objects for organizing a project, keeping track of variable
values and configuring the project for use on the target and in the net‐
work (global variables, variable configuration, sampling trace, PLC con‐
figuration, task configuration, watch and recipe manager).
– The variable configuration is used for configuring global variables,
which can be used in the entire project or network.
–Sampling trace provides a functionality similar to an oscilloscope
with memory function: PLC data (variable values) can be recorded
and traced.
– The PLC configuration makes it possible to configure the PLC
hardware. "IndraMotion MLD-S" does not require a PLC configura‐
tion, since the device inputs/outputs can be distributed between
drive and PLC and addressed with the commissioning software.
– It is possible, but not required, to control the processing of a project
(control the program) via tasks; if no task configuration is available,
the project has to contain the "PLC_PRG" function block.
– The watch manager allows the values of the entered variables to
be displayed in online mode. The recipe manager allows variables
to be preset with constant values.
● A task is a time unit in the processing of an IEC program. It is defined by
a name, a priority and a type. The type determines which condition will
trigger the start of the task. This condition can either be defined by a
time (cyclic interval, freewheeling) or by an internal or external event
that is to trigger the task, e.g., the rising edge of a global project variable
or an interrupt event of the control unit.
● A function is a block with the following properties:
– A function returns exactly one piece of data (which can also con‐
tain multiple elements, such as arrays or structures) when it is exe‐
cuted.
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– A function can be called in textual languages as an operand used
in expressions.
– A function has no "memory", i.e., the contents of variables are not
stored.
– A function does not need an instance.
● A function block has the following properties:
– A function block can return several values.
– A function block has a "memory", i.e., the contents of variables are
stored.
– A function block requires an instance be specified.
●Programs are globally known in the entire project. Programs are not in‐
stantiated. The variables of the program only exist once. Programs can
be called in a task. A task can call several programs and a program can
call functions, function blocks or other programs.
● The boot project is a project loaded on the target (here a drive controller
from the "Rexroth IndraDrive" range with the functional firmware pack‐
age for "IndraMotion MLD") and started when booting up the drive con‐
troller depending on the setting (cf. "P-0-1367, PLC configuration").
PLCopen
PLCopen is an organization in which several manufacturers have collabora‐
ted to standardize programming interfaces, commissioning and maintenance,
and therefore harmonize programming access to motion control.
Independence from the control architecture is achieved by encapsulating
functionality and function block data, i.e., applications programmed according
to the standard developed by PLCopen ("PLCopen Motion Control Profile", a
set of IEC 61131-3 function blocks) are independent of the executing hard‐
ware and therefore can be reused beyond platform limits.
IEC 61131
As is common in IEC 61131, libraries are provided with the IndraWorks
packages of "IndraMotion MLD". They contain ready-made functions, function
blocks and variables which are used as black boxes. There are two types of
libraries:
● Firmware libraries: They do not contain any code, just declarations. The
code is hard coded in the firmware.
● IEC libraries: They have been programmed in accordance with
IEC 61131-3 and, if required, their codes can be write- or read-protec‐
ted.
1.5.7 Function overview and system properties
General basic functions of the integrated PLC
Freely programmable PLC in accordance with IEC 61131
By defining the industry standard for programming in automation,
IEC 61131-3 has for the first time established the basics of combined logic
and motion control. These are, in essence:
● Defining the SFC (Sequential Function Chart) as a powerful program‐
ming tool for data flow-oriented programs, such as controllers
● Defining the Pascal-esque ST (Structured Text) high-level language as
a powerful instrument even for programming complex (e.g., mathemati‐
cal) functionalities
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Introduction
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