Bosch Rexroth CKL Series Guide

Commissioning the CKL Drive
Controller
USL00010
01.2015

Bosch Rexroth Corp., USL00010, 01.2015
The data specied only serve to describe the
product. No statements concerning a certain
condition or suitability for a certain application
can be derived from our information. Catalog
specications do not constitute assured
characteristics. The information given does
not release the user from the obligation of
own judgment and verication. It must be
remembered that our products are subject to a
natural process of wear and aging.
© This document, as well as the data,
specications and other information set forth in
it, are the exclusive property of Bosch Rexroth
Corp. It may not be reproduced or given to
third parties without its consent.
Original instruction manual.
2

01.2015, USL00010, Bosch Rexroth Corp.
Contents
1 General 4
2 Commissioning 4
3 Commissioning Flowcharts 5
4 Preconditions 8
5 Network Connection 9
6 Firmware 11
7 Language Selection 14
8 Master Communication 15
9 Power Supply 16
10 Scaling/Mechanical System 17
11 Limit Values 19
12 Motor 21
13 Motor Encoder 26
14 Data Reference Motor Encoder 27
15 Axis Control Parameters 28
16 Commutation Settings 29
17 Easy Startup Mode 30
18 Drive Error Diagnostics 31
19 DetermineCommutationOset 33
20 Enable Drive Power 34
21 VerifyCommutationOset 35
22 Home Axis 36
23 Stop Initial Commissioning Mode 37
24 Save/Backup Parameters 38
25 Move Axis 39
26 Optimize Control Loops 40
3Contents

Bosch Rexroth Corp., USL00010, 01.2015
1 General
1.1 Scope and purpose of the documentation
• This document is intended to be a guideline for initial axis commissioning of the CKL Linear
Motor Module.
• The parameters found within are based solely on the use of Bosch Rexroth IndraDrive Cs
servo drives.
• For 3rd Party Servo Drives, while items on the initial parameter set may be the same, expect
minor adjustment requirements depending on the Drives‘ Manufacturer recommendations.
2 Commissioning
• Verify actual CKL system in-hand and all Preconditions (see page 5).
• Print or display the “Commissioning Flowchart” Part 1 and Part 2 relevant to Hall sensor
type as you commission the CKL system.
• Step through the owchart by reading the relevant instruction pages.
• Please be advised, the instruction pages are NOT meant to be completely read straight-
through in page order. For example, if using analog Hall sensor, not all instruction pages are
necessary (see owchart). Furthermore, depending on success/failure of a step, looping
through previous steps might be required (see owchart).
4General Information

01.2015, USL00010, Bosch Rexroth Corp.
3 Commissioning Flowcharts
3.1 Commissioning Flowchart – Part 1

Digitalornone
Analog
StartInitialCommissioning
NetworkConnection
Firmware
LanguageSelection
MasterCommunication
PowerSupply
Scaling/MechanicalSystem
LimitValues
DataReferenceMotorEncoder

Preconditions
Motor

MotorEncoder

HallSensor?
AnalogHall
DigitalHallorwithoutHall
AxisControlParameters

Proceed to Part 2 for relevent Hall Sensor type.
5Commissioning Flowcharts

Bosch Rexroth Corp., USL00010, 01.2015
3.2 Commissioning Flowchart – Part 2 – Analog Hall
AnalogHall
Yes
No
EasyStartupMode

PMtoOM?
DriveErrorDiagnostics

HomeAxis

FinishedInitialCommissioning
EnableDrivePower

Yes,with
Basic
Parameters
Yes,withOptimizedParameters
No
SaveBasicParameters

OptimizeControlLoops

MoveAxis

MotionOK?
SaveOptimizedParameters

6Commissioning Flowcharts

01.2015, USL00010, Bosch Rexroth Corp.
3.3 Commissioning Flowchart – Part 2 – Digital Hall or without Hall
No
Yes
DigitalHallorwithoutHall
No
Yes
No
CommutationSettings

EasyStartupMode

PMtoOM?
DriveErrorDiagnostics

DetermineCommutationOffset

Successful?
VerifyCommutationOffset

StopInitialCommissioningMode

SaveBasicParameters

DisableDrivePower

FinishedInitialCommissioning
EnableDrivePower

OptimizeControlLoops

ManuallyRepositionAxistoAllow
UnrestrictedMovement

MoveAxis

MotionOK?
SaveOptimizedParameters

HomeAxis

Yes,with
Basic
Parameters
Yes,withOptimizedParameters
NotOK
OK
P519Bit1=1,commutationoffsetoptimizedtoref(homed)point
P519Bit1=0,commutationoffsetnotoptimized
7Commissioning Flowcharts

