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Electric Drives
and Controls
Hydraulics
Linear Motion and
Assembly Technologies
Pneumatics
Service

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Bosch Rexroth AG | Electric Drives

and Controls

Title

Rexroth IndraDrive | Release Notes

Rexroth IndraDrive
MPH-, MPB-, MPD-, MPC-07
Version Notes

Type of Documentation
Document Typecode
Internal File Reference
Purpose of Documentation

Release Notes
DOK-INDRV*-MP*-07VRS**-RN01-EN-P
RS-cc459015a2e3a9d80a6846a000bd6663-1-en-US-3
The Release Notes contain an overview of the firmware function or the subject
of the section. The Release Notes can contain, for example, general basics,
the most important features of the function, overviews and examples of appli
cation.
The last chapter of the Release Notes contains the compatible and incompat
ible functional extensions, as well as lists of new, modified and no longer
existing parameters and diagnostic messages.

Record of Revision

Edition

Release Date

DOK-INDRV*-MP*-07VRS**-RN01-EN-P 2009-11-06

Copyright

Notes
First edition

Bosch Rexroth AG, 2009

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).

Validity

Published by

The specified data is for product description purposes only and may not be
deemed to be guaranteed unless expressly confirmed in the contract. All rights
are reserved with respect to the content of this documentation and the availa
bility of the product.
Bosch Rexroth AG
Bgm.-Dr.-Nebel-Str. 2 D-97816 Lohr a. Main
Telephone +49 (0)93 52/ 40-0 Fax +49 (0)93 52/ 40-48 85
http://www.boschrexroth.com/
Dept. DCC/EDY
E-mail: [email protected]

Note

This document has been printed on chlorine-free bleached paper.

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Release Notes | Rexroth IndraDrive

Electric Drives | Bosch Rexroth AG

and Controls

I/XIV

Table of Contents

Table of Contents
Page

1
1.1
1.1.1
1.1.2

1.1.3

1.2
1.2.1
1.2.2
1.2.3
1.2.4
1.2.5
1.2.6
1.2.7
1.3
1.3.1
1.3.2
1.3.3

1.4
1.4.1
1.4.2
1.5
1.6
1.6.1

1.6.2

1.6.3

System Overview......................................................................................................... 15
General Information.............................................................................................................................. 15
About This Documentation................................................................................................................ 15
How to Use This Documentation....................................................................................................... 16
Structure of the Functional Description.......................................................................................... 16
Markers and Terms........................................................................................................................ 17
Cross References........................................................................................................................... 17
Reference Documentations............................................................................................................ 17
Overview of Drive Firmware.............................................................................................................. 19
Firmware Variants.......................................................................................................................... 19
Organization of the Firmware......................................................................................................... 20
Terms, Basic Principles........................................................................................................................ 20
Parameters........................................................................................................................................ 20
Data Storage and Parameter Handling............................................................................................. 20
Password........................................................................................................................................... 21
Commands........................................................................................................................................ 22
Operation Modes............................................................................................................................... 22
Warnings........................................................................................................................................... 23
Errors................................................................................................................................................. 23
Drive Controllers................................................................................................................................... 24
Overview............................................................................................................................................ 24
Standard Design of the IndraDrive Controllers............................................................................... 24
Power Sections.................................................................................................................................. 25
Control Sections................................................................................................................................ 26
Available Control Section Designs................................................................................................. 26
Supported Control Section Configurations..................................................................................... 26
Supported Motors and Measuring Systems.......................................................................................... 28
Supported Motors.............................................................................................................................. 28
Supported Measuring Systems......................................................................................................... 28
Overview of Master Communication..................................................................................................... 28
Overview of Functions/Functional Packages........................................................................................ 29
Overview............................................................................................................................................ 29
General Information........................................................................................................................ 29
Scaling the Drive Functionality....................................................................................................... 29
Brief Description of the Functional Packages................................................................................. 31
Firmware Types.............................................................................................................................. 32
Base Packages.................................................................................................................................. 33
General Information........................................................................................................................ 33
Basic Functions.............................................................................................................................. 33
Scope of Functions of Base Packages........................................................................................... 34
Alternative Functional Packages....................................................................................................... 34
General Information........................................................................................................................ 34
Servo Function............................................................................................................................... 34
Synchronization.............................................................................................................................. 35

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II/XIV

Bosch Rexroth AG | Electric Drives

and Controls

Rexroth IndraDrive | Release Notes

Table of Contents
Page
1.6.4

1.7
1.7.1

1.7.2
1.7.3
1.7.4
1.7.5
1.7.6
1.7.7

2
2.1
2.1.1
2.1.2
2.2

3
3.1
3.2
3.2.1
3.2.2
3.2.3
3.2.4
3.3
3.3.1
3.3.2
3.3.3
3.3.4
3.3.5
3.3.6
3.3.7
3.3.8

4
4.1
4.1.1

Main Spindle Function.................................................................................................................... 36

Additive Functional Packages........................................................................................................... 36
General Information........................................................................................................................ 36
IndraMotion MLD (Drive-Integrated PLC)....................................................................................... 36
Integrated Safety Technology......................................................................................................... 37
Performance Data................................................................................................................................. 38
Overview............................................................................................................................................ 38
Levels of Control Performance....................................................................................................... 38
Performance and Clock Rates........................................................................................................ 38
Control Section Design and Performance......................................................................................... 39
Selecting Performance via Parameter P-0-0556............................................................................... 40
PWM Frequency Reduction Depending on Load.............................................................................. 41
PWM Frequency Reduction Depending on Speed ........................................................................... 41
Rotor-Synchronous PWM.................................................................................................................. 41
Restricted Performance With Certain Functional Packages.............................................................. 41

Important Directions for Use ....................................................................................... 43

Appropriate Use ................................................................................................................................... 43
Introduction........................................................................................................................................ 43
Areas of Use and Application............................................................................................................ 43
Inappropriate Use................................................................................................................................. 44

Safety Instructions for Electric Drives and Controls .................................................... 45

Definitions of Terms.............................................................................................................................. 45
General Information.............................................................................................................................. 46
Using the Safety Instructions and Passing Them on to Others......................................................... 46
Requirements for Safe Use............................................................................................................... 46
Hazards by Improper Use.................................................................................................................. 47
Explanation of Safety Symbols and Hazard Classification................................................................ 48
Instructions with Regard to Specific Dangers....................................................................................... 48
Protection Against Contact with Electrical Parts and Housings......................................................... 48
Protective Extra-Low Voltage as Protection Against Electric Shock ................................................ 49
Protection Against Dangerous Movements....................................................................................... 50
Protection Against Magnetic and Electromagnetic Fields During Operation and Mounting.............. 52
Protection Against Contact with Hot Parts......................................................................................... 52
Protection During Handling and Mounting......................................................................................... 53
Battery Safety.................................................................................................................................... 53
Protection Against Pressurized Systems........................................................................................... 53

Master Communication................................................................................................ 55
Basic Functions of Master Communication.......................................................................................... 55
Brief Description................................................................................................................................ 55
General Information........................................................................................................................ 55
Features......................................................................................................................................... 55
Pertinent Parameters...................................................................................................................... 55

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Release Notes | Rexroth IndraDrive

Electric Drives | Bosch Rexroth AG

and Controls

III/XIV

Table of Contents
Page
4.1.2

4.1.3

4.1.4

4.2
4.2.1
4.2.2
4.3
4.3.1
4.4
4.4.1

4.4.2

4.4.3

4.4.4

4.5
4.5.1

4.5.2

Pertinent Commands...................................................................................................................... 56
Setting the Axis Address................................................................................................................... 57
Overview......................................................................................................................................... 57
Address Setting via Standard Control Panel.................................................................................. 57
Address Setting via Parameter Access.......................................................................................... 58
Command Processing....................................................................................................................... 59
Overview......................................................................................................................................... 59
Command Execution...................................................................................................................... 59
Command Change Bit.................................................................................................................... 60
Device Control and State Machines.................................................................................................. 61
Overview......................................................................................................................................... 61
Device-Internal State Machine....................................................................................................... 62
State Machine of Master Communication....................................................................................... 64
Communication Phases of Master Communication........................................................................ 67
Control Words and Status Words of Master Communication......................................................... 69
Timing Diagrams for Device Control............................................................................................... 71
Commands and Diagnostic Messages for Mode Change and Phase Switch................................ 74
Control Options/Additional Functions................................................................................................... 77
Configurable Signal Control Word..................................................................................................... 77
Brief Description............................................................................................................................. 77
Configurable Signal Status Word...................................................................................................... 78
Brief Description............................................................................................................................. 78
Multiplex Channel................................................................................................................................. 78
Brief Description................................................................................................................................ 78
Operating Modes of Master Communication........................................................................................ 79
Introduction and Overview................................................................................................................. 79
Overview of Operating Modes and Possibilities of Command Triggering...................................... 79
Normal Operation (via Internal or External Control Unit)................................................................ 81
Local Setting-Up Mode/Emergency Mode ("Easy Startup Mode")................................................. 82
Normal Mode (Remote or Local)....................................................................................................... 82
Remote Mode With External Control Unit and Active Master Communication............................... 82
MLD Mode With Permanent Control (Stand-Alone Motion Control)............................................... 83
Setting-Up Mode (Easy Startup Mode).............................................................................................. 83
Brief Description of Easy Startup Mode.......................................................................................... 83
Functional Description of Easy Startup Mode................................................................................ 84
Notes on Commissioning for Easy Startup Mode........................................................................... 86
Local Mode........................................................................................................................................ 91
Overview......................................................................................................................................... 91
MLD Mode With Temporary Control (Intelligent Servo Axis).......................................................... 91
Emergency Mode (When Master Communication has Failed)....................................................... 91
Profile Types (With Field Bus Interfaces)............................................................................................. 92
Supported Profile Types.................................................................................................................... 92
Overview......................................................................................................................................... 92
Basic Principles and Terms............................................................................................................ 93
I/O Mode (Positioning and Preset Velocity)....................................................................................... 94
Brief Description............................................................................................................................. 94

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IV/XIV

Bosch Rexroth AG | Electric Drives

and Controls

Rexroth IndraDrive | Release Notes

Table of Contents
Page
4.5.3
4.6
4.6.1
4.7
4.7.1
4.8
4.8.1
4.9
4.9.1
4.10
4.10.1
4.11
4.11.1
4.11.2

4.11.3

4.11.4

4.12
4.12.1

4.12.2

4.12.3
4.12.4
4.12.5

5
5.1
5.1.1
5.1.2

State Machine in I/O Mode............................................................................................................. 95

Freely Configurable Mode (IndraDrive Profile Type)......................................................................... 98
Brief Description............................................................................................................................. 98
SERCOS Interface (SERCOS II).......................................................................................................... 99
Brief Description................................................................................................................................ 99
PROFIBUS-DP................................................................................................................................... 101
Brief Description.............................................................................................................................. 101
CANopen Interface............................................................................................................................. 104
Brief Description.............................................................................................................................. 104
DeviceNet Interface............................................................................................................................ 105
Brief Description.............................................................................................................................. 105
Parallel Interface................................................................................................................................. 107
Brief Description.............................................................................................................................. 107
Analog Interface.................................................................................................................................. 108
Brief Description.............................................................................................................................. 108
Functional Description..................................................................................................................... 111
Control.......................................................................................................................................... 111
Analog Command Value Input...................................................................................................... 112
Emulation of Position Value.......................................................................................................... 113
Notes on Commissioning/Parameterization.................................................................................... 113
Encoder Emulation....................................................................................................................... 113
Analog Inputs................................................................................................................................ 113
Main Spindle Drive With Analog Interface and Parallel Interface................................................. 113
Diagnostic and Status Messages.................................................................................................... 115
Information on General Drive Status............................................................................................ 115
Status of Digital Inputs/Outputs and Analog Inputs...................................................................... 115
MultiEthernet....................................................................................................................................... 115
Brief Description, Basic Function..................................................................................................... 115
General Information...................................................................................................................... 115
Notes on Commissioning.............................................................................................................. 116
EtherCAT...................................................................................................................................... 117
Brief Description........................................................................................................................... 117
Notes on Commissioning.............................................................................................................. 120
PROFINET.................................................................................................................................... 120
Brief Description........................................................................................................................... 120
EtherNet/IPTM Interface.................................................................................................................... 124
Brief Description........................................................................................................................... 124
SERCOS III..................................................................................................................................... 126
Brief Description........................................................................................................................... 126

Motor, Mechanical Axis System, Measuring Systems............................................... 131

General Information on Operation of Motors With IndraDrive............................................................ 131
Basics on the Motors to be Controlled............................................................................................. 131
Brief Description........................................................................................................................... 131
Motor Temperature Monitoring........................................................................................................ 132
Brief Description........................................................................................................................... 132

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Electric Drives | Bosch Rexroth AG

and Controls

V/XIV

Table of Contents
Page
5.2
5.2.1
5.2.2

5.2.3

5.3
5.3.1
5.3.2

5.3.3
5.4
5.4.1
5.4.2
5.5
5.5.1
5.5.2
5.5.3
5.5.4
5.5.5

5.6
5.6.1
5.7
5.7.1

6
6.1
6.1.1

Rexroth Motors................................................................................................................................... 133

Basics on Rexroth Motors............................................................................................................... 133
Rexroth Housing Motors.................................................................................................................. 134
Rexroth Housing Motors With Encoder Data Memory.................................................................. 134
Rexroth Housing Motors Without Encoder Data Memory............................................................. 135
Rexroth Kit Motors........................................................................................................................... 135
General Information...................................................................................................................... 135
Rexroth Kit Motors, Synchronous................................................................................................. 135
Rexroth Kit Motors, Asynchronous............................................................................................... 136
Third-Party Motors at IndraDrive Controllers ..................................................................................... 137
General Information on Third-Party Motors..................................................................................... 137
General Information on Controlling Third-Party Motors................................................................... 137
Pertinent Parameters and Diagnostic Messages......................................................................... 137
Hardware Data............................................................................................................................. 138
Determining the Parameter Values of Third-Party Motors............................................................... 138
General Information on How to Determine the Parameter Values............................................... 138
Motor Holding Brake .......................................................................................................................... 140
Operating Behavior of the Motor Holding Brake.............................................................................. 140
Brief Description........................................................................................................................... 140
Function Check of Motor Holding Brake, Drive-Controlled.............................................................. 141
Brief Description........................................................................................................................... 141
Measuring Systems............................................................................................................................ 142
Basics on Measuring Systems, Resolution..................................................................................... 142
Brief Description........................................................................................................................... 142
Monitoring the Measuring Systems................................................................................................. 144
Brief Description........................................................................................................................... 144
Absolute Measuring Systems.......................................................................................................... 145
Brief Description........................................................................................................................... 145
Relative Measuring Systems........................................................................................................... 146
Brief Description........................................................................................................................... 146
Establishing the Position Data Reference....................................................................................... 147
General Information on Establishing the Position Data Reference.............................................. 147
Establishing Position Data Reference for Absolute Measuring Systems (Set Absolute Measuring). . .
149
Establishing Position Data Reference for Relative Measuring Systems (Homing)....................... 150
Shifting the Position Data Reference for Absolute and Relative Measuring Systems (Shift Coordinate
System Procedure)....................................................................................................................... 158
Detecting the Marker Position...................................................................................................... 158
Mechanical Axis System and Arrangement of Measuring Systems................................................... 159
Brief Description.............................................................................................................................. 159
Scaling of Physical Data..................................................................................................................... 162
Brief Description.............................................................................................................................. 162

Drive Control.............................................................................................................. 165

Overview of Drive Control................................................................................................................... 165
Basic Principles and Terms............................................................................................................. 165

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VI/XIV

Bosch Rexroth AG | Electric Drives

and Controls

Rexroth IndraDrive | Release Notes

Table of Contents
Page
6.1.2

6.1.3

6.1.4

6.2
6.2.1

6.2.2
6.2.3
6.2.4

6.2.5
6.2.6

6.3
6.3.1
6.4
6.4.1

6.4.2
6.4.3
6.4.4

Principles of Drive Control............................................................................................................... 166

Overview of Open-Loop Axis Control........................................................................................... 166
Overview of Closed-Loop Axis Control......................................................................................... 166
Control Loop Structure.................................................................................................................... 167
General Information...................................................................................................................... 167
Control Loop Structure With Setting Parameters......................................................................... 168
Control Loop Structure With Display Parameters......................................................................... 169
Features of the Control Loops......................................................................................................... 170
Performance (Controller Cycle Times)......................................................................................... 170
Current Loop................................................................................................................................. 170
Velocity Loop................................................................................................................................ 170
Position Loop................................................................................................................................ 171
Motor Control...................................................................................................................................... 171
General Information on Motor Control............................................................................................. 171
Overview of Motor Control Methods............................................................................................. 171
Notes on Selection of Motor Control Method................................................................................ 173
Motor Control Frequency................................................................................................................. 176
Brief Description........................................................................................................................... 176
Voltage-Controlled Open-Loop Operation (U/f Control).................................................................. 177
Brief Description........................................................................................................................... 177
Field-Oriented Current Control (FOC Control)................................................................................. 178
Brief Description........................................................................................................................... 178
General Function of Field-Oriented Current Control..................................................................... 181
Field-Oriented Current Control of a Synchronous Machine.......................................................... 182
Field-Oriented Current Control of an Asynchronous Machine...................................................... 183
Sensorless Motor Operation, Flux-Controlled (FXC Control) ......................................................... 185
Brief Description........................................................................................................................... 185
Automatic Setting of Motor Control.................................................................................................. 187
Brief Description........................................................................................................................... 187
Overview of Motor and Motor Control Parameters....................................................................... 189
Determining the Parameter Values by Means of Type Plate Data............................................... 191
Identifying and Optimizing the Motor Parameter Values.............................................................. 193
Calculating the Motor Control Parameters From the Motor Parameters...................................... 194
Open-Loop Axis Control (Open-Loop Operation)............................................................................... 195
Brief Description.............................................................................................................................. 195
Closed-Loop Axis Control (Closed-Loop Operation).......................................................................... 196
General Information on Closed-Loop Axis Control.......................................................................... 196
Control Loop Structure................................................................................................................. 196
Features of the Control Loops...................................................................................................... 196
Possibilities of Access to Included Control Loops........................................................................ 197
Command Value Processing Depending on Operating Mode...................................................... 198
Automatic Setting of Closed-Loop Axis Control............................................................................... 198
Brief Description........................................................................................................................... 198
Velocity Loop (Including the Respective Filters).............................................................................. 200
Brief Description........................................................................................................................... 200
Position Loop (With Respective Feedforward Functions and Actual Value Adjustment)................ 202

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Release Notes | Rexroth IndraDrive

Electric Drives | Bosch Rexroth AG

and Controls

VII/XIV

Table of Contents
Page
6.5
6.5.1

6.5.2
6.5.3
6.5.4
6.6
6.6.1
6.6.2

6.6.3
6.6.4
6.7
6.7.1

7
7.1
7.1.1
7.1.2

7.2
7.2.1
7.2.2

7.2.3

7.3
7.3.1
7.3.2

Brief Description........................................................................................................................... 202

Commutation Setting.......................................................................................................................... 203
Basics on Commutation Setting...................................................................................................... 203
Brief Description........................................................................................................................... 203
Overview of Methods for Determining the Commutation Offset................................................... 206
Commutation Setting for Rexroth Motors MLF ............................................................................... 208
Brief Description .......................................................................................................................... 208
Saturation Method........................................................................................................................... 209
Brief Description .......................................................................................................................... 209
Sine-Wave Method.......................................................................................................................... 210
Brief Description .......................................................................................................................... 210
Limitations........................................................................................................................................... 210
Overview of Limitations................................................................................................................... 210
Current and Torque/Force Limitation............................................................................................... 211
Brief Description........................................................................................................................... 211
Torque/Force Limitation................................................................................................................ 213
Current Limitation......................................................................................................................... 215
Velocity Limitation............................................................................................................................ 221
Brief Description........................................................................................................................... 221
Position Limitation/Travel Range Limit Switches............................................................................. 221
Brief Description........................................................................................................................... 221
Power Supply...................................................................................................................................... 222
Possibilities of Power Supply for IndraDrive.................................................................................... 222
Brief Description........................................................................................................................... 222
Possible Device Combinations and Mains Connection................................................................ 224

Operation Modes....................................................................................................... 227

General Information on the Operation Modes.................................................................................... 227
Supported Operation Modes........................................................................................................... 227
Operation Mode Handling................................................................................................................ 227
Selecting the Operation Mode...................................................................................................... 227
Changing the Operation Mode..................................................................................................... 230
Command Value Acceptance and Acknowledgment.................................................................... 230
Torque/Force Control.......................................................................................................................... 231
Brief Description.............................................................................................................................. 231
Command Value Adjustment in Torque/Force Control.................................................................... 233
Principle of Command Value Adjustment..................................................................................... 233
Notes on Commissioning for Command Value Limitation............................................................ 233
Current Loop.................................................................................................................................... 234
Operating Principle of the Current Loop....................................................................................... 234
Notes on Commissioning for the Current Loop............................................................................ 234
Velocity Control................................................................................................................................... 234
Brief Description.............................................................................................................................. 234
Command Value Adjustment in Velocity Control............................................................................. 237
Overview....................................................................................................................................... 237
Command Value Generation via Memory of Fixed Command Values......................................... 238

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VIII/XIV

Bosch Rexroth AG | Electric Drives

and Controls

Rexroth IndraDrive | Release Notes

Table of Contents
Page

7.3.3

7.4
7.4.1
7.4.2
7.4.3
7.5
7.5.1
7.5.2
7.5.3
7.6
7.6.1
7.6.2

7.6.3
7.6.4
7.7
7.7.1
7.7.2
7.7.3

7.7.4

7.8
7.8.1

Command Value Generation via Motor Potentiometer................................................................. 239

Inverting the Velocity Command Value........................................................................................ 239
Masking the Command Value...................................................................................................... 239
Ramp-Function Generator............................................................................................................ 240
Jerk Limitation.............................................................................................................................. 241
Command Value Limitation.......................................................................................................... 242
Fine Interpolation.......................................................................................................................... 242
Velocity Control Loop...................................................................................................................... 242
Velocity Loop................................................................................................................................ 242
Current Loop in Velocity Control Loop.......................................................................................... 242
Possibilities of Filtering................................................................................................................. 243
Position Control With Cyclic Command Value Input........................................................................... 243
Brief Description.............................................................................................................................. 243
Command Value Adjustment in Position Control............................................................................. 245
Position Loop................................................................................................................................... 247
Drive-Internal Interpolation................................................................................................................. 248
Brief Description.............................................................................................................................. 248
Command Value Adjustment With Drive-Internal Interpolation....................................................... 250
Position Loop With Drive-Internal Interpolation............................................................................... 250
Drive-Controlled Positioning............................................................................................................... 250
Brief Description.............................................................................................................................. 250
Command Value Adjustment With Drive-Controlled Positioning..................................................... 252
Overview....................................................................................................................................... 252
Position Target Interpreter............................................................................................................ 253
Positioning Generator................................................................................................................... 257
Position Loop With Drive-Controlled Positioning............................................................................. 257
Jog Mode With Drive-Controlled Positioning ("Jogging")................................................................. 257
Positioning Block Mode...................................................................................................................... 258
Brief Description.............................................................................................................................. 258
Command Value Adjustment With Positioning Block Mode............................................................ 260
Single-Block Processing.................................................................................................................. 260
Description of Basic Function....................................................................................................... 260
Absolute Positioning..................................................................................................................... 265
Relative Positioning Without Residual Path Storage.................................................................... 266
Relative Positioning With Residual Path Storage......................................................................... 269
Infinite Travel in Positive/Negative Direction................................................................................ 274
Sequential Block Processing........................................................................................................... 276
Basic Function.............................................................................................................................. 276
Position-Dependent Block Advance............................................................................................. 276
Switch-Signal-Dependent Block Advance.................................................................................... 281
Synchronization Modes...................................................................................................................... 287
Basic Functions of the Synchronization Modes............................................................................... 287
Overview....................................................................................................................................... 287
Master Axis Adjustment................................................................................................................ 291
Command Value Processing for Slave Axis Depending on Operation Mode............................... 294
Dynamic Synchronization of the Slave Axis................................................................................. 295

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IX/XIV

Table of Contents
Page

7.8.2

7.8.3

7.8.4

7.8.5

8
8.1
8.2
8.2.1
8.3
8.3.1
8.3.2

8.3.3
8.3.4

8.4
8.4.1
8.5
8.5.1

Command Value Addition for Slave Axis...................................................................................... 305

Extended Functions (Command Value Cycle and Actual Value Cycle) ...................................... 306
Velocity Synchronization With Real/Virtual Master Axis.................................................................. 309
Brief Description........................................................................................................................... 309
Overview of the Operation Mode.................................................................................................. 311
Master Axis Adjustment................................................................................................................ 311
Command Value Adjustment........................................................................................................ 311
Synchronization With Velocity Synchronization............................................................................ 312
Phase Synchronization With Real/Virtual Master Axis.................................................................... 313
Brief Description........................................................................................................................... 313
Overview of the Operation Mode.................................................................................................. 316
Master Axis Adjustment................................................................................................................ 317
Command Value Adjustment........................................................................................................ 317
Synchronization............................................................................................................................ 318
Electronic Cam With Real/Virtual Master Axis................................................................................. 318
Brief Description........................................................................................................................... 318
Overview of the Operation Mode.................................................................................................. 321
Master Axis Adjustment................................................................................................................ 321
Command Value Adjustment........................................................................................................ 322
Synchronization............................................................................................................................ 322
MotionProfile With Real/Virtual Master Axis.................................................................................... 323
Brief Description........................................................................................................................... 323
Overview of the Operation Mode.................................................................................................. 326
Master Axis Adjustment................................................................................................................ 327
Command Value Adjustment........................................................................................................ 327
Synchronization............................................................................................................................ 327

Extended Axis Functions........................................................................................... 329

Availability of the Extended Axis Functions........................................................................................ 329
Drive Halt............................................................................................................................................ 330
Brief Description.............................................................................................................................. 330
Error Reactions................................................................................................................................... 331
Overview of Error Reactions............................................................................................................ 331
Best Possible Deceleration.............................................................................................................. 332
Brief Description........................................................................................................................... 332
Time Flow of the Error Reaction................................................................................................... 333
Package Reaction on Error............................................................................................................. 333
Brief Description........................................................................................................................... 333
Control Reaction on Error................................................................................................................ 335
NC Reaction on Error................................................................................................................... 335
MLD Reaction on Error................................................................................................................. 335
E-Stop Function.................................................................................................................................. 335
Brief Description.............................................................................................................................. 335
Compensation Functions / Corrections............................................................................................... 336
Friction Torque Compensation........................................................................................................ 336
Brief Description........................................................................................................................... 336

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Rexroth IndraDrive | Release Notes

Table of Contents
Page
8.5.2
8.5.3
8.5.4
8.5.5
8.6
8.6.1
8.7
8.7.1
8.8
8.8.1
8.9
8.9.1
8.10
8.10.1
8.11
8.11.1
8.12
8.12.1
8.12.2
8.13
8.13.1
8.13.2

8.13.3
8.13.4
8.13.5

8.13.6

9
9.1
9.2
9.2.1
9.3
9.3.1
9.4

Encoder Error Correction................................................................................................................. 337

Brief Description........................................................................................................................... 337
Axis Error Correction....................................................................................................................... 337
Brief Description........................................................................................................................... 337
Quadrant Error Correction............................................................................................................... 338
Brief Description........................................................................................................................... 338
Cogging Torque Compensation....................................................................................................... 338
Brief Description........................................................................................................................... 338
Measuring Wheel Mode...................................................................................................................... 339
Brief Description.............................................................................................................................. 339
Positive Stop Drive Procedure............................................................................................................ 341
Brief Description.............................................................................................................................. 341
Redundant Motor Encoder.................................................................................................................. 341
Brief Description.............................................................................................................................. 341
Spindle Positioning............................................................................................................................. 342
Brief Description.............................................................................................................................. 342
Parameter Set Switching.................................................................................................................... 343
Brief Description.............................................................................................................................. 343
Drive-Controlled Oscillation................................................................................................................ 344
Brief Description.............................................................................................................................. 344
Parking Axis........................................................................................................................................ 345
Brief Description.............................................................................................................................. 345
Functional Description..................................................................................................................... 345
Integrated Safety Technology............................................................................................................. 346
General Information......................................................................................................................... 346
Product Presentation....................................................................................................................... 346
What is "Integrated Safety Technology"?..................................................................................... 346
Integrated Safety Technology as IndraDrive Platform Solution.................................................... 347
Characteristics and Classification of Safety Technology.............................................................. 347
Safe Torque Off (STO).................................................................................................................... 348
Brief Description........................................................................................................................... 348
Integrated Safety Technology.......................................................................................................... 349
Functions of the Integrated Safety Technology............................................................................... 350
Overview....................................................................................................................................... 350
States of Integrated Safety Technology....................................................................................... 351
Notes on Commissioning................................................................................................................. 352
Safe Torque Off............................................................................................................................ 352
Safe Motion.................................................................................................................................. 352

Optional Device Functions......................................................................................... 353

Availability of the Optional Device Functions...................................................................................... 353
Cross Communication (CCD)............................................................................................................. 353
Brief Description.............................................................................................................................. 353
Rexroth IndraMotion MLD (Drive-Integrated PLC)............................................................................. 360
Brief Description.............................................................................................................................. 360
Digital Inputs/Outputs......................................................................................................................... 364

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Table of Contents
Page
9.4.1

9.5
9.5.1
9.6
9.6.1
9.7
9.7.1
9.8
9.8.1
9.9
9.9.1
9.10
9.10.1
9.11
9.11.1
9.12
9.12.1
9.13
9.13.1

10
10.1
10.1.1
10.1.2
10.1.3
10.1.4
10.2
10.2.1
10.2.2
10.2.3
10.2.4
10.3
10.3.1
10.3.2

Brief Description.............................................................................................................................. 364

General Information...................................................................................................................... 364
Digital Inputs/Outputs on Control Section..................................................................................... 364
Digital Inputs/Outputs on Optional Module MD1.......................................................................... 366
Analog Inputs...................................................................................................................................... 366
Brief Description.............................................................................................................................. 366
Analog Outputs................................................................................................................................... 370
Brief Description.............................................................................................................................. 370
Virtual Master Axis Generator............................................................................................................. 373
Brief Description.............................................................................................................................. 373
Drive-Integrated Command Value Generator..................................................................................... 377
Brief Description.............................................................................................................................. 377
Drive-Internal "Command Value Box"................................................................................................. 379
Brief Description.............................................................................................................................. 379
Encoder Emulation............................................................................................................................. 380
Brief Description.............................................................................................................................. 380
Programmable Position Switch........................................................................................................... 382
Brief Description.............................................................................................................................. 382
Probe Function................................................................................................................................... 383
Brief Description.............................................................................................................................. 383
Measuring Encoder............................................................................................................................. 385
Brief Description.............................................................................................................................. 385

Handling, Diagnostic and Service Functions............................................................. 387

Parameters, Basics............................................................................................................................. 387
Properties/Features of Parameters................................................................................................. 387
Brief Description........................................................................................................................... 387
Loading, Storing and Saving Parameters........................................................................................ 387
Brief Description........................................................................................................................... 387
IDN Lists of Parameters.................................................................................................................. 389
General Information...................................................................................................................... 389
Using a Password............................................................................................................................ 389
Brief Description........................................................................................................................... 389
Device Configuration.......................................................................................................................... 390
Controller Design............................................................................................................................. 390
Circuit Board Code.......................................................................................................................... 395
Brief Description........................................................................................................................... 395
Operating Hours Counter................................................................................................................ 397
Brief Description........................................................................................................................... 397
Error Memory (Power Section and Control Section)....................................................................... 398
Brief Description........................................................................................................................... 398
Diagnostic System.............................................................................................................................. 398
Coded Diagnostic Messages of the Drive....................................................................................... 398
Brief Description........................................................................................................................... 398
Status Classes, Status Displays, Control Parameters..................................................................... 399
General Information...................................................................................................................... 399

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Table of Contents
Page

10.4
10.4.1
10.4.2
10.5
10.5.1
10.6
10.6.1

10.6.2

10.6.3

10.6.4
10.7
10.7.1

10.7.2

10.8
10.8.1
10.9
10.9.1
10.9.2
10.9.3

Status Classes.............................................................................................................................. 399

Fixed Status Displays................................................................................................................... 399
Control Parameters...................................................................................................................... 401
Control Panels of the IndraDrive Controllers...................................................................................... 401
General Information on the Operation Options ............................................................................... 401
Control Panel Variants.................................................................................................................. 401
Standard Control Panel................................................................................................................... 402
Brief Description........................................................................................................................... 402
MultiMediaCard (MMC)....................................................................................................................... 403
Brief Description.............................................................................................................................. 403
Firmware Replacement....................................................................................................................... 404
General Notes on How to Replace the Firmware............................................................................ 404
Basic Principles............................................................................................................................ 404
Preparations and Conditions for Firmware Replacement............................................................. 405
Firmware Release Update............................................................................................................... 405
General Information...................................................................................................................... 405
Loading New Firmware to MMC................................................................................................... 406
Variant 1: Release Update With MMC.......................................................................................... 407
Variant 2: Release Update With "IndraWorks Ds/D/MLD"............................................................ 408
Firmware Version Upgrade.............................................................................................................. 409
General Information...................................................................................................................... 409
Save Parameter Values................................................................................................................ 410
Loading New Firmware to MMC................................................................................................... 411
Variant 1: Version Upgrade With MMC (With Safety Technology)............................................... 411
Variant 2: Version Upgrade With MMC (Without Safety Technology).......................................... 413
Variant 3: Version Upgrade With "IndraWorks Ds/D/MLD".......................................................... 413
Possible Problems During Firmware Replacement......................................................................... 414
Notes on How to Replace the Devices............................................................................................... 415
Replacing the Supply Unit............................................................................................................... 415
General Information...................................................................................................................... 415
How to Replace the Supply Unit................................................................................................... 416
Replacing the Controller.................................................................................................................. 416
Overview....................................................................................................................................... 416
Replacing the Controller Without Stationarily Plugged MMC....................................................... 417
Replacing the Controller With Stationarily Plugged MMC............................................................ 421
Replacing the Controller Without MMC........................................................................................ 424
Possible Problems During Controller Replacement..................................................................... 426
Enabling of Functional Packages....................................................................................................... 426
Brief Description.............................................................................................................................. 426
Extended Diagnostic Possibilities....................................................................................................... 427
Monitoring Function......................................................................................................................... 427
Brief Description........................................................................................................................... 427
Logbook Function............................................................................................................................ 427
Brief Description........................................................................................................................... 427
Patch Function................................................................................................................................. 427
Brief Description........................................................................................................................... 427

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Table of Contents
Page
10.10
Oscilloscope Function......................................................................................................................... 428
10.10.1
Brief Description.............................................................................................................................. 428

11
11.1
11.1.1

11.1.2

11.2
11.2.1
11.3
11.3.1
11.3.2
11.3.3

11.4
11.4.1

12
12.1
12.1.1

12.1.2

12.2
12.2.1
12.2.2
12.2.3
12.3
12.3.1
12.4
12.4.1
12.4.2

Engineering/Diagnostic Interfaces............................................................................. 431

Serial Communication......................................................................................................................... 431
Overview of Serial Communication................................................................................................. 431
General Information...................................................................................................................... 431
Interface Mode.............................................................................................................................. 431
Transmission Protocols................................................................................................................ 431
Functional Principle Independent of Protocol.................................................................................. 432
Basic State After Applying the Control Voltage............................................................................ 432
Setting the Drive Address............................................................................................................. 432
Communication Via RS232 Interface........................................................................................... 433
Communication Via RS485 Interface........................................................................................... 433
TCP/IP Communication...................................................................................................................... 435
Brief Description.............................................................................................................................. 435
SIS Ethernet Parameter Channel....................................................................................................... 436
Parameter Structure........................................................................................................................ 436
Telegram Structure, Telegram Scope ............................................................................................ 437
Basic Telegram Structure............................................................................................................. 437
Communication via SIS Protocol..................................................................................................... 437
Addressing a Drive....................................................................................................................... 437
Supported Services and Subservices........................................................................................... 437
File Handling by FTP via Ethernet...................................................................................................... 438
Brief Description.............................................................................................................................. 438

Commissioning.......................................................................................................... 441
Commissioning Motors....................................................................................................................... 441
Checking the Installation/Assembly................................................................................................. 441
Checking the Assembly................................................................................................................ 441
Checking the Installation.............................................................................................................. 441
Initial Commissioning/Serial Commissioning................................................................................... 441
Brief Description........................................................................................................................... 441
Notes on Commissioning.............................................................................................................. 442
Initial Start in "Easy Startup" Mode..................................................................................................... 444
Brief Description.............................................................................................................................. 444
Functional Description..................................................................................................................... 446
Notes on Commissioning................................................................................................................. 451
Initial Start with the Commissioning Tool............................................................................................ 454
Brief Description.............................................................................................................................. 454
Commissioning Machine Axes............................................................................................................ 455
Procedure for Commissioning......................................................................................................... 455
Commissioning Real Operation....................................................................................................... 455
Brief Description........................................................................................................................... 455
Schematic Sequence.................................................................................................................... 456

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Rexroth IndraDrive | Release Notes

Table of Contents
Page
12.4.3

13
13.1
13.1.1

13.1.2

13.2
13.2.1
13.2.2
13.2.3
13.3
13.3.1
13.3.2
13.3.3

14

Simulation Mode.............................................................................................................................. 457

Brief Description........................................................................................................................... 457

Notes on Application.................................................................................................. 459

Functions............................................................................................................................................ 459
Compatible New Functions and Functional Modifications............................................................... 459
System Overview.......................................................................................................................... 459
Master Communication................................................................................................................. 459
Motor, Mechanical Axis System, Measuring Systems.................................................................. 460
Drive Control................................................................................................................................. 461
Operation Modes.......................................................................................................................... 464
Extended Axis Functions.............................................................................................................. 466
Optional Device Functions............................................................................................................ 467
Handling, Diagnostic and Service Functions................................................................................ 470
Incompatible Functional Modifications............................................................................................. 473
System Overview.......................................................................................................................... 473
Master Communication................................................................................................................. 473
Drive Control................................................................................................................................. 473
Operation Modes.......................................................................................................................... 474
Extended Axis Functions.............................................................................................................. 474
New or Modified Parameters.............................................................................................................. 476
New Parameters.............................................................................................................................. 476
Modified Parameters....................................................................................................................... 481
No Longer Existing Parameters....................................................................................................... 489
New, Modified or no Longer Existing Diagnostic Messages............................................................... 489
New Diagnostic Messages.............................................................................................................. 489
Modified Diagnostic Messages........................................................................................................ 490
No Longer Existing Diagnostic Messages....................................................................................... 493

Service and Support.................................................................................................. 495

Index.......................................................................................................................... 497

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System Overview

System Overview

1.1

General Information

1.1.1

About This Documentation

Means of Representation in This

Documentation

To make the reading of this documentation easier for you, the table below con
tains the means of representation and notations of recurring terms.
What?

How?

For example...

Important facts which are to be Boldface

highlighted in continuous text

Transmission of freely configura

ble external process data (com
mand values and actual values of
the external control unit)

Parameter names, diagnostic Quotation

message names, function des marks
ignations

The device function "cross com

munication (CCD)" is character
ized by the following features:

Fig.1-1:

Conventions of Notation

All important notes are highlighted. A symbol tells you what kind of note is used
in the text. The symbols have the following significances:

...
DANGER

DANGER indicates a hazardous situation which, if not avoided, will result in

death or serious injury.

...
WARNING

WARNING indicates a hazardous situation which, if not avoided, could result

in death or serious injury.

...
CAUTION

CAUTION indicates a potentially hazardous situation which, if not avoided,

could result in injury or property damage.

This box contains important information which you should take into
consideration.
This symbol highlights useful tips and tricks.
Your Feedback

Your experience is important for our improvement processes of products and

documentations.
If you discover mistakes in this documentation or suggest changes, you can
send your feedback to the following e-mail address:
[email protected]
We need the following information to handle your feedback:

The number indicated under "Internal File Reference" .

The page number.

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Rexroth IndraDrive | Release Notes

System Overview

1.1.2

How to Use This Documentation

Structure of the Functional Description

The functional descriptions of the IndraDrive firmware are divided into fixed
chapters. The individual subjects of the firmware description are assigned to
these chapters according to their content.
The description of the respective firmware functionality is basically divided into
the following sections:

Brief Description

Functional Description

Notes on Commissioning

Diagnostic and Status Messages, Monitoring Functions

Within one subject, these sections are always contained in the mentioned order,
but for practical and formal reasons they are not always existing or may have
a different title.
Brief Description

The brief description contains an overview of the firmware function or the sub
ject of the section. The brief description can contain, for example, general
basics, the most important features of the function, overviews and examples of
application. At the end of the brief description you can find, where possible and
useful, a list of the parameters and diagnostic messages that are associated
with this functions.

Functional Description

The section "Functional Description" explains the operating principle of the re

spective drive function in an application-oriented way. The relevant parameters
of this function are described with regard to their settings and effects. The pa
rameter configuration is only explained in detail where this is necessary for the
description of the function. As a basic principle, the functional description con
tains references to the separate documentations for parameters and diagnostic
messages.
The detailed description of the parameters, their function and structure is
contained in the separate documentation "Rexroth IndraDrive, Parameter De
scription".
The detailed description of the diagnostic messages, their causes and
measures for remedy is contained in the separate documentation
"Rexroth IndraDrive, Troubleshooting Guide" (description of diagnostic mes
sages).

Notes on Commissioning

The section "Notes on Commissioning" or "Notes on Parameterization" pro

vides the user with the steps required for commissioning the function, similar
to a checklist. The necessary parameter settings are described in compact form
and, if necessary, instructions are given for activating the function and the di
agnostic messages of the immediate functional sequence are mentioned.

Diagnostic and Status Messages,

Monitoring Functions

The section "Diagnostic and Status Messages" (also "Monitoring Functions", if

necessary) summarizes the diagnostic messages and possible status displays
available for the respective function and describes them briefly. If there are
function-specific monitoring functions, they are also described in this section.
The detailed description of the diagnostic messages, their causes and
measures for remedy is contained in the separate documentation
"Rexroth IndraDrive, Troubleshooting Guide" (description of diagnostic mes
sages).

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Release Notes | Rexroth IndraDrive

Electric Drives | Bosch Rexroth AG

and Controls

17/505

System Overview

Markers and Terms

The complete functionality of the IndraDrive firmware is divided into functional
packages (base packages and optional expansion packages). The scope of the
available functions does not only depend on the hardware design, but in the
majority of cases also on the variant and characteristic of the firmware.
The descriptions of the master communication, the drive functions and the op
erating modes have a marker containing information on the availability of this
functionality in the respective functional package of the firmware, e.g.:
Assignment to functional firmware package, see chapter "Availa
bility of the Optional Device Functions".
Terms

The application-specific scalability of the hardware and firmware provides a

multitude of possibilities. For detailed information, the following terms are used
in the Functional Description:

Firmware range e.g. IndraDrive

Firmware design single-axis, double-axis (multi-axis)

Firmware variant e.g. MPH, MPB, MPD, MPC

Firmware version e.g. MPH-07VRS

Firmware characteristic open-loop/closed-loop

Firmware performance Basic/Advanced

Firmware type complete firmware type designation

Cross References
Many basic subfunctions of the firmware, as well as necessary settings and
definitions, are of multiple use within the overall functionality or have an effect
on neighboring areas of the drive functionality. Such subfunctions normally are
described only once. Descriptions that are part of other IndraDrive documen
tations (Parameter Description, Troubleshooting Guide, Project Planning Man
uals ...) are only repeated in detail in exceptional cases. Cross references
indicate the source for more detailed information.
For cross references to other sections or documentations, we make the follow
ing distinction:

References to sections within this documentation are specified by indi

cating the title of the respective section and the designation of the super
ordinate topic, if necessary (both can be easily found via the index).

References to other documentations are additionally signaled by the

"info icon", unless contained in a note, in a table or in brackets.

Reference Documentations
Drive Systems, System Components
Title

Kind of documentation

Rexroth IndraDrive

Document typecode1)

Part number

DOK-INDRV*-

R911

Drive System

Project Planning Manual

SYSTEM*****-PRxx-EN-P

309636

Mi Drive Systems

Project Planning Manual

KCU+KSM****-PRxx-EN-P

320924

Supply Units, Power Sections

Project Planning Manual

HMV-S-D+HCS-PRxx-EN-P

318790

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18/505

Bosch Rexroth AG | Electric Drives

and Controls

Rexroth IndraDrive | Release Notes

System Overview
Title

Kind of documentation

Rexroth IndraDrive

Document typecode1)

Part number

DOK-INDRV*-

R911

Drive Controllers Control Sections

Project Planning Manual

CSH********-PRxx-EN-P

295012

Additional Components

Project Planning Manual

ADDCOMP****-PRxx-EN-P

306140

1)

In the document typecodes, "xx" is a wild card for the current edition of
the documentation (example: PR01 is the first edition of a Project Plan
ning Manual)

Fig.1-2:

Documentations Drive Systems, System Components

Motors
Kind of documentation

Title
Rexroth IndraDyn

Document typecode1)

Part number

DOK-MOTOR*-

R911

A Series Asynchronous Motors

Project Planning Manual

MAD/MAF****-PRxx-EN-P

295781

H Frameless Synchronous Spindle

Motors

Project Planning Manual

MBS-H******-PRxx-EN-P

297895

L Synchronous Linear Motors

Project Planning Manual

MLF********-PRxx-EN-P

293635

S MSK Synchronous Motors

Project Planning Manual

MSK********-PRxx-EN-P

296289

T Synchronous Torque Motors

Project Planning Manual

MBT********-PRxx-EN-P

298798

1)

In the document typecodes, "xx" is a wild card for the current edition of
the documentation (example: PR01 is the first edition of a Project Plan
ning Manual)

Fig.1-3:

Documentations Motors

Cable
Kind of documentation

Title
Rexroth Connection Cables

Selection Data
1)

Fig.1-4:

Document typecode1)

Part number

DOK-CONNEC-

R911

CABLE*STAND-AUxx-EN-P

282688

In the document typecodes, "xx" is a wild card for the current edition of
the documentation (example: AU03 is the third edition of the documen
tation "Selection Data")

Documentations Cables

Firmware
Title

Kind of documentation

Rexroth IndraDrive

Document typecode1)

Part number

DOK-INDRV*-

R911

Firmware for Drive Controllers

Functional Description

MP*-02VRS**-FKxx-EN-P

299223

Firmware for Drive Controllers

Functional Description

MP*-03VRS**-FKxx-EN-P

308329

Firmware for Drive Controllers

Functional Description

MP*-04VRS**-FKxx-EN-P

315485

Firmware for Drive Controllers

Functional Description

MP*-05VRS**-FKxx-EN-P

320182

Firmware for Drive Controllers

Functional Description

MP*-06VRS**-FKxx-EN-P

Firmware for Drive Controllers

Parameter Description

GEN-**VRS**-PAxx-EN-P

297317

Firmware for Drive Controllers

Troubleshooting Guide

GEN-**VRS**-WAxx-EN-P

297319

Integrated Safety Technology

Functional and Application

Description

SI*-**VRS**-FKxx-EN-P

297838

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and Controls

19/505

System Overview
Title

Kind of documentation

Document typecode1)

Part number

DOK-INDRV*-

R911

Rexroth IndraDrive
Rexroth IndraMotion MLD

Application Manual

MLD-**VRS**-AWxx-EN-P

306084

Rexroth IndraMotion MLD Library

Library Description

MLD-SYSLIB*-FKxx-EN-P

309224

1)

In the document typecodes, "xx" is a wild card for the current edition of
the documentation (example: PA02 is the second edition of a Parameter
Description)

Fig.1-5:

1.1.3

Documentations Firmware

Overview of Drive Firmware

Firmware Variants
For the IndraDrive range, there are different application-related firmware types
available that are characterized by their scope of functions and their perform
ance:

MTH: Drives for Machine Tool Applications With SERCOS interface

(Advanced Performance and Functionality)

MPx: drives for general automation (incl. machine tool applications) with
SERCOS interface, field bus interfaces, parallel and analog interface (the
variants of design are MPH, MPB, MPD and MPC; see below)
The first two letters of the firmware designation identify the appli
cation and profile of the firmware:

MT:"Machine Tool" Drives for machine tool applications with

SERCOS interface
(drive profile according to SERCOS)

MP:"Multi Purpose" drives for general automation (incl. ma

chine tool applications) with SERCOS interface, field bus in
terface as well as parallel and analog interface (drive profile
according to SERCOS)

The third letter of the firmware designation identifies the hardware,

as well as the performance and functionality of the firmware (x con
tains H, B, D and C):

H: Single-axis firmware with Advanced performance and func

tionality

B: Single-axis firmware with Basic performance and function

ality

D: Double-axis firmware with Basic performance and func

tionality

C: Single-axis firmware with Advanced performance and func

tionality plus CCD + MLD-M functions

This documentation describes the functionality of the following firmware types:

FWAINDRV*MPH07VRSD5

FWAINDRV*MPB07VRSD5

FWAINDRV*MPD07VRSD5

FWAINDRV*MPC07VRSD5

The "IndraWorks Ds/D/MLD" commissioning tool is available for commissioning

these firmware variants.

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Bosch Rexroth AG | Electric Drives

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Rexroth IndraDrive | Release Notes

System Overview

Organization of the Firmware

For application-specific definition of drive functionality, the firmware functions
are divided into different "functional packages". There are a generally available
base package and various additional functional packages (e.g. integrated safe
ty technology, IndraMotion MLD) that can be optionally activated.
The scope of functions of the functional packages and their possible
combinations are described in section "Overview of functions/func
tional packages" section.

1.2

Terms, Basic Principles

1.2.1

Parameters
Communication between master and drive takes place, with a few exceptions,
by means of parameters.
Parameters are used for:

Determining the configuration

Parameterizing the control loop

Triggering and controlling drive functions and commands

Transmitting command values and actual values (according to require

ments, cyclically or acyclically)

All operating data are mapped to parameters!

The operating data stored in parameters can be identified by means of the IDN.
They can be read and transferred, if required. The user write access to param
eters depends on the properties of the respective parameter and the current
communication phase. Specific parameter values (operating data) are checked
for validity by the drive firmware.

1.2.2

Data Storage and Parameter Handling

Data Memory

Several non-volatile data memories are available in an IndraDrive device:

In the controller

In the motor encoder (depending on motor type)

As a MultiMediaCard (MMC), optional

In addition, a volatile data memory (working memory) is available in the con

troller.
Condition as Supplied

Condition as supplied of the Rexroth drive components:

The controller memory contains the drive firmware and the controller-spe
cific parameter values.

The motor encoder memory contains the encoder-specific and, depending

on the motor type, the motor-specific parameter values.

The MMC contains the drive firmware and the basic parameter sets.

Storing the Application-Specific Pa

rameter Values

The application-specific parameter values are stored in the controller. Due to

the limited number of writing cycles of non-volatile storage media, applicationspecific parameter values can be stored in the working memory (volatile mem
ory), too.

Storing of Parameter Values

Saving application-specific parameter values is required in the following cases:

After initial commissioning of the machine axis or the motor

Before replacing the controller for servicing (if possible)

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System Overview
Application-specific parameter values can be saved via:

Parameter IDN Lists

Loading of Parameter Values

MMC copying the parameter values by command

"IndraWorks Ds/D/MLD" commissioning tool Saving the parameter val

ues on external data carrier

Control master saving the parameter values on master-side data carrier

The drive supports master-side saving of parameter values by listing parameter

identification numbers (IDNs). Using these lists guarantees complete storage
of the application-specific parameter values. It is also possible to determine IDN
lists defined by the customer.
Loading parameter values is required in the following cases:

Initial commissioning of the motor (loading basic parameter values and

motor-specific parameter values)

Serial commissioning of machine axes at series machines (loading the

values saved after initial commissioning)

Reestablishing a defined initial status (repeated loading of the values

saved after initial commissioning)

Replacing the controller for servicing (loading the current parameter val
ues saved before servicing)

Possibilities of loading parameter values to the controller:

Checksum of Parameter Values

1.2.3

Motor encoder data memory loading the parameter values by command

or via the control panel during initial motor commissioning

MMC loading the parameter values by command

"IndraWorks Ds/D/MLD" Commissioning tool Loading the parameter

values from external data carrier

Control master loading the parameter values from master-side data

carrier

By means of checksum comparison, the control master can determine whether

the values of the application-specific parameter values currently active in the
drive correspond to the values saved on the master side.

Password
IndraDrive controllers provide the possibility to protect parameter values
against accidental or unauthorized change by means of a password. With re
gard to write protection, there are 3 groups of parameters that can be written:

Kinds of Passwords

Parameters that are write-protected as a standard, such as motor param

eters, hardware code parameters, encoder parameters, error memory,
etc. ("administration parameters"). The values of these parameters guar
antee correct function and performance of the drive.

Parameters the customer can combine in groups and protect them with a
so-called customer password. This allows protecting parameter values,
that are used for adjusting the drive to the axis, after having determined
them.

All other parameters that can be written and are not contained in the
above-mentioned groups. They are not write-protected.

The drive firmware allows activating and deactivating the write protection for
parameter values by means of three hierarchically different passwords:

Customer Password
The parameter values of a parameter group combined by the customer
can be protected.

Control Password

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System Overview
Parameters protected by a customer password can be written; "adminis
tration parameters" remain write-protected.

Master Password
All parameters that can be written, including "administration parameters"
and parameters protected by a customer password, can be changed.

1.2.4

Commands
Commands are used to activate and control complex functions or monitoring
features in the drive. The higher-level master can start, interrupt or clear com
mands.
Each command is assigned to a parameter by means of which the execution
of the command can be controlled. During the execution of the command the
display of the control panel reads "Cx", "Cx" representing the diagnostic com
mand message and "x" representing the number of the command.
Each command that was started must be actively cleared again.
All commands available in the drive are stored in the parameter "S00025,
IDN-list of all procedure commands".
Kinds of Commands

There are 3 different kinds of commands:

Drive control commands

Can cause automatic drive motion

can be started only when drive enable has been set,

Deactivate the active operation mode during its execution

Monitor commands

Activate or deactivate monitorings or functions in the drive

Administration commands

Carry out administration tasks

cannot be interrupted.

See also section "Command Processing"

1.2.5

Operation Modes
The selection of operation modes defines which command values will be pro
cessed in which way, in order to lead to the desired drive motion. The operation
mode does not determine how these command values are transmitted from the
master to the slave.
One of the four or eight (for SERCOS) operation modes that are defined in
parameters is always active if the conditions below are fulfilled:

Control section and power section are ready for operation

Drive enable signal sees a positive edge

Drive follows command value

"Drive Halt" function has not been activated

No drive control command is active

No error reaction is carried out

The display of the control panel reads "AF" when an operation mode was ac
tivated.
All implemented operation modes are stored in the parameter
"S00292, List of supported operation modes".

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System Overview
See also chapter "Operation Modes"

1.2.6

Warnings
Depending on the active operating mode and the parameter settings, many
monitoring functions are carried out. If a status is detected that still allows cor
rect operation but in case this status persists will cause an error to occur and
therefore cause the drive to be automatically switched off, the drive firmware
generates a warning message.
Warnings do not cause automatic shutdown (exception: fatal warn
ings).
Classes of Warnings

Warnings are classified in different warning classes which determine whether

the drive, when the warning is generated, carries out an automatic reaction or
not.
The warning class can be recognized by the diagnostic message.
The following classes of warnings are distinguished:

Without drive reaction diagnostic message number E2xxx, E3xxx,

E4xxx

With drive reaction diagnostic message number E8xxx

Warnings cannot be cleared. They persist until the condition that
activated the warning is no longer fulfilled.

1.2.7

Errors
Depending on the active operating mode and the parameter settings, many
monitoring functions are carried out. If a status is detected that affects or pre
vents correct operation the drive firmware generates an error message.
Error Classes

Errors are classified in different error classes. There are 6 error classes with
different drive error reactions.
The error class can be recognized by the diagnostic message num
ber.
Diagnostic message
number

Fig.1-6:

Error class

F2xxx

Non-fatal error

F3xxx

Non-fatal safety technology error

F4xxx

Interface error

F6xxx

Travel range error

F7xxx

Safety technology error

F8xxx

Fatal error

F9xxx

Fatal system error

E-xxxx

Fatal system error "processor exception"

Overview of Error Classes

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System Overview
Apart from the mentioned error classes that can occur during op
eration, errors can occur when the devices are booted and during
firmware download. These errors are not displayed at the control
panel with a diagnostic message number of the "Fxxxx" pattern, but
with a short text. Booting and firmware download errors are descri
bed in the separate documentation "Troubleshooting Guide" (de
scription of diagnostic messages).
Error Reactions of the Drive

If the drive controller is in control and an error status is detected, the execution
of a drive error reaction is automatically started. The diagnostic message num
ber "Fxxxx" flashes on the display of the control panel.
The drive reaction in the case of interface errors and non-fatal errors is deter
mined in parameter "P00119, Best possible deceleration". At the end of each
error reaction, the drive goes torque-free.
See also "Error Reactions"

Clearing an Error Message

Error messages are not cleared automatically, but by the following action:

Triggering the command "S00099, C0500 Reset class 1 diagnostics"

- or

Actuating the "Esc" key on the control panel

If the error status persists the error message is immediately generated again.
Clearing Error Messages when
Drive Enable was set

If a drive error occurs while operating with drive enable having been set, the
drive carries out an error reaction. The drive automatically deactivates itself at
the end of each error reaction; in other words, the output stage is switched off
and the drive switches from an energized to a de-energized state.
To reactivate the drive:

Error Memory

Clear the error message and

Input a positive edge for drive enable again.

The diagnostic message numbers of occurring errors are written to an error

memory. This memory contains the diagnostic message numbers of the last
50 errors that occurred and the time when they occurred. Errors caused by a
shutdown of the control voltage (e.g. "F8070 +24Volt DC error") are not stored
in the error memory.
The diagnostic message numbers in the error memory are mapped to the
"P00192, Error memory of diagnostic numbers" parameter and can be dis
played by means of the control panel. By means of the "IndraWorks Ds/D/
MLD" commissioning tool it is possible to display the diagnostic message num
bers and the respective times at which the errors occurred.

1.3

Drive Controllers

1.3.1

Overview

Standard Design of the IndraDrive Controllers

As a standard, IndraDrive controllers consist of two hardware components:

Power Section

Control Section

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Fig.1-7:
Power Section

Design of the IndraDrive Controllers

The following are connected to the power section:

Supply unit (DC bus voltage)

24 V control voltage

Motor
Each of the two types of the control section is described in a sepa
rate documentation; e.g. "Supply Units and Power Sections, Project
Planning Manual" (DOK-INDRV-HMS+HMD****-PR**-EN-P; part
no.: R911318790).

Control Section

The control section is a separate part of the IndraDrive controller and is plugged
in the power section. The drive controller is supplied ex works complete with
control section. The control section may only be replaced by a qualified service
engineer.
The available control sections are described in the separate docu
mentation "Control Sections for Drive Controllers; Project Planning
Manual"
(DOK-INDRV*-CSH********-PR**-EN;
part
no.:
R911295012).

1.3.2

Power Sections
The following power sections for the standard design of IndraDrive controllers
can be operated with the firmware MPx-07VRS:

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System Overview
IndraDrive M

IndraDrive C

Single-axis power sec Double-axis power sec Single-axis converters

tions
tions
in 300mm type of
constr.
HMS01.1N-W

HMD01.1N-W

HMS02.1N-W

Single-axis converters
in 400mm type of
constr.

Single-axis converter

HCS02.1E-W

HCS03.1E-W

HCS04.2E-W....

HCS02.1E-F

HCS04.1E-W
HCS03.1E-F

Fig.1-8:

1.3.3

Power Sections for IndraDrive Firmware

Control Sections

Available Control Section Designs

The following control sections can be operated with the appropriate
MPx-07VRS firmware variant:
Control section characteristic

Basic device range

Firmware derivate

MPC, Advanced, high-performance CSH01.3

drive functions as well as single- and
multi-axis control functions

MPC07

MPH, Advanced, high-performance CSH01.1

drive functions as well as single- and
multi-axis control functions

MPH07

MPB, Basic single-axis, medium-per CSB01.1C

formance drive functions, designs
CSB01.1N

MPB07

KMC01.2-B (IndraDrive motor-integra

ted)
KMS01.2-B (IndraDrive motor-close)
MPD, Basic double-axis,

CDB01.1

Fig.1-9:

MPD07

Control Section Support

Configurable control sections

ADVANCED (single-axis; type CSH01.1)

ADVANCED (single-axis; type CSH01.3)

BASIC UNIVERSAL (single-axis; type CSB01.xC...)

BASIC UNIVERSAL double-axis (type CDB01.xC...)

Non-configurable control sections

BASIC OPENLOOP (single-axis; type CSB01.xN-FC-...)

BASIC SERCOS (single-axis; type CSB01.xN-SE-...)

BASIC PROFIBUS (single-axis; type CSB01.xN-PB-...)

BASIC ANALOG (single-axis; type CSB01.xN-AN-...)

Supported Control Section Configurations

The configurable control sections differ with regard to the scope of their con
figurability. It basically depends on the control section type and the correspond
ing firmware variant.
The following overview contains the theoretically possible configurations of
control sections as regards the support by the MPx-07VRS firmware. The ab

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System Overview
breviations in the first column identify the configuration of control sections in the
type designation.
Our sales representative will help you with the current status of
available control section types.
Control section type
Firmware variant

CSH01.1

CSH01.3

CSB01.xC...

CDB01.xC...

MPH-07VRS

MPC-07VRS

MPB-07VRS

MPD-07VRS

Optional modules for master communication

AN

Analog Interface

CO

CANopen/DeviceNetTM (connected via

spring terminal)

CD

CANopen/DeviceNetTM (connected via DSUB connector)

ET

EtherCAT/SERCOS III

ET

PROFINET/Ethernet

PB

PROFIBUS-DP

PL

Parallel interface

S3

SERCOS III

SERCOS II

Cross communication

SE
CCD

1)

Optional modules for encoder evaluation and I/O extension

EN1

Encoder interface for HSF, resolver

EN2

Encoder interface for EnDat, 1Vpp sine

and TTL signals

ENS

Encoder interface for MSK motors and HI

PERFACE encoders

MA1

Analog I/O extension

MD1

Digital I/O Extension

MD2

Digital I/O extension

(with SSI interface)

MEM

Encoder emulation

Optional modules for safety technology

L2

Starting lockout

S2

Safety technology

1)

Fig.1-10:

Only required for CCD master

Supported Control Section Configurations

The type codes of the individual designs of IndraDrive control sec

tions and the respective assignment of possible optional modules
to the slots are described in the separate documentation "Control
Sections for Drive Controllers; Project Planning Manual" (DOKINDRV*-CSH********-PR**-EN; part no.: R911295012).

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System Overview

1.4

Supported Motors and Measuring Systems

1.4.1

Supported Motors
The following table contains an overview of the Rexroth motors which can be
operated at IndraDrive controllers.
Rexroth housing motors

Rexroth kit motors

Synchronous

Asynchronous

Synchronous

Asynchronous

MSK (IndraDyn S)

MAD (IndraDyn A)

MLF (IndraDyn L)

1MB

MHD

MAF (IndraDyn A)

MBS (Standard)

MKD

MAL

MBSxx2 (IndraDyn H)

MKE

MBT (IndraDyn T)

MSP
SF (by Bosch)

Fig.1-11:

1.4.2

Appropriate Rexroth Motors for IndraDrive

Supported Measuring Systems

Motor Encoder and External Op

tional Encoders

Measuring Encoder

In addition to the encoders integrated in the Rexroth motors, the IndraDrive

firmware can evaluate the following measuring systems as motor encoders or
as external optional control encoders:

GDS or GDM encoders from Bosch Rexroth (single-turn or multi-turn type)

Resolvers according to Rexroth signal specification (single-turn or multiturn type)

Encoders with sine signals and EnDat2.1 interface (1 Vpp)

Encoders with sine signals (1 Vpp)

Encoders with square-wave signals (TTL)

Hall sensor box and encoder with sine signals (1 Vpp)

Hall sensor box and encoder with square-wave signals (TTL)

Encoders with sine signals and HIPERFACE interface (1 Vss)

For measuring purposes the firmware can evaluate the following measuring
systems (measuring encoders, no control encoders):

GDS or GDM encoders from Bosch Rexroth (single-turn or multi-turn type)

Encoders with sine signals and EnDat2.1 interface (1 Vpp)

Encoders with sine signals (1 Vpp)

Encoders with square-wave signals (TTL)

Encoders with sine signals and HIPERFACE interface (1 Vss)

Motor encoders of MSK, MHD, MAD, MAF motors

SSI encoders
Resolvers cannot be evaluated as measuring encoders!

1.5

Overview of Master Communication

The firmware MPx-07VRS supports the following interfaces for master com
munication:

SERCOS II

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System Overview

SERCOS III

PROFIBUS-DP

EtherCAT

EtherNet/IPTM

PROFINET

CANopen interface

DeviceNetTM interface

Parallel interface (not for double-axis design MPD)

Analog Interface

1.6

Overview of Functions/Functional Packages

1.6.1

Overview

General Information
The
application-specific
scope
of
usable
functions
FWAINDRV*MP*-07VRS drive firmware depends on

of

the

the available control section and, if available, its configuration

- and

the licensed functional firmware packages.

Depending on the hardware design, the scope of firmware func
tionality can be determined according to the respective application
(scalability of the firmware functionality). The scope of correspond
ing parameters depends on the available functions.

Scaling the Drive Functionality

Firmware Scaling by Control Sec
tion Configuration

The control sections of the IndraDrive controllers have a maximum of 4 optional

card slots and a master communication slot. Depending on the available op
tional cards, it is possible to activate certain functions (incl. corresponding
parameters), e.g.:

Master communication

Safety technology (starting lockout, standard safety technology)

Analog I/O extension card

Digital I/O extension card

The functions and parameters for the evaluation of the measuring
systems as control encoders or measuring encoders do not depend
on the control section configuration, since their functions can be
freely assigned to the various optional encoder modules.

See also section "Drive Controllers"

Firmware Scaling by Functional
Packages

The firmware functionality is divided into the following package groups:

Base packages (open-loop or closed-loop)

Optional expansion packages:

Alternative functional packages (expansion packages for servo func

tion, main spindle function, synchronization)

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System Overview

Additive functional package "IndraMotion MLD"

(drive-integrated PLC and technology functions)

Depending on the hardware configuration, the base packages are available

without any access enable. Using the optional expansion packages, however,
requires licensing.
The desired scope of firmware functions should preferably be de
fined when the firmware is ordered. This guarantees that the re
quired functional packages have been enabled when the firmware
is delivered. In individual cases, it is possible to provide access en
able subsequently (additional licensing) or to reduce the activated
scope of functions.
This procedure is described in the section "Enabling of Functional
Packages" .
The drive-integrated safety technology is a functionality only scal
able by means of the hardware and does not require any additional
enabling of functions!
The figure below contains an overview of the possibilities of firmware scaling
by functional packages:

Fig.1-12:

Functional Packages of IndraDrive Firmware MPx07 Depending on

Control Performance

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System Overview
With Basic performance, the option "IndraMotion MLD-S" is not al
lowed for free programming!

Brief Description of the Functional Packages

The overall functionality of an IndraDrive device is divided into groups of func
tions, the so-called "functional packages". The firmware FWA-INDRV*MP*-07VRS supports the functional packages listed below.
Each of the listed packages is available in Basic or Advanced char
acteristic which differ with regard to their performance and func
tionality.
Base Packages

The following base packages are available:

Base package "open-loop" (open-loop motor control)

No position evaluation and functions depending thereof and no position
control modes are possible

Base package "closed-loop" (closed-loop motor control)

Position evaluation and functions and operating modes depending
thereof are possible

Alternative functional packages

The following alternative functional packages are available:

Servo functions 1)
This package makes available all specific expansions for servo applica
tions, such as compensations and correction functions (e.g. axis error
correction, quadrant error correction).

Synchronization 1)
With this package the possibilities of synchronization of the drive can be
used (support of synchronization modes, measuring encoder function,
probe function ...).

Main spindle functions 1)

This package contains the specific functions for the use of main spindles
(e.g. spindle positioning, parameter set switching).
1)...These

functional packages cannot be activated simultaneously

(only individually)! Alternative functional packages
Additive Functional Packages

There is also an additional functional package available:

IndraMotion MLD
For single-axis devices (ADVANCED and BASIC) the expansion
package "IndraMotion MLD" can be activated in addition to a pos
sibly available alternative package.

Overview of Dependencies

The overview below illustrates how the individual functional packages are de
pending on the respective hardware and the firmware type:

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System Overview
Firmware variant

MPB

MPD

MPH

MPC

CDB01.1

CSH01.1

CSH01.3

CSB01.1
Control section design

CSB01.1N
KMC01.2-B
KMS01.2-B

Control section range

Basic functions
Base pack
age

OL

CL

OL

CL

OL

CL

BASIC

ADVANCED

Base package
"closed-loop"

BASIC

ADVANCED

BASIC

ADVANCED

BASIC

ADVANCED

BASIC

ADVANCED

Synchronization

Main spindle
Additive
functional
package

CL

Base package
"open-loop"

Servo function
Alternative
functional
packages

OL

IndraMotion MLD

BASIC

ADVANCED
MPB
MPD
MPH
MPC
KMC01.2-B
KMS01.2-B
OL
CL
1)

Fig.1-13:

1)

1)

Single-axis firmware with Basic performance

Double-axis firmware with Basic performance
Single-axis firmware with Advanced performance
Single-Axis firmware with Advanced performance and CCD + MLD-M
functions
Basic device range IndraDrive motor-integrated
Basic device range IndraDrive motor-close
Open-loop characteristic
Closed-loop characteristic
No free programming and only MLD-S

Dependence of Functional Packages on Hardware and Firmware Var

iant

Firmware Types
Structure of the Firmware Type
Designation

IndraDrive
firmware

The type designation of the IndraDrive firmware consists of the following type
code elements:
Base pack
age of variant
(depending Version
on control
section)

Release

Lan
guage

Alternative
OL/CL expansion
packages

Additive ex
pansion
packages

Basic single-axis

FWA-INDRV*

-MPB-

07

VRS-

D5-

x-

xxx-

xx

Basic double-axis

FWA-INDRV*

-MPD-

07

VRS-

D5-

x-

xxx-

xx

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System Overview
Base pack
age of variant
(depending Version
on control
section)

IndraDrive
firmware

Release

Lan
guage

Alternative
OL/CL expansion
packages

Additive ex
pansion
packages

Advanced single-axis

FWA-INDRV*

-MPH-

07

VRS-

D5-

x-

xxx-

xx

Advanced single-axis

FWA-INDRV*

-MPC-

07

VRS-1)

D5-

x-

xxx-

xx

OL
CL
1)

Fig.1-14:
Function-Specific Abbreviations in
Type Designation of IndraDrive
Firmware

Open-loop characteristic
Closed-loop characteristic
MPC0602 and MPC0604 operable on CSH1.2, as of MPC06V06 the
MPC is only operable on CSH1.3

Basic Structure of the Firmware Type Designation

Base package (application and performance):

MPB Single-axis firmware with Basic performance

MPD Double-axis firmware with Basic performance

MPH Single-axis firmware with Advanced performance

MPC Single-axis firmware with Advanced performance

Firmware characteristic:

0 Open-loop

1 Closed-loop

Alternative expansion packages:

NNN Without alternative expansion package

SRV Functional package "servo function"

SNC Functional package "synchronization"

MSP Functional package "main spindle"

ALL All alternative expansion packages

Additive expansion packages:

NN Without additive expansion package

TF IndraMotion MLD for using the technology functions (for MPB firm
ware)

ML IndraMotion MLD for free programming; incl. use of technology

functions (for MPH firmware)

MA IndraMotion MLD Advanced (only for MPH firmware)

The sales representative in charge will help you with the current
status of available firmware types.

1.6.2

Base Packages

General Information
In the base packages of the firmware, the minimum scope of functionalities is
available depending on the respective firmware characteristic ("open-loop" or
"closed-loop"). They contain the basic functions of a drive firmware and a num
ber of other fundamental functions.

Basic Functions
The following basic functions are available for every drive and contain the fun
damental basic functions of a digital drive (available in the firmware character
istics "open-loop" and "closed-loop"):

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System Overview

Extensive diagnostic functions:

Drive-internal generation of diagnostic messages

Monitoring function

Analog output

Patch function

Status displays, status classes

Oscilloscope function

Code of optional card

Parameter value check

Operating hours counter, logbook function, error memory

Undervoltage monitor

Output of control signals

Limitations that can be parameterized

Serial communication

Scope of Functions of Base Packages

Apart from the basic functions, there are other functions available in the base
package of the firmware. Their scope depends on the firmware variant and its
characteristic ("open-loop" or "closed-loop").
See "Supported Operation Modes" in section "Operation Modes: General In
formation"
See "Availability of the Extended Axis Functions"
See "Availability of the Optional Device Functions"

1.6.3

Alternative Functional Packages

General Information
Apart from the base packages that are always available, we offer optional ex
pansion packages. Part of the expansion packages is the group of alternative
functional packages; from this group only one package can be activated at a
time (alternative activation).
At present, there are the following alternative expansion packages available:

Expanded servo function

Synchronization

Main spindle function

Servo Function
Depending on the firmware variant and characteristic, the expansion package
"servo function" has the following scope of functions:
Firmware variant

MPB

MPD

MPH

MPC

Functions of the
expansion package

OL

CL

OL

CL

OL

CL

OL

CL

Relative return motion

Precision axis error correction

"Servo function"

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System Overview
Firmware variant

MPB

MPD

MPH

MPC

Functions of the
expansion package

OL

CL

OL

CL

OL

CL

OL

CL

Temperature error correction

Quadrant error correction

Cogging torque compensation

Programmable position switch

Set/shift coordinate system

Parameter set switching (without

motor/gear switching)

"Servo function"

OL
CL

Open-loop characteristic
Closed-loop characteristic

Fig.1-15:

Overview Expansion Package "Servo Function"

With "BASIC ..." hardware design, the probe input is only available
for the control sections BASIC SERCOS, BASIC PROFIBUS and
BASIC UNIVERSAL (CSB01.1***).

Synchronization
Depending on the firmware variant and characteristic, the expansion package
"synchronization" has the following scope of functions, in addition to the func
tions available in the base package:
Firmware variant
Functions of the expansion package

MPB

MPD

MPH

MPC

OL

CL

OL

CL

OL

CL

OL

CL

Velocity synchronization

Phase synchronization

Electronic cam

Motion profile

Cogging torque compensation

Measuring wheel mode

Virtual master axis generator

Programmable position switch

"Synchronization"

Measuring encoder

Parameter set switching (without motor/

gear switching)
OL
CL
1)

Fig.1-16:

1)

1)

Open-loop characteristic
Closed-loop characteristic
Only with control section BASIC UNIVERSAL

Overview Expansion Package "Synchronization"

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Rexroth IndraDrive | Release Notes

System Overview
With "BASIC ..." hardware design, the probe input is only available
for the control sections BASIC SERCOS, BASIC PROFIBUS and
BASIC UNIVERSAL (CSB01.1***).

Main Spindle Function

Depending on the firmware variant and characteristic, the expansion package
"main spindle" has the following scope of functions, in addition to the functions
available in the base package:
Firmware variant
Functions of the expansion
package "main spindle"

MPD

MPH

MPC

OL

CL

OL

CL

OL

CL

OL

CL

Spindle positioning

Parameter set switching

Drive-controlled oscillation

OL
CL

Fig.1-17:

1.6.4

MPB

Open-loop characteristic
Closed-loop characteristic

Overview Expansion Package "Main Spindle"

Additive Functional Packages

General Information
The so-called additive functional packages are part of the optional expansion
packages. Additive functional packages can be used in addition to the basic
function and one of the alternative functional packages (additive activation).
At present, there is the following additive functional package available (in dif
ferent designs):

IndraMotion MLD (drive-integrated PLC and technology functions)

The drive-integrated safety technology is a functionality only scal
able by means of the hardware and is not part of the expansion
packages that can be enabled!

