Bosch Rexroth NYCe 4000 User manual

NYCe 4000
Multi-axis motion control system
SERCOS III Master Module NY4150/10
Instructions
R911337377
Edition 05

NYCe 4000 Multi-axis motion control
system
List of trademarks
Products in this publication are referred to by their general trade names. In
most, if not all cases, these designations are claimed as trademarks or
registered trademarks of their respective companies.
Copyright
© Bosch Rexroth AG 2021
All rights reserved, also regarding any disposal, exploitation, reproduction,
editing, distribution, as well as in the event of applications for industrial
property rights.
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
documentation and the availability of the product.
Published by
Bosch Rexroth AG
P.O. Box 7170 ■ 5605 JD Eindhoven ■ The Netherlands
http://www.boschrexroth.com
RS-285a379aab3e874d0a347e860e2f1549-1-en-US-9

Table of Contents
Page
1 About this Documentation..................................................................... 1
1.1 Overview – target groups & product phases.......................................... 1
1.2 Intended audience................................................................................. 1
1.3 Availability.............................................................................................. 1
1.4 Included parts........................................................................................ 2
1.5 Variations............................................................................................... 2
1.6 Further available documentation........................................................... 2
1.7 Additional parts..................................................................................... 2
2 Product Identification and Scope of Delivery........................................ 3
2.1 Product identification............................................................................ 3
2.2 Scope of delivery................................................................................... 4
3 Using the Safety Instructions................................................................. 4
3.1 Safety instructions - structure............................................................... 4
3.2 Explaining signal words and safety alert symbols.................................. 5
4 Intended Use.......................................................................................... 6
5 Accessories, Spare Parts and Wear Parts.............................................. 6
6 Ambient Conditions............................................................................... 6
7 Technical Data........................................................................................ 7
7.1 Logic power supply................................................................................ 7
8 Standards.............................................................................................. 7
8.1 Used standards...................................................................................... 7
8.2 CE marking............................................................................................. 7
8.3 UL certification...................................................................................... 8
8.4 China RoHS 2 marking........................................................................... 9
9 Interfacing.............................................................................................. 9
10 Installation and Removal........................................................................ 9
10.1 General.................................................................................................. 9
10.2 Mechanical dimensions........................................................................ 10
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Table of Contents
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Page
10.3 Installation of the SERCOS III Master module..................................... 11
10.4 Removal of the SERCOS III Master module......................................... 11
11 Commissioning.................................................................................... 11
11.1 General................................................................................................ 11
11.2 Logic power supply.............................................................................. 12
11.3 Configuration....................................................................................... 12
12 Description of the SERCOS III Master module.................................... 12
13 Diagnosis............................................................................................. 12
14 IT-security............................................................................................ 13
15 Maintenance........................................................................................ 14
16 Disposal............................................................................................... 14
16.1 Products.............................................................................................. 14
16.2 Packaging materials............................................................................. 14
16.3 Environmental protection.................................................................... 14
17 Service and support............................................................................ 15
18 Appendix – Declaration of Conformity................................................. 16
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Table of Contents
NYCe 4000 Multi-axis motion control
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Bosch Rexroth AG R911337377_Edition 05

1 About this Documentation
1.1 Overview – target groups & product phases
The target groups, product phases and activities that can refer to this document
are marked in rounded boxes in the following figure.
Presales Aftersales
Selection Mounting
(assembly/installation)
Engineering
Commissioning
Operation
Decommissioning
Product
phases
Target
groups
Activities
Design engineer
Programmer
Technologist
Process
specialist
Select
Prepare
Design
Construct
Mechanic/
electrician
Unpack
Mount
Install
Programmer
Commissioning engineer
Parameterize
Program
Configure
Simulate
Technologist
Process specialist
Optimize
Test
Machine
operator
Maintenance
technician
Service
Operate
Maintain
Remove
faults
Create
the NC program
Mechanic/
electrician
Disposal company
Dismount
Dispose
Fig. 1-1: Target groups, product phases and activities
1.2 Intended audience
This document explains technical and service personnel of the machine builder
how to safely install the SERCOS III Master module mechanically and electrically.
This document is not the usage manual.
1.3 Availability
These Instructions are part of the SERCOS III Master module product delivery
and must always be available for the user. If the SERCOS III Master module is
handed over to another person, these Instructions must be handed over as well.
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About this Documentation
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1.4 Included parts
Type code Material number Description
NYM04.1-SE3-MAST-NY4150/10 R911172782 NY4150/10
DOK-NY4000-SIII*NY4150-ITxx-yy-P R911337377 Instructions
xx 2-digit version number
yy language indication
Tab. 1-1: Available SERCOS III Master module
1.5 Variations
These Instructions apply to the NYCe 4000 SERCOS III Master module with the
following type code:
●NYM04.1-SE3-MAST-NY4150/10
1.6 Further available documentation
The following documentation contains detailed information. Use the listed
documentation or a newer version, if available.
Title and type code Material number
Rexroth NYCe 4000 Hardware System Manual
DOK-NY4000-HW***SYSTEM-PRRS-EN-E R911337671
Rexroth NYCe 4000 Standard Housings & Accessories Manual
DOK-NY4000-HOUSING*ACC-PRRS-EN-E R911337672
Tab. 1-2: Available documentation
1.7 Additional parts
Standard housings, Motion Control Units, host adapter, fan units, connection
cables, and more are listed in the project planning manuals (see chapter 1.6) or
on www.boschrexroth.com.
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About this Documentation
NYCe 4000 Multi-axis motion control
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Bosch Rexroth AG R911337377_Edition 05

