Bosch Rexroth NYS04.1-ST-01-LMS-SERCOS-NY4078 User manual

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1 About this Documentation
1.1 Overview – target groups & product phases
The target groups, product phases and activi-
ties that can refer to this document are marked
in rounded boxes in the following figure.
Selection Mounting
(assembly/installation)
Engineering
Commissioning
Operation De-commissioning
Product phases
Presales Aftersales
Design engineer
Programmer
Technologist
specialist
Mechanic/
electrician
Process
Commissioning engineer
Programmer
Technologist
Process specialist
Machine
operator
Maintenance
technician
Service
Mechanic/
electrician
Disposal company
To select
To prepare
To design
To construct
To unpack
To mount
To install
To parameterize
To program
To configure
To simulate
To optimize
To test
To operate
To maintain
To remove
faults
To create
the program
To dismount
To dispose
Target groups
Activities
1.2 Intended audience
This document explains technical and service
personnel of the machine builder how to safely
install the system housing mechanically and
electrically. This document is not the usage
manual.
1.3 Availability
These Instructions are part of the NYS04.1-ST-
01-LMS-SERCOS-NY4078 system housing
product delivery and must always be available
for the user.
If the system housing is handed over to another
person, these Instructions must be handed over
as well.
1.4 Included parts
Headers for the 24V System and SE connectors
are also included.
1.5 Variations
These Instructions apply to the NYCe 4000
system housings with the following type code:
•NYS04.1-ST-01-LMS-SERCOS-NY4078
1.6 Further available documentation
1.7 Additional parts
Motion Control Units, host adapter, SERCOS
III Master module, fan unit, connection cables,
and more are listed in the project planning
manuals or on www.boschrexroth.com
2 Product Identification and Scope of
Delivery
2.1 Product identification
The NYS04.1-ST-01-LMS-SERCOS-NY4078
has two slots, one for the Motion Control Unit
(MCU) and one for the SERCOS III Master
module.
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
Type code
Material
number
Description
NYS04.1-ST-01-LMS-SERCOS-
NY4078
R911172617
System housing
DOK-NY4000-LMS*SERCOS*-IT07-
EN-P
R911336853
Instructions
EN
Instructions
Rexroth NYS04.1-ST-01-LMS-SERCOS-NY4078
Bosch Rexroth AG
Electric Drives and Controls
Bgm.-Dr.-Nebel-Str. 2
D-97816 Lohr am Main
Telefon [phone]
Telefax [phone]
www.boschrexroth.com

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Page 2 of 10
View of the NYS04.1-ST-01-LMS-SERCOS-NY4078
Consult the documentation for
detailed information.
The Power Marking label indicates the rating
of the system housing and other information.
1 2 3
4
5
8
10
9
11
12
Bosch Rexroth AG Bgm.-Dr.-Nebel-Str. 2, D-97816 Lohr a. Main
16
15
14
13
6
7
Example of the Power Marking label
See the following table for an explanation of
the fields indicated by a number.
1
Logotype
2
Type code
3
Division number / plant number
4
Change index
5
Rated voltage and current
6
UL marking
7
Consult documentation marking
8
Degrees of protection provided by
enclosure (IP code)
9
Designation of origin
10
Date of manufacture (yyWww)
11
Rexroth bar code
12
Serial number
13
Company address
14
Test marking
15
CE marking
16
Material number
2.2 Scope of delivery
The product delivery consists of the following
items.
•NYS04.1-ST-01-LMS-SERCOS-NY4078
system housing, material number
R911172617
•DOK-NY4000-LMS*SERCOS*-IT07-EN-
P Instructions, material number
R911336853.
•Cable connector parts for 24V System, SE.
3 Using the Safety Instructions
3.1 Safety instructions - structure
The safety instructions are structured as fol-
lows.
3.2 Explaining signal words and safety alert
symbol
The safety instructions in this documentation
contain specific signal words (danger, warning,
caution, notice) and, if necessary, a safety alert
symbol (according to ANSI Z535.6-2006).
The signal word is meant to draw the reader’s
attention to the safety instruction and signifies
the degree of danger.

