REXROTH SYNAX200 Technical manual

Project Planning Manual: Version 07
DOK-SYNAX*-SY*-07VRS**-PR01-EN-P
SYNAX200
Decentralized System for the
Synchronization of Machine Axes

About this Documentation SYNAX200
DOK-SYNAX*-SY*-07VRS**-PR01-EN-P
SYNAX200
Decentralized System for the
Synchronization of Machine Axes
Project Planning Manual: Version 07
DOK-SYNAX*-SY*-07VRS**-PR01-EN-P
•Sy107E_O.doc
•Document Number 120-2200-B311-01/EN
This documentation assists
•in the selection of units and hardware components and
•in the basic control cabinet construction
Description Release
Date Notes
DOK-SYNAX*-SY*-07VRS**-PR01-EN-P 05.00 Version 07VRS
2000 Rexroth Indramat GmbH
Copying this document, giving it to others and the use or communication
of the contents thereof without express authority, are forbidden. Offenders
are liable for the payment of damages. All rights are reserved in the event
of the grant of a patent or the registration of a utility model or design (DIN
34-1).
All rights are reserved with respect to the content of this documentation
and the availability of the product.
Rexroth Indramat GmbH
Bgm.-Dr.-Nebel-Str. 2 •D-97816 Lohr a. Main
Telephone [phone] •Tx 689421 •Fax [phone]
http://www.rexroth.com/indramat
Dept. ESP (STS/TI)
This document has been printed on chlorine-free bleached paper..
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Note

SYNAX200 Contents I
DOK-SYNAX*-SY*-07VRS**-PR01-EN-P
Contents
1 Determing Drive and System Configurations 1-1
1.1 General...........................................................................................................................................1-1
2 Important Directions for Use 2-1
2.1 Appropriate Use.............................................................................................................................2-1
Introduction ..............................................................................................................................2-1
Areas of Use and Application...................................................................................................2-2
2.2 Inappropriate Use...........................................................................................................................2-2
3 Safety Instructions for Electric Servo Drives and Controls 3-1
3.1 Introduction.....................................................................................................................................3-1
3.2 Explanations...................................................................................................................................3-1
3.3 Hazards by Inappropriate Use .......................................................................................................3-2
3.4 General Information .......................................................................................................................3-3
3.5 Protection Against Contact with Electrical Parts............................................................................3-4
3.6 Protection by Protective Low Voltage (PELV) Against Electrical Shock........................................3-6
3.7 Protection Against Dangerous Movements....................................................................................3-6
3.8 Protection Against Magnetic and Electromagnetic Fields During Operations and Mounting........3-8
3.9 Protection Against Contact with Hot Parts.....................................................................................3-9
3.10 Protection During Handling and Installation...................................................................................3-9
3.11 Battery Safety...............................................................................................................................3-10
3.12 Protection Against Pressurized Systems.....................................................................................3-10
4 PPC Motion Control Configuration 4-1
4.1 Brief Description.............................................................................................................................4-1
4.2 Installation Dimensions ..................................................................................................................4-2
PPC-R01.2 and PPC-R02.2.....................................................................................................4-2
Installation dimensions of module carrier RMB02.2-02...........................................................4-3
Installation dimensions of module carrier RMB02.2-04...........................................................4-4
4.3 Installation Instructions...................................................................................................................4-5
Installing the module carriers...................................................................................................4-5
Arrangement of the module carriers ........................................................................................4-5
Installing the modules..............................................................................................................4-5
Grounding ................................................................................................................................4-6
4.4 Slot Addressing of the Module Carriers.........................................................................................4-7
4.5 Combination Options Module Carrier - PPC - I/O Module.............................................................4-8
4.6 Specifications.................................................................................................................................4-9
General Information .................................................................................................................4-9