IndraMotion MLD (Drive-Integrated PLC)

Depending on the structure (type designation), the extension package
"IndraMotion MLD" offers the following scope of functions:

Integrated logic control (type designation "ML")

Standard PLC tasks

Integrated multi-axis/single-axis motion control (type designation "ML")

Motion function block according to PLCopen for single-axis positioning on
local and remote axes and synchronization mode (synchronous running,
cam shaft) "low-level motion functions"

Basis for technology functions (type designation "TF" or "ML")

Examples: Following-on cutting devices, pick&place, process controller
(register controller, winding computation, etc.), preventive maintenance,
free function block combination

IndraMotion MLD advanced (type designation "MA")

Firmware variant

Integrated logic control

MPB

MPD

MPH

MPC

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System Overview
Integrated multi-axis motion control

Integrated single-axis motion control

Basis for technology functions

IndraMotion MLD Advanced

Fig.1-18:

Overview Expansion Package "IndraMotion MLD"

Integrated Safety Technology

The drive-integrated safety technology is a functionality only scal
able by means of the hardware and does not require any additional
enabling of functions! The requirement for using this function is the
use of the optional safety technology modules L1 or S1 depending
on the control section configuration.
The following safety function is supported in conjunction with the optional mod
ule "starting lockout" (safety module L1):

Safety related starting lockout

The following safety functions are supported in conjunction with the optional
module "safety technology I/O" or PROFIsafe in the different operating states
(safety module S1):

In normal operation

Safely-limited maximum velocity

Safe direction

Safety related limited absolute end position

In status "safety related halt"

Safety related standstill

Safety related operational stop

Safety related braking and holding System

Safety related drive interlock

In status "safe motion"

Safety related reduced speed

Safe direction

Safely-limited increment

Safety related limited absolute position

Auxiliary functions

Safely-monitored stopping process

Safe homing procedure

Safe brake check

Safe parking axis

Safety functions for "safe feedback"

Safe diagnostic outputs

Safe control of a door locking device (not with PROFIsafe)

Safe inputs/outputs

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Rexroth IndraDrive | Release Notes

System Overview

1.7

Performance Data

1.7.1

Overview

Levels of Control Performance

For the control performance of the IndraDrive range, we basically distinguish
three levels with regard to the clock rates (cycle times):

Advanced performance
Highest degree of control performance by high internal clock rates for
the control loops and the signal processing of inputs/outputs or drive-in
tegrated PLC (IndraMotion MLD)

Basic performance
Standard control performance by medium internal clock rates for the
control loops and the signal processing of inputs/outputs or drive-integra
ted PLC (IndraMotion MLD)

Economy performance
Low control performance by reduced clock rates for the control loops
and the signal processing of inputs/outputs or drive-integrated PLC
(IndraMotion MLD)

Performance and Clock Rates

In this documentation the clock rate data refer to the following characteristic
values:

Current loop clock TA_current

Velocity loop clock TA_velocity

Position loop clock TA_position

Cycle time of PLC (IndraMotion MLD) TMLD

Cycle time of master communication TMastCom

The table below contains an overview of the clock rates depending on the re
spective control performance. The detailed assignment of clock rate to control
section design, performance level and parameter setting is contained in the
table "Performance depending on the control section design" in the section
"Control Section Design and Performance" (see below).
Performance
Advanced
Basic
Economy
1)

Fig.1-19:

TA_current

TA_velocity

TA_position

TMLD

TMastCom

62,5/83,3/125

125

250

1000

250

62,5/83,3/125/250

250

500

2000

500

83,3/125/250

500

1000

2000

1000 1)

With half the quantity of cyclic data

Clock Rates (in s)

The control performance is not equivalent to the control section de

sign (Advanced or Basic), because it is determined by several
factors (e.g. P00556, bits 2 and 5).
The available performance depends on the following requirements and param
eter settings:

Control section design (SH, CSB or CDB) and the corresponding drive
firmware (MPH, MPB, MPD and MPC)

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System Overview

Activation of functional packages (cf. P-0-2004)

Performance level in "P00556, Config word of axis controller" (bits 2 and

5)

Switching frequency in "P00001, Switching frequency of the power

output stage"

See also "Overview of Drive Control"

1.7.2

Control Section Design and Performance

The control section design differs with regard to the performance levels that can
be reached (cycle times or switching frequencies).
The table below contains an overview of the performance levels and clock rates
that can be reached depending on the control section design and parameter
settings.
Rotor-

Control
section/
firmware

Functional
packages
1)

CHS01.3
/MPC

CSH01.1
/MPH

All

PWM
reduc.
4)

syn
chro
nous
PWM

No

No

250

500

500 s 1000 s 500 s

No

No

125

250

500 s 1000 s 500 s

8 kHz

Yes

Yes

125

250

500 s 1000 s 500 s

Basic

12 kHz

Yes

Yes

83.3 s

250

500 s 1000 s 500 s

Basic

16 kHz

Yes

Yes

62.5 s

250

500 s 1000 s 500 s

Advanced

4 kHz

No

No

125 s

125 s

250

1000 s

250

Advanced

8 kHz

Yes

Yes

62.5 s

125 s

250

1000 s

250

Advanced

16 kHz

Yes

Yes

62.5 s

125 s

250

1000 s

250

Basic

2 kHz 3)

No

No

250 s

500 s

500 s 1000 s 500 s

Basic

4 kHz

No

No

125 s

250 s

500 s 1000 s 500 s

Basic

8 kHz

Yes

Yes

125 s

250 s

500 s 1000 s 500 s

Basic

12 kHz

Yes

Yes

83.3 s

250 s

500 s 1000 s 500 s

Basic

16 kHz

Yes

Yes

62.5 s

250 s

500 s 1000 s 500 s

Advanced

4 kHz

No

Yes

125 s

125 s

250 s 1000 s 250 s

Advanced

8 kHz

Yes

Yes

62.5 s

125 s

250 s 1000 s 250 s

Advanced

16 kHz

Yes

Yes

62.5 s

125 s

250 s 1000 s 250 s

P-0-0556

Perform
ance level

fPWM 2)

Basic

2 kHz 3)

Basic

4 kHz

Basic

Bit 2 Bit 5

TA_current TA_velocity

TA_posi
tion

TMLD

TMast
Com

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Bosch Rexroth AG | Electric Drives

and Controls

Rexroth IndraDrive | Release Notes

System Overview
RotorControl
section/
firmware

Functional
packages
1)

All, except
SY and
MLD

CSB01.1
/MPB

SY and
MLD

CDB01.1
/MPD

All

PWM
reduc.
4)

syn
chro
nous
PWM

No

No

250 s

250 s

500 s

--

500 s

No

No

125 s

250 s

500 s

--

500 s

8 kHz

Yes

No

125 s

250 s

500 s

--

500 s

Economy

2 kHz 3)

No

No

250 s

500 s

1000
s

--

1000
s 5)

Economy

4 kHz

No

No

125 s

500 s

1000
s

--

1000
s 5)

Economy

8 kHz

Yes

No

125 s

500 s

1000
s

--

1000
s 5)

Economy

12 kHz

Yes

No

83.3 s

500 s

1000
s

--

1000
s 5)

Economy

2 kHz 3)

No

No

250 s

500 s

1000
1000
2000 s
s
s 5)

Economy

4 kHz

No

No

125 s

500 s

1000
1000
2000 s
s
s 5)

Economy

8 kHz

Yes

No

125 s

500 s

1000
1000
2000 s
s
s 5)

Economy

12 kHz

Yes

No

83.3 s

500 s

1000
1000
2000 s
s
s 5)

Basic

4 kHz

No

No

125 s

250 s

500 s

--

500 s

Basic

8 kHz

No

No

125 s

250 s

500 s

--

500 s

P-0-0556

Perform
ance level

fPWM 2)

Basic

2 kHz 3)

Basic

4 kHz

Basic

Bit 2 Bit 5

1)
2)
3)
4)
5)
P-0-0556

Fig.1-20:

1.7.3

TA_current TA_velocity

TA_posi
tion

TMLD

TMast
Com

SY Synchronization; MLD IndraMotion MLD

Switching frequency of the power output stage (can be set via P00001)
Only with power section HCS04.1 and MAD/MAF
Reduction of PWM frequency depending on work load or PWM switch
ing depending on speed
With half the quantity of cyclic data
Config word of axis controller

Performance Depending on the Control Section Design

Selecting Performance via Parameter P-0-0556

For certain applications it is necessary to use the same clock rates in all axes
so that the slowest drive sets the clock. It is therefore possible to specifically
reduce the performance via bit 2 and bit 5 of parameter "P00556, Config word
of axis controller" .

For BASIC control sections it is possible to select the performance levels

"Basic" or "Economy" via bit 5 of P00556.

For ADVANCED control sections it is possible to select the performance

levels "Advanced" or "Basic" via bit 2 of P00556.

See also Parameter Description "P00556, Config word of axis

controller"

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System Overview
The effective clock rates of the active performance level can be
contained in the table "Performance depending on the control sec
tion design" in section "Control Section Design and Performance".

1.7.4

PWM Frequency Reduction Depending on Load

For switching frequencies of 8kHz,12 kHz or 16 kHz and corresponding per
formance settings in the parameters "P00556, Config word of axis controller
and P00045, Control word of current controller"
reduction of the switching frequency depending on the thermal load of the con
troller is possible.
When the load-dependent reduction of the PWM frequency is used,
the switching frequency of the power output stage is changed, but
not the cycle times!
See "Current Limitation: Dynamic Current Limitation"

1.7.5

PWM Frequency Reduction Depending on Speed

For switching frequencies of 8kHz,12 kHz or 16 kHz and corresponding per
formance settings in the parameters "P00556, Config word of axis
controller" and "P00045, Control word of current controller"
reduction of the switching frequency depending on the electric output frequency
of the controller is possible.
When the speed-dependent reduction of the PWM frequency is
used, the switching frequency of the power output stage is changed,
but not the cycle times!
See "Motor Control"

1.7.6

Rotor-Synchronous PWM
For switching frequencies of 8kHz,12 kHz or 16 kHz and corresponding per
formance settings in the parameters "P00556, Config word of axis
controller" and "P00045, Control word of current controller"
reduction of the switching frequency depending to the electric output frequency
of the controller is possible.
When the speed-dependent reduction of the PWM frequency is
used, the cycle time of the current loop and the switching frequency
of the power output stage are changed!
See "Motor Control"

1.7.7

Restricted Performance With Certain Functional Packages

If you use extensive and complex functions, the internal clock rates for BASIC
control sections (CSB with firmware MPB and CDB with firmware MPD) are
automatically reduced. This applies to the use of the following functional pack
ages:

Drive-integrated PLC "IndraMotion MLD" (functional package "ML")

Expansion package "synchronization" (functional package "SNC")

If you use one of these functional packages for BASIC control sections, the
clock rates (position loop, velocity loop) are reduced to the lowest performance
level "Economy"!

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Rexroth IndraDrive | Release Notes

System Overview
For ADVANCED control sections (CSH with firmware MPH or MPC)
the clock rates are not reduced depending on the functional pack
ages that are used (reduction possible via P00556).
The effective clock rates of the active performance level are con
tained in the table "Performance depending on the control section
design" in section "Control Section Design and Performance" (see
above).

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Important Directions for Use

Important Directions for Use

2.1

Appropriate Use

2.1.1

Introduction
Rexroth products represent state-of-the-art developments and manufacturing.
They are tested prior to delivery to ensure operating safety and reliability.

Personal injury and property damage caused by incorrect use of the

products!
WARNING

The products have been designed for use in the industrial environment and may
only be used in the appropriate way. If they are not used in the appropriate way,
situations resulting in property damage and personal injury can occur.
Rexroth 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 forfei
ted. The user alone carries all responsibility of the risks.
Before using Rexroth products, make sure that all the pre-requisites for an ap
propriate use of the products are satisfied:

2.1.2

Personnel that in any way, shape or form uses our products must first read
and understand the relevant safety instructions and be familiar with ap
propriate use.

If the products take 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.

Areas of Use and Application

Drive controllers made by Rexroth are designed to control electrical motors and
monitor their operation.
Control and monitoring of the Drive controllers may require additional sensors
and actors.
The drive controllers may only be used with the accessories and
parts specified in this documentation. If a component has not been
specifically named, then it may neither be mounted nor connected.
The same applies to cables and lines.
Operation is only permitted in the specified configurations and com
binations of components using the software and firmware as speci
fied in the relevant Functional Descriptions.
Drive controllers have to be programmed before commissioning, making it pos
sible for the motor to execute the specific functions of an application.
Drive controllers of the Rexroth IndraDrive line have been developed for use in
single- and multi-axis drive and control tasks.
To ensure application-specific use of Drive controllers, device types of different
drive power and different interfaces are available.
Typical applications include, for example:

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Bosch Rexroth AG | Electric Drives

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Rexroth IndraDrive | Release Notes

Important Directions for Use

Handling and mounting systems,

Packaging and food machines,

Printing and paper processing machines and

Machine tools.

Drive controllers may only be operated under the assembly and installation
conditions described in this documentation, in the specified position of normal
use and under the ambient conditions as described (temperature, degree of
protection, humidity, EMC, etc.).

2.2

Inappropriate Use
Using the Drive controllers outside of the operating conditions described in this
documentation and outside of the indicated technical data and specifications is
defined as "inappropriate use".
Drive controllers must not be used, if ...

they are subject to operating conditions that do not meet the specified
ambient conditions. This includes, for example, operation under water,
under extreme temperature fluctuations or extremely high maximum tem
peratures.

Furthermore, Drive controllers must not be used in applications which

have not been expressly authorized by Rexroth. Please carefully follow
the specifications outlined in the general Safety Instructions!
Components of the drive system Rexroth IndraDrive are products
of category C3 (with restricted distribution) according to
IEC 618003. These components are not provided for use in a public
low-voltage mains supplying residential areas. If these components
are used in such a mains, high-frequency interference is to be ex
pected. This can require additional measures of radio interference
suppression.

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Safety Instructions for Electric Drives and Controls

Safety Instructions for Electric Drives and Controls

3.1

Definitions of Terms
Application Documentation

The entire documentation used to inform the user of the product about the use
and safety-relevant features for configuring, integrating, installing, mounting,
commissioning, operating, maintaining, repairing and decommissioning the
product. The following terms are also used for this kind of documentation: User
Guide, Operation Manual, Commissioning Manual, Instruction Manual, Project
Planning Manual, Application Manual, etc.

Component

Combination of elements with a specified function, which are part of a piece of

equipment, device or system. Components of a drive and control system are,
for example, supply units, drive controllers, mains choke, mains filter, motors,
cables, etc.

Control System

Several interconnected control components placed on the market as a single

functional unit.

Device

Finished product with a defined function, intended for users and placed on the
market as an individual piece of merchandise.

Drive System

A group of components consisting of electric motor(s), motor encoder(s) and

cable(s), supply units and drive controllers, as well as possible auxiliary and
additional components, such as mains filter, mains choke, etc.

Electrical Equipment

Objects used to generate, convert, transmit, distribute or apply electrical ener

gy, such as machines, transformers, switching devices, cables, lines, powerconsuming devices, circuit board assemblies, plug-in units, control cabinets,
etc.

Installation

Several devices or systems interconnected for a defined purpose and on a de

fined site which, however, are not intended to be placed on the market as a
single functional unit.

Machine

Entirety of interconnected parts or units at least one of which is movable. Thus,

a machine consists of the appropriate machine drive elements, as well as con
trol and power circuits, which have been assembled for a specific application.
A machine is, for example, intended for processing, treatment, movement or
packaging of a material. The term "machine" also covers a combination of ma
chines which are arranged and controlled in such a way that they function as a
unified whole.

Manufacturer

Individual or legal entity bearing responsibility for the design and manufacture
of a product which is placed on the market in the individual's or legal entity's
name. The manufacturer can use finished products, finished parts or finished
elements, or contract out work to subcontractors. However, he must always
have overall control and possess the required authority to take responsibility
for the product.

Product

Produced device, component, part, system, software, firmware, among other

things.

Project Planning Manual

Part of the application documentation used to support the dimensioning and

planning of systems, machines or installations.

Qualified Persons

In terms of this application documentation, qualified persons are those persons

who are familiar with the installation, mounting, commissioning and operation
of the components of the drive and control system, as well as with the hazards
this implies, and who possess the qualifications their work requires. To comply
with these qualifications, it is necessary, among other things,

to be trained, instructed or authorized to switch electric circuits and devi

ces safely on and off, to ground them and to mark them,

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Bosch Rexroth AG | Electric Drives

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Rexroth IndraDrive | Release Notes

Safety Instructions for Electric Drives and Controls

User

to be trained or instructed to maintain and use adequate safety equipment,

to attend a course of instruction in first aid.

A person installing, commissioning or using a product which has been placed

on the market.

3.2

General Information

3.2.1

Using the Safety Instructions and Passing Them on to Others

Do not attempt to install and operate the electric components of the drive and
control system without first reading all documentation provided with the product.
Read and understand these safety instructions and all user documentation prior
to working with these components. If you do not have the user documentation
for the components, contact your responsible Rexroth sales partner. Ask for
these documents to be sent immediately to the person or persons responsible
for the safe operation of the components.
If the component is resold, rented and/or passed on to others in any other form,
these safety instructions must be delivered with the component in the official
language of the user's country.

WARNING

Improper use of these components, failure to follow the safety instruc

tions in this document or tampering with the product, including disabling
of safety devices, could result in property damage, injury, electric shock
or even death.
Observe the safety instructions!

3.2.2

Requirements for Safe Use

Read the following instructions before initial commissioning of the electric com
ponents of the drive and control system in order to eliminate the risk of injury
and/or property damage. You must follow these safety instructions.

Rexroth is not liable for damages resulting from failure to observe the
safety instructions.

Read the operating, maintenance and safety instructions in your language

before commissioning. If you find that you cannot completely understand
the application documentation in the available language, please ask your
supplier to clarify.

Proper and correct transport, storage, mounting and installation, as well

as care in operation and maintenance, are prerequisites for optimal and
safe operation of the component.

Only qualified persons may work with components of the drive and control
system or within its proximity.

Only use accessories and spare parts approved by Rexroth.

Follow the safety regulations and requirements of the country in which the
electric components of the drive and control system are operated.

Only use the components of the drive and control system in the manner
that is defined as appropriate. See chapter "Appropriate Use".

The ambient and operating conditions given in the application documen

tation at hand must be observed.

Safety-relevant applications are only allowed if clearly and explicitly speci

fied in the application documentation "Integrated Safety Technology". If

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Safety Instructions for Electric Drives and Controls

this is not the case, they are excluded. Safety-relevant are all such appli
cations which can cause danger to persons and property damage.

The information given in the application documentation with regard to the

use of the delivered components contains only examples of applications
and suggestions.
The machine and installation manufacturer must

make sure that the delivered components are suited for his individual
application and check the information given in this application docu
mentation with regard to the use of the components,

make sure that his individual application complies with the applicable
safety regulations and standards and carry out the required meas
ures, modifications and complements.

Commissioning of the delivered components is only allowed once it is sure

that the machine or installation in which the components are installed
complies with the national regulations, safety specifications and standards
of the application.

Operation is only allowed if the national EMC regulations for the applica
tion are met.

The instructions for installation in accordance with EMC requirements can

be found in the section on EMC in the respective application documenta
tion.
The machine or installation manufacturer is responsible for compliance
with the limit values as prescribed in the national regulations.

The technical data, connection and installation conditions of the compo

nents are specified in the respective application documentations and must
be followed at all times.

National regulations which the user must take into account

European countries: According to European EN standards

United States of America (USA):

National Electrical Code (NEC)

National Electrical Manufacturers Association (NEMA), as well as

local engineering regulations

Regulations of the National Fire Protection Association (NFPA)

Canada: Canadian Standards Association (CSA)

Other countries:

International Organization for Standardization (ISO)

International Electrotechnical Commission (IEC)

3.2.3

Hazards by Improper Use

High electrical voltage and high working current! Danger to life or serious
injury by electric shock!

High electrical voltage by incorrect connection! Danger to life or injury by

electric shock!

Dangerous movements! Danger to life, serious injury or property damage

by unintended motor movements!

Health hazard for persons with heart pacemakers, metal implants and
hearing aids in proximity to electric drive systems!

Risk of burns by hot housing surfaces!

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3.2.4

Risk of injury by improper handling! Injury by crushing, shearing, cutting,

hitting!

Risk of injury by improper handling of batteries!

Risk of injury by improper handling of pressurized lines!

Explanation of Safety Symbols and Hazard Classification

The safety instructions describe the following hazard classification. The hazard
classification informs about the consequences resulting from non-compliance
with the safety instructions:
Safety symbol

Fig.3-1:

Signal
word

Hazard classification according to ANSI Z535.4-2002

Danger

Death or serious injury will occur.

Warning

Death or serious injury could occur.

Caution

Minor or moderate injury or property damage may oc

cur.

Hazard Classification (According to ANSI Z535.4-2002)

3.3

Instructions with Regard to Specific Dangers

3.3.1

Protection Against Contact with Electrical Parts and Housings

This section concerns components of the drive and control system
with voltages of more than 50 volts.
Contact with parts conducting voltages above 50 volts can cause personal
danger and electric shock. When operating components of the drive and control
system, it is unavoidable that some parts of these components conduct dan
gerous voltage.

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Safety Instructions for Electric Drives and Controls

High electrical voltage! Danger to life, risk of injury by electric shock or

serious injury!
WARNING

Only qualified persons are allowed to operate, maintain and/or repair the
electric components of the drive and control system.

Follow the general installation and safety regulations when working on

power installations.

Before switching on, the equipment grounding conductor must have been
permanently connected to all electric components in accordance with the
connection diagram.

Even for brief measurements or tests, operation is only allowed if the

equipment grounding conductor has been permanently connected to the
points of the components provided for this purpose.

Before accessing electrical parts with voltage potentials higher than 50 V,

you must disconnect electric components from the mains or from the pow
er supply unit. Secure the electric component from reconnection.

With electric components, observe the following aspects:

Always wait 30 minutes after switching off power to allow live capacitors
to discharge before accessing an electric component. Measure the elec
trical voltage of live parts before beginning to work to make sure that the
equipment is safe to touch.

Install the covers and guards provided for this purpose before switching
on.

Never touch electrical connection points of the components while power

is turned on.

Do not remove or plug in connectors when the component has been pow
ered.

As a basic principle, residual-current-operated circuit-breakers cannot be

used for electric drives to prevent direct contact.

Secure built-in devices from penetrating foreign objects and water, as well
as from direct contact, by providing an external housing, for example a
control cabinet.

High housing voltage and high leakage current! Danger to life, risk of
injury by electric shock!
WARNING

3.3.2

Before switching on and before commissioning, ground or connect the

components of the drive and control system to the equipment grounding
conductor at the grounding points.

Connect the equipment grounding conductor of the components of the

drive and control system permanently to the main power supply at all
times. The leakage current is greater than 3.5 mA.

Establish an equipment grounding connection with a copper wire of a

cross section of at least 10 mm2 (8 AWG) or additionally run a second
equipment grounding conductor of the same cross section as the original
equipment grounding conductor.

Protective Extra-Low Voltage as Protection Against Electric Shock

Protective extra-low voltage is used to allow connecting devices with basic in
sulation to extra-low voltage circuits.
All connections and terminals with voltages between 5 and 50 volts at the com
ponents of the Rexroth drive and control system are PELV ("Protective ExtraLow Voltage") systems. It is allowed to connect devices equipped with basic

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insulation (such as programming devices, PCs, notebooks, display units) to
these connections.

Danger to life, risk of injury by electric shock! High electrical voltage by

incorrect connection!
WARNING

3.3.3

If extra-low voltage circuits of devices containing voltages and circuits of more

than 50 volts (e.g., the mains connection) are connected to Rexroth products,
the connected extra-low voltage circuits must comply with the requirements for
PELV ("Protective Extra-Low Voltage").

Protection Against Dangerous Movements

Dangerous movements can be caused by faulty control of connected motors.
Some common examples are:

Improper or wrong wiring or cable connection

Operator errors

Wrong input of parameters before commissioning

Malfunction of sensors and encoders

Defective components

Software or firmware errors

These errors can occur immediately after equipment is switched on or even

after an unspecified time of trouble-free operation.
The monitoring functions in the components of the drive and control system will
normally be sufficient to avoid malfunction in the connected drives. Regarding
personal safety, especially the danger of injury and/or property damage, this
alone cannot be relied upon to ensure complete safety. Until the integrated
monitoring functions become effective, it must be assumed in any case that
faulty drive movements will occur. The extent of faulty drive movements de
pends upon the type of control and the state of operation.

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Safety Instructions for Electric Drives and Controls

Dangerous movements! Danger to life, risk of injury, serious injury or

property damage!
WARNING

A risk assessment must be prepared for the installation or machine, with

its specific conditions, in which the components of the drive and control
system are installed. As a result of the risk assessment, the user must
provide for monitoring functions and higher-level measures on the instal
lation side for personal safety. The safety regulations applicable to the
installation or machine must be taken into consideration. Unintended ma
chine movements or other malfunctions are possible if safety devices are
disabled, bypassed or not activated.

To avoid accidents, injury and/or property damage:

Keep free and clear of the machines range of motion and moving machine
parts. Prevent personnel from accidentally entering the machines range
of motion by using, for example:

Safety fences

Safety guards

Protective coverings

Light barriers

Make sure the safety fences and protective coverings are strong enough
to resist maximum possible kinetic energy.

Mount emergency stop switches in the immediate reach of the operator.

Before commissioning, verify that the emergency stop equipment works.
Do not operate the machine if the emergency stop switch is not working.

Prevent unintended start-up. Isolate the drive power connection by means

of an emergency stop circuit or use a safe starting lockout.

Make sure that the drives are brought to a safe standstill before accessing
or entering the danger zone.

Additionally secure vertical axes against falling or dropping after switching

off the motor power by, for example,

mechanically securing the vertical axes,

adding an external braking/arrester/clamping mechanism or

ensuring sufficient equilibration of the vertical axes.

The standard equipment motor holding brake or an external holding brake

controlled by the drive controller is not sufficient to guarantee personal
safety!

Disconnect electrical power to the components of the drive and control

system using the master switch and secure them from reconnection for:

Maintenance and repair work

Cleaning of equipment

Long periods of discontinued equipment use

Prevent the operation of high-frequency, remote control and radio equip

ment near electric/electronic components of the drive and control system
and their supply leads. If the use of these devices cannot be avoided,
check the machine or installation, before initial commissioning of the drive
and control system, for possible malfunctions when operating such highfrequency, remote control and radio equipment in its possible positions of
normal use. It might possibly be necessary to perform a special electro
magnetic compatibility (EMC) test.

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Safety Instructions for Electric Drives and Controls

3.3.4

Protection Against Magnetic and Electromagnetic Fields During Oper

ation and Mounting
Magnetic and electromagnetic fields generated by current-carrying conductors
or permanent magnets of electric motors represent a serious danger to persons
with heart pacemakers, metal implants and hearing aids.

Health hazard for persons with heart pacemakers, metal implants and
hearing aids in proximity to electric components!
WARNING

3.3.5

Persons with heart pacemakers and metal implants are not allowed to
enter the following areas:

Areas in which components of the drive and control systems are

mounted, commissioned and operated.

Areas in which parts of motors with permanent magnets are stored,

repaired or mounted.

If it is necessary for somebody with a heart pacemaker to enter such an

area, a doctor must be consulted prior to doing so. The noise immunity of
implanted heart pacemakers differs greatly so that no general rules can
be given.

Those with metal implants or metal pieces, as well as with hearing aids,
must consult a doctor before they enter the areas described above.

Protection Against Contact with Hot Parts

Hot surfaces of components of the drive and control system. Risk of
burns!
CAUTION

Do not touch hot surfaces of, for example, braking resistors, heat sinks,
supply units and drive controllers, motors, windings and laminated cores!

According to the operating conditions, temperatures of the surfaces can

be higher than 60 C (140 F) during or after operation.

Before touching motors after having switched them off, let them cool down
for a sufficiently long time. Cooling down can require up to 140 minutes!
The time required for cooling down is approximately five times the thermal
time constant specified in the technical data.

After switching chokes, supply units and drive controllers off, wait 15 mi
nutes to allow them to cool down before touching them.

Wear safety gloves or do not work at hot surfaces.

For certain applications and according to the respective safety regulations,

the manufacturer of the machine or installation has to take measures to
avoid injuries caused by burns in the end application. These measures
can be, for example: Warnings at the machine or installation, guards
(shieldings or barriers) or safety instructions in the application documen
tation.

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Safety Instructions for Electric Drives and Controls

3.3.6

Protection During Handling and Mounting

Risk of injury by improper handling! Injury by crushing, shearing, cutting,
hitting!
CAUTION

3.3.7

Observe the relevant statutory regulations of accident prevention.

Use suitable equipment for mounting and transport.

Avoid jamming and crushing by appropriate measures.

Always use suitable tools. Use special tools if specified.

Use lifting equipment and tools in the correct manner.

Use suitable protective equipment (hard hat, safety goggles, safety shoes,
safety gloves, for example).

Do not stand under hanging loads.

Immediately clean up any spilled liquids from the floor due to the risk of
slipping.

Battery Safety
Batteries consist of active chemicals in a solid housing. Therefore, improper
handling can cause injury or property damage.

Risk of injury by improper handling!

CAUTION

Do not attempt to reactivate low batteries by heating or other methods (risk

of explosion and cauterization).

Do not attempt to recharge the batteries as this may cause leakage or

explosion.

Do not throw batteries into open flames.

Do not dismantle batteries.

When replacing the battery/batteries, do not damage the electrical parts

installed in the devices.

Only use the battery types specified for the product.

Environmental protection and disposal! The batteries contained in
the product are considered dangerous goods during land, air, and
sea transport (risk of explosion) in the sense of the legal regulations.
Dispose of used batteries separately from other waste. Observe the
national regulations of your country.

3.3.8

Protection Against Pressurized Systems

According to the information given in the Project Planning Manuals, motors and
components cooled with liquids and compressed air can be partially supplied
with externally fed, pressurized media, such as compressed air, hydraulics oil,
cooling liquids and cooling lubricants. Improper handling of the connected sup
ply systems, supply lines or connections can cause injuries or property damage.

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Safety Instructions for Electric Drives and Controls

Risk of injury by improper handling of pressurized lines!

WARNING

Do not attempt to disconnect, open or cut pressurized lines (risk of explo

sion).

Observe the respective manufacturer's operating instructions.

Before dismounting lines, relieve pressure and empty medium.

Use suitable protective equipment (safety goggles, safety shoes, safety

gloves, for example).

Immediately clean up any spilled liquids from the floor due to the risk of
slipping.
Environmental protection and disposal! The agents (e.g., fluids)
used to operate the product might not be environmentally friendly.
Dispose of agents harmful to the environment separately from other
waste. Observe the national regulations of your country.

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Master Communication

Master Communication

4.1

Basic Functions of Master Communication

4.1.1

Brief Description

General Information
The basic functions of master communication for IndraDrive devices apply to
SERCOS interface, SERCOS III, field bus interface, parallel and analog inter
face.

Features
All variants of master communication supported by IndraDrive have the follow
ing functional features in common:

Address assignment
Communication address to be freely parameterized (via master com
munication, serial and control panel) via parameters "P04025, Drive
address of master communication" and "S01040, Drive address of
master communication"

Command Processing
Drive commands to be externally activated (via master communication,
serial and control panel)

Device control (state machine)

Individual state machines for master communication and device

According to the variant of master communication, the master com

munication state machine has different functionality and complexity.
The communication-specific states are distinguished and mapped to
the status words of the corresponding master communication (e.g.
for SERCOS: S00014, S00135, S01045).

The device state machine is independent of the variant of master

communication and maps the device-specific states to parameter
"S00424, Status parameterization level" ab. We always distinguish
operating mode (OM) and parameter mode (PM).

Extended possibilities of control

Signal control word (S00145) and signal status word (S00144)

Multiplex Channel

See section "Control Options / Additional Functions"

The state machine of the master communications is briefly outlined
in this section; it will be described in detail, i.e. including the indi
vidual status transitions, in the main chapter of the respective
master communication.

Pertinent Parameters
The following parameters are used independent of the variant of master com
munication:
Parameters for State Machine and
Phase Switch

S00011, Class 1 diagnostics

S00012, Class 2 diagnostics

S00013, Class 3 diagnostics

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Master Communication

Operation Mode Parameters

Device-Specific Control and Status

Words

SERCOS-Specific Parameters

S00014, Interface status

S00420, C0400 Activate parameterization level 1 procedure command

S00422, C0200 Exit parameterization level procedure command

S00423, IDN-list of invalid data for parameterization levels

S00424, Status parameterization level

P04086, Master communication status

P04088, Master communication: Drive configuration

S00032, Primary mode of operation

S00033, Secondary operation mode 1

S00034, Secondary operation mode 2

S00035, Secondary operation mode 3

S00284, Secondary operation mode 4

S00285, Secondary operation mode 5

S00286, Secondary operation mode 6

S00287, Secondary operation mode 7

S00099, C0500 Reset class 1 diagnostics

S00144, Signal status word

S00145, Signal control word

P00115, Device control: status word

P00116, Device control: control word

P04028, Device control word

For the "SERCOS interface" the following additional parameters are used:

S00021, IDN-list of invalid operation data for CP2

S00022, IDN-list of invalid operation data for CP3

S00127, C0100 Communication phase 3 transition check

S00128, C5200 Communication phase 4 transition check

S01044, SERCOS III: Device Control (C-Dev)

S01045, SERCOS III: Device Status (S-Dev)

For the "SERCOS III" interface the following additional parameters are used:

Field-Bus-Specific Parameters

Specific Parameters for Parallel/

Analog Interface

S00134, Master control word

S00135, Drive status word

The following additional parameters are used for field buses:

P04068, Field bus: control word IO

P04077, Field bus: control word

P04078, Field bus: status word

For the parallel/analog interface, the following additional parameters are used:

P04028, Device control word

P00115, Device control: status word

C0100 Communication phase 3 transition check

C5200 Communication phase 4 transition check

Pertinent Commands

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Master Communication

4.1.2

C0200 Exit parameterization level procedure command

C0400 Activate parameterization level 1 procedure command

C5300 SERCOS III: Command SYNC delay measurement

Setting the Axis Address

Overview
Each drive is identified by its own address.
Multiple addressing is not allowed; i.e. an address number may only
be assigned once in the drive group!
The drive address can be set in the following ways:

Direct writing to parameters "P04025, Drive address of master

communication" and "S01040, Drive address of master
communication" via master communication

- or

Changing the content of "P04025, Drive address of master

communication" via the control panel (see below)
The address entered in parameter "P04025, Drive address of
master communication" takes effect during the transition from
P0 P1. This address is displayed in parameter"P04031,
Overview of device addresses".
For SERCOS III the parameter "S01040, Drive address of master
communication" always takes effect immediately, as it is already
required in P0.

Condition as Supplied

In the condition as supplied the address "99" is set.

Address Setting via Standard Control Panel

The drive address for IndraDrive controllers can be set via the standard control
panel at the front of the device.

Fig.4-1:

Standard Control Panel (Example of Display)

The address is set via the control panel as follows:

1. Change to "commands/settings" mode

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Master Communication

Fig.4-2:

Activating the "Commands/Settings" Mode

2. Select element "2.1 drive address" by means of "Up/Down" keys, then

confirm by means of "Enter" key
3. set drive address by means of "Up/Down" keys, then confirm by means of
"Enter" key

First set tens digit

The display reads "2.1.1 drive address"

Then set units digit

The display reads "2.1.2 drive address"
The tens or units digit is accepted by pressing the "Enter" key. To
return press the "Esc" key.

Fig.4-3:

Selecting and Setting the Drive Address

Address Setting via Parameter Access

The drive address can also be set by writing the parameter "P04025, Drive
address of master communication". This is particularly interesting if you ad
ministrate the axis data in centralized form in the control unit and want to set
the address from the control unit when replacing devices.
In this connection see "Notes on How to Replace the Devices"

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Master Communication
The address written to parameter "P04025, Drive address of
master communication" will only take effect after repeated booting
process or, in the case of SERCOS devices, after the transition from
P-1 P1.

4.1.3

Command Processing

Overview
Commands are used to control complex functions in the drive. For example,
the functions "Drive-controlled homing procedure" or "Transition check for com
munication phase 4" are defined as commands.
All commands available in the drive are stored in the parameter
"S00025, IDN-list of all procedure commands".
Kinds of Commands

We distinguish 3 kinds of commands:

Drive control commands

Can cause automatic drive motion

Can only be started when drive enable has been set

Deactivate the active operation mode during its execution

Monitor commands

Activate or deactivate monitorings or functions in the drive

Administration commands

Carry out administration tasks

Cannot be interrupted

Command Execution
General Information

Observe the following aspects for command execution:

Belonging to each command there is a parameter with which the command

execution can be controlled.

The higher-level master can start, interrupt or clear commands.

While a command is being executed, the diagnostic message "Cx" ap

pears on the display, "x" representing the number of the command.

Each command that was started by the master must be actively cleared
again.

Damage to the internal memory (flash) caused by cyclic command ex

ecution (write access to the flash)!
CAUTION

Controlling the Command Execu

tion

During the execution of some commands (see description of the respective

diagnostic command message; e.g. C0500), data are written to the internal
memory (flash), too. This memory, however, only allows a limited number of
write access. For this reason, you should make sure that such write access is
not carried out too often.
The command execution is controlled and monitored by command input and
command acknowledgment. In the input the drive is informed on whether the
command execution is to be started, interrupted or completed. The input takes
place via the operating data of the respective parameter.
Commands are started or terminated by:

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Master Communication

Directly writing data to the respective command parameter (e.g. parame

ter S00099 in the case of command C0500) via serial interface of master
communication

- or

A 0-1 edge when the command was assigned to a digital input

See also the following sections:
"Configurable Signal Control Word"
"Parallel Interface"
"Digital Inputs/Outputs"

Possible Command Inputs

Command Acknowledgment

For command execution, we distinguish the following inputs (= content of com

mand parameter):

0: Not set and not enabled

1: Interrupted

3: Set and enabled

In the command acknowledgment, the drive informs about the current status of
the command execution. The current status is contained in the data status of
the command parameter.
The command status can be obtained by executing a command to
write data to the parameter element 1 (data status) of the command
parameter.

Command Status

The command status can be:

0x0: Not set and not enabled

0x7: In process

0xF: Error, command execution impossible

0x5: Command execution interrupted

0x3: Command correctly executed

Command Change Bit

For master-side detection of a change of the command acknowledgment by the
drive the "command change bit" (KA bit) is available for SERCOS in "S00135,
Drive status word".

The drive sets this bit when the command acknowledgment changes from
the status "in process (0x7)" to one of the following states:

Error, command execution impossible (0xF)

- or

Command correctly executed (0x3)

The bit is cleared when the master clears the input (0x0), i.e. writes "0" to
the parameter belonging to the command.
The command change bit is only set if the command is activated via
master communication.

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Master Communication

4.1.4

Fig.4-4:

Input, Acknowledgment and Command Change Bit in the Case of Cor

rect Execution

Fig.4-5:

Input, Acknowledgment and Command Change Bit in the Case of In

correct Execution

Device Control and State Machines

Overview
The drive status (e.g. Drive Halt, drive error) represents a specific internal and
external drive behavior. The drive status can be exited by defined events (e.g.
drive commands, switching of operating modes). Corresponding status transi
tions are assigned to the events. The status transitions or the interaction of
control and status bits are called state machine.
We distinguish between:

Device-internal state machine (defines the device-specific states which

determine the behavior of the device)

State machine of master communication

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Master Communication

S00127
S00128
S00420
S00422
P04088

Fig.4-6:

C0100 Communication phase 3 transition check

C5200 Communication phase 4 transition check
C0400 Activate parameterization level 1 procedure command
C0200 Exit parameterization level procedure command
Master communication, configuration

Overview: State Machines of Master Communications and Device

Device-Internal State Machine

Parameter Mode/Operating Mode

For the device-internal state machine we distinguish the following states:

Parameter mode (PM)

Allows write access to all drive parameters which are not passwordprotected

Operating mode (OM)

Only allows write access to all drive parameters which can be changed
in operation and preferably can be cyclically transmitted

Switching

You can change between these two states via the following commands:

S00420, C0400 Activate parameterization level 1 procedure command

S00422, C0200 Exit parameterization level procedure command

Observe the following aspects for switching:

Switching is generally possible by direct execution of the transition com

mands S00420 or S00422.

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Master Communication

Control Word and Status Word

For field bus devices, switching can additionally take place in the freely
configurable operating mode (P04084 = 0xFFFE or 0xFFFD) by preset
ting the desired mode via bit 1 in "P04077, Field bus: control word":

For the "SERCOS interface" the state machine of the master communi
cation is connected to the device-internal state machine. This means that
when master communication is switched (communication phase 2 com
munication phase 4 or back), the device-internal state machine is switch
ed, too. Via parameter "P04088, Master communication: Drive
configuration" this dependence can be deactivated.

In the case of master communication other than SERCOS interface, the

device-internal state machine changes to the operating mode after the
booting process. This behavior, too, can be set via the parameter
"P04088, Master communication: Drive configuration".

The device-specific states are mapped to the following parameters:

S00424, Status parameterization level

P00115, Device control: status word

P00116, Device control: control word

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Master Communication

State Machine of Master Communication

Fig.4-7:

Device Control (General State Machine)

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Master Communication
For the state machine of master communication, we distinguish 3 characteris
tics which differ with regard to functionality and complexity:

SERCOS State Machine

Field Bus State Machine

Parallel/analog state machine

The following sections only describe the most important states
which are described in detail in the section of the respective master
communication.

SERCOS State Machine

For the master communication "SERCOS interface", we distinguish the follow

ing states specific to this kind of communication:

Fig.4-8:

State Machine of the Communication Phases of the Drive According to

SERCOS II Specification

See also "SERCOS Interface"

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Master Communication

Fig.4-9:

State Machine of the Communication Phases of the Drive According to

SERCOS III Specification

The currently valid communication phase is contained in parameter

"S00014, Interface status" (bit 0...2).
Field Bus State Machine

For field bus master communication, we distinguish the following states specific
to this kind of communication:

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Master Communication

Fig.4-10:

State Machine for Field Bus Interfaces

See also sections on the respective variants of the field bus master communi
cation

Communication Phases of Master Communication

The supported communication phases, as well as the handling of the switching
between the communication phases (e.g. parameter and operating mode), de
pend on the master communication that is used.
The currently valid communication phase is contained in parame
ter"S00014, Interface status" (bit 0...2) and for field bus drives
additionally in parameter"P04078, Field bus: status word" (bit 0,1).
Communication Phases According
to SERCOS Specification

According to SERCOS specification, the individual communication phases

(states) have the following significance:

P-1: After it is switched on, the drive goes to phase -1 and carries out a
baud rate scan. As soon as the drive receives valid SERCOS telegrams
from the master, it changes to phase 0.

P0: The master checks the SERCOS ring by sending synchronization

telegrams. During phase 0, communication between master and drive isn't
possible yet.

P1: When the ring is closed, the master changes to phase 1 and scans
the slaves. In addition, it checks the configuration of the ring.

P2: In phase 2, the complete drive parameterization can be carried out.

The following kinds of parameters can only be changed in phase 2:

Communication parameters (according to SERCOS)

Configuration of axis control (sampling times)

All factory-specific settings (can only be changed via master pass

word)

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Master Communication

P3: When changing from P2 P3, only the parameters that can be
changed in phase 2 (see above) are checked.
In phase 3, the following parameters can be changed:

Parameters for operating mode configuration

Error reaction settings

Motor configuration parameters, holding brake parameters

Encoder configuration parameters

Mechanical transmission elements (gear, feed constant)

Scaling and polarity parameters, position data format, modulo value

Configuration of analog and digital inputs/outputs

Configuration of switch-on / switch-off sequence of drive enable

(waiting times, ...)
According to SERCOS specification, the parameter mode is divided
into phases 2 and 3. In phase 3, the limit values for all scaling-de
pendent parameters are not yet known. When these parameters
are written in phase 3, the extreme value check is only carried out
during phase switch to phase 4.

P4: In phase 4, the so-called "operating mode", only the cyclic data can
be changed, the configuration parameters cannot. The switch to the op
erating mode always causes a new initialization of all functions available
in the drive.

The following aspects have to be observed for phase switch:

After the controller has been switched on, it does not automatically go to
the operating mode, but has to be switched to this mode by the master.

This switching of the drive controller to the operating mode is closely con
nected to establishing the readiness for operation.

The procedure comprises several steps and is controlled by the master

by presetting communication phases -1 to 4 and starting/completing the
following commands:

S00127, C0100 Communication phase 3 transition check

S00128, C5200 Communication phase 4 transition check

SERCOS devices support all 5 communication phases (as well as
phase 1 baud rate scan). According to SERCOS specification,
switching takes place by the master setting the communication
phase.

Communication Phases for Field

Bus Interface

Communication Phases for Parallel

or Analog Interface

For devices with field bus interface, there only is the status "Data Exchange",
apart from the basic initialization. In the status "Data Exchange" we distinguish
the following device states:

Parameter mode

Operating mode

Basically, the same communication phases apply to devices with analog or

parallel interface and to devices with field bus interface.
Switching always takes place when the transition check commands are exe
cuted.

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Master Communication
After the drive controller has been switched on, it automatically
changes to the operating mode!

Control Words and Status Words of Master Communication

The control word and status word of the respective master communication are
an essential part of the communication between the master communication
master and the drive.
Depending on the master communication, different parameters are used:

SERCOS interface:

S00134, Master control word

S00135, Drive status word

SERCOS III:

S01044, SERCOS III: Device Control (C-Dev)

S01045, SERCOS III: Device Status (S-Dev)

Field bus interface (e.g. PROFIBUS, CANopen, DeviceNetTM)

P04077, Field bus: control word

- or P04068, Field bus: control word IO

P04078, Field bus: status word

- or S00144, Signal status word

Analog/parallel interface (analog mode):

P04028, Device control word

P00115, Device control: status word

The following device-specific parameters are used drive-internally:

P00115, Device control: status word

P00116, Device control: control word

The figure below illustrates the interaction of the above control and status
words:

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Master Communication

Fig.4-11:

Interaction of the Existing Control and Status Words According to

SERCOS II Specification

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Master Communication

Fig.4-12:

Interaction of the Existing Control and Status Words According to

SERCOS III Specification

See also separate documentation "IndraMotion MLD".

The internal control and status words can only be directly reached
via the PLC integrated in the drive (functional package "IndraMotion
MLD" as optional expansion). If this function has not been activated,
it is always the specific control and status words that are accessed
via the master communication. But it is always possible to read the
parameters P00115 and P00116 in order to obtain information
on the internal device status.

Timing Diagrams for Device Control

The control bits in parameter "S00134, Master control word" are
input externally via the master communication (the following exam
ples apply to SERCOS)!

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Master Communication
Bit Sequence During Switch-On
Process

S00206

Drive on delay time

S00207

Drive off delay time

Fig.4-13:

Bit Sequence During Switch-On Process

Bit Sequence During Switch-Off

Process

Fig.4-14:

Bit Sequence During Switch-Off Process

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Master Communication
Bit Sequence During Error Reac
tion

S00099

C0500 Reset class 1 diagnostics

Fig.4-16:

Bit Sequence During Change of Operating Modes

Fig.4-15:

Bit Sequence During Error Reaction

Bit Sequence During Change of

Operation Modes

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Master Communication

Commands and Diagnostic Messages for Mode Change and Phase Switch
Distinguishing the Commands

According to the desired action, the commands are related to the following
groups:

Commands for changing between parameter mode and operating mode:

S00420, C0400 Activate parameterization level 1 procedure

command

S00422, C0200 Exit parameterization level procedure command

Commands for transition check to communication phases 3 and 4 (only

with SERCOS!):

S00127, C0100 Communication phase 3 transition check

S00128, C5200 Communication phase 4 transition check

With SERCOS, the command C0200 (S00422) is automatically
called during the execution of command C5200 (S00128). This is
why a diagnostic command message C02xx can be displayed after
the command C5200 has been started.

Communication Phase 3 Transition

Check

By executing the command "S00127, C0100 Communication phase 3

transition check", a number of checks and parameter conversions are carried
out that can possibly cause the listed diagnostic command messages:

Checking validity of parameters required for switching to phase 3

If one of these parameters has never been written or the backup was car
ried out incorrectly, the error message "C0101" generated. The IDNs of
the faulty parameters are listed in parameter "S00021, IDN-list of invalid
operation data for CP2". These parameters have to be set valid by writing
correct values to them.

Checking device configuration

C0101 Invalid parameters (-> S-0-0021)

C0132 Invalid settings for controller cycle times

Checking telegram configuration, especially in the case of configured tele

grams
In this case a check is run to find out whether the parameters selected for
the configurable data block in the cyclic command value channel (MDT)
or actual value channel (AT) may be configured and whether the allowed
length of the configurable data blocks is complied with.

C0104 Config. IDN for MDT not configurable

C0105 Maximum length for MDT exceeded

C0106 Config. IDNs for AT not configurable

C0107 Maximum length for AT exceeded

C0170 Config. IDNs for connection not configurable

C0171 Maximum length for connections exceeded

C0173 Connections (number) not configurable

C0174 Connection configuration not allowed

If necessary, checking timing parameters for SERCOS communication in

phases 3 and 4 for validity and compliance with requirements

C0108 Time slot parameter > Sercos cycle time

C0109 Telegram offset unsuitable

C0110 Length of MDT (S-0-0010) odd

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Master Communication

Communication Phase 4 Transition

Check or Command "Exit Parame
terization Level Procedure"

C0111 ID9 + Record length - 1 > length MDT (S-0-0010)

C0112 TNcyc (S-0-0001) or TScyc (S-0-0002) error

C0113 Relation TNcyc (S-0-0001) to TScyc (S-0-0002) error

C0114 T4 > TScyc (S-0-0002) - T4min (S-0-0005)

C0115 T2 too small

C0116 T3 (S-0-0008) within MDT (S-0-0089 + S-0-0010)

C0139 T2 (S-0-0089)+length MDT (S-0-0010)>TScyc (S-0-0002)

C0175 Producer cycle time of a connection not correct

Limit value check of communication parameters and system

C0102 Limit error in parameter (-> S-0-0021)

C0103 Parameter conversion error (->S-0-0021)

C0131 Switching to phase 3 impossible

C0172 Delay measurement (S-0-1024) not carried out

With the command "S00128, C5200 Communication phase 4 transition

check" or "S00422, C0200 Exit parameterization level procedure command"
the following checks and initializations are carried out that can possibly cause
the listed command errors:

Checking whether functional package selection was changed

C0299 Configuration changed. Restart

Drive has to be rebooted before it is possible to switch to the op
erating mode (OM)

Checking validity of parameters required for subsequent initializations

C0201 Invalid parameters (->S-0-0423)

C0212 Invalid control section data (->S-0-0423)

Checking device configuration

C0223 Invalid settings for controller cycle times

If necessary, checking parameters for field bus communication for validity

and compliance with requirements

C0229 Field bus: IDN for cycl. command val. not configurable

C0230 Field bus: Max. length for cycl. command val. exceeded

C0231 Field bus: IDN for cycl. actual val. not configurable

C0232 Field bus: Length for cycl. actual values exceeded

C0233 Field bus: Tcyc (P-0-4076) incorrect

C0234 Field bus: P-0-4077 missing for cycl. command values

Checking configuration of multiplex channel

C0238 Order of cyclic command value configuration incorrect

C0239 IDN for command value data container not allowed

C0240 IDN for actual value data container not allowed

Checking motor and encoder configuration

C0210 Feedback 2 required (->S-0-0423)

C0219 Max. travel range too large

C0270 Error when reading encoder data => motor encoder

C0271 Incorrect parameterization of motor encoder (hardware)

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Master Communication

C0272 Incorr. parameteriz. of motor enc. (mechanical system)

C0273 Modulo value for motor encoder cannot be displayed

C0274 Motor encoder unknown

C0275 Error when reading encoder data => optional encoder

C0276 Incorrect parameterization of optional enc. (hardware)

C0277 Incorr. parameteriz. of opt. enc. (mechanical system)

C0278 Modulo value for optional encoder cannot be displayed

C0279 Optional encoder unknown

C0280 Maximum travel range cannot be displayed internally

C0284 Invalid motor data in encoder memory (->S-0-0423)

C0285 Type of construction of motor P-0-4014 incorrect

C0286 Several motor encoders connected

C0287 Error during initialization of motor data (->S-0-0423)

C0288 Rotary scaling not allowed

C0289 Error at init. of synchr. motor with reluctance torque

C0290 Error when reading encoder data => measuring encoder

C0291 Incorr. prarmeterization of measuring enc. (hardware)

C0292 Measuring encoder unknown

C0293 Modulo value for measuring encoder cannot be displayed

C0294 Incorrect measuring encoder configuration

Checking modulo range

C0244 Act. modulo value cycle greater than max. travel range

Checks during encoder initialization

C0220 Error when initializing position of encoder 1

C0221 Initialization velocity encoder 1 too high

C0224 Error when initializing position of encoder 2

C0225 Initialization velocity encoder 2 too high

C0227 Error when initializing position of measuring encoder

C0228 Initialization velocity measuring encoder too high

Initializing optional additional functions (digital I/Os)

C0243 Brake check function not possible

C0250 Probe inputs incorrectly configured

C0260 Incremental enc. emulator resol. cannot be displayed

Initializing integrated safety technology

C0254 Configuration error PROFIsafe

C0255 Safety command for system init. incorrect

C0256 Safety technology configuration error

C0257 Error in safety technology encoder initialization

Limit value check

C0202 Parameter limit error (->S-0-0423)

C0203 Parameter conversion error (->S-0-0423)

General system checks

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Master Communication

C0246 Trav. range lim. switch not ass. to dig. input

C0247 Dig. output already assigned to other axis

C0248 Dig. input assigned differently to axes

C0249 Dig. I/Os: Bit number too large

Checking interface configuration

"Error-Free" Message

C0251 Error during synchronization to master communication

Checking whether boot error is present or firmware download has been

carried out

C0242 Multiple configuration of a parameter (->S-0-0423)

Checking master communication

C0258 Error in relation TNcyc (S-0-0001) to fine interpol.

Initializing digital inputs/outputs

C0245 Operation mode configuration (->S-0-0423) not allowed

Initializing fine interpolator

C0298 Impossible to exit parameterization level

Checking whether it was possible to switch CCD group without error

C0265 Incorrect CCD address configuration

C0266 Incorrect CCD phase switch

C0267 CCD timeout phase switch

When the drive has reached communication phase 4 without error, the display
reads "bb". The corresponding diagnostic message is:

A0013 Ready for power on

4.2

Control Options/Additional Functions

4.2.1

Configurable Signal Control Word

Brief Description
The signal control word allows writing individual control bits, that are available
in different parameters, by a freely configurable collective parameter. The con
figurable signal control word is used to accept a maximum of 16 copies of bits
from other drive parameters.
The bits in the signal control word are processed in every interface
cycle at the point of time defined in parameter "S00008, Command
value valid time (T3)".
Examples of Use

This functionality can be used, for example,

for freely configuring the digital inputs

for setting-up mode via digital inputs

for setting bits in drive parameters and for starting commands via the cyclic
channel (master communication)
For SERCOS and field bus interface the parameter "S00145,
Signal control word" must be accordingly configured in the cyclic
data so that the configured control bits are evaluated.

Pertinent Parameters

S00027, Configuration list for signal control word

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Master Communication

4.2.2

S00145, Signal control word

S00329, Assign list signal control word

S00399, IDN-list of configurable data in signal control word

Configurable Signal Status Word

Brief Description
The configurable signal status word is used to accept a maximum of 16 copies
of bits from other drive parameters. The user can thereby freely configure a bit
list with status bits. This allows defining a bit list which contains all important
status information of the drive for the control unit.
The bits in the signal status word are configured in every master
communication cycle at the point of time defined in parameter
"S00007, Feedback acquisition starting time (T4)".
Pertinent Parameters

S00026, Configuration list for signal status word

S00144, Signal status word

S00328, Assign list signal status word

S00398, IDN-list of configurable data in signal status word

4.3

Multiplex Channel

4.3.1

Brief Description
The multiplex channel is an expansion of the limited cyclic data channel. By
means of index assignment and switching, cyclic access to list elements is
possible for the multiplex channel, too.
To be able to use the "multiplex channel" mechanism it is necessary
to use master communication via SERCOS or field bus (e.g.
PROFIBUS-DP) and configure the multiplex parameters in the cy
clic real-time channel.
Features

Possible Applications

8 multiplex containers with 4 bytes each are available for cyclic command
value data (MDT) and cyclic actual value data (AT)

Multiplex data to be transmitted is addressed via parameter "S00368,

Data container A: addressing" (L-byte for MDT; H-byte for AT)

Individual elements from list parameters can be addressed via parameters

S00362 and S00366

Multiplex data are transmitted in communication cycle

By means of the multiplex channel it is possible:

To increase the number of transmittable bytes in the cyclic real-time chan

nel (command and actual values) by multiplexing data,

To transmit the multiplex data with a cycle time of "Tscyc x number of mul
tiplex data" by incrementing the addressing index (S00368)

To achieve operating mode dependent configuration of the cyclic data by

index switching in case the operating mode is changed.
When IndraMotion MLC is used, the multiplex channel is used for
communication between MLC and drive and therefore cannot be
freely used any more!

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Master Communication
Pertinent Parameters

Parameters for command value channel:

S00362, Data container A: list index command values

S00368, Data container A: addressing

S00360, Data container A: command value 1

S00450, Data container A: command value 2

- to S00456, Data container A: command value 8

Parameters for actual value channel:

S00366, Data container A: list index feedback values

S00364, Data container A: feedback value 1

S00480, Data container A: feedback value 2

- to S00486, Data container A: feedback value 8

Configuration lists of the command value data containers:

S00370, Data container A: configuration list command value-1

S00490, Data container A: configuration list command value 2

- to S00496, Data container A: configuration list command value 8

Configuration lists of the actual value data containers:

S00371, Data container A: configuration list feedback value-1

S00500, Data container A: configuration list feedback value 2

- to S00506, Data container A: configuration list feedback value 8

Pertinent Diagnostic Messages

C0238 Order of cyclic command value configuration incorrect

C0151 IDN for command value data container not allowed

C0152 IDN for actual value data container not allowed

E4008 Invalid addressing command value data container A

E4009 Invalid addressing actual value data container A

4.4

Operating Modes of Master Communication

4.4.1

Introduction and Overview

Overview of Operating Modes and Possibilities of Command Triggering

Command triggering for the drive can take place by an external control master
(remote mode) or internally via IndraMotion MLD or the inputs/outputs which
are available (local mode).
The figure below contains an overview of the possibilities of drive command
triggering.

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Master Communication

Fig.4-17:
Operating Modes and Changes of
States

Overview of Possibilities of Command Triggering for an IndraDrive De

vice

The overview below shows the basically possible operating states and the ac
tions required for change/transition from one operating mode to the other.

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Master Communication

Fig.4-18:
Device Control and State Machine

Operating States and Operating Modes of Master Communication

According to the kind of master communication or setting of the device control,

different control words take effect. Internally, however, all relevant control bits
are always displayed in parameter "P00116, Device control: control word".
The actual state machines of master communication are described
in section "Device Control and State Machines" !

Normal Operation (via Internal or External Control Unit)

In the so-called normal operation, the command triggering for the drive takes
place via an internal (IndraMotion MLD) or external control unit (e.g.
IndraMotion MTX or MLC); we distinguish the following cases:

Remote mode with active master communication (standard case)

Command triggering for the axis takes place via the master communi
cation (SERCOS, field bus, analog/parallel).
Special cases (respective configuration via parameter P04088):

Analog mode for SERCOS or field bus devices (master communi

cation has been deactivated and a device with SERCOS or field bus
interface is permanently operated via the digital/analog inputs/out
puts)

EtherNet/IPTM communication via the engineering interface

MLD mode (stand-alone "Motion Control")

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Master Communication
The PLC integrated in the drive (IndraMotion MLD) takes over command
triggering of the axis or, in conjunction with cross communication (CCD),
of an entire axis group.
Configuration via parameter P01367 (see also "Stand-Alone Motion
Control" in the separate documentation "IndraMotion MLD, Application
Manual")

Local Setting-Up Mode/Emergency Mode ("Easy Startup Mode")

During operation, the drive can, due to the situation, change to a local mode
for setting-up or to remedy an emergency (e.g. bus failure). We distinguish the
following operating modes:

Setting-up mode (easy startup mode)

For commissioning or the setting-up procedure, the drive can tempora
rily be moved via the inputs/outputs (digital and analog), independently of
the external master (e.g. field bus interfaced PLC or NC) or the the internal
control (IndraMotion MLD).

Emergency mode in the case of bus failure (freezing the last command
values)
Even if the master communication fails, it is possible to continue oper
ating the drive in an emergency mode via the (local) inputs/outputs at the
device.
Using the emergency mode requires the corresponding configura
tion in the parameter "P04088, Master communication: Drive
configuration"; the automatic activation of the easy startup mode
can be set in this parameter, if necessary.

4.4.2

Normal Mode (Remote or Local)

Remote Mode With External Control Unit and Active Master Communication
In the standard case, the command triggering for the axis takes place externally
via the master communication (remote). In this case, command values and ac
tual values are exchanged with the external control unit via the master com
munication interface (incl. control word and status word).
See description of the respective master communication:

SERCOS interface

SERCOS III

PROFIBUS-DP

EtherNet/IPTM interface

CANopen interface

DeviceNetTM interface

Parallel interface

Analog interface

When using field bus interfaces, also take the profile types for this kind of master
communication into account (see "Profile Types (With Field Bus Interfaces)").
Ethernet/IPTM and the analog operation with optional module avail
able for these master communications require specific configura
tion and handling (see "Notes on Commissioning and Utilization:
Special Cases of Operation With External Control Unit").

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Master Communication

MLD Mode With Permanent Control (Stand-Alone Motion Control)

Using IndraMotion MLD requires the functional firmware pack
age"ML" or "MA" and the corresponding MLD software!
With small, stand-alone subsystems, command triggering often takes place di
rectly in the drive with an integrated PLC (IndraMotion MLD). In this case,
IndraMotion MLD can independently communicate with external devices via all
interfaces available in the drive (master communication, digital/analog inputs/
outputs, serial interface, ...).
Observe the following aspects for commissioning and utilization:

4.4.3

You have to configure the MLD mode with permanent control in parameter
"P01367, PLC configuration".

The configuration can only be changed in the parameter mode (PM) and
only takes effect after repeated run-up to the operating mode (OM).

Command value input by an external control unit is interrupted and has to

be freely programmed with IndraMotion MLD.

Setting-Up Mode (Easy Startup Mode)

Brief Description of Easy Startup Mode

The setting-up mode as so-called "easy startup mode" allows moving the drive
without connected or active control unit (or master communication master) or
external command value box. When using a Rexroth motor with encoder data
memory, this is also possible without using a commissioning PC, because all
motor and controller parameters are stored in the encoder data memory.
Fields of Application

The easy startup mode is particularly suited for

initial commissioning of individual axes without active master communi

cation

maintaining a configurable emergency mode (local mode) when the inter

nal or external control unit (or master communication) has failed
See also section "Introduction and Overview: Local Setting-Up Mode/
Emergency Mode (Easy Startup Mode)"

Features

The easy startup mode has the following features:

Activation/deactivation of the easy startup mode:

by writing to parameter "P04085, Command Activate easy startup

mode"

Via control panel of controller (incl. switch-off)

Command triggering (axis control) via digital inputs/outputs by

predefined digital I/O configuration in operation mode "velocity con

trol" with a velocity command value (default) that can be parameter
ized

freely configurable I/O configuration and operating mode with active

easy startup mode

selecting the travel direction (positive/negative) via digital input sig

nals

activating and changing the fixed velocity command values via stand
ard control panel

Switching off command triggering by master communication interface (see

"P04077, Interface status", "S00134, Interface status") and possibly
available drive-integrated PLC (IndraMotion MLD)

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Rexroth IndraDrive | Release Notes

Master Communication
Pertinent Parameters

Pertinent Diagnostic Messages

S00014, Interface status

P00120, Control word easy startup

P00300, Digital I/Os, assignment list

P00301, Digital I/Os, bit numbers

P00302, Digital I/Os, direction

P01200, Control word 1 velocity control

P01206, Memory of velocity command values

P04085, Command Activate easy startup mode

P04086, Master communication status

P04088, Master communication: Drive configuration

When the easy startup mode is used, simple diagnostic texts appear on the
display of the control panel in "light writing":

When the easy startup mode has been activated, the display changes
between the drive address and the message "CM" (Commissioning
Mode).

During commissioning, the relevant messages appear on the display (see

fig. "Activating the Easy Startup Mode Via the Control Panel").

Functional Description of Easy Startup Mode

In the setting-up mode (easy startup mode), the drive can be controlled either
via the digital and analog inputs or via the commissioning interface (serial or
Ethernet).
Control via Digital or Analog Inputs

If the drive is to be controlled via the digital or analog inputs, the inputs must
have been configured accordingly. The form and point of time of the configu
ration is set in parameter "P04088, Master communication: Drive
configuration":

Automatically by activating the easy startup mode

- or
Automatic Configuration of the In
puts

Manually before or after the easy startup mode has been activated

For automatic configuration of the inputs, the following actions are carried out:

Deactivation of master communication interface and activation of drive

enable in parameter "P00120, Control word easy startup"

Setting of operation mode "velocity control" with values from memory of

fixed command values (P01206)

Assignment of the command velocity selected via the control panel (in
percent) of "S00091, Bipolar velocity limit value" to element 1 or 2 of
parameter "P01206, Memory of velocity command values" (with positive
sign to element 1, with negative sign to element 2).

Assignment of allocation of inputs

The actual configuration of the inputs/outputs depends on the avail
able digital inputs of the control section (see tables below).
The automatic configuration of the inputs/outputs for the easy start
up mode takes place in volatile form, i.e. any I/O configuration
existing before is reestablished when the command is completed.
This is not the case, if the I/O configuration was specifically (man
ually) changed with the command being active.

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Master Communication
IndraDrive single-axis control sections (CSB, CSH)
Connection

Signal

Function

I/O assignment

X31.3

I_1

Motor potentiometer, ramp +

P01200, Control word 1 velocity control (bit 8)

X31.4

I_2

Drive Enable

P00120, Control word easy startup (bit 15)

X31.7

I_5

Motor potentiometer, ramp

P01200, Control word 1 velocity control (bit 9)

X32.7

I/O_9

Selection of memory of fixed com P01200, Control word 1 velocity control (bit 0)
mand values

X32.8

I/O_10

Selection of memory of fixed com P01200, Control word 1 velocity control (bit 1)
mand values

Fig.4-19:

Automatic I/O Configuration for Easy Startup Mode With Single-Axis

Control Sections

IndraDrive double-axis control sections (CDB)

Connection

Signal

axis

Function

I/O assignment

X33.4

I_15

Motor potentiometer, ramp +

P01200, Control word 1 velocity control (bit 8)

X33.1

I_12

Drive Enable

P00120, Control word easy startup (bit 15)

X33.5

I_16

Motor potentiometer, ramp

P01200, Control word 1 velocity control (bit 9)

X33.2

I_13

Selection of memory of fixed

command values

P01200, Control word 1 velocity control (bit 0)

X33.3

I_14

Selection of memory of fixed

command values

P01200, Control word 1 velocity control (bit 1)

X34.4

I_21

Motor potentiometer, ramp +

P01200, Control word 1 velocity control (bit 8)

X34.1

I_18

Drive Enable

P00120, Control word easy startup (bit 15)

X34.5

I_22

Motor potentiometer, ramp

P01200, Control word 1 velocity control (bit 9)

X34.2

I_19

Selection of memory of fixed

command values

P01200, Control word 1 velocity control (bit 0)

X34.3

I_20

Selection of memory of fixed

command values

P01200, Control word 1 velocity control (bit 1)

Fig.4-20:

Automatic I/O Configuration for Easy Startup Mode With Double-Axis

Control Sections

IndraDrive Mi (KSM)
Connection

Signal

Function

I/O assignment

X37.2

I/O_3

Drive Enable

P00120, Control word easy startup (bit 15)

X37.4

I/O_1

Selection of memory of fixed com P01200, Control word 1 velocity control (bit 0)
mand values

X38.4

I/O_2

Selection of memory of fixed com P01200, Control word 1 velocity control (bit 1)
mand values

Fig.4-21:

Automatic I/O Configuration for Easy Startup Mode With IndraDrive Mi

IndraDrive Mi (motor-integrated inverter drive) only has a limited

number of digital inputs/outputs (4 inputs/outputs), it has no analog
input and no control panel!

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Master Communication

See also "Optional Modules for Control Sections" in the separate docu
mentation "Control Sections for Drive Controllers; Project Planning Manual"
Manual Configuration of the Inputs

Necessary manual configuration of the digital/analog inputs (see also "Digital

Inputs/Outputs" or "Analog Inputs"):

Connect 24V/0V power supply to respective terminal connectors

+24 V for activation of drive enable (P00120, bit 15)

Alternatively, you can additionally set the following manual configurations:

Input of analog speed command value (P01460), if command value input

is to take place via analog value

Setting of source for velocity command values in parameter "P01200,

Control word 1 velocity control":
Selection of memory of fixed command values, if command value input
is to take place via predefined fixed values
- or Setting that command value input is to take place via motor potentiom
eter function

Operating the Drive via Serial Inter

face or Ethernet

The drive can also be controlled via the commissioning interface (serial or
Ethernet) via which it is possible to write the control word and the command
values.
The following has to be taken into account:

The digital inputs must not have been assigned to the parameter
"P01200, Control word 1 velocity control".

Parameter "P01460, PLC/setting-up mode, velocity command value"

must not have been assigned to any analog input

Drive enable mustn't have been assigned to any digital input (P00120).

Property damage caused by errors when controlling motors and moving

parts!
CAUTION

It is necessary to wire the E-Stop input at the drive so that the drive can be
shut down when the commissioning interface fails.

Notes on Commissioning for Easy Startup Mode

Requirements

The following requirements and conditions must have been fulfilled for using
the easy startup mode:

For Rexroth motors with encoder data memory there is no commissioning

PC required; for motors without encoder data memory, the motor param
eters have to be manually written during commissioning.

Master communication or IndraMotion MLD should not be active, as the

easy startup mode switches off any possibly active command triggering
via master communication or IndraMotion MLD!

There mustn't be any error message present in the drive, not even a tran
sition command error (C01xx, C02xx).

The drive must be ready for operation (bb).

In the case of conventional field bus interfaces (e.g. CANopen,

PROFIBUS or DeviceNetTM) the drive is automatically ready for
operation (bb) after run-up, even if master communication is not ac
tive. In this way, the requirements for manual mode basically are
always fulfilled!

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Master Communication

Possibilities of Activation

With SERCOS interface, Ethernet interface, , the drive after runup is not ready for operation if master communication is not active
(e.g. communication phase "P-1" with SERCOS).

The easy startup mode is activated by starting "P04085, Command Activate

easy startup mode" in one of the following ways:

Activate the corresponding menu item on standard control panel

Set a digital input on which the command parameter P04085 has been
configured

Write the parameter P04085 via master communication, via serial inter
face or via EtherNet/IPTM (if available)

Automatically by internal command start in the case of bus failure, if con

figured accordingly (see P04088)
If the drive already is in the easy startup mode and this mode is
activated again, the display reads "easymode active"!

Activation via Control Panel

The command P04085 can be activated and deactivated via the standard
control panel of the IndraDrive controllers.
The figure below shows the sequence for activating the easy startup mode via
the control panel:

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Rexroth IndraDrive | Release Notes

Master Communication

Fig.4-22:

Activating the Easy Startup Mode Via the Control Panel

See also "Control Panels of the IndraDrive Controllers"

Activation Via Digital Input

To activate the easy startup mode via a digital input, bit 0 of parameter P04085
has to be assigned to a digital input.
See "Digital Inputs/Outputs"

Activation via Serial Interface

To activate the easy startup mode via the serial interface, parameter P04085
has to be written via SIS telegrams.
See "Serial Communication"
Parameter P04085 can also be directly written via the master
communication (e.g. SERCOS or field bus), but in this way the
master would deactivate itself!

Acknowledgment of Activation

The activation of the easy startup mode is acknowledged by:

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Master Communication

Setting bit 8 in parameter "P04086, Master communication status"

Changing the display on the control panel between "CM" (Commissioning

Mode) and the drive address

Clearing the bit "drive follows (ext.) command value input" in parameter
P00115 (bit 3)
With active easy startup mode, the active operating mode is not
acknowledged in the status word (see P00115)!

Deactivating/Exiting the Easy Start

up Mode

The easy startup mode is deactivated by completing the command activation.

The command can also be completedxxx by writing parameter P04085 or by
confirming the corresponding menu item with the standard control panel.
After you have exited the easy startup mode, the previously active
status becomes active again. The command triggering of the drive
again takes place via the master communication (see P04077,
S00134, ) or IndraMotion MLD and the originally active operat
ing modes are carried out.

Control Parameter P00120

The control parameter "P00120, Control word easy startup" active in the easy
startup mode can be changed or influenced in the following ways:

Via digital inputs, if they were accordingly configured before

Via the serial interface by direct writing of parameter P00120

In this case, the parameter has to be actively written at least every 2 s,
otherwise the drive will automatically clear drive enable!

Invalid Commands

The commands for backup of working memory ("C2200 Backup working

memory procedure command" and "C2400 Selectively backup working
memory procedure command") should not be triggered in the easy startup
mode, because otherwise the settings of the easy startup mode will be stored
in the non-volatile memory and will be active again after the drive is switched
on the next time!

Commissioning With Easy Startup

Mode

The figure below summarizes the commissioning sequence with the easy start
up mode:

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Master Communication

1)

Fig.4-23:

See assignment tables for the different hardware designs under "Auto
matic Configuration of the Inputs"

Commissioning Sequence With the Easy Startup Mode

For "load defaults procedure" see "Default Settings in the Motor Encoder Data
Memory" in "Overview of Drive Control".

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Master Communication
Special Case: Commissioning Mo
tors Without Encoder Data Memory

Initial commissioning of Rexroth motors without encoder data memory or of

third-party motors is only possible in the manual mode in conjunction with the
commissioning tool "IndraWorks Ds/D/MLD", in order to load or enter the values
for motor control parameters and motor encoder parameters. For synchronous
motors with absolute measuring system, the commutation offset only has to be
determined at initial commissioning. For synchronous motors with relative
measuring system, the commutation offset is automatically determined every
time drive enable is set for the first time after transition "PM OM".
If for synchronous motors the commutation offset can only be determined by
supplying current, this is only possible in the operating status "Ab" with active
easy startup mode!
See "Commissioning Motors: Initial Start With the Commissioning Tool"

Danger of property damage during initial start in the easy startup mode
caused by incorrect parameter values!
CAUTION
Recommissioning

For motors without encoder data memory, the required motor and controller
parameters have to be checked before initial start in the easy startup mode!
In the easy startup mode, recommissioning (after initial commissioning having
been carried out) of drives is possible without any problem, because the correct
values of motor control parameters and motor encoder parameters are already
available in the drive.
Only the commutation setting of synchronous motors with relative measuring
system is automatically determined again every time drive enable is set for the
first time after transition "PM OM"!

4.4.4

Local Mode

Overview
During operation and in a setting-up or emergency mode, it is possible, de
pending on the situation, to change to digital and analog inputs/outputs of the
controller or to the control panel:

MLD mode with temporary control by IndraMotion MLD (intelligent servo

axis) to carry out, for example, an intelligent error reaction.

Emergency run (local mode) for bus failure With the corresponding con
figuration, you can continue using the drive in an emergency mode, even
if master communication (field bus, SERCOS, ) has failed.

MLD Mode With Temporary Control (Intelligent Servo Axis)

Starting from any status (except for setting-up mode), you can get temporary
control (see parameter "P01367, PLC configuration" and function block
"MX_SetControl") over the axis with IndraMotion MLD and thereby interrupt the
command value input of an external control unit. As IndraMotion MLD can be
freely programmed, this provides high flexibility for drive control which can be
used, for example, for realizing an intelligent error reaction.
Using the MLD mode with temporary control requires the functional
firmware package "ML" and the corresponding MLD software!

Emergency Mode (When Master Communication has Failed)

Behavior in the Case of Bus Failure

For bus failure (line interruption), bus stop or PLC stop, the reaction of the drive
can be set in the parameter "P04088, Master communication: Drive
configuration":

Bus failure as error

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Rexroth IndraDrive | Release Notes

Master Communication
The drive normally switches off, generates the message of an interface
error (e.g. "F4009") and carries out the defined error reaction (best pos
sible deceleration).

Bus failure as warning

In the case of bus failure, the drive does not react by switching off and
generating an error message, but the status of the last command triggering
is maintained (command value and control word are "frozen") or the easy
startup mode is automatically activated and the warning "E4005 No
command value input via master communication" is output.

See also section "Setting-Up Mode (Easy Startup Mode)"

See also Parameter Description "P04088, Master communication: Drive
configuration"

Property damage caused by errors when controlling motors and moving

parts!
CAUTION
Status Display

If bus failure has been configured as a warning, the E-Stop input should be
wired at the drive. It is no longer possible to switch the drive off via the master
communication.
The parameter "S00014, Interface status" displays the current status of the
master communication interface.

4.5

Profile Types (With Field Bus Interfaces)

4.5.1

Supported Profile Types

Overview
When a field bus interface is used for master communication, IndraDrive con
trollers support the following profile types (modes):

I/O mode positioning

I/O mode preset velocity

Freely configurable mode (IndraDrive profile type)

The tables below contain an overview of the most important properties and
features of these 3 profile types:
I/O mode positioning
Content of "P04084, Master commu
Field bus: profile type" nication
Field bus or drive operating mode
0xFF82

PROFIBUS
CANopen

I/O mode positioning (positioning

block mode, encoder 1, lagless)

Features
- up to 64 positioning blocks can be control
led via field bus
- apart from control and status word, other
real-time data can be configured (in
P-0-4080 and P-0-4081)

DeviceNetTM

- bits can be freely defined in signal

status word via function "configurable signal
status word"

Fig.4-24:

Profile Type "I/O Mode Positioning"

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Master Communication
I/O mode preset velocity
Content of "P04084, Master commu
Field bus: profile type" nication
Field bus or drive operating mode
0xFF92

PROFIBUS

I/O mode preset velocity

CANopen
DeviceNetTM

Features
- fixed velocity command values can be con
trolled and ramp-function generator can be
operated via field bus
- apart from control and status word, other
real-time data can be configured (in
P-0-4080 and P-0-4081)
- bits can be freely defined in signal
status word via function "configurable signal
status word"

Fig.4-25:

Profile Type I"O Mode Preset Velocity"

Freely configurable mode

Content of "P04084, Master commu
Field bus: profile type" nication
Field bus or drive operating mode
0xFFFE

PROFIBUS

Features

Freely configurable mode

- possible use of complete drive functionali

(default assignment is "drive-control ty
by free configuration of real-time data
led positioning" with corresponding
and operating mode selection
required cyclic data)

CANopen
DeviceNetTM

- control word and status word have a

Rexroth-specific structure
- selection suited for operation with
analog command values in
commissioning phase

0xFFFD

like profile 0xFFFE, but reduced field bus control word

(relevant for MLD applications, for example)

Fig.4-26:
Pertinent Parameters

Profile Type "Freely Configurable Mode"

S00026, Configuration list for signal status word

S00144, Signal status word

S00328, Assign list signal status word

P04068, Field bus: control word IO

P04071, Field bus: length of cyclic command value data channel

P04074, Field bus: data format

P04077, Field bus: control word

P04078, Field bus: status word

P04080, Field bus: config. list of cyclic actual value data ch.

P04081, Field bus: config. list of cyclic command value data ch.

P04082, Field bus: length of cyclic actual value data channel

P04083, Field bus: length of parameter channel

P04084, Field bus: profile type

Basic Principles and Terms

Drive Profile

The drive profile defines

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Master Communication

the structure of the field bus control word (P04077) and of the field bus
status word (P04078),

the structure and content of real-time channel (P04080, P04081),

the active operating mode (S00032, S00033, S00034, S00035),

the drive states and their transitions (state machine of IndraDrive profile
type or I/O mode).

By selecting a profile type, the commissioning of field bus drives becomes very
easy for the user. The advantage of the profile selection is that all important
basic settings for the desired drive function are thereby made automatically in
the drive. As the profile types are defined independently of the bus, the transfer
of applications from one field bus to the other is also facilitated.
State Machine

Abbreviations

4.5.2

A status (e.g. Drive Halt, drive error, ...) represents a specific internal and ex
ternal behavior. The status can be exited by defined events (e.g. drive com
mands, switching of operating modes, ...). Corresponding status transitions are
assigned to the events. The interaction of control and status bits and the status
transitions are called state machine.

i16: 16-bit variable with sign (1 word) in Intel format

i32: 32-bit variable with sign (2 words) in Intel format

u16: 16-bit variable without sign (1 word) in Intel format

u32: 32-bit variable without sign (2 words) in Intel format

ZKL1: Class 1 diagnostics

ZKL2: Class 2 diagnostics

I/O Mode (Positioning and Preset Velocity)

Brief Description
We distinguish the following variants of the profile type "I/O mode":

General Features

I/O mode positioning (functionality similar to parallel interface)

I/O mode preset velocity (e.g. for open-loop applications)

The I/O mode has the following features:

Optional parameter channel can be activated, if required, via "P04083,

Field bus: length of parameter channel" (max. 8 words)
Default: P04083 = 0 Without parameter channel

Real-time channel consists of at least one word (16 bits), the field bus
control word (P04068) and the signal status word (S00144)

Freely expandable real-time channel by configuration of real-time data:

Master slave (drive)

Configuration of "P04081, Field bus: config. list of cyclic
command value data ch."

Slave master (drive)

Configuration of "P04080, Field bus: Config. list of cyclic actual
value data channel"

Freely configurable field bus status word (cf. S00144)

Relationship between profile type selection and operating mode which

takes effect:

In the I/O modes there is a determined relationship between profile

type (P-0-4084) and predefined primary operation mode (S00032).

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Master Communication

The freely configurable mode allows free selection of the operating

modes (S-0-0032, S-0-0033, ).
The respective default settings are activated by selecting the profile
type and subsequent action "load default communication parame
ters" (see also P04090 and S00262).

Structure of the Real-Time Channel

Data direction

Word1

Format

Master slave

P04068, Field bus: Control word IO

u16 (1 word)

Slave master

S00144, Signal status word

u16 (1 word)

Fig.4-27:
Features "I/O Mode Positioning"

Features "I/O Mode Preset Veloci

ty"

Structure of the Real-Time Channel for the I/O Modes

Specific features of "I/O mode positioning":

The drive is operated in "positioning block mode, lagless, encoder 1" (see
also description of the operation mode "Positioning Block Mode").

In this operating mode, 64 programmable positioning blocks can be se

lected and started via 6 bits (in the 16 bit wide control word).

The jog function can be activated in "P04068, Field bus: control word
IO". "Drive-controlled positioning" was set as the 1st secondary operation
mode (see also description of the operation mode "Drive-Controlled Po
sitioning").

Specific features of "I/O mode preset velocity":

The drive is operated in the "velocity control" mode (see also description
of the operation mode "Velocity Control").

In this operating mode you can, for example, select and start 5 program
mable fixed velocity command values (in the 16 bit wide control word) and
operate the function of the ramp-function generator.

State Machine in I/O Mode

Interaction of control and status bits (state machine):

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Master Communication

Fig.4-28:

Device Control of Variants of I/O Mode (State Machine)

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Master Communication
The figure illustrates the status word (S-0-0144) in its default con
figuration. If required, it can be given any configuration.