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The safety alert symbol (a triangle with an ex-
clamation 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 in-
struction, death or serious injury will occur.
______________________________________
______________________________________
In case of non-compliance with this safety in-
struction, death or serious injury can occur.
______________________________________
______________________________________
In case of non-compliance with this safety in-
struction, minor or moderate injury could oc-
cur.
______________________________________
______________________________________
In case of non-compliance with this safety in-
struction, property damage could occur.
______________________________________
4 Intended Use
The system housing is for indoor use only, and
may only be used with parts indicated in this
document. Not explicitly mentioned parts may
not be installed or connected. This also applies
to cables. Usage is only allowed in explicitly
indicated configurations and combinations of
parts and with the specified software and
firmware.
Do not install and use this system housing
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 system housing.
The system housing has no certified func-
tional safety on board. This means that all pre-
cautions for a safe operation must be ensured
by external components.
5 Accessories, Spare Parts and Wear
Parts
The following accessories are available for this
system housing.
The system housing does not contain any re-
placeable or wear parts. In case of failure, the
entire system housing must be replaced.
6 Ambient Conditions
Free air flow in vertical direction is required
above and below the system housing for a dis-
tance of minimal 10 cm for forced cooled sys-
tems and 20 cm for convection cooled systems.
If convection cooling is used (instead of
forced cooling) the system housing must be in-
stalled vertical to ensure sufficient free air flow
through the ventilation holes. In particular,
bend cables away from the ventilation holes as
near to the connectors as possible.
7 Technical Data
Requirements on Mains Circuits.
•Mains Circuits of overvoltage category II
up to 300 V AC rms.
7.1 Power supply
The power supply specifications for the system
housing are the following.
Typecode
Material
number
Description
NYA04.1-FAN-1DRV-
NY4922/00
R911328062
Fan unit - 1 drive slot
NYA04.1-STRAIN-RELIEF-
5PCS-4110-NY4901
R911322873
Strain relief for
NYM04.1-MCU-
NNNN-NY4110
NYA04.1-STRAIN-RELIEF-
41XX-NY4901/10
R911172941
Strain relief for
NYM04.1-MCU-
NNNN-NY4110,
NYM04.1-MCU-
FCAT-NY4111
System housing power supply
Voltage and current
Nominal voltage
24V DC ± 5 %
Maximum supply current
3A
Inrush current 6A for 10 ms
Operating
Storage and transport
Maximum environ-
ment temperature
+5 ... +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, broadband:
IEC 60068-2-64:2008
Shock:
IEC 60068-2-27:2008
Pollution degree
2
2
Overvoltage category
II
Maximum altitude
4000 m

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8 Standards
8.1 Used standards
The components of the system housing corre-
spond to the following standard.
•EN61010-1:2010 (IEC61010-1:2010)
(Safety requirements for electrical equip-
ment for measurement, control and labor-
atory use - Part 1: General requirements)
•EN61000-6-2:2005 (IEC61000-6-2:2005)
(Immunity for industrial environments)
•EN61000-6-4:2007/A1:2011
(IEC61000-6-4:2006/A1:2010)
(Emission for industrial environments)
8.2 CE marking
Declaration of Conformity
The system housings described in the present
instructions, comply with the requirements and
the target of the following EU directive and
with the following harmonized European
standards:
•Low Voltage Directive 2006/95/EC
This product is a built-in unit which, owing to
its installation characteristics, is not able to
comply with the regulations for complete appa-
ratus, 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 (for-
eign bodies, moisture) after it has been in-
stalled in the product intended for the final us-
er. After the product has been installed, its
EMC properties may change. Hence the prod-
uct intended for the final user (complete appa-
ratus, machines or installations) should be in-
spected with regard to its EMC properties by
the manufacturer of the product intended for
the final user.
•EMC Directive 2004/108/EC
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 real-
ized. 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
The system housing
-NYS04.1-ST-01-LMS-SERCOS-NY4078
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 device.
______________________________________
Loss of UL conform-
ity due to changes to the system housing.
The UL marking is only valid for the system housing
in its delivery status. After any modification by the
customer to the system housing the UL compliance
is to be verified.
______________________________________
8.4 China RoHS 2 marking
The NYS04.1-ST-01-LMS-SERCOS-NY4078
complies with the requirements of the Admin-
istrative Measures for the Restriction of the
Use of Hazardous Substances in Electrical and
Electronic Products, known as China RoHS 2.

