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..
Title
Type of Documentation
Document Typecode
Internal File Reference
Purpose of Documentation
Record of Revisions
Copyright
Validity
Published by
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