2 Product Identification and Scope of Delivery
2.1 Product identification
Fig. 2-1: View of the NYM04.1-SE3-MAST-NY4150/10
The NYM04.1-SE3-MAST-NY4150/10 can be identified by the cover plate and the
label on the rear side of the circuit board.
●Cover plate identification.
Two LEDs are visible at the top. Below the LEDs is the text "DRV" and "NET".
At the bottom of the cover plate is the text "NY4150/10".
Two RJ45 sockets marked "PORT 1" and "PORT 2". Underneath each RJ45
socket are two LEDs.
●Label on the rear side of the circuit board.
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Product Identification and Scope of Delivery
R911337377_Edition 05 Bosch Rexroth AG

6
1
5
4
2
3
Fig. 2-2: NY4150/10 product label
1 Type code
2 Version level and status
3 Date of manufacture (yyWww)
4 Material number
5 Serial number
6 2D bar code
Tab. 2-1: NY4150/10 product label and explanation
2.2 Scope of delivery
The product delivery consists of the following items.
●NYM04.1-SE3-MAST-NY4150/10 SERCOS III Master module, material number
R911172782.
●DOK-NY4000-SIII*NY4150-ITxx-yy-P Instructions (where "xx" represents a 2-
digit version number, and "yy" the language indication), material number
R911337377.
3 Using the Safety Instructions
3.1 Safety instructions - structure
The safety instructions are structured as shown in the following example.
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Using the Safety Instructions
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Bosch Rexroth AG R911337377_Edition 05

Fig. 3-1: Safety instruction lay-out
3.2 Explaining signal words and safety alert symbols
The safety instructions in this documentation contain specific signal words
(danger, warning, caution, notice) and if necessary, a safety alert symbol
(according to ANSI Z535.6-2011).
The signal word is meant to draw the reader’s attention to the safety instruction
and signifies the degree of danger. The safety alert symbol (a triangle with an
exclamation point), which precedes the signal words "danger", "warning" and
"caution" is used to alert the reader to personal injury hazards.
In case of non-compliance with this safety
instruction, death or serious injury will occur.
DANGER
In case of non-compliance with this safety
instruction, death or serious injury can occur.
WARNING
In case of non-compliance with this safety
instruction, minor or moderate injury could
occur.
CAUTION
In case of non-compliance with this safety
instruction, property damage could occur.
NOTICE
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Using the Safety Instructions
R911337377_Edition 05 Bosch Rexroth AG