Automatic restart after bus failure!

DANGER

Field Bus Control Word in I/O Mode

In the case of bus failure (message "F4009" or "E4005"), an error reaction must
be carried out in the control unit, too, to prevent automatic restart after the bus
has been reestablished. This means that the bits "Drive Halt", "drive enable"
and "drive ON" (e.g. bits 13, 14 and 15 in parameter "P04077, Field bus: con
trol word") should be reset in the control unit in the case of bus failure.
The bits in parameter "P04068, Field bus: control word IO" are fixed by
Bosch Rexroth and the user cannot change them. If additional control bits
should be required, the parameter "S00145, Signal control word" has to be
configured accordingly and transmitted to the real-time channel of the field bus.
See Parameter Description "P04068, Field bus: control word IO"
See Parameter Description "S00145, Signal control word"

Signal Status Word

in I/O Mode

n the I/O modes (P04084 = 0xFF82 or 0xFF92), the parameter

"S00144, Signal status word" is transmitted instead of the field bus status
word (P04078). The configuration of S00144 is given by default setting
(see below).

According to the selected I/O profile type, there is a different default con
figuration for S00144 (see below).

The tables below show the two default configurations for S00144 which de
pend on the profile type:
Bit
0

Pin assignment

Significance

Active Operating Mode

1: Jogging (S00437)
0: Positioning

Position switch point

(PSP)

1: To the right of PSP

In reference

1: Drive has been homed (S00403)

In motion

0: In motion (S00331)

In position

1: Drive is in positioning window

& no sequential block (P-0-4061)

Drive error
(error flag)

1: Error (P00115)

0: To the left of PSP (S00060)

0: No error

Readiness for operation; 1: Ready for operation (P00115)

display "bb"

Power switched on;

display "Ab"

1: Power has been switched on (P00115)

138

Positioning block ac
knowledgment

P04051, Positioning block acknowledgment

1514

Not assigned

Fig.4-29:

Default Assignment of Parameter "S00144, Signal Status Word" for

"I/O Mode Positioning" (P04084 = 0xFF82)

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Master Communication
Bit

Pin assignment

Significance

Status of ramp-function
generator

1: Run-up stop active (P-0-1210, bit 1)

Status of ramp-function
generator

1: Acceleration active (P01210, bit 2)

Status of ramp-function
generator

1: Deceleration active (P01210, bit 3)

In motion

1: Message "n_act = 0" (S00331, bit 0)

Status of ramp-function
generator

1: Cmd value reached (P01210, bit 0)

Drive error
(error flag)

1: Error (P00115)
0: No error

Readiness for operation; 1: Ready for operation (P00115)

display "bb"

Power switched on;

display "Ab"

1: Power has been switched on (P00115)

Status of ramp-function
generator

1: Cmd value within masking window (P01210,

bit 4)

Status of ramp-function
generator

1: V-ramp within masking window (P01210, bit

5)

1510

Fig.4-30:

Not assigned

Default Assignment of Parameter "S00144, Signal Status Word" for

"I/O Mode Velocity " (P04084 = 0xFF92)

As the parameter "S00144, Signal status word" is already used as

field bus status word in the I/O mode, it cannot be configured again
in the cyclic channel.
See Parameter Description "S00144, Signal status word"

4.5.3

Freely Configurable Mode (IndraDrive Profile Type)

Brief Description
To use the extensive and numerous functions of a Rexroth drive with field bus
interface it is necessary, in addition to the I/O modes, to define another profile,
the freely configurable mode. This implies the use of a specific control and sta
tus word ("P04077, Field bus: control word" and "P04078, Field bus: status
word").
Features

The structure (content) of the real-time data channel must be defined via
the configuration parameters P04080 and P04081. No profile-depend
ent settings and checks are carried out!

In this profile type, it is the Rexroth-specific definitions for the field bus
control and status words which apply. Some bits in the parameters
"P04077, Field bus: control word" and "P04078, Field bus: status
word" can only be used in conjunction with certain operation modes.

This profile type allows using the entire drive functionality (e.g. velocity
synchronization, drive-controlled positioning, ...).

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Master Communication

The primary mode of operation and the secondary operating modes can
be freely determined in the parameters S00032, S00033 etc.

The operation mode "drive-controlled positioning" is set as default with the

command values S00282, S00259 and twice S00000 and the actual
values S00386, S00040, S00390 (see also below "Exemplary Con
figurations: Drive-Controlled Positioning").
One of the parameters "P04077, Field bus: control word" or
"P04078, Field bus: status word" must always be contained in the
1st place in the configuration parameters P04080 and P04081.

Real-Time Channel

In the real-time channel of the field bus the data configured in parameters
"P04081, Field bus: config. list of cyclic command value data ch." and
"P04080, Field bus: config. list of cyclic actual value data ch." are transmitted
between master and drive (slave).
Data direction
Master slave

Slave master

Fig.4-31:

Word1

Format

P04077, Field bus: control word

u16 (1 word)

Optional command values

According to se
lection

P04078, Field bus: status word

u16 (1 word)

Optional command values

According to se
lection

Structure of the Real-Time Channel in the Freely Configurable Mode

The IDNs of the parameters of the cyclic configurable command

and actual values are listed in "S00188, List of configurable data
in the MDT" and "S00187, List of configurable data in the AT".
Data direction

Word1

Word2

...

Master slave

P04077

Command
value 1

...

Slave master

P04078

Feedback
value 1

...

Fig.4-32:

Content and Order of Data in Real-Time Channel in the Freely Config

urable Mode

4.6

SERCOS Interface (SERCOS II)

4.6.1

Brief Description
General Features

Word_n

Cyclical data exchange of command and actual values in equal time in

tervals

Data transfer via fiber optic cables; except for converter in motor (in this
case, copper conductor)

Service channel for parameterization and diagnosis

Free configuration of telegram contents

Synchronization between time command value takes effect and meas

urement starting time of the actual values for all drives on a ring

Overall synchronization of all connected drives to the control unit

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Master Communication
Firmware-Specific Features

Cycle time Min. 250/500 s, max. 65 ms (multiples of position clock

250 s or 500 s can be set)

SERCOS compatibility class C

Baud rate: Optionally 2, 4, 8 or 16 MBaud

Automatic baud rate detection; active baud rate displayed in a parameter

Transmission power can be set via indication of transmission length (set

ting via control panel)

Max. quantity of configurable data in the MDT: 48 bytes

Max. quantity of configurable data in the AT: 48 bytes

The number of configurable bytes in the MDT/AT depends on the
relation of the position cycle time (P-0-0556, bit 2) to the SERCOS
cycle time.
SERCOS cycle time = position cycle time max. length 24 bytes
SERCOS cycle time > position cycle time max. length 48 bytes
For more detailed information, see SERCOS specification.

Pertinent Parameters

S00001, NC cycle time (TNcyc)

S00002, SERCOS cycle time (TScyc)

S00003, Minimum AT transmit starting time (T1min)

S00004, Transmit/receive transition time (TATMT)

S00005, Minimum feedback acquisition time (T4min)

S00006, AT Transmission starting time (T1)

S00007, Feedback acquisition starting time (T4)

S00008, Command value valid time (T3)

S00009, Position of data record in MDT

S00010, Length of master data telegram

S00014, Interface status

S00015, Telegram type parameter

S00016, Configuration list of AT

S00024, Configuration list of MDT

S00028, MST error counter

S00029, MDT error counter

S00088, Receive to receive recovery time (TMTSY)

S00089, MDT Transmit starting time (T2)

S00090, Command value proceeding time (TMTSG)

S00096, Slave arrangement (SLKN)

S00097, Mask class 2 diagnostics

S00098, Mask class 3 diagnostics

S00134, Master control word

S00135, Drive status word

S00143, Sercos interface version

S00185, Length of the configurable data record in the AT

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Master Communication

Pertinent Diagnostic Messages

S00186, Length of the configurable data record in the MDT

S00187, List of configurable data in the AT

S00188, List of configurable data in the MDT

S00301, Allocation of real-time control bit 1

S00303, Allocation of real-time control bit 2

S00305, Allocation of real-time status bit 1

S00307, Allocation of real-time status bit 2

S00413, Bit number allocation of real-time control bit 1

S00414, Bit number allocation of real-time control bit 2

S00415, Bit number allocation of real-time status bit 1

S00416, Bit number allocation of real-time status bit 2

P04027, Transmission length SERCOS interface

P04029, Diagnostic report SCSB module

P04087, Baud rate SERCOS interface

C0104 Config. IDN for MDT not configurable

C0105 Maximum length for MDT exceeded

C0106 Config. IDNs for AT not configurable

C0107 Maximum length for AT exceeded

C0108 Time slot parameter > Sercos cycle time

C0109 Telegram offset unsuitable

C0110 Length of MDT (S-0-0010) odd

C0111 ID9 + Record length - 1 > length MDT (S-0-0010)

C0112 TNcyc (S-0-0001) or TScyc (S-0-0002) error

C0113 Relation TNcyc (S-0-0001) to TScyc (S-0-0002) error

C0114 T4 > TScyc (S-0-0002) - T4min (S-0-0005)

C0115 T2 too small

C0116 T3 (S-0-0008) within MDT (S-0-0089 + S-0-0010)

C0139 T2 (S-0-0089)+length MDT (S-0-0010)>TScyc (S-0-0002)

F4001 Sync telegram failure

F4002 RTD telegram failure

F4003 Invalid communication phase shutdown

F4004 Error during phase progression

F4005 Error during phase regression

F4006 Phase switching without ready signal

4.7

PROFIBUS-DP

4.7.1

Brief Description
It is possible to operate IndraDrive controllers with a PROFIBUS interface as
master communication module. Via this module it is possible to exchange realtime data with a PROFIBUS-DP master.
The following communication channels are distinguished:

Cyclic data channel (PROFIBUS-DP)

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The field bus provides data containers in which useful data can be cycli
cally transmitted. This section is referred to as cyclic data channel. The
cyclic data channel is divided into:

One (optional) device-specific parameter channel for reading and

writing of all parameters via PROFIBUSDP.
Note: This parameter channel does not fulfill "real-time properties"!

One (optional) safety, axis-specific Process data channel

(PROFIsafe), which enables the transmission of safety relevant sig
nals, depending on the firmware and hardware (see also section
"Integrated Safety Technology"),

One axis-specific process data channel (real-time channel) which

contains fixed, selected information that can be directly interpreted
by the receiver.

Acyclic data channel (DPV1 parameter communication)

The following are supported:

One class-1 connection

Two class-2 connections

Fig.4-33:

Overview of Cyclic Data Channel

To simplify field bus communication, Bosch Rexroth makes availa

ble function blocks for different programmable logic controllers
(PLCs). The principles applied can be easily used for other field bus
masters.
Features

The slave PROFIBUS-DP circuit with master communication module PL has

the following functional features:

Support of RS485 interfaces according to IEC 611582

Support of all data rates according to IEC 611582, with exclusive use of
PROFIBUS-DP (9.6 kBaud, 19.2 kBaud, 45.45 kBaud, 93.75 kBaud,
187.5 kBaud, 500 kBaud,1.5 MBaud, 3 MBaud, 6 MBaud, 12 Mbaud)

Automatic baud rate detection

Configurable cyclic data up to 15 parameters (incl. field bus control word

and field bus status word) in both data directions
(max. 48 bytes or 24 words)

Additional optional parameter channel in the cyclic channel with up to 16

bytes (8 words)

Monitoring of the cyclical data exchange (watchdog function)

LED for diagnosing the PROFIBUS interface

Supported DPV0 services:

Slave_Diag (read diagnostic data)

Get_Cfg (read configuration data)

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Master Communication

Set_Prm (send parameterization data)

Chk_Cfg (check configuration data)

Data Exchange (transfer I/O data)

Global Control (synchronization)

RD_Outp (read output data)

RD_Inp (read input data)

Parameter access with DPV1-class-1 services

DDLM_Initiate (establishment of connection)

DDLM_Read (acyclic read access)

DDLM_Write (acyclic write access)

DDLM_Abort (abortion of connection)

DDLM_Idle (connection monitoring)

Support of up to two DPV1-class-2 connections

Supported field bus profiles:

Hardware Requirements

0xFF82: I/O mode "positioning" with configurable real-time data

0xFF92: I/O mode " preset velocity" with configurable real-time data

0xFFFE: Freely configurable mode

Access to all device parameters according to PROFIdrive specification

Using the master communication "PROFIBUS-DP" requires the following con

trol section design:

Single-axis BASIC PROFIBUS (not configurable) (CSB01.1N-PB)

In addition, communication via "PROFIBUS-DP" is possible for with the follow

ing configurable control sections, if they are equipped with the optional module
"PB":

Pertinent Parameters

Single-axis BASIC UNIVERSAL (CSB01.1C)

Single-axis ADVANCED (CSH01.1C)

Double-axis BASIC UNIVERSAL (CDB01.1C)

Communication parameters
Specific parameters for communication via PROFIBUS-DP:

P03290, PROFIsafe: F_Destination_Address

P04069, Field bus: module diagnosis

Parameters for general communication via field bus interfaces:

P04073, Field bus: diagnostic message

P04074, Field bus: data format

P04075, Field bus: watchdog

P04076, Field bus: cycle time (Tcyc)

P04079, Field bus: baud rate

Profile type parameters

Apart from mere communication parameters, we use parameters in conjunction
with the profile types.
See "Profile Types (With Field Bus Interfaces)"
Parameters for extended communication
We use additional parameters for extended communication.

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See following sections:

Pertinent Diagnostic Messages

"Configurable Signal Control Word"

"Configurable Signal Status Word"

" Multiplex Channel"

C0154 Field bus: IDN for cycl. command val. not configurable

C0155 Field bus: max. length for cycl. command val. exceeded

C0156 Field bus: IDN for cycl. actual val. not configurable

C0157 Field bus: length for cycl. actual values exceeded

C0158 Field bus: Tcyc (P-0-4076) incorrect

C0159 Field bus: P-0-4077 missing for cycl. command values

F4009 Bus failure

F4012 Incorrect I/O length

4.8

CANopen Interface

4.8.1

Brief Description
It is possible to operate IndraDrive controllers with a CANopen interface as
master communication module. This requires the control section with the op
tional module "CANopen/DeviceNet" (CO). Via this optional module, it is pos
sible to exchange real-time data with a CANopen master. The "CANopen"
protocol (according to Draft Standard DS301, version 4.0.2) has been imple
mented in the drive controller.
Communication Channels

We distinguish the following communication channels:

Cyclic data channel (process data objects PDO)

The field bus provides data containers in which useful data can be cycli
cally transmitted in real time (process data objects).

Acyclic data channel (service data objects SDO)

The field bus provides data containers in which useful data (service data
objects) can be acyclically transmitted.
The process data are always transmitted via PDOs.

Features

Simple configuration through use of "Predefined Connection Set" and

"Minimal Boot-Up" according to DS301

Baud rates of 20, 50, 125, 250, 500, 800 and 1000 kbit/s specified by
CANopen according to DS301 are supported

Configurable cyclic data up to 12 parameters (incl. field bus control word

and field bus status word) in both data directions
(max. 24 bytes or 12 words)

Functional compatibility with EcoDrive functions through profile selection

(I/O mode)

Node monitoring (heartbeat function and node guard function)

LED displays at the front panel of the master communication module for
simple diagnosis of bus functions and most important communication re
lationships between drive and field bus (2 LEDs: "Run" status and
"Error" status)

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Master Communication

Hardware Requirements

Pertinent Parameters

All parameters of the drive can be directly read via SDO and, if permitted,
can be written

Upload/download function for all parameters of the drive possible with

SDO services

Event-controlled or synchronous transmission of process data

CANopen Device profile DSP402 is not supported; field bus profiles ac

cording to DSP402 are partly supported (see "Profile Types (With Field
Bus Interfaces)")

The optional module with CANopen interface is available for the following con
figurable control sections:

Single-axis BASIC UNIVERSAL (CSB01.1C)

Single-axis ADVANCED (CSH01.xC)

Communication parameters
Specific parameters for CANopen communication:

P03610, CANopen: Heartbeat/NodeGuard Configuration

P03611, CANopen: COB-IDs

P03612, CANopen: Transmission Types

P03613, CANopen: List of the Event Parameters

Parameters for general field bus communication:

P04025, Drive address of master communication

P04073, Field bus: diagnostic message

P04074, Field bus: data format

P04075, Field bus: watchdog

P04076, Field bus: cycle time (Tcyc)

P04079, Field bus: baud rate

Profile type parameters

Apart from mere communication parameters, we use parameters in conjunction
with the profile types.
See "Profile Types (With Field Bus Interfaces)"
Parameters for extended communication
We use additional parameters for extended communication.
See following sections:

Pertinent Diagnostic Messages

"Configurable Signal Control Word"

"Configurable Signal Status Word"

F4001 Sync telegram failure

F4002 RTD telegram failure

F4009 Bus failure

F4012 Incorrect I/O length

4.9

DeviceNet Interface

4.9.1

Brief Description
It is possible to operate IndraDrive controllers with a DeviceNet interface as
master communication module. This requires the control section with the op
tional module "CANopen/DeviceNet" (CO). Via this optional module, it is pos

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Master Communication
sible to exchange real-time data with a DeviceNet master. The drive supports
the protocol "DeviceNet" according to ODVA version 2.0.
We distinguish the following communication channels:

Cyclic data channel (polled I/O)

The field bus provides data containers in which useful data can be cycli
cally transmitted in real time.

Acyclic data channel (Explicit Message)

The field bus provides an object directory of the device. The objects can
be acyclically read and, if allowed, can be written.
The process data are always transmitted via "polled I/O".

To achieve the highest possible system flexibility, all parameters of the drive
are accessible via objects. With DeviceNet, these objects can be addressed
through class, instance and attribute. Some of these objects can be assigned
to the "polled I/O" as real-time data and thus be cyclically transmitted. There is
also the option of transmitting via "Explicit Message", but no objects defined in
the real-time channel (P04081) may be written by the master via "Explicit
Message".
Features

Hardware Requirements

Pertinent Parameters

DeviceNet interface completely galvanically decoupled

"Open Pluggable Connector" according to specification 2.0 (Phoenix

COMBICON connector)

"DeviceNet Generic Device" according to specification ODVA 2.0

Easy configuration by implementing "Group 2 only Server"

All data rates supported:

125 kbit/s (up to a distance of 500 m)

250 kbit/s (up to a distance of 250 m)

500 kbit/s (up to a distance of 100 m)

Freely configurable process data channel (max. 24 words, max. 15 IDN)

in both data directions via drive parameters P04080 and P04081

Monitoring of the process data channel (watchdog function)

All parameters of the drive can be acyclically read via "Explicit Mes
sage" and, if allowed, can be written

LED displays at the front panel of the master communication module for
simple diagnosis of bus functions and most important communication re
lationships between drive and field bus (2 LEDs: module status and
network status)

The optional module with DeviceNet interface is available for the following con
figurable control sections:

Single-axis BASIC UNIVERSAL (CSB01.1C)

Single-axis ADVANCED (CSH01.1C)

Communication parameters
Parameters for general field bus communication (incl. DeviceNet):

P04025, Drive address of master communication

P04073, Field bus: diagnostic message

P04074, Field bus: data format

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Master Communication

P04075, Field bus: watchdog

P04076, Field bus: cycle time (Tcyc)

P04079, Field bus: baud rate

Profile type parameters

Apart from mere communication parameters, we use parameters in conjunction
with the profile types.
See "Profile Types (With Field Bus Interfaces)"
Parameters for extended communication
We use additional parameters for extended communication.
See following sections:

Pertinent Diagnostic Messages

"Configurable Signal Control Word"

"Configurable signal status word"

" Multiplex channel"

F4009 Bus failure

F4012 Incorrect I/O length

4.10

Parallel Interface

4.10.1

Brief Description
It is possible to operate IndraDrive controllers with a parallel interface as master
communication module. This requires the control section design with the op
tional module "parallel interface" (PL), with 16 digital inputs and 16 digital
outputs.
Features

Hardware Requirements

Pertinent Parameters

Free configuration of the total of 16 digital inputs by means of the signal

control word function (see S00145)

Free configuration of the total of 16 digital outputs by means of the signal

status word function (see S00144)

The optional module with parallel interface is available for the following config
urable control sections:

Single-axis BASIC UNIVERSAL (CSB01.1C)

Single-axis ADVANCED (CSH01.1C)

S00026, Configuration list for signal status word

S00027, Configuration list for signal control word

S00144, Signal status word

S00145, Signal control word

S00328, Assign list signal status word

S00329, Assign list signal control word

S00346, Positioning control word

S00398, IDN-list of configurable data in signal status word

S00399, IDN-list of configurable data in signal control word

S00437, Positioning status

P00115, Device control: status word

P00116, Device control: control word

P04026, Positioning block selection

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Pertinent Diagnostic Messages

P04028, Device control word

P04060, Positioning block control word

P04061, Positioning block status word

F2044 External power supply X15 error

4.11

Analog Interface

4.11.1

Brief Description
Overview

Apart from the digital master communication interfaces (SERCOS,

PROFIBUS), the drive controllers of the IndraDrive range provide an interface
for analog master communication (analog interface). This allows assigning an
analog command value to a drive parameter (e.g. "S00036, Velocity
command value").
In conjunction with encoder emulation (SSI or incremental encoder), the posi
tion control loop can be closed in a higher-level control unit. The drive provides
the possibility of, for example, emulating the actual position value for evaluation
in the control unit.
The figures below illustrate the structure of drive solutions with analog interface
and open-loop or closed-loop operation.

Fig.4-34:

Open-Loop Operation With Analog Interface (With Optional Position

Feedback to Open-Loop Control)

Fig.4-35:

Closed-Loop Operation With Analog Interface (With Analog Command

Value Input and SSI Emulation)

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Master Communication
This section describes the basic functions of the analog interface and contains
notes on commissioning and parameterization. The individual functions used,
"analog inputs" and "encoder emulation", are described in separate chapters.
See also "Encoder Emulation"
See also "Analog Inputs"
Features

The analog interface is an interface for master communication with analog

command values and digital I/Os (drive enable, Drive HALT...).
Features of the analog inputs:

Analog inputs (14 bit) which can be assigned to parameters, with smooth
ing to be set (number of analog inputs depending on control section
design)

Sampling of the analog inputs in the position loop clock Tposition (see "Per
formance Data"

Features of the analog assignment:

Two assignments to parameters are possible; offset and scaling of the

analog input can be set for each assignment

Sampling rates for analog input assignment:

Assignment channel A assignment in position loop clock Tposition

Assignment channel B assignment in clock of 2 ms

Features of encoder emulation:

Freely configurable incremental encoder and SSI emulation of the differ

ent position values in the drive (actual position value, position command
value...) load- or motor-related via position scaling (S00076)

Features of absolute encoder emulation:

Adjustable relationship via command "set absolute measuring" (C0300)

Resolution to be set, only binary resolution (incr./motor rev. or mm)

Power failure bit available

Features of incremental encoder emulation:

Emulation of the reference pulse

Reference pulse offset to be set; dead time compensation

Resolution to be set (incr./motor rev. or mm)

Monitoring of the maximum frequency

Features of the digital inputs/outputs:

Digital control and status information determined via configuration of the

digital inputs of the control section:

Hardware Requirements

Digital control inputs for analog master communication:

Signals "Drive enable" and "Drive HALT"

Zero switch, limit switch (+/-); clearing errors and E-Stop

Digital status outputs for analog master communication:

Ready and warning output

Relay output for readiness for operation

Master communication with analog interface is possible via the following control
sections or control section designs:

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Analog command value input for open-loop operation (also for closed-loop
operation):

Single-axis BASIC for open-loop operation (CSB01.1N-FC)

Single-axis BASIC ANALOG (CSB01.1N-AN)

Single-axis ADVANCED (CSH01.xC)

Double-axis BASIC UNIVERSAL (CDB01.1C)

In addition, the following (configurable) control sections are possible,

when they are equipped with the optional module for analog inputs/outputs
(MA1):

Single-axis BASIC UNIVERSAL (CSB01.1C)

Analog command value input for closed-loop operation with position feed
back via encoder emulation:

Single-axis BASIC ANALOG (CSB01.1N-AN)

In addition it is possible to use the following configurable control sections

if they have been designed with the optional module for encoder emulation
(MEM):

Single-axis ADVANCED (CSH01.xC)

Double-axis BASIC UNIVERSAL (CDB01.1C)

With double-axis devices the function "analog interface" is available
once per axis.

Pertinent Parameters

Control and status parameters:

P00115, Device control: status word

P00116, Device control: control word

P04028, Device control word

Digital inputs/outputs:

P00300, Digital I/Os, assignment list

P00301, Digital I/Os, bit numbers

P00302, Digital I/Os, direction

P00303, Digital I/Os, inputs

P00304, Digital I/Os, outputs

Analog inputs:

P00208, Analog input 5

P00209, Analog input 6

P00210, Analog input 1

P00211, Analog input 2

P00212, Analog input, list of assignable parameters

P00213, Analog input, assignment A, target parameter

P00214, Analog input, assignment A, scaling per 10V full scale

P00215, Analog input, assignment A, signal value at 0V

P00216, Analog input, assignment A, dead zone

P00217, Analog input 1, time constant input filter

P00218, Analog input, control parameter

P00219, Analog input, maximum value for adjustment

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Master Communication

P00220, C2800 Analog input adjustment command

P00228, Analog input 3

P00229, Analog input 4

P00231, Analog input 2, time constant input filter

P00232, Analog input 3, time constant input filter

P00233, Analog input 4, time constant input filter

P00234, Analog input 5, time constant input filter

P00235, Analog input 6, time constant input filter

P00236, Analog input, assignment B, target parameter

P00237, Analog input, assignment B, scaling per 10V full scale

P00238, Analog input, assignment B, signal value at 0V

P00239, Analog input, assignment B, dead zone

P03901, Adjustment values of control section

P03904, Adjustment values analog I/O interface 3-4

Encoder emulation:

4.11.2

P00900, Encoder emulation signal selection list

P00901, Encoder emulation signal selection

P00902, Encoder emulation control parameter

P00903, Encoder emulation resolution

P00904, Encoder emulation zero pulse offset

Functional Description

Control
With the analog interface, the drive is controlled via the digital inputs of the
control section. Via the list parameter "P00300, Digital I/Os, assignment
list", the pins of the connectors X31, X32, X33 and X11 at the control section
are assigned to drive parameters. Depending on the control section design,
there is a default assignment of the pins of these terminal strips. The preset
default assignment can be modified according to the application-specific re
quirements.
See Parameter Description "P00300, Digital I/Os, assignment list"
As a matter of principle, using an ADVANCED control section with
analog interface requires manual configuration of the digital I/Os.
See also "Overview of Functions and Interfaces" in the documentation
"Control Sections for Drive Controllers; Project Planning Manual"
Drive Enable

The activation of the drive requires a positive edge of the "drive enable" signal
(connector pin assignment see corresponding section in the documentation
"Drive Controllers, Control Sections; Project Planning Manual").
The "drive enable" signal is mapped to the parameters "P04028,
Device control word" and "P00116, Device control: control
word".
See also "Device Control and State Machines"

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Master Communication
The enable signal is accepted, i.e. the drive switches from its de-energized
status to its energized status, when the following conditions have been fulfilled:

There mustn't be any drive error present.

The drive must be in operating mode (phase 4).

Power must have been switched on and the DC bus voltage must be
above the defined minimum threshold.
The drive displays this status on the control panel with "Ab". The diagnostic
drive message in parameter "S00095, Diagnostic message" is "A0012
Control and power sections ready for operation".

"Drive HALT"Signal

When drive enable is set and the "Drive HALT" signal is active (P04028 or
P00116, bit 13 = 0),

the display of the control panel changes to "AH" and

the diagnostic drive message then is "A0010 Drive HALT" and thereby
signals the activation of "Drive Halt".

If the "Drive HALT" signal is then deactivated (P04028 or P00116, bit 13 = 1),

the display of the control panel changes to "AF" and

the diagnostic drive message depends on the active operation mode (see
description of the respective diagnostic message in the separate docu
mentation "Troubleshooting Guide (description of diagnostic messag
es)")
The "Drive HALT" signal is status-controlled and active when the
signal = 0 V; this means that for signal =0 V the drive is in status
"Drive HALT"

Clear Error

A positive edge at the "clear error" input starts the command for error clearing.
For this purpose, the command C0500 has to be assigned to a digital input:

Configure parameter "S00099, C0500 Reset class 1 diagnostics" in

"P00300, Digital I/Os, assignment list"

Set bit 0 for the element of S00099 in parameter "P00301, Digital I/Os,
bit numbers"

Set the data direction for the element of S00099 to input (value "0") in
parameter "P00302, Digital I/Os, direction"

See also "Digital Inputs/Outputs"

All drive errors are cleared by activating the command for error
clearing!

Analog Command Value Input

The number of analog inputs, which differs according to control section, is used
to input the analog command value.
For IndraDrive devices, the analog inputs are cyclically sampled and evaluated:

Assignment channel A works in position loop clock (see "Performance

Data")

Assignment channel B works in 2-ms clock

See "Analog Inputs"

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Master Communication

Emulation of Position Value

In order to close the position control loop via the master, it is necessary to
transmit the axis position to the master. This is done by means of encoder
emulation (incremental or SSI).
See "Encoder Emulation"

4.11.3

Notes on Commissioning/Parameterization

Encoder Emulation
In spite of its high degree of functionality and performance, the encoder emu
lation available for IndraDrive devices is subject to some systematic restrictions.
See "Encoder Emulation"
If the higher-level master and the drive have not been synchronized,
beat effects can occur during sampling due to the different clockpulse rates. Bosch Rexroth therefore recommends not to use the
analog interface in high end applications, but in these cases use
digital interfaces, such as SERCOS interface.

Analog Inputs
For inputting the cyclic command value, you should preferably use assignment
channel A as it has a higher sampling rate than assignment channel B.
In spite of their high degree of functionality and performance, the analog inputs
available for IndraDrive devices are subject to certain restrictions. These re
strictions are explained in detail in section "Analog Inputs".
See also "Analog Inputs"
If the drives with analog command value input have not been
synchronized, beat effects can occur during sampling in spite of the
8-fold oversampling. Bosch Rexroth therefore recommends not to
use the analog interface in high end applications, but in these cases
use digital interfaces, such as SERCOS interface.

Main Spindle Drive With Analog Interface and Parallel Interface

In the case of main spindle drives, operating states that are important for the
working cycle have to be transmitted to the master so that it can process or
advance the command blocks in accordance with the process and in a fail-safe
way.
The "position spindle" command allows aligning the spindle for tool change
without the master having to leave the "velocity control" mode mainly used for
spindles.
In the case of master communication with analog interface, the required mes
sages have to be made available to the master via the digital outputs. The
"position spindle" command has to be started via a digital input. For this pur
pose, the main spindle messages are assigned to the digital outputs, the
command parameter to a digital input.
Messages

The following messages are relevant for main spindle drives:

Speed reached ("S00330, Status "n_feedback = n_command"")

Spindle has stopped ("S00331, Status "n_feedback = 0"")

Speed value has fallen below threshold ("S00332, Status "n_feedback

< nx"")

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Master Communication

In target position during spindle positioning ("S00336, Status "In

position"")

Torque limit value reached ("S00334, Status "T >= Tlimit"")

Torque threshold exceeded ("S00333, Status "T >= Tx"")

Speed value exceeded ("S00335, Status "n_command > n_limit"")

Power threshold exceeded ("S00337, Status "P >= Px"")

See also descriptions of the respective parameters in the separate doc

umentation "Parameter Description"
Bit in signal sta
tus word

Configured pa
rameter

Configured bit
in parameter

S00330

n_actual = n_command

S00331

n_feedback = 0

S00332

nactual < nx

S00333

T Tx

S00334

T Tlimit

S00335

n command > n limit

S00336

In_Position

S00337

P Px

--

--

10

--

--

11

--

--

12

--

--

13

--

--

14

--

--

15

--

--

Fig.4-36:
Command

Function/significance

Example of Configuration for Main Spindle Messages via Digital Outputs

The following command is relevant for main spindle drives:

C0900 Position spindle command (S00152)

Bit in signal
control word

Configured pa
rameter

Configured bit
in parameter

S00152

--

--

15

--

--

Fig.4-37:

Function/significance
Spindle positioning

Example of Configuration for Main Spindle Command via Digital Inputs

See also "Spindle Positioning"

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Master Communication

4.11.4

Diagnostic and Status Messages

Information on General Drive Status

In parameter "P00115, Device control: status word", all important status bits
of the state machine of the drive are mapped. Reading and interpreting pa
rameter P00115 provides information on the current status of the drive.
See Parameter Description "P00115, Device control: status word"

Status of Digital Inputs/Outputs and Analog Inputs

All digital and analog input values can already be read via parameters before
assignment to the internal drive parameters. The following applies:

Digital inputs/outputs of the control module are mapped to parameter

"P00303, Digital I/Os, inputs"

Analog inputs values are displayed in the following parameters:

P00208, Analog input 5

P00209, Analog input 6

P00210, Analog input 1

P00211, Analog input 2

P00228, Analog input 3

P00229, Analog input 4

See also "Diagnostic and Status Messages" in the following sections:

"Digital Inputs/Outputs"

"Analog Inputs"

"Encoder emulation"

4.12

MultiEthernet

4.12.1

Brief Description, Basic Function

General Information
Operating IndraDrive controllers with a MultiEthernet-Interface is possible. This
allows operation of the following master communications:

SERCOS III

EtherCAT

PROFINET

EtherNet/IPTM

The protocol is selected or deactivated via "P04089.0.1, Master

communication: Protocol". The change does not take effect until the device has
been restarted.
Engineering via master communication (TC/IP communication) can also be
made via the MultiEthernet interface. This function is maintained, even if the
master communication is deactivated.
Features

Protocol selection via control

communication: Protocol"

panel

or

"P04089.0.1,

Master

SERCOS III, EtherCAT, PROFINET, EtherNet/IPTM protocols are sup

ported

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Master Communication

Hardware Requirements

IP engineering (TC/IP communication) is supported, depending on the

protocol

Master communication engineering is supported depending on the proto

col

The description used for the MultiEthernet interface in the type codes is ET.

Single-axis ADVANCED (CSH01.xC)

Single-axis BASIC UNIVERSAL (CSB01.1C)

Double-axis BASIC UNIVERSAL (CDB01.xC)

Pertinent Parameters

For controls which cannot access 32-bit EIDN parameters certain

relevant parameters were mapped to 16-bit IDN parameters; for al
location see table of pertinent parameters below.
32-bit EIDN parameters

16-bit IDN parameters

P04089.0.1,
Protocol

Master

communication: P02310,
Protocol

Master

communication:

P04089.0.2,
Device name

Master

communication: P02311, Master communication: Device

name

P04089.0.10, Master communication: P02312, Master communication: MAC

MAC address device
address device
P04089.0.11, Master communication: P02313, Master communication: MAC
MAC address Port1
address Port1
P04089.0.12, Master communication: P02314, Master communication: MAC
MAC address Port2
address Port2
P04089.0.13, Master communication: IP P02315, Master communication: IP
address
address
P04089.0.14, Master communication: P02316,
Master
Network mask
Network mask

communication:

P04089.0.15, Master communication: P02317,

Master
Gateway address
Gateway address

communication:

Fig.4-38:
Pertinent Diagnostic Messages

Pertinent Parameters

C0299 Configuration changed. Restart

Notes on Commissioning
Protocol Selection
Protocol Selection

The protocol is selected via parameter P04089.0.1. Setting is made either via
the menu or through the "Display" or via the "IndraWorks" commissioning tool.

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Master Communication

Fig.4-39:

MultiEthernet, Protocol Selection

After parameters "P04089.0.1, Master communication: Protocol" has been

changed, perform a reboot at the drive. If the attempt is made to switch to the
operating mode (OM) without performing a reboot, the drive will signal "C0299
Configuration changed. Restart".

4.12.2

EtherCAT

Brief Description
Topology

1
2
3
4

Fig.4-40:

Engineering via optional Ethernet switch port

Engineering via optional Ethernet switch port
Engineering via third-party control by means of ADS interface
Engineering via RS232 or existing engineering port at CSH01.3

EtherCAT Topology

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Master Communication
IndraDrive controllers with MultiEthernet interface (ET) can also be operated
as EtherCAT master communication. Via this modules it is possible to ex
change real-time data with a EtherCAT master. The "Servo Drive Profile over
EtherCAT" which is based on the SERCOS II profile is supported.
The following communication channels are distinguished:

Cyclic data channel (process data)

Data container for cyclic transmission of useful data (process data) in
real time

Acyclic data channel (service channel)

EtherCAT mailbox procedure for acyclic transmission of useful data
(service data).

General Features

Transmission rate 100 Mbit/s

Data transmission via Ethernet cable (CAT5e copper)

Topology: "Line"

Addressing:
There is no connection between the master communication ad
dress (S-0-1040) shown on the display and the address set in the
master (e.g. SystemManager by BECKHOFF). The drives identify
themselves only via the order in the bus (Ex.: Address = "1" in the
master corresponds to "1st drive" in the line).

Access to 16-bit SERCOS parameter of the

drive via "SoE" protocol (Servo Drive Profile
over EtherCAT)

EtherCAT mailbox procedure for parame

terization and diagnosis

Cyclic data exchange of command values

and actual values

Free configuration of telegram contents

Max. length of configurable MDT/AT data

15 IDNs with max. 48 bytes; if bus cycle time
=position cycle time the max. length is re
duced by half to 24 bytes

Cycle time Min. 500s (multiples of position

cycle time can be set)

"Distributed clock synchronization" (exact

adjustment of distributed clocks)

Synchronization between time command

value takes effect and measurement start
ing time of the actual values for all drives on
a ring

Overall synchronization of all connected

drives to the master

No support from
CAT" (CoE)

Currently only released in conjunction with

"Beckhoff TwinCAT"

"CAN

over

Ether

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Master Communication
Hardware Requirements

Using the master communication "EtherCAT" requires the following control

section design:

Single-axis ADVANCED (CSH01.xC)

Single-axis BASIC UNIVERSAL (CSB01.1C)

Double-axis BASIC UNIVERSAL (CDB01.xC)

The option ET must be available as master communication module.

Pertinent Parameters

Pertinent Diagnostic Messages

S00001, NC cycle time (TNcyc)

S00002, SERCOS cycle time (TScyc)

S00005, Minimum feedback acquisition time (T4min)

S00006, AT Transmission starting time (T1)

S00007, Feedback acquisition starting time (T4)

S00008, Command value valid time (T3)

S00014, Interface status

S00015, Telegram type parameter

S00016, Configuration list of AT

S00024, Configuration list of MDT

S00028, MST error counter

S00089, MDT Transmit starting time (T2)

S00097, Mask class 2 diagnostics

S00098, Mask class 3 diagnostics

S00134, Master control word

S00135, Drive status word

S00185, Length of the configurable data record in the AT

S00186, Length of the configurable data record in the MDT

S00187, List of configurable data in the AT

S00188, List of configurable data in the MDT

S00301, Allocation of real-time control bit 1

S00303, Allocation of real-time control bit 2

S00305, Allocation of real-time status bit 1

S00307, Allocation of real-time status bit 2

S00413, Bit number allocation of real-time control bit 1

S00414, Bit number allocation of real-time control bit 2

S00415, Bit number allocation of real-time status bit 1

S00416, Bit number allocation of real-time status bit 2

C0104 Config. IDN for MDT not configurable

C0105 Maximum length for MDT exceeded

C0106 Config. IDNs for AT not configurable

C0107 Maximum length for AT exceeded

C0108 Time slot parameter > Sercos cycle time

C0112 TNcyc (S-0-0001) or TScyc (S-0-0002) error

C0113 Relation TNcyc (S-0-0001) to TScyc (S-0-0002) error

C0114 T4 > TScyc (S-0-0002) - T4min (S-0-0005)

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Master Communication

E4005 No command value input via master communication

F4002 RTD telegram failure

F4009 Bus failure

Notes on Commissioning
For this purpose Bosch Rexroth provides a commissioning description
(IndraDrive with EtherCAT an BECKHOFF TwinCAT.pdf, for further informa
tion please contact Drive Support ) which explains the essential steps for
commissioning an IndraDrive with EtherCAT at a BECKHOFF TwinCAT.
When setting up an EtherCAT network with IndraDrive C/M con
trollers ensure that

slot X23 is to be used as input and

slot X22 as output.

There is no connection between the master communication ad

dress (S-0-1040) shown on the display and the address set in the
master (e.g. SystemManager by BECKHOFF). The drives identify
themselves only via the order in the bus. (Ex.: Address = "1" in the
master corresponds to "1st drive" in the line).

4.12.3

PROFINET

Brief Description
Topology

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Master Communication

1
2
3
4

Fig.4-41:

Engineering via free PROFINET port of a bus node

Engineering via optional Industrial-Ethernet switch
Engineering via third-party control by means of TCI (in preparation)
Engineering via RS232 or existing engineering port at CSH01.3

PROFINET Topology

IndraDrive controllers with MultiEthernet interface (ET) can also be operated

as PROFINET master communication. Via this module it is possible to ex
change real-time data with a PROFINET controller.
The field bus provides data containers in which useful data can be cyclically
transmitted. This section is called cyclic data channel (PROFINET).
The cyclic data channel is divided as follows:

(Optional) device-specific parameter channel for reading and writing of all

parameters via PROFINET.
The device-specific parameter channel does not fulfill "real-time
properties"!

(Optional) safety-related,
(PROFIsafe).

axis-specific

process

data

channel

The safety-related, axis-specific process data channel is not avail

able in MPx06VRS. For configuration, however, the module "Fmodule not used" has to be integrated!

Axis-specific process data channel (real-time channel) which contains

fixed, selected information that can be directly interpreted by the receiver.

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Master Communication

Fig.4-42:

Overview of Cyclic Data Channel

To simplify field bus communication, Bosch Rexroth makes availa

ble function blocks for different programmable logic controllers
(PLCs). The principles applied can be easily used for other field bus
masters.
Features

The PROFINET device circuit with MultiEthernet interface has the following
features:

Ethernet according to IEEE 802.3 and prioritization according to IEEE

802.1Q

Transmission rate 100 Mbit/s

Data transmission via Ethernet cable (CAT5e copper)

Topologies: "Star", "line" (by means of integrated cut-through switch)

Assignment of IP addresses via DCP protocol (Discovery and Basic

Configuration

Configurable cyclic data up to 15 parameters (incl. field bus control word

and field bus status word) in both data directions
(max. 48 bytes or 24 words)

Min. cycle time

Max. quantity of process data/set

ting P04076
Notes

0,5 ms (TA_pos)

16 bytes P04076 = 0.5ms

32 bytes P04076 = 1ms
48 bytes P04076 = 1ms

Fig.4-43:

Additionally a maximum of
16 bytes parameter chan
nel for PROFIBUS

Quantity of Cyclic Data Depending on P04076

Valid values for P04076: 0,5 ms, 1 ms, 2 ms, 3 ms, 4 ms, 5 ms,

Additional optional parameter channel in the cyclic channel with up to 16

bytes (8 words)

LED for diagnosis of PROFINET status (network status)

LEDs for display of link/activity status

For reasons of compatibility with IndraDrive drive controllers with

PROFIBUS master communication module, diagnoses and alarms are
not used.

PROFINET IRT is not supported.

Operation in PROFINET IRT networks not possible

Supported field bus profiles:

0xFF82: I/O mode "positioning" with configurable real-time data

0xFF92: I/O mode " preset velocity" with configurable real-time data

0xFFFD: Freely configurable mode "operation modes neutral"

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Master Communication

Hardware Requirements

0xFFFE: Freely configurable mode

Using the master communication "PROFINET" requires the following control

section design:

Single-axis ADVANCED (CSH01.xC)

Single-axis BASIC UNIVERSAL (CSB01.1C)

The option ET must be available as master communication module.

Pertinent Parameters

Communication parameters
Specific parameters for communication via PROFINET:

P04089.0.11, Master communication: MAC address Port1

P04089.0.12, Master communication: MAC address Port2

Parameters for general communication via field bus interfaces:

P04073, Field bus: diagnostic message

P04074, Field bus: data format

P04075, Field bus: watchdog

P04076, Field bus: cycle time (Tcyc)

P04079, Field bus: baud rate

P04088, Master communication: Drive configuration

P04089.0.2, Master communication: Device name

P04089.0.10, Master communication: MAC address device

P04089.0.13, Master communication: IP address

P04089.0.14, Master communication: Network mask

P04089.0.15, Master communication: Gateway address

Profile type parameters

Apart from mere communication parameters, we use parameters in conjunction
with the profile types.
See "Profile Types (With Field Bus Interfaces)"
Parameters for extended communication
We use additional parameters for extended communication.
See following sections:

Pertinent Diagnostic Messages

"Configurable Signal Control Word"

"Configurable signal status word"

" Multiplex Channel"

C0229 Field bus: IDN for cycl. command val. not configurable

C0230 Field bus: Max. length for cycl. command val. exceeded

C0231 Field bus: IDN for cycl. actual val. not configurable

C0232 Field bus: Length for cycl. actual values exceeded

C0233 Field bus: Tcyc (P-0-4076) incorrect

C0234 Field bus: P-0-4077 missing for cycl. command values

E4005 No command value input via master communication

F4009 Bus failure

F4012 Incorrect I/O length

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Master Communication

4.12.4

EtherNet/IPTM Interface

Brief Description
Topology

1
2
3
4

Fig.4-44:

Engineering via free EtherNet/IPTM port of a bus node

Engineering via optional Industrial-Ethernet switch
Engineering via third-party control not possible
Engineering via RS232 or existing engineering port at CSH01.3

EtherNet/IP Topology

IndraDrive controllers with MultiEthernet interface can also be operated as

EtherNet/IPTM master communication. Via this module it is possible to ex
change real-time data withan EtherNet/IPTM scanner.
Real-time data can be transmitted via this interface by means of I/O connection
(Class 1 connection).
Features

Transmission rate 100Mbit/s (full duplex)

Data transmission via Ethernet cable (CAT5e copper)

Topologies: "Star", "line" (by means of integrated cut-through switch)

Auto negotiation is supported, as a prerequisite the transmission rate

mentioned above must be met

Profile type is "Generic Device", specified in ODVA 2.0 (Open DeviceNet

Vendors Association)

EtherNet/IPTM Level 2 server

Cyclic exchange via "Ethernet/IPTM-I/O-Messaging" (Class 1)

Configurable cyclic data up to 15 parameters (incl. field bus control word

and field bus status word) in both data directions
(max. 48 bytes or 24 words)

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Master Communication

Min. cycle time

Max. quantity of process data/setting

P04076

0,5 ms (TA_pos)

16 bytes P04076 = 0.5ms

Notes

32 bytes P04076 = 1ms

48 bytes P04076 = 1ms

Fig.4-45:

Quantity of Cyclic Data Depending on "P04076, Field Bus:: Cycle Time

(Tcyc)"

Valid values for P04076: 0,5 ms, 1 ms, 2 ms, 3 ms, 4 ms, 5 ms,

Hardware Requirements

Supported field bus profiles:

0xFF82: I/O mode "positioning" with configurable real-time data

0xFF92: I/O mode " preset velocity" with configurable real-time data

0xFFFD: Freely configurable mode "operation modes neutral"

0xFFFE: Freely configurable mode

Using the master communication "EtherNet/IPTM" requires the following control

section design:

Single-axis ADVANCED (CSH01.xC)

Single-axis BASIC UNIVERSAL (CSB01.1C)

Double-axis BASIC UNIVERSAL (CDB01.xC)

The option ET must be available as master communication module.

Pertinent Parameters

P04073, Field bus: diagnostic message

P04074, Field bus: data format

P04075, Field bus: watchdog

P04076, Field bus: cycle time (Tcyc)

P04079, Field bus: baud rate

P04088, Master communication: Drive configuration

P04089.0.2, Master communication: Device name

P04089.0.10, Master communication: MAC address device

P04089.0.13, Master communication: IP address

P04089.0.14, Master communication: Network mask

P04089.0.15, Master communication: Gateway address

Profile type parameters

Apart from mere communication parameters, we use parameters in conjunction
with the profile types.
See "Profile Types (With Field Bus Interfaces)"
Parameters for extended communication
We use additional parameters for extended communication.
See following sections:

Pertinent Diagnostic Messages

"Configurable Signal Control Word"

"Configurable signal status word"

" Multiplex channel"

C0229 Field bus: IDN for cycl. command val. not configurable

C0230 Field bus: Max. length for cycl. command val. exceeded

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Rexroth IndraDrive | Release Notes

Master Communication

4.12.5

C0231 Field bus: IDN for cycl. actual val. not configurable

C0232 Field bus: Length for cycl. actual values exceeded

C0233 Field bus: Tcyc (P-0-4076) incorrect

C0234 Field bus: P-0-4077 missing for cycl. command values

C0299 Configuration changed. Restart

E4005 No command value input via master communication

F4009 Bus failure

SERCOS III

Brief Description
Topology

1
2
3
4

Fig.4-46:

Engineering via free SERCOS III port of a bus node

Engineering via optional SERCOS III-netSWITCH
Engineering via IndraWorks on SERCOS III control
Engineering via RS232 or existing engineering port at CSH01.3

SERCOS III - Topology

Operation of IndraDrive controllers with an MultiEthernet interface (ET) or the

option module "SERCOS III" (S3) as SERCOS III master communication is
possible. Via this modules it is possible to exchange real-time data with a
SERCOS III master.
The following communication channels are distinguished:

Cyclic data channel (consumer, producer)

Data container for cyclic transmission of useful data (process data) in
real time

Acyclic data channel (service channel)

Data container for acyclic transmission of useful data (service data).

Non-real time channel (NRT channel)

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Master Communication
Defined time slot within the cycle time for transmission of standard
Ethernet telegrams
General Features

Transmission rate 100 Mbit/s

Cyclical data exchange of command and actual values in equal time in

tervals

Topologies: "Line" (= simple ring) or "ring" (= contra-rotating double ring)

Data transmission via Ethernet cable (CAT5e copper)

Service channel for parameterization and diagnosis

Free configuration of telegram contents

Synchronization between time command value takes effect and meas

urement starting time of the actual values for all drives on a ring

Overall synchronization of all connected drives to the master

Firmware-Specific Features

BASIC

Advanced

MPB-06VRS

MPH-06VRS

Tposition

500

250

min

500

250

Max.

ms

65

65

Byte

24

24

IDN

12

12

Byte

48

48

IDN

16

16

CC connections

Byte

10

10

[incl. 2 bytes connection control word

(C_Con)]

IDN

Position loop cycle

Master communication
cycle time

MotionData
for each MDT/AT

Fig.4-47:

TSercos=Tposition
TSercos>Tposition

SERCOS III Characteristic Numbers

Cycle time Min. 250s, max. 65ms (multiples of position clock 250s or
500s can be set)

max number of configurable consumer data: 52 bytes/16 identification

numbers

max number of configurable producer consumer data: 52 bytes/16 iden

tification numbers
The number of configurable bytes in the consumer/producer con
nections depends on the relation of the position cycle time
(P-0-0556, bit 2) to the SERCOS cycle time:

SERCOS cycle time = position cycle time max. length 28

bytes/12 identification numbers

SERCOS cycle time = position cycle time max. length 52

bytes/16 identification numbers

The NRT channel is only possible, if a time slot of more than 125
s is available.
Hardware Requirements

The optional module with SERCOS III interface is available for the following
configurable control sections:

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Master Communication

Single-axis ADVANCED (CSH01.xC)

Single-axis BASIC UNIVERSAL (CSB01.1C)

Double-axis BASIC UNIVERSAL (CDB01.xC)

The option ET or S3 must be available as master communication module.

Pertinent Parameters

Specific parameters for SERCOS III communication:

S01000, SERCOS III: SCP Type & Version

S01002, SERCOS III: Communication Cycle time (tScyc)

S01005, SERCOS III: Minimum feedback processing time (t5)

S01006, SERCOS III: AT0 transmission starting time (t1)

S01007, SERCOS III: Feedback acquisition capture point (t4)

S01008, SERCOS III: Command value valid time (t3)

S01009, SERCOS III: Device Control (C-Dev) offset in MDT

S01010, SERCOS III: Lengths of MDTs

S01011, SERCOS III: Device Status (S-Dev) offset in AT

S01012, SERCOS III: Length of ATs

S01013, SERCOS III: SVC offset in MDT

S01014, SERCOS III: SVC offset in AT

S01015, SERCOS III: Ring delay

S01016, SERCOS III: Slave delay (P/S)

S01017, SERCOS III: NRT transmission time

S01019, Master comm. engineering over IP: MAC address

S01020, Master comm. engineering over IP: IP address

S01021, Master comm. engineering over IP: Network mask

S01022, Master comm. engineering over IP: Gateway address

S01023, SERCOS III: SYNC jitter

S01024, C5300 SERCOS III: SYNC delay measuring procedure

command

S01026, SERCOS III: Version of communication hardware

S01027.0.1, SERCOS III: Requested MTU

S01027.0.2, SERCOS III: Effective MTU

S01031, SERCOS III: Signal assignment TSx

S01035, SERCOS III: Error counter Port1 & Port2

S01040, Drive address of master communication

S01041, SERCOS III: AT Command value valid time (t9)

S01044, SERCOS III: Device Control (C-Dev)

S01045, SERCOS III: Device Status (S-Dev)

S01046, SERCOS III: List of SERCOS addresses in device

S01050.x.1, SIII-Connection: Connection setup

S01050.x.2, SIII-Connection: Connection number

S01050.x.3, SIII-Connection: Telegram assignment

S01050.x.4, SIII-Connection: Max. length of connection

S01050.x.5, SIII-Connection: Current length of connection

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Master Communication

S01050.x.6, SIII-Connection: Configuration list

S01050.x.8, SIII-Connection: Connection control (C-Con)

S01050.x.10, SIII-Connection: Producer cycle time

S01050.x.11, SIII-Connection: Allowed data losses

S01050.x.12, SIII-Connection: Error counter data losses

S01050.x.20, SIII-Connection: IDN allocation of real-time bit

S01050.x.21, SIII-Connection: Bit allocation of real-time bit

S01051, SIII-Connection: Image of connection setups

Additional pertinent parameters according to "SERCOS interface":

Pertinent Diagnostic Messages

S00014, Interface status

S00015, Telegram type parameter

S00097, Mask class 2 diagnostics

S00134, Master control word

S00135, Drive status word

S00187, List of configurable data in the AT

S00188, List of configurable data in the MDT

P01044, Master comm. engineering over IP: Status IP communication

C0108 Time slot parameter > Sercos cycle time

C0109 Telegram offset unsuitable

C0112 TNcyc (S-0-0001) or TScyc (S-0-0002) error

C0113 Relation TNcyc (S-0-0001) to TScyc (S-0-0002) error

C0170 Config. IDNs for connection not configurable

C0171 Maximum length for connections exceeded

C0172 Delay measurement (S-0-1024) not carried out

C0173 Connections (number) not configurable

C0174 Connection configuration not allowed

C0175 Producer cycle time of a connection not correct

C5301 SERCOS III: Delay measurement failed

E4001 Double MST failure shutdown

E4005 No command value input via master communication

E4007 SERCOS III: Consumer connection failed

E4010 Slave not scanned or address 0

F4001 Sync telegram failure

F4002 RTD telegram failure

F4003 Invalid communication phase shutdown

F4004 Error during phase progression

F4005 Error during phase regression

F4006 Phase switching without ready signal

F4017 S-III: Incorrect sequence during phase switch

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Motor, Mechanical Axis System, Measuring Systems

Motor, Mechanical Axis System, Measuring Systems

5.1

General Information on Operation of Motors With IndraDrive

5.1.1

Basics on the Motors to be Controlled

Brief Description
With the controllers of the IndraDrive range it is possible to control both syn
chronous motors and asynchronous motors.
Types of Construction

The following types of construction are possible:

Rotary motors

Linear motors

Both types can be used in housing design (motor with an output shaft that in
cludes the bearing) or in kit design (stator and rotor as individual components).
Thermal Monitoring

When IndraDrive is used, the controlled motors are protected against thermal
damage when they are provided with a temperature sensor connected to the
controller. The controllers are equipped for evaluating the following temperature
sensors:

NTC thermistor K227 (manufacturer: Siemens)

PTC thermistor KTY84 (manufacturer: Siemens)

Thermal contact and thermal switch SNM150DK (manufacturer: Thermik)

In addition, it is possible to evaluate temperature sensors not listed above, but

their specific resistance characteristics have to be entered manually!
Diagnostic Data of Motor Operation

The firmware provides the option to collect dynamic operating data of the motor
and store them in the motor or the controller (operating hours counter, thermal
and mechanical operating data, operational performance).

Adjusting Motor/Controller

The IndraDrive controllers are adjusted to the motor to be controlled by pro

viding or inputting the motor-specific data.

In the case of Rexroth motors, this can be done without any problem, be
cause the manufacturer provides a specific data set for adjusting each
motor type. The data are documented by the manufacturer as parameter
values, stored and made available in motor-specific parameters.

In the case of third-party motors, it is necessary to check, by means of the

motor data and the data of the possibly available motor encoder, whether
they are basically suited for operation with IndraDrive. The parameter val
ues for adjusting the controller have to be specifically determined for each
motor.
Rexroth motors, by motor-specific parameter values made availa
ble and temperature evaluation adjusted in an optimum way, guar
antee easy commissioning, full drive performance and a high
degree of operational safety!

Motor Holding Brakes

Hardware Data

IndraDrive allows controlling and monitoring holding brakes that are mechani
cally connected to the motor:

Electrically releasing brakes (self-holding)

Electrically holding brakes (self-releasing)

For the electrical connection of the motors to the controller, see the Project
Planning Manuals for the IndraDrive controllers. A complete connection dia

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gram for the use of Rexroth motors is contained in the respective Project
Planning Manual.
Pertinent Parameters

Motor parameters:

S00109, Motor peak current

S00111, Motor current at standstill

S00113, Maximum motor speed

S00141, Motor type

P00018, Number of pole pairs/pole pair distance

P00051, Torque/force constant

P00510, Rotor inertia

P00640, Cooling type

P04014, Type of construction of motor

P04048, Stator resistance

Asynchronous motor parameters:

P00532, Premagnetization factor

P04004, Magnetizing current

Field-weakening range parameters:

Other Motor-Relevant Parameters

5.1.2

P00533, Voltage loop proportional gain

P00534, Voltage loop integral action time

P00535, Motor voltage at no load

P00536, Maximum motor voltage

In connection with the motor, there are other important parameters of the fol
lowing parameter groups:

Measuring system parameters

Motor holding brake parameters

Temperature sensor parameters

Default control loop parameters

Motor Temperature Monitoring

Brief Description
See "Basics on the Motors to be Controlled"
Pertinent Parameters

Pertinent Diagnostic Messages

S00201, Motor warning temperature

S00204, Motor shutdown temperature

S00383, Motor temperature

P00512, Temperature sensor

P00513, Temperature sensor characteristic

E2021 Motor temperature outside of measuring range

E2051 Motor overtemp. prewarning

F2019 Motor overtemperature shutdown

F2021 Motor temperature monitor defective

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5.2

Rexroth Motors

5.2.1

Basics on Rexroth Motors

Classification

Bosch Rexroth's "Electric Drives and Controls" technology field offers a wide
range of motors for equipping machines and installations with drives.
Due to their types of construction, Rexroth electric motors can be divided into:

Adjusting Motor/Controller

Housing motors with output shaft and flange or mounting supports

Kit motors to be installed in machines and installations; consisting of in

dividual components that are mounted to a moving and a static part of the
mechanical system

The controllers can be adjusted to Rexroth motors without any problem be

cause the manufacturer provides the respective data set for each motor type.
These data are available as parameter values.

In the case of housing motors with data memory in the motor encoder, the
parameter values are delivered as an integral part of the motor. At the
initial commissioning they are automatically loaded to the controller.

In the case of kit motors (individual components) and housing motors

without data memory in the motor encoder, the respective motor param
eters are not delivered with the motor. They can be easily loaded to the
controller, however, from a data base in the "IndraWorks Ds/D/MLD" com
missioning tool.

The motor parameter values determined by the manufacturer guarantee that

the motor can be loaded in accordance with its operating characteristic, if the
required current and the corresponding power are provided by controller and
supply unit.
Thermal Motor Monitoring

Rexroth motors are thermally monitored by the controller and protected against
overheating. To do this the current motor temperature is determined by thermo
sensors installed in the motor winding. Depending on temperature thresholds
that can be set, the controller generates a warning or switches the motor off.
Rexroth motors, by motor parameters made available and temper
ature evaluation adjusted in an optimum way, guarantee easy
commissioning, full drive performance and a high degree of opera
tional safety!

Measuring System

As a standard, Rexroth housing motors are equipped with a position measuring

system. The individual motor series have different measuring systems which
allows offering cost-efficient motors depending on the application.
The following measuring systems are used:

HSF ("high-resolution servo feedback"), single- or multi-turn type

Resolver, single- or multi-turn type

Together with Rexroth kit motors it is possible to use different encoder systems:

Encoder with sine signals and EnDat interface, 1Vpp, Heidenhain stand
ard

Encoder with sine signals, 1Vpp, Heidenhain standard

Encoder with square-wave signals, TTL, Heidenhain standard

Hall sensor box and encoder with sine signals, 1Vpp, Heidenhain standard
(only for Rexroth linear kit motors)

Hall sensor box and encoder with square-wave signals, TTL, Heidenhain
standard (only for Rexroth linear kit motors)

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5.2.2

Rexroth Housing Motors

Rexroth Housing Motors With Encoder Data Memory

Motor Lines
The following Rexroth housing motors are equipped with an encoder data
memory:

MSK, MHD, MKE, MKD, MSP, KSM

MAD, MAF
The Bosch motor with the type designation "SF..." that can be con
trolled with IndraDrive controllers is equipped with an encoder data
memory, too. As regards commissioning and parameters, SF mo
tors have the same behavior as Rexroth housing motors with en
coder data memory!

Brief Description
See section "Basics on Rexroth Motors"
Pertinent Parameters

The encoder data memory, amongst others, contains the parameters listed be
low.
Motor parameters:

P02109, Motor peak current, encoder memory

P02111, Motor current at standstill, encoder memory

P02113, Maximum velocity of motor, encoder memory

P02141, Motor type, encoder memory

P03002, Number of pole pairs/pole pair distance, encoder memory

P03003, Rotor inertia, encoder memory

P03005, Torque/force constant, encoder memory

P03007, Stator resistance, encoder memory

P03008, Commutation offset, encoder memory

P03050, Motor inductance, encoder memory

Parameters for measuring system:

P01000, Kind of encoder 1, encoder memory

P01001, Encoder 1 resolution, encoder memory

Only for absolute encoders (multi-turn):

P01002, Absolute encoder offset 1, encoder memory

Only for resolvers as absolute encoders (multi-turn resolvers):

P01003, Pulse wire encoder offset 1, encoder memory

P01004, Pulse wire encoder status 1, encoder memory

Parameter for motor holding brake (if available):

P03010, Torque of motor holding brake, encoder memory

Default control loop parameters:

P02100, Velocity loop proportional gain, encoder memory

P02101, Velocity loop integral-action time, encoder memory

P02104, Position loop Kv-factor, encoder memory

P02106, Current loop proportional gain 1, encoder memory

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P02107, Current loop integral-action time 1, encoder memory

P03004, Speed loop smoothing time constant, encoder memory

At a command, default control loop parameters can be loaded to the controller.

They are useful starting values for further control loop optimization.
Pertinent Diagnostic Messages

C0700 Load defaults procedure com. (load controller param.) (C07_0)

C0702 Default parameters not available

C0703 Default parameters invalid

C0704 Parameters not copyable

C0706 Error when reading the controller parameters

F2008 RL The motor type has changed.

F2104 Commutation offset invalid

Rexroth Housing Motors Without Encoder Data Memory

Motor Lines
The following Rexroth housing motor does not have an encoder data memory:

MAL

Brief Description
See section "Basics on Rexroth Motors"
Pertinent Parameters

5.2.3

The parameters mentioned in "Basics on the Motors to be Controlled" are used

for these motors.

Rexroth Kit Motors

General Information
Kit motors consist of individual components that are mounted to a moving and
as static part of the machine's mechanical system and functionally put together
to form a motor.
A kit motor consists of the following components:

Electrically active part with thermo sensor

Electrically passive part

Measuring System

Storage

The electrical parts of the kit motor are supplied by Rexroth, the measuring
system and the bearing are provided on the machine side.
Rexroth kit motors are manufactured according to the "asynchronous motor" or
"synchronous motor" functional principles. With regard to control, the functional
principles have different requirements:

In the case of synchronous motors, the current in the windings of the stator
must have a fixed allocation to the permanent magnetic field of the rotor
so that the maximum torque or the maximum force is generated.

In the case of asynchronous motors there is no fixed allocation between

stator and rotor required in order to generate the maximum torque or the
maximum force.

Rexroth Kit Motors, Synchronous

Brief Description
The following Rexroth kit motors are manufactured according to the "synchro
nous motor" functional principle:

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Motor, Mechanical Axis System, Measuring Systems

Linear motor MLF

Rotary motors MBS and MBT

As the motor is assembled in the machine, stator, rotor and measuring system
can only be put together on site. The electric-magnetic-mechanical allocation
of the synchronous motor is therefore only to be made on site. This is done by
determining and setting the commutation offset.
The measuring system should be realized with high resolution and
as a motor encoder to be evaluated in absolute form (see also
"Absolute Measuring Systems"). If it is necessary to use an incre
mental measuring system the use of encoders with square-wave
signals should be avoided!
Determining the Commutation Off
set

The commutation offset can be determined with different methods. The method
is chosen in accordance with the axis geometry, the practicability and the chan
ces of success of the respective method depending on the mechanical axis
system:

Calculation method for relative motor encoder when using the Hall sensor
box
Distance measurement, currentless (only possible for Rexroth linear kit
motors)

Measuring method for motor encoders that can be evaluated in absolute

form
Distance measurement, currentless (only possible for Rexroth linear kit
motors)

Saturation method (axis needs to be blocked or at standstill)

With current (possible with all types of construction in combination with
motor encoders that can be evaluated in absolute form or with relative
motor encoders)

Sine-wave method (requires unrestricted movement of axis)

With current (possible with all types of construction in combination with
motor encoders that can be evaluated in absolute form or with relative
motor encoders)
In the case of absolute measuring systems, the commutation offset
only has to be determined once (at initial commissioning), in the
case of incremental measuring systems this has to be done each
time the drive is switched on again!

Description of the method for commutation setting, see "Drive Control: Com
mutation setting"

Rexroth Kit Motors, Asynchronous

Brief Description
The following Rexroth kit motors are manufactured according to the "asynchro
nous motor" functional principle:

Rotary motors 1 MB

As the motor is assembled in the machine, stator, rotor and measuring system
can only be put together on site. After loading the specific parameter values for
motor and measuring system the assembled motor can be put into operation
independent of rotor position and allocation of the measuring system.

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The measuring system should be realized with high resolution and
as an absolute encoder! Avoid using encoders with square-wave
signals!
The parameters mentioned under "Basics on the Motors to be Controlled" are
used for these motors.

5.3

Third-Party Motors at IndraDrive Controllers

5.3.1

General Information on Third-Party Motors

Today, machine axes are mainly moved with electric drives. Motors of standard
design are used in most cases, as this is the most cost-efficient solution.
Special Requirements

Due to special requirements at machine axes, constructional or safety-related

aspects, it may be necessary for the machine manufacturer to use a motor
construction diverging from the standard.

Motor Design not Included in Prod

uct Range

For these cases there is the demand on the drive supplier to realize, apart from
the deliverable standard drive consisting of (standard) motor, controller, cable
and, if required, machine control unit, drives with motors that are not included
in his own product range due to the special design.
With Rexroth controllers of the IndraDrive range, it is also possible to control
third-party motors.

Checking Whether Third-Party Mo

tors Can be Controlled

How to do Project Planning?

For successfully and fail-safely controlling a third-party motor, it is necessary

to check beforehand

whether the third-party motor to be controlled meets the requirements of

the controller,

whether the third-party motor has the required minimum inductance,

whether the mounted position measuring system can be evaluated by the

controller or which position measuring system can be selected for kit mo
tors,

whether the motor can be protected against inadmissible temperature rise

in the case of overload,

which controller, including supply, is suitable due to the motor power to be

delivered.

The requirements relevant in the system combination are documented in the

Project Planning Manual of the drive system.
See documentation "Rexroth IndraDrive Drive System, Project Planning
Manual" (DOK-INDRV*-SYSTEM*****-PR**-EN-P; part no.: R911309636)!

How to Commission?

The motor parameter values have to be determined first (see section "Deter
mining the Parameter Values for Motor and Motor Control"). The parameter
values of motor control are calculated by command internally in the firmware.
It is advisable to document the determined motor parameter values in the forms
contained in the section "Forms for Parameter Values".

5.3.2

General Information on Controlling Third-Party Motors

Pertinent Parameters and Diagnostic Messages

See "Automatic Setting of Motor Control"

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Hardware Data
For the electrical connection of the motors to the controller, see the Project
Planning Manuals for the IndraDrive Controllers. A complete connection dia
gram for the use of Rexroth motors is contained in the respective Project
Planning Manual.

5.3.3

Determining the Parameter Values of Third-Party Motors

General Information on How to Determine the Parameter Values

As Bosch Rexroth cannot make available parameter values for motor control
of third-party motors, these values have to be determined before or during the
commissioning of the third-party motor. The determination of these parameter
values is supported by the following commands:

C3200 Command Calculate motor data

For asynchronous motors, drive-internal calculation of the values for the
motor control parameters from the data on the type plate

C3600 Command Motor data identification

For asynchronous motors, drive-internal optimization of the motor con
trol parameter values calculated by means of the command C3200

C4600 Command Calculate motor control parameters

Calculating the motor control parameter values from the motor-specific
data for synchronous motors and, if necessary, also for asynchronous
motors (after manual input of motor-specific data in addition to the data
from the type plate)

The specific motor data have to be made available by the motor manufacturer.
To collect all required manufacturer-side data of the motor, use the appropriate
forms to copy below.

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1)
2)
3)
C-tool

Fig.5-1:

According to form "Motor Parameters for Synchronous Motors"

in parameter "P04032, Motor type plate data"
According to form "Motor Parameters for asynchronous Motors"
commissioning tool (e.g. IndraWorks Ds/D/MLD)

Determining the Values for the Motor Control Parameters

For detailed explanations on the scope of functions of the mentioned com

mands see "Automatic Setting of Motor Control"!

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5.4

Motor Holding Brake

5.4.1

Operating Behavior of the Motor Holding Brake

Brief Description
Motor holding brakes are used to hold axes with drive enable having been
switched off. This is particularly important for non-equilibrated vertical axes.
With IndraDrive controllers it is possible to control and monitor motor holding
brakes in a wear-resistant way.
Holding brakes at Rexroth motors normally aren't designed for de
celerating when in operation. Increased wear caused by decelera
tion in operation can destroy the holding brake at an early stage!
The following motor holding brake types are possible:

Electrically releasing brakes (self-holding) for servo drives

Electrically holding brakes (self-releasing) for main drives

The motor holding brake can be directly mounted on the motor shaft, e.g. in the
case of Rexroth housing motors, or directly connected to the mechanical axis
system, e.g. in the case of linear kit motors.
IndraDrive controllers include application-specific controls of the holding brake
in order to minimize wear of the brake in the case of error. The following two
functional principles of holding brake control are supported:

Control of holding brake for servo drives

Control of holding brake for main drives

Control of the holding brake is linked with drive enable, considering holding and
releasing delays. In special cases it may be appropriate to avoid this program
med link and release or apply the holding brake independently. This, too, is
possible with IndraDrive!
Hardware Requirements

The motor holding brake is controlled via a controller-internal relay contact.

Power supply is realized by the controller via the 24V control voltage. The hold
ing brake must be suited for the voltage that is output, the holding brake current
must not exceed the allowed maximum value of the respective device (see
documentation "Supply Units and Power Sections; Project Planning Manual for
Controllers"), If necessary, the holding brake has to be controlled separately.
The optionally available holding brakes of Rexroth motors can be
directly controlled via the controller!

Pertinent Parameters

Pertinent Diagnostic Messages

S00206, Drive on delay time

S00207, Drive off delay time

S00273, Maximum drive off delay time

P00525, Holding brake control word

P00539, Holding brake status word

P00540, Torque of holding brake

P00542, C2000 Command Release holding brake

P00543, C3800 Command Apply holding brake

C2000 Command Release motor holding brake

C2001 Command not enabled

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5.4.2

C3800 Command Apply motor holding brake

F6024 Maximum braking time exceeded

Function Check of Motor Holding Brake, Drive-Controlled

Brief Description
If the brake torque of holding brakes is too low due to wear and corrosion, this
can interrupt the service and endanger safety in machines and installations.
IndraDrive controllers have the advantage of monitoring the effectiveness of
the holding brake and recording the monitoring intervals:

Automatically each time drive enable is set and reset

Depending on the situation at a command of the control master

This allows cyclic brake check according to EN 13849-1, cat. 2 or dynamization/

check of one of two redundant holding systems according to
EN 13849-1, cat. 3.
In the case of corrosion, the effectiveness of the holding brake can be rees
tablished by a drive-controlled "resurfacing procedure".
Pertinent Parameters

Pertinent Diagnostic Messages

P00525, Holding brake control word

P00539, Holding brake status word

P00540, Torque of holding brake

P00541, C2100 Holding system check command

P00544, C3900 Command Holding brake resurfacing

P00545, Test torque for releasing holding system

P00546, Starting torque for releasing holding system

P00547, Nominal load of holding system

P00549, Oper. hours control sec. at last succ. holding system check

P00550, Time interval holding system check

C2100 Command Holding system check

C2101 Holding system check only possible with drive enable

C2103 Holding brake: Torque too low

C2104 Command execution impossible

C2105 Load of holding system greater than test torque

C2106 Test torque of holding system not reached

C3900 Command Holding brake resurfacing

C3901 Resurfacing of holding brake only possible with drive enable

C3902 Error during resurfacing of holding brake

C3903 Command execution impossible

E2069 Holding brake torque too low

E3115 Prewarning, end of brake check time interval

F2069 Error when releasing the motor holding brake

F3115 Brake check time interval exceeded

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5.5

Measuring Systems

5.5.1

Basics on Measuring Systems, Resolution

Brief Description
Control Loops and Measuring Sys
tems

Operating drives in the closed control loop requires measuring systems in order
to metrologically acquire the current status of the physical value to be control
led, the so-called actual value.
The following drive control loops are distinguished:

Torque/force control loop

Actual value by evaluating the current measuring system and converting
the value

Velocity control loop

Actual value by evaluating the position measuring system and timederivation

Position control loop

Actual value by evaluating the position measuring system

The actual value of the torque/force control loop is generated by means of the
internal current measurement. The measuring system is inaccessible for the
user and has a fixed configuration.
Possibilities of Position Measuring

For acquiring the actual values of the velocity and position control loop there
are position measuring systems available that provide the user possibilities of
configuration. Position measurement can be carried out:

At the motor only (measurement via motor encoder)

- or

Both at the motor and at the mechanical axis system (measurement via
motor encoder and "external" or "optional" encoder).
Position measurement via motor encoder is always required, meas
urement at the mechanical axis system is optional, the encoder at
the mechanical axis system is therefore called "optional encoder" It
is also called "external encoder" because this encoder is not instal
led internally at the motor, but externally at the axis.

Types of Position Measuring Sys

tems

Position measuring systems are available for the different kinds of motion in
adapted types of construction:

Rotary encoders

Linear encoders

With the appropriate signal specification, encoders in both types of construction

can be evaluated by IndraDrive controllers.
Evaluating Position Measurement

Depending on their design and the mechanical arrangement at the axis, the
position encoders can be evaluated as

Relative encoders (incremental encoders)

- or
Relative Position Measurement

Absolute encoders (absolute value encoders).

In the case of relative position measurement, only position differences can be

evaluated by means of the measuring system. The actual position values sig
naled by the measuring system refer to the (mostly undefined) position at the
time the drive is switched on. To operate the drive within a limited travel range

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a position reference must be established (homing) after each time the drive is
switched on again.
Absolute Position Measurement

Precision, Resolution

Monitoring Functions

In the case of absolute position measurement, the encoder signals actual po

sition values with a fixed encoder-dependent reference point to the controller.
After each time the drive is switched on the correct actual position value is
immediately available with each axis position. Due to the mostly undefined
mounting situation of the encoder to motor or mechanical axis system, it is
necessary to determine the position offset (setting the absolute value) once at
the initial commissioning.
The precision of the position measurement depends on:

The resolution of the measuring system (division periods = DP)

The absolute encoder precision

The digitalization quality of the analog encoder signals

The dimension of the travel range of the axis

Correct position information is of fundamental importance for reliable drive be

havior and motion according to contour. The encoder signals are therefore
monitored for validity and compliance with the allowed tolerances.
In addition, it is possible to monitor drives with an encoder that can be evaluated
in absolute form for compliance with the position when switching on compared
to the last time the drive was switched off.
It is also possible to monitor the difference between the actual position values
of motor encoder and external encoder.
See also "Monitoring the Measuring Systems"

Hardware Requirements

For connecting the measuring systems to the controller there are three optional
interfaces available. "P00077, Assignment motor encoder->optional slot" and
"P00078, Assignment optional encoder->optional slot" the determine the in
terface to which the respective encoder is connected. It must be equipped with
the encoder input appropriate for the encoder.
See also separate documentation "Drive Controllers, Control Sections;
Project Planning Manual"
The following rules apply to P00077 and P00078:

Pertinent Parameters

In the case of motors with encoder data memory (MHD, MKD,

MKE), the value for P00077 is automatically set correctly.

In the case of motors without encoder data memory (rotary and

linear kit motors), the value for P00077 must be set manually.

In the case of optional encoders, the value for parameter

P00078 has to be set manually, too.

S00051, Position feedback value 1

S00053, Position feedback value 2

S00115, Position feedback 2 type

S00116, Resolution of feedback 1

S00117, Resolution of feedback 2

S00256, Multiplication 1 (motor encoder)

S00257, Multiplication 2 (optional encoder)

S00277, Position feedback 1 type

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5.5.2

S00278, Maximum travel range

P00074, Encoder type 1 (motor encoder)

P00075, Encoder type 2 (optional encoder)

P00129, Internal position data format

Monitoring the Measuring Systems

Brief Description
Monitoring the Encoder Signals

Correct position information is the prerequisite for reliable drive behavior and
motion according to contour. In order to guarantee best possible position eval
uation the encoder signals are therefore monitored for validity and compliance
with the allowed tolerances.
Monitoring the encoder signals allows detecting faulty states, such as:

Encoder is dirty

Noise injection in the case of inappropriate wire routing or wire design

Exceeding the max. allowed encoder velocity (limit frequency of the en

coder signals)

Wire break or short circuit on wire

Monitoring the Axis Position when

Switching On

In addition it is possible to monitor drives with an encoder that can be evaluated

in absolute form for compliance with the position when switching on compared
to the last time the drive was switched off. This allows detecting, for example,
whether a vertical axis moved down after the machine was switched off or
whether an axis was moved away from the position it had when the machine
stopped.

Monitoring Mechanical Transfer El

ements

Motor control methods with encoder are only safe to operate if the motor en
coder is connected to the movable part without slip. Slip and too little stiffness
in the motor encoder connection are detected and indicated with a tolerance to
be specified.
It is also possible to monitor the difference between the actual position values
of motor encoder and external encoder. This allows, for example, detecting slip
due to wear in mechanical transfer elements between motor and axis at an early
stage.

Monitoring the Position Data Refer

ence
Pertinent Parameters

If the loss of the position data reference of absolute encoders (motor encoder
or optional encoder) is detected due to changes in parameter values, e.g. of
the mechanical drive system, the drive will signal this faulty status.