II Contents SYNAX200
DOK-SYNAX*-SY*-07VRS**-PR01-EN-P
Power supply............................................................................................................................4-9
Digital inputs and outputs.........................................................................................................4-9
EMC.......................................................................................................................................4-10
Interfaces ...............................................................................................................................4-10
4.7 Connecting the Power Supply......................................................................................................4-11
4.8 Connecting Inputs and Outputs ...................................................................................................4-11
4.9 Connector Pin Assignments.........................................................................................................4-12
X1 (11-way Phoenix female connector).................................................................................4-12
PROG / COM interface (X10, X16)........................................................................................4-12
BT bus (X15)..........................................................................................................................4-13
4.10 Motion Control Configuration when Using the PPC-R.................................................................4-14
5 Determining Basic Drive Configuration 5-1
5.1 Procedure.......................................................................................................................................5-1
a) Definition of Precision Requirements ..................................................................................5-1
b) Selecting the Suitable Motor/Controller Combinations........................................................5-2
c) Determining the Drive Configuration Labelling....................................................................5-2
5.2 Rotary Axes....................................................................................................................................5-4
Drive with Step-Down Gear and Indirect Position Detection...................................................5-4
Drive with Step-Down Gears and Direct Incremental Position Detection................................5-6
Drive with Step-Down Gear and Direct Absolute Position Detection.......................................5-8
Drive with Indirect Position Detection ....................................................................................5-10
Drive with Direct Incremental Position Detection...................................................................5-12
Drive with Direct Absolute Position Detection........................................................................5-14
5.3 Linear Axes ..................................................................................................................................5-17
Drive with Indirect Position Detection ....................................................................................5-17
Drive with Direct Incremental Position Detection...................................................................5-19
Drive with Direct Absolute Position Detection........................................................................5-21
Drive with Linear Motor and Incremental Position Detection.................................................5-23
Drive with Linear Motor and Absolute Position Detection......................................................5-25
6 Determining the Control-Related Plug-In Cards 6-1
6.1 Determining Parallel I/Os...............................................................................................................6-1
6.2 Combination Options of the External I/O (Drive Internal) ..............................................................6-2
6.3 Determining the Master Axis..........................................................................................................6-3
6.4 Determining Analog Inputs.............................................................................................................6-6
6.5 Master Axis Position Output...........................................................................................................6-6
SSI Emulation ..........................................................................................................................6-6
Incremental Encoder Emulation...............................................................................................6-7
6.6 Encoder Branching DGA 01.2 for Encoders with Sinusoidal Voltage Signals 1Vss......................6-8
General ....................................................................................................................................6-8
Terminal Diagram ....................................................................................................................6-9
Technical Data.......................................................................................................................6-10
7 Drive Configurations 7-1
7.1 General Informations......................................................................................................................7-1

SYNAX200 Contents III
DOK-SYNAX*-SY*-07VRS**-PR01-EN-P
7.2 Drive Configurations DIAX03 Based on the Basic Configuration BE12 ........................................7-1
7.3 Drive Configurations DIAX03 Based on Basic Configuration BE32...............................................7-3
7.4 Drive Configuration DIAX03 Based on Basic Configuration BE37 ................................................7-5
7.5 Drive Configuration DIAX03 Based on Basic Configuration BE45 ................................................7-7
7.6 Drive Configuration DIAX04 Based on Basic Configuration HS12................................................7-9
7.7 Drive Configuration DIAX04 Based on Basic Configuration HS32..............................................7-11
7.8 Drive Configuration DIAX04 Based on Basic Configuration HS37..............................................7-13
7.9 Drive Configuration DIAX04 Based on Basic Configuration HS45..............................................7-15
7.10 Example .......................................................................................................................................7-17
Motion Control Configuration.................................................................................................7-17
Drive Configuration ................................................................................................................7-18
8 Set-Up SYNAX200 Ring 8-1
8.1 Data Transmission via Fibre-Optics Cable ....................................................................................8-1
Optical Transmission Ring Structure .......................................................................................8-1
Constructing the Transmission Path........................................................................................8-2
Types of Fibre-Optics Cables ..................................................................................................8-2
Fibre-Optics Cable Accessories...............................................................................................8-3
8.2 Project Planning Notes...................................................................................................................8-4
General Notes..........................................................................................................................8-4
Maximum Lengths of the Fibre-Optics Cables.........................................................................8-4
Technical Data of Available Fibre-Optics Cables ....................................................................8-4
General Safety Guidelines.......................................................................................................8-5
Handling...................................................................................................................................8-5
8.3 Set-Up............................................................................................................................................8-6
Preparations.............................................................................................................................8-6
Setting Drive Address..............................................................................................................8-8
Check Distortion Display..........................................................................................................8-8
8.4 Clearing Errors...............................................................................................................................8-8
Use of Distortion Display..........................................................................................................8-9
Setting the Transmission Rate.................................................................................................8-9
Setting the Optic Output Power .............................................................................................8-11
Checking the Fibre-Optics Cables.........................................................................................8-11
9 PPC Link 9-1
9.1 General Information .......................................................................................................................9-1
9.2 PPC Link with Simple Ring ............................................................................................................9-2
9.3 PPC Link With Double Ring...........................................................................................................9-3
9.4 Configuration Example with PPC...................................................................................................9-4
9.5 Commissioning the PPC Link ........................................................................................................9-4
General Information .................................................................................................................9-4
Commissioning ........................................................................................................................9-5
Clearing Errors.........................................................................................................................9-5
10 Set-Up Interfaces 10-1
10.1 General Information .....................................................................................................................10-1