4 Intended Use
The SERCOS III Master module is for indoor use only, and may only be used in
combination with parts indicated in this document and NYCe 4000 software and
firmware. Not explicitly mentioned parts may not be installed or connected.
Do not install and use this SERCOS III Master module before you have read all
relevant documents. You must read the safety instructions and all other
directions for use before you start any work or activity with this SERCOS III
Master module.
The SERCOS III Master module has no certified functional safety on board. This
means that all precautions for a safe operation must be ensured by external
components.
5 Accessories, Spare Parts and Wear Parts
The following accessories are available for the SERCOS III Master module.
Type code and description Material number
NYA04.1-STRAIN-RELIEF-41XX-NY4901/10
Network cable strain relief bracket
R911172941
NYA04.1-STRAIN-RELIEF-4150-NY4901/40
Network cable strain relief bracket
R911403465
RK8011/xxx.x SERCOS III cable
(specify cable length when ordered)
R911316888
Tab. 5-1: Accessories for SERCOS III Master module
The SERCOS III Master module does not contain any replaceable or wear parts.
In case of failure, the entire SERCOS III Master module must be replaced.
6 Ambient Conditions
Operating Storage and transport
Maximum environment
temperature +5 °C .. +55 °C –40 °C .. +85 °C
Relative Humidity 10 % .. 90 % (non-condensing) 5 % .. 95 % (non-condensing)
Mechanical strength
Vibration: IEC 60068-2-6:2007
Vibration, broad-band:
IEC 60068-2-64:2008
Shock: IEC 60068-2-27:2008
Pollution degree 2 2
Overvoltage category II -
Maximum altitude 4000 m
Tab. 6-1: Ambient conditions
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Ambient Conditions
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Bosch Rexroth AG R911337377_Edition 05

7 Technical Data
7.1 Logic power supply
Power supply required for the logic of the SERCOS III Master module is supplied
by the Motion Control Unit in the system housing.
Type code Supply voltage Power consumption
NYM04.1-SE3-MAST-NY4150/10 Derived from MCU 3.15 W
Tab. 7-1: Logic power supply
8 Standards
8.1 Used standards
The SERCOS III Master module corresponds to the following standards.
●IEC61010-1:2010 (Safety requirements for electrical equipment for
measurement, control and laboratory use - Part 1: General requirements)
●IEC61000-6-2:2005) (Electromagnetic compatibility (EMC) - Part 6-2: Generic
standards - Immunity for industrial environments)
●IEC61000-6-4:2018 (Electromagnetic compatibility (EMC) - Part 6-4: Generic
standards - Emission standard for industrial environments)
8.2 CE marking
Declaration of Conformity
Fig. 8-1: CE logo
The SERCOS III Master module described in the present instructions complies
with the requirements and the target of the following EU directive and with the
following harmonized European standards:
●Low Voltage Directive 2014/35/EU
This product is a built-in unit which, owing to its installation characteristics, is
not able to comply with the regulations for complete apparatus, machines or
installations from the outset. For this reason, it may only be used for built-in
purposes. The product may only be assessed with regard to its electrical and
mechanical safety as well as to environmental effects (foreign bodies, moisture)
after it has been installed in the product intended for the final user. After the
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Standards
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product has been installed, its EMC properties may change. Hence the product
intended for the final user (complete apparatus, machines or installations)
should be inspected with regard to its EMC properties by the manufacturer of
the product intended for the final user.
●EMC Directive 2014/30/EU
Maintaining the EMC directive presuppose an EMC adapted installation of the
devices within the installation of the machine. The complied limit values and
standards are specified in the Rexroth Manual of associated product. The
regulations for the structure and the installation in this manual must be
maintained and realized. Tests were run using a typical installation in a test
assembly that conforms with the standards. These Rexroth products are built-in
devices for a product for the final user. The test results cannot be transferred to
every state as installed in every product intended for the final user. This
declaration does not therefore assure the EMC characteristics of the product for
the final user.
8.3 UL certification
Fig. 8-2: UL Recognized logo
The SERCOS III Master module
●NYM04.1-SE3-MAST-NY4150/10
is certified according to
●UL 61010-1:2012
UL file no. E353498
However, there can exist combinations with modules or accessories with limited
or missing certification. Therefore, verify the registration according to the UL
marking on the components.
Loss of UL conformity due to changes to the
Master module.
NOTICE
The UL marking is only valid for the Master module in its delivery status. After
any modification by the customer to the Master module the UL compliance is to
be verified.
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Standards
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Bosch Rexroth AG R911337377_Edition 05