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9 Interfaces
9.1 Overview
9.2 24V System – Power supply connection
The connector ‘24V SYSTEM’connects the
24V power supply to the system housing for all
modules in the module holder.
Connect the minus at the power supply side of
the cable to the housing and/or to protective
earth (if this is not already the case). If the ca-
ble has a shield, connect the shield at the sys-
tem housing side to the shield pin in the con-
nector or the connector housing, and connect
the shield on the other side of the cable to the
housing of the power supply.
Make sure that the power supply cable diame-
ter is suitable for the maximum rated current.
9.3 SE – Service connection
The connector ‘SE’are inputs to set the opera-
tion mode of the system to “service mode” and
to execute an as fast as possible shutdown,
called “stop axes”.
9.4 Fan – Fan connection
The connector ‘FAN’is a power supply con-
nector for the fan unit that can be installed un-
derneath the module holder for forced cooling.
9.5 MUX – LMS MUX Control connection
These connectors connect the analog output
signals and digital input selection lines to con-
trol the LMS MUX.
•MUX0 connects analog input 0 and 1.
•MUX1 connects analog input 2 and 3.
•MUX2 connects analog input 4 and 5.
•MUX3 connects analog input 6 and 7.
Always use shielded cables with twisted pairs
for each differential signal. Connect the shield
at the system housing side to the connector
housing. If the equipment on the other end has
metal parts, connect the shield to the equip-
ment housing. If the equipment on the other
end does not have metal parts, connect the
shield to the equipment ground via a 100 Ωre-
sistor.
Never connect the GND or minus wire of these
signals to other GND connections, otherwise
malfunction of the module is possible.
9.6 Other interfaces
The system housing will always have a Motion
Control Unit (MCU) installed in the leftmost
slot, and a SERCOS III Master module in the
slot at the right side. The MCU has three con-
nections available to connect to other system
housing(s) and/or a PC. Depending on the
MCU type the connection is Ethernet or
IEEE 1394b. On the SERCOS III Master mod-
ule are two RJ45 sockets to connect two SER-
COS III cables to IndraDrives. More infor-
mation can be found in the NYCe 4000 Project
Planning manuals.
10 Installation and Removal
______________________________________
Damage to components
may occur if power is applied during instal-
lation or removal.
•Make sure power supplies are switched
off before installation or removal of the
system housing.
•Do not apply power until the system
housing is installed.
______________________________________
Connector data
MC 1,5/ 4-STF-3,5
minimum
maximum
Tightening torque
1,95 lbs*inch (0,22 Nm)
2,21 lbs*inch (0,25 Nm)
Wire diameter
30 AWG (0,14 mm2)
14 AWG (1,5 mm2)
Connector data
MC 1,5/ 3-STF-3,5
minimum
maximum
Tightening torque
1,95 lbs*inch (0,22 Nm)
2,21 lbs*inch (0,25 Nm)
Wire diameter
30 AWG (0,14 mm2)
14 AWG (1,5 mm2)
Designation
on base plate
Connection type
Connection
(base plate)
Connection
(cable)
24V System
24V DC system
power supply
3-pin male
Phoenix
MC 1,5/ 3-STF-3,5
SE
Service inputs
4-pin male
Phoenix
MC 1,5/ 4-STF-3,5
Fan
System fan unit
2-pin male
MUX0
MUX1
MUX2
MUX3
LMS MUX
Control
15-pin
Sub-D male
Protective earth
connection
M5 threaded
screw