IV Contents SYNAX200
DOK-SYNAX*-SY*-07VRS**-PR01-EN-P
10.2 Connecting the PPC.....................................................................................................................10-1
10.3 RS485 Link...................................................................................................................................10-2
11 Appendix 11-1
11.1 Dimensional Sheets, Terminal Diagrams RECO.........................................................................11-1
Mounting Dimensions Module Carrier RMB02.2-02..............................................................11-1
Mounting Dimensions Module Carrier RMB02.2-04..............................................................11-2
PPC-R01.2 and PPC-R02.2...................................................................................................11-3
DAQ03.1R..............................................................................................................................11-4
Profibus Interface DPS01 ......................................................................................................11-5
INTERBUS Interface IBS03...................................................................................................11-6
DeviceNet Interface DNS03...................................................................................................11-7
RME02.2-16-DC024 Input Module ........................................................................................11-8
RME02.2-32-DC024 Input Module ......................................................................................11-10
RME02.2-16-AC115 Input Module.......................................................................................11-12
RMA02.2-16-DC024-200 Output Module ............................................................................11-14
RMA02.2-32-DC024-050 Output Module ............................................................................11-16
RMA02.2-16-AC230-200 Output Module.............................................................................11-18
RMA02.2-16-RE230-200 Output Module.............................................................................11-20
11.2 Dimensional Sheet, Terminal Diagrams Drives.........................................................................11-22
SERCOS interface DSS02.1M.............................................................................................11-22
Input / Output interface DEA................................................................................................11-23
Encoder interface DAG01.2M (EnDat or SSI interface) ......................................................11-25
Analog interface with Actual Position Value Output DAE02.1M..........................................11-26
Absolute Encoder Emulator DSA01.1M...............................................................................11-27
Position interface for Square-Wave Signals DEF01.1M......................................................11-28
Encoder interface DFF01.1M...............................................................................................11-29
High-Resolution Position interface for Sinusoidal Signals DLF01.1M.................................11-30
Gear Wheel Encoder interface DZF02.1M ..........................................................................11-31
Gear Wheel Encoder interface DZF03.1M ..........................................................................11-32
Dimensional Sheet DGA01.2...............................................................................................11-33
List of Connectors and Ready-Made Cable.........................................................................11-34
11.3 Supplementary Documentation..................................................................................................11-36
12 Index 12-1
13 Kundenbetreuungsstellen - Sales & Service Facilities 13-1

SYNAX200 Determing Drive and System Configurations 1-1
DOK-SYNAX*-SY*-07VRS**-PR01-EN-P
1 Determing Drive and System Configurations
1.1 General SYNAX200 systems are built of up to 40 digital intelligent drives of the
DIAX03 (DKR), DIAX04 and ECODRIVE03 drive family, a motion control
PPC-R, one LWL connection between these components meeting
SERCOS interface standards (IEC 61491 or EN 61491) as well as a
number of optional plug-in cards for the digital intelligent drives and option
modules for the PPC.
RECO
8888
PPC-R01.2
H1
PROG
U2
X10
X1
I1
I3
I2
Q1
Q2
24Ve
0Ve
Bb
Bb
24V
0V
S1
RX
TX
U1
RESET
S2
H2
DIST
SY7PR101.FH7
PPC-R02.2PPC-R01.2
PPC-R02.2
H1
PROG
U2
X10
X1
Q1
Q2
24Ve
0Ve
Bb
Bb
24V
0V
S1
RX
TX
U1
RESET
S2
H2
DIST
COM
X16
U3 U4
8888
I1
I3
I2
RECO
Fig. 1-1: Motion control PPC-R