S00115, Position feedback 2 type

S00277, Position feedback 1 type

S00391, Monitoring window feedback 2

P00095, Absolute encoder monitoring window for motor encoder

P00096, Absolute encoder monitoring window for opt. encoder

P00177, Absolute encoder buffer 1 (motor encoder)

P00178, Absolute encoder buffer 2 (optional encoder)

P00185, Control word of encoder 2 (optional encoder)

P00328, Type of position encoder for measuring encoder

P00391, Actual position value difference encoder1 - encoder2

P00520, Encoder validation error threshold factor

P00620, Encoder validation monitoring signal

P00621, Encoder validation upper monitoring threshold

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Pertinent Diagnostic Messages

5.5.3

P00622, Encoder validation lower monitoring threshold

E2074 Encoder 1: Encoder signals disturbed

E2075 Encoder 2: Encoder signals disturbed

F2036 Excessive position feedback difference

F2042 Encoder 2: Encoder signals incorrect

F2048 External power supply X15 error

F2074 Actual pos. value 1 outside absolute encoder window

F2075 Actual pos. value 2 outside absolute encoder window

F2174 Loss of motor encoder reference

F2175 Loss of optional encoder reference

F8022 Enc. 1: Enc. signals incorr. (can be cleared in ph. 2)

F8023 Error mechanical link of encoder or motor connection

Absolute Measuring Systems

Brief Description
Evaluating Position Measurement

Depending on their design and the mechanical arrangement at the axis, posi
tion encoders can be evaluated by IndraDrive controllers as

Relative encoders (incremental encoders)

- or

absolute encoders (absolute value encoders)

if they have the required signal specification.

Rexroth position encoders and motor encoders of Rexroth housing motors are
available in one of the two designs:

Single-turn encoders (absolute actual position values over one encoder

shaft revolution)

Multi-turn encoders (absolute actual position values over 4096 encoder

shaft revolutions).

These encoders can be evaluated as absolute encoders if the travel range of

the axis can be represented within the absolute actual position value range of
the encoder:

Encoders of Rexroth Housing Mo

tors

In the case of single-turn encoders within one encoder shaft revolution

In the case of multi-turn encoders within 4096 encoder shaft revolutions

As a standard, Rexroth housing motors are equipped with a position measuring

system. The individual motor series have different measuring systems which
allows offering cost-efficient motors depending on the application.
The following measuring systems are used:

Absolute Encoders for Kit Motors

and External Encoders

HSF ("high-resolution servo feedback"), single- or multi-turn type for MHD,

MAD, MAF motors

HIPERFACE encoder (only such types authorized by Rexroth) for MSK

motors

Resolver, single- or multi-turn type for MKD, MKE motors

For kit motors or directly at the mechanical axis system, the following measuring
systems, that can be evaluated in absolute form, can be used:

EnDat linear encoders (Heidenhain) for linear motors or linear axes

Rotary EnDat encoders (Heidenhain) or Rexroth single-turn or Rexroth

multi-turn encoders for rotary kit motors or rotary axes

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Establishing Axis-Related Absolute
Distance

The actual position values of an absolute encoder first only relate to the encoder
itself. Due to the mostly undefined mounting situation of the encoder to the
motor or the mechanical axis system, it is necessary to determine the position
offset between encoder and axis zero point once at the initial commissioning
(see also "Establishing the Position Data Reference:) Establishing Position Da
ta Reference for Absolute Measuring Systems").

Hardware Requirements

For the signal specification of third-party encoders for position and homing sig
nals with regard to amplitude and phase angle, see the "Drive Controllers,
Control Sections; Project Planning Manual".
Rexroth encoders correspond to the required signal specification!

Pertinent Parameters

5.5.4

S-0-0115, Position feedback 2 type

S-0-0277, Position feedback 1 type

S-0-0278, Maximum travel range

S-0-0378, Absolute encoder range of motor encoder

S-0-0379, Absolute encoder range of optional encoder

P-0-0019, Initial position value

Relative Measuring Systems

Brief Description
Evaluating Position Measurement

IndraDrive controllers can evaluate the signals of both absolute and relative
measuring systems, if the encoder signals correspond to the specification.
The disadvantages of relative encoders as opposed to encoders that can be
evaluated in absolute form are as follows:

Axes with relative position encoder must go through a homing procedure

after switching on so that they can be operated in position control.

Relative encoders are unsuitable as motor encoders for synchronous mo

tors because each time the drive is restarted it has to go through a
procedure for setting the commutation offset. Therefore, the immediate
readiness for operation is not guaranteed for synchronous motors!

The advantages of relative encoders as opposed to encoders that can be eval

uated in absolute form are as follows:

Aspects of Use

Longer travel distances are possible for linear encoders.

The costs of the encoder are mostly lower given equal absolute precision
and number of lines or division period length.

Due to the above disadvantages, relative measuring systems are not used as
motor encoders for synchronous Rexroth housing motors. For asynchronous
motors there aren't any disadvantages when using relative motor encoders.
For kit motors it can be necessary, however, to use relative encoders as motor
encoders if absolute encoders of the required design are not available:

Establishing Axis-Related Absolute

Distance

Great encoder lengths for long travel distances in the case of linear motors

Hollow-shaft encoders with special bore diameters or encoders for high

maximum speeds in the case of rotary kit motors

The actual position values of relative encoders first do not have any position
reference. In any axis position the actual position value of the respective relative
encoder, when switching the drive on, is written with the so-called initial position
value, if no other encoder being in reference has been connected.
There are two ways to establish the axis-related absolute distance:

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Moving to a defined axis position with reproducible precision.

- or

detecting a defined axis position by "passing" two distance-coded refer

ence marks of the encoder.

At a defined position, the actual position value of the encoder to be homed is

written with the corresponding absolute value of the axis (see "Establishing the
Position Data Reference: Establishing Position Data Reference for Relative
Measuring Systems").
Hardware Requirements

Pertinent Parameters

5.5.5

For the signal specification for position and homing signals with regard to am
plitude and phase angle, see the documentation "Drive Controllers, Control
Sections; Project Planning Manual".

S00115, Position feedback 2 type

S00116, Resolution of feedback 1

S00117, Resolution of feedback 2

S00165, Distance-coded reference offset A

S00166, Distance-coded reference offset B

S00277, Position feedback 1 type

P00019, Initial position value

Establishing the Position Data Reference

General Information on Establishing the Position Data Reference

Brief Description
During the initial commissioning of a drive the actual position values transmitted
by the measuring systems do not yet have any reference to the machine axis.
This applies to

Relative measuring systems and

Absolute measuring systems.

For more detailed information on relative and absolute evaluation of measuring

systems, see "Absolute Measuring Systems".
Relative Measuring Systems

The position data reference of a relative measuring system to the axis has to
be reestablished after each time the drive is switched on or after the position
data reference is lost. For this it is necessary to move to a defined axis position
and the actual position value is set to an axis-related value in a defined position
(exception: For relative encoders with distance-coded reference marks move
ment is only required via two marks!)

Absolute Measuring Systems

The position data reference of an absolute measuring system to the axis has
to be established once during initial commissioning after replacing the motor or
encoder (motor encoder or external encoder) and changes in the mechanical
axis system. The position data reference still is maintained and the actual po
sition values are axis-related immediately after the drive is switched on.

Establishing the Position Data Ref

erence, Drive-Controlled

For establishing the position data reference in a drive-controlled way, the po

sition data reference is automatically established by the drive by master-side
triggering of a command. The procedure depends on the kind of measuring
system:

In the case of a relative measuring system without distance-coded refer

ence marks, the axis moves to the reference point or to a dedicated point
and then automatically switches to axis-related actual position values.

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In the case of a relative measuring system with distance-coded reference

marks, the axis moves between two reference marks and then automati
cally switches to axis-related actual position values.

In the case of an absolute measuring system, the automatic switching to

the axis-related actual position value is carried out with the axis in stand
still.

The presettings for establishing the position data reference are made via as
signed parameters.
Establishing the Position Data Ref
erence, NC-Controlled

For establishing the position data reference in an NC-controlled way, the drive
makes available three commands to the master. The master has to generate
the travel motion for searching the mark:

The master starts the command "NC-controlled homing" and for searching
the reference point or dedicated point of the axis has to move the axis by
inputting command values.

To calculate the offset and switch to axis-related actual position values it

is necessary to start further commands.

The presettings for establishing the position data reference are made via as
signed parameters.
Displaying the Position Data Refer
ence

A position status parameter shows whether the position data reference of a

measuring system evaluated by the controller has been established.

Motor Encoder and External En

coders

In addition to the motor encoder an external (optional) encoder can be available.

Both encoders, in any combination of relative and absolute measuring systems,
can

have position data reference to the axis independently of each other (both
encoders have different actual position values)

- or

have position data reference to the axis depending on each other (both
encoders have the same actual position values).

This is configured via parameters and realized with the commands for estab
lishing the position data reference.
Actual Position Value Offset

The difference of the actual position value before and after establishing the
position data reference is displayed, related to the motor encoder or external
encoder, in one parameter respectively.
See also the following sections:

Pertinent Parameters

"Establishing Position Data Reference for Absolute Measuring Systems"

"Establishing Position Data Reference for Relative Measuring Systems"

S00115, Position feedback 2 type

S00175, Offset parameter 1

S00176, Offset parameter 2

S00277, Position feedback 1 type

S00403, Position feedback value status

P00074, Encoder type 1 (motor encoder)

P00075, Encoder type 2 (optional encoder)

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Establishing Position Data Reference for Absolute Measuring Systems (Set Absolute Measur
ing)
Brief Description
Base package of all variants in closed-loop characteristic

See also section "General Information on Establishing the Position Data Ref
erence"
The position data reference of an absolute measuring system to the axis has
to be established once during initial commissioning, after replacing the motor
or encoder (motor encoder or external encoder) and changes in the mechanical
axis system.
Establishing Position Data Refer
ence via Drive Commands

In the case of measuring systems to be evaluated in absolute form, the position

data reference is automatically established by the drive by starting the "set ab
solute measuring" command.
In the case of measuring systems to be evaluated in absolute form, the position
data reference can be automatically established by the drive by starting the
command

"Set absolute measuring"

- or

"Drive-controlled homing procedure".

The position data reference once established is maintained until one of the two
commands is started again. The actual position values therefore are axis-rela
ted ("homed") immediately after the drive is switched on.
Motor Encoder and External En
coder

If two absolute measuring systems have been connected to the controller, the
position data reference can be separately established for both measuring sys
tems. If the position data reference was only set for one of the measuring
systems, both actual position values are equal at the position at which the po
sition data reference was established.
If the position data reference was only set for one encoder, the ac
tual position values of both encoders remain equal as long as
mechanical axis system and encoder systems are mechanically
connected without slip (slip control is possible!).

"Set Absolute Measuring" Com

mand

It is recommended to start the "set absolute measuring" command when the

axis is in standstill without drive enable. In the cases in which the axis, for es
tablishing the position data reference, is to be brought to a defined position on
the master side and be held in this position by the drive, "set absolute meas
uring" can also be executed with active drive.

"Drive-Controlled Homing Proce

dure" Command

When the command "drive-controlled homing procedure" (without previous

start of "set absolute measuring") is started, the drive automatically moves the
axis to a dedicated position, defined by a home switch and/or the zero position
of the absolute encoder, and at this position establishes the position data ref
erence.
For absolute encoders, the command "drive-controlled homing procedure" can
be advantageously used after loss of position data reference after:

encoder replacement in conjunction with a home switch,

encoder error with peripheral causes in the case of modulo-scaled axes

(e.g. encoder cable damage).

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"Active drive" means the drive that is in control. Drive enable
("AF") has been set.
Assigning the Axis-Related Actual
Position Value with "Set Absolute
Measuring"

By starting the "set absolute measuring" command the previous actual position
value of an encoder at a dedicated position of the axis is set to a new value.
This value is the current axis position related to the coordinate system of the
machine.
The dedicated position is defined by:

the current axis position

- or

The positioning of the axis at a "striking" axis position (e.g. value "0")

The required assignments and configurations for "setting absolute measur

ing" are realized via parameter settings.
Assigning the Axis-Related Actual
Position Value With "Drive-Control
led Homing Procedure"

By starting the "drive-controlled homing procedure" command the previous ac

tual position value of an encoder at a dedicated position of the axis is set to a
new value. This value is the current axis position related to the coordinate sys
tem of the machine.
The required assignments and configurations for "drive-controlled homing" are
realized via parameter settings (see information on "Drive-Controlled Homing
Procedure"in section "Establishing Position Data Reference for Relative Meas
uring Systems").

Pertinent Parameters

Pertinent Diagnostic Messages

S00052, Reference distance 1

S00054, Reference distance 2

P00012, C0300 Set absolute position procedure command

P00177, Absolute encoder buffer 1 (motor encoder)

P00178, Absolute encoder buffer 2 (optional encoder)

P00612, Set absolute position control

P01002, Absolute encoder offset 1, encoder memory

P01012, Absolute encoder offset 2, encoder memory

C0300 Set absolute position procedure command

C0301 Measuring system unavailable

C0302 Absolute evaluation of measuring system impossible

C0303 Absolute encoder offset cannot be saved

Establishing Position Data Reference for Relative Measuring Systems (Homing)

Brief Description
Base package of all firmware versions in closed-loop characteristic.

See also section "General Information on Establishing the Position Data Ref
erence"
Actual Position Value of Relative
Measuring Systems when Switch
ing On

After the drive is switched on the actual position values signaled by relative
measuring systems do not yet have any reference to the machine axis. Meas
uring systems can be installed at the motor (motor encoder) and directly at the
mechanical axis system (external or optional encoder).
For information on encoder arrangement and mechanical axis system see also
"Mechanical Axis System and Arrangement of Measuring Systems"

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The position data reference of relative measuring systems to the axis has to be
established again each time after the drive was switched on or after all proce
dures that cause the position data reference to get lost (homing procedure).
Establishing the Position Data Ref
erence, Drive-Controlled

After start of the respective command by the master, the drive can automatically
establish the position data reference.
To do this, the drive moves the axis until the controller can detect a dedicated
point. The actual position values then are automatically switched to axis refer
ence. The presettings for the sequence for establishing the position data
reference are made via assigned parameters.

Establishing the Position Data Ref

erence, NC-Controlled

As an alternative to establishing the position data reference in a drive-controlled

way, the NC ("master") can control the homing procedure.
In this case the master inputs the command values for moving the axis to the
dedicated point and controls the homing procedure via commands and as
signed parameters.
The NC-controlled homing procedure can be advantageous for drives with a
rigid mechanical connection (e.g. for Gantry axes), because the master can
input coordinated command values for the drives for the homing motion.

Dedicated Point for Establishing

the Position Data Reference

The dedicated point for establishing the position data reference, in the case of
linear axes, is at one end of the travel range. This allows finding the dedicated
point from any axis position (situation when switched on) by moving in a defined
direction. Rotary axes do not have an axis end position, the dedicated point is
at a defined position within the travel range.

Reference Mark for Relative Meas

uring Systems

The precision with which this dedicated point is detected considerably influen
ces the absolute precision of the axis. Apart from the signals for position
detection, relative measuring systems therefore also provide a signal for exact
determination of a dedicated point. This signal is called "reference marker".
Depending on their type, relative measuring systems have one or several ref
erence marks over the range of measurement.

Reference Mark and

Home Switch

Especially in the case of rotary measuring systems (e.g. motor encoder) at axes
moved in a linear way, the reference mark of the encoder can occur several
times over the entire travel range. In this case it is required, by axis-side acti
vation of a switch contact at the end of the travel range, to identify one reference
mark signal. This defines an unequivocal dedicated point that can be found with
reproducible precision. This operating status is called "home switch". A possibly
available travel range limit switch can be used like a home switch, too.
In addition, a reference mark signal can be identified by detecting axis blocking
when positive stop at the end of the axis has been reached.
Independent of the number of reference marks over the travel range, an axisside additional device (home switch or travel range limit switches or positive
stop), is indispensable for linear axes for detecting the axis end position!
If only one reference mark occurs over the travel range in the case of rotary
axes, the home switch in most cases is not required!

Dedicated Point and Reference

Point of an Axis

The dedicated point identified by an encoder reference mark and, if necessary,

by a home switch, in most cases is not identical to the reference point of the
axis. The distance between reference point and zero point normally is deter
mined on the machine side. Especially in the case of serial machines, this
distance should be equal for axes of the same kind. The position of the dedi
cated point, however, is influenced by the kind of encoder arrangement and
therefore differs from axis to axis.

Reference Offset

The position difference between dedicated point and reference point of the axis
can be compensated by an offset value (reference offset).

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See also section "General Information on Establishing the Position Data Ref
erence"
Pertinent Parameters

Parameters for relative measuring systems:

S00041, Homing velocity

S00042, Homing acceleration

S00052, Reference distance 1

S00054, Reference distance 2

S00108, Feedrate override

S00147, Homing parameter

S00148, C0600 Drive-controlled homing procedure command

S00150, Reference offset 1

S00151, Reference offset 2

S00173, Marker position A

S00174, Marker position B

S00191, C1500 Cancel reference point procedure command

S00298, Reference cam shift

S00299, Home switch offset

S00349, Bipolar jerk limit

S00400, Home switch

S00403, Position feedback value status

P00153, Optimum distance home switch-reference mark

Parameters for NC-controlled homing:

S00146, C4300 NC-controlled homing procedure command

S00171, C4400 Calculate displacement procedure command

S00172, C4500 Displacement to referenced system procedure

command

S00175, Offset parameter 1

S00176, Offset parameter 2

S00404, Position command value status

S00407, Homing enable

S00408, Reference marker pulse registered

Parameters for relative measuring systems, distance-coded:

S00165, Distance-coded reference offset A

S00166, Distance-coded reference offset B

S00177, Absolute offset 1

S00178, Absolute offset 2

Parameters for homing at travel range limit switches:

P00090, Travel range limit parameter

P00222, Travel range limit switch inputs

Parameters for homing at positive stop:

S00082, Torque/force limit value positive

S00083, Torque/force limit value negative

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Pertinent Diagnostic Messages

S00092, Bipolar torque/force limit value

S00124, Standstill window

S00331, Status "n_feedback = 0"

S00333, Status "T >= Tx"

Diagnostic messages for drive-controlled homing:

C0600 Drive-controlled homing procedure command

C0601 Homing only possible with drive enable

C0602 Distance home switch - reference mark erroneous

C0604 Homing impossible with absolute encoder

C0606 Reference mark not detected

C0607 Home switch input not assigned

Diagnostic messages for NC-controlled homing:

C4302 Distance home switch - reference mark erroneous

C4304 Homing impossible with absolute encoder

C4306 Reference mark not detected

C4307 Home switch input not assigned

C4308 Pos. stop a. HW lim. switch not allowed f. modulo axes

C4400 Calculate displacement procedure command

Drive-Controlled Homing Procedure

General Information
Basic Sequence of
"Search for Dedicated Point"

After activation of "S00148, C0600 Drive-controlled homing procedure

command", the drive for searching the dedicated point moves the axis accord
ing to the reference travel direction set in "S00147, Homing parameter". When
the controller has detected the position of the dedicated point, e.g. by reference
mark detection of the encoder selected in S00147, the position data reference
of the actual position values to the axis can be established.
Determining the homing appropriate procedure for the existing axis type (set
tings in S00147) ensures that during the search for the dedicated point the
axis only moves within the allowed travel range!
For information on the actual position value after establishing the position data
reference for motor encoder and external encoder see section "General Infor
mation on Establishing the Position Data Reference"

Functional Sequence "Drive-Controlled Homing Procedure"

Command Value Profile for Homing
Procedure

After activation of "S00148, C0600 Drive-controlled homing procedure

command", the drive moves the axis according to the reference travel direction
set in "S00147, Homing parameter". The command value profile generated
by the controller depends on:

S00041, Homing velocity

S00042, Homing acceleration

S00108, Feedrate override

The controller ignores command values of the control master during the exe
cution of command C0600!

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If the respective encoder, at the start of command C0600, should
have already been homed, the reference is cleared first!
See also Parameter Description "S00437, Position feedback
value status"
Homing Motion

At the start of command C0600, two situations have to be distinguished with

regard to the initial position of a linear axis. The moving part of the axis is

within the travel range, the home switch or travel range limit switch has
not been activated,

- or

near the end of the travel range, the home switch or travel range limit
switch has been activated, the positive stop, possibly used for homing, is
almost reached.

If the switch has not been activated or positive stop has not yet been reached,
the drive moves the axis in reference travel direction.
When the home switch has already been activated, the drive moves the axis
against the reference travel direction.
In the case of non-distance-coded encoders, the drive reverses the direction of
motion for searching the dedicated point as soon as the home switch is detected
to be "not activated".
In the case of distance-coded encoders, the search for the dedicated point is
carried out against the determined reference travel direction.
When positive stop is used for homing, the search for the dedicated point, after
axis blocking has been detected, is always carried out against the reference
travel direction!
Jerk Limitation

To limit acceleration jumps it is possible to additionally activate a jerk limit. This

is made by the input in "S00349, Bipolar jerk limit".

Motion Range for Homing

The process for searching the dedicated point requires axis motion. The axis
motion to be expected depends on the selected measuring system and on the
position of the axis at the start of drive-controlled homing (for information on
axis motion see above under the description of the respective paragraph "Iden
tifying the Dedicated Point by Means of ").

Maximum Velocity

As in the case of all drive-controlled functions, the maximum velocity can be

directly influenced with a feedrate factor when executing the homing procedure.
The effective maximum velocity then results from the product of the values of
"S00041, Homing velocity"and "S00108, Feedrate override".

Shutdown

After the controller has detected the dedicated point of the axis by the homing
procedure, the actual position values are switched to axis-related values. The
drive then shuts down the axis with the homing acceleration (S00042). Shut
down can be carried out as:

"Stopping"
Non-target-oriented immediate braking motion that possibly is of shorter
duration

- or

"positioning"
Target-oriented motion to the reference point (axis-related value in
"S00052, Reference distance 1" or "S00054, Reference distance 2"),
if the reference point is within the allowed travel range

- or -

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"Run path" (only possible for distance-coded encoders!)

Moving over a defined path (double reference mark distance), even if
the dedicated point had already been detected

The kind of shutdown ("positioning", "stop" or "run path") is set in "S00147,

Homing parameter".

1
2
S00041
S00042
S00108

Fig.5-2:

start point
reference point
Homing velocity
Homing acceleration
Feedrate override

Command Value Profile for Drive-Controlled Homing With Constant

Feedrate Factor and "Positioning" Shutdown

If "S00108, Feedrate override" starts with zero, the warning

"E2055 Feedrate override S-0-0108 = 0" will be output.

Actions of the Control Unit in the Case of Drive-Controlled Homing

Starting Command C0600

The control master starts the command by writing to "S00148, C0600 Drivecontrolled homing procedure command". The command has to be set and
enabled. The command acknowledgment has to be taken from the data status
of the same parameter. The command execution is completed when the com
mand change bit in "S00135, Drive status word" has been set and the
acknowledgment changes from "in process" to "command executed" or to
"command error".

Interrupting Command C0600

If the command is interrupted by the control master during its execution, the
drive reacts by activating the "Drive HALT" function. The command execution
is continued by removing the interruption.
See also "Drive HALT"

Completing Command C0600

When the control master wants to operate the drive in position control after
resetting command C0600, it has to read the drive-internal position command
value from "P00047, Position command value control" and preset it as the
position command value. By resetting the command the control master takes
over the axis without jerk or position offset occurring.

NC-Controlled Homing Procedure

General Information
Sequence of NC-Controlled Hom
ing

For NC-controlled homing the master (NC control unit) controls the homing
motion for searching the dedicated point of the axis. To do this the master ac
tivates

S00146, C4300 NC-controlled homing procedure command

and presets the command value for axis motion, according to the active oper
ating mode.

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When the drive has detected the dedicated point, it informs the master of this
fact and stores the position of the dedicated point. The master then completes
the execution of command C4300 and afterwards activates

S00171, C4400 Calculate displacement procedure command.

The required displacement of the actual position values is now calculated in the
drive controller, in order to establish the reference of the actual position value
to the axis zero point.
When the displacement required for establishing the position data reference
has been determined, the master completes the execution of command C4400
and then activates

S00172, C4500 Displacement to referenced system procedure

command.

Drive-internally the actual position value now is changed by the calculated ab

solute displacement value and thereby the reference of the actual position value
to the axis zero point is established. The master has to adjust its command
value input to the changed actual position value, before it completes the NCcontrolled homing procedure by deactivating command C4500.

Functional Sequence "NC-Controlled Homing Procedure"

Searching the Dedicated Point,
Basic Procedure

After the master has started NC-controlled homing by activating "S00146,

C4300 NC-controlled homing procedure command", it has to preset a com
mand value for the drive for the axis motion to identify the dedicated point.
For non-distance-coded encoders, the dedicated point can only be identified,
if "S00407, Homing enable" has been set on the master side. If a home switch
was connected to the drive controller (setting in parameter S00147), it has to
be detected as "activated". For distance-coded encoders, the master-side hom
ing enable (S00407) is not required, because the dedicated point can be
unequivocally identified by arbitrary neighboring reference marks.
For details on the search for the dedicated point in the case of NC-controlled
homing, see section above "Identifying the Dedicated Point by Means of Ref
erence Mark and Home Switch"!
When the drive has found the dedicated point of the encoder selected in
"S00147, Homing parameter", this is displayed in "S00408, Reference
marker pulse registered". The position of the dedicated point or the detected
reference marks is stored:

For non-distance-coded encoders, the detected dedicated position is stor

ed in "S00173, Marker position A".

For distance-coded encoders, the first detected reference mark is stored

in parameter "S00173, Marker position A", the second one in "S00174,
Marker position B".

The correct, time-optimized sequence of the execution of command C4300 re

quires the following assignments:

Bit "homing enable" (S00407) in real-time control bit of "S00134,

Master control word"

Bit "reference mark detected" (S00408) in real-time status bit of

"S00135, Drive status word"

When the bit "reference mark detected" (S00408) has been set, the master
can complete the execution of the command C4600.
Drive-Side Calculation of Actual
Position Value Displacement for
Zero Point Reference

By master-side activation of "S00171, C4400 Calculate displacement

procedure command" the actual position value offset is calculated for the en
coder selected in "S00147, Homing parameter".
Basis for the calculation of displacement:

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For non-distance-coded encoders, the non-homed actual position value

at the dedicated point (S00173) and the values of reference distance 1/2
(S00052/S00054) and reference offset 1/2 (S00150/S00151).

For distance-coded encoders, the non-homed actual position values of the

detected reference marks (S00173 and S00174) and the values of
"S00177, Absolute offset 1" (motor encoder) or "S00178, Absolute
offset 2" (external encoder).

The calculated displacement value is displayed in

S00175, Offset parameter 1 (motor encoder)

- or

S00176, Offset parameter 2 (external encoder).

When the required displacement of the actual position value has been deter
mined, the master can complete the execution of the command C4400.
The displacement could also be calculated on the master side and
directly preset for the drive via the parameters S00175 or
S00176. In this case the execution of command C4400 wouldn't
be required!
Displacement of Actual Position
Value for Zero Point Reference

To switch the actual position values to axis reference the master now activates
"S00172, C4500 Displacement to referenced system procedure command".
The displacement of the actual position value for the encoder selected in
"S00147, Homing parameter" is thereby carried out.
The calculated displacement value (S00175 or S00176) is now added to the
non-homed actual position value; the new actual position value is displayed in:

S00051, Position feedback value 1

- or

S00053, Position feedback value 2.

The homing status of the encoders connected to the drive is also displayed in
parameter "S00403, Position feedback value status". By means of this pa
rameter the master recognizes when the position command value is to be
switched to axis reference. When the switching to the homed position command
value was carried out, the master indicates this to the drive in parameter
"S00404, Position command value status". The drive then signals the execu
tion of command C4500 to have been completed and the master on its part can
complete the execution of command C4500.
The correct, time-optimized execution of the command C4500 requires the fol
lowing assignments:

Position command value status bit (S00404) in real-time control bit of

"S00134, Master control word"

Reference encoder status bit (S00403) in real-time status bit of

"S00135, Drive status word"

For information on the actual position value after establishing the position data
reference for motor encoder and external encoder see section "General Infor
mation on Establishing the Position Data Reference"

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Shifting the Position Data Reference for Absolute and Relative Measuring Systems (Shift Co
ordinate System Procedure)
Brief Description
Expansion package servo function (order code SRV) of all firmware
variants in closed-loop characteristic.
The existing position data reference of the measuring systems to the axis can
be shifted if the respective command was activated by the master. It is possible
to shift the data reference in standstill or while the axis is moving. This does not
affect the position reference of the axis because it is only the actual position
values output for the master that are displayed in "shifted" form. Internally the
original ("non-shifted") position data reference is maintained.
Shifting the position data reference affects the motor encoder and, if available,
the external encoder, independent of which encoder is the active encoder for
position control. If different actual position values are valid for the encoders
(both encoders possibly have position data reference independent of each oth
er), the actual position values of both measuring systems are shifted by the
same difference.
Pertinent Parameters

Pertinent Diagnostic Messages

S00197, C3300 Set coordinate system procedure command

S00198, Initial coordinate value

S00199, C3400 Shift coordinate system procedure command

S00275, Coordinate offset value

S00283, Current coordinate offset

C3300 Set coordinate system procedure command

C3400 Shift coordinate system procedure command

Detecting the Marker Position

Brief Description
Base package of all firmware versions in closed-loop characteristic.

The "get marker position" function, that is activated via the respective com
mand, can be used for:

Checking the correct detection of the reference mark of an incremental

measuring system

- or

Determining the position of the reference mark in case the homing pro
cedure is carried out by the control master. In this case, the coordinate
system is switched in the master with the position information of the ref
erence mark.
A possibly available home switch is not evaluated with this function!

Pertinent Parameters

Pertinent Diagnostic Messages

S00173, Marker position A

P00014, C1400 Command Get marker position

C1400 Command Get marker position

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5.6

Mechanical Axis System and Arrangement of Measuring Sys

tems

5.6.1

Brief Description
Motor encoder

Controlled motor activation requires a position measuring system that meas

ures the current rotor position or the position of the moving part as opposed to
the static part of the motor.
This position measurement is required for the:

Current control loop,

velocity control loop and

if required, position control loop.

The precision and resolution of the position measurement is decisive for the
quality of the actual values, especially in the velocity and position control loop.
External Encoders

Depending on the mechanical properties of the mechanical system between

driven motor shaft and machine axis it can be required to carry out the position
control by means of an external position encoder (not integrated in the motor)
directly at the moving part of the axis, e.g. in the case of

mechanical system with slip,

gear play or a low degree of stiffness of the mechanical system, etc.

The external (optional) encoder can also be used as a measuring wheel en

coder (frictionally engaged on transported material).
See "Measuring Wheel Mode"
For information on encoder evaluation and encoder monitoring see also "Basics
on Measuring Systems, Resolution" and "Monitoring the Measuring Systems"
Motor Encoders of Rexroth Hous
ing Motors

Rexroth housing motors have integrated position measuring systems:

HSF encoders for MHD motors of high precision requirements

Resolver encoders for MKD and MKE motors for lower precision require
ments

They are optionally available as

Relative measuring system ("single-turn motor encoder")

- or

Absolute measuring system ("multi-turn motor encoders", range of values

4096 motor revolutions)

The measuring systems of Rexroth housing motors support the commissioning

because the data for encoder type and resolution are stored in the encoder.
They are loaded to the controller when the controller is switched on.
Motor Encoders for Rexroth Kit Mo
tors and Third-Party Encoders

Rexroth kit motors are delivered as individual components and assembled in

the machine to form the motor. It consists of a moving and a static part, the
bearing and the motor encoder.
The following measuring systems can be used as a motor encoder:

GDS/GDM encoders from Rexroth (rotary single-turn or multi-turn encod

ers with housing and shaft)

Incremental encoders with sine signals

(compatible with signal specification of Heidenhain)

combined encoder of incremental encoder with sine signals (compatible

with signal specification of Heidenhain) and "Hall sensor box
SHL01.1" (Rexroth-compatible signal specification)

Encoders with EnDat interface from Heidenhain

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Incremental encoders with square-wave signals (compatible with signal

specification of Heidenhain)

Combined encoder of incremental encoder with square-wave signal (com

patible with signal specification of Heidenhain) and "Hall sensor box
SHL01.1" (Rexroth-compatible signal specification)
Do not use incremental encoders with square-wave signals as mo
tor encoders! Bad drive characteristics are to be expected!

The mentioned measuring systems can be used as motor encoders for thirdparty kit motors and third-party housing motors. The combined encoders are
an exception; they can only be used for Rexroth synchronous linear motors (see
also "Rexroth Kit Motors, Synchronous")!
For synchronous kit motors or synchronous third-party motors it is
recommended that you use a measuring system, which can be
evaluated in absolute form, as a motor encoder so that you have to
determine the commutation offset of the motor only once (during
initial commissioning) (see also "Absolute Measuring Systems").
Motor Encoder with Gear

Especially with rotary kit motors it is sometimes impossible to connect the motor
encoder directly to the motor shaft. IndraDrive provides the possibility to eval
uate a motor encoder connected via a gear.
For synchronous motors in combination with a motor encoder which
can be evaluated in absolute form, the advantage of setting the
commutation offset only once (see above) can only be used with an
encoder gear with i = 1 or when there is no encoder gear available!

External Encoders at Machine Ax

es

Possibilities of Arranging Measur

ing Systems

IndraDrive controllers can evaluate the following measuring systems as exter

nal encoders:

GDS/GDM encoders from Rexroth (rotary single-turn or multi-turn encod

ers with housing and shaft)

Incremental encoders with sine signals

(compatible with signal specification of Heidenhain)

Encoders with EnDat interface from Heidenhain

Incremental encoders with square-wave signals (compatible with signal

specification of Heidenhain)

The figure below shows an overview of arrangement possibilities of mechanical

drive system and measuring systems.

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1)
S-0-0051
S-0-0053
S-0-0076
S-0-0115
S-0-0116
S-0-0117
S-0-0121
S-0-0122
S-0-0123
S-0-0277
P-0-0074
P-0-0075
P-0-0121
P-0-0122
P-0-0124
P-0-0125
P-0-0123
P-0-0185

Fig.5-3:
Hardware Requirements

Pertinent Parameters

S-0-0051 or S-0-0053 depending on scaling (S-0-0076)

Position feedback 1 value
Position feedback 2 value
Position data scaling type
Position feedback type 2
Feedback 1 Resolution
Feedback 2 Resolution
Input revolutions of load gear
Output revolutions of load gear
Feed constant
Position feedback type 1
Encoder type 1 (motor encoder)
Encoder type 2 (optional encoder)
Gear 1 motor-side (motor encoder)
Gear 1 encoder-side (motor encoder)
Gear 2 load-side (optional encoder)
Gear 2 encoder-side (optional encoder)
Feed constant 2 (optional encoder)
Control word of encoder 2 (optional encoder)

Overview of Arrangement Possibilities of Mechanical Drive System and

Measuring Systems

For connecting the measuring systems to the controller there are 3 optional
interfaces available. The interface to which the respective encoder is connected
is determined by writing to "P-0-007, Assignment motor encoder->optional
slot" and "P-0-0078, Assignment optional encoder->optional slot". The interface
must be equipped with the appropriate encoder input for the encoder (see also
documentation "Control Sections for Drive Controllers; Project Planning Man
ual")!

S-0-0115, Position feedback 2 type

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S-0-0121, Input revolutions of load gear

S-0-0122, Output revolutions of load gear

S-0-0123, Feed constant

S-0-0277, Position feedback 1 type

P-0-0121, Gear 1 motor-side (motor encoder)

P-0-0122, Gear 1 encoder-side (motor encoder)

P-0-0123, Feed constant 2 (optional encoder)

P-0-0124, Gear 2 load-side (optional encoder)

P-0-0125, Gear 2 encoder-side (optional encoder)

P-0-0185, Control word of encoder 2 (optional encoder)

5.7

Scaling of Physical Data

5.7.1

Brief Description
The controller via data maps the drive to an internal mathematical model. The
status variables of the drive are determined on the basis of the following meas
urements:

Position Measurement

Current measurement

Temperature measurement

The measured values collected in this way are converted into physical data:

Position, velocity, acceleration and jerk data

Current data, torque and force data

Temperature data and load data

The master transmits command values to the drive that are used by the con
troller for transforming them at the motor output shaft or mechanical axis
system. The drive in return registers and transmits actual values, signals op
erating and command states and, if necessary, generates error messages and
warnings.
Communication between drive and master also takes place by exchanging da
ta.
Scaling

An operating data (numeric value) can only be evaluated as a physical value,

when the numeric value is connected to a physical unit and the position of the
decimal point (decimal places). The data thereby is "scaled" in a qualitative and
quantitative way.

Parameters

All data are stored in parameters and transmitted as parameter values (for ex
planations on parameters see "Parameters, Basics"). The scaling of the pa
rameters containing data of the following physical values can be defined by the
customer:

Preferred Scaling/Parameter Scal

ing

Position

Velocity

Acceleration

Torque/force

Temperature

To simplify the scaling definition so-called "preferred scalings" were predefined.

But physical data can also be exchanged in the control-internal format, i.e.

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without specific reference to physical units. To do this, the scaling for certain
data can be freely set ("parameter scaling").
Linear and Rotary Data

Depending on the kind of motion of motor or load, the data can be displayed
as follows:

In linear form (linear axis or motor motion)

- or
Motor Reference/Load Reference

In rotary form (rotary axis or motor motion)

In the drive firmware there are mechanical transfer elements between motor
and load mapped by means of mathematical models. The physical data can
thereby be referred to

the point where the load takes effect (load-side data reference)

- or
Absolute/Modulo Evaluation

the point where the force is input (motor-side data reference).

For technical reasons, the value range of the position data the controller can
display is limited.
In the case of axes with limited travel range (e.g. linear axes), the current axis
position within the controller-side value range can be unequivocally displayed
(see "Basics on Measuring Systems, Resolution").
In the case of axes with unlimited travel range (e.g. rotary axes) it is useful to
limit the infinite value range of the position data to a finite value. With continuous
motion, the value range is recurrently run from minimum to maximum value
("modulo" evaluation of the actual position value).

Pertinent Parameters

S-0-0043, Velocity polarity parameter

S-0-0044, Velocity data scaling type

S-0-0045, Velocity data scaling factor

S-0-0046, Velocity data scaling exponent

S-0-0055, Position polarities

S-0-0076, Position data scaling type

S-0-0077, Linear position data scaling factor

S-0-0078, Linear position data scaling exponent

S-0-0079, Rotational position resolution

S-0-0085, Torque/force polarity parameter

S-0-0086, Torque/force data scaling type

S-0-0093, Torque/force data scaling factor

S-0-0094, Torque/force data scaling exponent

S-0-0103, Modulo value

S-0-0121, Input revolutions of load gear

S-0-0122, Output revolutions of load gear

S-0-0123, Feed constant

S-0-0160, Acceleration data scaling type

S-0-0161, Acceleration data scaling factor

S-0-0162, Acceleration data scaling exponent

S-0-0208, Temperature data scaling type

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Drive Control

6.1

Overview of Drive Control

6.1.1

Basic Principles and Terms

The IndraDrive firmware supports the following two basic principles of drive
control:

Open loop axis control (U/f control, flux-controlled FXC operation)

Open-loop-controlled operation without encoder information

Closed loop axis control (various methods of control)

Closed-loop-controlled operation with encoder feedback (position, ve
locity and current)
When selecting the functional packages, take the desired method
of control into account as you have to choose between "openloop" and "closed-loop base package"!

Operating mode / command

value adjustment

Control mode

U/f control with command val

Voltage-control
ue adjustment of the velocity
led operation
control

Torque/Force Control

Field-oriented
current control

Velocity control / velocity syn

Velocity control
chronization

Position control, drive-control

led positioning, positioning
Position control
block mode, phase synchroni
zation, electronic Cam
1)

Fig.6-1:

Functional
principle of
motor

Encoder
available

Required base
package
Method of control

Yes

Closed-loop

No

Open-loop

Asynchro
nous

Yes

Closed-loop

No

--

Synchro
nous

Yes

Closed-loop

No

--

Asynchro
nous

Yes

Closed-loop

FOC control

No

Open-loop

FXC control

Synchro
nous

Yes

Closed-loop

FOC control

No

Open-loop

FXC control

Asynchro
nous

Yes

Closed-loop

FOC control

No

Closed-loop

FXC control 1)

Synchro
nous

Yes

Closed-loop

FOC control

No

Closed-loop

FXC control 1)

Asynchro
nous

Not relevant
U/f Control
FOC control
No procedure available
FOC control
No procedure available

Only with external encoder

Overview: Operating Modes and Available Control Methods

For scaling the drive firmware, we distinguish between the func

tional base packages with "open-loop" and "closed-loop" charac
teristic; in this case, however, the meaning is not identical to how
the terms are used in conjunction with drive control!
See also section "Overview of Functions/Functional Packages"
((edited until here on March 27, 2009))

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6.1.2

Principles of Drive Control

Overview of Open-Loop Axis Control

The axis control (and/or "open loop operation") allows open-loop-controlled
operation of the drive without motor encoder (U/f control).
The primary operation mode "velocity control" is configured, but only the com
mand value processing specific to this operation mode takes effect. Closedloop control (position and velocity) and functions and operating modes
depending thereof are not possible.
See "Voltage-Controlled Open-Loop Operation (U/f Control)"

Fig.6-2:

Principle of Drive Control (Open-Loop Operation)

See also section "Closed-Loop Axis Control (Closed-Loop Operation)"

See also section "Overview of Functions/Functional Packages"

Overview of Closed-Loop Axis Control

The base package "closed-loop" also contains the functions of the
base package "open-loop".
The axis control (and/or "open loop operation") allows controlled operation of
the drive; we distinguish between two principles of drive control:

Operation with encoder

The velocity control loop and the position control loop are closed by means
of the encoder feedback so that the following operating modes are sup
ported by field-oriented current control with encoder feedback:

Velocity control

Position Control With Cyclic Command Value Input

Positioning modes (e.g. drive-controlled positioning)

Synchronization Modes

Operation without encoder

The velocity control loop is closed by means of a motor model (monitor)
so that field-oriented current control without encoder feedback supports
velocity control without encoder.

See section "Field-Oriented Current Control"

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Fig.6-3:

Principle of Drive Control (Closed-Loop Operation)

See also section "Open-Loop Axis Control (Open-Loop Operation)"

See also section "Overview of Functions/Functional Packages"

6.1.3

Control Loop Structure

General Information
The drive controller has a so-called cascade structure, i.e. the individual loops
(position, velocity and current) are interconnected in cascaded form. Depending
on the active operating mode, only the torque/force control loop, the torque/
force control loop and the velocity control loop or, in addition to these two control
loops, the position control loop are closed in the drive.
Torque/Force Control

The "torque/force control" mode actually is not torque or force control but cur
rent control. Therefore, only the current control loop is closed in the drive.
See also "Torque/Force Control"

Velocity Control

In the "velocity control" mode, the velocity control loop, apart form the current
control loop, is closed in the drive, too.
See also "Velocity Control"

Position Control

For the following position control modes, the position control loop, apart from
the current and velocity control loops, is closed internally (in the drive):

Position Control With Cyclic Command Value Input

Drive-Internal Interpolation

Drive-Controlled Positioning

See also description of the respective operating mode

The figures in the following two paragraphs contain an overview of the structure
and the interaction of the control loops (distinguished according to the illustra
tion of the setting parameters and the display parameters).

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Control Loop Structure With Setting Parameters

TA

Fig.6-4:

Sampling times (see table in the chapter "Features of the Control

Loops")

Overall Structure of the Control Loops With Points at Which the Setting
Parameters Take Effect (Example for Field-oriented Control With En
coder)

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Control Loop Structure With Display Parameters

TA

Fig.6-5:

Sampling times (see table in the chapter "Features of the Control

Loops")

Overall Structure of the Control Loops With Display Parameters (Exam

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ple)

6.1.4

Features of the Control Loops

Performance (Controller Cycle Times)

The internal controller cycle times (current, velocity and position) depend on
the following conditions and parameters:

Control section design (CSH, CSB or CDB)

Activation of the functional packages

P00001, Switching frequency of the power output stage

P00556, Config word of axis controller (bits 2 and 5)

Depending on these factors, the following cycle and switching times can be
achieved:
ADVANCED control BASIC control sec
sections
tions
PWM switching frequency

max. 16 kHz

max. 8 kHz

Current loop clock (TA_current)

62.5 s

125 s

Velocity loop clock (TA_velocity)

125 s

250 s

Position loop clock (TA_position)

250 s

500 s

Fig.6-6:

Cycle and Switching Times to be Achieved With IndraDrive

All performance data are listed under "System Overview: Perform

ance Data" .

Current Loop
The current loop is characterized by the following features:

PI loop for d-axis and q-axis of the field-oriented d-q coordinate system
(S-0-0106, S-0-0107)

Inductance feedforward for decoupling d-axis and q-axis (P04017,

P04016) for synchronous motors

Inductance characteristic for adjusting the current loop parameters in the

case of saturation phenomena

Precontrol of e.m.f.

Velocity Loop
The velocity loop is characterized by the following features:

Standardization of the output value at the velocity loop to Newton (N) or

Newton meter (Nm); therefore, depending on the motor type, the following
unit results for "S-0-0100, Velocity loop proportional gain":

Rotary motor Nm * s/rad

Linear motor N * min/mm

Extended filter possibilities for filtering resonance frequencies (4 filters of

2nd degree available; setting via P01120, P01121, P01122 and
P01123)

Limiting the acceleration in velocity control by setting in "S00138, Bipolar

acceleration limit value"

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Position Loop
The position loop is characterized by the following features:

Jerk limitation in the operation mode "cyclic position control" in "S00349,

Bipolar jerk limit" can be set; filter degree of smoothing filter (moving aver
age) in "P00042, Current position command average value filter order"
can be set

Velocity feedforward (degree of feedforward) can be set in "P00040,

Velocity feedforward evaluation" (0% ... 100%)

Input value for "S00348, Acceleration feedforward gain":

Inertia in kg*m2 (for rotary motors)

- or

Mass in kg (for linear motors)

6.2

Motor Control

6.2.1

General Information on Motor Control

Overview of Motor Control Methods

Classification of Motor Control Methods
There are different methods available to control the motor; the main difference
between these methods is the fact whether a motor encoder is required or not.
Motor Control With Motor Encoder

Motor Control Without Motor En

coder

Motor control with position feedback via a motor encoder (field-oriented current
control FOC) is the highest-quality method of motor control providing the best
control performance. It can be used for synchronous and asynchronous motors
and, within the precision and performance of motor and controller determined
by the hardware, allows unrestricted motor operation in the following operating
modes:

Position control modes

Velocity control

Torque/force control

For sensorless motor control, there are different model-based methods avail
able for synchronous and asynchronous motors.

For asynchronous motors:

Voltage-controlled open-loop operation (U/f control)

Flux-controlled operation ("FluX Control" FXC)

For synchronous motors:

Current-controlled closed-loop operation with indirect rotor position

detection (field-oriented current control, sensorless FOCsl)

Regarding the possible operating modes when using these methods, observe
the following restrictions:

Position control modes ("positioning") can only be used with sensorless

synchronous motors, or with asynchronous motors only in flux-controlled
operation (FXC) and with an external encoder. In these cases, generally
take the performance losses into account!

Velocity control, too, can only be used with performance losses!

Torque/force control cannot be used for motor control without motor
encoder!

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Motor Control Method and Func
tional Principle of Motor

Motor encod
er?

Functional princi
ple of motor

With

Synchronous mo
tor

Motor encoder

The motor control method is defined in "P-0-0045, Control word of current

controller". Make sure that the requirements regarding functional principle of
motor and motor encoder have been fulfilled for specified motor control mode.
The table below contains an overview for selecting the method.
Motor control
method

FOC

Asynchronous
motor
Synchronous mo
tor

Without
Motor encoder

FOCsl
FXC

Asynchronous
motor

U/f Control

Fig.6-7:

Specific information for use

Parallel operation of linear motors

MLF is possible!
Difference in inductance between dand q-axis is required!
Only single-motor operation!

Possible operating modes

Position control modes
Velocity control
Torque/force control
Position control modes
Velocity control

Parallel operation of motors is possi

Velocity control
ble!

Overview of Motor Operation With and Without Motor Encoder

See also "Overview of Drive Control"

Pertinent Parameters

P-0-0001, Switching frequency of the power output stage

P-0-0045, Control word of current controller

P-0-0556, Config word of axis controller

Field-Oriented Current Control With Motor Encoder (FOC)

Features and Use

Field-oriented current control with position feedback via motor encoder (FOC)
is characterized by the following features:

Highest-quality method of motor control

To be used when there are high demands on the quality of control and
the dynamic response!

Operating Modes With FOC

Can be used for synchronous and asynchronous motors

Within the hardware-side precision and performance of motor and controller,

field-oriented current control with position feedback via motor encoder allows
unrestricted motor operation in the following operating modes:

Position control modes

Velocity control

Torque/force control

See main section "Field-Oriented Current Control (FOC Control)"

Model-Based Current Control Without Motor Encoder (FXC, FOCsl)

Features and Use

Model-based current control without motor encoder is characterized by the fol

lowing features:

Cost-saving motors, compared to the FOC method, can be used, as no

motor encoder is required (however, performance losses)

With asynchronous motors flux-controlled method (FXC) can be used

without motor-specific restrictions

For synchronous motors FOCsl method; only applicable with motors that
have a difference in inductance between d- and q-axis (few sizes of the
MSK motor range)

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Operating Modes With FXC and
FOCsl

Current control without motor encoder allows using the following operating
modes:

Velocity control (only suited for single motors, parallel operation of motors
is not possible)

Position control modes depending on functional principle of motor

With synchronous motors, actual position value detection is possible

without encoder

With asynchronous motors, actual position value detection via ex

ternal encoder is required
Torque/force control cannot be used for sensorless (model-based)
motor control!

See main section "Sensorless Motor Operation, Flux-Controlled (FXC Con

trol)"

Voltage-Controlled Open-Loop Operation (U/f Control)

Features and Use

Operating Mode With U/f Control

Voltage-controlled motor operation without motor encoder is characterized by

the following features:

Cost-saving motors, compared to the FOC method, can be used, as no

motor encoder is required (however, performance losses)

Can only be used for asynchronous motors

Linear or square U/f characteristic can be selected

For voltage-controlled operation without motor encoder, you can only use the
"velocity control" mode with the following features:

Parallel operation of motors is possible

Adjustment of motor control to velocity-proportional increase in load (e.g.

with blowers) by adjusted ("square") U/f characteristic to reduce the motor
losses

Performance losses compared to velocity control with motor encoder

Torque/force control and position control modes cannot be used for
voltage-controlled operation without motor encoder!

See main section "Voltage-Controlled Open-Loop Operation (U/f Control)"

Notes on Selection of Motor Control Method

Motor Control Performance

The performance of motor control significantly depends on the type of control

section including the corresponding firmware, as well as on the PWM frequency
of the power output stage which has been set.
An overview of the performance to be achieved and the clock rates
depending on control section design and parameter settings is con
tained in the section "Performance Data" .

Selecting the Motor Control Method

The motor control method is defined in "P-0-0045, Control word of current

controller". By means of a dialog, the commissioning tool "IndraWorks Ds/D/
MLD"supports the assignment of the motor control method.

Selection Criteria

The following criteria have to be taken into account when selecting the appro
priate motor control method:

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Motor type
Synchronous motor
without reluctance tor
que

Motor encoder
available?

Parallel connection of
motors?
Rotary: no

Yes

Linear: Yes 1)

No
Synchronous motor
with reluctance torque

Motor control meth

Notes on use
od
Field-oriented cur
rent control

No
Rotary: no

Yes

Field-oriented cur
rent control

Linear: Yes 1)

Yes

Only allowed with approval by the

drive development department
For standard applications with high
demands on quality of control and dy
namic response

No

For standard applications with medi

Flux-controlled cur
um demands on quality of control and
rent control
dynamic response

Yes

U/f Control

For standard applications with low de

mands on quality of control and dy
namic response

No

Field-oriented cur
rent control

For standard applications with high

demands on quality of control and dy
namic response

No
Asynchronous motor

For standard applications with high

demands on quality of control and dy
namic response

1)

Fig.6-8:

observe mechanical setup according to motor data

Basic Selection Criteria for the Motor Control Method

See also "Overview of Drive Control"

Operating Properties for Control of
Synchronous Motors

Observe the following differences for controlling synchronous motors in oper

ation with and without motor encoder:

Motor characteristic

Control with encoder

Control without encoder

Basic speed range

Yes

(with reduced maximum

speed)

Field weakening range

Yes

Torque/force control

Yes

Yes
Speed working ranges

Velocity control (incl. synchro

Supported operation modes nization)
Position control/positioning
(incl. synchronization)

Yes
Yes

No
(no field weakening range)
No
Yes
(with restrictions)
Yes
(with restrictions)

Torque limitation

Yes

Yes

Maximum torque

high

medium

Dynamic response

high

low to medium

high
Running smoothness/speed quality

Torque ripple
Required precision of the motor parameters

(depending on measuring sys

tem, motor type, mechanical
system)

medium

low (< 5%)

high

low

high

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Motor characteristic

Control with encoder

Control without encoder

Robustness

high

low

Sensitivity against disturbances

low

high

Absolute encoder: in PM + OM

Only when motor supplied

with current ("AF" in OM)

Validity (availability) of the position information

PM
OM

Fig.6-9:
Operating Properties for Control of
Asynchronous Motors

Supported operation
modes

Parameter mode
Operating mode

Comparison of Motor Control Without Encoder and With Encoder for

Synchronous Motors

Observe the following differences for controlling asynchronous motors as re

gards operation with and without encoder:
Control with encoder

Control without
encoder

U/f Control

Basic speed range

Yes

Yes

Yes

Field weakening range

Yes

Yes

Yes

Torque/force control

Yes

No

No

Velocity control (incl. syn

chronization)

Yes

Yes

Yes

(with restrictions)

(with restrictions)

Position control/positioning
(incl. synchronization)

Yes

Only with external

position encoder

No

Yes

No

Motor characteristic
Speed working ranges

Relative encoder: in OM

Torque limitation

Yes

Maximum torque

high

medium

low

Dynamic response

high

medium

low

(depending on measur
ing system, motor type,
mechanical system)

medium

low

low (< 5%)

high

high

low

High, if high perform

ance must be reached

(only stall protection

loop)

high
Running smoothness/speed quality

Torque ripple
Required Accuracy of the motor parameters

low

Robustness

high

medium

low

Sensitivity against disturbances

low

high

high

Depending on
load-side encoder
type used

not available

Validity (availability) of the position information

PM
OM

Fig.6-10:

Absolute encoder: in PM
+ OM
Relative encoder: on
ly in OM
Parameter mode
Operating mode

Comparison of Motor Control Without Encoder and With Encoder for

Asynchronous Motors

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6.2.2

Motor Control Frequency

Brief Description
General Information

The speed of three-phase AC motors depends on the frequency of the voltage

applied to the motor. The maximum frequency of the motor voltage provided by
the controller depends on the PWM frequency with which the power output
stage is controlled (clocked).
The control of the power output stage can be made in different ways. Depending
on the relation of the motor control frequency to the output stage frequency,
different procedures are possible for IndraDrive controllers:

Features

"Static PWM" for low and medium output frequency

"Dynamic PWM" for high output frequency

Compared to the "static PWM", the maximum motor control frequency - and
thus the motor speed - can be significantly increased through the "dynamic
PWM" and no-load losses of a dynamic PWM are reduced for high speeds:
PWM frequency in Hz
Max. motor control frequency in Hz
Value in P00001
Dynamic PWM
Static PWM*)
4000
400
-8000
800
1330
12000
1200
2000
16000
1600
2660
*)see also "Supply Units and Power Sections; Project Planning Manual"

Fig.6-11:
Note on Dimensioning

PWM Frequency Settings and Maximum Motor Control Frequency for

Static and Dynamic PWM

Make sure that the required PWM frequency is observed when se

lecting the controller as the continuous current of the controller is
influenced by the setting of the PWM frequency:

Set PWM Frequency as low as possible because of continu

ous current of the controller

Set PWM frequency as high as necessary because of motor

control frequency

Advantageous Behaviour

Due to the Reduction of the Continuous Current for PWM Frequencies above
4kHZ the Controller can set Automatically the Most Favorable PWM Frequency.

Availability

Depending on the control section design and the setting of the PWM frequency,
"dynamic PWM" or the "most favorable PWM", depending on the velocity, can
be used
Programmable
PWM or

Control section

Firmware

Possible PWM fre

most favorable PWM
quencies
depending on the
speed

CSB

as of MPB06VRS

4000

CDB

as of MPD06VRS

8000

4000
CSH

Fig.6-12:

as of MPH06VRS

8000

12000

16000

Hardware and Firmware Dependencies

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Pertinent Parameters
Pertinent Diagnostic Messages

6.2.3

P00001, Switching frequency of the power output stage

P00045, Control word of current controller

Switching of the PWM frequency is displayed in the respective bit of "P00046,

Status word of current controller".

Voltage-Controlled Open-Loop Operation (U/f Control)

Brief Description
The drive function "voltage-controlled operation of asynchronous motors with
out encoder in open-loop U/f control" is made available in the base package
"open-loop" in the "velocity control" mode. When the expansion package "syn
chronization" has been enabled, the operation mode "velocity synchronization
with real/virtual master axis" is additionally available.

Fig.6-13:

Principle of U/f Control

U/f motor control is characterized by the following features or core functions:

Features

Monitoring and limitation of the maximum stator frequency slope that re

sults from the command velocity change

Stall protection loop (PI loop that can be optionally activated to prevent
breakdown of the machine when the torque limits are attained)

Slip compensation (feedforward of estimated slip of the machine by means

of slip compensation factor)

Calculation of output voltage by means of U/f characteristic based on mo

tor model data

Subsequent trimming of magnetization via premagnetization factor, as

well as linear or square characteristic to be selected

IxR boost (adjustable load-dependent feedforward of the output voltage

due to the voltage drop on the motor winding resistance)

Oscillation damping (adjustable load-dependent feedforward to prevent

velocity oscillations in the partial load and idling ranges)

Current limitation loop to protect the output stage of the drive controller,
as well as limitation to the effective peak current

Velocity search mode of a coasting machine after switching drive enable

on (can be set for the preset rotational direction or both rotational direc
tions)

D.C. braking to reach standstill more quickly

User-side torque/force limitation via enabled stall protection loop

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Pertinent Parameters

Pertinent Diagnostic Messages

6.2.4

S-0-0040, Velocity feedback value

S-0-0106, Current loop proportional gain 1

S-0-0107, Current loop integral action time 1

P-0-0043, Torque-generating current, actual value

P-0-0044, Flux-generating current, actual value

P-0-0045, Control word of current controller

P-0-0046, Status word of current controller

P-0-0048, Effective velocity command value

P-0-0063, Torque-generating voltage, actual value

P-0-0064, Flux-generating voltage, actual value

P-0-0065, Absolute voltage value, actual value

P-0-0440, Actual output current value (absolute value)

P-0-0442, Actual value torque limit positive (stationary)

P-0-0443, Actual value torque limit negative (stationary)

P-0-0532, Premagnetization factor

P-0-0556, Config word of axis controller

P-0-0568, Voltage boost

P-0-0569, Maximum stator frequency slope

P-0-0570 , Stall protection loop proportional gain

P-0-0571 , Stall protection loop integral action time

P-0-0572 , Slip compensation factor

P-0-0573, IxR boost factor

P-0-0574, Oscillation damping factor

P-0-0575, Search mode: search current factor

P-0-0576, Search mode: finding point slip factor

P-0-0577, Square characteristic: lowering factor

P-0-0578, Current for deceleration, absolute value

P-0-0579, Current for deceleration, time period

P-0-4036, Rated motor speed

P-0-4046, Effective peak current

E8040 Torque/force actual value limit active

E8041 Current limit active

E8260 Torque/force command value limit active

Field-Oriented Current Control (FOC Control)

Brief Description
Base package of all firmware versions in closed-loop characteristic

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The current loop was preset for all motors by Bosch Rexroth and
the parameter values have been stored in the motor encoder data
memory or in the commissioning tool (IndraWorks Ds/D/MLD,
DriveTop).
For notes on how to commission the current loop for third-party
motors, see "Third-Party Motors at IndraDrive Controllers"!
Principle of Field-Oriented Current
Control

In the case of field-oriented current control, the internal control task consists in
generating the transformed currents Id and Iq in controlled form:

Id (flux-generating current) PI loop for Id

Iq (torque-generating current) PI loop for Iq

The figure below illustrates the principle of field-oriented current control for op
eration with motor encoder:

v-loop
I-loop

Fig.6-14:
Working Ranges

Velocity Loop
Current Loop

Simplified Schematic Diagram for Field-Oriented Current Control With

Higher-Level Velocity Control

Field-oriented current control of asynchronous and synchronous motors allows

operation in the entire speed range.
The speed range is divided into the following working ranges:

General Features

Features of Synchronous Motor

Control

Basic speed range constant torque

Field weakening range 1 constant power

Field weakening range 2 power limit range

Field-oriented current control has the following general features:

Control of the motor current according to the principle of field orientation,

i.e. separate control of the torque-generating current and the flux-gener
ating current

Compensation of the cross coupling of the d and q axes to increase dy

namics

Voltage loop for operation in the field weakening range

Activation of the optimum current loop proportional gain value, depending

on the current PWM frequency during the load defaults procedure

In the case of synchronous motors, field-oriented current control additionally

has the following features:

Limitation of the Iq command value at the voltage limit for protection

against too little control margin

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Features of Asynchronous Motor

Control

Utilization of the reluctance effect to increase the available torque in the

basic speed range

Support of synchronous motors with reluctance torque, i.e. motors with

significantly different inductances in the d and q axes

In the case of asynchronous motors, field-oriented current control has the fol
lowing features in addition to the general features:

Pertinent Parameters

Optimum torque linearity, even in the field weakening range, by:

Permanent correction of the torque constant and the slip factor by

means of the currently calculated rotor flux

Rotor flux model taking temperature and saturation behavior of the

magnetizing inductance into account

Improved dynamic behavior by:

Voltage- and load-dependent flux feedforward

Voltage loop for correcting the flux feedforward

Flux loop for dynamically generating the rotor flux

Possibility of reducing the magnetizing current for low-loss operation at no

load or in partial load range

Current loop setting:

S-0-0106, Current loop proportional gain 1

S-0-0107, Current loop integral action time 1

P-0-0001, Switching frequency of the power output stage

P-0-0045, Control word of current controller

P-0-4002, Charact. of quadrature-axis induct. of motor, inductances

P-0-4003, Charact. of quadrature-axis inductance of motor, currents

Voltage loop setting:

P-0-0533, Voltage loop proportional gain

P-0-0534, Voltage loop integral action time

P-0-0535, Motor voltage at no load

P-0-0536, Maximum motor voltage

Rotor flux control for asynchronous motors:

P-0-0528, Flux control loop proportional gain

P-0-0529, Scaling of stall current limit

P-0-0530, Slip increase

P-0-0532, Premagnetization factor

Power monitoring:

S-0-0158, Power threshold Px

S-0-0337, Status "P >= Px"

S-0-0382, DC bus power

Encoder monitoring (in operation with encoder):

P-0-0520, Error threshold for encoder monitoring

Display parameters:

S-0-0380, DC bus voltage

P-0-0046, Status word of current controller

P-0-0063, Torque-generating voltage, actual value

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Pertinent Diagnostic Messages

P-0-0064, Flux-generating voltage, actual value

P-0-0065, Absolute voltage value, actual value

C0132 Invalid settings for controller cycle times

E8025 Overvoltage in power section

E8028 Overcurrent in power section

F2077Current measurement trim wrong

F8023 Error mechanical link of encoder or motor connection

F8060 Overcurrent in power section

General Function of Field-Oriented Current Control

Torque/Force Control

In contrast to the functional principle used in the "torque/force control" mode,

this actually is current control, as the actual current value is measured and not
the force or the motor torque. This means that open-loop control of torque/force
takes place, the torque or the force being directly connected with the torque-/
force-generating current via the torque/force constant.
In the case of asynchronous motors, the torque constant is corrected according
to the active rotor flux:

Field Weakening Operation

With the firmware, it is possible to operate asynchronous and synchronous

motors in the entire speed range (including field weakening range).
We basically distinguish 3 working ranges that are illustrated in the following
figure and described below.

A
B
C

Fig.6-15:
Basic Speed Range

Basic Speed Range

Field weakening range 1
Field Weakening Range 2 (Power Limit Range)

Three Working Ranges of the Speed Range

The base speed range is characterized by constant torque and fixed torque/
force constant (P-0-0051).
In the case of asynchronous motors, the programmed, effective magnetizing
current flows in no-load operation. The motor voltage is less than the maximum
controller output voltage. The corner speed n1 is directly proportional to the DC
bus voltage.

Field Weakening Range 1 (Con

stant Power)

The field weakening range 1 is characterized by constant power, the motor

voltage is kept constant. In the case of asynchronous motors, the no-load cur
rent is reduced as the speed increases. This reduces the magnetization and

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the torque constant, the slip increases accordingly. The adjustment of magnet
izing current and slip is automatically carried out by the voltage loop.
Field Weakening Range 2 (Power
Limit Range)

The field weakening range 2 is the range of decreasing peak power. An asyn
chronous motor works at the stall current limit in this range, through vector
control, the current is maintained at an efficient and stable level. The peak cur
rent is reduced in such a way that the point of maximum power is not exceeded.
Further increase in current would only lead to increased power dissipation and
less shaft output. The peak power in range 3 is proportional to the square of
the DC bus voltage. It is ensured that the maximum possible power is reached
for each DC bus voltage without parameter adjustment.
Due to this causal connection, it is clear that the power in range 3
cannot be increased by using a more powerful controller. In this
section, performance can only be increased by increasing the volt
age of the DC bus!
In the following sections, we distinguish control of synchronous machines (with
motor encoder) and asynchronous machines (with and without motor encoder).

Field-Oriented Current Control of a Synchronous Machine

For synchronous motors, field-oriented current control is only pos
sible with motor encoder (with closed-loop base package)!
Synchronous motors with a motor encoder in field-oriented current control can
be operated in all available operating modes. The figure below illustrates the
control loop structure and the points at which the individual parameters take
effect for a synchronous machine.

Fig.6-16:
Voltage Loop for Synchronous Mo
tors

Simplified Schematic Diagram of the Current Control Loop for a Syn

chronous Machine

For field control (or voltage control), a voltage loop designed as a PI loop is
used that can be set via the following parameters:

P-0-0533, Voltage loop proportional gain

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P-0-0534, Voltage loop integral action time

The command value of the voltage loop is preset by "P-0-0536,
Maximum motor voltage".

The voltage loop becomes active when the current loop output exceeds a de
fined absolute voltage value (see "P-0-0536, Maximum motor voltage"). By
generating a field counteracting the permanent field-linked direct-axis flux
( negative Id command value), the reduction of the output voltage can be ob
tained.
The output value of the voltage loop is the command value for the
field-generating component of the subsequent current loop (see
figure above).
Field Weakening of Synchronous
Motors

In the case of synchronous motors with field weakening, a command value of

Id_cmd = 0 is run in the basic speed range, as in the case of synchronous motors
without field weakening.
When entering the field weakening, Id_cmd is increased towards negative values
and therefore allows higher motor velocities.

Closed-Loop Control of Synchro

nous Motors With Distinctive Reluc
tance Torque

Closed-loop control of synchronous motors with reluctance torque, i.e. motors

with significantly different inductances in the d and q axes, requires the separate
input of Ld and Lq in the respective parameters:

P04016, Direct-axis inductance of motor (Ld)

P04017, Quadrature-axis inductance of motor (Lq)

Utilization of the reluctance effect allows increasing the available
torque in the basic speed range.

Field-Oriented Current Control of an Asynchronous Machine

Field-oriented control of the asynchronous machine differs from control of the
synchronous machine in the additional function blocks "flux feedforward" and
"flux loop incl. field model".
The figure below illustrates the control loop structure of field-oriented current
control:

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Fig.6-17:
Flux Feedforward and Flux Model

Simplified Schematic Diagram of the Current Control Loop for an Asyn

chronous Machine

The flux feedforward calculates the optimum rotor flux command value for each
working point of the machine. The limiting variable is the motor voltage that
increases with the speed. As limit value the flux feedforward uses the value in
"P-0-0535, Motor voltage at no load".
In addition, the following motor data have an influence on flux feedforward and
flux model:

PP-0-4004, Magnetizing current

P-0-4039, Stator leakage inductance

P-0-4040, Rotor leakage inductance

P-0-4041, Motor magnetizing inductance

P-0-4042, Characteristic of motor magnetizing inductance

P-0-4043, Rotor time constant

On the basis of the above motor data and the active value of the flux-generating
current Id, the flux model calculates the actual value of the rotor flux. This value
is used as actual value for the flux loop (see below) and additionally determines
the torque constant and the slip frequency of the asynchronous machine re
quired for generating the torque.
Voltage Loop

The voltage loop works as a PI loop and in the absolute value limits the voltage
output by the current loop to a maximum value. The setting is made via the
following parameters:

P-0-0533, Voltage loop proportional gain

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P-0-0534, Voltage loop integral action time

P-0-0536, Maximum motor voltage

When the maximum motor voltage is exceeded, the output of the
voltage loop interferes in a corrective way in the output value of the
flux feedforward.

Flux Loop

The flux loop works as a P-loop with command value feedforward. It compares
the actual value from the rotor flux model to the command value from flux feed
forward and voltage loop and by the corresponding input of the flux-generating
current component Id-cmd provides for rapid rotor flux generation. This is of im
portance for applications with dynamic speed response (field weakening
range). The amplification can be set in "P-0-0528, Flux control loop proportional
gain".
In the case of asynchronous motors, the field or rotor flux control
has a decisive influence on the torque generation and dynamic re
sponse of the machine, particularly in the field weakening range.
For Rexroth motors the corresponding value is stored in the "Driv
eBase" database.

Stall Current Limit

The stall current limit only takes effect in the power limit range of the field weak
ening range (C). The maximum allowed torque-generating current is calculated
by means of the active rotor flux and the motor data. This absolute limit value
can be relatively changed via the setting in "P-0-0529, Scaling of stall current
limit" (in percent).
When operating a motor without field weakening it is only the ef
fective magnetizing current that is applied as command value for
the field-generating current component.

Determining the Rotor Flux Angle

6.2.5

For field-oriented control of an asynchronous motor, the current rotor flux angle
is continuously required. This angle is generated from the position information
of the motor encoder.

Sensorless Motor Operation, Flux-Controlled (FXC Control)

Brief Description
Base package of all firmware variants in open-loop and closedloop characteristic
For asynchronous and synchronous motors, flux-controlled, sensorless motor
operation is available in the base packages "open-loop" and "closed-loop" of
all firmware variants and can be used in the "velocity control" mode and in po
sition-controlled operation modes which use position encoder 2 (external en
coder).
When using the firmware expansion package "synchronization", you can also
run the operation mode "velocity synchronization with real/virtual master ax
is".

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Fig.6-18:
Features

Principle of Sensorless, Flux-Controlled Motor Operation

Limitation of the maximum stator frequency slope that results from the
command velocity change

"Stable" motor operation

To maintain the maximum possible torque

Slip compensation for asynchronous motors (estimated motor slip taken

into account for calculating actual velocity value)
To minimize the stationary speed deviations, due to slip, from the com
mand value when the asynchronous motor is loaded

Pertinent Parameters

Motor speed does not tend to oscillation in operation at partial load and
no-load operation

Velocity search mode of a coasting asynchronous motor after switching

drive enable on

Possibility of taking user-side torque/force limitation into account

Motor control parameters of sensorless, flux-controlled motor operation:

P04033, C3200 Command Calculate motor data

P00532, Premagnetization factor

P00565, C3600 Command Motor data identification

P00578, Current for deceleration, absolute value

P00579, Current for deceleration, time period

P00580, Motor frequency

P00593, FXC: Total flux loop proportional gain

P00594, FXC: Total flux loop integral action time

P00595, FXC: Frequency loop proportional gain

P00596, FXC: Frequency loop scaling factor of inertia

P00597, FXC: Current loop proportional gain

P00598, FXC: Current loop integral action time

P00599, FXC: Slip frequency filter time constant

P00600, FXC: Rated slip frequency

P00602, FXC: Minimum no-load current

Motor data parameters:

P00510, Rotor inertia

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P04004, Magnetizing current

P04032, Motor type plate data

Axis data parameters:

P04010, Load inertia

Control parameters:

6.2.6

P00045, Control word of current controller

P00601, Configuration motor data identification

Automatic Setting of Motor Control

Brief Description
Base package of all firmware variants in open-loop and closedloop characteristic
For operating motors, it is necessary to collect the values for motor parameters
(resistance values, inductances, ...), in order to determine the motor control
parameters (flux loop, voltage loop, current loop, ...) with these values.
Depending on the manufacturer and type of the motor to be controlled, the
values for motor parameters and motor control parameters are made available
to the controller in different ways.
Motors by Bosch Rexroth

For Rexroth motors, the values for the motor and motor control parameters are
optimized and made available by the manufacturer. The automatic setting of
the motor control parameters by the drive firmware is not required and not al
lowed for Rexroth motors!

For motors with motor encoder data memory:

Parameters Loaded Automatically When Drive is Switched on (see
"Default Settings in the Motor Encoder Data Memory ("Load Defaults Pro
cedure")")

For motors without motor encoder data memory:

Loading the parameters via the commissioning tool "IndraWorks D"

from the motor data base (DriveBase)
- or -

Third-Party Motors

Individual parameters manually written via the serial interface or the

master communication interface by means of a motor parameter list

For third-party motors, the drive firmware possesses commands by means of

which the values for the motor and motor control parameters are generated
depending on the available output data and the functional principle of the motor.
The following commands are available for calculating values for the motor and
motor control parameters:

C3200Command Calculate motor data

1.1 Calculating the motor parameter values for asynchronous motors
from the data on the type plate
1.2 Calculating the values to be set for the motor control parameters

C3600Command Motor data identification

2.1 Identifying (or optimizing) the motor parameter values for asynchro
nous motors
Note: Appropriate start values already have to be available!
2.2 Calculating the values of the motor control parameters

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C4600 Command Calculate motor control parameters

Calculating the values of the motor control parameters from the motor
parameters for synchronous motors and, if necessary, for asynchronous
motors (after manual input of motor data in motor parameters)
Basically, the prerequisite is the form "Manufacturer-Side Data of
Synchronous Motors" or "Manufacturer-Side Data of Asynchronous
Motors" in the section "Third-Party Motors at IndraDrive Control
lers", to be completed by the motor manufacturer!

Overview

The figure below illustrates an overview of the possibilities of determining the

motor and motor control parameters for motors without motor encoder data
memory:

P04032

Fig.6-19:

Motor type plate data

Determining Motor and Motor Control Parameters for Motors Without

Motor Encoder Data Memory

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In addition to collecting or determining the motor and motor control
parameters, further data on measuring system, temperature sen
sor, motor temperature model, motor holding brake and, if neces
sary, position and velocity loop are required.
See "Closed-Loop Axis Control (Closed-Loop Operation)"
See "Notes on Commissioning" in section "Third-Party Motors at
IndraDrive Controllers"
Pertinent Parameters

Pertinent Diagnostic Messages

P00565, C3600 Command Motor data identification

P00566, C4600 Command Calculate motor control parameters

P04032, Motor type plate data

P04033, C3200 Command Calculate motor data

C3200Command Calculate motor data

C3201Incorrect input for current

C3202Incorrect input for voltage

C3203Incorrect input for frequency

C3204Incorrect input for speed

C3205Incorrect input for power factor

C3206Incorrect input for power

C3207Type plate list incomplete

C3208 Error when writing parameters (->S-0-0423)

C3600 Command Motor data identification

C3601 Motor not or not correctly connected

C3602 Determined values invalid

C3603 Device current limit too low

C3604 Error when writing parameters (->S-0-0423)

C3605 Motor turning

C3606 Type of construction of motor not allowed

C4600 Command Calculate motor control parameters

C4601 Error when writing parameters (->S-0-0423)

Overview of Motor and Motor Control Parameters

Motor Parameters

The table below contains an overview of the motor parameters for synchronous
and asynchronous motors:
Motor parameters

Synchronous motor

Asynchronous motor

P04014, Type of construction of motor

P04014, Type of construction of motor

S00109, Motor peak current

S00109, Motor peak current

S00111, Motor current at standstill

S00111, Motor current at standstill

S00113, Maximum motor speed

S00113, Maximum motor speed

P00018, Number of pole pairs/pole pair distance

P00018, Number of pole pairs/pole pair distance

P00051, Torque/force constant

P00051, Torque/force constant

P00510, Rotor inertia

P00510, Rotor inertia

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Motor parameters
Synchronous motor

Asynchronous motor

P04048, Stator resistance

P04048, Stator resistance

P04013, Current limit value of demagnetization

P00530, Slip increase

P04016, Direct-axis inductance of motor

P04004, Magnetizing current

P04017, Quadrature-axis inductance of motor

P04036, Rated motor speed

P04002, Charact. of quadrature-axis induct. of motor,

inductances

P04039, Stator leakage inductance

P04003, Charact. of quadrature-axis inductance of motor,

currents

P04040, Rotor leakage inductance

P04005, Flux-generating current, limit value

P04041, Motor magnetizing inductance

P04042, Characteristic of motor magnetizing inductance
P04043, Rotor time constant

Fig.6-20:
Motor Control Parameters

Overview of Motor Parameters for Synchronous and Asynchronous Mo

tors

The following tables contain an overview of the motor control parameters for
synchronous and asynchronous motors that are used for field-oriented current
control (with and without encoder) and voltage-controlled operation:

Motor control parameters for voltage-controlled operation (U/f)

Synchronous motor

Asynchronous motor
S00106, Current loop proportional gain 1
S00107, Current loop integral action time 1
P00532, Premagnetization factor
P00568, Voltage boost
P00569, Maximum stator frequency slope
P00570, Stall protection loop proportional gain
P00571, Stall protection loop integral action time
P00572, Slip compensation factor
P00573, IxR boost factor
P00574, Oscillation damping factor
P00575, Search mode: search current factor
P00576, Search mode: finding point slip factor
P00577, Square characteristic: lowering factor

Fig.6-21:

Overview of Motor Control Parameters for Synchronous and Asynchro

nous Motors and Voltage-Controlled Operation (U/f)

Motor control parameters for field-oriented current control (FOC)

Synchronous motor

Asynchronous motor

S00106, Current loop proportional gain 1

S00106, Current loop proportional gain 1

S00107, Current loop integral action time 1

S00107, Current loop integral action time 1

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Motor control parameters for field-oriented current control (FOC)
Synchronous motor

Asynchronous motor

P00533, Voltage loop proportional gain

P00533, Voltage loop proportional gain

P00534, Voltage loop integral action time

P00534, Voltage loop integral action time

P00535, Motor voltage at no load

P00535, Motor voltage at no load

P00536, Maximum motor voltage

P00536, Maximum motor voltage

P00528, Flux control loop proportional gain
P00529, Scaling of stall current limit
P00532, Premagnetization factor

Fig.6-22:

Overview of Motor Control Parameters for Synchronous and Asynchro

nous Motors and Field-Oriented Current Control (FOC)

Motor control parameters for sensorless motor operation, flux-controlled (FXC)

Synchronous motor

Asynchronous motor
P00532, Premagnetization factor
P00578, Current for deceleration, absolute value
P00579, Current for deceleration, time period
P00593, FXC: Total flux loop proportional gain
P00594, FXC: Total flux loop integral action time
P00595, FXC: Frequency loop proportional gain
P00596, FXC: Frequency loop scaling factor of inertia
P00597, FXC: Current loop proportional gain
P00598, FXC: Current loop integral action time
P00599, FXC: Slip frequency filter time constant
P00600, FXC: Rated slip frequency

Fig.6-23:

Overview of Motor Control Parameters for Synchronous and Asynchro

nous Motors and Sensorless, Flux-Controlled Motor Operation (FXC)

Determining the Parameter Values by Means of Type Plate Data

Command "Calculate Motor Da
ta" (C3200)

For asynchronous motors it is possible via "C3200 Command Calculate motor

data" to calculate the values for motor parameters from the type plate data and
then the values of the motor control parameters. The activation of C3200 first
requires manual input of the motor data from the type plate of the asynchronous
motor in "P04032, Motor type plate data".
See description of "P04032, Motor type plate data"
The command C3200 can only be used for asynchronous motors
and can only be activated in communication phases "P2" or "P3"!
The figure below illustrates the scope of functions of the command C3200:

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Fig.6-24:

Functions of "C3200 Command Calculate Motor Data"

The type plate does not contain the complete information required
for safe operation of the third-party motor!
All required data are part of the form of manufacturer-side motor
data which has to be available in completed form. The additional
data, however, are not required for executing the command C3200.
Internally Calculated Parameter
Values

By activating the command C3200 (P04033), the following parameter values

are calculated from the data of the asynchronous motor entered in list param
eter P04032:

Notes on Operating Principle

Motor parameters

Motor parameters, general

Specific motor parameters for asynchronous motors

Motor control parameters

Motor control parameters for voltage-controlled operation (U/f) of

sensorless asynchronous motors

Motor control parameters for field-oriented current control (FOC) of

asynchronous motors

Motor control parameters for flux-controlled operation (FXC) of asyn

chronous motors without encoder

As regards the operating principle of the command C3200, observe the follow
ing points:

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The input in P04032 is irrelevant unless the command C3200 has been
started.