Bosch Rexroth Corp., USL00010, 01.2015
4 Preconditions
4.1 Commissioning the CKL drive controller
4.1.1 Hardware
Compact Module CKL
System size Carriage length Primary part Secondary part
CKL 110 180 mm MCP030B-V180-NI-xxCN-NNNN MCS030-3S-xxxx-NNNN
240 mm MCP030C-V180-NI-xxCN-NNNN MCS030-3S-xxxx-NNNN
300 mm MCP030D-V180-NI-xxCN-NNNN MCS030-3S-xxxx-NNNN
CKL 145 244 mm MCP040C-V300-NI-xxCN-NNNN MCS040-3S-xxxx-NNNN
364 mm MCP040E-V300-NI-xxCN-NNNN MCS040-3S-xxxx-NNNN
484 mm MCP040G-V300-NI-xxCN-NNNN MCS040-3S-xxxx-NNNN
CKL 200 237 mm MCP070C-V300-NI-xxCN-NNNN MCS070-3S-xxxx-NNNN
297 mm MCP070D-V300-NI-xxCN-NNNN MCS070-3S-xxxx-NNNN
417 mm MCP070F-V300-NI-xxCN-NNNN MCS070-3S-xxxx-NNNN
xx: L0 = digital Hall, L1 = analog Hall, N0 = without Hall
xxxx: 0120, 0180, 0300 = secondary part length mm, select any value
HCS01 IndraDrive Cs with Firmware MPx-17V08 or greater
Supported feedback combinations:
Firmware Encoder HCS01
connector
Hall unit HCS01
connector
Additional hardware requirement
MPE/B/C analog X4 without without none
MPE/B/C digital X4 without without none
MPE/B/C analog X4 digital X4 with SHL03 Hall sensor box
MPB/C digital X4 analog X8 with HCS01 dual encoder interface (EC-EC)
MPB/C analog X4 analog X8 with HCS01 dual encoder interface (EC-EC)
Firmware: MPE=Economy, MPB=Basic, MPC=Advanced
Encoder: digital encoder is supported but analog encoder is recommended with IndraDrive!
For detailed descriptions of rmware and encoders, please see the IndraDrive MPx-17 (or later) Functions
Applications Manual.
4.1.2 Software
• IndraWorks Ds 13VRS (recommended)
• IndraWorks Ds 12VRS (possible with caution*)
4.1.3 Operating System
• Windows 7 (recommended)
• Windows XP (possible with caution*)
NOTE: Caution* = software bugs, unexpected behavior, limited tests
8Preconditions

01.2015, USL00010, Bosch Rexroth Corp.
5 Network Connection
5.1 Connect PC to IndraDrive via the Non-Real Time (NRT) channel for
drive commissioning
5.1.1 Stepsforconguringthenetworkconnection:
1. Right mouse button click on Local Area Connection and select Properties in the pop-up
menu.
2. Select Internet Protocol (Windows XP) or Internet Protocol Version 4 (Windows 7).
3. Press the Properties button.
9Network Connection

Bosch Rexroth Corp., USL00010, 01.2015
5.1.1 Stepsforconguringthenetworkconnection(continued)
4. Enter a unique IP address for the PC (must be dierent than the IndraDrive, see
below note), then click inside the Subnet mask eld, the Subnet mask will default to
255.255.255.0.
5. Open IndraWorks Ds.
6. Enter the IP address of the IndraDrive, the default factory setting is 192.168.0.1.
7. Press the Browse button.
8. The connected IndraDrive appears with device information.
9. Press the OK button.
NOTE: If the IP address of the IndraDrive is 192.168.0.1, then the PC’s rst three dot-decimal
numbers must be the same (for example, 192.168.0.x). The fourth number (x) must be
dierent from that of the IndraDrive’s IP address, and be a number between 0 to 255.
10 Network Connection

01.2015, USL00010, Bosch Rexroth Corp.
6 Firmware
6.1 CheckcompatibilityandupdateIndraDrivermware
6.1.1 Stepsforcheckingrmwarecompatibility:
1. Select the Help pull-down menu, then select Info.
2. Verify that rmware version MPx-17VRS or later is supported. If not, install a later release
of IndraWorks Ds.
11Firmware

Bosch Rexroth Corp., USL00010, 01.2015
6 Firmware (continued)
6.1.1 Steps for checkingrmwarecompatibility (continued)
3. In the Explorer tree, right mouse button click on the Axis and select Properties in the
pop-up menu.
4. Verify that rmware version MPx-17V08 or later is on the IndraDrive. If not, download
new rmware to the drive.
12 Firmware

01.2015, USL00010, Bosch Rexroth Corp.
6 Firmware (continued)
6.1.2 Stepsforupdatingrmwaretothedrive:
1. Select the Diagnosis / Service pull-down menu, then select Firmware Management.
2. Press the […] browse button, select the new rmware .ibf le obtained from Rexroth
support based on the following compatibility table:
Drive Controller Type Functionality/Communication Firmware
HCS01.1E-…-E-S3-… ECONOMY / SERCOS III FWA-INDRV*-MPE-…
HCS01.1E-…-B-ET-… BASIC / Multi-Ethernet FWA-INDRV*-MPB-…
HCS01.1E-…-A-CC-… ADVANCED / SERCOS III-Master Cross Comm FWA-INDRV*-MPC-…
3. Press the Download button, the Progress bars will indicated download progression.
4. When download is complete, press the Close button.
13Firmware