1-2 Determing Drive and System Configurations SYNAX200
DOK-SYNAX*-SY*-07VRS**-PR01-EN-P
Barcode
0
1
2
3
4
5
6
7
8
9
0
1
2
3
4
5
6
7
8
9
H1
S1
S3 S2
Barcode Typenschild
123456789 1234
111213141516 1718 5678
1234
5678
XE2
XE1
L+
L-
L1
L2
L3
A1
A2
A3
Readandfollow
InstructionsforElectrical Drives"
manual,
DOK-GENERL-DRIVE******-SVS...
DANG
High oltage.
Dangerofelectrical shock.
Donottouch electricalconnections
for
5minutesafter switching
ECODRIVE03
SY7PR102.FH7
DIAX04
UVW
Readand follow
Instructionsfor Electrical Drives"
manual,
DOK-GENERL-DRIVE******-SVS...
DANG
High oltage.
Dangerof electrical shock.
Do not touch electrical connections
fo
5minutes after switching
UVW
Readand follow
Instructionsfor Electrical Drives"
manual,
DOK-GENERL-DRIVE******-SVS...
DANG
High oltage.
Dangerof electrical shock.
Do not touch electrical connections
fo
5minutes after switching Readand follow
Instructionsfor Electrical Drives"
manual,
DOK-GENERL-DRIVE******-SVS...
DANG
High oltage.
Dangerof electrical shock.
Donot touch electrical connections
fo
5minutes after switching
HDD02.2
Readand follow
Instructionsfor Electrical Drives"
manual,
DOK-GENERL-DRIVE******-SVS...
DANG
High oltage.
Dangerof electrical shock.
Donot touch electrical connections
fo
5minutes after switching
single axis unit double axis unit
DIAX03
Readand follow
Instructionsfor Electrical Drives"
manual,
DOK-GENERL-DRIVE******-SVS...
DANG
High oltage.
Dangerof electrical shock.
Do not touch electrical connections
fo
5minutes after switching
HDS 04.2
Readand follow
Instructionsfor Electrical Drives"
manual,
DOK-GENERL-DRIVE******-SVS...
DANG
High oltage.
Dangerof electrical shock.
Do not touch electrical connections
fo
5minutes after switching
HDS 03.2HDS 02.2
Readand follow
Instructionsfor Electrical Drives"
manual,
DOK-GENERL-DRIVE******-SVS...
DANG
High oltage.
Dangerof electrical shock.
Do not touch electrical connections
fo
5minutes after switching
DKC**.3-040 DKC**.3-100
Barcode
0
1
2
3
4
5
6
7
8
9
0
1
2
3
4
5
6
7
8
9
H1
S1
S3 S2
Readandfollow
InstructionsforElectricalDrives"
manual,
DOK-GENERL-DRIVE******-SVS...
DANG
High oltage.
Dangerofelectricalshock.
Donottouch electrical connec tions
for
5minutesafterswitching
Barcode Typenschild
123456789 1234
111213141516 1718 5678
10
Barcode
0
1
2
3
4
5
6
7
8
9
0
1
2
3
4
5
6
7
8
9
H1
S1
S3 S2
Barcode Typenschild
123456789 1234
1011121314 15161718 5678
Readandfollow
InstructionsforElectricalDrives"
manual,
DOK-GENERL-DRIVE******-SVS...
DANG
High oltage.
Dangerofelectricalshock.
Donottouch electrical connec tions
for
5minutesafterswitching
DKC**.3-200
Readand follow
Instructionsfor Electrical Drives"
manual,
DOK-GENERL-DRIVE******-SVS...
DANG
High oltage.
Dangerof electrical shock.
Do not touch electrical connections
fo
5minutes after switching
HDS 05.2
DKR 3.1 DKR 4.1DKR 2.1
DIGITAL COMPACT CONTROLLER DKR
220 V
Steuer-
spannung
Aux.
Netz/Mains
L3
L2L1
Motor
A3A1 A2 B2B1NL L+L-
H1
X4
X2
U5
U2
S2
U4
U1 U3
X9
1
6
1
7
X8
H2
S1
X3
X7
1
10
1
1
X3
H1
X4
X2
U5
U2
S2
U4
U1 U3
X9
1
6
1
7
X8
H2
S1
X3 X7
1
10
1
1
X3
DIGITAL COMPACT CONTROLLER DKR
Netz/Mains
L3L2L1
Motor
A3A1 A2 B2B1
220V
Steuerspannung
Aux.
NLK
X5
X10
TM+ TM- BR
• • • •
X6
DIGITAL COMPACT CONTROLLER
DKR 4
H1
X4
X2
U5
U2
S2
U4
U1 U3
X9
1
6
1
7
X8
H2
S1
X3 X7
1
10
1
11
X3
Fig. 1-2: Drive controller