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Power supplies must be switched on/off
with the disconnecting device installed in the
cabinet.
The system housing 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 safety of any
system incorporating the system housing is the
responsibility of the assembler of the system.
The system housing 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 rein-
forced insulation from all hazardous voltages
according to the standard UL61010-1 third edi-
tion.
10.1 Mechanical dimensions
The dimensions of the system housings are the
following:
You can see the dimensions of the system
housing in the following views. The dimen-
sions given in the view exclude free clearance
space required for attached cables, accessories
and cooling requirements.
Dimensions (front view) NYS04.1-ST-01-LMS-SERCOS-NY4078
Dimensions (side view) NYS04.1-ST-01-LMS-SERCOS-NY4078
10.2 Mechanical installation of the system hous-
ing
Make sure that you observe the minimum ven-
tilation space at the top and bottom side of the
system housing, see the following picture.
Type code
Width
Height
Depth
NYS04.1-ST-01-LMS-SERCOS-
NY4078
125
mm
170
mm
157.9
mm

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Page 7 of 10
≥100 mm
≥200 mm
F
L R
The minimum distance above and below the
module holder is required for cooling. Free
clearance space in front of the module holder
(“F”) is needed for the optional strain relief
brackets and for bending the IEEE 1394b and
SERCOS III cable(s). As a rule of thumb, 100
mm is sufficient. The free distance on the left
side (L) of the system housing must be suffi-
cient to access the connectors at those sides.
For convection cooled systems the system
housing must be installed vertically to allow
free air flow from bottom to the top. For forced
cooled systems it is allowed to install the sys-
tem housing horizontally.
Install the system housing on a vertical
metal surface, and ensure electrical contact be-
tween the system housing and this surface, ei-
ther by means of washers under the screw
heads or use the protective earth post on the
system housing with washers and nuts. Ensure
that there is electrical contact between the sys-
tem housing and the mounting base of all other
equipment installed on the metal frame or
mounting base.
Each protective earth connection may be
routed in the most convenient manner for the
equipment concerned. The NYCe 4000 system
put no extra requirements on the protective
earth wiring – no central earth point or similar
constraint.
10.3 Mechanical removal of the system housing
Make sure that all power supplies are switched
off before you remove the system housing.
Then disconnect the 24V System power
supply connector. Finally, disconnect all re-
maining connectors and protective earth con-
nections.
Remove the screws that mount the system
housing on the metal surface in the machine.
10.4 Protective Earth connection
For safety reasons, a protective earth connec-
tion via the threaded earth post is mandatory.
The protective earth connection must be
connected before any other cables are connect-
ed to the system housing.
The protective earth connection must be
realized using an as short as possible cable, or
better a braided band, with a faston at the sys-
tem housing side.
The protective earth connection is fastened
on the M5 threaded post on the system housing
using a ring, the faston with the cable or the
braided band, a spring washer and a nut, in that
order. Tighten the nut with a nut spanner.
You must adhere to the installation re-
quirements of your country.
10.5 Configuration
The left side of the system housing is the side
where the ‘24V System’ power supply con-
nector is located.
The slot on the left side is called ‘MCU’
and is a slot dedicated for the installation of the
Motion Control Unit (MCU).
The slot at the right side of the MCU module
in the module holder is called ‘SIII’ and is a
slot dedicated for the installation of the
NYM04.1-SE3-MAST-NY4150 SERCOS III
Master module.
10.6 System power supply connection
A power on/off switch or circuit breaker is not
part of the system housing. You must imple-
ment the following in the installation.
•A switch or circuit breaker must be
included in the installation.
•The switch or circuit breaker must be
placed at a suitable location and must be
easy accessible.