8.4 China RoHS 2 marking
Fig. 8-3: China RoHS 2 logo
The SERCOS III Master module
●NYM04.1-SE3-MAST-NY4150/10
complies with the requirements of the Administrative Measures for the
Restriction of the Use of Hazardous Substances in Electrical and Electronic
Products, known as China RoHS 2.
9 Interfacing
The connector blocks on the circuit board at the rear side plug into the system
backplane of the system housing. More information is available in the NYCe 4000
Hardware System Manual.
10 Installation and Removal
10.1 General
Damage to components may occur if power is
applied during installation or removal.
NOTICE
●Make sure power supplies are switched off before installation or removal of
the SERCOS III Master module.
●Do not apply power until the module is installed.
Damage to components may occur due to
electrostatic discharges.
NOTICE
Comply with all ESD protective measures while working with modules and
components. Avoid electrostatic discharges.
Power supplies must be switched on/off with the disconnecting device installed
in the cabinet.
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Installation and Removal
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The SERCOS III Master module may only be used as build-in equipment in a
cabinet, which means that the end-user must provide a suitable fire and
electrical safe enclosure.
The SERCOS III Master module may only be used in combination with external
approved power supplies. The supply voltage 24V System for the system must
be separated at least by reinforced insulation from all hazardous voltages
according to the standard UL61010-1 third edition.
10.2 Mechanical dimensions
The dimensions of the SERCOS III Master module are the following.
Type code Width (mm) Height (mm) Depth (mm)
NYM04.1-SE3-MAST-NY4150/10 21.7 128.4 148.5
Tab. 10-1: SERCOS III Master module mechanical dimensions
You can see the dimensions of the SERCOS III Master module in the following
views.
Fig. 10-1: Dimensions of the SERCOS III Master module
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Installation and Removal
NYCe 4000 Multi-axis motion control
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Bosch Rexroth AG R911337377_Edition 05

10.3 Installation of the SERCOS III Master module
The SERCOS III Master module is intended for installation in a NYCe 4000
system housing with a Bosch Rexroth backplane. The SERCOS III Master module
is always installed in a slot marked with the text "DRV0", or a slot marked with
the text "S III".
Position the SERCOS III Master module in the front slot guides and gently slide
the module into the slot. Align the connectors of the module with the
connectors on the system backplane. Then push the module into the connector.
Do not use excessive force to prevent damage to the connector pins.
Tighten the two screws on the cover plate of the SERCOS III Master module to
lock the module in its slot.
If you have a SERCOS III network cable strain relief bracket as described in
chapter 5, do the following. Put the hook of the cable strain relief bracket on the
lower handle of the SERCOS III Master module and install the bracket with the
screw on the cover plate of the module. Note that some form of cable strain
relief is required.
10.4 Removal of the SERCOS III Master module
Make sure that all power supplies are switched off, the "DRV" LED on the
SERCOS III Master module is off, and capacitors in the system are fully
discharged before you remove the SERCOS III Master module.
Loosen the SERCOS III network cables from the cable strain relief bracket, then
disconnect the SERCOS III network cables.
Loosen the two screws that hold the SERCOS III Master module in the slot of
the system housing. Gently pull the SERCOS III Master module out of the slot of
the system housing. Note that you do not need to remove the cable strain relief
bracket to remove the SERCOS III Master module.
11 Commissioning
11.1 General
Damage to components may occur if power is
applied during installation or removal.
NOTICE
●Make sure power supplies are switched off before installation or removal of
the SERCOS III Master module.
●Do not apply power until the module is installed.
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Commissioning
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11.2 Logic power supply
Power supply for the logic of the SERCOS III Master module is connected via the
connector blocks at the rear side of the SERCOS III Master module and is
supplied by the Motion Control Unit in the system housing.
11.3 Configuration
The flash memory on the Motion Control Unit (MCU) contains the gateware and
microware for the logic on the SERCOS III Master module. The flash memory on
the MCU also contains a bootloader to communicate with the NYCe 4000 tools.
With the tools you can download from the PC to the MCU the required firmware
for the MCU and the required gateware and microware for the SERCOS III
Master module installed in the system housing. See for more information the
NYCe 4000 documentation delivered with the NYCe 4000 Software Release.
12 Description of the SERCOS III Master module
The SERCOS III Master module has two blocks of connectors at the rear edge of
the circuit board, which connect the SERCOS III Master module to the
backplane in the system housing. All power supply connections and interface
connections to other modules and headers on the base plate of the system
housing are established via these connector blocks.
The front side of the SERCOS III Master module has a cover plate. On the cover
plate are two LEDs visible. The LEDs are marked "DRV" and "NET". Further, on
the cover plate are two RJ45 SERCOS III network sockets marked "PORT 1" and
"PORT 2".
13 Diagnosis
After the installation of the SERCOS III Master module in the system housing
(which includes an installed Motion Control Unit), and connection of the power
supply, you can check the operation of the SERCOS III Master module.
The "DRV" LED shows the status of the SERCOS III Master module.
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Diagnosis
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Bosch Rexroth AG R911337377_Edition 05