SYNAX200 Determing Drive and System Configurations 1-3
DOK-SYNAX*-SY*-07VRS**-PR01-EN-P
Fig. 1-3: Rotary motors
Fig. 1-4: Linear motors

1-4 Determing Drive and System Configurations SYNAX200
DOK-SYNAX*-SY*-07VRS**-PR01-EN-P
PPC Motion Control
The motion control PPC can be adapted to meet numerous application
requirements by using various option modules.
The motion control itself is mounted on a module carrier. Module carrier
can also be fitted with I/O modules.
PPCs not fitted with option modules are basic devices.
The following option modules are available:
•ARCNET-/PPC link assembly.
•Fieldbus modules.
This option module with designation DAQ serves for coupling of PPCs
and serves for communication with higher automation level (e.g., SPS) via
ARCNET interface.
Fieldbus slave interfaces are available for the fieldbusses Profibus (DPS),
Interbus (IBS) and DeviceNet (DNS).
Note: The SYNAX200 system is adapted to the hardware on the
machine in two steps:
•First the drive concept in terms of the motor is
determined. This includes drive amplifiers and linear
scale (as part of the basic drive configuration).
•Then PPC motion control function and plug-in card
assignment to the PPC motion controls is determined.
Basic devices
Option modules
ARCNET-/PPC link assembly
Fieldbus module

SYNAX200 Determing Drive and System Configurations 1-5
DOK-SYNAX*-SY*-07VRS**-PR01-EN-P
Readandfollow
InstructionsforElectrical Drives"
manual,
DOK-GENERL-DRIVE******-SVS...
DANG
High oltage.
Dangerofelectrical shock.
Donot touch electricalconnections
fo
5minutesafter switching
UVW
Readandfollow
InstructionsforElectrical Drives"
manual,
DOK-GENERL-DRIVE******-SVS...
DANG
High oltage.
Dangerofelectrical shock.
Donot touch electricalconnections
fo
5minutesafter switching Readandfollow
InstructionsforElectrical Drives"
manual,
DOK-GENERL-DRIVE******-SVS...
DANG
High oltage.
Dangerofelectrical shock.
Donot touch electricalconnections
fo
5minutesafter switching Readandfollow
InstructionsforElectrical Drives"
manual,
DOK-GENERL-DRIVE******-SVS...
DANG
High oltage.
Dangerofelectrical shock.
Donot touch electricalconnections
fo
5minutesafter switching
SY7PR001.FH7
PC, PLC
master computer
service
SERCOS interface
fiber optics cable ring
PPC-R
PPC-R02.2
H1
PROG
U2
X10
X1
Q1
Q2
24Ve
0Ve
Bb
Bb
24V
0V
S1
RX
TX
U1
RESET
S2
H2
DIST
COM
X16
U3 U4
8888
I1
I3
I2
RECO
Fig. 1-5: PPC configurations
SY7PR081.FH7
DAQ
DPS
IBS
DNS
PPC link
and/or
ARCNET coupling card
e.g. SPS
e.g. SPS
e.g. SPS
e.g. SPS
Profibus
slave circuit
Interbus
slave circuit
DeviceNet
slave circuit
Fig. 1-6: Functional assignment of the PPC option modules with SYNAX200-
system configuration