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•The switch or circuit breaker must be
marked as the disconnecting device for
the system housing power supply.
11 Commissioning
-Check that the system housing is mechani-
cally solid mounted in the machine.
-Verify that the protective earth connection is
correctly connected.
-Check that proper cabling is used.
-Check that the shielding of shielded cables is
correctly connected.
-Check that cables are not damaged.
Install the MCU module in the leftmost slot
called ‘MCU’ and the SERCOS III Master
module in the slot at the right side called ‘SIII’
in the module holder of the system housing.
See the Instructions of the MCU module and
SERCOS III Master module.
The flash memory on the MCU contains a
bootloader to communicate with the
NYCe 4000 tools such as NYCeConfigurator.
The NYCe 4000 tools are available if the
NYCe 4000 software is installed on the PC.
With the tools you can download from the PC
to the MCU the required firmware for the
MCU and the required gateware for the drive
modules installed in the system housing.
12 Description of the system housing
The system housing has no indicators. All in-
dications (LED) are on the MCU and SERCOS
III Master module. See the Instructions of the
MCU module and drive modules.
4
5
123
6
1
24V System, SE, Fan connectors
2
Motion Control Unit slot
3
SERCOS III Master module slot
4
Mounting screw opening (4)
5
Protective earth post
6
MUX I/O connectors (4)
13 Diagnosis
Diagnostic activities are only possible after the
system housing is installed and the 24V Sys-
tem power supply is connected. Further, an
MCU module must be installed in the leftmost
slot of the module holder. The LED indicators
on the cover plate of the MCU will show that
power is present. See the NYCe 4000 Hard-
ware System Manual for more information
about the LED indicators on the MCU and
SERCOS III Master module.
Note that the NYCe 4000 software must be
installed on the PC and an IEEE 1394b cable
must be connected from the PC to the MCU to
communicate with the system.
If the NYCe 4000 software is installed on
the PC, you can start the NYCe 4000 tools to

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Page 9 of 10
do a further analysis in case of any problems.
See the NYCe 4000 Tools Manual for more in-
formation.
14 Maintenance
The system housing has no special mainte-
nance requirements.
15 Disposal
15.1 Products
Our products can be returned to us free of
charge for disposal. It is a precondition, how-
ever, that the products are free of oil, grease or
other dirt. In addition, when returned the prod-
ucts must not contain any undue foreign matter
or foreign component.
Please send the products “free domicile” to the
following address:
Bosch Rexroth AG
Electric Drives and Controls
Bürgermeister-Dr.-Nebel-Straße 2
D-97816 Lohr am Main, Germany
15.2 Packaging materials
The packaging materials consist of cardboard,
wood and polystyrene. They can be easily re-
cycled. For ecological reasons you should not
return the empty packages to us.
15.3 Environmental protection
•No release of hazardous substances.
Our products do not contain any hazard-
ous substances that they can release in the
case of appropriate use. Normally there
are not any negative effects on the envi-
ronment to be expected.
•Materials contained in the products.
Electronic devices
Electronic devices mainly contain:
- steel
- aluminum
- copper
- synthetic materials
- electronic components and modules
•Recycling.
Due to their high content of metal most
of the product components can be recy-
cled. In order to recycle the metal in the
best possible way it is necessary to disas-
semble the products into individual mod-
ules. The metals contained in the electric
and electronic modules can also be recy-
cled by means of specific separation pro-
cesses.
The synthetic materials remaining after
these processes can be thermally recy-
cled.
16 Service and Addresses
16.1 Service
Our service department at our main facility
Bosch Rexroth AG
Bgm.-Dr.-Nebel-Str.2
D-97816 Lohr am Main
is always available for information and help.
You can reach us at:
•TelephoneMon. - Fri.: 7:00 - 18:00 CET
[phone]
•Fax : [phone]
•Email: [e-mail]
Outside service office hours you can reach
Service Deutschland directly at:
•[phone] or
•[phone]
Please check the internet company addresses
for hotline call numbers in other countries.
16.2 Addresses
You can find the addresses of our companies
on www.boschrexroth.com.
On the website you can also find addi-
tional information for service, repair (for ex-
ample supplier addresses) and training.
Please contact your nearest supplier or repre-
sentative in your country first before contact-
ing Service Deutschland, if you are outside
Germany.

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Page 10 of 10
Notes