When the command was processed without error, the calculated values
of motor and motor control parameters are operational.

Identifying and Optimizing the Motor Parameter Values

"Command Motor Data Identifica
tion" (C3600)

For asynchronous motors it is possible via "C3600 Command Motor data

identification" to automatically identify and optimize the optimum motor and
motor control parameters on the basis of appropriate start values.
The command C3600 can only be used for asynchronous motors
and can only be activated in the operating mode (communication
phase "P4")!
The figure below illustrates the scope of functions of the command C3600:

Fig.6-25:
Requirements

Functions of "C3600 Command Motor Data Identification"

To execute the command C3600, the following requirements must have been
fulfilled:

Manual input of motor data from type plate in "P04032, Motor type plate
data" and then execution of "C3200 Command Calculate motor data"
- or -

Procedure

Manual input of all motor data in the motor parameters according to man
ufacturer's specification in completed motor data form

In status "ready for power output" ("Ab"), current and voltage test signals are
transmitted to the motor with the execution of command C3600. In this way, the
motor parameters for asynchronous motors (see above) are checked and, if
necessary, optimized.
A possibly available holding brake continues remaining in the status of control
as existing in the operating status "Ab".
After having successfully completed the command execution, the motor and
motor control parameters have been optimized and stored.
The following parameters have been recalculated:

Motor control parameters for voltage-controlled operation (U/f) of sensor

less asynchronous motors

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Notes on Operating Principle

Motor control parameters for field-oriented current control (FOC) of asyn

chronous motors

Motor control parameters for flux-controlled operation (FXC) of asynchro

nous motors without encoder

As regards the operating principle of the command C3600, observe the follow
ing points:

Motor motion is not required; the motor holding brake possibly applied at
"Ab" remains applied. The motor does not generate torque. With little fric
tion and inertial mass, little motion can however occur!

When the command was processed without error, the calculated values
of motor and motor control parameters are operational. If the command
execution is aborted during the measurement, all motor and motor control
parameters remain unchanged.

Calculating the Motor Control Parameters From the Motor Parameters

Command "Calculate Motor Con
trol Parameters" (C4600)

For synchronous motors and in special cases (see Requirements) for asyn
chronous motors it is possible via "C4600 Command Calculate motor control
parameters" to calculate the motor control parameters from the motor param
eters.
The command C4600 can only be activated in the operating mode
(OM)!
Communication phase P4 ("bb" or "Ab")
The figure below illustrates the scope of functions of the command C4600:

Fig.6-26:
Requirements

Function of "C4600 Command Calculate Motor Control Parameters"

To execute the command C4600, the following requirements must have been
fulfilled:

Synchronous third-party motors require manual input of the motor data in

the motor parameters (see "Third-Party Motors at IndraDrive Control
lers").

For asynchronous third-party motors the command C4600 is only useful,

if the motor control parameters are to be generated from specific, manually
input motor parameters (e.g. from equivalent circuit diagram data, see
"Third-Party Motors at IndraDrive Controllers"). The calculated values for
the motor control parameters thereby might possibly be more exact! It is
easier, however, to use the commands C3200 and C3600 (see above) for
asynchronous motors.

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Notes on Operating Principle

As regards the operating principle of the command C4600, observe the follow
ing points:

When the command was processed without error, the calculated values
of motor and motor control parameters are operational.

6.3

Open-Loop Axis Control (Open-Loop Operation)

6.3.1

Brief Description
In operation without encoder (open-loop operation) the velocity control loop is
not closed in the drive, but the drive is operated in a velocity-controlled way
(without feedback) via open-loop U/f control.
The method of open-loop/closed-loop motor control can be selected
via bit 14 of "P00045, Control word of current controller".
See also section "Motor Control"

Fig.6-27:
Features

Principle of Drive Control in Open-Loop Operation

The velocity control has the following features:

Fine interpolation of the velocity command value (can be switched off)

Monitoring of the velocity control loop is possible (can be switched off via
P00556; bit 1)

Parameterizable filtering of the actual velocity value

Additive velocity command value (S00037)

Display of the resulting command value (in P00048)

Monitoring and limitation of the maximum stator frequency slope that re

sults from the command velocity change

Stall protection loop (PI loop that can be optionally activated to prevent
breakdown of the machine when the torque limits are attained)

Slip compensation (feedforward of estimated slip of the machine by means

of rotor time constant and slip compensation factor)

Calculation of output voltage by means of U/f characteristic based on mo

tor model data

Subsequent trimming of magnetization via premagnetization factor (linear

or square characteristic to be selected)

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Pertinent Parameters

Pertinent Diagnostic Messages

S00091 Exceeded

IxR Boost (adjustable load-dependent feedforward of the output voltage

due to the voltage drop on the motor winding resistance

Oscillation damping (adjustable load-dependent feedforward to prevent

velocity oscillations in the partial load and idling ranges)

Current limitation loop to protect the output stage

Velocity search mode of a coasting machine after switching drive enable

on (can be set for one or both rotational directions)

S00037, Additive velocity command value

S00040, Velocity feedback value

S00091, Bipolar velocity limit value

P00048, Effective velocity command value

P00049, Effective torque/force command value

P00555, Status word of axis controller

P00556, Config word of axis controller

F8079 Velocity limit value exceeded (S00091)

6.4

Closed-Loop Axis Control (Closed-Loop Operation)

6.4.1

General Information on Closed-Loop Axis Control

Control Loop Structure

The drive controller has a so-called cascade structure, i.e. the individual loops
(position, velocity and current) are interconnected. Depending on the operating
mode there are different control loop structures with different points of input and
paths of the command values. Depending on the active mode of operation, only
the torque control loop, the torque control loop and the velocity control loop or,
in addition to these two control loops the position control loop can be closed in
the drive.
The structure and the interaction of the control loops are illustrated in the two
graphics in the section "Overview of Drive Control" (see "Control Loop Structure
with Setting Parameters" or "Control Loop Structure with Display Parame
ters").

Features of the Control Loops

For the simplification of the parameterization of the control loops and for an
increase in performance, a number of standardizations and structural changes
have been carried out.
Performance (Controller Cycle
Times)

The internal controller cycle times (current, velocity and position) depend on
the following conditions and parameters:

Control section design (CSH, CSB or CDB)

Activation of the functional packages

P00001, Switching frequency of the power output stage

P00556, Config word of axis controller (bits 2 and 5)

Depending on these factors, the following cycle and switching times can be
achieved:

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ADVANCED control BASIC control sec
sections
tions
PWM switching frequency

max. 16 kHz

max. 8 kHz

Current loop clock (TA_current)

62.5 s

125 s

Velocity loop clock (TA_velocity)

125 s

250 s

Position loop clock (TA_position)

250 s

500 s

Fig.6-28:

Cycle and Switching Times to be Achieved With IndraDrive

All data about performance are summarized in the section "Per

formance Data" .
Position Loop

Velocity Loop

Jerk limitation in operation mode "cyclic position control" by introduction

of "S00349, Bipolar jerk limit". The filtering degree of the smoothing filter
(moving average value) can be set in "P00042, Current position
command average value filter order".

Velocity feedforward, i.e. degree of feedforward, to be set via "P00040,

Velocity feedforward evaluation" (0% ... 100%)

Input calue for "S00348, Acceleration feedforward gain" can be the re

spective inertia in kg*m2 (for rotary motor) or the mass in kg (for linear
motor).

Standardization of the output value at the velocity loop to Newton (N) or

Nowton meter (Nm). Therefore, sepending on the motor type, the following
unit is obtained for S-0-0100 in IndraDrive:

Rotary motor Nm * s/rad

Linear motor N * min/mm

Possibility of extending the filter options for filtering the resonance fre
quencies. There are 4 filters of 2nd degree available that can be set via
P01120, P01121, P01122 and P01123.

Limiting the acceleration in velocity control by setting in "S00138, Bipolar

acceleration limit value"

Possibilities of Access to Included Control Loops

For operation in a higher-level mode of operation, it is possible to access an
included control loop. Depending on the basic mode of operation, the following
parameters are available:
In position control:

P00059, Additive position command value, controller

S00037, Additive velocity command value

S00081, Additive torque/force command value

In velocity control:

S00037, Additive velocity command value

S00081, Additive torque/force command value

In current control:

S00081, Additive torque/force command value

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S00037
S-0-0047
S00081
S00100
S00101
S00104
P00059

Fig.6-29:

Additive velocity command value

Position command value
Additive torque/force command value
Velocity loop proportional gain
Velocity loop integral action time
Position loop Kv-factor
Additive position command value, controller

Structural Overview With Access Options

Command Value Processing Depending on Operating Mode

Position Control

For the following modes of operation, the position control loop is closed inter
nally (in the drive) in addition to the velocity and the current control loops:

Position Control With Cyclic Command Value Input

Drive-Internal Interpolation

Drive-Controlled Positioning

See also description of the respective mode of operation

Velocity Control

In the "velocity control" mode, the velocity control loop, apart form the current
control loop, is closed in the drive, too.
See also "Velocity Control"

Torque/Force Control

The "torque/force control" mode actually is not torque or force control but cur
rent control. Therefore, only the current control loop is closed in the drive.
See also "Torque/Force Control"

6.4.2

Automatic Setting of Closed-Loop Axis Control

Brief Description
To facilitate drive parameterization, the IndraDrive firmware provides automatic
control loop setting in closed-loop operation. "P00163, Damping factor for
autom. controller setting" and "P00164, Application for autom. controller

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setting" can be used to influence the result of the control loop setting (obtained
control loop dynamics).
To carry out the automatic control loop setting, it is necessary to
move the drive. The velocity and position control loops are opti
mized.
Features

Definition of a travel range for movement control for the automatic control
loop setting by

Absolute position limits for the travel range

- or

Pertinent Parameters

Pertinent Diagnostic Messages

Entering a travel distance based on the current actual position

Use of drive-internal interpolation and its parameters

Possible settings in "P00165, Drive optimization, control word" can be

used for:

Velocity Loop

Position loop

acceleration feedforward

Determination of the load inertia

Determination of the maximum acceleration

Oscillation movement / unipolar movement

Absolute travel limits / relative movement around start position

P00162, C1800 Command Drive optimization / command value box

P00163, Damping factor for autom. controller setting

P00164, Application for autom. controller setting

P00165, Drive optimization, control word

P00166, Drive optimization, end position negative

P00167, Drive optimization, end position positive

P00168, Maximum acceleration to be parameterized

P00169, Drive optimization, travel distance

C1800 Command Drive optimization / command value box

C1801 Start requires drive enable

C1802 Motor feedback data not valid

C1803 Inertia detection failed

C1804 Automatic controller setting failed

C1805 Travel range invalid

C1806 Travel range exceeded

C1807 Determining travel range only via travel distance

E2049 Positioning velocity >= limit value (S00091)

E2055 Feedrate override S-0-0108 = 0

F2039 Maximum acceleration exceeded

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6.4.3

Velocity Loop (Including the Respective Filters)

Brief Description
In closed-loop operation, in addition to the field-oriented current controller, the
velocity control loop is also closed in the drive by means of the drive software
(PI cascade structure).
The controlled-loop operation (current and velocity) can be carried with encoder
for all types of motors and for asynchronous motors also without encoders.
The selection of the type of motor control is carried out by means
of "P00048, Control word of current controller" (bits 14, 15)

Fig.6-30:

Structure of the Velocity Loop

The following description is restricted to the velocity loop including

the respective options of filtration and feedforward. The processing
of the velocity command value is described within the operation
mode "Velocity control" .
Features

Digital PI controller with anti-windup function, can be set by means of the

following parameters:

S00100, Velocity loop proportional gain

S00101, Velocity loop integral action time

Setting can be carried out by

Executing the "load defaults procedure" function once

- or -

Manual optimization (see description below)

- or -

Automatic parameterization of the axis controller (see "Automatic

Setting of Axis Control").

Depending on the control performance which has been set, the cycle time
TA_velocity is used for velocity loop calculations (see "Performance Data").

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Pertinent Parameters

Pertinent Diagnostic Messages

Possibility of mixing the velocities of motor encoder and optional encoder

4 freely configurable filters of 2nd order (e.g. band-stop filters) for filtering
resonance frequencies

Moving average filter of the control loop deviation for a maximum of 16

controller clocks (as "feedback filter", in the case of low-resolution motor
measuring systems)

Low-pass filter to attenuate interference frequencies, to be set via

P-0-0004 (VZ1)

Fine interpolation of the command values of the position loop (can be

switched on by P00556, Bit 0)

Monitoring of the velocity control loop (can be switched off by P00556;

Bit 1)

Optional acceleration feedforward from the torque command value (with

filtering option)

S00037, Additive velocity command value

S00040, Velocity feedback value

S00081, Additive torque/force command value

S00084, Torque/force feedback value

S00091, Bipolar velocity limit value

S00100, Velocity loop proportional gain

S00101, Velocity loop integral action time

S00149, C1300 Positive stop drive procedure command

S00155, Friction compensation

S00164, Acceleration feedback value 1

S00347, Velocity error

P00004, Velocity loop smoothing time constant

P00048, Effective velocity command value

P00049, Effective torque/force command value

P00180, Acceleration feedforward smoothing time constant

P00451, Actual acceleration torque/force value

P00452, Actual process torque/force value

P00555, Status word of axis controller

P00556, Config word of axis controller

P01119, Velocity mix factor feedback 1 & 2

P01120, Velocity control loop filter: filter type

P01121, Velocity control loop filter: limit frequency of low pass

P01122, Velocity control loop filter: bandwidth of band-stop filter

P01123, Vel. cont. loop filter: center frequency of band-stop filter

P01126, Velocity control loop: acceleration feedforward

P02100, Velocity loop proportional gain, encoder memory

P02101, Velocity loop integral-action time, encoder memory

P03004, Speed loop smoothing time constant, encoder memory

E2059 Velocity command value limit active

E8260 Torque/force command value limit active

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6.4.4

F8078 Speed loop error

Position Loop (With Respective Feedforward Functions and Actual Val

ue Adjustment)

Brief Description
The following section only describes the position loop with the respective feed
forward possibilities (velocity and acceleration feedforward).

Fig.6-31:

Structure of the Position Loop

The preprocessing of the position command value (command value

adjustment) is described in the corresponding section of the posi
tion control mode (e.g. position control with cyclic command value
input, positioning block mode, ...).
Features

Digital proportional loop, can be set via the following parameter:

S00104, Position loop Kv-factor

Lag error is minimized by:

Variable velocity feedforward (see P00040)

- and -

Pertinent Parameters

Variable acceleration feedforward (see S00348), including smooth

ing filter

Depending on the control performance which has been set, the cycle time
TA_position is used for position loop calculations (see "Performance Data").

With lag error or lagless, i.e. with velocity feedforward

Model monitor for the lag error (see also F2028)

Possibility of evaluating a "hybrid actual position value" from motor en

coder and external position control encoder (up to now only motor encoder
and measuring wheel encoder)

S00032, Primary mode of operation

Bit 3 = 1 Activation of lagless operation

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Pertinent Diagnostic Messages

S00038, Positive velocity limit value

S00039, Negative velocity limit value

S00040, Velocity feedback value

S00048, Additive position command value

S00051, Position feedback value 1

S00053, Position feedback value 2

S00091, Bipolar velocity limit value

S00092, Bipolar torque/force limit value

S00104, Position loop Kv-factor

S00189, Following distance

S00348, Acceleration feedforward gain

S00386, Active position feedback value

S00520, Control word of axis controller

00521, Status word of position loop

P00040, Velocity feedforward evaluation

P00048, Effective velocity command value

P00049, Effective torque/force command value

P00059, Additive position command value, controller

P00109, Torque/force peak limit

P00180, Acceleration feedforward smoothing time constant

P00241, Actual pos. smoothing time constant for hybrid pos. control

P00434, Position command value of controller

P00454, Velocity feedforward actual value

P00455, Acceleration feedforward actual value

P00556, Config word of axis controller

P00691, Additive position command value, process loop

F2028 Excessive deviation

F2036 Excessive position feedback difference

F2037 Excessive position command difference

6.5

Commutation Setting

6.5.1

Basics on Commutation Setting

Brief Description
The following Rexroth kit motors are manufactured according to the "synchro
nous motor" functional principle:

Linear motor MLF

Rotary motors MBS and MBT

As the motor is assembled in the machine, stator, rotor and measuring system
cannot be put together by the manufacturer. The customer will make the elec
tric-magnetic-mechanical allocation of the synchronous motor on site by deter
mining and setting the commutation offset.
The same applies for the Rexroth housing motor MSP.

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Measuring Systems for Synchro
nous Rexroth Motors

Absolute measuring systems should ideally be used for synchronous Rexroth

kit motors. The advantage in this case is the absolute position detection of the
rotor position which immediately ensures, when drive enable is set, the correct
assignment of current in the primary part to the magnetic field in the secondary
part. This is realized by the commutation offset stored at initial commissioning.
For some applications it is necessary to use relative measuring systems, be
cause the available length of absolute measuring systems is limited, for exam
ple. The disadvantage in this case is that absolute detection of the rotor position
is impossible. It is therefore necessary, after each time the drive is switched on
again or after having changed the communication phase from "P2"to
"P4" ("bb" or "Ab"), to set the commutation offset again. For linear motors, this
disadvantage can be removed by using the Hall sensor box SHL01.1, because
with regard to commutation setting the relative motor encoder then behaves
like an absolute measuring system.
If you use a relative motor encoder, using the Hall sensor box
SHL01.1 is absolutely recommended for linear motors! In this way,
you achieve highest safety with regard to correct motor function and
compliance with the power data!

Measuring Systems for Synchro

nous Third-Party Motors

Overview of the Synchronous Mo

tors to be Used for Motor Measuring
Systems

Concerning operationally reliable drives with synchronous third-party motors

and IndraDrive controllers, there are, with regard to the selected measuring
system, the same principles applying as to synchronous Rexroth kit motors (see
above); the Hall sensor box SHL, however, cannot be used for linear third-party
motors!
Motor measur
ing system

Synchronous
Rexroth kit
motor
(rotary, linear)

Absolute

--

Relative

+
o
--

Fig.6-32:

Synchronous Rexroth Synchronous thirdkit motor (linear) with

party motor
SHL01.1

Advantageous combination
Combination possible, initial commissioning might possibly require es
pecially trained staff
Combination not useful

Possible Combinations of Motor Measuring System and Synchronous

Motors for Which Commutation Setting is Required

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The measuring system should be realized with high resolution and
as a motor encoder to be evaluated in absolute form. If it is neces
sary to use a relative measuring system, you should avoid using
encoders with square-wave signals!
For synchronous motors in combination with a motor encoder which
can be evaluated in absolute form, the advantage of setting the
commutation offset only once (see above) can only be used with an
encoder gear with i = 1 or when there is no encoder gear available!
As of MPx06V08
In special cases a motor encoder to be evaluated in absolute form
encoder gear can use the one-time setting of the commutation off
set (rotary encoders, only).
There are 2 cases to be distinguished:

Case 1, single-turn or (multi-turn) encoder:

If n-fold motor revolution (n integral) causes exactly one en
coder rotation

Case 2, multi-turn encoder:

If exactly one motor rotation causes m-fold encoder rotation
(m integral)

See also "Absolute Measuring Systems" and "Mechanical Axis Sys

tem and Arrangement of Measuring Systems"
Pertinent Parameters

Pertinent Diagnostic Messages

Apart from the motor parameters (see parameter overview in "Basics on the
Motors to be Controlled), " there are further parameters available for commu
tation setting:

P00506, Amplitude for angle acquisition

P00507, Test frequency for angle acquisition

P00508, Commutation offset

P00517, Commutation: required harmonics component

P00518, C5600 Command subsequent optimization of commutation

offset

P00521, Effective commutation offset

P00522, Control word for commutation setting

P00523, Commutation setting measured value

P00524, C1200 Commutation offset setting command

P03008, Commutation offset, encoder memory

C1200 Commutation offset setting command

C1204 Error in offset calculation

C1208 No adjustment with asynchronous motor

C1209 Proceed to phase 4

C1211 Commutation offset could not be determined.

C1214 Command only possible with linear synchronous motor

C1215 Command only possible in 'bb'

C1216 Commutation determination not selected

C1217 Setting only possible in 'Ab'

C1218 Automatic commutation: Current too low

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C1219 Automatic commutation: Overcurrent

C1220 Automatic commutation: Timeout

C1221 Automatic commutation: Iteration without result

C1222 Error when writing offset parameters

C5600 Command subsequent optimization of commutation offset

C5601 Command requires drive enable

C5602 Axis blocked

C5603 Timeout: Axis in motion

F2032 Validation error during commutation fine adjustment

F8010 Autom. commutation: Max. motion range when moving back

F8011 Commutation offset could not be determined

F8012 Autom. commutation: Max. motion range

F8013 Automatic commutation: Current too low

F8014 Automatic commutation: Overcurrent

F8015 Automatic commutation: Timeout

F8016 Automatic commutation: Iteration without result

Overview of Methods for Determining the Commutation Offset

Methods for Determining the Com
mutation Offset

The commutation offset can be determined with different methods. The method
is chosen in accordance with the axis geometry, the practicability and the chan
ces of success of the respective method depending on motor and mechanical
axis system.
The following methods are possible:

Calculation method
For relative motor encoder when using the hall sensor box (distance
measurement, currentless only possible with rexroth linear kit motors,
see documentation "Hall Sensor Box SHL01.1")

Measuring method
For motor encoder that can be evaluated in absolute form (distance
measurement, currentless only possible with Rexroth linear kit motors)

Saturation method (axis needs to be blocked or at standstill, with current)

Possible with all types of construction in combination with motor en
coders that can be evaluated in absolute form and with relative motor
encoders; but see "restrictions for saturation method" in table below

Sine-wave method (requires unrestricted movement of axis, with current)

Possible with all types of construction in combination with motor en
coders that can be evaluated in absolute form and with relative motor
encoders; but see "restrictions for sine method" in table below

Recommendations for selecting the determination method:

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Determination method
Calculation method
(with Hall sensor box)

Measuring meth
od

Saturation method

Sine-wave meth
od

Relative, linear

Absolute, linear

Absolute/relative

Absolute/relative

--

--

--

--

MBTxx0

--

--

MBTxx1

--

--

MLF

MSP

--

--

Motor type

Measuring system
used

MBSxx0
MBSxx2
(high speed)

+
o
--

Fig.6-33:

Recommended method
Method not recommended
Method not possible

Recommendations for Selecting Determination Method for Commuta

tion Offset Depending on Motor Type (for Rexroth Motors)

The sine-wave method (generally requires unrestricted movement

of axis) should only be used if the saturation method cannot be
used!
Restrictions for saturation method

Applications of synchronous motors

Restrictions for saturation method

Third-party motors without or with only little

saturation effects

Saturation method cannot be used for

determining commutation offset!

Applications with relative measuring system Max. torque/force can be reduced by

(without using the optimum commutation off approx. 15% compared to the optimum
set value with regard to the reference point) value (autom. Determining the Com
mutation Offset for "AF")!
Applications with relative measuring system
that are using the optimum commutation off
set value with regard to the reference point

Max. torque/force until reference mark

is passed can be reduced by approx.
15%!

Drives that can be in motion during the deter Saturation method only possible for
mination of the commutation offset, e.g.
motors in standstill!
coasting spindles, printing roller drives etc.
Drives with a low degree of overload capacity Saturation method only possible if am
plifier current is sufficiently high (2...4fold continuous motor current re
quired)!

Fig.6-34:

Typical Applications and Restrictions for Saturation Method

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Restrictions for Sine-Wave Method

Applications of synchronous motors

Restrictions for sine-wave method

Linear axis with single motor or parallel motor Only balanced (e.g. horizontal) axes
with little friction!
Linear axes in Gantry arrangement

Only balanced (e.g. horizontal) axes

with little friction! In addition, both
drives have to carry out sequential
commutation settings, "AF" then must
not be active at the other drive!

Rotary axes with single drive

Only balanced axes with little friction;

high inertia can cause problems!

Rotary axes, mechanically connected

See above "Linear Axes in Gantry Ar

rangement"!

Fig.6-35:
Significance of Commutation Offset

Typical Applications and Restrictions for Sine-Wave Method

A synchronous motor can only generate the torque or the force specified ac
cording to motor data, when the commutation offset is correct. If the value for
the commutation offset is incorrect, lower action torque / force is to be expected;
a highly incorrect value implies the danger of the motor having a "runaway ef
fect".
Therefore, "P00521, Effective commutation offset" is write-protected. For in
itial commissioning of Rexroth kit motors, however, it is required to allow writing
of P00521 in order to set and optimize the value, if necessary. The initial
commissioning mode must be activated for this purpose (see "P00522,
Control word for commutation setting"). During the initial commissioning of the
motor, you have to determine the commutation offset value with due diligence.
For synchronous Rexroth motors with integrated motor encoder
(MSK, MHD, MKD, MKE motors), it is not necessary to set the com
mutation offset! The correct value is provided in the motor encoder
data memory and is automatically activated.
Depending on the motor encoder used, you have to determine the commutation
offset for the following situations:

With absolute motor encoder only during initial commissioning of the drive

With relative motor encoder both during initial commissioning and each
time the drive has been switched on (recommissioned)
Deviating values when determined again (recommissioning with
relative motor encoder) can occur, this can cause deviating drive
behavior (remedy: "optimum commutation offset with regard to ref
erence point", see below)!

6.5.2

Commutation Setting for Rexroth Motors MLF

Brief Description
Linear Rexroth kit motors of the MLF and LSF lines are manufactured according
to the "synchronous motor" functional principle. For kit motors, the motor com
ponents stator, rotor and measuring system are finally assembled on the
customer side in the machine.
With Absolute Motor Encoder

The electric-magnetic-mechanical allocation of the synchronous motor there

fore can only be made on site by determining and setting the commutation
offset. This is done once during initial commissioning of the motor, if it has been
equipped with a motor encoder to be evaluated in absolute form.

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With Relative Motor Encoder

When a relative motor encoder is used, it is necessary to determine the com

mutation offset again each time after the drive was switched off.
Deviating commutation offset values when determined again (recommissioning
with relative motor encoder) can occur, this can cause deviating drive behavior.
To avoid this, it is recommended that you use the Hall sensor box SHL01.1
which was developed for linear Rexroth motors.

Hall Sensor Box SHL01.1

The Hall sensor box SHL01.1 is an absolute measuring system within one pole
pair distance of linear Rexroth motors. Via the signals of the Hall sensors, the
controller detects the position of the motor windings compared to the magnetic
field of the motor; therefore, the commutation setting is only required during
initial commissioning. When the drive is recommissioned, the correct commu
tation offset is already available at drive enable ("AF").

1
2
3

Fig.6-36:

secondary part
Primary part
Hall sensor box SHL

Linear Rexroth Motor With Hall Sensor Box SHL

For information on mounting and connection see the documentation on Hall

Sensor Box SHL01.1.

6.5.3

Saturation Method

Brief Description
For rotary synchronous Rexroth kit motors, IndraDrive controllers only provide
methods with current to determine the commutation offset. The saturation
method is one of these methods; when it is used, "motor standstill is necessa
ry". A possibly available holding brake should remain applied!
For synchronous Rexroth motors with integrated motor encoder
(MSK, MHD, MKD, MKE motors), it is not necessary to set the com
mutation offset! The correct value is provided in the motor encoder
data memory and is automatically activated.
The saturation method can also be used for linear synchronous Rexroth kit
motors, if they have only been equipped with a relative measuring system
(without Hall sensor box SHL), and for motors with an absolute measuring sys
tem for which distance measurement at the axis is impossible due to the
mounting.
As a prerequisite for successful application of the saturation method, the iron
material of the motor must be magnetically saturated when current is supplied,
i.e. the controller must be able to provide sufficiently high current to the motor.
For synchronous motors which are not magnetically saturated at maximum al
lowed current, this method is unsuited for determining the commutation offset!
If the saturation method cannot be used, the controller provides the
sine-wave method (works with current, too) for determining the
commutation offset.

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When the requirements have been fulfilled, the saturation method can be used
both for initial commissioning and for recommissioning.
The restrictions to be observed when using the saturation method
are described in the "Basics on Commutation Setting". This section
outlines the different methods which can be used for determining
the commutation offset.

6.5.4

Sine-Wave Method

Brief Description
For synchronous motors, IndraDrive controllers, in addition to the saturation
method, provide the sine-wave method, also with current, to determine the
commutation offset. When this method is used, "unrestricted movement of axis
is required". The axis must be able to move easily and freely!
Before using the sine-wave method, carefully check whether it is possible to
use the saturation method, because unrestricted movement of the axis gener
ally causes problems. For the saturation method movement of axis is not
necessary, it should be blocked, if possible.
When the requirements have been fulfilled, the sine-wave method is suited to
only a limited extent for initial commissioning and for recommissioning.
The restrictions to be observed when using the sine method are
described in the "Basics on Commutation Setting". This section
outlines the different methods which can be used for determining
the commutation offset.

6.6

Limitations

6.6.1

Overview of Limitations
To protect the mechanical axis system, the controllers and the motors against
overload, IndraDrive devices have different possibilities of limitation:

Torque/Force Limitation

Axis-side torque/force limit values, depending on the preceding sign

Axis-side torque/force limit values, related to the absolute value (in

dependent of the preceding sign)

Current limitation

Absolute current limit values, depending on controller or motor

Dynamic current limitation, depending on the thermal load of con

troller or motor

Velocity limitation

Motor-side velocity limit values

Axis-side velocity limit values

Position limitation

Evaluation of axis-side travel range limit switches

Firmware-side travel range limit values

The existing limiting facilities are active depending on the method of motor
control.

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Voltage-Controlled Open-Loop Op
eration (U/f Control)

Closed-Loop Operation of Motors

(FXC, FOC, FOCsl)

6.6.2

With voltage-controlled, sensorless operation, the following limitations are

available to protect the device or motor:

Torque/force limitation via stall protection loop

Current limitation via current limitation loop

Position limitation by

Travel range limit switches

Software limit switches

In closed-loop operation (flux-controlled or current-controlled), there are the

following parameterizable limitations to protect the device or motor:

Torque/force limitation

Current limitation

Velocity limitation

Position limitation by

Travel range limit switches

Software limit switches

Current and Torque/Force Limitation

Brief Description
Current limitation and torque/force limitation avoid mechanical overload of the
axis and thermal overload of motor and controller.
Torque/force limit values due to axis conditions and processing take effect stat
ically as positive and negative limits of the torque/force command value. The
thermal overload protection might possibly reduce these limits dynamically,
depending on the current thermal load of motor and controller.
Features

User-side limit values for torque/force (drive-internally converted to cur

rent limit values):

Bipolar limit values (S-0-0092, P-0-0109)

Unipolar limit values (S-00082, S00083)

Display of current torque/force command value in "P-0-0049, Effective

torque/force command value"

Display of process torque resp. process force in "S-0-0084, Torque/force

feedback value"

Absolute current limit values on the drive-side in "S-0-0110, Amplifier peak

current" and "S-0-0109, Motor peak current"

Dynamic current limitation depending on work load reduces maximum

current to the thermally allowed continuous current on the basis of motor
and amplifier temperature model (depending on motor type and possibly
selected cooling type, as well as on PWM frequency and amplifier type);
currently available maximum current and thermally possible continuous
current displayed in the parameters:

P-0-4045, Maximum possible continuous current

P-0-4046, Effective peak current

Resulting torque/force limit values from the user-side torque/force limita

tions and the (dynamic) current limitation depending on work load are
displayed in the parameters:

P-0-0442, Actual value torque limit positive (stationary)

P-0-0443, Actual value torque limit negative (stationary)

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Status word for analysis of the currently active torque/current limitation

(P00445)

Display of effective torque-generating current command value ("limited"

current command value) in parameter

Pertinent Parameters

Pertinent Diagnostic Messages

P-0-0444, Actual value peak torque limit

P-0-0038, Torque-generating current, command value

Display of actual current values in the parameters

P-0-0440, Actual output current value (absolute value)

P-0-0043, Torque-generating current, actual value

P-0-0044, Flux-generating current, actual value

S-0-0082, Torque/force limit value positive

S-0-0083, Torque/force limit value negative

S-0-0092, Bipolar torque/force limit value

S-0-0109, Motor peak current

S-0-0110, Amplifier peak current

S-0-0111, Motor current at standstill

S-0-0112, Amplifier nominal current

S-0-0384, Amplifier temperature

P-0-0001, Switching frequency of the power output stage

P-0-0038, Torque-generating current, command value

P-0-0049, Effective torque/force command value

P-0-0051, Torque/force constant

P-0-0109, Torque/force peak limit

P-0-0141, Thermal drive load

P-0-0440, Actual output current value (absolute value)

P-0-0441, Overload warning

P-0-0442, Actual value torque limit positive (stationary)

P-0-0443, Actual value torque limit negative (stationary)

P-0-0444, Actual value peak torque limit

P-0-0445, Status word torque/current limit

P-0-0556, Config word of axis controller

P-0-0640, Cooling type

P-0-4034, Thermal time constant of winding

P-0-4035, Thermal time constant of motor

P-0-4037, Thermal short-time overload of winding

P-0-4045, Maximum possible continuous current

P-0-4046, Effective peak current

P-0-4058, Amplifier type data

P-0-4059, Electric type data of power section

E2050 Device overtemp. Prewarning

E2051 Motor overtemp. prewarning

E2056 Torque limit = 0

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E2061 Device overload prewarning

E8055 Motor overload, current limit active

E8057 Device overload, current limit active

F2018 Device overtemperature shutdown

F2019 Motor overtemperature shutdown

F2021 Motor temperature monitor defective

F2022 Device temperature monitor defective

Torque/Force Limitation
The torque/force limit can be freely parameterized by the user and provides
bipolar and unipolar limits.
Parameters for bipolar limits:

S-0-0092, Bipolar torque/force limit value

P-0-0109, Torque/force peak limit

Parameters for unipolar limits:

S-0-0082, Torque/force limit value positive

S-0-0083, Torque/force limit value negative

It is always the lowest value of the torque/force limit values entered
in S00082, S00083, S00092 or P-0-0109 that takes effect!

Depending on the method of motor control, the torque/force limitation influences

the control of the motor in different ways.
Motor Control Methods
FOC, FOCsl, FXC

In closed-loop motor operation, the unipolar torque limitation takes effect on the
torque command value output by the velocity loop. The bipolar torque/force
limitation takes effect on the value limited in unipolar form, including possibly
added feedforward values.
In addition to the user-side static limit values, the current limitation takes effect
dynamically, via "P-0-4046, Effective peak current" on the resulting torque/force
limit values (converted via "P-0-0051, Torque/force constant").

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S-0-0081
S-0-0082
S-0-0083
S-0-0092
S-0-0155
P-0-0038
P-0-0049
P-0-0051
P-0-0109
P-0-0442
P-0-0443
P-0-0444
P-0-0455
P-0-4046

Fig.6-37:

U/f Control

Additive torque/force command value

Torque/force limit value positive
Torque/force limit value negative
Bipolar torque/force limit value
Friction compensation
Torque-generating current, command value
Effective torque/force command value
Torque/force constant
Torque/force peak limit
Actual value torque limit positive (stationary)
Actual value torque limit negative (stationary)
Actual value peak torque limit
Acceleration feedforward actual value
Effective peak current

Torque/Force Limitation With the Motor Control Methods FOC, FOCsl

and FXC

In voltage-controlled, sensorless motor operation (U/f), the torque limitation

only takes effect on the stall protection loop. The static negative and positive
torque limit values are generated from the lowest values of the torque/force limit
values entered in S00082, S00083, S00092 or P-0-0109 .
In addition to the user-side static limit values, the current limitation takes effect
dynamically, via "P-0-4046, Effective peak current" on the resulting torque/force
limit values (converted via "P-0-0051, Torque/force constant").

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S-0-0040
P-0-0048
P-0-0051
P-0-0442
P-0-0443
P-0-4046

Fig.6-38:

Velocity feedback value

Effective velocity command value
Torque/force constant
Actual value torque limit positive (stationary)
Actual value torque limit negative (stationary)
Effective peak current

Torque/Force Limitation in Sensorless U/f Operation of the Motor

Current Limitation
Principles of Current Limitation
The current limitation cannot be parameterized by the user; it takes
effect automatically and protects the motor and the amplifier against
inadmissible load.
We basically distinguish the following principles of current limitation:

Absolute current limitation (depending on maximum possible peak cur

rents and continuous currents of motor and drive controller)

Dynamic peak current limitation (depending on work load, realized by mo

tor and amplifier temperature models)

Absolute Current Limitation

The figure below illustrates the generation of the maximum values for continu
ous current and peak current from the motor- and controller-specific current
data (without thermal load of motor and controller).

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S-0-0111
P-0-0001
P-0-0640
P-0-4045
P-0-4046

Fig.6-39:

Maximum Possible Continuous

Current (P-0-4045)

Motor current at standstill

Switching frequency of the power output stage
Cooling type
Maximum possible continuous current
Effective peak current

Generating the Maximum Values for Continuous Current and Peak Cur
rent

The maximum possible continuous current (P-0-4045) is the minimum value

from the maximum allowed continuous current of the controller and the motor,
with the following dependencies:

The continuous current of the controller depends on the switching fre

quency of the power output stage (P-00001).

The continuous current of the motor depends on the motor current at

standstill (S0-0111); for motor with variable cooling type (MSK, MHD,
MKD), it additionally depends on the realized cooling type and the corre
sponding setting in "P-0-0640, Cooling type".

Continuous Current of the Control

ler

The continuous current of the controller basically depends on the switching

frequency of the power section. With a setting of 12 kHz or 16 kHz in P-00001,
the currently effective switching frequency can be reduced depending on the
work load. This increases the allowed continuous current compared to the value
at higher switching frequency (see below "Continuous Current of Controller
Depending on Work Load at PWM of 12 kHz or 16 kHz").

Continuous Current of the Motor

The continuous motor current is determined internally from the value of

"S-0-0111, Motor current at standstill" and the "cooling type factor". This factor
is selected in "P-0-0640, Cooling type" by a characteristic value, depending on
the motor type and possibly of the selected cooling type.

Cooling
type factor
S-0-0111

Fig.6-40:

see Parameter Description "P-0-0640, Cooling type"

Motor current at standstill

Internal Calculation of the Continuous Motor Current

The maximum possible continuous current (P0-4045) is the 1.15-fold value of

the continuous motor current, if the continuous current of the controller (power
section) allows this.
Effective Peak Current (P-0-4046)

The output current of the controller us dynamically limited, depending on the

thermal load of the motor or controller. The current limit value is displayed in
"P-0-4046, Effective peak current". The maximum value results from the mini
mum of the values of "S-0-0109, Motor peak current" and "S-0-0110, Amplifier
peak current".

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Dynamic Current Limitation

With dynamic current limitation, the thermal load of controller and motor is de
termined by means of temperature model calculation, depending on the value
in "P-0-0440, Actual output current value (absolute value)" and the duration of
effectiveness of this current. Due to the current load, the maximum possible
amplifier current or motor current can be limited to the continuously possible
current (continuous current):

Limitation of amplifier current

It is used to protect the drive controller against overload. The firmwareside temperature model calculation takes place on the basis of the ampli
fier type data determined by the hardware.
Note: The Amplifier Type Data is Determined at the Factory and Stored in
"P-0-4058, Amplifier type data" on the Power Section.

Limitation of motor current

It is used for overload protection of the motor with peak load and shorttime overload operation. The firmware-side temperature model calculation
takes place on the basis of motor-specific temperature model data.
Note: In Addition, the Temperature Sensor of the Motor Might Possibly
Support Thermal Overload Protection (Continuous Current, rms Current).

S-0-0109
S-0-0111
P-0-0001
P-0-0440
P-0-0640
P-0-4034
P-0-4035
P-0-4037
P-0-4046
P-0-4058

Fig.6-41:
Properties

Motor peak current

Motor current at standstill
Switching frequency of the power output stage
Actual output current value (absolute value)
Cooling type
Thermal time constant of winding
Thermal time constant of motor
Thermal short-time overload of winding
Effective peak current
Amplifier type data

Generating the Dynamic Peak Current Limit Value (Temperature Model)

Basic properties of dynamic current limitation:

The value taking effect is always the lowest value resulting from motor
current or amplifier current limitation.

The currently maximum possible continuous current is displayed in

P04045, the effective peak current in P04046.

Depending on the method of motor control, the current limitation influences the
control of the motor in different ways.

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Motor Control Methods
FOC, FOCsl, FXC

In closed-loop motor operation, the current limitation, via the value of parameter
"P-0-4046, Effective peak current", possibly takes a reducing effect on the userside, static torque/force limit values. The dynamic torque/force limit value
resulting from the value of P-0-4046 is determined via the "P-0-0051, Torque/
force constant".
The current (limited) torque/force command value is displayed in P00049, the
corresponding torque-generating command current in parameter P-0-0038.

U/f Control

In voltage-controlled, sensorless motor operation (U/f), the current limitation

takes effect on the current limitation loop and the stall protection loop:

For the current limitation loop, the effective peak current (P04046) is the
limit value to which the actual output current value (P-0-0440) is limited by
reducing the motor voltage by means of a control process.

For the stall protection loop, the current limitation, in addition to the userside static limit values, takes effect dynamically via the effective peak
current (P04046) on the resulting positive and negative torque/force limit
values (P-0-0442, P-0-0443) (converted via "P-0-0051, Torque/force
constant").
The static negative and positive torque limit values are generated
from the lowest values of the torque/force limit values entered in
S00082, S00083, S00092 or P-0-0109 .

Motor Temperature Model

The value "P-0-4046, Effective peak current" is only generated by the motor
temperature model, if the controller has been sufficiently dimensioned com
pared to the motor. When the motor has not been thermally preloaded, the
following curve results at full motor load:

S-0-0109
S-0-0110
S-0-0111
P-0-4037
P-0-4046
t1
t2
KB
KF

Fig.6-42:

Motor peak current

Amplifier peak current
Motor current at standstill
Thermal short-time overload of winding
Effective peak current
max. duration after which the motor temperature model reduces to the
max. KB current
max. duration after which the motor temperature model reduces to the
max. continuous current
Short-time operation (KB = "Kurzzeitbetrieb")
Cooling type factor (see note below)

Curve of Effective Peak Current (P-0-4046) at Motor Load, Generated

by Motor Temperature Model

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Depending on the load current of the motor, the times t1 or t2 can be determined.
They apply to motors which have not been thermally loaded and therefore are
theoretical maximum values. In motor operation, t1 and t2 depend on the fol
lowing factors:

Motor-controller combination

Thermal preload of drive

Load cycle

The time t1 applies to load currents greater than, the time t2 to load currents
smaller than the maximum allowed short-time operation current. The values are
determined according to the following formula:

t1

Max. duration after which the motor temperature model reduces to the
max. KB current
Max. duration after which the motor temperature model reduces to the
max. continuous current
Assumed load current (> max. KB current)
Assumed load current (max. continuous current < I_L2 < max. KB cur
rent)
Motor current at standstill
Thermal time constant of winding
Thermal time constant of motor
Thermal short-time overload of winding
Cooling type factor (see note below)

t2
IL1
IL2
S-0-0111
P-0-4034
P-0-4035
P-0-4037
KF

Fig.6-43:

Calculating the Time for the Effective Peak Current (at Starting Condi
tion "Motor has not Been Thermally Loaded")

The cooling type factor depends on the cooling type and the result
ing setting of "P-0-0640, Cooling type" (see also Parameter De
scription):

Amplifier Temperature Model

1.0 For Standard Cooling (MAD, MAF, MBT, MBS, MLF) and
for non-Ventilated Motors MHD, MSK, MKD, MKE

1.5 For ventilation (only MHD, MSK, MKD, MKE)

1.9 For liquid cooling (only MHD, MSK, MKD, MKE)

In addition to the motor temperature model, the value of "P-0-4046, Effective

peak current" is limited by the amplifier temperature model. The variables of
the model calculation are:

Chronological sequence of "P-0-0440, Actual output current value

(absolute value)"

P-0-4058, Amplifier type data

P-0-0001, Switching frequency of the power output stage

Output frequency of the motor voltage

The value of "S-0-0112, Amplifier nominal current" (maximum continuous cur

rent of the controller) depends on the setting in "P-0-0001, Switching frequency

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of the power output stage". At motor standstill (below an output frequency
threshold), however, the allowed continuous current value is reduced, com
pared to the value of S-0-0112, by the temperature model calculation (dynamic
reduction of continuous current at motor standstill). At the corresponding motor
load, the value of "P-0-4046, Effective peak current" falls below the value of
S00112 (unless the motor is the current-limiting component!).
The current data of the amplifiers (power sections of the IndraDrive con
trollers) for continuous and cyclic load are contained in the separate "Supply
Units and Power Sections; Project Planning Manual" .
The physical data of motor-controller combinations for servo, main
drive and S1 print applications can be retrieved via the selection list
program "DriveSelect" (Intranet). "DriveSelect" takes the influence
of the motor and amplifier temperature models into account!
Continuous Current of Controller
Depending on Work Load at PWM
of 12 kHz or 16 kHz

The continuous current of the controller is reduced as the switching frequency

of the power output stage (PWM frequency) is increased. When the value in
"P-0-0001, Switching frequency of the power output stage" has been set to
12 kHz or 16 kHz, it is possible, however, to reduce the switching frequency
depending on the thermal load of the controller. This reduces the thermal load
of the power output stage and increases the allowed continuous current of the
controller. The respective setting is made in "P-0-0556, Config word of axis
controller". This causes the following behavior:

If the value of "P-0-0141, Thermal drive load" rises to the value set in
"P-0-0441, Overload warning", the switching frequency is internally re
duced to 8 kHz. The message "E2061 device overload prewarning" is
generated.

If the value of "P-0-0141, Thermal drive load" falls below a controller-spe

cific threshold, the value of the switching frequency entered in P-0-0001
takes effect again. The warning "E2061 Device overload prewarning" dis
appears.
The reduction of the switching frequency depending on the work
load only influences the allowed continuous current of the controller.
The maximum output current remains at the value belonging to the
switching frequency set in P-0-0001! The respective documentation
of the power sections contains the current data related to the con
troller (see "Supply Units and Power Sections; Project Planning
Manual").

When the default values for the control loop parameters are loaded ("RL" or
command C07_0), the values of the current loop parameters, which have been
stored in the encoder data memories of the motors and relate to the PWM fre
quency of 4 kHz, are converted to the value set in P-0-0001. When the option
"reduction of switching frequency depending on work load" has been activated,
conversion to the reduced switching frequency takes place!
In the case of manual optimization of the current loop parameters,
select the lower switching frequency (PWM). For this purpose enter
the value "0" in "P-0-0441, Overload warning", before optimizing!

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Drive Control

6.6.3

Velocity Limitation

Brief Description
A unipolar velocity limitation was implemented in the drive that allows limiting
the velocity command value to a positive and negative threshold freely defina
ble and differing with regard to the absolute value.
Features

Pertinent Parameters

Pertinent Diagnostic Messages

6.6.4

Unipolar velocity limit values (S00038, S00039)

Cyclically configurable, bipolar velocity limit value (S00091)

S00036, Velocity command value

S00037, Additive velocity command value

S00038, Positive velocity limit value

S00039, Negative velocity limit value

S00091, Bipolar velocity limit value

E2059 Velocity command value limit active

E2063 Velocity command value > limit value

F8079 Velocity limit value exceeded

Position Limitation/Travel Range Limit Switches

Brief Description
To avoid accidents and damages to the machine, comprehensive preventive
safety precautions are provided. Part of these safety precautions is the limita
tion of the allowed working range (travel range) by the drive. For this purpose,
position monitoring functions and position limitations have been implemented
in the drive.

CAUTION
Realizing Travel Range Monitoring

The travel range monitoring function (travel range limit switches or soft
ware limit switches) only fulfills the requirements for protecting machi
nery, but is not sufficient for personal protection!
The drive provides two possibilities of determining and monitoring a limitation
of the working range (travel range):

Monitoring of position limit values (software limit switches)

Monitoring of the motor position for exceeding one of the two position limit
values (positive/negative S00049/S00050) by the homed actual po
sition value (S00403), i.e. value related to the machine zero point.

Monitoring of travel range limit switches

Monitoring for activation of one of the two travel range limit switches (Limit
+, Limit-) that are connected to the digital inputs of the drive.
The functionality of the travel range limit switches is only guaran
teed, if the corresponding digital inputs have been configured for
this purpose!
See "Digital Inputs/Outputs"

Features of Travel Range Limit

Switch

2 travel range limit switches (Limit+, Limit-) can be monitored at the drive

Signal behavior of travel range limit switches (N/C and N/O) can be set

Travel range limit switches activated via parameter

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Drive Control

Features of Position Limit Values

Pertinent Parameters

Pertinent Diagnostic Messages

Reaction (error/warning) when exceeding travel range can be set

Status display of travel range limit switches

Command values monitored for validity when limit switch activated

Travel range limit switches evaluated and position limit value monitor ac
tivated in 2 ms clock

2 position limit values ("software limit switch") that can be parameterized;

only operational when axis has been homed

Reaction (error/warning) when exceeding position limit values can be set

Position limit values activated via parameter

Automatic reference to measuring system that has been homed

Command values monitored for validity when position limit values excee
ded

S00012, Class 2 diagnostics

S00049, Positive position limit value

S00050, Negative position limit value

S00055, Position polarities

S00147, Homing parameter

S00403, Position feedback value status

P00090, Travel range limit parameter

P00222, Travel range limit switch inputs

E2053 Target position out of travel range

E8029 Positive position limit exceeded

E8030 Negative position limit exceeded

E8042 Both travel range limit switches activated

E8043 Positive travel range limit switch activated

E8044 Negative travel range limit switch activated

F6029 Positive position limit exceeded

F6030 Negative position limit exceeded

F6042 Both travel range limit switches activated

F6043 Positive travel range limit switch activated

F6044 Negative travel range limit switch activated

6.7

Power Supply

6.7.1

Possibilities of Power Supply for IndraDrive

Brief Description
For IndraDrive devices we basically distinguish two lines:

Modular line, consisting of supply unit and modular inverter (IndraDrive M)

Non-modular line, so-called converter devices, including power supply

and inverter (IndraDrive C)

The power supply of the motors controlled via inverter is realized by a direct
voltage power bus (DC bus). In the case of the modular line, this bus is supplied
by the supply unit connected to the mains. Converters are supplied by the mains
connection via the integrated supply unit.

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Drive Control
Pertinent Parameters

Pertinent Diagnostic Messages

S00380, DC bus voltage

P00114, Undervoltage threshold

P00118, Power supply, configuration

P00460, Module group, control word

P00461, Module group, status word

P00806, Current mains voltage crest value

P00809, Properties of charging circuit

P00810, Minimum mains crest value

P00815, Nominal mains voltage crest value

P00816, Amplifier temperature 2

P00819, Energy counter

P00833, Braking resistor threshold

P00844, Braking resistor load

P00858, Data of external braking resistor

P00859, Data of internal braking resistor

P00860, Converter configuration

P00861, Power supply status word

E2026 Undervoltage in power section

E2040 Device overtemperature 2 prewarning

E2050 Device overtemp. Prewarning

E2061 Device overload prewarning

E2086 Prewarning supply module overload

E2802 HW control of braking resistor

E2810 Drive system not ready for operation

E2814 Undervoltage in mains

E2816 Undervoltage in power section

E2818 Phase failure

E2819 Mains failure

E2820 Braking resistor overload prewarning

E2829 Not ready for power on

E8025 Overvoltage in power section

E8028 Overcurrent in power section

E8057 Device overload, current limit active

E8058 Drive system not ready for operation

F2026 Undervoltage in power section

F2086 Error supply module

F2087 Module group communication error

F2814 Undervoltage in mains

F2816 Softstart fault power supply unit

F2817 Overvoltage in power section

F2818 Phase failure

F2819 Mains failure

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Drive Control

F2820 Braking resistor overload

F2821 Error in control of braking resistor

F2825 Switch-on threshold braking resistor too low

F2833 Ground fault in motor line

F2834 Contactor control error

F2836 DC bus balancing monitor error

F2840 Error supply shutdown

F2860 Overcurrent in mains-side power section

F8838 Overcurrent external braking resistor

Possible Device Combinations and Mains Connection

The possible device combinations are only described in principle
for the purpose of explanation. As regards combinations of device
types actually possible and specific facts to be observed, see sep
arate documentation "Rexroth IndraDrive Drive System, Project
Planning Manual" (DOK-INDRV*-SYSTEM*****-PR**-EN-P; part
no.: R911309635) .
Central Supply

The figures below illustrates the principle of central supply:

Fig.6-44:

Mains Supply via Supply Unit

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Drive Control

Fig.6-45:
Group Supply

Mains Supply via Converter

The figure below illustrates the principle of group supply:

Fig.6-46:

Mains Supply via all Devices

Communication in Drive Group

Depending on the task of a drive system or of several drives cooperating in a

process, it can be appropriate to rapidly carry out a common reaction to certain
events. This requires the exchange of signals (communication) between the
cooperating devices. For this purpose, IndraDrive devices are interconnected
via the module bus.

Note Regarding Converters

A converter combines supply unit and inverter in one device. In a "drive sys
tem" (several drives the DC buses and module buses of which are intercon
nected) a converter can fulfill the following functions:

Supplying its integrated inverter and further inverters

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Drive Control
- or

Operation only as inverter on a DC bus (only for HCS02.1)

Regenerated Energy

In the case of regenerative operation (e.g. deceleration mode) of the motors

connected to a drive controller, the regenerated energy is first absorbed by the
DC bus. Depending on the supply unit or supply section, the absorbed energy
is regenerated to the supply mains or converted to heat via a braking resistor.

Braking Resistor

The braking resistor is connected on the DC bus side. Depending on the device
line, an internal braking resistor is available or an external braking resistor can
be connected.

Description of Hardware

As regards hardware, connections and signals, the module bus is described in

the documentations of the devices (Project Planning Manuals).
Recommendations on mains connection and control of the power
supply, including external braking resistor and DC bus short circuit,
are contained in the separate documentation "Rexroth
IndraDrive Drive System, Project Planning Manual" (DOKINDRV*-SYSTEM*****-PR**-EN-P; part no.: R911309635) .

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Operation Modes

Operation Modes

7.1

General Information on the Operation Modes

7.1.1

Supported Operation Modes

The operation modes supported by the firmware are depending on
the hardware and firmware and are contained in p"S00292, List
of supported operation modes".
The following overview illustrates by which basic or functional packages the
respective operation mode is supported (if not stated otherwise, this applies for
all 3 firmware variants).
In functional package ...
In base package

Operation mode

(characteristic)

(on the basis of a base package with the following character

istics)
Servo function

Synchronization

Main spindle

CL

- Velocity control

OL/CL

- Position control

CL

- Drive-internal interpolation

CL

- Drive-controlled positioning

CL

- Positioning block mode

CL

- Velocity synchronization

OL/CL

- Phase synchronization

CL

- Electronic cam

CL

- MotionProfile

CL

Standard operation modes:

- Torque/force control

Synchronization modes:

OL
CL

Fig.7-1:

Open-loop characteristic
Closed-loop characteristic

Supported Operation Modes

To use a functional package, it must have been activated (enabled). The cur
rently enabled functional packages are displayed in "P02004, Active
functional packages".
See also "Enabling of Functional Packages"

7.1.2

Operation Mode Handling

Selecting the Operation Mode

It is possible to configure up to 8 different operation modes (depending on
"S00292, List of supported operation modes") in the drive. Assignment and
configuration are made via the following parameters:

S00032, Primary mode of operation

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Operation Modes

S00033, Secondary operation mode 1

S00034, Secondary operation mode 2

S00035, Secondary operation mode 3

S00284, Secondary operation mode 4

S00285, Secondary operation mode 5

S00286, Secondary operation mode 6

S00287, Secondary operation mode 7

If the value "0" was entered in one of these parameters, the "F2007
Switching to non-initialized operation mode" error message is gen
erated when this operation mode is activated.

Activating the Operation Mode

The operation mode is activated and controlled via bits 8, 9 and 11 in "P00116,
Device control: control word":
The following applies to P00116:

Bits 8 and 9 Selecting primary mode of operation and secondary oper.

modes 1 to 3

Bit 11 Selecting secondary operation modes 4 to 7 (only SERCOS)

The secondary operation modes 4 to 7 can only be used via
SERCOS interface. Bit 11 therefore only takes effect in the control
word of the device control (P00116) in conjunction with S00134
(master control word for SERCOS)!

The figure below illustrates the interrelation of the control word of the respective
master communication and the device control word/device status word with
regard to the operation mode selection.

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Operation Modes

Fig.7-2:

Operation Mode Selection via Control Word

The control bits (8 and 9) contained in P00116 are also contained

in the control words depending on the master communication (cf.
S00134, P04077, P04068 and P04028) and can therefore be
written via the control words.
An operation mode defined via the operation mode selection is active when:

The drive (control section and power section) is ready for operation

- and
Acknowledging the Active Opera
tion Mode

The drive enable signal sees a positive edge.

As regards the activation of an operation mode, there are the following kinds of
feedback:

With active operation mode the display of the control panel reads "AF".

In "S00390, Diagnostic message number" the respective diagnostic

message number of the active operation mode is displayed (e.g.
"A0101" in "velocity control" mode).

In "S00095, Diagnostic message", the active operation mode is dis

played in text form (e.g. "A0101 Velocity control").

In "P00115, Device control: status word", bit 3 ("drive follows external

command values") is used to acknowledge whether the drive is running in
the preset operation mode or not.

In "P00115, Device control: status word", bits 8, 9 and 10 ("acknowledg

ment of operation mode") are used to signal the operation mode presently
active.

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Operation Modes
The status bits contained in P00115 (3, 8, 9 and 10) are also con
tained in the status words depending on the master communication
(S00135, P04078) and can therefore be read in the status words.
Bit 10, however, is only activated with SERCOS interface!
See also "Device Control and State Machines"

Changing the Operation Mode

When drive enable is activated, the drive, after having gone through the initial
ization routines, changes to the operation mode that was selected via bits 8 and
9 of the specific control word of the respective master communication
(S00134, P04077, P04068 4028 or P00116).
The change of operation modes is carried out within one position
loop clock (Advanced: 250 s; Basic: 500 s). Another position loop
clock passes until the command values of the activated operation
mode become effective, because the initialization of the operation
mode is carried out first.
Special Cases

With the following exceptional circumstances, the desired operation mode is

not carried out in spite of the operation mode having been correctly selected:

Drive error is present

The corresponding error reaction is carried out.

Fatal warning was triggered

The corresponding reaction is carried out.

A "drive command" (e.g. homing procedure, set absolute measuring, ...)

is executed
The command started is carried out.

Drive HALT
This drive function is carried out.

See also "Device Control and State Machines"

Drive-Controlled Change of Opera
tion Mode

In order to achieve a quick and smooth change of operation mode in running

operation, it is possible to make a "drive-controlled change of operation
mode". Drive-internally this procedure ensures that, when the operation mode
is changed, the transition is carried out in a synchronized way, even if the com
mand value changes abruptly.
See also "Command Value Adjustment with Position Control"

Command Value Acceptance and Acknowledgment

Immediate Command Value Ac
ceptance

Each preset command value is accepted immediately, when the respective

command value parameter (e.g. S00036, S00080, S00258, ) is written
in the case of the operation modes:

Torque/Force Control

Velocity Control

Position Control With Cyclic Command Value Input

Drive-Internal Interpolation

Synchronization Modes:

Velocity Synchronization With Real/Virtual Master Axis

Phase Synchronization With Real/Virtual Master Axis

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Operation Modes

Command Value Acceptance After

Master Request

Electronic Cam With Real/Virtual Master Axis

MotionProfile With Real/Virtual Master Axis

In the positioning modes (drive-controlled positioning, positioning block mode),

however, the command value (target position, velocity, positioning block, ...) is
only accepted, when the master explicitly requests this by a "command value
acceptance".
The command value acceptance is carried out in a different way, according to
the positioning mode or profile type:

Operation mode "drive-controlled positioning"

Acceptance of preset command value (position, velocity) by toggling bit 0
of "S00346, Positioning control word"
Toggle mechanism

Operation mode "positioning block mode"

Acceptance of the positioning block selected via "p04026, Positioning
block selection" by a 0-1 edge of bit 0 of "p04060, Positioning block
control word", when the parallel interface or, in the case of field buses, the
I/O mode is used as master communication
Edge control
When the positioning block mode is used for field buses in the freely
configurable operating mode (P04084 = 0xFFFE) or with
SERCOS interface, the toggle mechanism is used in spite of the
above rule.

Command Value Acknowledgment

The explicit acknowledgment of the command value acceptance only takes

place for the positioning modes (drive-controlled positioning, positioning block
mode).
It is possible to check in the master whether and when the preset command
value was accepted in the drive (command value acceptance handshake).
The command value acknowledgment is carried out in a different way, accord
ing to the positioning mode:

Operation mode "drive-controlled positioning"

The drive acknowledges the command value acceptance by toggling bit 0
of "S00419, Positioning command acknowledge".

Operation mode "positioning block mode"

The drive acknowledges the command value acceptance by displaying
the effective positioning block in "P04051, Positioning block
acknowledgment".
In the positioning block mode, too, the acceptance of a new posi
tioning block causes bit 0 of S00419 to be toggled, because in this
case the internal processing of the positioning command values is
identical to the "drive-controlled positioning" mode.

7.2

Torque/Force Control

7.2.1

Brief Description
Assignment to functional firmware package, see chapter "Suppor
ted Operation Modes".

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Operation Modes
In the "torque/force control" mode, a torque/force command value is preset for
the drive. If required, this command value can be filtered. When the operation
mode has been activated, the diagnostic message is "A0100 Torque con
trolTorque control".

Fig.7-3:
Features

Pertinent Parameters

Pertinent Diagnostic Messages

"Torque/Force Control" Block Diagram

Torque/force control with regard to the sum of the command values preset
in parameters "S00080, Torque/force command value" and "S00081,
Additive torque/force command value"

Torque/force command value is generated internally by the velocity loop;

value of S00081 can be added as additive component

Limitation of the preset command value to limit value that can be para
meterized

Filtering the command value by means of "S00822, Torque/force

ramp" and "S00823, Torque/force ramp time"

S00080, Torque/force command value

S00081, Additive torque/force command value

S00082, Torque/force limit value positive

S00083, Torque/force limit value negative

S00092, Bipolar torque/force limit value

S00109, Motor peak current

S00110, Amplifier peak current

S00111, Motor current at standstill

S00822, Torque/force ramp

S00823, Torque/force ramp time

S00824, Status "Torque/force command value attained"

P00001, Switching frequency of the power output stage

P00038, Torque-generating current, command value

P00049, Effective torque/force command value

P00051, Torque/force constant

P00109, Torque/force peak limit

P04046, Effective peak current

A0100 Torque control

E8057 Device overload, current limit active

E8260 Torque/force command value limit active

F8079 Velocity limit value exceeded

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Operation Modes

7.2.2

Command Value Adjustment in Torque/Force Control

Principle of Command Value Adjustment

Filtering the Command Value

The command value preset by "S00080, Torque/force command value" is fil

tered. The filter effect can be changed by setting of "S00822, Torque/force
ramp" and "S00823, Torque/force ramp time".
The message "torque/force command value reached" (S00824) signals that
the output value of the filter has reached the input value (S00080).

Additive Current Command Value

Command Value Limitation

In addition, it is possible to add an unfiltered additive command value via

"S00081, Additive torque/force command value". If required, this value can
be cyclically configured.
We distinguish the following command value limitations:

Torque/Force Limitation

Current limitation

On the user side, it is only possible to directly set the torque/force limits. By
setting the switching frequency (P00001), the value of the current limit is in
directly influenced.
Output Variable

The output variable of the command value adjustment for torque/force control
is the torque-generating component of the current command value Iqcmd
(P00038).

Block Diagram

The figure below illustrates command value processing in the "torque/force

control" mode as a block diagram.

Fig.7-4:

Command Value Adjustment in Torque/Force Control

The currently effective actual limit values are displayed (P00442, P00443,
P00444; P04045, P04046); so is the output variable of the command value
adjustment in torque/force control, the torque-generating component of the
current command value (P00038).
Velocity Monitor

In torque/force control, the velocity of the drive is reached depending on the

component of the drive torque or the drive force acting on the acceleration. As
the velocity of a motor or an axis has to stay within the allowed range in order
to avoid damage, the actual velocity value is monitored, as soon as it is outside
the standstill window S00124.
If the value of "S00040, Velocity feedback value" exceeds the 1.125-fold value
of "S00091, Bipolar velocity limit value", the drive generates the error mes
sage "F8079 Velocity limit value exceeded" and switches off with the error
reaction that was set.

Notes on Commissioning for Command Value Limitation

On the user side, the following limitations are available:

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Operation Modes

Maximum allowed torque/force (S00092, P00109)

Motive and regenerative load at stationary velocity (S00082, S00083)

See also separate documentation "Parameter Description for IndraDrive

Controllers"
It is also possible to directly view (in N or Nm) the value of
"P00049, Effective torque/force command value" as intermediate
value.
The content of "P00046, Status word of current controller" results
from the current and torque limits.
See also section below "Current Loop"

7.2.3

Current Loop

Operating Principle of the Current Loop

The current loop is a typical PI loop and can be set via the following parameters:

S00106, Current loop proportional gain 1

S00107, Current loop integral action time 1

See also "Control Loop Structure"

See also "Motor Control"
In fact, the torque is not closed-loop controlled but open-loop con
trolled. Given the linear relation between torque and current (see
P00051), it is possible, however, to assume closed-loop torque/
force control. Just the absolute torque precision is limited due to
manufacturing tolerances of the motor (max. 10%).
Control Loop Performance and Cy
cle Times

According to the available hardware (Basic or Advanced design), the current

control loop is closed every 62.5 s (Advanced) or 125 s (Basic). (See also
"P00556, Config word of axis controller", bit 2.)

Notes on Commissioning for the Current Loop

The parameter values for the current loop of Rexroth motors are defined by the
manufacturer. In the case of motors with encoder data memory, they are au
tomatically written with the correct values during commissioning.
In the case of motors without encoder data memory, the correct values for the
current loop parameters and other motor parameters can be loaded via the
"IndraWorks Ds/D/MLD" commissioning tool.

7.3

Velocity Control

7.3.1

Brief Description
Assignment to functional firmware package, see chapter "Suppor
ted Operation Modes".
In the "velocity control" mode a velocity command value is preset for the drive.
The velocity command value is limited by ramps and filters.

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Operation Modes

Fig.7-5:
Features

"Velocity Control" Block Diagram

Inputting a Velocity Command Value (sum of

"S00036, Velocity command value" and "S00037, Additive velocity
command value") via Analog Inputs or Master Communication Inter
face(SERCOS, Field bus, ...)

Pertinent Parameters

Selection of predefined and internally stored velocity command values

(31 fixed values) is possible via binarily coded digital inputs (e.g. for jog
ging forward/backward, feeding, setting up, ...) with separately definable
acceleration and deceleration ramps (31 different ramps), as well as jerk
filter to be set (31 different time constants)

Use of a Drive-Internal Command Value Generator for Generating Com

mand Value Ramps ("Motor Potentiometer"

Inversion of the provided velocity command value before it is processed

in the ramp-function generator

Window Comparator for Masking Critical Velocity Ranges in the Com

mand Value Channel (e.g. Machine Resonances) With Corresponding
Acceleration Adjustment (see P01209)

Ramp-Function Generator With Separately Adjustable, two-Stage Accel

eration and Deceleration Limits of the Preset Velocity Command Value;
Switching From Ramp 1 to Ramp 2 is Done With Selectable Velocity and
run-up Stop that can be Parameterized

Velocity control via a digital PI loop with extensive filter measures

Monitoring the Command Velocity and Actual Velocity for Exceeding Pa

rameter "S00091, Bipolar velocity limit value"

Smoothing of velocity control loop difference via filter that can be para
meterized

Smoothing of preset command value by means of average filter (jerk lim

itation by means of moving average filter)

Fine interpolation of the velocity command values; transmission of these

command values in the position loop clock; fine interpolator can be switch
ed on or off (P00556, bit 0)

Velocity control loop monitoring (cannot be parameterized) to prevent the

drive from running away; monitor can be switched on or off (P00556,
bit 1)

Velocity Loop Internally Generates the Torque/Force Command Value to

Which the Value of Parameter "S00081, Additive torque/force command
value" can be Added as an Additive Component.

Control word and Status Word Especially for "Velocity Control" Mode
(P01200 and P01210)

S00036, Velocity command value

S00037, Additive velocity command value

S00091, Bipolar velocity limit value

S00100, Velocity loop proportional gain

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Operation Modes

Pertinent Diagnostic Messages

S00101, Velocity loop integral action time

P00004, Velocity loop smoothing time constant

P00048, Effective velocity command value

P00556, Config word of axis controller

P01119, Velocity mix factor feedback 1 & 2

P01120, Velocity control loop filter: filter type

P01126, Velocity control loop: acceleration feedforward

P01200, Control word 1 velocity control

P01201, Ramp 1 pitch

P01202, Final speed ramp 1

P01203, Ramp 2 pitch

P01206, Memory of velocity command values

P01207, Lower limit of velocity masking window

P01208, Upper limit of velocity masking window

P01209, Acceleration factors for velocity masking window

P01210, Status word of velocity control mode

P01211, Deceleration ramp 1

P01213, Deceleration ramp 2

P01214, Control word 2 velocity control

P01215, Motor potentiometer, acceleration

P01216, Motor potentiometer, deceleration

P01217, Motor potentiometer, step size

P01218, Motor potentiometer, command value

P01222, Velocity command filter

P01223, List of acceleration ramps

P01224, List of deceleration ramps

P01225, List of smoothing time constants

A0101 Velocity control

E2059 Velocity command value limit active

E2063 Velocity command value > limit value

F8078 Speed loop error

F8079 Velocity limit value exceeded

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7.3.2

Command Value Adjustment in Velocity Control

Overview

Fig.7-6:

Command Value Adjustment in Velocity Control

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The value of "S00037, Additive velocity command value" can be
added to "S00036, Velocity command value" directly at the input
of the velocity loop.
In the "velocity control" mode velocity command values can be input in the fol
lowing ways:

Cyclic Command Value Input by Means of Parameter "S00036, Velocity

command value" via the Master Communication (Analog Interface,
SERCOS, Field bus) or IndraMotion MLD

Using Velocity Command Values Internally Stored in the Drive in

"P01206, Memory of velocity command values" (List Parameter); Selec
tion via Digital Inputs, Master Communication Interface (SERCOS, Field
Bus) or IndraMotion MLD, for Example

Internal generation of command value ramps by a so-called motor poten

tiometer

Generation of a cyclic command value by means of the drive-integrated

PLC (IndraMotion MLD) in conjunction with MC blocks (cf. P01460)

The velocity command value is processed by the so-called ramp-function gen

erator.
Information on the status of the ramp-function generator is con
tained in P01210.
See Parameter Description "P01210, Status word of velocity
control mode"

Command Value Generation via Memory of Fixed Command Values

Via the selection bits of parameter "P01200, Control word 1 velocity
control" (bit 0...4), you can choose from up to 31 velocity command values
(P01206) stored in the drive.
By default, you can only select 5 fixed command values via
P01200; one fixed command value is assigned to each individual
bit (0...4).
Activating the Fixed Command Val
ues

As soon as at least one of the bits 0...4 has been set in parameter P01200,
the corresponding element from the list parameter "P01206, Memory of
velocity command values" takes effect.
The following assignment applies to the selection via bits 40 of P01200:

For direct selection (P01214, bit 8 = 0)

00000 Value from S00036 active

00001 Fixed value 1 from P01206 selected and active

00010 Fixed value 2 from P01206 selected and active

00100 Fixed value 3 from P01206 selected and active

01000 Fixed value 4 from P01206 selected and active

10000 Fixed value 5 from P01206 selected and active

For binary selection (P01214, bit 8 = 1)

00000 Value from S00036 active

00001 Fixed value 1 from P01206 selected and active

00010 Fixed value 2 from P01206 selected and active

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00011 Fixed value 3 from P01206 selected and active

etc.

11111 Fixed value 31 from P01206 selected and active

Via the same control bits of parameter P01200, it is in addition possible to

select ramp pitches, as well as time constants for the command value smooth
ing filter (see sections "Ramp-Function Generator" and "Jerk Limitation").
See also Parameter Descriptions "P01200, Control word 1 velocity
control" and "P01214, Control word 2 velocity control"

Command Value Generation via Motor Potentiometer

In the operation mode "velocity control", the command value generator (socalled motor potentiometer) provides the possibility of generating a velocity
command value characteristic (parameter P01218, Motor potentiometer,
command value) via digital input signals ("ramp+" and "ramp").
The motor potentiometer is activated by setting bit 0 = 1 in "P01214, Control
word 2 velocity control".

Inverting the Velocity Command Value

Before it is processed in the ramp-function generator, the provided velocity
command value can be inverted. The motor potentiometer is inverted by setting
bit 10 = 1 in "P01200, Control word 1 velocity control".

Masking the Command Value

The masking windows (max. 4) that can be defined via "P01207, Lower limit
of velocity masking window" and "P01208, Upper limit of velocity masking
window" are used to suppress resonance phenomena of a machine or in an
installation. The drive should not be permanently moved at velocities within
these windows. A velocity command value within the value range of one of the
4 definable windows is either reduced to the lower limit (P01207) or increased
to the upper limit (P01208).

P01207
P01208
vcmd
vr

Fig.7-7:

Lower limit of velocity masking window

Upper limit of velocity masking window
Velocity Command Value
Velocity ramp

Function "Velocity Masking Window With Hysteresis"

See also Parameter Descriptions "P01207, Lower limit of velocity

masking window" and "P01208, Upper limit of velocity masking window"
The subsequent ramp-function generator passes the range of the velocity win
dow; the values indicated in "P01209, Acceleration factors for velocity

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masking window" have a multiplying effect on the acceleration values of the
ramp-function generator (P01201, P01203, P01211 and P01213).

P01207
P01208
P01209
vcmd
vr

Fig.7-8:

Lower limit of velocity masking window

Upper limit of velocity masking window
Acceleration factors for velocity masking window
Velocity Command Value
Velocity ramp

Operating Principle of the Acceleration Factors From P01209

See also Parameter Description "P01209, Acceleration factors for

velocity masking window"

Ramp-Function Generator
For the ramp-function generator, we make the following distinction:

Cyclic command value input via S00036 or motor potentiometer

2 ramps (acceleration and deceleration) and a jerk filter take effect
Note: For Command Value Input via S00036 Also the Ramp Pitches and
the Filter Time Constants can be Selected From the List Parameters
P01223, P01224, P01225 by the Control bits in P01200. This Option
is Activated via bit 9 in "P01214, Control word 2 velocity control".

Command value input via memory of fixed command values (P01206)

31 sets with individually definable command velocities, jerk limits and
acceleration and deceleration ramps can be defined

Command Value Input via

S00036 or Motor Potentiometer

The increase (acceleration) and deceleration of the velocity command value

input via "S00036, Velocity command value" or a motor potentiometer can be
limited in steps via 2 ramps.

Acceleration process
In the First Step, the Increase of the Command Value is Limited via
"P01201, Ramp 1 pitch" (Acceleration Ramp 1). If the command velocity
exceeds the threshold entered in "P01202, Final speed ramp 1" the in
crease of the command value is limited with the value "P01203, Ramp
2 pitch" (acceleration ramp 2).

Deceleration or braking process

For deceleration "P01211, Deceleration ramp 1" resp. "P01213,
Deceleration ramp 2" are used accordingly.
This allows parameterizing different ramps for the acceleration and
braking process.

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Command Value Input via Memory
of Fixed Command Values

With command value input via the memory of fixed command values
(P01206), separate ramp values can be defined for each of the 31 fixed com
mand values via the following list parameters:

P01223, List of acceleration ramps

P01224, List of deceleration ramps

These are single-step ramps, i.e. one ramp pitch applies to the entire speed
range. Via control bits (bits 04) in "P01200, Control word 1 velocity
control", the single-step ramps can be selected.
The fixed command values (P01206) and the corresponding time
constants of the jerk filter (P01225) are selected via the control
bits in parameter P01200!
The assignment of bits 0...4 of parameter P01200 depends on bit 8 of pa
rameter "P01214, Control word 2 velocity control" (see "Activating the Fixed
Command Values" in section "Command Value Generation via Memory of
Fixed Command Values").
Run-Up Stop

When there is acceleration-dependent torque limitation occurring or due to in

stallation-dependent failures/irregularities, it is necessary to interrupt the ac
celeration ramp. For this purpose, the function "run-up stop" was introduced
that is controlled via parameter "P01200, Control word 1 velocity control".
Possible settings for activating the function "run-up stop" via the respective bits
of P01200:

Activation of the function without additional condition

Triggering of torque limitation (E2060)

Triggering of command value limitation (cf. S00091)

Triggering of command value or torque limitation

While a speed masking window is passed, the function "run-up
stop" is deactivated.

Jerk Limitation
The velocity command value, the increase and maximum of which are limited,
is jerk-limited by means of a 1st order filter.
For jerk limitation, we make the following distinction:

Cyclic command value input via S00036 or motor potentiometer

Jerk limitation takes effect as set in parameter P01222

Command value input via memory of fixed command values (P01206)

Jerk limitation can be separately defined for each of the 31 fixed com
mand values by an individual smoothing time constant (P01225)

Command Value Input via

S00036 or Motor Potentiometer

The command value input via "S00036, Velocity command value" or a motor
potentiometer is jerk-limited according to the settings in "P01222, Velocity
command filter".

Command Value Input via Memory

of Fixed Command Values

With command value input via the memory of fixed command values
(P01206), an individual filter time constant (P01225, List of smoothing time
constants) can be configured for each of the 31 fixed command values; the filter
time constant is selected via the control bits (bits 04) of parameter "P01200,
Control word 1 velocity control".

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The control bits in parameter P01200 are also used to select the
fixed command values (P-0-1206) and the corresponding ramp
pitches (P01223 and P01224)!
The assignment of bits 0...4 of parameter P01200 depends on bit 8 of pa
rameter "P01214, Control word 2 velocity control" (see "Activating the Fixed
Command Values" in section "Command Value Generation via Memory of
Fixed Command Values").

Command Value Limitation

The effective velocity command value (sum of values from S00036 and
S00037) is limited to the value indicated in parameter "S00091, Bipolar
velocity limit value" resp. in the parameters "S00038, Positive velocity limit
value" or "S00039, Negative velocity limit value".
See also "Velocity Limitation"
When the limitation takes effect, the drive generates the message
"E2059 Velocity command value limit active".