1-6 Determing Drive and System Configurations SYNAX200
DOK-SYNAX*-SY*-07VRS**-PR01-EN-P
Motors
All rotary and linear motors which belong to the product line MKD, MKE,
MHD, 2AD, 1MB, MBW, MBS, LAF and LSF can always be used.
Drive Controller
Digital drive controllers of the type DIAX03 (DKR) and DIAX04 can be
adapted to meet numerous application requirements by using various
plug-in modules. For this reason, drive controllers are equipped with ports
for plug-in modules.
Digital drive controller of the type ECODRIVE03 are compact controller
with integrated command interface card and evaluation interfaces. The
DIAX04 drive configuration described in this project planning are also
possible with ECODRIVE03, but ECODRIVE03 has a reduced range of
capacity.
Drive controllers not fitted with plug-in modules are basic devices.
The following plug-in modules are available:
•Command interface card module
•Modules for evaluating position measurement systems
•Input/output modules to evaluate SPS signals or to export signals to
the SPS
•Software modules
•Module for evaluating analog inputs
•Encoder emulation modules
The DSS plug-in module is used as a command interface card module.
This module occupies in most cases slot U1 in the drive controller.
A basic device fitted with additional plug-in modules is called a configured
drive controller.
Every hardware configuration is designated by a letter/number sequence,
e.g., HS04-01-FW. Digital drive controllers are delivered as configured
drive controllers which may be equipped with various components,
according to the selected configuration.
The plug-in cards functionally assigned to the PPC motion control are
addressed directly via the SERCOS interface. The digital intelligent drives
thus fill a two-fold purpose. In addition to their intelligent drive functions,
they also serve as a decentralized unit rack for the control-related plug-in
cards (see Fig. 1-6).
Only configured drive controllers are delivered for logistical reasons. In
other words, basic units or individual cards are only available for service.
Basic devices
Plug-in modules
Command interface card module
Configured drive controller
Hardware configuration

SYNAX200 Determing Drive and System Configurations 1-7
DOK-SYNAX*-SY*-07VRS**-PR01-EN-P
SY7PR048.FH7
high-resolution
master axis
encoder interface
DEA
digital input
and output
interface
DZF
high-resolution
gear-tooth
encoder interface
DFF
high-resolution
master axis
encoder interface
DEA04/
DEA08
DZF
DFF
Plug-in modules functionally assigned
to the drives:
gear-tooth encoder
rack-and-pinion
encoder
SERCOS
interface
Plug-in modules functionally assigned
to the PPC control unit:
e.g. PLC
fiber optic cable
travel limit switch
referencing switch
measuring input
Interface module assigned to either the drive
or the PPC control unit:
DSS
high-resolution
digital servo
feedback
interface
motor feedback
with MHD, MKD
GDS 1.1
GDS 1.1
X4
X4
master axis
position SSI-
output interface DSA SSI
EnDat/SSI
encoder
interface
Weg SSI
SSI
DAG
Weg
DLF
high resolution
position interface DLF
DEF
position interface for
square-wave signals DEF
Weg
motor feedback or
master axis encoder
EnDat
DAE
analogue interface
with position value
output (only ELS5)
DAE +/- 10V analog
incremental
encoder emulation
DEA
digital input
and output
interface
DEA05/
DEA06/
DEA09/
DEA10
e.g. PLC
drive cam
Fig. 1-7: Functional assignment of the drive plug-in modules with SYNAX200
system configuration

1-8 Determing Drive and System Configurations SYNAX200
DOK-SYNAX*-SY*-07VRS**-PR01-EN-P

SYNAX200 Important Directions for Use 2-1
DOK-SYNAX*-SY*-07VRS**-PR01-EN-P
2 Important Directions for Use
2.1 Appropriate Use
Introduction
Rexroth Indramat products represent state-of-the-art developments and
manufacturing. They are tested prior to delivery to ensure operating safety
and reliability.
The products may only be used in the manner that is defined as
appropriate. If they are used in an inappropriate manner, then situations
can develop that may lead to property damage or injury to personnel.
Note: Rexroth Indramat, as manufacturer, is not liable for any
damages resulting from inappropriate use. In such cases, the
guarantee and the right to payment of damages resulting from
inappropriate use are forfeited. The user alone carries all
responsibility of the risks.
Before using Rexroth Indramat products, make sure that all the pre-
requisites for appropriate use of the products are satisfied:
•Personnel that in any way, shape or form uses our products must first
read and understand the relevant safety instructions and be familiar
with appropriate use.
•If the product takes the form of hardware, then they must remain in
their original state, in other words, no structural changes are permitted.
It is not permitted to decompile software products or alter source
codes.
•Do not mount damaged or faulty products or use them in operation.
•Make sure that the products have been installed in the manner
described in the relevant documentation.