"DRV" LED indication
(visible color)
Description
Red continuously
Default setting when the SERCOS III Master module starts, power up.
Fatal error on the SERCOS III Master module, or gateware or microware
or SERCON100M is not or not correctly loaded, or module not
operational, because a communication problem is detected.
The NYM04.1-SE3-MAST-NY4150/10 is only supported in NYCe 4000
Software Release 40V00 or higher.
Orange continuously Gateware, microware and SERCON100M loaded, but node not yet
operational, because other drive modules in the node are initializing.
Green continuously SERCOS III Master module OK.
Tab. 13-1: "DRV" LED status
The "NET" LED shows the status of the microprocessor and the SERCOS III
network connected to the SERCOS III Master module.
"NET" LED indication
(visible color)
Description
Off
Microprocessor not (yet) started. The MCU is starting, and has not yet
started the microprocessor.
After downloading new software to flash memory of the
microprocessor a reset is required to start the new software.
Orange continuously During the power-up of the microprocessor, POST (Power On Self
Test), or downloading software or SERCON100M bitfile.
Green continuously SERCOS III network is ready.
Red flashing The SERCOS III network is not ready. Cables not connected, loop not
closed, IndraDrive not powered or network is being enumerated.
Tab. 13-2: "NET" LED status
On the NYM04.1-SE3-MAST-NY4150/10 two LEDs for information indication of
the SERCOS ring are mounted underneath the RJ45 sockets. The left (orange)
LED indicates that data is transported over the Ethernet connection. The right
(green) LED indicates that the Ethernet cable is correctly connected.
See the NYCe 4000 Hardware System Manual for more information.
If the NYCe 4000 software is installed on the PC and the PC is connected to the
Motion Control Unit, you can start the NYCeConfigurator program and download
the required gateware. See the NYCe 4000 Tools Manual for more information.
14 IT-security
The operation of installations, systems and machines requires the
implementation of an integral concept for state-of-the-art IT security. Bosch
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IT-security
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Rexroth products are part of this integral concept. Bosch Rexroth product
characteristics have to be taken into consideration in an integral IT security
concept. The relevant characteristics are documented in the IT security guideline
(R911342562).
15 Maintenance
The SERCOS III Master module has no special maintenance requirements.
16 Disposal
16.1 Products
Our products can be returned to us free of charge for disposal. It is a
precondition, however, that the products are free of oil, grease or other dirt. In
addition, when returned the products must not contain any undue foreign
matter or foreign component.
Please send the products “free domicile” to the following address:
Bosch Rexroth AG
Bgm-Dr.-Nebel-Str. 2
97816 Lohr a.Main, Germany
16.2 Packaging materials
The packaging materials consist of cardboard, wood and polystyrene. They can
be easily recycled. For ecological reasons you should not return the empty
packages to us.
16.3 Environmental protection
●No release of hazardous substances.
Our products do not contain any hazardous substances that they can release
in the case of appropriate use. Normally there are not any negative effects on
the environment to be expected.
●Materials contained in the products.
Electronic devices.
Electronic devices mainly contain
– steel
– aluminum
– copper
– synthetic materials
– electronic components and modules
●Recycling.
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Disposal
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Due to their high content of metal most of the product components can be
recycled. In order to recycle the metal in the best possible way it is necessary
to disassemble the products into individual modules. The metals contained in
the electric and electronic modules can also be recycled by means of specific
separation processes.
The synthetic materials remaining after these processes can be thermally
recycled.
17 Service and support
Our worldwide service network provides an optimized and efficient support.
Our experts offer you advice and assistance should you have any queries. You
can contact us 24/7.
Service Germany
Our technology-oriented Competence Center in Lohr, Germany, is responsible
for all your service-related queries for electric drive and controls.
Contact the Service Hotline and Service Helpdesk under:
Phone: [phone]
Fax: [phone]
E-mail: [e-mail]
Internet: http://www.boschrexroth.com
Additional information on service, repair (e.g. delivery addresses) and training
can be found on our internet sites.
Service worldwide
Outside Germany, please contact your local service office first. For hotline
numbers, refer to the sales office addresses on the internet.
Preparing information
To be able to help you more quickly and efficiently, please have the following
information ready:
●Detailed description of malfunction and circumstances
●Type plate specifications of the affected products, in particular type codes
and serial numbers
●Your contact data (phone and fax number as well as your e-mail address)
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Service and support
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18 Appendix – Declaration of Conformity
Fig. 18-1: EU Declaration of conformity - page 1
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Appendix – Declaration of Conformity
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Bosch Rexroth AG R911337377_Edition 05