Fine Interpolation
The limited command value available at the output of command value process
ing can be adjusted, by means of linear fine interpolation, for further processing
in the velocity loop. To do this, a command value input in the position loop clock
is fine interpolated in the velocity loop clock.
This function has to be activated via bit 0 of parameter "P00556, Config word
of axis controller".

7.3.3

Velocity Control Loop

Velocity Loop
The velocity loop is a typical PI loop and can be set via the following parameters:

S00100, Velocity loop proportional gain

S00101, Velocity loop integral action time

See also "Control Loop Structure"

Control Loop Performance and Cy
cle Times

The minimum possible control loop cycle time of the velocity loop depends

on the available control section (CSH, CSB, CDB),

on the respective firmware variant (MPH, MPB or MPD)

- and

in the case of variant MPH, on the parameterized performance (Basic or

Advanced; see "P00556, Config word of axis controller").

See "Performance Data"

Current Loop in Velocity Control Loop

In velocity control, the outer current control loop (cascade structure), that can
be set via the following parameters, always takes effect, too:

S00106, Current loop proportional gain 1

S00107, Current loop integral action time 1

P00001, Switching frequency of the power output stage

See also "Torque/Force Control: Current Loop"

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Possibilities of Filtering
To filter noise components possibly present in the actual velocity value or to
attenuate resonance frequencies, the following filter settings can be made:

Via "P00004, Velocity loop smoothing time constant" the low-pass filter
that filters the control difference for the velocity loop can be set.

To filter the control deviation it is possible to configure four filters connec

ted in series as low-pass filters or band-stop filters with "P01120, Velocity
control loop filter: filter type".
The "S00081, Additive torque/force command value" is added to
the output signal of the velocity loop and the resulting value is
transmitted to the current and torque/force limit (see also "Current
and Torque/Force Limitation").

7.4

Position Control With Cyclic Command Value Input

7.4.1

Brief Description
Assignment to functional firmware package, see chapter "Suppor
ted Operation Modes".
In the "position control" mode, a cyclic position command value is preset for the
drive in NC cycle time. This command value is fine interpolated in the drive and
jerk-limited via filters, if necessary, before being transmitted to the position loop.
To minimize the lag error, variable acceleration feedforward is available in ad
dition to variable velocity feedforward.
There are different forms of the "position control" mode which result in the cor
responding diagnostic messages when the operation mode was activated (see
below "Pertinent Diagnostic Messages").

Fig.7-9:
Features

Block Diagram "Position Control With Cyclic Command Value Input"

Position control with regard to the command value preset in "S-0-0047,

Position command value"

NC-controlled or drive-controlled position control with internal, dynamic

synchronization when changing operation modes

Timebase for cyclic command value input defined by "S-0-0001, NC cycle

time (TNcyc)"

Monitoring the position command value difference for exceeding

"S-0-0091, Bipolar velocity limit value"

Position command values of the control unit smoothed by means of ad

justable average value filter; calculation from acceleration and jerk limit
values; display in "P-0-0042, Current position command average value
filter order"

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Operation Modes

fine interpolation of position command value of the control unit to position

controller clock; can be switched by means of parameter"P-0-0187,
Position command processing mode"

Adjustable deceleration of position command value in position clocks

(P00456), maximum 32 clocks.

Position control with regard to actual position value encoder 1 (motor en

coder) or actual position value encoder 2 [external (load-side) encoder],
can be dynamically switched

Velocity feedforward through adjustable factor of 0150 % (de

fault = 100 %)

Acceleration monitor for position command value can be switched on

(P00556, bit 15)
The condition for this operation mode is synchronous communica
tion between the control unit and the drive, as it is the case with
SERCOS interface, for example.

Pertinent Parameters

Pertinent Diagnostic Messages

S-0-0047, Position command value

S-0-0091, Bipolar velocity limit value

S-0-0138, Bipolar acceleration limit value

S-0-0520, Control word of axis controller

P-0-0010, Excessive position command value

P-0-0011, Last valid position command value

P-0-0041, Position command average value filter time constant

P-0-0042, Current position command average value filter order

P-0-0047, Position command value control

P-0-0059, Additive position command value, controller

P-0-0099, Position command smoothing time constant

P-0-0142, Synchronization acceleration

P-0-0143, Synchronization velocity

P-0-0187, Position command processing mode

P-0-0434, Position command value of controller

P-0-0456, Position command value delay

P-0-0457, Position command value generator

P-0-0556, Config word of axis controller

A0102 Position mode, encoder 1

A0103 Position mode, encoder 2

A0104 Position mode lagless, encoder 1

A0105 Position mode lagless, encoder 2

A0154 Position mode drive controlled, encoder 1

A0155 Position mode drive controlled, encoder 2

A0156 Position mode lagless, encoder 1 drive controlled

A0157 Position mode lagless, encoder 2 drive controlled

F2036 Excessive position feedback difference

F2037 Excessive position command difference

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7.4.2

Command Value Adjustment in Position Control

NC- or Drive-Controlled Position

Control

We distinguish the following characteristics of the operation mode "position

control with cyclic command value input":

NC-controlled position control (cf. A0102 to A0105)

The drive generally follows the position command values cyclically input
by the master in the NC cycle.

Drive-controlled position control (cf. A0154 to A0157)

In the case of a change of operation mode to cyclic position control, the
drive realizes the corresponding synchronization process, i.e. it gener
ates, internally by means of the internal synchronization parameters
(P-0-0142, P-0-0143, P-0-0154, P-0-015), a smooth transition of the in
ternal position command value from the current actual position to the new
command value characteristic input by the NC. After the synchronization
process has been completed, the drive follows the position command val
ues input by the master in the NC cycle.
The command value cyclically transmitted by the control unit is dis
played in "P-0-0047, Position command value control".
The internal position command value at the position controller is
displayed in "P-0-0434, Position command value of controller". If
required, it can also be written via "S-0-0047, Position command
value".

Command Value Filtering (Jerk

Limitation)

The position command values preset by the control unit can be smoothed via
an average value filter that can be set ("P-0-0041, Position command average
value filter time constant", moving average filter for a maximum of 64 values).
The resulting filter degree is displayed via "P-0-0042, Current position
command average value filter order". This filter can be used for jerk limitation.
In the case of drive-controlled position control, a jump of the position command
value is traveled by a change of the position command average value filter with
synchronization motion in control.
The PT1 filter for jerk limitation that can be parameterized via
"P-0-0099, Position command smoothing time constant" only takes
effect for linear fine interpolation.

Fine Interpolation of the Position

Command Value

The position command value cyclically transmitted in the NC cycle time by the
control unit can be fine interpolated in the drive, if necessary.
Via "P-0-0187, Position command processing mode", it is possible to switch
between:

Cubic fine interpolator (according to contour),

Linear fine interpolator or

Cubic approximator.

See also Parameter Description "P-0-0187, Position command

processing mode"
It is recommended to use the cubic fine interpolator according to
contour (default setting), because it provides clearly higher quality
of velocity and acceleration feedforward, particularly with lagless
position control.

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Position Command Value Deceler
ation

The position command value can be delayed by maximum 32 position clocks

after the fine interpolator, before it is fed in the position controller. This allows
synchronous control of a master axis with the controlled slave axis. The number
of position clocks is set with the position command value delay (P00456). The
position command value generator without delay (P00457) is entered in a ring
buffer and then the position command value with delay is applied in the position
command value controller (P00434).

Drive-Controlled Change of Opera

tion Mode

During drive-controlled change of operation mode, the drive makes sure inter
nally that when the operation mode is changed, the transition is carried out in
a synchronized way, even if the command value changes abruptly.

P-0-0142
P-0-0143

Fig.7-10:

Synchronization acceleration
Synchronization velocity

Chronological Diagram "Drive-Controlled Change of Operation Mode"

See also "Changing the Operation Mode"

Block Diagram

The figure below illustrates command value processing in the "position con
trol" mode as a block diagram.

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Fig.7-11:

Command Value Adjustment in Position Control

See also "Position Loop" in the same section

See also "Velocity Loop" in section "Velocity Control"
See also "Current Loop" in section "Torque/Force Control"

7.4.3

Position Loop
The position controller is a simple P-controller, its proportional gain can be set
with the value of "S-0-0104, Position loop Kv-factor".
See also "Control Loop Structure"

Control Loop Performance and Cy

cle Times

The position control loop is closed according to the available performance de

sign (see "Performance Data").
According to the application it is possible to set via bit 3 of the operation mode
parameters (S-0-0032 to S-0-0035):

Lagless operation (with velocity feedforward)

Operation with lag error (without velocity feedforward)

The lag error is the difference between position command value and actual
position value. The current value is stored in "S-0-0189, Following distance".
The kind of position control (lagless, with lag error) can be set via "S-0-0520,
Control word of axis controller".
If the mechanical system and the application permit it, lagless op
eration should always be selected.
Possibilities of Feedforward

In lagless operation variable acceleration feedforward can be activated in ad

dition to variable velocity feedforward ("P-0-0040, Velocity feedforward
evaluation").
To do this, the acceleration-proportional feedforward component (additive cur
rent command value) is set via parameter "S-0-0348, Acceleration feedforward
gain" and the velocity-proportional feedforward component (additive velocity
command value) is set via "P-0-0040, Velocity feedforward evaluation".
This allows setting the lag error to a desired percentage value at constant ve
locity.

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In lagless operation and with P-0-0040 = 100%, there is a minimum
lag error of "0" at constant velocity.
In addition, it is possible to realize feedforward via "P-0-1126,
Velocity control loop: acceleration feedforward", but this feedfor
ward is derived from the velocity command value. Therefore, you
have to make sure that you didn't activate both feedforward values
by mistake!
See also "Axis Control: Position Loop (With Respective Feedforward Functions
and Actual Value Adjustment)"

7.5

Drive-Internal Interpolation

7.5.1

Brief Description
Assignment to functional firmware package, see chapter "Suppor
ted Operation Modes".
The operation modes "drive-internal interpolation" and "drive-controlled posi
tioning" allow time-optimized positioning of a single axis. The "drive-internal
interpolation" mode is the basis for the more comprehensive functionality of the
"drive-controlled positioning" mode.
In the "drive-internal interpolation" mode, a target position is directly preset for
the drive. In the internal positioning generator, a position command value char
acteristic is generated (interpolated), from the preset value for the target posi
tion considering preset positioning data (velocity, acceleration and jerk), as the
input value for the position loop.
There are different forms of the "drive-internal interpolation" mode which result
in the corresponding diagnostic messages when the operation mode was ac
tivated (see below "Pertinent Diagnostic Messages").

Fig.7-12:
Features

Block Diagram "Drive-Internal Interpolation"

Drive-internal generation of a position command value profile to travel to

a preset target position (S00258) while maintaining the positioning ve
locity (S00259) and positioning acceleration (S00260) or positioning
deceleration (S00359) that can be set; can be set separately

Jerk limitation of the generated position command value via "S00193,

Positioning Jerk"

Setting of the average value filter (jerk limitation) to fixed filter time with
IPO command value average value filter time constant (P00641)

Adjustable deceleration of position command value in position clocks

(P00456, Position command value delay), maximum 32 clocks.

Evaluation of the positioning velocity with "S00108, Feedrate override"

Monitoring of the positioning velocity for exceeding "S00091, Bipolar

velocity limit value"

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Monitoring of the target position for compliance with the position limit val
ues

Command value mode can be set (S00393) in modulo format (shortest

distance, only positive or only negative direction)

Position control with regard to "S00051, Position feedback value 1" (mo
tor encoder) or "S00053, Position feedback value 2" [external (load-side)
encoder]

Acceleration and deceleration ramps, can be set separately

No change in direction of motion when "command value mode in modulo

format" equal "shortest distance", if vact > S00417

"Shortest distance" mode when "command value mode in modulo for

mat" equal "only positive/negative direction of motion" and target position
within "S00418, Target position window in modulo mode"
In this operation mode, it is possible to separately parameterize the
acceleration and deceleration processes. This allows optimum ad
justment to the respective application-specific requirements.

Pertinent Parameters

Pertinent Diagnostic Messages

S00108, Feedrate override

S00138, Bipolar acceleration limit value

S00193, Positioning Jerk

S00258, Target position

S00259, Positioning velocity

S00260, Positioning acceleration

S00342, Status "Target position attained"

S00343, Status "Interpolator halted"

S00359, Positioning deceleration

S00393, Command value mode

S00417, Positioning velocity threshold in modulo mode

S00418, Target position window in modulo mode

S00430, Effective target position

S00437, Positioning status

P00059, Additive position command value, controller

P00434, Position command value of controller

P00456, Position command value delay

P00457, Position command value generator

P00556, Config word of axis controller

P00641, Interpolation cmd value average value filter time constant

A0106 Drive controlled interpolation, encoder 1

A0107 Drive controlled interpolation, encoder 2

A0108 Drive controlled interpolation, lagless, encoder 1

A0109 Drive controlled interpolation, lagless, encoder 2

E2049 Positioning velocity >= limit value

E2053 Target position out of travel range

E2055 Feedrate override S-0-0108 = 0

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7.5.2

F2057 Target position out of travel range

Command Value Adjustment With Drive-Internal Interpolation

The target position can be cyclically preset via "S00258, Target position".
The drive generates the position command value profile necessary to move to
the target position, considering the requirements defined in the following pa
rameters:

S00108, Feedrate override

S00193, Positioning Jerk

S00259, Positioning velocity

S00260, Positioning acceleration

S00359, Positioning deceleration

The target position preset by the control master is displayed in
"S00430, Effective target position".

The figure below illustrates command value processing in the "drive-internal

interpolation" mode as a block diagram.

Fig.7-13:

7.5.3

Command Value Adjustment With "Drive-Internal Interpolation"

Position Loop With Drive-Internal Interpolation

The position command value generated at the output of the command value
generator is displayed in p"P00434, Position command value of controller"
and can be output at the analog output.
In this operation mode, the same information as relevant in the "position control
with cyclic command value input" mode applies to the position control loop.
See also "Control Loop Structure"
See also "Position Loop" in section "Position Control With Cyclic Command
Value Input"

7.6

Drive-Controlled Positioning

7.6.1

Brief Description
Assignment to functional firmware package, see chapter "Suppor
ted Operation Modes".

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Operation Modes
The operation modes "drive-internal interpolation" and "drive-controlled posi
tioning" allow time-optimized positioning of a single axis. The "drive-internal
interpolation" mode is the basis for the more comprehensive functionality of the
"drive-controlled positioning" mode.
In the "drive-controlled positioning" mode, a positioning command value is pre
set for the drive. The drive can continue processing this value internally in
absolute (position target) or relative (travel distance) form. In the internal inter
polator, a position command value characteristic is generated as the input value
for the position loop from the preset positioning data (effective target position,
velocity, acceleration and jerk).
There are different forms of the "drive-controlled positioning" mode which result
in the corresponding diagnostic messages when the operation mode was ac
tivated (see below "Pertinent Diagnostic Messages").

Fig.7-14:
Features

Block Diagram "Drive-Controlled Positioning"

Processing of an absolute target position or a relative travel distance

Drive-internal generation of a position command value profile to travel to

the positioning command value (S00282) while maintaining the posi
tioning velocity (S00259) and positioning acceleration (S00260) or
positioning deceleration (S00359) that can be set; can be set separately

Acceptance of the positioning command value via toggle bit (S00346,

bit 0)

Jerk limitation of the generated position command value with "S00193,

Positioning Jerk"

Setting of the average value filter (jerk limitation) to fixed filter time with
IPO command value average value filter time constant (P00641)

Adjustable deceleration of position command value in position clocks

(P00456), maximum 32 clocks.

Evaluation of the positioning velocity with "S00108, Feedrate override"

Monitoring of the positioning velocity for exceeding the value in "S00091,

Bipolar velocity limit value"

Monitoring of the target position for compliance with the position limit val
ues (see "S00049, Positive position limit value", "S00050, Negative
position limit value")

Command value mode can be set in modulo format in "S00393,

Command value mode" (shortest distance, positive only or negative only
direction, no reversal of direction of rotation)

Position control with regard to "S00051, Position feedback value 1" (mo
tor encoder) or "S00053, Position feedback value 2" [external (load-side)
encoder]

Acceleration and deceleration ramps can be set separately ("S00260,

Positioning acceleration" or "S00359, Positioning deceleration")

Position limit values taken into account when accepting target position,
positioning velocity and positioning acceleration

Jog mode ("infinite travel" positive/negative; S00346, bits 1 and 2)

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Operation Modes

Residual path processing can be activated

"On-the-fly acceptance" of the new target position or intermediate stop

In this operation mode, it is possible to separately parameterize the
acceleration and deceleration processes in order to achieve opti
mum adjustment to the respective application-specific require
ments.

Pertinent Parameters

Pertinent Diagnostic Messages

7.6.2

S00108, Feedrate override

S00138, Bipolar acceleration limit value

S00193, Positioning Jerk

S00259, Positioning velocity

S00260, Positioning acceleration

S00282, Positioning command value

S00342, Status "Target position attained"

S00343, Status "Interpolator halted"

S00346, Positioning control word

S00359, Positioning deceleration

S00393, Command value mode

S00417, Positioning velocity threshold in modulo mode

S00418, Target position window in modulo mode

S00419, Positioning command acknowledge

S00430, Effective target position

S00437, Positioning status

P00059, Additive position command value, controller

P00434, Position command value of controller

P00456, Position command value delay

P00457, Position command value generator

P00556, Config word of axis controller

P00641, Interpolation cmd value average value filter time constant

A0150 Drive-controlled positioning, encoder 1

A0151 Drive-controlled positioning, encoder 1, lagless

A0152 Drive-controlled positioning, encoder 2

A0153 Drive-controlled positioning, encoder 2, lagless

E2049 Positioning velocity >= limit value

E2053 Target position out of travel range

E2055 Feedrate override S-0-0108 = 0

E2064 Target position out of num. range

F2050 Overflow of target position preset memory

F2057 Target position out of travel range

Command Value Adjustment With Drive-Controlled Positioning

Overview
The figure below illustrates command value processing in the "drive-controlled
positioning" mode as a block diagram.

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Operation Modes

Fig.7-15:

Command Value Adjustment With "Drive-Controlled Positioning"

Position Target Interpreter

Accepting and Acknowledging the
Command Value

The acceptance and internal processing of "S00282, Positioning command

value" to a value entered in "S00430, Effective target position" is controlled
via "S00346, Positioning control word".
At every edge of bit 0 (toggle bit) of S00346, the content of "S00282,
Positioning command value", depending on bit 3 of S00346, is

copied to S00430
(when bit 3 = 0 absolute target position)

- or

added to the value of S00430

(when bit 3 = 1 travel distance).
If a positioning process is aborted by switching bits 1 and 2 of
S00346 from status "00" to "01", "10" or "11", repeated edge re
versal has to take place in bit 0 in order to start a new positioning
process! A residual path possibly present is cleared, i.e. the status
of bit 4 of S00346 is automatically interpreted as "1" during the
next positioning process.

Via "S00419, Positioning command acknowledge" (bit 0), the drive acknowl
edges that it has applied the positioning command value. This allows realizing
a data handshake for monitoring the command value acceptance between
master and drive.
The active target position is displayed in "S00430, Effective target
position".

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Operation Modes

Fig.7-16:

Positioning Command Value Acceptance and Acknowledgment

Time taccept (see illustration above) defines the time that passes between status
change of the acceptance bit by the control unit and the reception of acknowl
edgment in the master. The time is made up of the effective transmission time
of the command values and actual values and thus depends on the configura
tion of the interface to the master (e.g. SERCOS/field bus timing parameter).
If the "drive-controlled positioning" mode is not yet active, the ac
ceptance of the new positioning command value is not acknowl
edged.
If bit 0 of S00346 is unequal bit 0 of S00419 while the operation
mode is active, the positioning command value from S00282 is
immediately accepted and the drive immediately moves to this
command value.
The acknowledgment of acceptance takes place when the new positioning
command value is accepted from the intermediate memory to "S00430,
Effective target position" and thus to the position command value generator.

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Operation Modes

Fig.7-17:
Acknowledgment With Error "Posi
tioning Command Value Overflow"

Acknowledgment of Positioning Command Value Acceptance in Mode

"Complete Move to Positioning Command Value (k+2)"

When trying, in the "complete move to positioning command value" mode, to

preset a new positioning command value by toggling "S00346, Positioning
control word", although the previous positioning command value (k+1) was not
accepted [because the drive had not yet moved to the previous positioning
command value (k)], the error message "F2050 Overflow of target position
preset memory" is generated.

Fig.7-18:

Acknowledgment With Error "Positioning Command Value Overflow"

In addition to bit 0 for mere block acceptance, "S00346, Positioning control

word" contains further control bits which are explained below.
Positioning Modes to be Selected

Via bit 1 and bit 2 of S00346, you can determine different positioning modes:

"Infinite travel" (jog positive or negative Jog mode) when:

Bit 2/1 = 01 "Infinite travel" positive

Bit 2/1 = 10 "Infinite travel" negative

"Stopping" (with "S00359, Positioning deceleration") when:

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Reference of Active Target Position

Bit 2/1 = 11

Via bit 4 of S00346, it is possible to determine the reference of the active target
position.

Bit 4 = 0 Reference for positioning is the "old target position", i.e. a

residual path that possibly hasn't been traveled yet is traveled before the
drive moves to the new target
Incremental dimension is maintained in the case of successive posi
tioning procedures

Bit 4 = 1 Reference for positioning is the current actual position value,

a possibly existing residual path is not traveled
Incremental dimension reference is maintained
Bit 4 takes effect with every new travel job (edge on bit 0). Residual
path processing is only carried out, during the first positioning proc
ess after the operation mode was activated, when the position
status has been set and bit 2 = 1 in S00393. In this case the re
sidual path, after the operation mode was activated, is traveled
without start edge.

Reaction to New Target Position In

put

Via bit 5 of S00346, it is possible to determine the time of the reaction to a

new target position input:

Bit 5= 0 The drive travels to the last preset target before positioning at
the new target. The target is considered to have been reached when the
following applies:
Target position actual position value < positioning window

Bit 5 =1 The previous target is rejected and the drive immediately travels
to the new target.
Immediate block change
See also Parameter Description "S00346, Positioning control word"

Processing in Modulo Format

"S00393, Command value mode" controls the drive behavior in the case of
position processing in modulo format. The following definition applies to
S00393:

Bit 1/0 = 00 Positive direction of rotation

Bit 1/0 = 01 Negative direction of rotation

Bit 1/0 = 10 Shortest distance

See also Parameter Description "S00393, Command value mode"

Special Cases

The following special cases apply to the evaluation of the settings for "S00393,
Command value mode":

If the absolute value of the current actual velocity is greater than the ve
locity threshold for positioning (S00417, Positioning velocity threshold in
modulo mode), the drive always moves in the last active direction of ro
tation.

If the target position is within the target position window (S00418), po

sitioning is always carried out according to the "shortest distance" mode.
If the velocity threshold for positioning behavior was parameterized
with very low values that are within the noise level of the actual
velocity value, this can cause unpredictable behavior.

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Operation Modes

See also Parameter Description "S00417, Positioning velocity threshold

in modulo mode" and "S00418, Target position window in modulo mode" and
"S00430, Effective target position"

Positioning Generator
The drive generates the position command value profile necessary to move to
the target position, considering the conditions defined in the following param
eters:

7.6.3

S00108, Feedrate override

S00193, Positioning Jerk

S00259, Positioning velocity

S00260, Positioning acceleration

S00359, Positioning deceleration

Position Loop With Drive-Controlled Positioning

The position command value generated at the output of the command value
generator is displayed in p"P00434, Position command value of controller"
and can be output at the analog output.
In this operation mode, the same information as relevant in the "position control
with cyclic command value input" mode applies to the position control loop.
See also "Control Loop Structure"
See also "Position Loop" in section "Position Control With Cyclic Command
Value Input"

7.6.4

Jog Mode With Drive-Controlled Positioning ("Jogging")

The jog mode is part of the positioning mode and not an individual
operation mode! This means that there aren't any separate param
eters for the jog mode, but you have to use the parameters of the
operation mode "drive-controlled positioning".
Activating the Jog Mode

To use the jog mode, make the following settings:

Activate the operation mode "drive-controlled positioning"

- and -

Parameterizing the Jog Mode

Select the positioning mode "infinite travel" (jog positive or negative jog
mode) via bits 1 and 2 of parameter "S00346, Positioning control word"

When jogging, the following parameters are relevant for operation:

S00108, Feedrate override

To achieve online, if necessary, the reduction of the jog velocity by
means of a "potentiometer"

S00193, Positioning Jerk

S00259, Positioning velocity

S00260, Positioning acceleration

S00282, Positioning command value

S00346, Positioning control word

To select the jog direction ("Jog+", "Jog-" and "stopping")

S00359, Positioning deceleration

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Operation Modes
Bits 1 and 2 of S00346 are parts of the field bus control word and,
if required, can be assigned to the digital inputs.
See "Profile Types (With Field Bus Interfaces)"
See "Digital Inputs/Outputs"

7.7

Positioning Block Mode

7.7.1

Brief Description
Assignment to functional firmware package, see chapter "Suppor
ted Operation Modes".
In the "positioning block mode" it is possible to run up to 64 programmed po
sitioning blocks. The drive moves to the target position in position control, while
maintaining velocity, acceleration, deceleration and jerk limits as defined in the
respective positioning block.

Fig.7-19:
Features

Block Diagram "Positioning Block Mode":

Parameterization of up to 64 positioning blocks; each with target position/

travel distance, velocity, acceleration, deceleration and jerk

Jerk limitation of the generated position command value via "P04009,

Positioning block jerk"

Setting of the average value filter (jerk limitation) to fixed filter time with
IPO command value average value filter time constant (P00641)

Adjustable deceleration of position command value in position clocks

(P00456, Position command value delay), maximum 32 clocks.

Defined block acceptance by toggling bit 0 in "S00346, Positioning

control word" with reaction time tR_strobe = tposition
Note: With field bus drives, the I/O mode and control via the parallel in
terface are exceptions. In these cases, acceptance takes place by a 0-1
edge of bit 0 in P04060.
Block selection and acknowledgment via separate parameters (hand
shake principle)

Positioning modes to be freely parameterized:

Relative positioning

Absolute positioning

Infinite travel (positive or negative)

Single-block or sequential block mode with different conditions for ad

vance:

Block advance with switch cams

Block advance at defined position value

Block transition with "old" or "new" positioning velocity

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Operation Modes

Fields of Application

Pertinent Parameters

Positioning block transition with freely definable delay time (P04018)

Positioning while taking command value mode into account (shortest dis
tance, positive direction, ...)

Residual path processing can be activated ( no loss of incremental di

mension)

"Slow travel" mode can be activated

Velocity override to be set

Sequential block processing allows executing several positioning blocks in di

rect sequence without having to give a new start signal each time. Typical fields
of application are:

There is none or only a very simple higher-level control unit available and
control is realized via digital I/Os only or a field bus control word (I/O mode
with field bus interface).

There are quick reaction times or block advances required. The required
motion profiles can be represented in the drive by the maximum possible
64 positioning blocks.

There are positioning processes required which cover long distances at

high speeds (rapid traverse) and then position at the end position at low
speed without any intermediate stops; for example:

Taking up or putting down transport goods in handling robots

Execution of joining processes in assembly facilities

S00138, Bipolar acceleration limit value

S00259, Positioning velocity

S00346, Positioning control word

S00393, Command value mode

S00419, Positioning command acknowledge

S00430, Effective target position

S00437, Positioning status

P00059, Additive position command value, controller

P00434, Position command value of controller

P00456, Position command value delay

P00457, Position command value generator

P00556, Config word of axis controller

P00641, Interpolation cmd value average value filter time constant

P04006, Positioning block target position

P04007, Positioning block velocity

P04008, Positioning block acceleration

P04009, Positioning block jerk

P04018, Positioning block delay time

P04019, Positioning block mode

P04026, Positioning block selection

P04051, Positioning block acknowledgment

P04052, Positioning block, last accepted

P04053, Positioning block, last active

P04057, Positioning block, input linked blocks

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Operation Modes

P04060, Positioning block control word

P04061, Positioning block status word

P04063, Positioning block deceleration

S00259 is used in positioning block mode to reduce positioning
velocity (see also "P04060, Positioning block control word").

Pertinent Diagnostic Messages

7.7.2

A0162 Positioning block mode

A0206 Positioning block mode, encoder 1

A0207 Positioning block mode lagless, encoder 1

A0210 Positioning block mode, encoder 2

A0211 Positioning block mode lagless, encoder 2

E2049 Positioning velocity >= limit value

E2053 Target position out of travel range

E2054 Not homed

E2055 Feedrate override S-0-0108 = 0

E2058 Selected positioning block has not been programmed

E2064 Target position out of num. range

F2028 Excessive deviation

Command Value Adjustment With Positioning Block Mode

The figure below illustrates command value processing in the "positioning block
mode" mode as a block diagram.

Fig.7-20:

7.7.3

Command Value Adjustment With Positioning Block Mode

Single-Block Processing

Description of Basic Function

General Information
Positioning Block Elements

A positioning block is defined by the values of the following list parameters:

P04006, Positioning block target position

P04007, Positioning block velocity

P04008, Positioning block acceleration

P04009, Positioning block jerk

P04018, Positioning block delay time

P04019, Positioning block mode

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Operation Modes

P04063, Positioning block deceleration

Each parameter contains 64 elements, elements of the same num
ber generate the travel profile of the respective positioning block.

The drive reaches the relevant positioning block velocity after an acceleration
phase with the corresponding positioning block acceleration (P04008).
Effective Positioning Velocity

The effective velocity during a positioning process is calculated as follows:

vmax
P04007
S00108

Fig.7-21:
Effective Acceleration and Deceler
ation

Velocity
Positioning block velocity
Feedrate override

Effective Velocity During a Positioning Process

The maximum
deceleration".

delay

is

specified

by"P04063,

Positioning

block

Property damage!
CAUTION

If the acceleration or deceleration values are equal to zero, the drive can no
longer brake. The specified target is never reached or overrun.
Set acceleration value > 0!
Further limitation takes place by the value of "S00138, Bipolar
acceleration limit value" because this limit value takes effect in all
operation modes with position control.

Jerk Limitation by Jerk Filter

In the "drive-internal interpolation" mode the position command value can be

filtered at the output of the positioning generator. We distinguish between two
cases for setting of the filter order.
Case 1: Calculating the filter order from A / R
This means that the parameterized acceleration or deceleration only becomes
effective after t = P00042 TA_position.
In this case, TA_position is the cycle time of the position loop or the
positioning generator. Therefore, the cycle time to be used is dif
ferent according to the control performance (Advanced: 250 s,
Basic: 500 s).

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Operation Modes

P00042
P04008
P04063
P04009

Current position command average value filter order

Positioning block acceleration
Positioning block deceleration
Positioning block jerk

Fig.7-22:

Internally Determining the Value of P-0-0042 for Positioning Block Mode

The setting P04009 = 0 switches the smoothing filter off; i.e. the
desired acceleration or deceleration is immediately reached.
Case 2: Constant filter order
The filter order can also be set to a constant value. This is made via parameter
"P00641, Interpolation cmd value average value filter time constant". The filter
order is calculated from the time constant related to the position clock TA_posi
tion. In the case of an order > 0 the function "filter order constant" is active and
the calculation A/R without effect. A new filter order can only take effect during
initialization of the operation mode and during change of blocks. As before, the
current filter order is displayed in "P00391, Current position command
average value filter order"!
Position Command Value Deceler
ation

The position command value can be delayed by maximum 32 position clocks

after the jerk filter, before it is fed in the position controller. This allows syn
chronous control of a master axis with the controlled slave axis. The number of
position clocks is set with the position command value delay (P00456). The
position command value generator without delay (P00457) is entered in a ring
buffer and then the position command value with delay is applied in the position
command value controller (P00434).

Positioning Block Control Word

With parameter "P04060, Positioning block control word" (bit 1), the position
ing velocity can be limited to the value defined in "S00259, Positioning
velocity".

Position Feedback

When a positioning block is completed, bit 4 (end position reached) is set in

"P04061, Positioning block status word".
|S00430 S00051/53| < S00057 && no sequential block

Interrupting a Positioning Block

Positioning Block Modes

The positioning block mode can be interrupted by:

Removing drive enable

Activating "Drive HALT"

Changing the operation mode

Jogging

Positioning stop or operational stop (S00346, bit 1 and bit 2 = 1)

A drive error occurring

"P04019, Positioning block mode" determines how the target position is pro
cessed in "P04006, Positioning block target position". There are the following
options:

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Operation Modes

Absolute positioning

Relative positioning

Relative positioning with residual path storage

Infinite Travel in Positive/Negative Direction

Sequential block processing

See Parameter Description "P04019, Positioning block mode"
It is possible to define an individual positioning mode for each po
sitioning block.

Command Value Mode (S00393)

"S00393, Command value mode" controls the drive behavior in case "modulo
format" was set as processing format of the position data.
See also Parameter Description "S00393, Command value mode"
The following modes are distinguished:

Shortest distance

Positive direction

Negative direction

The following limiting conditions have to be taken into account:

If the absolute value of the current actual velocity is greater than the ve
locity threshold for positioning in modulo format (S00417), the drive
always moves in the last active direction of rotation.

If the target position is within the target position window in modulo format
(S00418), positioning is always carried out according to the "shortest
distance" mode.
If the velocity threshold for positioning in modulo format was para
meterized with very low values that are within the noise level of the
actual velocity value, this can cause unpredictable behavior.

See Parameter Description "S00417, Positioning velocity threshold in

modulo mode"
See Parameter Description "S00418, Target position window in modulo
mode"

Activating Positioning Blocks

Requirements

"Positioning block mode" must have been entered as the primary mode of op
eration.
This is done by the respective selection of the active operation
mode in the status word, by activating drive enable and by setting
"Drive Halt" = 1.

Command Value Acceptance

Depending on the master communication, a positioning block is started by:

- or -

Toggling bit 0 in "S00346, Positioning control word"

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Operation Modes

0-1 edge of bit 0 in "P04060, Positioning block control word", with parallel
interface orfield bus interface in I/O mode

The positioning command value is thereby copied to the effective target position
S00430 (absolute target position) or added (relative position target, travel
distance).
The block acceptance is confirmed by updating "P04051,
Positioning block acknowledgment" and "S00419, Positioning
command acknowledge". In addition, bit 0 of S00346 is toggled
internally, too, in the case of a 0-1 edge of bit 0 of P04060.
According to master communication and profile type, the block acceptance re
quires different configurations in the cyclic command value channel:

SERCOS interface

"S00346, Positioning control word" has to be configured in the cy

clic data channel (MDT)

Field bus interface

In the freely configurable mode (profile type P04084 = 0xFFFE),

bit 0 of P04077 is mapped to bit 0 of S00346.

In the "I/O mode positioning" (profile type P04084 = 0xFF82), bit 3

of P04068 is mapped to bit 0 of "P04060, Positioning block control
word".
As an alternative, the start in the I/O mode can also take place by
setting the start signal (P04068, bit 1).

Parallel interface

Bit 0 of P04060 has to be configured on a digital input (see also

"Digital Inputs/Outputs")

See also "Command Value Acceptance and Acknowledgment" in section

"General Information on the Operation Modes"
If bit 0 is different in S00346 and in S00419 when the operation
mode is activated, the selected positioning block is immediately ac
cepted and executed.
Block Selection

In the positioning block mode, block selection is always carried out via the con
tent of "P04026, Positioning block selection".
Depending on the master communication, P04026 can be written in different
ways:
Master communication
SERCOS
interface

Field bus
interface

Parallel in
terface

Via cyclic data channel

--

Via digital inputs

Via serial interface

Via field bus control word

--

--

Configuration of P04026

Fig.7-23:

Possibilities of Writing Parameter P04026 Depending on the Master

Communication

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Operation Modes
The assignment of P04026 to digital inputs requires, among other
things, "S00144, Signal status word" and "S00145, Signal
control word".

Absolute Positioning
Parameter Setting
Function

"P04019, Positioning block mode" = 0000 0000 0000 000X

In an absolute positioning block, the target position is a fixed (absolute) position
within the machine coordinate system.
For absolute positioning the drive must have been homed.

Requirements

Requirements for executing absolute positioning blocks are:

The drive must have been homed.

The travel range can be limited with position limit values. Absolute posi
tioning blocks are only executed, if the target position is within the allowed
travel range.

Example:
Absolute positioning with target position = 700 (current position = 200)

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Operation Modes

Fig.7-24:

Absolute Positioning Block

According to master communication, positioning block acceptance

takes place by toggling bit 0 in S00346 or by a 0-1 edge of bit 0 in
P04060.

Relative Positioning Without Residual Path Storage

Parameter Setting

"P04019, Positioning block mode" = 0000 0000 0000 001X

Dedicated Position

In the case of relative positioning blocks without residual path storage, the tar
get position contained in the positioning block is added to the current position.
Relative positioning blocks are also executed, if the drive has not been homed.

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Operation Modes
Incremental Dimension Reference

By sequencing relative positioning blocks it is possible to position with incre

mental dimension. If a relative positioning block without residual path storage
is interrupted, the incremental dimension reference gets lost.
If the positioning block is completed (i.e. the drive reaches target position and
message "end position reached" is active), positioning is possible without losing
the incremental dimension reference.
If infinite positioning in either a forward or backward direction is
achieved by sequencing relative positioning blocks (transport belt),
the position data must be scaled in modulo format (modulo value =
length of transport belt or modulo value = 2 maximum travel dis
tance).
Example:
Relative positioning without residual path storage with travel distance = 700
(current position = 200; target position = 900)

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Operation Modes

Fig.7-25:

Relative Positioning Block Without Residual Path Storage

According to master communication, positioning block acceptance

takes place by toggling bit 0 in S00346 or by a 0-1 edge of bit 0 in
P04060.
Example:
Relative positioning without residual path storage with target position = 700
(current position = 200); interrupting and restarting a relative positioning block
without residual path storage

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Operation Modes

Fig.7-26:

Interrupting a Relative Positioning Bock Without Residual Path Storage

According to master communication, positioning block acceptance

takes place by toggling bit 0 in S00346 or by a 0-1 edge of bit 0 in
P04060.

Relative Positioning With Residual Path Storage

Basic Function
Parameter Setting
Residual Path

"P04019, Positioning block mode" = 0000 0001 0000 001X

If positioning blocks are interrupted, a distance still to be traveled up to the target
position remains. This remaining distance is the residual path.

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Operation Modes
In a relative positioning block with residual path storage, the target position is
a relative distance that relates to the target position at which the message "end
position reached"was last active.
Relative positioning blocks with residual path storage are also executed, if the
drive has not been homed.
Incremental Dimension Reference

By sequencing relative positioning blocks it is possible to position with incre

mental dimension. If a relative positioning block with residual path storage is
interrupted, the incremental dimension reference is retained.
If another positioning block is started while such a positioning block
is being executed, the residual path is rejected. If this new block is
also a relative positioning block with residual path storage, the tar
get position is related to the current actual position as a relative
distance.
Example:

Dedicated Position

Relative positioning with residual path storage with travel distance = 700
(plus residual path = 20 of positioning block n-1)

Without interruption

Current position = 180; new target position = 900

The last valid target position is used as dedicated position (in the example,
position = 200 of positioning block n-1).

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Operation Modes

Fig.7-27:

Relative Positioning Block With Residual Path Storage

According to master communication, positioning block acceptance

takes place by toggling bit 0 in S00346 or by a 0-1 edge of bit 0 in
P04060.

Relative Positioning Block With Residual Path Storage After Activating

Drive Enable
Example:
Interrupted relative positioning block with residual path storage after activation
of drive enable with travel distance = 400 (current position = 200; target position
= 800).

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Operation Modes
Dedicated Position

The position command value at the last "end position reached" (position = 200)
message is used as the reference position.
The incremental dimension reference is ensured.

Fig.7-28:

Relative Positioning Block With Residual Path Storage After Activating

Drive Enable

According to master communication, positioning block acceptance

takes place by toggling bit 0 in S00346 or by a 0-1 edge of bit 0 in
P04060.

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Operation Modes

Relative Positioning Block With Residual Path Storage After Interrupting

With Jog Mode
Example
Dedicated Position
Behavior

Interrupted relative positioning block with residual path storage after jog mode
with target position = 600 without overrunning the target position while jogging
Positioning is always continued at the current actual position value.
An interruption by means of jogging or positioning stop clears the residual path
memory.
The incremental dimension reference is no longer ensured!

Fig.7-29:

Relative Positioning Block With Residual Path Storage After Jog Mode

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Operation Modes
According to master communication, positioning block acceptance
takes place by toggling bit 0 in S00346 or by a 0-1 edge of bit 0 in
P04060.

Relative Positioning Block With Residual Path Storage After Switching

Drive Controller Control Voltage Off and On
If an absolute encoder is used, the incremental dimension reference can be
retained after switching control voltage off and on. The previously calculated
target position is stored at power shutdown. The rest of the distance is traveled
after the interrupted relative positioning block with residual path storage is ac
tivated.
If a single-turn encoder is used, the residual path is rejected and positioning
continues at the actual position.
Dedicated Position

The position command value at the last "end position reached" (position = 100)
message is used as the reference position.
If a positioning block is not accepted, the drive behaves as if the
positioning block had not been started.

Infinite Travel in Positive/Negative Direction

If an axis is to be moved with defined velocity, acceleration and jerk without a
specific target position, the travel block mode"Travelling in positive direction"
or "Travelling in negative direction" must be specified. The drive moves in the
indicated direction until the start signal is reset or one of the position limit values
or the travel range limit switch is reached.
The target position which was set is irrelevant in this positioning mode.
Parameter Setting

"P04019, Positioning block mode" = 0000 0000 0000 010X

Travel in positive direction

"P04019, Positioning block mode" = 0000 0000 0000 100X

Travel in negative direction

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Operation Modes

Fig.7-30:

Example: Infinite Travel in Positive/Negative Direction

According to master communication, positioning block acceptance

takes place by toggling bit 0 in S00346 or by a 0-1 edge of bit 0 in
P04060.

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Operation Modes

7.7.4

Sequential Block Processing

Basic Function
For sequential block processing, it is first of all the same basic rules
as for single-block processing which apply (see that section). In
addition to mere positioning block functions with defined positioning
blocks and block acceptance, there also is a defined block transition
to be parameterized.
Selecting and Activating a Sequen
tial Block

A positioning block with sequential block is selected and activated in the usual
way, only the first block of the sequential block chain being selected. The se
quential block is the block with the next higher block number. A sequential block
can also have a sequential block so that after a start block up to 63 sequential
blocks can be set.
The potential sequential block of the last valid block is block 0.

Conditions to Advance in Sequen

tial Block Mode

There are two basically different modes for block advance; these modes can
be subdivided:

Position-Dependent Block Advance

Block transition with old positioning velocity

Block transition with new positioning velocity

Block transition with intermediate stop and defined delay time (see
P04018)

Switch-Signal-Dependent Block Advance

Position-Dependent Block Advance

General Information
With position-dependent block advance, switching to the sequential block is
carried out at the target position of the start block.
There are three different types of block transition:

Block Transition With Old Positioning Velocity (Mode 1)

Block Transition With New Positioning Velocity (Mode 2)

Block Transition With Intermediate Stop and Defined Delay Time

Block Transition With Old Positioning Velocity (Mode 1)

Parameter Setting

"P04019, Positioning block mode" = 0000 0000 0001 000X

"P04019, Positioning block mode" = 0000 0000 0001 001X

Absolute block with sequential block

Relative block with sequential block

"P04019, Positioning block mode" = 0000 0000 0001 010X

Infinite block in positive direction with sequential block

"P04019, Positioning block mode" = 0000 0000 0001 100X

Infinite block in negative direction with sequential block

Function

In this mode, the target position of the start block is run through at the velocity
of the start block. Then the positioning velocity is switched to that of the se
quential block.

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Operation Modes
With relative and absolute positioning blocks with block advance, the drive
moves in the direction of the target position. As soon as the target position is
passed, the drive switches to the next travel block n+1.
With infinite positioning blocks, the drive moves in positive or negative direction.
As soon as the target position is passed, the drive switches to next positioning
block n+1, the block n representing the positioning block currently in process.
If the target position is not in the selected travel direction, the drive
moves in the direction of the target position. Thus the drive always
reaches the switching position.

Fig.7-31:

Example: Position-Dependent Block Advance (Mode 1)

According to master communication, positioning block acceptance

takes place by toggling bit 0 in S00346 or by a 0-1 edge of bit 0 in
P04060.

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Operation Modes

Block Transition With New Positioning Velocity (Mode 2)

Parameter Setting

"P04019, Positioning block mode" = 0000 0000 0010 000X

Absolute block with sequential block

"P04019, Positioning block mode" = 0000 0000 0010 001X

Relative block with sequential block

"P04019, Positioning block mode" = 0000 0000 0010 010X

Infinite block in positive direction with sequential block

"P04019, Positioning block mode" = 0000 0000 0010 100X

Infinite block in negative direction with sequential block

Function

In this mode, the target position of the start block is run through at the positioning
velocity of the sequential block. The deceleration or acceleration processes
required to adjust the velocity are already carried out in the start block.
The drive moves in the direction of the target position xn (with infinite blocks in
the preset direction) set in current positioning block n. In due time before that,
the acceleration is used to accelerate or decelerate to the next positioning ve
locity vn+1 so that the velocity vn+1 is reached at the target position xn.
But switching to the next positioning block does not occur until the target posi
tion is overrun.

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Operation Modes

Fig.7-32:

Example: Position-Dependent Block Advance (Mode 2)

According to master communication, positioning block acceptance

takes place by toggling bit 0 in S00346 or by a 0-1 edge of bit 0 in
P04060.

Block Transition With Intermediate Stop and Defined Delay Time

Parameter Setting

"P04019, Positioning block mode" = 0000 0000 0100 000X

Absolute block with sequential block

"P04019, Positioning block mode" = 0000 0000 0100 001X

Relative block with sequential block

Function

In this mode, the drive positions at the target position of the start block. Once
the position command value is at the target position, the sequential block is
automatically started without a new start signal having been given externally.

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Operation Modes
If a delay time (P04018) was parameterized for the positioning block, the se
quential block is only started when the delay time is over.
Another operating mode is switching when overrunning the target position with
intermediate stop.
In this case, the drive is decelerated to speed "0" at the target position and then
accelerated to the new positioning velocity.
Advance takes place when the internal command value generator
has reached the target position and a possibly parameterized delay
time (P04018) has passed. With very low jerk values, the resulting
dwell time is relatively long.

Fig.7-33:

Example: Sequential Block Advance for Target Position With Intermedi

ate Stop

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Operation Modes
According to master communication, positioning block acceptance
takes place by toggling bit 0 in S00346 or by a 0-1 edge of bit 0 in
P04060.
This mode should be used if there is a change in direction in the
case of two consecutive sequential blocks within one sequential
block chain. Otherwise, the position at which the direction is
changed will be inevitably overrun.

Switch-Signal-Dependent Block Advance

For switch-signal-dependent block advance, there are the following positioning
modes:

"P04019, Positioning block mode" = 0000 0000 1000 000X

"P04019, Positioning block mode" = 0000 0000 1000 001X

Absolute block with sequential block

Relative block with sequential block

"P04019, Positioning block mode" = 0000 0000 1000 010X

Infinite block in positive direction with sequential block

"P04019, Positioning block mode" = 0000 0000 1000 100X

Infinite block in negative direction with sequential block
Advance to the block with the next higher block number is triggered
by an externally applied switch signal.

Switching With Cams

The switch-signal-dependent block advance allows transition to a sequential

block, triggered by an external switch signal. As input for this switch signal, there
are two sequential block inputs/probe inputs available.
he status of the hardware signals is displayed in "P04057, Positioning block,
input linked blocks".

Function

The drive switches to the next travel block n+1, as soon as the input for the
sequential block cam 1 changes from "0" to "1". If the target position is not
reached, switching to the new positioning block is carried out while traveling.
The drive switches to the next travel block n+1, as soon as the input for the
sequential block cam 2 changes from "0" to "1". If a sequential block cam is
activated during this travel, the drive switches to the positioning block after the
next.

Dedicated Position

A following relative positioning block refers to the position at which the sequen
tial block cam was switched.
The sequential block cams are sampled in the position loop clock
(see "Performance Data"). The precision of position detection
therefore strongly depends on the velocity during overrun.

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Operation Modes
Assignment Table for Cams

Cam 2

Cam 1

01

Block n+1 is started

01

Block n+2 is started

n
x

Fig.7-34:

Drive reaction
Drive moves to target position of block n

Positioning block preselected via the parallel inputs or "P04026,

Positioning block selection"
Not relevant

Drive Reaction With Different Switch Signal Sequences

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Operation Modes

Fig.7-35:

Example: Switch-Signal-Dependent Block Advance

According to master communication, positioning block acceptance

takes place by toggling bit 0 in S00346 or by a 0-1 edge of bit 0 in
P04060.

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Operation Modes
Failure of Switch Signal for Block
Advance

If the start block of a switch-signal-dependent sequential block is an absolute

or relative positioning block, the drive positions at target position, if the switch
signal for block advance is not received. The drive thus only generates the
message "end position reached" after the sequential block chain is completed.
If a switch signal is then applied, the drive will carry out the sequential block.

Fig.7-36:

Example: Switch-Signal-Dependent Block Advance (Behavior With Fail

ure of Switch Signal)

According to master communication, positioning block acceptance

takes place by toggling bit 0 in S00346 or by a 0-1 edge of bit 0 in
P04060.

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Operation Modes
All conditions for advance are constantly queried and evaluated to
be able to switch to the correct sequential block, even after the se
quential block chain was interrupted. Only the first condition for
advance occurring during an interruption is recognized, however.
All other conditions are not taken into account!
Interrupting a Sequential Block
Chain

There are two basically different behaviors when a sequential block chain is
interrupted:

Residual path is rejected when interruption by:

Positioning stop (S00346, bit 1 and bit 2 = 1)

Jogging +/-

Control voltage "Off"

After interruption with "positioning stop" and "jogging +/-" positioning al

ways continues at the current actual position. The sequential block chain
interrupted before is not completed, but the currently selected block is
executed. Thereby the incremental dimension reference gets lost!

Residual path is maintained when interruption by:

Removing drive enable

Removing the "drive start" signal

Changing the operation mode

Depending on the block type of the sequential block chain that was interrupted
and the events occurring during this interruption, the sequential block chain is
processed differently after a restart.
In sequential block mode, relative positioning blocks without resid
ual path storage are not allowed, as otherwise the incremental
dimension reference would get lost in the case of interruption.
Given an interruption, a restart will end the sequential block chain.
Dedicated Position

The dedicated position is the original start position of the sequential block chain.
The incremental dimension reference is retained, as only absolute
and relative positioning blocks with residual path storage are used
in sequential block mode!

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Operation Modes

Fig.7-37:

Example: Sequential Block Interruption With Same Block Selected

According to master communication, positioning block acceptance

takes place by toggling bit 0 in S00346 or by a 0-1 edge of bit 0 in
P04060.
Changing to Different Operation
Mode

When changing the operation mode during an interruption, the sequential block
chain interrupted before is completed at the restart, if there hadn't been any
new block selected.
Given a sequential block with advance due to target position, only the overrun
of the target position of the current positioning block will be detected. The pro
cessing of the sequential block is completed from this position.
The advance condition due to switch signals is always detected.

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Operation Modes
Interrupting a Sequential Block
Chain With Selection of New Posi
tioning Block
Dedicated Position

If a new positioning block is selected during an interruption (e.g. with "Drive

HALT"), the previously interrupted sequential block chain is not completed after
a restart, but the currently selected block is executed.
The dedicated position is the current actual position value.
The incremental dimension reference gets lost, if the sequential
block is interrupted.
The conditions for the interruption of sequential blocks also apply after the con
trol voltage is switched off, if an absolute encoder is used.

Interrupting a Sequential Block

Chain With Absolute Sequential
Blocks

An interruption with absolute positioning blocks does not represent any prob
lem, as the position data reference is always guaranteed.
When a new block number is selected in the case of an interruption, the se
quential block interrupted before is not completed when toggling bit 0 in
"S00346, Positioning control word" or with a 0-1 edge of bit 0 in "P04060,
Positioning block control word", but the currently selected block is executed.
When no new block number is selected in the case of an interruption, the se
quential block interrupted before is completed when toggling bit 0 in "S00346,
Positioning control word" or with a 0-1 edge of bit 0 in "P04060, Positioning
block control word".

7.8

Synchronization Modes

7.8.1

Basic Functions of the Synchronization Modes

Overview
General Information on Synchronization Modes
The synchronization modes allow the drive to run synchronously with regard to
a real or virtual master axis. The synchronization modes are basically divided
into the following groups:

Velocity synchronization with real/virtual master axis

Synchronous position control modes:

Phase Synchronization With Real/Virtual Master Axis

Electronic Cam With Real/Virtual Master Axis

MotionProfile With Real/Virtual Master Axis

The figure below illustrates how the synchronization modes are integrated in
the control loop structure.

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Operation Modes

Fig.7-38:

General Block Diagram of the Synchronization Modes

All synchronization modes have the following identical or similar basic functions
which are comprehensively described in this section:

Adjustment of master axis, consisting of

Generation of master axis

Master axis offset and modulo limitation

Electronic gear with fine adjustment

Drive-controlled dynamic synchronization

The individual synchronization modes basically differ in the follow
ing function blocks:
- Command value processing specific to operation mode
- Command value addition for slave axis
These function blocks are described specific to operation mode in
the individual sections on the respective synchronization modes.

The figure below illustrates the interaction of the individual basic functions
(function blocks) of the synchronization modes.

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Operation Modes

P00048
P00052
P00053
P00054
P00434
P00692
P00694
P00761
P00764
P00775
P00776
P00777
P00778
P00779

Fig.7-39:

Effective velocity command value

Actual position value of measuring encoder
Master axis position
Additive master axis position
Position command value of controller
Additive position command value, process loop
Gear ratio fine adjustment, process loop
Master axis position for slave axis
Master Axis Speed
Resulting Master Axis Position
Effective master axis position
Effective master axis velocity
Synchronous position command value
Synchronous velocity

Function Blocks of the Synchronization Modes

Explanation of Terms
Master axis:
The drive which makes available the master axis position for generating the
synchronous position command value for the slave axis is called master axis.
Slave axis:
The drive which in position control follows a synchronous position command
value internally derived from the master axis is called slave axis.
Actual value cycle:
The modulo range within which the actual position values of the slave axis are
to be found is called actual value cycle. It can also be used to limit the travel
range during synchronization.
The modulo range of the actual value cycle corresponds to the integral multiple
of the synchronization range.
Command value cycle:
The modulo range within which the synchronous position command values of
the slave axis are to be found is called command value cycle. If necessary
(depending on P00155), it can be used to limit the actual position value in the
actual value cycle (cf. P00753).

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Operation Modes

Configuring and Controlling the Synchronization Modes

The synchronization modes are configured and controlled by means of the fol
lowing synchronization parameters:
Pertinent Parameters (Synchroni
zation Parameters)

S00520, Control word of axis controller

S00521, Status word of position loop

P00086, Configuration word synchronous operation modes

P00088, Control word synchronization modes

P00089, Status word synchronization modes

After having selected the required synchronization mode, you can make,
among other things, the following settings via these parameters:

Position control with lag error or lagless

Use of encoder 1 or encoder 2

See also "Operation Mode Handling"

Command Value Addition

This section contains an overview of the basic possibilities of adding command
values. The characteristics and details specific to operation mode are described
in the section of the respective synchronization mode.
Pertinent Parameters

S00037, Additive velocity command value

S00048, Additive position command value

P00048, Effective velocity command value

P00054, Additive master axis position

P00060, Filter time constant additive position cmd value

P00434, Position command value of controller

P00686, Additive position command value, positioning velocity

P00687, Additive position command value, positioning acceleration

P00688, Additive master axis position, positioning velocity

P00689, Additive master axis position, positioning acceleration

P00690, Additive velocity command value, process loop

P00691, Additive position command value, process loop

P00692, Additive master axis position, process loop

P00693, Filter time constant, add. master axis pos., process loop

The figure below contains a rough overview of the command values which can
act on the master and slave axis and of how they can be influenced.

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Operation Modes

Fig.7-40:

Possibilities of Command Value Addition for Master and Slave Axis

Master Axis Adjustment

Brief Description
Master Axis Generation

Master Axis Offset and Modulo Lim

itation

Possible signal sources for the effective master axis of the synchronization
modes:

Real master axis

Virtual master axis, external

Virtual master axis, internal

For internal adjustment or processing of the master axis information, there are
the following options:

Addition of components (= offset) to the incoming master axis angle:

via "P00054, Additive master axis position"

via "P00692, Additive master axis position, process loop"

Limitation to modulo range of master axis

Electronic Gear Function

By means of factors to be set (e.g. input revolutions, output revolutions, polar

ity), the electronic gear function can influence the master axis position relevant
to the operation mode as compared to the master axis position preset by master
axis evaluation.

Pertinent Parameters

The following parameters are used in conjunction with master axis adjustment:

P00052, Actual position value of measuring encoder

P00053, Master axis position

P00054, Additive master axis position

P00084, Number of bits per master axis revolution

P00688, Additive master axis position, positioning velocity

P00689, Additive master axis position, positioning acceleration

P00692, Additive master axis position, process loop

P00693, Filter time constant, add. master axis pos., process loop

P00750, Master axis revolutions per master axis cycle

P00761, Master axis position for slave axis

P00764, Master axis speed

P00765, Modulo factor measuring encoder

P00775, Resulting master axis position

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The following parameters are used in conjunction with the electronic gear with
fine adjustment:

P00083, Gear ratio fine adjustment

P00108, Master drive polarity

P00156, Master drive gear input revolutions

P00157, Master drive gear output revolutions

P00694, Gear ratio fine adjustment, process loop

P00776, Effective master axis position

P00777, Effective master axis velocity

Master Axis Generation

The synchronization modes allow the drive to run synchronously with regard to
a real or virtual master axis. Command value input in the synchronization
modes takes place depending on the kind of master axis.
The firmware supports the following possibilities of input of the master axis po
sition:

Real master axis

For real master axes, the master axis position is input by evaluating the
signals of a master axis encoder (measuring encoder) via "P00052,
Actual position value of measuring encoder".
See also "Measuring Encoder"

Virtual master axis, external

For external virtual master axes, the master (e.g. MLD) cyclically inputs
command values in the NC clock via the master communication in
"P00053, Master axis position".

Virtual master axis, internal

For internal virtual master axes, the master axis position is generated by
the master axis generator contained in the drive and is input in the position
loop clock via "P00761, Master axis position for slave axis".
See also "Virtual Master Axis Generator"

Fig.7-41:

Function Block "Master Axis Generation" for Real/Virtual Master Axis

For the generation of the master axis (real or virtual) the following requirements
must be taken into consideration (with N = value from "P00084, Number of
bits per master axis revolution"):

The master axis position can only be processed in a binary format (1 mas
ter axis revolution = 2N increments).

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Operation Modes

The minimum/maximum value of "P00054, Additive master axis

position" at maximum corresponds to the master axis cycle
(P00750 2N).
Note: When "P00750, Master axis revolutions per master axis cycle"
equals zero, the resulting maximum value for parameter P00054 is
(231 1) increments and the minimum value is 231 increments.

Master Axis Offset and Modulo Limitation

In conjunction with master axis adjustment, it is possible to add an offset and
limit the preset master axis values.

Fig.7-42:
Additive Master Axis Position

Function Block "Master Axis Offset and Modulo Limitation" for Real/Vir
tual Master Axis

If required, the preset master axis can be influenced via additive master axis
values (offset):

For all master axes (real or virtual), the master axis position can be
changed by an additive component (= offset) via "P00054, Additive
master axis position".
Any change in the value of P00054 is traveled with a 2nd order interpo
lator, taking t"P00688, Additive master axis position, positioning
velocity" and "P00689, Additive master axis position, positioning
acceleration" into account.

Another master axis offset can be set via "P00692, Additive master axis
position, process loop". "P00693, Filter time constant, add. master axis
pos., process loop" determines the time constant of a 1st order filter by
means of which the value of P00692 is smoothed.

Resulting Master Axis Position

The resulting master axis position (P00775) is generated from the preset
master axis (P00052, P00053 or P00761) and the additive components
(P00054 and, if required, P00692).

Limiting the Master Axis Position

The resulting master axis position is limited to the modulo range of the master
axis with "P00750, Master axis revolutions per master axis cycle".
With N = value from "P00084, Number of bits per master axis revolution" the
following applies:
Modulo value master axis = P00750 2N
Observe the following aspects:

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Master Axis Speed

The master axis range is set as an integral multiple of a master axis rev
olution (= 2N increments) with "P00750, Master axis revolutions per
master axis cycle".

The sum from P-0-0052/P-0-0053, P-0-0054 and P-0-0765 mustn't ex

ceed the double master axis range (P00750 2N)!

The master axis speed is generated by differentiating the master axis position
and displayed in "P00764, Master axis speed". The component of an external
virtual master axis is generated in the NC clock.

Electronic Gear Function With Fine Adjustment

The input value for the electronic gear is the resulting master axis position
(P00775).

Fig.7-43:
Functional Principle

Function Block "Electronic Gear With Fine Adjustment"

The function block "electronic gear with fine adjustment" is divided into the fol
lowing subfunctions:

Electronic master axis gear with fine adjustment

The master axis position or master axis velocity is first multiplied with the
factor from P00157/P00156 (output/input revolutions).
The fine adjustment is carried out by multiplication of the resulting master
axis position or master axis velocity with the sum of 1 + P00083 (gear
ratio fine adjustment) and the subsequent multiplication with the sum of
1 + P00694 (gear ratio fine adjustment, process loop).

Polarity reversal of master axis position

Via "P00108, Master drive polarity", it is possible to invert the polarity of
the master axis position or master axis velocity.

Input Value of Electronic Gear

The input value for the electronic gear is the resulting master axis position
(P00775).

Output Value of Electronic Gear

The currently effective master axis position and master axis velocity after the
function block "electronic gear with fine adjustment" are generated in the posi
tion loop clock (see "Performance Data") and displayed in the following param
eters:

P00776, Effective master axis position

P00777, Effective master axis velocity

Command Value Processing for Slave Axis Depending on Operation Mode

When the output value of the electronic gear is processed, there are different
operations carried out, according to the synchronization mode, for generating
the position or velocity command value for the subsequent control loop (slave

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Operation Modes
axis). This "command value processing depending on operation mode" is de
scribed in the sections on the respective operation mode:

See "Velocity Synchronization"

See "Phase Synchronization"

See "Electronic Cam"

See "MotionProfile"

Dynamic Synchronization of the Slave Axis

Brief Description
Synchronization With Velocity Syn
chronization

Synchronization in Synchronous
Position Control Modes

Pertinent Parameters

Features of synchronization in the "velocity synchronization" mode:

Synchronization takes place as velocity adjustment

generation of status message "synchronization completed" (P00152;

bit 0)

Generation of status message "synchronous mode in synchroniza

tion" (P00089; bit 8)

Features of synchronization for synchronous position control modes:

Sequence of synchronization is single-step or double-step or double-step

optimized

Synchronization absolute (position and velocity adjustment) or relative

(only velocity adjustment)

Modulo ranges to be set for synchronization:

Modulo value (S00103)

Command value cycle slave axis (P00754)

Division for command value cycle (setting in P00751)

Direction for synchronization to be set for position adjustment of modulo

axes, shortest distance, positive or negative direction in "P00154,
Synchronization direction"; setting the tolerance window with only positive
or negative direction via "P00151, Synchronization window for modulo
format"

display of the difference between actual position value in the actual value
cycle and the synchronous position command value generated from the
master axis position in "P00034, Position command additional actual
value"

Generation of status message "synchronization completed" (P00152;

bit 0)

Mode "standard" or "register controller" for command value addition for

the slave axis

Generation of status message "synchronous mode in synchroniza

tion" ("P00089, Status word synchronization modes", bit 8)

The following parameters are used in conjunction with dynamic synchroniza

tion:

S00048, Additive position command value

S00183, Velocity synchronization window

S00228, Position synchronization window

P00043, Torque-generating current, actual value

P00060, Filter time constant additive position cmd value

P00071, C3100 Command Recalculate actual value cycle

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Operation Modes

P00142, Synchronization acceleration

P00143, Synchronization velocity

P00151, Synchronization window for modulo format

P00152, Synchronization completed

P00154, Synchronization direction

P00155, Synchronization mode

P00686, Additive position command value, positioning velocity

P00687, Additive position command value, positioning acceleration

P00691, Additive position command value, process loop

P00697, Synchronization, master axis synchronous position

P00698, Synchronization, master axis synchronization range

P00751, Synchronization divisions per command cycle slave axis

P00752, Load revolutions per actual value cycle slave axis

P00753, Position actual value in actual value cycle

P00754, Command value cycle

P00786, Modulo value actual value cycle

General Information on Synchronization

The synchronization process is a drive-controlled motion with the objective of
achieving absolute or relative synchronization between master axis and slave
axis. Depending on the synchronization mode, we distinguish the following
characteristics of dynamic synchronization:

Synchronization Mode

Synchronization with velocity synchronization (velocity adjustment)

Synchronization in synchronous position control modes (velocity and po

sition adjustment)

The basic settings for carrying out synchronization are made in "P00155,
Synchronization mode"; these settings comprise, for example:

Mode for command value addition

Synchronization "absolute" or "relative"

Range of synchronization

Reaction to other command value changes after absolute synchronization

had been reached for the first time
See Parameter Description "P00155, Synchronization mode"

The figure below contains an overview of the different possible settings for car
rying out synchronization and for adding command values in the synchroniza
tion modes:

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Fig.7-44:

Overview of Methods to be Selected for Synchronization and for Com

mand Value Addition

In the default setting of parameter P00155 all bits are at value

"0"!
Synchronization With Velocity Syn
chronization

Drive-controlled dynamic synchronization in the "velocity synchronization"

mode is carried out depending on bit 5 of parameter "P00155, Synchronization
mode".

Bit 5 = 0 Synchronization only when operation mode is activated

Bit 5 = 1 Synchronization is always active

By generating velocity command values, the drive accelerates or decelerates

during synchronization until the synchronous velocity has been reached. The
velocity command values are generated taking the preset synchronization ac
celeration (P00142) into account.

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Fig.7-45:
Synchronization in Synchronous
Position Control Modes

Function Block "Dynamic Synchronization" With Velocity Synchroniza

tion

In the synchronous position control modes (phase synchronization, cam shaft

and motion profile), drive-controlled dynamic synchronization is carried out
when a synchronous position control mode is activated.
In the case of double-step synchronization, the values of the "P00142,
Synchronization acceleration" and "P00143, Synchronization velocity" are
used for generating an additive command value for compensating the slave
axis which is not velocity- and position-synchronous.

Fig.7-46:

Function Block "Dynamic Synchronization" With Synchronous Position

Control Modes

All settings relevant for synchronization have to be made in

"P00155, Synchronization mode".

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Operation Modes
The drive is absolutely synchronous when the following condition has been
fulfilled:

S00228
P00753
S00048
P00691
P00778

Fig.7-47:

Position synchronization window

Position actual value in actual value cycle
Additive position command value
Additive position command value, process loop
Synchronous position command value

Condition of Synchronism for Synchronous Position Control Modes

The modulo range can be set depending on the mode of synchronization and
the command value addition:

Modulo value (S00103)

Command value cycle slave axis (P00754)

Division for command value cycle (setting in P00751)

In the case of absolute scaling, there is no modulo limitation!

Single-Step/Double-Step Synchronization
Depending on the synchronization mode, there are the following options:

Single-Step Synchronization

In the "velocity synchronization" mode, only single-step synchronization

is possible (braking or accelerating with the value from "P00142,
Synchronization acceleration").

In synchronous position control modes you can select either single-step,

double-step and optimized double-step synchronization.

Single-step synchronization is a master-axis-synchronous synchronization that

is added to the synchronous movement. The processing of the slave axis syn
chronization distance is carried out while the master axis is going through the
master axis synchronization range.
As a slave axis synchronization distance can only be calculated with absolute
synchronization (bit 1 = 0 in "P00155, Synchronization mode")) single-step
synchronization is only possible with absolute synchronization, as well.
Selecting is carried out via bit 6 of the parameter P00155.
In this case, the corresponding parameters take effect:

P00697, Synchronization, master axis synchronous position

P00698, Synchronization, master axis synchronization range

P00697 and P00698 refer to the output of the electronic gear.

By means of bit 7 = 1 in P00155 a relative master-axis-synchronous synchro

nization is set. As a consequence, synchronizing is immediately started at
activation of the synchronization mode. The parameter for the master axis syn
chronous position (P00697) does not take effect. Starting the synchronizing
process for inactive master axis, this will produce a velocity command value of
zero. This effect must be prevented for active slave axis.
With bit 7 = 0, you can set that the master-axis-synchronous synchronization
motion only starts when the master axis start position is passed (absolutely
master-axis-synchronous). This position results from subtraction of master axis
synchronous position and master axis synchronization range. Until the master
axis start position is passed, the axis decelerates or accelerates, based on the

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current actual velocity, with the parameterized synchronization acceleration
(P00142) in the direction of the synchronous velocity.
For single-step synchronization, observe the following notes on utilization:

Single-step synchronization is only active when the operation mode is ac

tivated. This means that, after the synchronous operation mode was
activated, synchronization starts the next time the master axis start posi
tion is passed.
The master axis position used for the comparison with the master axis
start position is defined:

In phase synchronization by "P00776, Effective master axis

position"

In cam shaft mode by "P00227, Cam table, access angle"

The profile for synchronization is determined by a 5th order polynomial.

The synchronous position command values, generated from the master

axis positions, take immediate effect when the master axis start position
is passed or at the beginning of the master axis synchronization range.

The velocity of the master axis should be constant when passing through
the master axis synchronization range.

The values set in t"P00142, Synchronization acceleration" und

"P00143, Synchronization velocity" are not taken into account for the
synchronization process.

Apart from by the other conditions of the synchronization mode, the re

sulting characteristics of velocity and acceleration can only be influenced
by the master axis synchronization range.

For modulo axes, the polarity of the slave axis synchronization distance
can be set by "P00154, Synchronization direction". However, this only
applies if the absolute value of the shortest synchronization distance is
greater than the value of "P00151, Synchronization window for modulo
format".

Synchronization is completed when the master axis position has gone

through the master axis synchronization range. Bit 0 of "P00155,
Synchronization mode" then defines how subsequent changes of
"S00048, Additive position command value" are processed (see below
section "Command Value Addition for Slave Axis").

To be noticed for single-step synchronization

With single-step synchronization, a profile "velocity in rest" (standard profile
"G-R" according to VDI 2143) is added to the synchronous position command
values:

The distance traveled with the added profile is determined by the differ
ence of synchronous position command value (+ "S00048, Additive
position command value" + "P00691, Additive position command value,
process loop") and actual position value at the starting point of time.

When modulo scaling has bee set, the distance is limited to the synchro
nization range set in "P00155, Synchronization mode".

"P00154, Synchronization direction" is evaluated in the case of modulo

scaling. The preferred direction set is taken into account, if the determined
synchronization distance is greater than the "P00151, Synchronization
window for modulo format".

The initial velocity of the profile is determined by the difference of actual

velocity and synchronous velocity at the starting point of time.

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Operation Modes

We assume that the acceleration of the slave axis at the starting point of
time equals zero.
For more details Details on the used profile "velocity in rest" see
section "MotionProfile" !

Double-Step Synchronization

The double-step synchronization process consists of velocity adjustment and

subsequent position adjustment.
Step 1 Velocity adjustment:

The drive either accelerates or decelerates from the current actual velocity
at the time of activation to the synchronous velocity.

The synchronous velocity is generated by differentiating the synchronous

position command value. The synchronous position command value
xsync is determined from the master axis position ("P00052, Actual
position value of measuring encoder" or "P00053, Master axis
position") according to the operation mode.

Velocity adjustment already takes place in position control. When accel

erating or decelerating, the drive takes the value in "P00142,
Synchronization acceleration" into account.

Step 2 Position adjustment:

After velocity adjustment, there is a difference between the active position
command value and the sum of the synchronous position command value
(xsync), additive position command value (S00048) and additive position com
mand value of the process loop (P00691).
The difference is calculated according to the following equation:

x
xsynch
S00048
P00691
P00434

Fig.7-48:

Difference (distance)
Synchronous position command value
Additive position command value
Additive position command value, process loop
Position command value of controller

Difference With Absolute Synchronization (Travel Distance)

In the second step of synchronization, the difference generated during velocity

adjustment is compensated by a travel motion taking"P00142,
Synchronization acceleration" and "P00143, Synchronization velocity" into
account. This position adjustment is added to the synchronous movement.
Optimized Double-Step Synchroni
zation

The third synchronization method available for selection is a mixture between

one-step and double-step synchronization. This method has the following char
acteristics:

not master-axis-synchronous

Immediate start when activating the synchronous mode

No separation between velocity and position adjustment

Superimposed synchronization motion with 2nd order interpolator

Limitation of synchronization motion by "P00142, Synchronization

acceleration" and "P00143, Synchronization velocity"

Reduce braking acceleration (deceleration) during positioning in order to

reduce the number of acceleration jumps

Specific features with modulo position scaling

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We distinguish between two cases:

At the start of the synchronization process, the braking distance is small

er than a synchronization range.
The initial velocity of the synchronization motion is so small that immediate
positioning is possible. For determining the synchronization distance
"P00154, Synchronization direction", in conjunction with "P00151,
Synchronization window for modulo format", is evaluated.

At the start of the synchronization process, the braking distance is great

er than a synchronization range.
The velocity of the synchronization motion is first reduced until the braking
distance is smaller than a synchronization range. In this case, a parame
terized synchronization direction is ignored, so that the velocity of the
synchronization motion has no change of sign

Relative/Absolute Synchronization
In the synchronous position control modes, it is possible to select either relative
or absolute synchronization:

Relative synchronization (P00155, bit 1 = 1)

There is no fixed position reference between master axis and slave axis.

Absolute synchronization (P00155, bit 1 = 0)

There is a fixed position reference between master axis position and
position command value that results from the master axis position and the
parameterized additive position command value.

Relative Synchronization

The figure below illustrates the relative synchronization to a virtual master axis,
the master axis being in standstill when the operation mode is activated.

Fig.7-49:

Example: Relative Synchronization out of Standstill

When the operation mode is activated, the synchronous velocity = 0.

Upon activation of the operation mode, the bits for "synchronization com
pleted" (P00152, bit 0 = 1) and "slave axis has been synchron
ized" (P00089, bit 8 = 1) are output.

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Operation Modes

When the machine starts, the axis, based on its current position, follows
the master axis position with relatively synchronous position.

The figure below illustrates the relative synchronization to a virtual master axis,
the master axis having a velocity 0 when the operation mode is activated.

Fig.7-50:

Absolute Synchronization

Example: Relative Synchronization in Running Operation

When the operation mode is activated, the master axis moves at constant
velocity.

Based on its current position, the slave axis accelerates to the synchro
nous velocity. While this is done, the synchronization acceleration
(P00142) is effective.

Upon reaching the synchronous velocity, the bits for "synchronization

completed" (P00152, Bit 0 = 1) and "slave axis has been synchron
ized" (P00089, bit 8 = 1) are output.

The figure below illustrates the absolute synchronization to a virtual master

axis, the master axis being in standstill when the operation mode is activated.

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Fig.7-51:

Example: Absolute Synchronization out of Standstill

When the operation mode is activated, the synchronous velocity = 0. The

current master axis position differs from the synchronous position.

The synchronization status signals "synchronization running" (P00152,

bit 0 = 0).

The absolute angle reference between slave axis and master axis position
is established. The master axis is turning with the parameterized synchro
nization velocity (P00143). During acceleration and deceleration, the
synchronization acceleration (P00142) is effective.

As soon as the position difference between master axis and slave axis is
smaller than the "position synchronization window" (S00228), the status
bit "slave axis has been synchronized" (P00089, bit 8 = 1) is output.
Bit 0 is set in P00152 when synchronization has been completed.

The figure below illustrates the absolute synchronization to a virtual master

axis, the master axis having a velocity 0 when the operation mode is activated.

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Operation Modes

Step 1
Step 2

Fig.7-52:

Velocity adjustment
Position adjustment

Example: Absolute Synchronization in Running Operation

When the operation mode is activated, the master axis moves at constant
velocity.

The synchronization status signals "synchronization running" (P00152,

bit 0 = 0).

Based on its current position, the slave axis accelerates to the synchro
nous velocity. While this is done, the synchronization acceleration
(P00142) is effective.

After velocity adjustment, the absolute position reference is established.

Position adjustment takes place with parameterized synchronization ac
celeration (P00142) and synchronization velocity (P00143).

As soon as the position difference between master axis and slave axis is
smaller than the "position synchronization window" (S00228), the status
bit "slave axis has been synchronized" (P00089, bit 8 = 1) is output.
Bit 0 is set in P00152 when synchronization has been completed.

Command Value Addition for Slave Axis

Brief Description
In the "velocity synchronization" mode, the addition of command values for the
slave axis is directly associated with the synchronization process.
In synchronous position control modes, the addition of command values for the
slave axis is an independent functional sequence for which you can choose
between the following modes as regards command value addition:

"Standard" mode

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Operation Modes
Changes are processed with the values from the parameters P00686
and P00687

"Register controller" mode

Changes are smoothed by a 1st order filter (time constant in parameter
P00060)

Extended Functions (Command Value Cycle and Actual Value Cycle)

Applications
The extended functions of synchronization (command value cycle and actual
value cycle) are required in conjunction with the following applications:

Change of format, i.e. variable master axis gear settings in operation

Necessity of mechanical relation of slave axis to master axis

Command value cycle and actual value cycle are only relevant for
the synchronization modes "phase synchronization", "cam shaft"
and "motion profile".

The figure below illustrates the interaction of the pertinent parameters for the
command value cycle and the actual value cycle:

Fig.7-53:
Command Value Cycle

Generation and Operating Principle of the Command Value and Actual

Value Cycle

The command value cycle defines a modulo limitation of the synchronous po

sition command values, which takes effect in a synchronous position control
mode during synchronization, in the slave axis.
The command value cycle is calculated internally by the drive and
displayed in "P00754, Command value cycle".

Fig.7-54:

Internal Calculation Formula of the Value for P00754

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Operation Modes
Actual Value Cycle

In the case of modulo position scaling (S00076, bit 7), the actual value cycle
determines the modulo range of the actual position values at the slave axis
relevant for the synchronization process.
The command value cycle is calculated internally by the drive and
displayed in "P00786, Modulo value actual value cycle".
For the setting of bit 4 in "P00155, Synchronization mode" we distinguish the
following cases:

Bit 4 = 1
The actual value cycle (P00786) equals the command value cycle
(P00754).

Bit 4 = 0
The actual value cycle is calculated internally by the drive and can be
modified by means of the setting in "P00752, Load revolutions per actual
value cycle slave axis".

Fig.7-55:

Internal Calculation Formula of the Value for P00786

The parameterization of the actual value cycle is required if, in the

case of phase synchronization, synchronization is to be carried out
in a range greater than the modulo value (S00103).
Position Actual Value in Actual Val
ue Cycle

In the case of "phase synchronization" or "cam and modulo position scaling",

the "P00753, Position actual value in actual value cycle" displays a current
actual position value of the slave axis limited via P00786.
When activating the synchronization mode, the travel distance for synchroni
zation is determined with the actual position value in the actual value cycle.
The value of P00753 is again limited to the synchronization range which has
been set (P00754 or S00103) and then is used as travel range for synchro
nization (see figure above).

Synchronization Range

In the case of modulo scaling, the range for synchronization can be set in
"P00155, Synchronization mode", i.e. the distance to be traveled is limited to
this range:

Modulo value (S00103)

Command value cycle (P00754)

Division of the command value cycle

The actual position value used for calculating the distance must be
unequivocal in the range in which synchronization is to take place.
The actual value cycle from which the actual position value is de
rived must therefore be determined in such a way that is a multiple
of the synchronization range.