2-2 Important Directions for Use SYNAX200
DOK-SYNAX*-SY*-07VRS**-PR01-EN-P
Areas of Use and Application
SYNAX200 made by Rexroth Indramat is designed for the
synchronization of machine axes (shaftless machines).
Control and monitoring of the drive system may require additional sensors
and actors.
Note: The components may only be used with the accessories and
parts specified in this document. If a component has not been
specifically named, then it may not be either mounted or
connected. The same applies to cables and lines.
Operation is only permitted in the specified configurations and
combinations of components using the software and firmware
as specified in the relevant function descriptions.
The motion control and every drive controller has to be parametrized/
programmed before starting it up, making it possible for the motor to
execute the specific functions of an application.
The motion control solution SYNAX200 has been developed for use in
single or multiple-axis drives and control tasks.
Typical applications of SYNAX200 are:
•printing and paper converting machines,
•textile machines,
•handling and assembly systems and
•packaging and foodstuff machines.
The motion control and drive system may only be operated under the
assembly, installation and ambient conditions as described here
(temperature, system of protection, humidity, EMC requirements, etc.)
and in the position specified.
2.2 Inappropriate Use
Using the SYNAX200 components outside of the above-referenced areas
of application or under operating conditions other than described in the
document and the technical data specified is defined as “inappropriate
use".
The SYNAX200 components may not be used if
•they are subject to operating conditions that do not meet the above
specified ambient conditions. This includes, for example, operation
under water, in the case of extreme temperature fluctuations or
extremely high maximum temperatures or if
•Rexroth Indramat has not specifically released them for that intended
purpose. Please note the specifications outlined in the general Safety
Guidelines!

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3 Safety Instructions for Electric Servo Drives and
Controls
3.1 Introduction
Read these instructions before the equipment is used and eliminate the
risk of personal injury or property damage. Follow these safety
instructions at all times.
Do not attempt to install, use or service this equipment without first
reading all documentation provided with the product. Read and
understand these safety instructions and all user documentation of the
equipment prior to working with the equipment at any time. If you do not
have the user documentation for your equipment contact your local
Rexroth Indramat representative to send this documentation immediately
to the person or persons responsible for the safe operation of this
equipment.
If the product is resold, rented or transferred or passed on to others, then
these safety instructions must be delivered with the product.
WARNING
Inappropriate use of this equipment, failure to
follow the safety instructions in this document
or tampering with the product, including
disabling of safety devices, may result in
product damage, personal injury, severe
electrical shock or death!
3.2 Explanations
The safety warnings in this documentation describe individual degrees of
hazard seriousness in compliance with ANSI:
Warning symbol with signal
word Degree of hazard seriousness
The degree of hazard seriousness
describes the consequences resulting from
non-compliance with the safety guidelines.
DANGER
Bodily harm or product damage will occur.
WARNING
Death or severe bodily harm may occur.
CAUTION
Death or severe bodily harm may occur.
Fig. 3-1: Classes of danger with ANSI

3-2 Safety Instructions for Electric Servo Drives and Controls SYNAX200
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3.3 Hazards by Inappropriate Use
DANGER
High voltage and high discharge current!
Danger to life, risk of severe electrical shock
and risk of injury!
DANGER
Dangerous movements! Danger to life and risk
of injury or equipment damage by unintentional
motor movements!
WARNING
High electrical voltage due to wrong
connections! Danger to life, severe electrical
shock and severe bodily injury!
WARNING
Health hazard for persons with heart
pacemakers, metal implants and hearing aids in
proximity to electrical equipment!
CAUTION
Surface of machine housing could be extremely
hot! Danger of injury! Danger of burns!
CAUTION
Risk of injury due to inappropriate handling!
Bodily injury caused by crushing, shearing,
cutting and mechanical shock or improper
handling of pressurized systems!
CAUTION
Risk of injury due to inappropriate handling of
batteries!