Bosch Rexroth Corp., USL00010, 01.2015
7 Language Selection
7.1 Select the language for drive parameter names, units and diagnostic/
error messages
7.1.1 Stepsforconguringthedrivelanguage:
1. Select the Parameter Editor or Parameter Search window.
2. If opened the Parameter Search window, type “language” in the Text search box, and
select parameter S-0-0265 from the list.
3. Enter the desired language by typing one of the following values:
• 0 = German [factory default]
• 1 = English
• 2 = French
• 3 = Spanish
• 4 = Italian
If necessary, the IndraWorks user interface language setting can be changed by selecting
Tools → Options → Environment → Language.
14 Language Selection

01.2015, USL00010, Bosch Rexroth Corp.
8 Master Communication
8.1 ConguremastercommunicationiftheIndraDriveisMulti-Ethernet
type (i.e. Basic Universal or Advanced)
8.1.1 Stepsforconguringmastercommunication:
1. In the Explorer tree, select Master Communication.
2. Select the desired master communication in the Basic setting pull-down menu, Sercos III
is the factory default setting.
• Please be advised, selecting EtherCAT disables the Ethernet engineering
communication. Therefore, for initial drive commissioning select No master comm.
activated or Sercos III to commission the drive axis, then select EtherCAT master
communication for application programming/operation.
3. Reboot the drive to activate the changes.
15Master Communication

Bosch Rexroth Corp., USL00010, 01.2015
9 Power Supply
9.1 Congurepowersupply
9.1.1 Stepsforconguringthepowersupply:
1. In the Explorer tree, select Power Supply.
2. If drive is connected to:
• 3-phase mains supply: check box Phase monitoring of mains voltage.
• 1-phase mains supply: uncheck box Phase monitoring of mains voltage.
NOTE: For all CKL linear motor sizes, allowed mains supply 1- or 3-phase AC 110-230V
connected to drive. If a drive for higher voltage is used (e.g. 3 ~ 400V with HCS01.1E-
W00xx-A-03-…), please use a transformer and limit bleeder to 390V.
16 Power Supply

01.2015, USL00010, Bosch Rexroth Corp.
10 Scaling/Mechanical System
10.1Congurescalingandmechanicalsystem
10.1.1 Stepsforconguringscalingandmechanicalsystem:
1. In the Explorer tree, select Scaling / Units
2. Select linear (this updates units in other windows, e.g. Scaling/Units Extended, Motor Encoder, etc)
3. Select negation: no = factory default = motor eective force and encoder positive counting
directions
4. (a) Press the Extended button or (b) select Scaling/Units Extended in the Explorer tree
5. Select extended options, e.g. change velocity scaling unit from factory default mm/min to mm/s
17Scaling/Mechanical System

Bosch Rexroth Corp., USL00010, 01.2015
10 Scaling/Mechanical System (continued)
10.1.1Congurescalingandmechanicalsystem(continued)
6. In the Explorer tree, select Mechanical Gear.
7. Enter Maximum travel range and Feed constant:
• Maximum travel range = see S-0-0278 parameter help for detailed description
• Feed constant = 1 for direct drive (factory default is 10)
8. Enter Load inertia. This is actually Load mass for a linear motor axis. The value does not
have to be exact, since it is used as an initial value for automatic control loop optimization
(see IndraDrive Firmware help for command C1800). The following are approximate values
with a cable chain and empty carriage:
• 4kg: for CKL 110 with motor primary MCP030
• 5kg: for CKL 145 with motor primary MCP040
• 6kg: for CKL 200 with motor primary MCP070
Add external payload if known.
18 Scaling/Mechanical System

01.2015, USL00010, Bosch Rexroth Corp.
11 Limit Values
11.1Conguremotionlimitvalues
11.1.1 Stepsforconguringmotionlimitvalues:
1. In the Explorer tree, select Motion Limit Values
2. If application requires software limit switches, to activate functionality on the drive check
box Position limit value monitoring (factory default is unchecked), then enter the positive
and negative position limit values or bipolar limit value for symmetric +/- limit
3. If application has hardware limit switches, to activate functionality on the drive check box
Travel range limit switch monitoring (factory default is unchecked), then select switch type
(normally closed or normally open) and drive reaction when travel range exceeded:
• Warning = axis stopped, command is allowed to move axis to permissible travel range
• Error = axis fault, drive power disabled
4. Enter Velocity limit values (limit is not active if value = 0)
5. Enter acceleration and jerk limit values (limit is not active if value = 0)
19Limit Values

Bosch Rexroth Corp., USL00010, 01.2015
11 Limit Values (continued)
11.2Conguretorque/forcelimitvalues
11.2.1 Stepsforconguringtorque/forcelimitvalues:
1. In the Explorer tree, select Torque / Force Limits
2. Based on application requirements, enter torque/force limit values (factory default is
400% of the nominal continuous torque/force, see motor datasheet)
NOTE: Per parameter S-0-0086, for linear kit motors, the reference value (100% value) also
corresponds to the continuous torque at standstill or the continuous force at standstill.
In this case, the cooling factor is “1.0” because the cooling type is invariable (P-0-0640
is inactive).
20 Limit Values