By setting "P00750, Master axis revolutions per master axis cycle" = 0, it is

possible to select absolute handling of the master axis within a range of
2048 revolutions.
Synchronization in the Command
Value Cycle

The distance traveled during synchronization is the result of the difference be

tween synchronous position command value (+ "S00048, Additive position
command value" + "P00691, Additive position command value, process

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loop") and the actual position value. The synchronization distance is limited to
the modulo command value cycle.

Fig.7-56:

Synchronization Distance During Synchronization in Command Value

Cycle

The range for the command value cycle at the slave axis is defined by the
master axis cycle and the electronic gear.

Modulo Scaling

Fig.7-57:

Command Value Cycle With Modulo Scaling

Linear modulo scaling

Fig.7-58:

Command Value Cycle With Linear Modulo Scaling

The active value is displayed in "P00754, Command value cycle". The com
mand value cycle describes the range containing the calculated synchronous
position command values.
For modulo division, the number of command value cycles per actual value
cycle is used. The number is calculated with the following formula:

Fig.7-59:
Synchronization in a Division of the
Command Value Cycle

Number of Command Value Cycles per Actual Value Cycle

The distance traveled during synchronization is the result of the difference be

tween synchronous position command value (+ "S00048, Additive position
command value" + "P00691, Additive position command value, process
loop") and the actual position value. The synchronization distance is limited to
a division of the modulo command value cycle.

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Operation Modes

Fig.7-60:

Synchronization Distance for Synchronization in a Division of the Com

mand Value Cycle

The actual position value in the division of the command value cycle is derived
from "P00753, Position actual value in actual value cycle". For modulo divi
sion, the number of divisions per actual value cycle is used. The number is
calculated with the following formula:

Fig.7-61:
Synchronization in the Modulo
Range

The distance traveled during synchronization is the result of the difference be

tween synchronous position command value (+ "S00048, Additive position
command value" + "P00691, Additive position command value, process
loop") and the actual position value. The synchronization distance is limited to
the modulo value.

Fig.7-62:

7.8.2

Number of Synchronization Divisions per Actual Value Cycle

Synchronization Distance for Synchronization in Modulo Range

Velocity Synchronization With Real/Virtual Master Axis

Brief Description
Assignment to functional firmware package, see chapter "Suppor
ted Operation Modes".
In the operation mode "velocity synchronization with real/virtual master axis",
the drive follows a preset master axis velocity in a velocity-synchronous way.
The real master axis velocity is generated by a measuring encoder, the virtual
master axis velocity is preset by the master or the integrated master axis gen
erator.
See also "Dynamic Synchronization of the Slave Axis" in section "Basic Func
tions of the Synchronization Modes"
Features

Determination of the effective velocity command value (P00048) from

the differentiated and fine interpolated sum of master axis position
(P00053) or measuring encoder position (P00052) and additive com
ponents of "P00054, Additive master axis position" and "P00692,
Additive master axis position, process loop", multiplied with master axis
gear and fine adjustment

Adjustable master axis polarity

Synchronization takes place in single-step form

Activation time for synchronization can be selected

The figure below illustrates the interaction of the individual subfunctions (func
tion blocks) of the "velocity synchronization" mode:

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P00048
P00052
P00053
P00761
P00777

Fig.7-63:

Variants of the Operation Mode

Effective velocity command value

Actual position value of measuring encoder
Master axis position
Master axis position for slave axis
Effective master axis velocity

Function Blocks of the Operation Mode "Velocity Synchronization With

Real/Virtual Master Axis"

There are the following variants of the operation mode to be selected:

Velocity synchronization with real master axis

Velocity synchronization with virtual master axis

Application of the Operation Mode

Velocity synchronization is used, for example, for simple transport rolls of print
ing machines. The drive runs with a velocity synchronous to the master axis.
The track speed at the circumference of the transport roll or the winder is preset
by the electric gear. A defined tension can be set by the fine adjustment of the
gear.

Pertinent Parameters

In addition to the general parameters of all synchronization modes, there are

other parameters involved in velocity synchronization:

S00103, Modulo value

S00183, Velocity synchronization window

P00088, Control word synchronization modes

P00089, Status word synchronization modes

P00159, Slave drive feed travel

P00777, Effective master axis velocity

See also "Pertinent Parameters" in the subsections of "Basic Functions of the

Synchronization Modes"
Pertinent Diagnostic Messages

In addition to the general diagnostic messages of all synchronization modes,

there are other diagnostic messages involved in velocity synchronization:

A0110 Velocity synchronization, virtual master axis

A0111 Velocity synchronization, real master axis

A0164 Velocity synchronization

E2063 Velocity command value > limit value

See also "Pertinent Diagnostic Messages" in the subsections of "Basic Func

tions of the Synchronization Modes"

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Overview of the Operation Mode

Fig.7-64:

Block Diagram: Velocity Synchronization With Real/Virtual Master Axis

Master Axis Adjustment

Master axis adjustment is realized by means of the following subfunctions:

Generation of master axis

Master axis offset and modulo limitation

Electronic gear with fine adjustment

See "Basic Functions of the Synchronization Modes"

Command Value Adjustment

Overview

Command value adjustment in the "velocity synchronization" mode consists of

the following basic functions:

Master axis adjustment

Command value processing specific to operation mode

Command value adjustment slave axis, consisting of

Dynamic synchronization

Command value addition

Only the function block "command value processing" specific to ve
locity synchronization is described in detail below. The detailed
descriptions of the other function blocks are contained in section
"Basic Functions of the Synchronization Modes".
See "Basic Functions of the Synchronization Modes"

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Fig.7-65:
Generating the Synchronous Ve
locity Command Value

Command Value Processing Specific to Operation Mode for Velocity

Synchronization

The synchronous velocity command value (dxsync) is generated in terms of the

selected master axis polarity (P00108) and the scaling type (S00044) that
was set, using one of the following equations:

dxsync

Synchronous velocity command value

Generating the Synchronous Velocity Command Value With Rotary
Scaling

dxsync

Synchronous velocity command value

Generating the Synchronous Velocity Command Value With Linear
Scaling

Fig.7-66:

Fig.7-67:

One master axis revolution is standardized to 2 N increments (with

N = value from "P00084, Number of bits per master axis
revolution"). This means that the LSB of the master axis position
corresponds to 2-N master axis revolutions.

Synchronization With Velocity Synchronization

The synchronization process is a drive-controlled motion with the aim of syn
chronizing the axis to the master axis velocity. The slave axis is velocitysynchronous when the following condition has been fulfilled:

dxsync
S00040

Fig.7-68:

Synchronization Process

Synchronous velocity command value

Velocity feedback value

Condition for Velocity Synchronism of the Slave Axis

Upon activation of the operation mode, a velocity adjustment is first executed.

This means that the drive either accelerates or decelerates from the current
actual velocity at the time of activation to the synchronous velocity.

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The drive generates the synchronous velocity by differentiating the master axis
position:

Fig.7-69:

Drive-Side Generation of the Synchronous Velocity

After the synchronous velocity has been reached, another change of the syn
chronous velocity is processed depending on "P00155, Synchronization
mode".
The following variants are available to do this:

P00155, bit 5 = 0
Velocity adjustment only carried out once, all following changes of ve
locity are carried out with maximum acceleration

P00155, bit 5 = 1
Every change of velocity is limited by the value of "P00142,
Synchronization acceleration"
See also Parameter Description "P00155, Synchronization mode"

7.8.3

Phase Synchronization With Real/Virtual Master Axis

Brief Description
Assignment to functional firmware package, see chapter "Suppor
ted Operation Modes".
In the operation mode "phase synchronization with real/virtual master axis", the
drive follows a preset master axis position in an absolute or relative phase syn
chronous way.
The real master axis velocity is generated by a measuring encoder, the virtual
master axis velocity is preset by the master or the integrated master axis gen
erator.
See also "Dynamic Synchronization of the Slave Axis" in section "Basic Func
tions of the Synchronization Modes"
Features

Determination of the position command value from the master axis posi
tion using the electronic gear with fine adjustment, adjustable master axis
polarity

Synchronization mode to be selected

Single-step or double-step synchronization

Absolute or relative phase synchronization

Synchronization range to be selected

The figure below illustrates the interaction of the individual subfunctions (func
tion blocks) of the "phase synchronization" mode:

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Operation Modes

P00052
P00053
P00434
P00761
P00776
P00777
P00778
P00779

Fig.7-70:

Variants of the Operation Mode

Actual position value of measuring encoder

Master axis position
Position command value of controller
Master axis position for slave axis
Effective master axis position
Effective master axis velocity
Synchronous position command value
Synchronous velocity

Function Blocks of the Operation Mode "Phase Synchronization With

Real/Virtual Master Axis"

There are the following variants of the operation mode to be selected:

Position synchronization

Phase synchronization with real master axis, encoder 1

Phase synchronization with real master axis, encoder 2

Phase synchronization with real master axis, encoder 1, lagless

Phase synchronization with real master axis, encoder 2, lagless

Phase synchronization with virtual master axis, encoder 1

Phase synchronization with virtual master axis, encoder 2

Phase synchronization with virtual master axis, encoder 1, lagless

Phase synchronization with virtual master axis, encoder 2, lagless

In the operation mode variant "position synchronization", select
phase synchronization and the master axis in "P00088, Control
word synchronization modes". The encoder selection and lagless
position control are set in "S00520, Control word of axis
controller".

Application "Absolute Phase Syn

chronization"

In machining processes that require absolute phase synchronization, e.g. print

ing, punching or perforating in printing machines, the absolute position refer
ence to the master axis is established in the operation mode "phase
synchronization". The drive synchronizes with a position command value that
is generated from master axis position and additive position command value.

Application "Relative Phase Syn

chronization"

For machining processes that only require relative phase synchronization, e.g.
synchronization of belts or feed rollers without defined starting point, a relative
position reference to the master axis is established. During the first synchroni
zation, there is only an adjustment to the synchronous velocity but no position
adjustment carried out.

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Operation Modes
Pertinent Parameters

In addition to the general parameters of all synchronization modes, there are

other parameters involved in phase synchronization:

S00103, Modulo value

S00520, Control word of axis controller

S00521, Status word of position loop

P00086, Configuration word synchronous operation modes

P00088, Control word synchronization modes

P00089, Status word synchronization modes

P00159, Slave drive feed travel

P00776, Effective master axis position

P00777, Effective master axis velocity

P00778, Synchronous position command value

P00779, Synchronous velocity

See also "Pertinent Parameters" in the subsections of "Basic Functions of the

Synchronization Modes"
Pertinent Diagnostic Messages

In addition to the general diagnostic messages of all synchronization modes,

there are other diagnostic messages involved in phase synchronization:

A0112 Phase synchronization, encoder 1, virtual master axis

A0113 Phase synchronization, encoder 2, virtual master axis

A0114 Phase synchronization, encoder 1, real master axis

A0115 Phase synchronization, encoder 2, real master axis

A0116 Phase synchr. lagless, encoder 1, virtual master axis

A0117 Phase synchr. lagless, encoder 2, virtual master axis

A0118 Phase synchr. lagless, encoder 1, real master axis

A0119 Phase synchr. lagless, encoder 2, real master axis

A0163 Position synchronization

See also "Pertinent Diagnostic Messages" in the subsections of "Basic Func

tions of the Synchronization Modes"

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Overview of the Operation Mode

Fig.7-71:

Block Diagram: Phase Synchronization With Real/Virtual Master Axis

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Operation Modes

Master Axis Adjustment

Master axis adjustment is realized by means of the following subfunctions:

Generation of master axis

Master axis offset and modulo limitation

Electronic gear with fine adjustment

See "Basic Functions of the Synchronization Modes"

Command Value Adjustment

Overview

Command value adjustment in the "phase synchronization" mode consists of

the following basic functions:

Master axis adjustment

Command value processing specific to operation mode

Command value adjustment slave axis, consisting of

Dynamic synchronization

Command value addition

Only the function block "command value processing" specific to
phase synchronization is described in detail below. The detailed
descriptions of the other function blocks are contained in section
"Basic Functions of the Synchronization Modes".
See "Basic Functions of the Synchronization Modes"

Fig.7-72:
Generating the Internal Position
Command Value

Command Value Processing Specific to Operation Mode for Phase Syn

chronization

In the operation mode "phase synchronization with real/virtual master axis", the
internal position command value (P00434) is generated by addition of the
synchronous position command value (xsync) with the components of the addi
tive position command value (S00048) and the additive position command
value of process loop (P00691).

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P00434
xsync
xadd
xadd_PR

Fig.7-73:

Position command value of controller

Synchronous position command value
Filter output of "S00048, Additive position command value"
Filter output of "P00691, Additive position command value, process
loop"

Generating the Internal Position Command Value

Note: In the synchronized status (P00089; bit 8 = 1), the following applies:

Fig.7-74:
Generating the Synchronous Posi
tion Command Value

Generating the Internal Position Command Value in the Synchronized

Status

The synchronous position command value (xsync) is generated in terms of the

selected master axis polarity (P00108) and the scaling type (S00076) that
was set, using the following equation:

Fig.7-75:

Generating the Synchronous Position Command Value With Modulo

Scaling

Fig.7-76:

Generating the Synchronous Position Command Value With Rotary Ab

solute Scaling

Fig.7-77:

Generating the Synchronous Position Command Value With Linear Ab

solute Scaling

One master axis revolution is standardized to 2 N increments (with

N = value from "P00084, Number of bits per master axis
revolution"). This means that the LSB of the master axis position
corresponds to 2-N master axis revolutions.

Synchronization
See "Basic Functions of the Synchronization Modes"

7.8.4

Electronic Cam With Real/Virtual Master Axis

Brief Description
Assignment to functional firmware package, see chapter "Suppor
ted Operation Modes".

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In the operation mode "electronic cam with real/virtual master axis", there is a
fixed relationship between the master axis position and the slave axis.
The real master axis velocity is generated by a measuring encoder, the virtual
master axis velocity is preset by the master or the integrated master axis gen
erator.
See also "Dynamic Synchronization of the Slave Axis" in section "Basic Func
tions of the Synchronization Modes"
Features

4 cam shaft profiles with a max. of 1024 data points (P00072, P00092,
P00780, P00781)

4 cam shaft profiles with a max. of 128 data points (P00783, P00784,
P00785, P00786)

Cubic spline interpolation of the cam data points

Dynamic angle offset and angle offset at begin of profile

Freely definable switch angle for cam and cam distance

Synchronization mode to be selected

Single-step or double-step synchronization

Absolute or relative phase synchronization

Synchronization range to be selected

Change of format "on the fly"

Cross cutter function

Clocked Pull Roll

The figure below illustrates the interaction of the individual subfunctions (func
tion blocks) of the "electronic cam" mode:

P00052
P00053
P00434
P00761
P00776
P00777
P00778
P00779

Fig.7-78:
Variants of the Operation Mode

Actual position value of measuring encoder

Master axis position
Position command value of controller
Master axis position for slave axis
Effective master axis position
Effective master axis velocity
Synchronous position command value
Synchronous velocity

Function Blocks of the Operation Mode "Electronic Cam"

There are the following variants of the operation mode to be selected:

Position synchronization

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Operation Modes

Cam with real master axis, encoder 1

Cam with real master axis, encoder 2

Cam with real master axis, encoder 1, lagless

Cam with real master axis, encoder 2, lagless

Cam with virtual master axis, encoder 1

Cam with virtual master axis, encoder 2

Cam with virtual master axis, encoder 1, lagless

Cam with virtual master axis, encoder 2, lagless

In the operation mode variant "position synchronization", select
electronic cam shaft and the master axis in "P00088, Control word
synchronization modes". The encoder selection and lagless posi
tion control are set in "S00520, Control word of axis controller".

Pertinent Parameters

In addition to the general parameters of all synchronization modes, there are

other parameters involved in this operation mode:

S00103, Modulo value

S00520, Control word of axis controller

S00521, Status word of position loop

P00061, Angle offset begin of table

P00072, Cam table 1

P00073, Cam distance 2

P00085, Dynamic angle offset

P00086, Configuration word synchronous operation modes

P00088, Control word synchronization modes

P00089, Status word synchronization modes

P00092, Cam table 2

P00093, Cam distance

P00094, Cam switch angle

P00144, Cam distance switch angle

P00158, Angle offset change rate

P00159, Slave drive feed travel

P00227, Cam table, access angle

P00695, Angle offset begin of profile, process loop

P00696, Filter time constant, angle offset profile, process loop

P00776, Effective master axis position

P00777, Effective master axis velocity

P00778, Synchronous position command value

P00779, Synchronous velocity

P00780, Cam table 3

P00781, Cam table 4

P00782, Cam table 5

P00783, Cam table 6

P00784, Cam table 7

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Operation Modes

P00785, Cam table 8

See also "Pertinent Parameters" in the subsections of "Basic Functions of the

Synchronization Modes"
Pertinent Diagnostic Messages

In addition to the general diagnostic messages of all synchronization modes,

there are other diagnostic messages involved in this operation mode:

A0128 cam shaft, Cam, encoder 1, virtual master axis

A0129 Cam, encoder 2, virtual master axis

A0130 Cam, encoder 1, real master axis

A0131 Cam, encoder 2, real master axis

A0132 Cam, lagless, encoder 1, virt. master axis

A0133 Cam, lagless, encoder 2, virt. master axis

A0134 Cam, lagless, encoder 1, real master axis

A0135 Cam, lagless, encoder 2, real master axis

A0163 Position synchronization

F2005 Cam table invalid

See also "Pertinent Diagnostic Messages" in the subsections of "Basic Func

tions of the Synchronization Modes"

Overview of the Operation Mode

Fig.7-79:

Block Diagram: Electronic Cam Shaft With Real/Virtual Master Axis

Master Axis Adjustment

Master axis adjustment is realized by means of the following subfunctions:

Generation of master axis

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Master axis offset and modulo limitation

Electronic gear with fine adjustment

See "Basic Functions of the Synchronization Modes"

Command Value Adjustment

Overview

Command value adjustment in the "electronic cam" mode consists of the fol
lowing basic functions:

Master axis adjustment

Command value processing specific to operation mode, consisting of

Cam shaft profiles (incl. access)

Adjustment of position format

Command value adjustment slave axis, consisting of

Dynamic synchronization

Command value addition

Only the function block "command value processing" specific to the
cam shaft mode is described in detail below. The detailed descrip
tions of the other function blocks are contained in section "Basic
Functions of the Synchronization Modes".
See "Basic Functions of the Synchronization Modes"

Fig.7-80:

Command Value Processing Specific to Operation Mode for Cam Mode

Synchronization
See "Basic Functions of the Synchronization Modes"

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Operation Modes

7.8.5

MotionProfile With Real/Virtual Master Axis

Brief Description
Assignment to functional firmware package, see chapter "Suppor
ted Operation Modes".
In the operation mode "MotionProfile with real/virtual master axis", there is a
fixed relationship between the master axis position and the slave axis.
The real master axis velocity is generated by a measuring encoder, the virtual
master axis velocity is preset by the master or the integrated master axis gen
erator.
See also "Dynamic Synchronization of the Slave Axis" in section "Basic Func
tions of the Synchronization Modes"
Features

2 sequences of motion with up to 8 motion steps per master axis revolution

Definition of a motion step by standardized profile or cam shaft profile

Motion laws can be selected (rest in rest, rest in velocity, velocity in rest,
velocity in velocity, constant velocity)

Motion laws realized by 5th order polynomial or, in the case of rest in rest,
alternatively by inclined sine curve

Individual distance for each motion step

Dynamic angle offset and angle offset at begin of profile

Absolute synchronization can be switched off

Synchronization mode to be selected

Absolute or relative processing of the motion steps to be selected

Synchronization range to be selected

Cross cutter function

The figure below illustrates the interaction of the individual subfunctions (func
tion blocks) of the "MotionProfile" mode:

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Operation Modes

P00052
P00053
P00434
P00761
P00776
P00777
P00778
P00779

Fig.7-81:

Variants of the Operation Mode

Actual position value of measuring encoder

Master axis position
Position command value of controller
Master axis position for slave axis
Effective master axis position
Effective master axis velocity
Synchronous position command value
Synchronous velocity

Function Blocks of Operation Mode "MotionProfile"

There are the following variants of the operation mode to be selected:

Position synchronization

Motion Profile synchronization with real master axis, encoder 1

Motion Profile synchronization with real master axis, encoder 2

MotionProfile with real master axis, encoder 1, lagless

MotionProfile with real master axis, encoder 2, lagless

MotionProfile with virtual master axis, encoder 1

MotionProfile with virtual master axis, encoder 2

MotionProfile with virtual master axis, encoder 1, lagless

MotionProfile with virtual master axis, encoder 2, lagless

In the operation mode variant "position synchronization", select
MotionProfile and the master axis in "P00088, Control word
synchronization modes". The encoder selection and lagless posi
tion control are set in "S00520, Control word of axis controller".

Pertinent Parameters

In addition to the general parameters of all synchronization modes, there are

other parameters involved in this operation mode:

S00103, Modulo value

S00520, Control word of axis controller

S00521, Status word of position loop

P00061, Angle offset begin of table

P00085, Dynamic angle offset

P00086, Configuration word synchronous operation modes

P00088, Control word synchronization modes

P00089, Status word synchronization modes

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Operation Modes

P00158, Angle offset change rate

P00159, Slave drive feed travel

P00227, Cam table, access angle

P00695, Angle offset begin of profile, process loop

P00696, Filter time constant, angle offset profile, process loop

P00700, MotionProfile, master axis switching position

P00701, Motion step 1, slave axis initial position

P00702, MotionProfile, diagnosis, set 0

P00703, Number of motion steps, set 0

P00704, Master axis velocity, set 0

P00705, List of master axis initial positions, set 0

P00706, List of motion laws, set 0

P00707, List of distances, set 0

P00708, List of slave axis velocities, set 0

P00709, MotionProfile, diagnosis, set 1

P00710, Number of motion steps, set 1

P00711, Master axis velocity, set 1

P00712, List of master axis initial positions, set 1

P00713, List of motion laws, set 1

P00714, List of distances, set 1

P00715, List of slave axis velocities, set 1

P00755, Gear reduction

P00776, Effective master axis position

P00777, Effective master axis velocity

P00778, Synchronous position command value

P00779, Synchronous velocity

See also "Pertinent Parameters" in the subsections of "Basic Functions of the

Synchronization Modes"
Pertinent Diagnostic Messages

In addition to the general diagnostic messages of all synchronization modes,

there are other diagnostic messages involved in this operation mode:

A0136 MotionProfile, encoder 1, virtual master axis

A0137 MotionProfile, encoder 2, virtual master axis

A0138 MotionProfile, encoder 2, real master axis

A0139 MotionProfile, encoder 1, real master axis

A0140 MotionProfile lagless, encoder 1, virtual master axis

A0141 MotionProfile lagless, encoder 2, virtual master axis

A0142 MotionProfile lagless, encoder 1, real master axis

A0143 MotionProfile lagless, encoder 2, real master axis

A0163 Position synchronization

F2003 Motion step skipped

F2004 Error in MotionProfile

See also "Pertinent Diagnostic Messages" in the subsections of "Basic Func

tions of the Synchronization Modes"

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Operation Modes

Overview of the Operation Mode

Fig.7-82:

Block Diagram: MotionProfile With Real/Virtual Master Axis

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Operation Modes

Master Axis Adjustment

Master axis adjustment is realized by means of the following subfunctions:

Generation of master axis

Master axis offset and modulo limitation

Electronic gear with fine adjustment

See "Basic Functions of the Synchronization Modes"

Command Value Adjustment

Overview

Command value adjustment in the "MotionProfile" mode consists of the follow

ing basic functions:

Master axis adjustment

Command value processing specific to operation mode, consisting of

Cam shaft profiles (incl. access)

Adjustment of position format

Command value adjustment slave axis, consisting of

Dynamic synchronization

Command value addition

In the following only the function block "command value process
ing" specific to operation mode for the MotionProfile will be descri
bed in detail. The detailed descriptions of the other function blocks
are contained in section "Basic Functions of the Synchronization
Modes".
See "Basic Functions of the Synchronization Modes"

Fig.7-83:

Command Value Processing Specific to Operation Mode with Motion

Profile

Synchronization
See "Basic Functions of the Synchronization Modes"

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Extended Axis Functions

Extended Axis Functions

8.1

Availability of the Extended Axis Functions

The following overview illustrates by which basic or functional packages the
respective extended axis function is supported (if not stated otherwise, this ap
plies to all 3 firmware versions, MPB, MPD, MPH and MPC).

Extended axis function

In base pack
age
(characteristic)

In functional package ...

(on the basis of a base package with the following charac
teristics)
Servo function

Synchronization

Main spindle

Drive halt

OL/CL

vcmd reset ("emergency halt")

OL/CL

vcmd reset with ramp ("quick stop")

OL/CL

vcmd reset while maintaining amax

OL/CL

Torque disable

OL/CL

Return motion

CL

Package reaction on error

OL/CL

NC reaction on error

OL/CL

OL/CL

Friction torque compensation

CL

Encoder error correction

CL

Backlash on reversal correction

CL

Precision axis error correction

CL 1)

Control-side axis error correction

CL 1)

Temperature error correction

CL

Quadrant error correction

CL

Cogging torque compensation

CL

Measuring wheel mode

CL

OL/CL

CL

Spindle positioning

CL

Parameter set switching

CL2)3)

OL/CL2)3)

OL/CL 2)

Drive-controlled oscillation

OL/CL 2)

MLD reaction on error

E-Stop function

Positive stop drive procedure

Redundant motor encoder

OL/CL

2)

1)

CL

1)

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Extended Axis Functions

In base pack
age

Extended axis function

(characteristic)
Parking axis

OL/CL

Integrated safety technology

In functional package ...

(on the basis of a base package with the following charac
teristics)
Servo function

Synchronization

Main spindle

Only available with the corresponding hardware configuration

OL
CL
1)
2)
3)

Fig.8-1:

Open-loop characteristic
Closed-loop characteristic
Not for the firmware version MPB
Not for the firmware version MPD
For parameter group control loop and application only

Availability of the Extended Axis Functions

To use a functional package, it must have been activated (enabled). The cur
rently enabled functional packages are displayed in "P02004, Active
functional packages".
See also "Enabling of Functional Packages"

8.2

Drive Halt

8.2.1

Brief Description
Assignment to functional firmware package, see chapter "Availa
bility of the Extended Axis Functions".
The "Drive Halt" function is used to shut down an axis with defined acceleration
and defined jerk.
In the case of default Drive Halt is carried out as quick stop in position control
or velocity control. The control mode position is activated if one of the operation
modes (S00032 ...) is defined with position control (incl. internal PLC opera
tion modes). Otherwise the control mode velocity is active.
The configuration Drive Halt (P00558, Bit 1,2) allows free selection of the
control mode.

Bit 1,2 = 1,1 position control

Bit 1,2 = 1,0 velocity control

The configuration "Drive Halt" (P00558, bit 0 = 1) allows switching to the func
tion "operational stop". The operation modes "velocity control", "drive-internal
interpolation", "drive-controlled positioning" and "positioning block" are then
stopped internally with V-command = 0. After removing "Drive Halt" the motion
becomes active again.
The adjustable deceleration of position command value in position clocks
(P00456) is limited to a maximum of 32 clocks.
Apart from the "Drive Halt" function there is an operational stop for
the operation modes "drive-controlled positioning" and "drive-inter
nal interpolation". However, this function has its own control signal.
Features

Activated via "halt bit" of master communication (see "Device Control and
State Machines")

Active operation mode interrupted; drive remains in control (after setting

the "halt bit" the interrupted operation mode is continued)

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Extended Axis Functions

Quick Stop in Position Control

Shutdown with acceleration (S00372) and jerk limit values (S00349)
in position control.

Quick Stop in Velocity Control

Shutdown with acceleration (S00372) and jerk limit values (S00349)
in velocity control.

Pertinent Parameters

Acknowledge "Drive Halt" in P00115

S00124, Standstill window

S00349, Bipolar jerk limit

S00372, Drive Halt acceleration bipolar

P00115, Device control: status word

P-0-0434, Position command value of controller

P-0-0456, Position command value delay

P-0-0457, Position command value generator

P00558, Drive Halt configuration

8.3

Error Reactions

8.3.1

Overview of Error Reactions

Depending on the operating mode that is used and some parameter settings,
the drive controller carries out monitoring functions. An error message is gen
erated by the drive controller, if a status is detected that no longer allows correct
operation.
Errors are classified in error classes. The error class is represented by the first
two digits of the diagnostic message number.
See also "Terms, Basic Principles"
See also "Diagnostic System"
If the drive controller is in control (drive enable was set) and an error occurs,
the drive controller automatically starts a drive error reaction.
This drive error reaction depends on:

The error class of the error occurred and

The settings of the following parameters:

P00117, Activation of control unit reaction on error

P00118, Power supply, configuration

P00119, Best possible deceleration

At the end of each error reaction, the drive goes torque-free. Power
off depends on the setting in P00118!

Error Classes

There are 8 error classes with different priority:

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Extended Axis Functions

Diagnos
tic mes
Error class
sage num
ber

Error reaction

F2xxx

non-fatal error

F3xxx

non-fatal safety technolo According to setting in "P00119, Best

gy error
possible deceleration" and "P00117,
Activation of control unit reaction on error"

F4xxx

interface error

According to setting in "P00119, Best

possible deceleration"

F6xxx

travel range error

Velocity command value reset ("emergency

halt")

safety technology error

According to setting in bit 9 of parameter

"P03210, Safety technology configuration"

F8xxx

Fatal error

Immediate torque disable, if this is the error

reaction for non-fatal errors, otherwise gener
al deceleration of the motor via short circuit of
motor windings

F9xxx

fatal system error

immediate torque disable

E-xxxx

Fatal system error "pro

cessor exception"

immediate torque disable

Not in
MPx16:

According to setting in parameters "P00119,

Best possible deceleration" and "P00117,
Activation of control unit reaction on error"

F7xxx

Fig.8-2:

Error Classes and Drive Reaction

The error class can be recognized by the diagnostic message num

ber and defines the drive behavior in the case of error.

8.3.2

Best Possible Deceleration

Brief Description
The error reaction "best possible deceleration" (to be set in "P00119, Best
possible deceleration") is carried out automatically in the case of the following
states:

Non-Fatal Errors (F2xxx)

Non-Fatal Safety Technology Errors (F3xxx)

Interface errors (F4xxx)

travel range errors (F6xxx)

Safety technology error (F7xxx) (however, depending on bit 9 of

"P03210, Safety technology configuration")

Fatal warnings which require the reaction "velocity command value re

set" (e.g. E8034, E6044)

Communication phase is reset

Drive enable is removed (see S00134 resp. P04077 or P00115, bit

15)

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Extended Axis Functions

In the case of fatal system errors (F9xxx/E-0800) the setting in
P00119 is ignored, the drive is shut down with immediate torque
disable.
One of the following reactions for "best possible deceleration" can be set in
P0-0119:

Velocity command value reset

Velocity command value reset with ramp and filter ("quick stop")

Velocity command value reset while maintaining the emergency halt de

celeration (S00429) is respected

Return motion (only with expansion package "servo function")

Torque disable

Deceleration via short circuit of motor windings

Time Flow of the Error Reaction

Time Flow With Motor Holding
Brake Available

The time flow of the error reaction with motor holding brake available and of the
output stage release in the case of velocity command value reset, is described
in the section "Functional Description: Error Situation 1" in "Operating Behavior
of the Motor Holding Brake" .
The activation and function of the motor holding brake depends on the setting
in parameter "P00525, Holding brake control word".
See also "Motor Holding Brake"

Deceleration in U/f Operation

8.3.3

In the case of open-loop-controlled U/f operation, deceleration at the torque

limit only takes place, when the stall protection loop has been activated (see
"P00045, Control word of current controller"). The maximum deceleration of
the shutdown is preset by the value entered in "P00569, Maximum stator
frequency slope".

Package Reaction on Error

Brief Description
Assignment to functional firmware package, see chapter "Availa
bility of the Extended Axis Functions".
"Package reaction" is the simultaneous error reaction of all axis drives supplied
by a common power bus (DC bus). Drive errors of a drive can be signaled to
all other axis drives via the module bus (signal bus) which allows the simulta
neous error reaction (according to setting in parameter "P00119, Best
possible deceleration") of all axis drives.
The settings for signaling drive errors and package reaction are made individ
ually for each drive in "P00118, Power supply, configuration". This allows
activating the package reaction only for individual axes. The behavior of the
axes for which the package reaction has not been activated has to be taken
into account for the case of error and must be controlled on the master side, if
necessary!
The supply unit switches off power supply only in the case of its own
errors and in the case of fatal drive errors (F8xxx), if the drive sig
naling errors signals F8 errors to the supply.
Fields of Application

Examples of applications with interactive (interpolating, synchronized) use of

drives that are supplied by a common power bus ("drive package"):

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Extended Axis Functions

Machine tools (e.g. milling, turning, grinding machines)

Gear cutting machines (gear wheel machining)

Printing mechanisms of printing machines, etc.

By setting the error reaction of the drive system devices according to the ap
plication, the following damages can be minimized:

Machine damages

Tool/workpiece/material damages
The package reaction is not suitable for avoiding personal injury!

Reaction to drive
errors

Priority of appropriate error re

actions for typical drive applica Setting in
tions
P00117

NC master-side
reaction

NC master-side priority of shut

down and power off

NC reaction ac
tive

No package reaction,
Drive with F8 error does
no signaling of drive er not decelerate!
rors

Drive reaction

Shutdown spindle drive (asyn

chronous motors)

NC reaction not
active

Package reaction, sig

naling of drive errors

Setting in P00118

Shutdown servo drives (syn

chronous motors)

Power off via NC master

NC reaction not
active

Package reaction,
signaling of drive er
rors,
signaling of F8 error to
supply

Power off only with F8

error, otherwise via NC
master with DC bus short
circuit

NC reaction not
active

Package reaction,
signaling of drive er
rors,
signaling of F8 error to
supply

Power off only with F8

error, otherwise via NC
master; no DC bus short
circuit, drive with F8 error
does not decelerate!

NC reaction not
active

Package reaction,
signaling of drive er
rors,
signaling of F8 error to
supply

Power off only with F8

error, otherwise via NC
master with DC bus short
circuit

Power off
Shutdown spindle drive (asyn
chronous motors) irrelevant
Power off
Shutdown spindle drive (asyn
chronous motors)
Shutdown servo drives (syn
chronous motors)
Power off
Shutdown servo drives (syn
chronous motors)
Shutdown spindle drive (asyn
chronous motors)

Fig.8-3:

Drive with F8 error does

not decelerate! ,
No DC bus short circuit

power off
Shutdown servo drives (syn
chronous motors)

General conditions

Examples of Settings in P00117 and P00118, Depending on the Pri

ority of Appropriate Error Reactions (With General Conditions)

The above examples are not binding and provide basic information
on the settings that have to be made according to the axis-specific
and application-dependent requirements.
Pertinent Parameters

P00118, Power supply, configuration

P00119, Best possible deceleration

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Extended Axis Functions

8.3.4

Control Reaction on Error

NC Reaction on Error
Brief Description
Assignment to functional firmware package, see chapter "Availa
bility of the Extended Axis Functions".
To avoid damages to the machine, some applications require that the master
(e.g. NC) retains control of the travel profile of the axes in the case of error, too,
and shuts down the machine axes in a coordinated way. For this case, the "NC
reaction on error" option was implemented; it can be activated via P00117.
The master is informed of an error in the drive controller via the drive status
word (see S00135) so that the master can shut down the machine axes in a
coordinated way and therefore avoid possible damage.
NC reaction on error is only possible with non-fatal errors (diag
nostic message F2xxx), otherwise the drive always reacts with an
immediate drive-side error reaction.
Pertinent Parameters

S00135, Drive status word

P00117, Activation of control unit reaction on error

P00119, Best possible deceleration

MLD Reaction on Error

Brief Description
Assignment to functional firmware package, see chapter "Availa
bility of the Extended Axis Functions".
As an alternative to the NC reaction, the IndraMotion MLD reaction on error can
also be realized for the (local) axis. In this, the MLD reaction and the NC reaction
are differentiated functionally inasfar that by means of IndraMotion MLD, even
for an interface error (F4xxx) an error reaction to be defined by the operator can
be executed for the (local) axis.
Prerequisite for the utilization of the MLD error reaction is an enable
of the PLC function in the drive (see "Enabling of Functional Pack
ages").
Pertinent Parameters

S00135, Drive status word

P00117, Activation of control unit reaction on error

P00119, Best possible deceleration

P02003, Selection of functional packages

8.4

E-Stop Function

8.4.1

Brief Description
Assignment to functional firmware package, see chapter "Availa
bility of the Extended Axis Functions".

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The E-Stop function is used to shut down the drive with selectable drive reaction
(see Parameter Description "P00008, Activation E-Stop function") via a digital
input of the drive controller.
To use the E-Stop function, you have the following options:

E-Stop with reaction to interface error (F4034 Emergency-Stop)

Reaction: Best possible deceleration (as set in P00119)

E-Stop with reaction to travel range error (F6034 Emergency-Stop)

Reaction: Velocity command value reset

E-Stop as fatal warning "E8034 Emergency-Stop"

Reaction: Best possible deceleration (as set in P00119)
If "E-Stop" was parameterized as a warning, it is not necessary to
clear the diagnostic message!

Pertinent Parameters

Pertinent Diagnostic Messages

P00008, Activation E-Stop function

P00119, Best possible deceleration

P00223, E-Stop input

E8034 Emergency-Stop

F4034 Emergency-Stop

F6034 Emergency-Stop

8.5

Compensation Functions / Corrections

8.5.1

Friction Torque Compensation

Brief Description
Assignment to functional firmware package, see chapter "Availa
bility of the Extended Axis Functions".
The behavior of a machine axis is negatively affected by static friction when
starting or when reversing the direction. The drive-internal friction torque com
pensation allows compensating the static friction by adding, depending on the
direction of movement, a torque/force command value.

Fig.8-4:

Friction Torque Curve With Static Friction

Friction torque compensation is mainly intended to be used in pre

cision machine tools and to reduce the path errors caused by static
friction. This applies particularly to circular errors at the quadrant
transitions.

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Pertinent Parameters

8.5.2

S00092, Bipolar torque/force limit value

S00124, Standstill window

S00155, Friction compensation

Encoder Error Correction

Brief Description
Assignment to functional firmware package, see chapter "Availa
bility of the Extended Axis Functions".
The quality of machining or the precision with which an axis can follow a given
path is determined by several factors. One of the factors of influence is the
precision with which a measuring system can identify the position of an axis or
shaft.
IndraDrive controllers provide the possibility of improving inaccuracy inherent
in position measuring systems with sinusoidal signals. This improves the ability
of a drive or an axis to follow the position and velocity command values. The
bandwidth of the control loops can also be improved in many cases by the
possibility of setting the control loop gain to a higher value.
Pertinent Parameters

Pertinent Diagnostic Messages

8.5.3

P00340, C3500 Command Determine encoder correction values

P00341, Control word for encoder correction

P00342, Correction value table for encoder correction

C3500 Command Determine encoder correction values

C3501 Acquisition velocity not allowed

C3502 Motor encoder not available

C3503 Optional encoder not available

C3504 Measuring encoder not available

C3505 No encoder selected

C3506 Correction value table cannot be stored

Axis Error Correction

Brief Description
The actual position value provided by the measuring system can differ from the
real actual position value at the axis, e.g. at the point of chip removal in the case
of metal-cutting machining, due to

inaccuracy of the measuring system,

transmission inaccuracy in mechanical transmission elements such as

gear, clutch, feed spindle etc.,

thermal expansion of machine parts of the drive system.

For compensating the mechanically determined position error sources,

IndraDrive controllers provide the following correction functions:

Backlash on reversal correction

Precision axis error correction

Control-side axis error correction

The control-side axis error correction is always active. The correction value can
be transmitted in the cyclic telegram or in the service channel. In addition, pre
cision axis error correction or reversal clearance can be activated, precision
axis error correction having higher priority.

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Moreover, it is possible to activate the temperature error correction. IndraDrive
controllers provide two possibilities of correcting temperature errors:

Pertinent Parameters

8.5.4

Independent of axis position

Depending on axis position

S00058, Reversal clearance

S00124, Standstill window

P00400, Axis correction external correction value

P00401, Axis correction active correction value

P00402, Axis correction reference temperature

P00403, Axis correction reference position for temp. corr.

P00404, Axis correction actual temperature pos.-dependent

P00405, Axis correction actual temperature pos.-independent

P00406, Axis correction temperature factor pos.-dependent

P00407, Axis correction temperature factor pos.-independent

P00408, Axis correction start position

P00409, Axis correction end position

P00410, Axis correction support point distance

P00411, Axis correction, correction table positive

P00412, Axis correction, correction table negative

P00413, Axis correction control word

Quadrant Error Correction

Brief Description
Assignment to functional firmware package, see chapter "Availa
bility of the Extended Axis Functions".
In the case of axis drives that are controlled, for example, in circular interpola
tion, static friction at the reversal points of the direction of motion can cause
distortion of the circular contour.
In order to compensate this contour error at the so-called "quadrant transi
tions" (velocity reversal), IndraDrive controllers provide the "quadrant error
correction" function.
This correction function is useful for such cases when drives are operated in
cyclic position control and in circular interpolation by the control master.
Pertinent Parameters

8.5.5

P00100, Position command value extension

P00435, Control word of position controller

P00436, Reference radius for quadrant error correction

P00437, Velocity time range for quadrant error correction

P00438, Velocity time range for quadrant error correction

P00439, Table of velocity pulse for quadrant error correction

Cogging Torque Compensation

Brief Description
Assignment to functional firmware package, see chapter "Availa
bility of the Extended Axis Functions".

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Extended Axis Functions

Motors for which the magnetic excitation is realized with permanent magnets
(e.g. synchronous motors) in many cases show cogging torques or cogging
forces. Cogging torques/cogging forces already act on the moving component
of the motor in the de-energized state and aim at moving it to a stable position.
When the motor is put into motion by control, the cogging torques/cogging
forces act on the motor in a decelerating or accelerating way, according to the
position. For applications in which minimum lag error or very constant velocity
is important, the position-dependent cogging torques/cogging forces can have
a negative effect.
To improve the synchronous operation and lag error behavior of synchronous
motors, IndraDrive controllers provide cogging torque and cogging force com
pensation for drives with high demands on lag error and synchronous operation
quality. For this purpose, additive torque command values take effect in drive
control in a position-dependent way.
Hardware Requirements

Pertinent Parameters

Pertinent Diagnostic Messages

The compensation of cogging torque/cogging force is possible for the use of

both measuring systems with absolute evaluation and measuring systems with
relative evaluation. The following restriction applies to relative measuring sys
tems:

The position measuring range may have only one reference mark or it is
equipped with distance-coded reference marks!

P00162, C1800 Command Drive optimization / command value box

P00165, Drive optimization, control word

P00170, Drive optimization, acceleration

P00171, Drive optimization, velocity

P01130, Table of cogging torque compensation values pos. Direction

P01131, Control word of cogging torque compensation

P01132, Table of cogging torque compensation values neg. direction

P01133, Status word of cogging torque compensation

P01134, Velocity threshold for attenuation of detent cogging compens

P01135, Velocity threshold for switching off cogging torque compens.

P01136, Lead time cogging torque compensation

P01138, C4800 Command Determine cogging torque compensation

table

C1808 Drive not homed

C4800 Command Determine cogging torque compensation table

C4801 Cogging torque compensation: Measuring vel. too high

C4802 Cogging torque compensation: Measuring vel. too low

C4803 Cogging torque compensation: Inadmissible acceleration

C4804 Cogging torque comp: Err. when storing corr. val table

C4805 Cogging torque comp.: Motor measuring system not homed

8.6

Measuring Wheel Mode

8.6.1

Brief Description
Assignment to functional firmware package, see chapter "Availa
bility of the Extended Axis Functions".

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The measuring wheel mode is used for material feed axes, e.g. in sheet-metal
machining. For direct measurement of the infeed of moved material, a rotary
encoder that is detecting the infeed length is driven via a measuring wheel with
frictionally engaged contact to the material surface.
The position control loop is closed via motor encoder and measuring wheel
encoder, possible slip between motor and material does not cause incorrect
measured values of material length.
The measuring wheel mode may only be activated when contact
has been established between measuring wheel and material sur
face.

Fig.8-5:
Hardware Requirements

Typical Arrangement of Drive for Material Infeed With Measuring Wheel

Encoder

The measuring wheel encoder is an optional (external) encoder that is con

nected according to the connection diagram contained in the "Drive Controllers,
Control Sections; Project Planning Manual" separate documentation.
See also Measuring Systems

Pertinent Parameters

The following parameters are used to parameterize this function:

S00520, Control word of axis controller

S00521, Status word of position loop

P00241, Actual pos. smoothing time constant for hybrid pos. control

P00242, Current actual slip value in %

P00243, Maximum occurred actual slip value in %

P00244, Monitoring window of slip in %

The following parameters are used to parameterize the measuring wheel en

coder:

S00115, Position feedback 2 type

S00117, Resolution of feedback 2

P00123, Feed constant 2 (optional encoder)

P00124, Gear 2 load-side (optional encoder)

P00125, Gear 2 encoder-side (optional encoder)

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Pertinent Diagnostic Messages

P00185, Control word of encoder 2 (optional encoder)

F2036 Excessive position feedback difference

8.7

Positive Stop Drive Procedure

8.7.1

Brief Description
Assignment to functional firmware package, see chapter "Availa
bility of the Extended Axis Functions".
For special applications, it is required to move machine axes operated in posi
tion or velocity control up to a limit stop in order to generate forces of pressure.
When an axis in the standard situation has moved up to a limit stop, the drive
should signal a drive error by the monitoring facilities of the position or velocity
control loop and react with shutdown.
But if the drive can detect the special case of operation "positive stop drive
procedure", it can ignore the messages of the position and motions monitors
and generate the required force of pressure, if necessary.
The control master signals this special case to the controller of IndraDrive de
vices via a command. Upon this command, the drive switches off the respective
monitors and acknowledges axis standstill to have been detected and a pa
rameterizable force or torque threshold to have been exceeded.
Pertinent Parameters

Pertinent Diagnostic Messages

S00082, Torque/force limit value positive

S00083, Torque/force limit value negative

S00092, Bipolar torque/force limit value

S00124, Standstill window

S00149, C1300 Positive stop drive procedure command

C1300 Positive stop drive procedure command

C1301 Class 1 diagnostics error at command start

8.8

Redundant Motor Encoder

8.8.1

Brief Description
Assignment to functional firmware package, see chapter "Availa
bility of the Extended Axis Functions".
Motor control of synchronous motors requires a position measuring system that
measures the position of the moving part of the motor as opposed to the static
part. If there is malfunction or defect in the position measuring system (motor
encoder), a synchronous motor can no longer be decelerated in a controlled
way.
Depending on the requirements, position control can require an external meas
uring system at the axis which detects the position at the load with the required
precision.
For axis control, the entire mechanical drive system between motor encoder
and load position of the external encoder is mapped via parameters. This allows
calculating the position of the motor encoder from the position of the external
encoder or determining the load position from the motor encoder position, if the
mechanical drive system is without slip.

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If there is a defect in the motor encoder, the motor position, when an external
encoder is used, can be determined via the position of the external encoder
and the synchronous motor can be decelerated in a controlled way.
For asynchronous motors with motor encoder, it is also possible to use an ex
ternal measuring system for controlled deceleration, if there is a defect in the
motor encoder. But if the asynchronous motor, depending on the drive task, is
operated without encoder, controlled deceleration via external encoder in the
case of error is not possible!
You can only use measuring systems with Upp = 1V or resolvers as
redundant motor encoders!
Pertinent Parameters

P00185, Control word of encoder 2 (optional encoder)

Pertinent Diagnostic Messages

F2031 Encoder 1 error: Signal amplitude incorrect

F2042 Encoder 2: Encoder signals incorrect

F8022 Enc. 1: Enc. signals incorr. (can be cleared in ph. 2)

F8042 Encoder 2 error: Signal amplitude incorrect

8.9

Spindle Positioning

8.9.1

Brief Description
Assignment to functional firmware package, see chapter "Availa
bility of the Extended Axis Functions".
With the drive function "spindle positioning", the drive, at a command of the
master, aligns the spindle independently with regard to the spindle zero posi
tion. The command position is transmitted to the drive controller via parameter
and can be preset as absolute or relative position.
By means of the "position spindle" command the spindle can be positioned in
a position-controlled way (e.g. within the "velocity control" mode) without having
to switch the operation mode from velocity to position control.
How to use the drive function "spindle positioning":

For milling and drilling spindles

For turning machine main spindles

To change the workpiece (if required)

To place balancing drillings for workpieces to be balanced

To index the workpiece for further machining

For revolving transfer machines

Hardware Requirements

To prepare tool change spindle remains at a defined position to

allow changing the tool

To advance the turntable in order to bring workpieces to a defined

machining position at the different stations

The use of a home switch may be required.

See "Establishing Position Data Reference for Relative Measuring Systems"

Pertinent Parameters

S00152, C0900 Position spindle procedure command

S00153, Spindle angle position

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Pertinent Diagnostic Messages

S00154, Spindle positioning parameter

S00180, Spindle relative offset

S00222, Spindle positioning speed

S00372, Drive Halt acceleration bipolar

S00417, Positioning velocity threshold in modulo mode

S00418, Target position window in modulo mode

S00437, Positioning status

S00041, Homing velocity

S00042, Homing acceleration

P01201, Ramp 1 pitch

P01202, Final speed ramp 1

P01203, Ramp 2 pitch

P01211, Deceleration ramp 1

P01213, Deceleration ramp 2

C0900 Position spindle command

C0902 Spindle positioning requires drive enable

C0903 Error during initialization

C0906 Error during search for zero pulse

8.10

Parameter Set Switching

8.10.1

Brief Description
Assignment to functional firmware package, see chapter "Availa
bility of the Extended Axis Functions".
IndraDrive devices have been equipped with eight parameter sets; it is possible
to switch between these sets in operation. One of the switchable parameter
sets is always active. Switching takes place upon command of the control mas
ter.
Notes on Applications

With the possibility of adjusting the values of different parameters to different

operating phases or machining processes by switching parameter sets, if nec
essary during operation, the IndraDrive firmware supports the work flow in
flexible production facilities.
Examples of application:

Classification of Switchable Param

eters

Changing from C-axis to roughing or finishing operation in the case of

spindles

Positioning mode for tool change with different gear ratios

Changing motor spindles for different machining phases

Adjusting the control loop gains to different load inertia or load masses
(e.g. with very different workpieces)

Star-delta switching of motors with switchable winding to increase the tor

que in short-time operation

Under the application-related point of view, the parameters to be switched are

divided into the following groups:

Application Parameters

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Pertinent Parameters

Control Loop Parameters

Load gear parameters, only in alternative functional package main spindle

function

Winding parameters, only in alternative functional package main spindle

function

Motor control and motor encoder parameters, only in alternative functional

package main spindle function

S00216, C4100 Switch parameter set command

S00217, Preselect parameter set command

S00219, IDN-list of parameter set

Note: List parameter S-0-0219 to S-7-0219 contain parameter sets no. 0
to no. 7

Pertinent Diagnostic Messages

S00254, Current parameter set

P02216, Parameter set switching, configuration

P02217, Parameter set switching, preselection range

P02218, Parameter set switching, delay time

C0273 Modulo value for motor encoder cannot be displayed

C0278 Modulo value for optional encoder cannot be displayed

C0280 Maximum travel range cannot be displayed internally

C4100 Switch parameter set command

C4101 Switching only possible without AF

C4103 Preselect parameter set forbidden value

C4104 Error during parameter set switching (->S-0-0423)

8.11

Drive-Controlled Oscillation

8.11.1

Brief Description
Assignment to functional firmware package, see chapter "Availa
bility of the Extended Axis Functions".
Upon a command of the control master, the drive ignores the cyclic command
value input and independently turns alternately in positive and negative direc
tion (speed oscillation). The cyclic speed characteristic can be set via param
eters and can be realized symmetrically or asymmetrically.
Notes on Applications

Pertinent Parameters

Pertinent Diagnostic Messages

With speed oscillation the main drive supports the following applications, for
example:

Meshing the toothed wheels when switching a gear train

Engaging positive clutches (e.g. connecting i.c. engine equipment under

test to test stands)

S00213, Oscillation speed

S00214, Oscillation offset speed

S00215, Oscillation cycle time

C4200 Drive-controlled oscillation command

C4201 Oscillation requires drive enable

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8.12

Parking Axis

8.12.1

Brief Description

C4202 Oscillation command speed cannot be reached

Assignment to functional firmware package, see chapter "Availa

bility of the Extended Axis Functions".
If individual axes within a master communication group (e.g. SERCOS ring,
PROFIBUS) are to be temporarily deactivated, without taking them out of the
axis group on the hardware and communication side, the function "parking ax
is" can be activated via command.
When a drive has been put into the status "parking axis", it behaves "neutral
ly" with regard to hardware and master communication. Errors possibly detec
ted by the drive are suppressed and have no effect on the axes in operation.
This allows, for example, uncoupling the motor and the motor encoder in the
status "parking axis" without errors being signaled.
The axis that has been "parked" behaves as if it would not exist!
Pertinent Parameters

S00139, C1600 Parking axis procedure command

Pertinent Diagnostic Messages

C1600 Parking axis command

8.12.2

Functional Description
The parameter "S00139, C1600 Parking axis procedure command" can only
be activated in parameter mode (communication phase "P2" or "P3"). Executing
the command causes the following actions:

Monitoring functions of measuring systems are deactivated

Motor temperature monitoring is deactivated

Reference bits in "position feedback value status" are disabled

Drive initializations are not carried out when "S00128, C5200

Communication phase 4 transition check" is executed

"PA" is displayed on control panel and in diagnostic system

Master-side drive enable is ignored

The execution of command C1600 is not acknowledged as com
pleted on the drive side, in order to keep the command change bit
of parameter "S00135, Drive status word" free for diagnosis of
other commands!

The command C1600 can only be cleared in communication phase "P2" or

"P3" or by switching back to "P0". Completing the execution of command C1600
causes the following actions:

Monitoring functions of measuring systems are activated

Motor temperature monitoring is activated

Standard diagnostic messages appear again on display and in diagnostic

system

Drive enable is possible again in communication phase "P4"

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As the position data reference of relative measuring systems gets
lost when command C1600 is started, the position data reference
for these measuring systems has to be established again (homing
procedure) after drive enable has been set!
To activate the function "parking axis", there is an alternative to
switching to communication phase "P2"; you can switch to the pa
rameter mode from the operating states "bb" or "Ab" via "S00420,
C0400 Activate parameterization level 1 procedure command". By
activating "S00422, C0200 Exit parameterization level procedure
command", the drive returns to the operating mode.

8.13

Integrated Safety Technology

8.13.1

General Information
The section below contains an overview of the integrated safety
functions of the IndraDrive hardware and the IndraDrive firmware.
Details concerning function, notes on commissioning and examples
of application are described in the separate documentation
"Rexroth IndraDrive: Integrated Safety Technology According to
IEC61508" (DOK-INDRV*-SI*-**VRS**-FK**-EN-P; part no.
R911327664).

8.13.2

Product Presentation

What is "Integrated Safety Technology"?

The control sections of the IndraDrive range can be equipped with one of the
following optional modules:

One optional module "Safe Torque Off" ("L2") or

One optional module "Safe Motion" ("S2")

By the mentioned optional modules, IndraDrive is equipped with integrated

safety technology which provides the user with an electronic starting lockout,
as well as with universally programmable safe motion and standstill monitoring.
Definition

"Safe Motion" means application-related safety functions which are applicable

for
personal
protection
at
machines
according
to
EN ISO 13849-1 Category 3 PL d and IEC EN 62061 SIL 2.
"Safe Torque Off" means application-related safety functions which are appli
cable
for
personal
protection
at
machines
according
to
EN ISO 13849-1 Category 3 PL e and IEC EN 62061 SIL 3.

Selecting the Function

Certification

The safety functions can be alternatively selected via

24 V inputs at the drive controller or

24 V inputs at the drive controller and master communication (one channel

each) or

The safe channel in PROFIBUS (PROFIsafe)

The safety technology was certified by TV Rheinland and has been listed by
TV Rheinland of North America (NRTL listing) (see (http://www.tuv.com/de/
index.html or http://www.us.tuv.com/ under "ID-Zertifikate" or "ID-Certificate")
[US+Canada NRTL-Certificate, certificate no. 72071176 (L2) and certificate no.
72071177 (S2)]. "NRTL" means Nationally Recognized Testing Laboratory;
products listed by such a testing laboratory may be used in the US in the ap
propriate way (according to NFPA 79).

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Certificates are available on the Internet/Extranet.
Requirements That Can Be Realiz
ed

The integrated safety technology is independent of the type of master commu

nication, the higher-level control units and the supply modules. It is available
as an optional module for the standard drive system. The requirements below
can be realized in the machine or in the installation:

Measures according to EN ISO 121002, if accessing the danger zone is

required, for example, for equipping, teaching or material withdrawal.

Requirements for safety-related parts of control units according to

EN ISO 13849-1 Category 3 PL d and IEC EN 62061 SIL 2 (when using
"Safe Motion") or EN ISO 13849-1 Category 3 PL d/PL e and
IEC EN 62061 SIL 2/SIL 3 (when using "Safe Torque Off"), as required in
EN 10101 (printing and paper converting machines), EN 12415 (turning
machines) and EN 12417 (machining centres).

Control functions in the case of error according to EN 602041 (see "Using

Diversity" in EN 602041).

Integrated Safety Technology as IndraDrive Platform Solution

The different characteristics (e.g. PROFIsafe) require different hardware:
Control section
type

Description

Characteristics of integrated safety technology

Safe Torque Off (op
tional module "L2")

Safe Motion (optional module "S2")

Digital I/Os

PROFIsafe

CSH01.1C

ADVANCED

CSH01.3C

ADVANCED

CSB01.1C

BASIC UNIVERSAL (single-axis)

CDB01.1C

BASIC UNIVERSAL (double-axis)

CSB01.1N-FC

BASIC OPENLOOP

CSB01.1N-AN

BASIC ANALOG

CSB01.1N-SE

BASIC SERCOS

CSB01.1N-PB

BASIC PROFIBUS

Fig.8-6:

Overview of the Hardware Requirements for the Integrated Safety Tech

nology

For using the integrated safety technology "Safe Motion" or "Safe

Torque Off" according to IEC EN 61508 or EN ISO 13849-1, at least
the firmware version MP*07VRS or higher must be used in the drive.
In addition to the optional module "S2", using PROFIsafe requires
the master communication module "PROFIBUS" (PB) together with
the respective firmware version (as of MP*07VRS)!

Characteristics and Classification of Safety Technology

Functionality Levels

The available integrated safety functions can be divided into 2 levels:

Level 1: Purely hardware-based safety technology, "Safe torque off" is part

of it (optional safety technology module "L2" required)

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Characteristics Regarding the In

terfaces

8.13.3

Level 2: Extensive integrated safety technology including all other safety

functions, such as "Safely-limited speed", "Safely-monitored position",...
(optional safety technology module "S2" required)

Apart from the classification of the safety functions, we distinguish the kinds of
control (e.g. digital I/Os or PROFIBUS). The following characteristics are sup
ported:

Digital I/Os

PROFIsafe

Safe Torque Off (STO)

Brief Description
Using the function "Safe torque off" requires the optional safety
technology module "L2".
The energy supply to the drive is safely interrupted with the safety function
"Safe torque off". The drive cannot generate any torque/force and, as a con
sequence, it cannot generate any dangerous motions, either.
Before activating the safety function "Safe torque off", the drive
system must be decelerated via the command value input; there is
no drive-controlled deceleration!

Lethal injury and/or property damage caused by unintended axis motion!

If external force influences are to be expected with the safety function "Safe
torque off", e.g. in the case of a vertical axis, this motion has to be safely pre
vented by additional measures, e.g. a mechanical brake or weight compensa
tion; for such axes, Bosch Rexroth recommends that you use the safe braking
and holding system.

DANGER
Features

The safety function "Safe torque off" has the following features:

Corresponds to stop category 0 according to EN 602041

Is suited for safety-relevant applications up to Category 3 PL d/PL e ac

cording to EN ISO 13849-1 or up to SIL 2/SIL 3 according to
IEC EN 62061.

The energy supply to the motor is safely interrupted via two channels.

The selection is made via two channels using either an N/C-N/O or an N/

C-N/C combination.
To attain SIL 3/PL e, selection must take place via a higher-level SIL 3
safety control unit.

The safe state is acknowledged by an N/C-N/O contact; the acknowledg

ment must always be evaluated.

For dynamization of the safety function selection, the function must be

activated at least every 168 hours (SIL 2/PL d) or 24 hours (SIL 3/PL e).
For this reason, the operating hours of the power section at which the
safety function "Safe torque off" was selected the last time are stored in
the parameter "P00102, Oper. hours power section at last activation of
STO".

Monitoring the validity of the selection: 100 ms after selection was

changed.

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Pertinent Parameters

Pertinent Diagnostic Messages

8.13.4

The time intervals for activating the safety function "Safe torque off" have
to be set via "P00103, Time interval of forced dynamization".

The history of the time intervals that were set is displayed in the parameter
"P00104, Change history time interval of forced dynamization".

The status of the safety function "Safe torque off" is displayed via the pa
rameter "P00106, Operating status of STO".

The following parameters are used in conjunction with the safety function "Safe
torque off":

P00101, Configuration for STO selector

P00102, Oper. hours power section at last activation of STO

P00103, Time interval of forced dynamization

P00104, Change history time interval of forced dynamization

P00106, Operating status of STO

The following diagnostic messages can be generated in conjunction with the

safety function "Safe torque off":

F8027 Safe torque off while drive enabled

F7043 Error of output stage interlock

F3130 Error when checking input signals

F3131 Error when checking acknowledgement signal

E3110 Time interval of forced dynamization exceeded

E8027 Safe torque off while drive enabled

With the safety function "Safe torque off" activated, "STO" is shown on the
display of the IndraDrive control panel.

Integrated Safety Technology

Features

Dual-channel selection on safety functions via digital inputs/outputs (24V)

or digital inputs/outputs (24V) and master communication or a safety re
lated process data channel for PROFIBUS-DP (PROFIsafe)

Integrated functionality for detecting "sleeping" errors:

Dual-channel data processing with structure by diversity

Cross comparison of the safety-relevant data

Dynamization of static states

Password protection for all safety technology parameters

Safety functions in normal operation and special mode

"Safe maximum speed", "Safe direction", "Safely-limited position"

Safety functions of safety technology function category "Safe standstill"

"Safe stop 1 (Emergency stop)", "Safe stop 1", "Safe stop 2", "Safe
braking and holding system"

Safety functions of safety technology function category "Safe motion"

"Safely-limited speed", "Safe direction", "Safely-limited increment",
"Safely-monitored position"

Auxiliary functions
"Safely-monitored stopping process", "Safe homing procedure", "Safe
brake check", "Safe parking axis"

Safety functions for "Safe feedback"

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"Safe diagnostic outputs", "Safe door locking device", "Safe inputs/
outputs"
[only
available
via
master
communication
"PROFIBUS" (PROFIsafe)]
Pertinent Parameters

The parameters for safety technology are assigned to the IDN range from
P03200 to P03399. For information on the pertinent parameters, see the
separate documentations "Integrated Safety Technology; Functional and Ap
plication Description" and "Parameter Description" .

Pertinent Diagnostic Messages

The pertinent diagnostic messages in connection with the integrated safety

technology are contained in the separate documentation "Integrated Safety
Technology According to IEC 61508 Functional Description" in the sections for
the respective safety functions.

8.13.5

Functions of the Integrated Safety Technology

Overview
We distinguish the following operating states of integrated safety technology:

Fig.8-7:
Principles for Error Detection

Operating States of the Integrated Safety Technology

In order to prevent danger for persons in the danger zone of a machine motion
in the case of temporary errors, precautions for minimizing motion errors due
to errors have to be taken.
During operation, the safety functions are monitored by the drive system. To
do this three principles for discovering static error states, so-called sleeping
errors, were realized in the system:

Dual-channel data processing with structure by diversity

Cross comparison of the safety-relevant data

Dynamization of static states

These measures guarantee that a single error cannot cause the safety func
tions to get lost.
The installation or machine manufacturer has to determine in how far this is
sufficient for an existing installation or machine by a risk analysis according to
annex I of Directive 98/37/EEC.
After 2009-12-31, the new Machinery Directive 2006/42/EG must
be applied.

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States of Integrated Safety Technology

Normal Operation and Special
Mode

The status "normal operation/special mode" supports the following safety func
tions:

Safe maximum speed

Defines a safe maximum speed in normal operation/special mode

Safely-limited position
Defines a positive and a negative safe position in normal operation/
special mode
Note: The safely-limited position requires establishing the safe reference!

Safe direction
2-channel monitoring for allowed direction of motion

Safe Standstill

The status "safe standstill" supports the following safety functions:

Safe stop 1
Corresponds to stop category 1 according to EN 60204-1; with drivecontrolled best possible deceleration and time monitoring

- As an alternative

Safe stop 2
Corresponds to stop category 2 according to EN 60204-1; i.e. the drive
control remains active, transition to standstill is carried out by the NC; drive
monitors reaching of standstill within preset tolerance time via two chan
nels

- Additionally

Safe stop 1 (Emergency stop)

Like "safe stop 1", but switching to "safe motion" by actuating the ena
bling control device not possible
Selection of "safe stop 1"/"safe stop 2" is made via the safety
switches S1/S2; selection of "safe stop 1 (Emergency stop)" is
made via dedicated switches

Safe braking and holding system

It is safely prevented that gravity-loaded axes move down accidentally

Safe Motion

In the status "safe motion", the following safety functions are supported by
"Safety on Board":

Safely-limited speed
2-channel monitoring for exceeding a speed threshold

Safe direction
2-channel monitoring for allowed direction of motion

Safely-limited increment
2-channel monitoring for allowed travel distance

Safely-monitored position
2-channel monitoring for monitored position
Note: The safely-monitored position requires establishing the safe refer
ence!

Auxiliary Functions

The following auxiliary functions are provided:

Safely-monitored stopping process

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2-channel monitoring of transition to safe standstill or safe motion

Safe homing procedure

To establish the reference for channel 1 and channel 2
Note: The safe reference is a prerequisite for the "safely-limited posi
tion" and the "safely-monitored position"!

Safe brake check

Cyclic test for both holding brakes (is required for the safe braking and
holding system)

Safe parking axis

Safe parking of the axis by safe locking of the output stage and ac
knowledgment of safety, although no encoder is available

Safety Functions "Safe Feedback"

The following safety functions are provided for "safe feedback":

Safe diagnostic outputs

To transmit the "safe state" to additional system components

Safe door locking device (not with PROFIsafe)

A drive that acts as the diagnostic master can summarize the safe state
of several axes within a protective zone and control a safety door.

Safe inputs/outputs (for PROFIsafe)

Safe inputs/outputs of the drive are used for connecting sensors and
actuators which the higher-level master controls via PROFIsafe.

8.13.6

Notes on Commissioning

Safe Torque Off

The use of the optional safety technology module "Safe Torque Off" (L2) does
not require any special kind of commissioning; the corresponding wiring is suf
ficient.
For detailed descriptions and information, see separate documentation
"Rexroth IndraDrive: Integrated Safety Technology According to IEC 61508"

Safe Motion
Commissioning of the optional safety technology module "Safe Motion" (S2) is
made through menu prompts via the commissioning tool "IndraWorks Ds/D/
MLD".
For detailed descriptions and information, see separate documentation
"Rexroth IndraDrive: Integrated Safety Technology According to IEC 61508"

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Optional Device Functions

Optional Device Functions

9.1

Availability of the Optional Device Functions

The following overview illustrates by which basic or functional packages the
respective optional device function is supported (if not stated otherwise, this
applies to all 4 firmware variants, MPB, MPD, MPH and MPC).
In functional package ...
In base package (on the basis of a base package with the following characteris
tics)
(characteristic)

Optional device function

Servo function

Synchronization

Cross communication (CCD)

Only available with the corresponding hardware configuration

IndraMotion MLD

Independent extension packages (ML, MA or TF)

Main spindle

Digital inputs/outputs 1)

OL/CL

Analog inputs

OL/CL

OL/CL

OL/CL

Command value generator

OL/CL

Command value box

OL/CL

CL

CL

CL

CL

OL/CL

OL/CL

OL/CL

1)

Analog outputs 1)
Virtual master axis generator

Encoder emulation
Programmable Position switch
Probe
Measuring encoder
OL
CL
1)

Fig.9-1:

Open-loop characteristic
Closed-loop characteristic
Depending on hardware configuration

Availability of the Optional Device Functions

To use a functional package, it must have been activated (enabled). The cur
rently enabled functional packages are displayed in "P02004, Active
functional packages".
See also "Enabling of Functional Packages"

9.2

Cross Communication (CCD)

9.2.1

Brief Description
Overview

The IndraDrive "cross communication" device function (Cross Communication

Drives CCD) allows electronic (digital) coupling of axes and the connection
of I/O modules for IndraMotion MLD.

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Optional Device Functions

Fig.9-2:

Hardware Topology of Drive Cross Communication (CCD)

Bus Topology

Configuration of the CCD slaves and communication with the external control
unit always takes place via the CCD master drive, as the individual CCD slaves
are connected to the master via a SERCOS III interface. Therefore, external
access always takes place via the drive acting as the CCD master, which re
quires a master communication interface (e.g. PROFIBUS) in addition to the
CCD optional module ("SERCOS III master connection").

CCD Modes (Kinds of Coupling)

When cross communication (CCD) is used between the drives, we distinguish

the following variants (CCD modes):

CCD System Mode

The CCD slaves have a direct logic connection to the field bus master;
command triggering and input of process data take place via en external
control unit.

CCD basic mode

The same functions as for the CCD system mode are available. However,
the user has to program them. It is not possible to use the MLD-M func
tionality in the master axis.

MLD-M system mode

The CCD slaves have no direct logic connection to the external control
unit, but only to the MLD-M in the CCD master. Command triggering and
input of process data take place by the MLDM in the CCD master.

Features

The device function "cross communication (CCD)" is characterized by the fol

lowing features:

Synchronization of CCD slaves to CCD master

Transmission of freely configurable external process data (command val

ues and actual values of the external control unit)

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Optional Device Functions

Fields of Application

Command value linking by transmission of freely configurable process

data of the CCD axes (e.g. master/slave, Gantry axis)

Connection of I/O extensions for SERCOS III via CCD (a maximum of 4

modules per CCD master)

CCD (SERCOS III) cycle time can be parameterized (0.25ms to 4ms; de

pends on CCD mode, controller performance and number of axes)

Max. baud rate: 100 MBaud

CCD communication protocol: SERCOS III (see "SERCOS III")

Data channels:

Parameter or service channel: 4 bytes

Parameterization of all axes in the CCD group via the CCD master inter
faces (RS232, Engineering Port, field bus, )

Command triggering of the CCD slaves depending on selected CCD mode

via external control unit or internally via MLD in CCD master

Max. number of CCD slaves: 7 resp. 9 (depending on CCD mode; see

below "Performance Features")

Typical fields of application for cross communication:

Hardware Requirements

Cyclic data channel (MDT, AT): Max. 48 bytes and 16 IDN

Restrictions

Control tasks for multi-axis applications

Anti backlash

Synchronous operation control

Load control of several axes

Simple command value linking

Position command value linking (gantry axes)

Torque/force linking

Simple motion controls with decentralized command value adjustment for

single-axis positioning and master axis linking

I/O extension by connection of I/O modules for SERCOS III via CCD

When using cross communication, observe the following restrictions:

With the cross communication function, "Coordinated Motion" is not pos

sible!

The higher-level master is usually a PLC with a field bus which does not
have real-time and synchronization ability (PROFIBUS, DeviceNet,
EtherNet/IP).

Using the drive function "cross communication" requires the following control
section design:

CCD master
ADVANCED control section with CCD module in optional slot 3
CSH-01.3C-xx-xxx-xxx-CCD-xx-x-..

CCD slaves
Control section with master communication interface "SERCOS III" (S3);
possible with the following designs:

BASIC UNIVERSAL single-axis CSB-01.xC-S3-xxx-xx-x

BASIC UNIVERSAL double-axis CDB-01.xC-S3-xxx-xx-x

ADVANCED single-axis CSH-01.xC-S3-xxx-xx-x

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Optional Device Functions

See documentation "Drive Controllers, Control Sections; Project Planning

Manual"
Firmware Requirements

Pertinent Parameters

When using the drive function "cross communication", observe the following
aspects regarding the firmware:

This drive function is supported as of the firmware version MPx04.

All drives of a CCD group (CCD master and CCD slaves) have to be op
erated with the same firmware version.

As for integrated safety technology, this firmware function does not require
separate enabling of functional packages; the function of drive cross com
munication is available with the corresponding hardware design.

The parameters listed below only exist for the CCD master:

P01600, CCD: configuration

P01601, CCD: addresses of projected drives

P01602, CCD: timing settings

P01603, CCD: Actual topology addresses

P01604, CCD: addresses of projected I/Os

P01605, CCD: command communication phase

P01606, CCD: actual communication phase

P01607, CCD: axis error

P01609, CCD: status word

P01610, CCD: cycle time

P01610.0.3, CCD: Actual topology

P01610.0.21, CCD: Slave addresses at end of line

P01610.0.30, CCD: Diagnostic message text

P01611, CCD: configuration list signal status word

P01612, CCD: configuration list signal control word

P01613, CCD: assignment list signal status word

P01614, CCD: assignment list signal control word

P01615, CCD: extrapolated cmd value IDN list signal selection

P01616, CCD: extrapolated cmd value signal selection

P01617, CCD: number of extrapolation steps

P01618, CCD: extrapolated command value

P01620.0.3, CCD: Command topology

P01620.0.21, CCD: Command Close ring

P01621, CCD: configuration list master communication cmd values

P01621.x.1, CCD: Slave address in high level network

P01621.x.2, CCD: S2 AT Transmission starting time (T1)

P01621.x.3, CCD: S2 Position of data record in MDT

P01621.x.4, CCD: SERCOS Telegram type parameter

P01621.x.5, CCD: Master comm. configuration list of AT

P01621.x.6, CCD: Master comm. configuration list of MDT

P01621.x.7, CCD: S2 Slave arrangement (SLKN)

P01621.x.8, CCD: S2 Mask class 3 diagnostics

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Optional Device Functions

P01621.x.9, CCD: Master comm. C0100 Comm. phase 3 transition

check

P01621.x.10, CCD: Master comm. C5200 Comm. phase 4 transition

check

P01621.x.11, CCD: Mater comm. master control word

P01621.x.12, CCD: Master comm. drive status

P01621.x.13, CCD: S2 Allocation of real-time control bit 1

P01621.x.14, CCD: S2 Allocation of real-time control bit 2

P01621.x.15, CCD: S2 Allocation of real-time status bit 1

P01621.x.16, CCD: S2 Allocation of real-time status bit 2

P01621.x.17, CCD: S2 Bit number allocation of real-time control bit 1

P01621.x.18, CCD: S2 Bit number allocation of real-time control bit 2

P01621.x.19, CCD: S2 Bit number allocation of real-time status bit 1

P01621.x.20, CCD: S2 Bit number allocation of real-time status bit 2

P01621.x.21, CCD: S2 Bit number allocation of real-time status bit 2

P01621.x.23, CCD: Master comm. diagnosis

P01622, CCD: configuration list master communication actual values

P01623, CCD: configuration list master cmd values

P01624, CCD: configuration list actual master values

P01625, CCD: configuration list slave cmd values

P01626, CCD: configuration list actual slave values

P01627, CCD: configuration list master cmd values I/Os

P01628, CCD: configuration list act. master values I/Os

P01629, CCD: configuration compact I/Os

P01630, CCD: diagnosis

P01630.x.1, CCD: Slave IP address

P01630.x.2, CCD: Device status word (S-Dev)

P01630.x.3, CCD: Connection-Control #0 (C-Con)

P01630.x.20, CCD: Resource-Status (S-Res)

P01631, CCD: AT error counter

P01632, CCD: system data 2 bytes

P01633, CCD: system data 4 bytes

P01635, CCD: command adjust slave addresses

P01636, CCD: Command topology addresses

P01637, CCD: error counter Port-1

P01638, CCD: error counter Port-2

P01639, CCD: allowed telegram failures

P01640, CCD: MAC address

P01641, CCD: IP address

P01642, CCD: network mask

P01643, CCD: gateway address

P01644, CCD: status IP communication

P01645.x.1, CCD connection: Configuration

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P01645.x.2, CCD connection: Connection number

P01645.x.3, CCD connection: Telegram assignment

P01645.x.4, CCD connection: Max. length of connection

P01645.x.5, CCD connection: Current connection length

P01645.x.6, CCD connection: Configuration list

P01645.x.8, CCD connection: Connection control (C-Con)

P01645.x.10, CCD connection: Producer cycle time

P01645.x.11, CCD connection: Allowed losses of producer data

P01645.x.12, CCD connection: Error counter data losses

P01645.x.20, CCD connection: IDN allocation of real-time bits

P01645.x.21, CCD connection: Bit number allocation of real-time bits

P01651, CCD: master control word, slave 1

(up to P01659)

P01660.x.2, CCD: Device control word (C-Res)

P01660.x.3, CCD: Conection-Control #1 (C-Con)

P01660.x.20, CDD: Resource-Control (C-Res)

P01661, CCD: drive status word, slave 1

(up to P01669)

P01670, CCD: active actual position value, master

P01671, CCD: active actual position value, slave 1

(up to P01679)

P01680, CCD: actual velocity value, master

P01681, CCD: actual velocity value, slave 1

(up to P01689)

P01690, CCD: actual torque/force value, master

P01691, CCD: actual torque/force value, slave 1

(up to P01699)

P01701, CCD: diagnostic message number slave 1

(up to P01709)

P01710, CCD: signal status word, master

P01711, CCD: signal status word, slave 1

(up to P01719)

P01720, CCD: signal control word, master

P01721, CCD: signal control word, slave 1

(up to P01729)

P01730, CCD: Command value data container 1, Master 4Byte

P01731, CCD: Command value data container 1, Slave 1 4Byte

(up to P01739)

P01740, CCD: Command value data container 2, Master 4Byte

P01741, CCD: Command value data container 2, Slave 1 4Byte

P01750, CCD: Command value data container 3, Master 4Byte

(up to P01749)

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Optional Device Functions

P01751, CCD: Command value data container 3, Slave 1 4Byte

(up to P01759)

P01760, CCD: Command value data container 4, Master 4Byte

P01761, CCD: Command value data container 4, Slave 1 4Byte

(up to P01769)

P01770, CCD: Actual value data container 1, Master 4Byte

P01771, CCD: Actual value data container 1, Slave 1 4Byte

(up to P01779)

P01780, CCD: Actual value data container 2, Master 4Byte

P01781, CCD: Actual value data container 2, Slave 1 4Byte

(up to P01789)

P01790, CCD: Actual value data container 3, Master 4Byte

P01791, CCD: Actual value data container 3, Slave 1 4Byte

(up to P01799)

P01800, CCD: Actual value data container 4, Master 4Byte

P01801, CCD: Actual value data container 4, Slave 1 4Byte

P01810, CCD: Status word synchronous operation modes, master

P01811, CCD: Status word synchronous operation modes, slave 1

(up to P01809)

(up to P01819)

P01820, CCD: Command value data container 1, Master 2Byte

P01821, CCD: Command value data container 1, Slave 1 2Byte

(up to P01829)

P01830, CCD: Command value data container 2, Master 2Byte

P01831, CCD: Command value data container 2, Slave 1 2Byte

(up to P01839)

P01840, CCD: Command value data container 3, Master 2Byte

P01841, CCD: Command value data container 3, Slave 1 2Byte

(up to P01849)

P01850, CCD: Command value data container 4, Master 2Byte

P01851, CCD: Command value data container 4, Slave 1 2Byte

(up to P01859)

P01860, CCD: Actual value data container 1, Master 2Byte

P01861, CCD: Actual value data container 1, Slave 1 2Byte

(up to P01869)

P01870, CCD: Actual value data container 2, Master 2Byte

P01871, CCD: Actual value data container 2, Slave 1 2Byte

(up to P01879)

P01880, CCD: Actual value data container 3, Master 2Byte

P01881, CCD: Actual value data container 3, Slave 1 2Byte

P01890, CCD: Actual value data container 3, Master 2Byte

(up to P01889)

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Optional Device Functions

P01891, CCD: Actual value data container 3, Slave 1 2Byte

(up to P01899)
For configuring the SERCOS III communication in the slaves, we
use the standard SERCOS III parameters (see S01001 et seq.).