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3.4 General Information
•Rexroth Indramat GmbH is not liable for damages resulting from
failure to observe the warnings given in these documentation.
•Order operating, maintenance and safety instructions in your language
before starting up the machine. If you find that due to a translation
error you can not completely understand the documentation for your
product, please ask your supplier to clarify.
•Proper and correct transport, storage, assembly and installation as
well as care in operation and maintenance are prerequisites for
optimal and safe operation of this equipment.
•Trained and qualified personnel in electrical equipment:
Only trained and qualified personnel may work on this equipment or
within its proximity. Personnel are qualified if they have sufficient
knowledge of the assembly, installation and operation of the product
as well as an understanding of all warnings and precautionary
measures noted in these instructions.
Furthermore, they should be trained, instructed and qualified to switch
electrical circuits and equipment on and off, to ground them and to
mark them according to the requirements of safe work practices and
common sense. They must have adequate safety equipment and be
trained in first aid.
•Only use spare parts and accessories approved by the manufacturer.
•Follow all safety regulations and requirements for the specific
application as practiced in the country of use.
•The equipment is designed for installation on commercial machinery.
European countries: see directive 89/392/EEC (machine guideline).
•The ambient conditions given in the product documentation must be
observed.
•Use only safety features that are clearly and explicitly approved in the
Project Planning manual.
For example, the following areas of use are not allowed: Construction
cranes, Elevators used for people or freight, Devices and vehicles to
transport people, Medical applications, Refinery plants, the transport
of hazardous goods, Radioactive or nuclear applications, Applications
sensitive to high frequency, mining, food processing, Control of
protection equipment (also in a machine).
•Start-up is only permitted once it is sure that the machine, in which the
product is installed, complies with the requirements of national safety
regulations and safety specifications of the application.
•Operation is only permitted if the national EMC regulations for the
application are met.
The instructions for installation in accordance with EMC requirements
can be found in the INDRAMAT document "EMC in Drive and Control
Systems”.
The machine builder is responsible for compliance with the limiting
values as prescribed in the national regulations and specific EMC
regulations for the application.
European countries: see Directive 89/336/EEC (EMC Guideline).
U.S.A.: See National Electrical Codes (NEC), National Electrical
Manufacturers Association (NEMA), and local building codes. The user of
this equipment must consult the above noted items at all times.
•Technical data, connections and operational conditions are specified in
the product documentation and must be followed at all times.

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3.5 Protection Against Contact with Electrical Parts
Note: This section refers to equipment with voltages above 50 Volts.
Making contact with parts conducting voltages above 50 Volts could be
dangerous to personnel and cause an electrical shock. When operating
electrical equipment, it is unavoidable that some parts of the unit conduct
dangerous voltages.
DANGER
High electrical voltage! Danger to life, severe
electrical shock and severe bodily injury!
⇒Only those trained and qualified to work with or on
electrical equipment are permitted to operate,
maintain or repair this equipment.
⇒Follow general construction and safety regulations
when working on electrical installations.
⇒Before switching on power the ground wire must be
permanently connected to all electrical units accor-
ding to the connection diagram.
⇒Do not operate electrical equipment at any time if the
ground wire is not permanently connected, even for
brief measurements or tests.
⇒Before working with electrical parts with voltage
potentials higher than 50 V, the equipment must be
disconnected from the mains voltage or power
supply.
⇒The following should be observed with electrical
drives, power supplies, and filter components:
Wait five (5) minutes after switching off power to
allow capacitors to discharge before beginning work.
Measure the voltage on the capacitors before
beginning work to make sure that the equipment is
safe to touch.
⇒Never touch the electrical connection points of a
component while power is turned on.
⇒Install the covers and guards provided with the
equipment properly before switching the equipment
on. Prevent contact with live parts at any time.
⇒A residual-current-operated protective device (r.c.d.)
must not be used on an electric drive! Indirect
contact must be prevented by other means, for
example, by an overcurrent protective device.
⇒Equipment that is built into machines must be
secured against direct contact. Use appropriate
housings, for example a control cabinet.
European countries: according to EN 50178/1998,
section 5.3.2.3.
U.S.A: See National Electrical Codes (NEC), National
Electrical Manufacturers Association (NEMA) and local
building codes. The user of this equipment must observe
the above noted instructions at all times.