Pertinent Diagnostic Messages

C0265 Incorrect CCD address configuration

C0266 Incorrect CCD phase switch

C0267 CCD timeout phase switch

C0403 Switching to CCD phase 2 impossible

C7000CCD: Command Close ring

C7001CCD: Impossible to close ring

C7100CCD: Command Close ring

C7101CCD: Impossible to close ring

E4012 Maximum number of CCD slaves exceeded

E4013 Incorrect CCD addressing

E4014 Incorrect phase switch of CCD slaves

E4016 CCD: Topology error

F2140CCD slave error

F4012Incorrect I/O length

F4140CCD communication error

F6140CCD slave error (emergency halt)

F8140Fatal CCD error

9.3

Rexroth IndraMotion MLD (Drive-Integrated PLC)

9.3.1

Brief Description
Assignment to functional firmware package: Extension package
IndraMotion MLD (order code ML, MA or TF)
The optional expansion packages "IndraMotion MLD" provide the function of a
PLC integrated in the drive according to IEC 61131-3 with the following scope
of functions:

Integrated logic control (standard PLC tasks)

IEC-61131-3-conform

Online change

Debugging

Offline simulation

Integrated multi-axis/single-axis motion control

Motion function block according to PLCopen positioning and synchro
nization operation

Programming via ST, SFC, FBD and LD

Library management with system and user libraries

Basis for technology functions

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Optional Device Functions

Examples: Following-on cutting devices, process controller (register
controller, winding computation, productivity agent, IndraMotion for han
dling, IndraMotion for metal forming,...
This optional extension of the drive functionality is described in de
tail in the separate documentation "Rexroth IndraMotion
MLD"
(DOKINDRV*MLD-**VRS**-AW**-ENP;
part
no.
R911306084).
Hardware Requirements

According to design, the expansion packages "IndraMotion MLD" require one

of the following control section designs:

IndraMotion MLD-M (multi-axis motion control)

IndraMotion MLD-S (single-axis motion control)

Single axis ADVANCED (CSH01.3C)

Single-axis ADVANCED (CSH01.1C, CSH01.3C)

Single-axis BASIC (CSB01.1)

The expansion packages "IndraMotion MLD" are not available for
double-axis control sections (CDB01.1C)!

Firmware Requirements

In the firmware MPx07VRS, the function "IndraMotion MLD" is available in the

following variants:

Advanced design (MPH)

Basic single-axis design (MPB)

Multi-axis design MLD-M (MPC)

Using the function "IndraMotion MLD" generally requires the ena
bling of one of the additive expansion packages ML, MA or TF.
See also sections:
- "Overview of functions/functional packages"
- "Enabling of Functional Packages"

Features/Characteristic Values

The functional packages "IndraMotion MLD" include the following general fea
tures/characteristic values:

Up to 4 preemptive user tasks are possible

Task types:

Periodic (min. cycle time: 1 ms for advanced; 2 ms for basic)

Free-running (permanently cyclic)

Event-controlled (min. reaction time: 1 ms for advanced; 2 ms for

basic)

Memory resources:

MPH, MPB: 350 kbytes program memory (with MMC expandable to

2 MB)

MPC: 350 kbytes program memory (with MMC expandable to 4 MB)

MPH, MPB: 512 kbytes data memory

MPC: 2 MB data memory

250 bytes retain or 32 kbytes with optional module MD1 or MD2 or

control section design CSH01.3C

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Optional Device Functions

Digital inputs/outputs:

7...11 digital inputs, 0...4 digital outputs on x31/x32 (with advanced

control section CSH)
PLC and drive are sharing the inputs!

12 digital inputs, 8 digital outputs on the optional module MD1 (op

tional)

16 digital inputs, 16 digital outputs on the optional module MD2 (op

tional)

16 digital inputs, 16 digital outputs on the optional module PL

(for parallel master communication)

1 relay output on x31/x32 (CSH control section)

PLC and drive are sharing the inputs!
Note: For BASIC control sections there are restrictions regarding the
available inputs/outputs (see documentation "Drive Controllers, Con
trol Sections; Project Planning Manual").

Analog inputs/outputs:

1 analog input (+/-10 V) on x31/x32 (CSH control section)

2 analog outputs (0-5 V) on 31/x32 (CSH control section)

Analog inputs/outputs (+/-10 V) on MA1 (optional)

Note: For BASIC control sections there are restrictions regarding the
available inputs/outputs (see documentation "Drive Controllers, Con
trol Sections; Project Planning Manual").

Inputs/outputs on remote axes:

Digital and analog inputs/outputs of the slaves connected to

SERCOS III can be read and written.

Number of inputs/outputs depends on the used control sections of

the slaves

SERCOS-III I/O

Evaluation of digital block inputs/outputs (every block with 32 inputs

or with 16 inputs and 16 outputs)

Parameters for general purpose:

Parameters for process image: Inputs Plls

20 input words per 2 bytes

8 input words per 4 bytes

Parameters for process image: Outputs POIs

20 output words per 2 bytes

Global registers (4 bytes)

32 buffered parameters

32 unbuffered parameters

List parameters (4 bytes)

1 list register with 8192 values (not buffered)

3 list registers with 1024 values (buffered)

2 global text registers with 255 characters each

Display format of the global register that can be parameterized

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Optional Device Functions

Pertinent Parameters

Name, unit and limit values of the global registers can be configured
via PLC functions

Other features:

Extensive debug possibilities (single-step, watch, force/write, break

points, powerflow)

File access from the PLC (save source code on MMC, ...)

Keep symbol file on MMC ready for access to PLC variables

Source download (only with MMC)

Access to serial interface

Access to ethernet interface

PLC parameters for general purpose

P01350, PLC control word

P01351, PLC status word

P01352, PLC user program administration data

P01362, PLC boot project info

P01363, PLC project info

P01367, PLC configuration

P01369, PLC internally reserved

User program (filing):

P01353, PLC user program area 0

P01354, PLC user program area 1

P01355, PLC user program area 2

P01356, PLC user program area 3

P01357, PLC user program area 4

P01358, PLC user program area 5

Process input images PIIs

P01390, PLC input WORD0 AT %IB0

to
P01409, PLC input WORD19 AT %IB38

P01440, PLC input DWORD25 AT %IB100

to
P01447, PLC input DWORD32 AT %IB128

Process output images POIs

P01410, PLC output WORD0 AT %QB0

to
P01429, PLC output WORD19 AT %QB38

Global PLC registers, unbuffered:

P01270, PLC Global Register A0

to
P01301, PLC Global Register A31

Global text registers, unbuffered:

P01387, PLC Global Register AT0

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Optional Device Functions

to
P01388, PLC Global Register AT1
Global list register, unbuffered:

P01368, PLC Global Register AL0

Global PLC registers, buffered:

P01370, PLC Global Register G0

to
P01385, PLC Global Register G15

P01316, PLC Global Register G16

to
P01331 PLC Global Register G31

Global list registers, buffered:

P01389, PLC Global Register GL0

P01311, PLC Global Register GL1

P01312, PLC Global Register GL2

To configure the display format of the registers:

P01386, PLC display format Global Register

9.4

Digital Inputs/Outputs

9.4.1

Brief Description

General Information
Assignment to functional firmware package, see chapter "Availa
bility of the Optional Device Functions".
In their basic configuration (without optional modules), all IndraDrive controllers
already have configurable digital inputs/outputs.
Hardware Requirements

The number, assignment and function of the digital inputs/outputs depend on

the type and configuration of the respective control section and are contained
in the respective hardware description (Project Planning Manual).
See separate documentation "Drive Controllers, Control Sections; Project
Planning Manual"

Digital Inputs/Outputs on Control Section

Features

Sampling of digital inputs and outputs or transmitting data to them in the

position loop clock TA_position(see ""Performance data"")

Configurable digital inputs/outputs with effective direction that can partly

be freely set (input or output):

ADVANCED control sections with firmware MPH:

4 digital inputs/outputs

3 digital inputs

2 inputs can alternatively be used as analog input (differential

input)

2 rapid inputs as probe inputs (in steps of s)

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Optional Device Functions

1 isolated relay switch contact (can be configured)

BASIC single-axis control sections with firmware MPB:

3 digital inputs/outputs

4 digital inputs

No analog input

1 rapid input as probe input (in steps of s)

1 isolated relay switch contact (can be configured)

BASIC double-axis control sections with firmware MPD:

4 digital inputs/outputs

6 digital inputs

2 inputs can alternatively be used as analog input (differential

input)

2 rapid inputs as probe inputs (in steps of s)

2 isolated relay switch contacts (can be configured)

All inputs/outputs (except for the relay contact) designed for level of 0 V
(LOW) or 24 V (HIGH)

Assignment of inputs/outputs to internal parameters or bits

Signal states of digital inputs and digital outputs mapped to individual pa

rameter

Signal states of digital inputs can be directly read by the control master

Digital outputs can be directly controlled by the control master, if not used
on drive-side

External 24 V supply of the digital outputs required

Inputs/outputs galvanically isolated from control section

Each individual input/output can be assigned to parameters of the
drive; IDN of the permitted parameters from IDN lists in S-0-0398
and S00399.

Pertinent Parameters

Pertinent Diagnostic Messages

S00398, IDN-list of configurable data in signal status word

S00399, IDN-list of configurable data in signal control word

P00300, Digital I/Os, assignment list

P00301, Digital I/Os, bit numbers

P00302, Digital I/Os, direction

P00303, Digital I/Os, inputs

P00304, Digital I/Os, outputs

C0246 Trav. range lim. switch not ass. to dig. input

C0247 Dig. output already assigned to other axis

C0248 Dig. input assigned differently to axes

C0249 Dig. I/Os: Bit number too large

F2010Error when initializing digital I/O (-> S-0-0423)

F2033External power supply X10 error

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Optional Device Functions

Digital Inputs/Outputs on Optional Module MD1

For the configurable ADVANCED control sections, it is possible to individually
configure, apart from the standard digital inputs/outputs, an extension of these
inputs/outputs.
This requires the optional module MD1 which can be used for the following
purposes:

Making available digital inputs/outputs to external control unit

Enabling input/output of drive parameters

Making available digital inputs/outputs to drive-integrated PLC (IndraMo

tion MLDS)

Extension of memory (32 kB non-volatile memory) for drive-integrated

PLC (IndraMotion MLD)
Utilization of digital I/O extension by using the optional module MD1
is only possible for ADVANCED control sections!

Features

Pertinent Parameters

Connection via 25-pin D-Sub connector

All inputs/outputs designed for level of 0 V (LOW) or 24 V (HIGH)

External 24 V supply of the digital outputs required

Inputs/outputs galvanically isolated from control section

Assignment of inputs/outputs to internal parameters or bits

Parameters P00081 and P00082 can be completely assigned to

parameters of the drive or of the integrated PLC

Free configuration of the digital inputs/outputs via "S00144, Signal

status word" and "S00145, Signal control word"

12 digital inputs (freely configurable and protected from reverse polarity)

8 digital outputs (max. output current 0.5 A and sustained short-circuitproof)

S00144, Signal status word

S00145, Signal control word

S00398, IDN-list of configurable data in signal status word

S00399, IDN-list of configurable data in signal control word

P00081, Parallel output 1

P00082, Parallel input 1

P00681, Assignment IDN -> parallel output 1

P00682, Assignment parallel input 1 -> IDN

9.5

Analog Inputs

9.5.1

Brief Description
Assignment to functional firmware package, see chapter "Availa
bility of the Optional Device Functions".
Overview

According to the control section type, IndraDrive controllers already have an

alog inputs in their basic configuration (without optional modules). Configurable
control sections can be upgraded with this function by using the optional module
MA1. Double-axis control section can alternatively also be equipped with an

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Optional Device Functions

extension for analog master communication, if the control section is operated
as analog device (control section configuration CDB01.xC-AN). The number
and function of the analog outputs differ according to the type and configuration
of control section (see "Hardware Requirements" below).

P00210
P00213
P00214
P00215
P00216
P00217
P00218

Fig.9-3:
Features

Analog input 1
Analog input, assignment A, target parameter
Analog input, assignment A, scaling per 10V full scale
Analog input, assignment A, signal value at 0V
Analog input, assignment A, dead zone
Analog input 1, time constant input filter
Analog input, control parameter

Overview: Analog Inputs and Their Assignments (Example of Control

Section CSH01.1C)

General features:

2 assignment mechanisms for analog inputs (assignment A or B)

Different sampling rates of assignments A and B

Assignment channel A works in position loop clock (see "Perform

ance Data")

Assignment channel B works in 2-ms clock

Assignment to command value/limit value/control parameters of the drive

by means of adjustable scaling

Possible assignment of max. 2 analog inputs to internal drive parameters

Variable scaling for 2 analog channels

Dead zone to be entered for suppressing the zero drift for both analog
channels

Offset and amplification adjust for both analog channels via command

Features of analog inputs at control section:

Number and resolution of analog inputs depend on control section design:

ADVANCED 1 analog input with resolution of 14 bits (by means of

8-fold oversampling for both analog channels)

BASIC OPENLOOP and BASIC ANALOG each have 2 analog in

puts with 12 bits (other Basic variants do not have any analog inputs)

BASIC UNIVERSAL double-axis 1 analog input with resolution of

14 bits (by means of 8-fold oversampling for both analog channels)
for both axes in common. The input can, however, be used by both
axes at the same time!

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Optional Device Functions

Low-pass filtering to be activated for both analog channels

Analog inputs designed as differential input

Input voltage range of 10 V

Features of analog inputs on optional module MA1:

The optional module MA1 was developed according to VDE 0411-part 500
(programmable logic controllers) and should be used according to the specifi
cations contained in this standard.
Properties of the analog inputs on the optional module MA1:

Connection via 15-pin D-Sub connector

2 analog inputs with resolution of 14 bits (by means of 8-fold oversampling

for both analog channels)

Low-pass filtering to be activated for both analog channels

Analog inputs designed as differential input

Input voltage range of 10 V

Features of analog inputs at optional module AN:

Hardware Requirements

4 analog inputs with resolution of 14 bits (by means of 8-fold oversampling

for all analog channels)

Low-pass filtering to be activated for both analog channels

Analog inputs designed as differential input

Input voltage range of 10 V

Connection via 12-pole terminal board by Phoenix

The table below shows the hardware requirements of the analog inputs and
their assignment to the connection points (terminal connectors) of the control
section (on basic circuit board, at optional module MA1 or at optional module
AN).
Analog input no.

Control section
type

X32 (4/5)

--

X32 (4/5)

--

--

--

X32 (4/5)

--

X32 (4/5)

--

X32 (4/5)

--

CSH01.xC,

CDB01.xC

... to be found
On basic circuit board

CSB01.xC

Optional module MA1

Optional slot 2

Optional slot 2

X8 (2/9)

X8 (4/11)

Optional slot 3

Optional slot 3

X10 (2/9)

X10 (4/11)

Optional slot 2

Optional slot 2

X8 (2/9)

X8 (4/11)

Optional slot 3

Optional slot 3

X8.1 (2/9)

X8.1 (4/11)

Optional slot 4

Optional slot 4

X8.2 (2/9)

X8.2 (4/11)

Optional slot 3
X8.1 (2/9)

--

--

--

--

--

--

--

--

--

--

Optional slot 3

Optional slot 4

Optional slot 4

X8.1 (4/11)

X8.2 (2/9)

X8.2 (4/11)

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Optional Device Functions

Analog input no.
Control section
type

CSB01.xN-AN

X32 (4/5)

X32 (1/2)

CSB01.xN-SE

--

--

CSB01.xN-PB

--

--

X32 (4/5)1)

X32 (1/2)1)

X36 (1/2) 2)

X36 (2/3) 2)

Optional module MA1

Control section type cannot be configured

On basic circuit board

CDB01.xC-AN

... to be found
On basic circuit board

CSB01.xN-FC

X32 (4/5)

Optional module AN

-1)
2)

Fig.9-4:

X39 (1/2)

X39 (4/5)

X39 (7/8)

X39 (10/11)

For voltage signals (selected via bit 12 in P00218)

For current signals (selected via bit 12 in P00218)

Overview of Hardware Requirements of Analog Inputs (Incl. Assignment

of Connection Points)

See also section "Optional Module MA1" In the documentation "Control

Sections for Drive Controllers; Project Planning Manual"
Pertinent Parameters

Configuring the analog inputs:

P00212, Analog input, list of assignable parameters

P00218, Analog input, control parameter

P00219, Analog input, maximum value for adjustment

P00220, C2800 Analog input adjustment command

P03901, Adjustment values of control section

P03904, Adjustment values analog I/O interface 3-4

P03905, Adjustment values analog I/O interface 5-6

P03906, Adjustment values analog inputs interface 3-6

Analog input values:

P00210, Analog input 1

P00211, Analog input 2

P00228, Analog input 3

P00229, Analog input 4

P00208, Analog input 5

P00209, Analog input 6

P00217, Analog input 1, time constant input filter

P00231, Analog input 2, time constant input filter

P00232, Analog input 3, time constant input filter

P00233, Analog input 4, time constant input filter

P00234, Analog input 5, time constant input filter

P00235, Analog input 6, time constant input filter

Assignment A:

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Optional Device Functions

P00213, Analog input, assignment A, target parameter

P00214, Analog input, assignment A, scaling per 10V full scale

P00215, Analog input, assignment A, signal value at 0V

P00216, Analog input, assignment A, dead zone

Assignment B:

Pertinent Diagnostic Messages

P00236, Analog input, assignment B, target parameter

P00237, Analog input, assignment B, scaling per 10V full scale

P00238, Analog input, assignment B, signal value at 0V

P00239, Analog input, assignment B, dead zone

C2800Analog input adjustment command

C2801Analog input not configured

C2802Oscillations of input signal outside tolerance range

C2803Measured values at zero point and max. value identical

C2804Automatic adjustment failed

9.6

Analog Outputs

9.6.1

Brief Description
Assignment to functional firmware package, see chapter "Availa
bility of the Optional Device Functions".
Overview

According to the control section type, IndraDrive controllers already have an

alog outputs in their basic configuration (without optional modules). Configura
ble control sections can be upgraded with this function by using the optional
module MA1. The number and function of the analog outputs differ according
to the type and configuration of control section (see "Hardware Require
ments" below).
The figure below illustrates the interaction of the two analog output channels
with the analog outputs.

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Optional Device Functions

MA1

Fig.9-5:

Optional module MA1 (analog I/O extension)

Assignment Mechanism for the Analog Outputs

The drive function "analog outputs" allows using analog signal values for com
missioning and optimizing drives with appropriate measuring devices (e.g.
oscilloscope, multimeter), as well as for visualizing the contents of drive pa
rameters.
Features

General features:

Number and characteristics of analog outputs depending on type and

configuration (with/without optional module MA1) of the control section

Up to 6 analog outputs available according to control section design

Update of analog outputs in velocity loop clock (see "Performance Da

ta")

Analog outputs can be written via master communication (cyclic or acyclic

channel)

Internal status variables and signals (= parameter contents) are output as

analog voltage signals at output terminal connectors of the drive controller
(see separate documentation "Drive Controllers, Control Sections; Project
Planning Manual")

Monitoring function with regard to double assignment of outputs

Variable scaling of analog outputs

Switching of the behavior at the limits of voltage range that can be dis
played between overflow and limitation

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Optional Device Functions

Parameterizable output offset or parameterizable reference value

Features of analog outputs at control section:

Number and resolution of analog outputs depend on control section de

sign:

ADVANCED 2 analog outputs with 8 bits

BASIC UNIVERSAL double-axis 2 analog outputs with 8 bits

BASIC OPENLOOP 2 analog outputs with 10 bits

Output voltage range: 0 to 5 V

(for BASIC OPENLOOP 0 to 10V)

Available quantization: 19.5 mV (= 5V/28)

Features of analog outputs at optional module MA1:

The optional module MA1 was developed according to VDE 0411-part 500
(programmable logic controllers) and should be used according to the specifi
cations contained in this standard.
Properties of analog outputs at optional module MA1:

Hardware Requirements

Connection via 15-pin D-Sub connector

2 analog outputs with 12 bits each

Output voltage range: 10V with reference to 0VA

Available quantization: 5mV (= 10V/211)

The table below shows the hardware requirements of the analog outputs and
their assignment to the connection points (terminal connectors) of the control
section (on basic circuit board or at optional module MA1).
Analog output no.

1
Control section
type
CSH01.1C,
CSH01.2C

CSB01.1C

CDB01.1C

... to be found
On basic circuit board
X32 (1)

X32 (2)

X32 (1)

X32 (2)

--

--

X32 (1)

X32 (2)

X32 (1)

X32 (2)

X32 (1)

X32 (2)

Optional module MA1

Optional slot 2

Optional slot 2

X8 (5)

X8 (14)

Optional slot 3

Optional slot 3

X10 (5)

X10 (14)

Optional slot 2

Optional slot 2

X8 (2/9)

X8 (4/11)

Optional slot 3

Optional slot 3

X8.1 (5)

X8.1 (14)

Optional slot 4

Optional slot 4

X8.2 (5)

X8.2 (14)

Optional slot 3
X8.1 (5)

--

--

--

--

--

--

--

--

--

--

Optional slot 3

Optional slot 4

Optional slot 4

X8.1 (14)

X8.2 (5)

X8.2 (14)

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Optional Device Functions

Analog output no.
1
Control section
type

... to be found
On basic circuit board

CSB01.1N-AN

X32 (4/5)

X32 (1/2)

CSB01.1N-SE

--

--

CSB01.1N-PB

--

--

CSB01.1N-FC

X32 (9)

X35 (3)
MA1

Fig.9-6:

Optional module MA1

Control section type cannot be configured

Optional module MA1 (analog I/O extension)

Overview of Hardware Requirements of Analog Inputs (Incl. Assignment

of Connection Points)

See also section "Optional Module MA1" in the documentation "Drive

Controllers, Control Sections; Project Planning Manual"
In the case of double-axis devices (control section CDB01.1...), the
analog outputs are used by both axes, simultaneous use of an an
alog output by both axes is impossible.
Pertinent Parameters

Configuring the analog outputs:

P00426, Analog output IDN list of assignable parameters

P00427, Control parameter of analog output

Analog output - assignment A:

P00418, Analog output, assignment A, signal value at 0V

P00420, Analog output, assignment A, signal selection

P00422, Analog output, assignment A, scaling [1/V]

Analog output - assignment B:

P00419, Analog output, assignment B, signal value at 0V

P00423, Analog output, assignment B, signal selection

P00425, Analog output, assignment B, scaling [1/V]

Analog output values:

P00139, Analog output 1

P00140, Analog output 2

P00414, Analog Output 3

P00415, Analog Output 4

P00416, Analog Output 5

P00417, Analog Output 6

9.7

Virtual Master Axis Generator

9.7.1

Brief Description
Assignment to functional firmware package, see chapter "Availa
bility of the Optional Device Functions".

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Optional Device Functions

The master axis generator serves for generating a master axis position, which
is used as input variable for the position synchronization operation modes and
the operation mode "velocity synchronization".
There are three ways of generating the master axis position:

Format conversion of an actual position value or a command position val

ue of the local axis or of an axis connected via CCD [1]

Generating a virtual actual position value via a positioning motion and

subsequent format conversion [2]

Phase-synchronous motion of the master axis position to a primary master

(secondary master mode) [3]

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Optional Device Functions

Fig.9-7:
Features

Possibilities of Generating the Master Axis Position for the Slave Axis

Features of generating the virtual actual position value with the master axis
generator:

2nd order command value interpolator with subsequent jerk limitation

Absolute, relative and additive positioning capability

"Infinite travel" (jogging) is possible

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Optional Device Functions

Position data format to be set:

Linear 0.0001 mm / 0.0001 inch

Rotary 0.0001 degrees

Modulo value to be set

"Absolute" or "modulo" master axis

Format conversion from position format "virtual master axis" to master axis
format (modulo value "virtual master axis" 2P00084 P00750)

Virtual master axis generator realized as virtual axis in IndraMotion MLD

with individual scaling system

Setting of virtual master axis generator, either directly via parameters or

via the following function blocks:

MC_MoveVelocity / MX_MoveVelocity

MC_MoveAbsolut / MX_MoveAbsolut

MC_MoveAdditiv / MX_MoveAdditiv

MC_MoveRelativ / MX_MoveRelativ

MC_Stop

MB_Stop

Note:
The function blocks for the virtual axis must behave exactly like those for
a real axis. The diagnostic and error messages, however, are different.
Features of the secondary master mode:

Pertinent Parameters

Real and virtual primary master can be selected

Electronic gear with fine adjust

Dynamic synchronization to the primary master

Additive master axis position can be changed as offset with parameterized

acceleration and velocity

Activating by means of the functional block "MB_GearInPos"; deactivating

by means of the functional block "MB_GearOut"

P00756, Virtual master axis, scaling type

P00757, Virtual master axis, modulo value

P00758, Virtual master axis, actual position value

P00759, Virtual master axis, actual velocity value

P00760, Virtual master axis, positioning control word

P00761, Master axis position for slave axis

P00766, Virtual master axis, positioning command value

P00767, Virtual master axis, effective target position

P00768, Virtual master axis, positioning status

P00769, Virtual master axis, command value mode

P00770, Virtual master axis, positioning velocity

P00771, Virtual master axis, positioning acceleration

P00772, Virtual master axis, positioning deceleration

P00774, Virtual master axis, positioning window shortest distance

P00911, Virtual master axis, positioning window

P00912, Virtual master axis, standstill window

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Optional Device Functions

Pertinent Diagnostic Messages

P00913, Virtual master axis, positioning jerk

P00914, Virtual master axis, velocity threshold positioning

P00917, Control word of master axis generator

P00919, Synchronization mode, secondary master

P00920, Synchronization acceleration, secondary master

P00921, Synchronization velocity, secondary master

P00922, Preferred synchronization direction, secondary master

P00923, Synchroniz. window for shortest distance, secondary master

P00924, Selection primary master

P00925, Master drive gear input revolutions, secondary master

P00926, Master drive gear output revolutions, secondary master

P00927, Master drive gear fine adjustment, secondary master

P00928, Additive master axis position, secondary master

P00929, Change velocity of add. master axis posit., secondary master

P00930, Change accel. of add. master axis posit., secondary master

E2100 Positioning velocity of master axis generator too high

F2063Internal overflow master axis generator

F2064Incorrect cmd value direction master axis generator

9.8

Drive-Integrated Command Value Generator

9.8.1

Brief Description
Assignment to functional firmware package, see chapter "Availa
bility of the Optional Device Functions".
The drive-integrated command value generator can be used for commissioning
and controller optimization of drives. The command value generator generates
the command values required for the active operating mode in different shapes
(square-wave, sine, noise); these command values are added to the main
command value in the closed control loop.
In conjunction with the integrated oscilloscope function and an ad
ditional FFT calculation, the drive-integrated command value gen
erator also provides the possibility of measuring the frequency
response.
The figure below illustrates the points at which the drive-integrated command
value generator can take effect:

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Optional Device Functions

S00037
S-0-0047
S00081
P00038
P00039
P00059
P01150
P01152

Fig.9-8:

Features

Additive velocity command value

Position command value
Additive torque/force command value
Torque-generating current, command value
Flux-generating current, command value
Additive position command value, controller
Command value generator output
Command value generator, target parameter assignment

Points at Which Function "Command Value Generator"

Possibility of generating different signal shapes that are added to the re

spective control loop command value (position, velocity or current)
The following signal shapes are possible:

Square-wave signals

Sine signals

Noise signals

Modified sine signals

Generating velocity and position command values in the position loop

clock; current command values in the velocity loop clock

With regard to amplitude and frequency, generated command values can

be freely defined
The drive-integrated PLC (IndraMotion MLD) provides further pos
sibilities of generating command values, but it can generate com
mand values with a clock rate of 1 ms.

Pertinent Parameters

P01150, Command value generator output

P01151, Command value generator, list of possible target parameters

P01152, Command value generator, target parameter assignment

P01153, Command value generator, control word

P01154, Command value generator, offset

P01155, Command value generator, amplitude

P01156, Command value generator, duration 1

P01157, Command value generator, duration 2

P01158, Command value generator, periodic time

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Optional Device Functions

P00028, Oscilloscope: control word

P00031, Oscilloscope: time resolution

P00032, Oscilloscope: size of memory

9.9

Drive-Internal "Command Value Box"

9.9.1

Brief Description
Assignment to functional firmware package, see chapter "Availa
bility of the Optional Device Functions".
With IndraDrive controllers, a so-called "command value box" is internally avail
able for manual drive optimization. It offers the possibility to internally (inde
pendent of the master) generate a command value characteristic that can be
defined by the user. By this, an axis drive can be moved in the same way as
with an external command value box, without an external command value being
effective ( drive-internal "command value box"). The drive enable must merely
be applied to the drive.
The command value characteristic that can be defined by the user, allows for
an axis to be moved within determinable position limits in continuous sequence
in the velocity control loop or position control loop. This can be made use of, in
order to manually optimize the control loop parameters of the drive, by e.g.
moving the drive with a low velocity command value and by evaluating the sta
tus variables "actual current value" and "actual velocity value".
More details on the manual control loop setting are described in the
"Overview of Drive Control: Notes on Commissioning for Control
Loop Setting" .
By the internal command value box, an axis can be continuously moved in an
"oscillating movement" (oscillating between two position limit values) or in
"stepper mode" (unidirectional moving over a defined path or a travel range).
The internal command value box is configured via a command word, the com
mand value characteristic is defined via the respective parameters. Activating
the internal command value box is carried out via a command.
Pertinent Parameters

Pertinent Diagnostic Messages

P-0-0162, C1800 Command Drive optimization / command value box

P-0-0165, Drive optimization, control word

P-0-0166, Drive optimization, end position negative

P-0-0167, Drive optimization, end position positive

P-0-0169, Drive optimization, travel distance

P-0-0170, Drive optimization, acceleration

P-0-0171, Drive optimization, velocity

P-0-0172, Drive optimization, dwell time

C1800Command Drive optimization / command value box

C1801Start requires drive enable

C1806Travel range exceeded

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Optional Device Functions

9.10

Encoder Emulation

9.10.1

Brief Description
Assignment to functional firmware package, see chapter "Availa
bility of the Optional Device Functions".
By means of encoder emulation is it possible to convert available encoder sig
nals (encoder 1, encoder 2 or measuring encoder) or internal position command
values into one of the following two formats:

5V-TTL signal of an incremental encoder with incremental encoder emu

lation (track A, track B and zero pulse)

Serial 24-bit position of an absolute encoder (SSI format) with absolute

encoder emulation

This allows, for example, evaluating the signals in a higher-level master in order
to close the position loop in the external control unit in conjunction with the freely
parameterizable resolution and the data reference.
Using the encoder emulation in precision applications (mostly in
machine tool applications) is considered as critical and always has
to be carefully considered beforehand!
For sophisticated applications for which the position control loop is
closed by means of emulation, Bosch Rexroth recommends to use
digital interfaces, such as SERCOS interface.
See "Restrictions" in section "Notes on Commissioning"
Incremental Encoder Emulation

Incremental encoder emulation is the simulation of a real incremental encoder

by the drive controller.
With incremental encoder emulation we distinguish between

Signal emulation
- and -

Motor encoder emulation.

In the form of incremental encoder signals, a higher-level numeric control (NC)

receives information about the velocity of the motor connected to the controller.
By integration of these signals, the control unit receives the required position
information and it is thereby possible to close a higher-level position control
loop.
Emulation takes place in scaling-dependent (see S00076) or en
coder-related form; the resolution is input in lines/revolution (1 line
corresponding to 4 increments) or in mm or inch.
Features of Incremental Encoder
Emulation

Cyclic calculation of the position or increments output by the emulator in

the position loop clock (see "Performance data")

Freely selectable position signals for emulation (P00900, P00901)

Resolution that can be parameterized (lines/revolution or mm resp. inch)

Encoder-related emulation (incremental)

Dead time compensation that can be activated (P00902, bit 3)

Shiftable zero pulse (P00904)

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Optional Device Functions

Absolute Encoder Emulation

Parameterizable cyclic zero pulse output for zero pulse distance

(P00904) and position data reference (P00902)

Encoder emulation can be switched off in operation ( pause)

Internal clock increase of incremental encoder emulation to reduce zero

pulse jitter and frequency jitter (not for BASIC ANALOG control sections)

Signal-related or motor-encoder-related emulation to be freely selected

( influence on position of zero pulse!)

Absolute encoder emulation means that the drive controller has the option of
simulating a real absolute encoder in SSI data format. It is thereby possible to
transmit the position in the SSI data format to the connected control unit (NC)
and to close the position control loop via the control unit.
Emulation takes place in scaling-dependent form (see S00076)
and the resolution is input in bits.

Features of Absolute Encoder Em

ulation

Hardware Requirements

Cyclic calculation of the position or increments output by the emulator in

the position loop clock (see "Performance data")

Freely selectable position signals for emulation (P00900, P00901)

Resolution that can be parameterized (bits)

Scaling-related emulation (S-0-0076)

Synchronization of SSI emulation to SSI clock can be activated (only for

ADVANCE control sections)

The firmware encoder emulation function requires the following control section
design:

Single-axis BASIC ANALOG (not configurable) (CSB01.1N-AN)

In addition, it is possible to use the following configurable control sections, if

they have been designed with the optional module for encoder emulation
(MEM):

Single-axis BASIC UNIVERSAL (CSB01.1C)

Single-axis ADVANCED (CSH01.xC)

Double-axis BASIC UNIVERSAL (CDB01.1C)

The encoder emulation is a device function. It can therefore only be
used once per device, i.e. in the case of double-axis devices (CDB),
it is only available for one of the two axes, as a standard.
Special case:
In the case of double-axes devices operated as purely analog de
vices with position feedback via encoder emulation, the encoder
emulation can be used for each axis, if the control section configu
ration CDB01.1C-AN-EN*-MEM-EN*-MEM is available.
In this case the following must be observed: For assignment of op
tional slots to the respective axis see documentation "Control Sec
tions for Drive Controllers; Project Planning Manual"" .

Pertinent Parameters

P00900, Encoder emulation signal selection list

P00901, Encoder emulation signal selection

P00902, Encoder emulation control parameter

P00903, Encoder emulation resolution

P00904, Encoder emulation zero pulse offset

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Optional Device Functions

P00905, Encoder emulation zero pulse distance

If the encoder emulation is operated as device function in the dou
ble-axis device (no "analog inputs" extension plugged), these pa
rameters are available once per device, except the control
parameter (P00902). If the "analog inputs" (AN) extension is plug
ged, these parameters are available once per axis.

Pertinent Diagnostic Messages

C0242 Multiple configuration of a parameter (->S-0-0423)

C0260 Incremental enc. emulator resol. cannot be displayed

F2053Incr. encoder emulator: Pulse frequency too high

F2054Incr. encoder emulator: Hardware error

9.11

Programmable Position Switch

9.11.1

Brief Description
Assignment to functional firmware package, see chapter "Availa
bility of the Optional Device Functions".
The firmware function "programmable position switch" can be used instead of
a mechanical position switch that has to be externally mounted.
Features

Realization of a maximum of 8 dynamic position switch points (switch

cams) in the position loop clock

Freely selectable reference signals (P00130) for generating the switch

cams, all 8 cams are referring to the same signal (P00131)

Switch-on and switch-off position can be separately parameterized via list

parameters (P00132, P00133); corresponding position switch bit can
be inverted by selecting the switch-on and switch-off threshold

Lead time that can be separately parameterized via list parameter

(P00134) for compensating internal processing times (dead time com
pensation)

8 position switch bits displayed in the position switch status word

(P00135) which can be assigned to digital outputs or cyclically transmit
ted via master communication interface

Permanently defined switch hysteresis to avoid position switch bit flicker

when the switch-on or switch-off threshold is reached
"Programmable position switch" is a device function and therefore
only available once for double-axis devices!

Pertinent Parameters

Pertinent Diagnostic Messages

P00130, Position switch signal selection list

P00131, Position switch signal selection

P00132, Position switch switch-on threshold

P00133, Position switch switch-off thresholds

P00134, Position switch lead times

P00135, Position switch status word

C0242 Multiple configuration of a parameter (->S-0-0423)

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Optional Device Functions

9.12

Probe Function

9.12.1

Brief Description
Assignment to functional firmware package, see chapter "Availa
bility of the Optional Device Functions".
Features

2 probe inputs per axis; depending on the hardware design of the control
section (CSH, CSB, CDB) two rapid probe inputs or one rapid and
one slow probe input

Measuring signals can be actual position values of motor encoder, exter

nal encoder or measuring encoder, in addition master axis position values

Simultaneous storage of two measuring signals when probe signal only

via one probe input

For control sections with only one probe input (rapid digital input), another
digital input can be used as probe input

Measurement of absolute actual position values, of actual position value

differences, detection of time intervals between measuring signals

Measurement triggered by positive and/or negative probe signal edges

Single measurement or continuous measurement to be selected, meas

urement events are counted in the case of continuous measurement

Position value range ("expectation window") per probe can be defined

within which measurement can take place (activation of a "failure coun
ter" when expectation window is passed through without measuring event)

Quick stop triggered via probe input

Sampling time for probe signals depends on performance which has been
set or is available:

Approx. 0.0416 s for Advanced performance

Approx. 0.0833 s for standard performance

Approx. 0.1666 s for Economy performance

Note: For sufficient noise immunity, signal edge reversal must last for at
least 4.0 s in order to be safely detected!

Hardware Requirements

dead time compensation can be set for every probe, separately for every
positive or negative edge up to 50000s

Accuracy of measurement depends on hardware design (see section

"Probe" in the documentation "Control sections for drive controllers; proj
ect planning manual")

The probe function is only possible in conjunction with control sections which
have at least one "rapid" digital input.
A second, slower digital input (standard digital input) can be configured as
probe input for BASIC control sections and for double axis control sections
which have one "rapid" digital input per axis. Realize the assignment of this
input for evaluation of probe 2 by means of corresponding parameter setting
(see below).
The following control section designs are available:

No rapid digital input ( probe function not possible):

CSB01.1N-FC- BASIC OPENLOOP

CSB01.1N-AN- BASIC ANALOG

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Optional Device Functions

One rapid digital input and one slow digital input per axis

CSB01.1N-SE- BASIC SERCOS

CSB01.1N-PB- BASIC PROFIBUS

CSB01.1C BASIC UNIVERSAL (single-axis)

CDB01.1C- BASIC UNIVERSAL (double-axis)

Two rapid digital inputs:

CSH01.1C-... ADVANCED

IndraDrive Mi

The terminal designations of the "rapid" digital inputs are contained in section
"I/O Extensions" in the documentation "Control Sections for Drive Controllers;
Project Planning Manual".
Pertinent Parameters

S00130, Probe value 1 positive edge

S00131, Probe value 1 negative edge

S00132, Probe value 2 positive edge

S00133, Probe value 2 negative edge

S00169, Probe control parameter

S00170, Probing cycle procedure command

S00179, Probe status

S00401, Probe 1

S00402, Probe 2

S00405, Probe 1 enable

S00406, Probe 2 enable

S00409, Probe 1 positive latched

S00410, Probe 1 negative latched

S00411, Probe 2 positive latched

S00412, Probe 2 negative latched

S00426, Signal selection probe 1

S00427, Signal selection probe 2

S00428, Probe, IDN-list signal selection

S00524, Dead time compensation, positive edge, probe 1

S00525, Dead time compensation, negative edge, probe 1

S00526, Dead time compensation, positive edge, probe 2

S00527, Dead time compensation, negative edge, probe 2

P00200, Start position probe function 2 active

P00201, End position probe function 2 active

P00202, Difference probe values 1

P00203, Difference probe values 2

P00204, Start position probe function 1 active

P00205, End position probe function 1 active

P00206, Probe 1, max. number of marker failures

P00207, Probe 2, max. number of marker failures

P00224, Probe 1, number of marker failures

P00225, Probe 2, number of marker failures

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Optional Device Functions

Pertinent Diagnostic Messages

P00226, Probe, extended control word

P00300, Digital I/Os, assignment list

P00301, Digital I/Os, bit numbers

P00302, Digital I/Os, direction

A0403 Quick stop with probe detection is active

C0250 Probe inputs incorrectly configured

9.13

Measuring Encoder

9.13.1

Brief Description
Assignment to functional firmware package, see chapter "Availa
bility of the Optional Device Functions".
Position Measurement

Measuring encoders are used for position evaluation of a rotary motion that
takes effect as a command variable for drive control. The actual position value
of the measuring encoder therefore is of command value nature for drive con
trol, the measuring encoder acts as a master axis encoder, for example.

Evaluating Position Measurement

Depending on its design and the mechanical arrangement at the axis, the
measuring encoder can be evaluated as

Relative encoder (incremental encoder)

- or

Absolute encoder (absolute value encoder).

Relative Position Measurement

In the case of relative position measurement, only position differences can be

evaluated by means of the measuring system. The actual position values sig
naled by the measuring system refer to the (mostly undefined) position at the
time the drive is switched on. If the actual position value is to refer to an axis or
shaft, it is necessary to establish position data reference ("homing").

Absolute Position Measurement

In the case of absolute position measurement, the encoder signals actual po

sition values with a fixed encoder-dependent reference point to the controller.
After the drive is switched on, the correct actual position value is immediately
available for each axis or shaft position. Due to the mostly undefined mounting
situation of the encoder, it is necessary during initial commissioning to once
adjust the actual position value to the axis or shaft ("set absolute measuring").

Precision, Resolution

Monitoring Functions

The precision of the position measurement depends on

the resolution of the measuring system (division periods = DP),

the absolute encoder precision,

the digitalization quality of the analog encoder signals,

the size of the selected modulo range of the encoder.

The correct position information of the measuring encoder is required for correct
recording of a command variable. The encoder signals are therefore monitored
for validity and compliance with the allowed tolerances.
In addition, it is possible to monitor drives with an encoder that can be evaluated
in absolute form for compliance with the position when switching on compared
to the last time the drive was switched off.
See "Monitoring the Measuring Systems"

Hardware Requirements

For connecting the measuring systems to the controller, the control section has
to be equipped with the corresponding interfaces. Parameter "P00079,

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Optional Device Functions

Assignment measuring encoder->optional slot" is used to determine the inter
face to which the respective encoder is connected.
For controllers with a double-axis control section (CDB01.1-...), it is only pos
sible to assign a measuring encoder to one axis. The assignment is made in
parameter "P00076, Encoder type 3 (measuring encoder)". If a measuring
encoder was assigned to both axes, an error message will be displayed!
See also separate documentation "Drive Controllers, Control Sections;
Project Planning Manual"
Pertinent Parameters

Pertinent Diagnostic Messages

P00052, Actual position value of measuring encoder

P00076, Encoder type 3 (measuring encoder)

P00079, Assignment measuring encoder->optional slot

P00084, Number of bits per master axis revolution

P00087, Actual position value offset of measuring encoder

P00097, Absolute encoder monitoring window for measuring encoder

P00127, Input revolutions of measuring gear

P00128, Output revolutions of measuring gear

P00179, Absolute encoder buffer 3 (measuring encoder)

P00326, Multiplication of measuring encoder

P00327, Encoder resolution of measuring encoder

P00328, Type of position encoder for measuring encoder

P00329, Smoothing of actual position value 3 of measuring encoder

P00330, Control word of measuring encoder

P00331, Status of measuring encoder

P00332, Actual velocity value of measuring encoder

P00334, Absolute encoder range of measuring encoder

P00347, Encoder 3, cosine signal

P00348, Encoder 3, sine signal

P00765, Modulo factor measuring encoder

P01020, Kind of encoder 3, encoder memory

P01021, Encoder 3 resolution, encoder memory

P01022, Absolute encoder offset 3, encoder memory

C0161 Incorr. prarmeterization of measuring enc. (hardware)

C0162 Measuring encoder unknown

C0163 Modulo value for measuring encoder cannot be displayed

C0227 Error when initializing position of measuring encoder

C0228 Initialization velocity measuring encoder too high

E2076 Measuring encoder: Encoder signals disturbed

F2043Measuring encoder: Encoder signals incorrect

F2076Actual pos. value 3 outside absolute encoder window

F2176Loss of measuring encoder reference

F2179Modulo limitation error of measuring encoder

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Handling, Diagnostic and Service Functions

10

Handling, Diagnostic and Service Functions

10.1

Parameters, Basics

10.1.1

Properties/Features of Parameters

Brief Description
The controller firmware via data maps the drive to an internal mathematical
model. All operating data relevant therefor are mapped to parameters. An iden
tification number (IDN) is assigned to each parameter. The IDN allows access
ing operating data via

the serial interface

- or

a master communication interface suited for data transfer.

The operating data stored in parameters can be identified by means of the IDN.
They can be read and transferred, if required. The user write access to param
eters depends on the properties of the respective parameter and the current
communication phase. Specific parameter values (operating data) are checked
for validity by the drive firmware.

10.1.2

Loading, Storing and Saving Parameters

Brief Description
Parameters
Data Memory

All relevant operating data are mapped to parameters and stored in the con
troller.
Several non-volatile data memories are available in an IndraDrive device:

In the controller

In the motor encoder (depending on motor type)

As a MultiMediaCard (MMC), optional

In addition, the controller has a volatile data memory (working memory).

Condition as Supplied

Condition as supplied of the Rexroth drive components:

The controller memory contains the drive firmware and the controller-spe
cific parameter values.

The motor encoder memory contains the encoder-specific and, depending

on the motor type, the motor-specific parameter values.

The MMC contains the drive firmware.

Storing the Application-Specific Pa

rameter Values

The application-specific parameter values are stored in the controller. Due to

the limited number of writing cycles of non-volatile storage media, applicationspecific parameter values can be stored in the working memory (volatile mem
ory), too.

Saving Parameter Values

Saving application-specific parameter values is required in the following cases:

After initial commissioning of the machine axis or the motor

Before replacing the controller for servicing (if possible)

Application-specific parameter values can be saved via:

MMC copying the parameter values by command

"IndraWorks Ds/D/MLD" commissioning tool Saving the parameter val

ues on external data carrier

Control master saving parameter values on master-side data carrier

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Handling, Diagnostic and Service Functions

Parameter IDN Lists

Loading Parameter Values

The drive supports master-side saving of parameter values by listing parameter

identification numbers (IDNs). Using these lists guarantees complete storage
of the application-specific parameter values. It is also possible to determine IDN
lists defined by the customer.
Loading parameter values is required in the following cases:

Initial commissioning of the motor (loading basic parameter values and

motor-specific parameter values)

Serial commissioning of machine axes at series machines (loading the

values saved after initial commissioning)

Reestablishing a defined initial status (repeated loading of the values

saved after initial commissioning)

Replacing the controller for servicing (loading the current parameter val
ues saved before servicing)

Possibilities of loading parameter values to the controller:

Checksum of Parameter Values

Pertinent Parameters

Pertinent Diagnostic Messages

Motor encoder data memory loading the parameter values by command

or via the control panel during initial motor commissioning

MMC loading the parameter values by command

"IndraWorks Ds/D/MLD" Commissioning tool Loading the parameter

values from external data carrier

Control master loading the parameter values from master-side data

carrier

By means of checksum comparison, the control master can determine whether

the values of the application-specific parameter values currently active in the
drive correspond to the values saved on the master side.

S00017, IDN-list of all operation data

S00192, IDN-list of all backup operation data

S00262, C07_x Load defaults procedure command

S00263, C2300 Load working memory procedure command

S00264, C2200 Backup working memory procedure command

S00269, Storage mode

S00270, IDN-list of selected backup operation data

S00293 , C2400 Selectively backup working memory procedure

command

S00326, Parameter checksum

S00327, IDN list of checksum parameter

S00531, Checksum of backup operation data

P00013, List of all IDNs not corresponding to default value

P04023, C0400 Communication phase 2 transition

P04065, Active non-volatile memory

P04070, Parameter storage configuration

P04090, Configuration for loading default values

P04091, C2500 Copy IDN from optional memory to internal memory

P04092, C2600 Copy IDN from internal memory to optional memory

Load defaults procedure (loading controller parameters):

C0700 Load defaults procedure com. (load controller param.)

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Handling, Diagnostic and Service Functions

C0702 Default parameters not available

C0703 Default parameters invalid

C0704 Parameters not copyable

C0706 Error when reading the controller parameters

Load defaults procedure (loading basic parameters):

C0750 Load defaults procedure com. (load basic parameters)

C0751 Parameter default value incorrect (-> S-0-0423)

C0752 Locked with password

Backup working memory procedure:

C2202 Error when writing data to non-volatile memory

C2200 Backup working memory procedure command

Loading working memory:

C2300 Load working memory procedure command

C2301 Error when reading non-volatile memory

C2302 Error when converting parameters

Selectively backup working memory procedure:

C2400 Selectively backup working memory procedure command

C2402 Error when saving parameters

Copy parameters from MMC to flash:

C2500 Copy IDN from optional memory to internal memory

C2502 Error when accessing the MMC

C2504 Error when writing data to internal memory

Copy parameters from flash to MMC:

C2600 Copy IDN from internal memory to optional memory

C2602 Error when accessing the MMC

C2604 Error when reading the internal memory

Other diagnostic messages:

10.1.3

F2100 Incorrect access to command value memory

F2101 It was impossible to address MMC

F2102 It was impossible to address I2C memory

F2103 It was impossible to address EnDat memory

IDN Lists of Parameters

General Information
Some of the parameters stored in the drive contain, as their operating data
(parameter value), a list of IDNs of drive parameters corresponding to a specific,
given criterion. These so-called IDN lists enable the master or a commissioning
software to handle drive parameters in a specific way.

10.1.4

Using a Password

Brief Description
IndraDrive controllers provide the possibility to protect parameter values
against accidental or unauthorized change by means of a password. With re
gard to write protection, there are 3 groups of parameters that can be written:

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Handling, Diagnostic and Service Functions

Parameters that are write-protected as a standard, such as motor param

eters, hardware code parameters, encoder parameters, error memory,
etc. ("administration parameters"). The values of these parameters guar
antee correct function and performance of the drive.

Parameters the customer can combine in groups and protect them with a
so-called customer password. This allows protecting parameter values,
that are used for adjusting the drive to the axis, after having determined
them.

All other parameters that can be written and are not contained in the
above-mentioned groups. They are not write-protected.

The drive firmware allows activating and deactivating the write protection for
parameter values by means of three hierarchically different passwords:

Customer password
The parameter values of a parameter group combined by the customer
can be protected.

Control password
Parameters protected by a customer password can be written; "admin
istration parameters" remain write-protected.

Master password
All parameters that can be written, including "administration parame
ters" and parameters protected by a customer password, can be changed.
The customer password can be defined by the customer, the control
password and the master password are defined by the manufac
turer!

Pertinent Parameters

S00192, IDN-list of all backup operation data

S00267, Password

S00279, IDN-list of password-protected operation data

P04064, Password level

10.2

Device Configuration

10.2.1

Controller Design
The drive controllers of the IndraDrive range consist of several modules. We
basically distinguish between:

Main module
Module directly communicates with the master

Submodule
Module only communicates with the master via main module

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Handling, Diagnostic and Service Functions

MC

Fig.10-1:

Master communication

Example of Design Including Device, Modules and Circuit Boards for

IndraDrive Controllers

The modular structure of the IndraDrive controllers allows a combinations of

control sections and power sections.
Power section
HCS04.2
Control section

HMS01

HMS02

HMD01

HCS02

HCS03

(prelimina
ry)

CSH01.1C 1)

CSH01.2C 1)

CSB01.1N 2)

CSB01.1C 1)

CDB01.1C 1)

CSH01.3C 1)
(preliminary)

1)
2)

Fig.10-2:

Allowed
Not allowed
Control section can be configured
Control section cannot be configured

Combination Control Section - Power Section

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Handling, Diagnostic and Service Functions

Do not exceed maximum number of plug-in actions!
For a drive controller, the control section mustn't be mounted and
dismounted more than a maximum of 20 times. If this number is
exceeded, the electrical data of the internal connection can be
above the specified minimum requirements. This can cause mal
function of the drive controllers.
Power sections require control sections with appropriate firmware.
Control section type

Firmware version

1)

CSB01

. 1

-FC

as of MPB-02VRS

CSB01

. 1

-AN

as of MPB-02VRS

CSB01

. 1

as of MPB-02VRS

CDB01

. 1

as of MPD-02VRS

CSH01

. 1

as of MPH-02VRS

CSH01

. 2

as of MPH-04VRS to MPH-05VRS

CSH01

. 3

as of MPC-06V06

1)

Fig.10-3:
Product
Line

HMS01.1N

HMS02.1N

Basic type without configuration

Required Firmware Version for Control Sections

Type
current

Design

Supported as of firmware ver

sion

- W0020

- A-07-

NNNN

MPH-02VRS; MPB-02VRS

- W0036

- A-07-

NNNN

MPH-02VRS; MPB-02VRS

- W0054

- A-07-

NNNN

MPH-02VRS; MPB-02VRS

- W0070

- A-07-

NNNN

MPH-02VRS; MPB-02VRS

- W0110

- A-07-

NNNN

MPH-02VRS; MPB-02VRS

- W0150

- A-07-

NNNN

MPH-02VRS; MPB-02VRS

- W0210

- A-07-

NNNN

MPH-02VRS; MPB-02VRS

- W0350

- A-07-

NNNN

MPH-02VRS; MPB-02VRS

- F0028

- A-07-

NNNN

MPH-05V16; MPB-05V16

- F0070

- A-07-

NNNN

MPH-05V16; MPB-05V16

- F0110

- A-07-

NNNN

MPH-05V16; MPB-05V16

- F0110

- A-07-

S003

MPH-05V16; MPB-05V16

- F0150

- A-07-

NNNN

MPH-05V16; MPB-05V16

- F0210

- A-07-

NNNN

MPH-05V16; MPB-05V16
MPH-02V24; MPB-02V24

- W0028

- A-07-

NNNN

MPH-03V12; MPB-03V12
MPH-02V24; MPB-02V24

- W0054

- A-07-

NNNN

MPH-03V12; MPB-03V12

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Handling, Diagnostic and Service Functions

Product
Line

Type
current

Design

Supported as of firmware ver

sion

- W0012

- A-07-

NNNN

MPD-02VRS

HMD01.1N - W0020

- A-07-

NNNN

MPD-02VRS

- W0036

- A-07-

NNNN

MPD-02VRS

Fig.10-4:
Product
Line

Required Firmware Versions for Inverters

Type
current

Design

Supported as of firmware ver

sion

- W0012

- A-03-

LNNN

MPH-02VRS; MPB-02VRS

- W0012

- A-03-

NNNN

MPH-02VRS; MPB-02VRS

- W0012

- A-03-

NNNV

MPH-02V20; MPB-02V20

- W0028

- A-03-

LNNN

MPH-02VRS; MPB-02VRS

- W0028

- A-03-

NNNN

MPH-02VRS; MPB-02VRS

- W0028

- A-03-

NNNV

MPH-02V20; MPB-02V20

HCS02.1E - W0028

- S-03-

NNNN

MPH-02VRS; MPB-02VRS

- W0054

- A-03-

LNNN

MPH-02VRS; MPB-02VRS

- W0054

- A-03-

NNNN

MPH-02VRS; MPB-02VRS

- W0054

- A-03-

NNNV

MPH-02V20; MPB-02V20

- W0070

- A-03-

LNNN

MPH-02VRS; MPB-02VRS

- W0070

- A-03-

NNNN

MPH-02VRS; MPB-02VRS

- W0070

- A-03-

NNNV

MPH-02V20; MPB-02V20

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Handling, Diagnostic and Service Functions

Product

Type
current

Line

- A-05-

LNBV

MPH-02VRS; MPB-02VRS

- W0070

- A-05-

LNNV

MPH-02V11; MPB-02V11

- W0070

- A-05-

NNBV

MPH-02VRS; MPB-02VRS

- W0070

- A-05-

NNNV

MPH-02V11; MPB-02V11

- W0070

- A-15-

PSPV

MPH-02VRS; MPB-02VRS

- W0100

- A-05-

LNBV

MPH-02VRS; MPB-02VRS

- W0100

- A-05-

LNNV

MPH-02V11; MPB-02V11

- W0100

- A-05-

NNBV

MPH-02VRS; MPB-02VRS

HCS03.1E - W0100

- A-05-

NNNV

MPH-02V11; MPB-02V11

- W0150

- A-05-

LNBV

MPH-02VRS; MPB-02VRS

- W0150

- A-05-

LNNV

MPH-02V11; MPB-02V11

- W0150

- A-05-

NNBV

MPH-02VRS; MPB-02VRS

- W0150

- A-05-

NNNV

MPH-02V11; MPB-02V11

- W0210

- A-05-

LNBV

MPH-02VRS; MPB-02VRS

- W0210

- A-05-

LNNV

MPH-02V11; MPB-02V11

- W0210

- A-05-

NNBV

MPH-02VRS; MPB-02VRS

- W0210

- A-05-

NNNV

MPH-02V11; MPB-02V11

- F0500

- A-05-

NNBV

MPH-04V10; MPB-04V10

HCS04.1E - W0500

- A-05-

NCBV

MPH-04V10; MPB-04V10

- W0500

- A-05-

NNBV

MPH-04V10; MPB-04V10

- W0290

- N-04-

NNNN

MPH-06V08; MPB-06V08

- N-04-

NNBN

MPB-06V08

...
- W1540

Fig.10-5:

Required Firmware Versions for Converters

Product
Line

Size,
length

KSM01.2B -

041C

061C

071C

076C

Fig.10-6:
Distributed Drive Controllers
KMS01

Supported as of firmware ver

sion

- W0070

HCS04.2E

Distributed Servo Drives KSM01

Design

Product

Other features
-

MPB-04V20

Required Firmware Versions for Distributed Servo Drives

Features

Supported as of firmware
version

B-A018-P-D7-SE-ENH-NN-NN

MPB-06VRS

Line
KMS01

Supported as of firmware version

B-A018-P-D7-SE-NNN-NN-NN

Fig.10-7:

Required Firmware Version for Distributed Drive Controllers

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Handling, Diagnostic and Service Functions

The devices are configured at the factory and can be read via pa
rameters, if required.

10.2.2

Circuit Board Code

Brief Description
The configurable control section of a drive controller consists of the basic con
trol section circuit board and one or several optional modules (see type code
in the documentation "Drive Controllers, Control Sections; Project Planning
Manual").
An individual parameter is assigned to each slot for circuit board or optional
module (cf. P01506 to P01514). The specific data (circuit board code) of the
circuit board that has been plugged are stored in these parameters.
The circuit board codes are stored directly on the circuit board or
the respective optional module.

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S00140
P01506
P01507
P01508
P01509
P01510
P01511
P01512
P01513
P01514
P01518
P01519
P01520

Fig.10-8:

Controller type
Circuit board code optional module 1
Circuit board code optional module 2
Circuit board code optional module 3
Circuit board code master communication
Circuit board code power section
Circuit board code control section
Circuit board code optional module 4
Circuit board code optional module 1 for safety technology
Circuit board code optional module 2 for safety technology
Module code of control section
Module code of power section
Control section type

Device Configuration and Circuit Board Code for IndraDrive

In the initialization phase (when booting), the drive firmware automatically

checks the arrangement (configuration) of the control section by means of the
individual circuit board codes, and on this basis generates the content of pa
rameter "P01520, Control section type". The configuration of the control
section used can be read via this parameter.
The control section is configured at the factory and the configuration
is displayed in parameter P01520 for diagnostic purposes (type
designation in plain text)!
Pertinent Parameters

S00140, Controller type

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Handling, Diagnostic and Service Functions

Pertinent Diagnostic Messages

P01506, Circuit board code optional module 1

P01507, Circuit board code optional module 2

P01508, Circuit board code optional module 3

P01509, Circuit board code master communication

P01510, Circuit board code power section

P01511, Circuit board code control section

P01512, Circuit board code of optional module 4

P01513, Circuit board code optional module 1 for safety technology

P01514, Circuit board code optional module 2 for safety technology

P01518, Module code of control section

P01519, Module code of power section

P01520, Control section type

During the initialization phase the drive, apart from checking the existing con
figuration, carries out some additional checks. Errors detected during the
checks are classified according to their cause.
General malfunction of a circuit board with specific error messages:

F8091 Power section defective

F8122 Control section defective

Configuration of control section not allowed, i.e. an optional card was plugged
into a slot that does not support this card (observe allowed combinations of the
individual optional modules; see documentation "Drive Controllers, Control
Sections; Project Planning Manual"):

10.2.3

F8118 Invalid power section/firmware combination

F8120 Invalid control section/firmware combination

Operating Hours Counter

Brief Description
There are operating hours counters available in the drive that separately record
the operating time for control section and power section. The respective oper
ating time is displayed in the parameters P00190 or P00191. These times
are directly stored from the control section or power section so that assignment
is maintained also for servicing.
Pertinent Parameters

P00190, Operating hours control section

P00191, Operating hours power section

Parameter "P00190, Operating hours control section" displays the operating

time of the control section of the drive. The unit is seconds.
The time the drive has been switched on is considered to be the operating time
of the control section.
Parameter "P00191, Operating hours power section" displays the operating
time of the power section of the drive with drive enable having been set. The
unit is seconds.
The time during which the output stage has been enabled is considered to be
the operating time of the power section.
Before delivery, the operating hours counters are set to a defined
value at the factory. They can therefore indicate the total runtime of
a component in field duty.

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In addition, there is an operating hours counter for motors with which the dy
namic operating data of the motor are collected and stored.
See section "Diagnostic Data of Motor Operation"

10.2.4

Error Memory (Power Section and Control Section)

Brief Description
In the drive, all errors occurred are recorded in an error memory on the control
section. If an error occurs in the power section, it is additionally stored in a
separate error memory on the power section. It is thereby made sure that the
relevant information is still available on the power section after separating the
power section and control section.
When an error occurs, the diagnostic message number and the
current count of the operating hours counter are automatically stor
ed.
Pertinent Parameters

S00390, Diagnostic message number

P00190, Operating hours control section

P00191, Operating hours power section

P00192, Error memory of diagnostic numbers

P00193, Error memory operating hours of control section

The contents of the parameters P00192 and P00193 are stored
on the control section. The content of parameter P00194 is stored
on the power section.

10.3

Diagnostic System

10.3.1

Coded Diagnostic Messages of the Drive

Brief Description
The drive provides a diagnostic system including different options that are ba
sically divided into two groups:

Recognizing and displaying the current drive status by means of driveinternal, priority-dependent generation of diagnostic messages

Collective messages for diverse status messages

Additionally, there are parameters for all important operating data the values of
which can be transmitted both via master communication (e.g. SERCOS) and
a parameterization interface (RS-232/485 in the ASCII protocol or SIS protocol;
see "Serial Communication").
Pertinent Parameters

S00030, Manufacturer version

S00095, Diagnostic message

S00140, Controller type

S00142, Application type

S00375, Diagnostic numbers list

S00390, Diagnostic message number

P00007, Display text of diagnostic message

P00009, Error number

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and Controls

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Handling, Diagnostic and Service Functions

P00478, Logbook event

P00479, Logbook time stamp

P03219, Extended safety technology diagnosis

For integrated safety technology, an extended diagnosis option is
provided in the form of a safety technology error code. When certain
safety technology errors occur, this error code can be read in pa
rameter "P03219, Extended safety technology diagnosis" which
allows quick error diagnosis.

10.3.2

Status Classes, Status Displays, Control Parameters

General Information
In the drive there are many parameters with important status information (bit
lists). Some of the bits contained in these lists can be used for configuring realtime status bits and additionally can be assigned to digital outputs or to the
configurable signal status word.
See "Digital Inputs/Outputs"
See "Configurable Signal Status Word"

Status Classes
Brief Description
The drive differentiates between 3 states (error, warning and message) for
which there is status information. To make the status information available,
there are so-called class diagnostics parameters (S00011, S00012,
S00013) which contain the respective status bits.
In addition to these class diagnostics parameters, there are change bits con
tained in the status word of the field bus (e.g. S00135 in the case of SERCOS)
which display changes in one of the above-mentioned class diagnostics pa
rameters (collective information).
Features

Pertinent Parameters

Class diagnostics parameter for errors (cf. S00011)

Class diagnostics parameter for warnings (cf. S00012)

Class diagnostics parameter for messages (cf. S00013)

Change bits in status word of master communication (e.g. S00135 in the

case of SERCOS)

Change bits of class 2 and 3 diagnostics (S00097 and S00098) can be

masked in status word of master communication (e.g. S00135 in the
case of SERCOS) to suppress individual bits or status messages

S00011, Class 1 diagnostics

S00012, Class 2 diagnostics

S00013, Class 3 diagnostics

S00097, Mask class 2 diagnostics

S00098, Mask class 3 diagnostics

S00135, Drive status word

Fixed Status Displays

Function-Related Status Parameters
In the drive there are parameters the content of which has a direct relation to
the status of the sequence of different drive functions. These parameters are
used to display the current status information of the assigned function.

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The following parameters are available for function-related status display:

S00014, Interface status

This parameter displays the status of the communication phase transition
and the cyclic communication.

S00135, Drive status word

This is the status word of the master communication (SERCOS) and con
tains all essential pieces of status information for the master.

S00403, Position feedback value status

This parameter contains status bits for the position data reference of the
individual measuring systems.

S00419, Positioning command acknowledge

This status information is used for acknowledgment in the "drive-controlled
positioning" mode.

P00046, Status word of current controller

This parameter contains status bits of the internal motor control (e.g. over
voltage in DC bus).

P00115, Device control: status word

This parameter contains status bits of device control (see also "Device
Control and State Machines").

P00222, Travel range limit switch inputs

This parameter displays the status of the travel range limit switch inputs
(see also "Limitations: Travel Range Limit Switches").

P00223, E-Stop input

This parameter displays the status of the E-Stop input (see also
"E-Stop Function").

P00455, Acceleration feedforward actual value

This parameter contains status bits to display the activation of torque/cur
rent limitation (see also "Limitations: Current and Torque/Force Limita
tion").

P00539, Holding brake status word

This parameter contains status bits for the status of the motor holding
brake (see also "Motor Holding Brake").

P00555, Status word of axis controller

This parameter displays messages with regard to velocity and limits that
have been reached.

P04029, Diagnostic report SCSB module

Parameter for reading master communication settings and states (with
SERCOS interface).

P04086, Master communication status

This parameter displays control information of the master communication
for handling phase switch, drive enable etc., defined during initialization.

Status Parameters for Real-Time Status Bits

The following list contains status parameters that only contain one bit and can
therefore be used for configuring real-time status bits (see "SERCOS Inter
face"):

S00330, Status "n_feedback = n_command"

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Electric Drives | Bosch Rexroth AG

and Controls

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Handling, Diagnostic and Service Functions

S00331, Status "n_feedback = 0"

S00332, Status "n_feedback < nx"

S00333, Status "T >= Tx"

S00334, Status "T >= Tlimit"

S00335, Status "n_command > n_limit"

S00336, Status "In position"

S00337, Status "P >= Px"

S00341, Status "In coarse position"

S00342, Status "Target position attained"

S00343, Status "Interpolator halted"

S00409, Probe 1 positive latched

S00410, Probe 1 negative latched

S00411, Probe 2 positive latched

S00412, Probe 2 negative latched

Control Parameters
Apart from the parameters for status display, there are parameters available in
the drive that are used to control the drive functions (see also description of
corresponding parameter):

P00045, Control word of current controller

P00427, Control parameter of analog output

P00522, Control word for commutation setting

P00556, Config word of axis controller

P00612, Set absolute position control

P04028, Device control word

10.4

Control Panels of the IndraDrive Controllers

10.4.1

General Information on the Operation Options

Control Panel Variants

IndraDrive controllers are equipped with a "control panel"; its front consists of
a display and keys located underneath it. The display shows operating states,
command and error diagnoses, as well as present warnings. By means of the
keys you can make settings, call information and trigger some commands.

Fig.10-9:

Standard Control Panel

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Variant

Description

Standard control panel

Component of the IndraDrive controller

Comfort control panel

Optional

Fig.10-10:

Control Panel Variants

Via the serial interface of the controller, it is additionally possible to connect an

independent VCP operator terminal that can, for example, be integrated in the
front of the control cabinet.
VCP operator terminals are separate components (terminals) that can be used
in addition to the standard or comfort control panel. They are connected to the
serial interface of the controller via a separate line. This allows integrating a
VCP operator terminal in the front of the control cabinet, for example.
By means of a configuration tool it is additionally possible to configure other
application-dependent settings, displays and command functions.

10.4.2

Standard Control Panel

Brief Description
The control panel of an IndraDrive controller has an 8-digit display and keys
located underneath it.
The display shows operating states, command and error diagnoses, as well as
present warnings, if any.
Using the four keys, the commissioning engineer or service technician can opt
to display extended diagnostic messages at the drive controller and to activate
simple commands (in addition to master communication using the commis
sioning tool or NC control unit).

Fig.10-11:
Possibilities of Display of Standard
Control Panel

Standard Control Panel With Display and Control Elements (Example of

Display)

The display of the IndraDrive controller automatically shows:

Status of the master communication

Operating status

Commands and diagnostic command messages

Warnings and diagnostic error messages

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Electric Drives | Bosch Rexroth AG

and Controls

403/505

Handling, Diagnostic and Service Functions

Possible Settings with Standard

Control Panel

Command Activation Using the

Standard Control Panel

Extended displays such as contents of error memories, diagnostic mes

sage memory, operating hours counter of control section, operating hours
counter of power section, type designation of firmware active in the device,
safety technology code (if safety technology option available)

The following settings can be made with the standard control panel:

Set the drive address (drive number in the bus system of the master com
munication)

Set the length of the fiber optic cable

Activating the master communication mode "Easy Startup"

The following commands can be activated via the standard control panel:

Activating "S00262, C07_x Load defaults procedure command" (load

controller parameters or basic parameters)

Activating other commands, such as:

C0200 Exit parameterization level procedure command

C0300 Set absolute position procedure command

C0400 Activate parameterization level 1 procedure command

C2000 Command Release motor holding brake

C2200 Backup working memory procedure command

C2300 Load working memory procedure command

C2800 Analog input adjustment command

C2900 Command Firmware update from MMC

10.5

MultiMediaCard (MMC)

10.5.1

Brief Description
The MultiMediaCard (MMC) is a storage medium that can be inserted in the
slot provided for this purpose at the front of the controller. The MMC can store
drive firmware, drive parameters and other files (such as PLC programs or userside files, e.g. with document properties). The MMC can be used optionally.
As stationarily (permanently) plugged storage medium, the MMC can be used
as:

"Programming module", as active, non-volatile memory containing the

current axis-specific parameter values and the firmware active in the drive.

As a temporarily plugged storage medium (backup or init/update medium), the

MMC can be used for:

Replacing firmware via command

Transmitting drive parameter sets and firmware to other drives for serial
commissioning via command

Saving the parameter values after initial commissioning

Reestablishing the initial parameter status of the drive (loading the saved
parameter values)
Note: Not for drives with absolute value encoder and modulo format!
See "Initial Commissioning/Serial Commissioning"

Storing/reestablishing of parameters centrally from control master (MLD)

Note: Not for drives with absolute value encoder and modulo format!
See "Initial Commissioning/Serial Commissioning"

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Without firmware or parameter loss the controller can be changed from MMC
device status "device without MMC or temporary backup MMC" to the status
"device with stationarily plugged MMC (programming module mode)" and vice
versa.
The MMC commands can be started via the control panel. This is
especially advantageous when replacing devices!
It is only allowed to use MMCs by Bosch Rexroth (type designation
PFM02.1-****-FW)! For storage media of other manufacturers we
cannot assume any guarantee for faultless operation.
Pertinent Parameters

Pertinent Diagnostic Messages

P04065, Active non-volatile memory

P04066, MMC identification number (CID)

P04070, Parameter storage configuration

P04072, C2900 Command Firmware update from MMC

P04091, C2500 Copy IDN from optional memory to internal memory

P04092, C2600 Copy IDN from internal memory to optional memory

Copying parameters from MMC to flash:

C2500 Copy IDN from optional memory to internal memory

C2502 Error when accessing the MMC

C2504 Error when writing data to internal memory

Copying Parameters from flash to MMC:

C2600 Copy IDN from internal memory to optional memory

C2602 Error when accessing the MMC

C2604 Error when reading the internal memory

Replacing firmware via MMC:

C2900 Command Firmware update from MMC

C2903 Error when accessing the MMC

C2904 Error when accessing the flash

C2905 Programmed firmware defective

Storage medium missing:

F2006 MMC was removed

F2120 MMC: Defective or missing, replace

10.6

Firmware Replacement

10.6.1

General Notes on How to Replace the Firmware

Basic Principles
Explanation of Terms

For firmware replacement, we distinguish the following cases:

Release update
An old firmware release (e.g. MPH07V02) contained in the device is re
placed by a new firmware release (e.g. MPH07V04).

Version upgrade
The old firmware version (e.g. MPH06V08) in the device is replaced by a
new firmware version (e.g. MPH07V02).

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Handling, Diagnostic and Service Functions

The paragraphs below describe the recommended options of firm
ware replacement by higher releases ("update") or versions
("upgrade"). The same conditions and sequences of actions apply
to firmware replacement by older releases or older firmware ver
sions.
Firmware for IndraDrive is replaced using the following hardware and software:

MultiMediaCard (MMC)

PC with software "IndraWorks Ds/D/MLD"

The commissioning software "IndraWorks Ds/D/MLD" can be or
dered from one of our sales and service facilities. The scope of
supply of "IndraWorks Ds/D/MLD" contains a documentation which
describes the operation of the program.

Preparations and Conditions for Firmware Replacement

Preparing the Firmware Replace
ment

You have to make the following preparations for firmware replacement:

1. Drive controller must be on (24 V supply).
2. Be absolutely sure to save parameter values before any firmware version
upgrade (for release update this is recommended), as otherwise complete
(re-)commissioning is required.
See Functional Description of firmware "Loading, Storing and Saving Pa
rameters"
3. Drive controller mustn't be in operating mode (communication phase 4)
(cf. P00115).

General Notes on How to Carry Out

Firmware Replacement

You have to observe the following points when carrying out the firmware re
placement:

Do not switch off the 24 V control voltage while replacing the firmware.

Firmware replacement always must be carried out completely, i.e. the

firmware on the optional safety technology module must be replaced, too.

For firmware replacement, we distinguish between release update and

version upgrade.
When the firmware is replaced in conjunction with the option "Safe
Torque Off" (L2), this does not require any specific measures, i.e.
the additional measures described below only apply to the use of
option "S2"!

10.6.2

Firmware Release Update

General Information
When firmware in a drive controller is replaced by firmware of a new release,
this is called firmware release update (e.g. FWAINDRV*MPH07V02D5 re
placed by FWAINDRV*MPH07V04D5).
The described sequences of the firmware release update depend on the con
figuration of the control section and the hardware (MMC or PC) used for update.
The basically recommended sequence of the firmware release update is illus
trated in the scheme below:

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CSH0x.x
CDB0x.x
CSB0x.xC
CSB0x.xN
Active memo
ry

Fig.10-12:

ADVANCED single-axis control section

BASIC double-axis control section
BASIC single-axis control section (configurable)
BASIC single-axis control section (not configurable)
"Programming module" operation of MMC (see P04065)

Schematic Sequence of Firmware Release Update

The actions to be taken which are marked with dark background in

this figure are described in the paragraphs below.

Loading New Firmware to MMC

Requirements

Loading Firmware to MMC

The following requirements must have been fulfilled for loading firmware to the
MMC of the drive:

New firmware available (ibf file)

PC with MMC reader

MMC with old firmware in drive

The following steps are required for loading the firmware to the MMC:
1. Switch drive off and remove MMC.

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Handling, Diagnostic and Service Functions

2. Plug MMC into MMC reader and open folder "Firmware" on MMC.
3. Delete old firmware (e.g., FWA-INDRV_-MPH-07V02-D5.ibf).
4. Copy new firmware (e.g., FWA-INDRV_-MPH-07V04-D5.ibf) to folder
"Firmware".
Only one firmware file may be stored in the folder "Firmware" on the
MMC. With several firmware files, the message "MMC not cor
rect" appears on the display of the drive after the booting process.
5. Remove MMC from MMC reader after writing process has been comple
ted.

Variant 1: Release Update With MMC

Selection Criterion

Carrying out the firmware release update with MMC makes sense when the
controller has not been equipped with a BASIC single-axis control section of
the CSB0x.xN type.

Firmware Update With MMC

The optional MultiMediaCard (MMC) allows transmitting drive firmware to the

drive controller in a quick and uncomplicated way.
As the MMC is a storage medium that can be written in a simple
way (e.g., via PC), it is recommended that you check the MMC
content before downloading the firmware. You have to make sure
that the MMC really contains the appropriate firmware type.
An MMC with the current release of the required firmware can be ordered from
one of our sales and service facilities.
Carrying out the firmware release update with MMC requires the following
steps:
1. Load firmware
Switch drive off!
Plug MMC with new firmware into corresponding slot at controller.
Restart drive with MMC plugged!
After drive has been booted, the following message appears:

"Firmware update?"

Acknowledge this message by pressing "Enter" key of control panel. By

doing this, firmware is loaded from plugged MMC to controller.
One of the following messages will be displayed, depending on the oper
ating status of the drive:

"Load Param from MMC" or "Load new param?"

"Activate new MMC?"

"F2120 MMC: Defective or missing, replace"

Switch off drive, remove MMC (if drive was operated without MMC plug
ged) and restart drive!
2. Put machine into ready-for-operation status
Put machine into ready-for-operation status again according to machine
manufacturer's instructions.
Check functions of drive.
3. Check safety technology parameters (only when safety technology has
been activated in the drive)

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In the case of a release update, the safety technology parameters are
retained. With safety technology activated, the following steps are addi
tionally required:
Check whether the correct safety technology parameter settings for
drive are still available!
To do this, check the following points:

CAUTION

Data in parameter "P03205, Safety technology device identifier"

Status of safety technology via parameter "P03207, Safety

technology password level" (in the case of active and locked safety
technology, level is 2)

Change counter of safety technology memory (parameter "P03201,

Change counter of safety technology memory")

Operating hours at last change of memory (parameter "P03202,

Operating hours at last change of memory")

If the integrated safety technology is used and a firmware release update

is carried out for firmware versions older than MPx02V20, it is necessary
to repeat the safety technology acceptance test.
After firmware release update, the safety technology acceptance test must be
carried out again!

Variant 2: Release Update With "IndraWorks Ds/D/MLD"

Selection Criterion

The following requirements should have been fulfilled in order that carrying out
the firmware release update with "IndraWorks Ds/D/MLD" makes sense:

Controller is operated without MMC.

- or
Firmware Update With "IndraWorks
Ds/D/MLD"

Controller has been equipped with BASIC single-axis control section of

type CSB0x.xN.

Carrying out the firmware release update with "IndraWorks Ds/D/MLD" requires
the following steps:
1. Load firmware
Start "IndraWorks".
Load project for corresponding axis or create new project; to do this,
address axis via a serial connection.
Switch project "online".
Select/highlight controller and call "Firmware Management" in context
menu.
A new window opens and firmware currently available in drive is displayed
on its right side. On left side of window, firmware available in current firm
ware directory is displayed.
Highlight new firmware (*.ibf file) and start firmware download via
"Download" button.
Firmware download runs automatically and all required firmware compo
nents are loaded to drive.
IndraWorks automatically goes to the offline mode. You will be
asked whether a backup of the parameters is to be made. Refuse
this with "No".

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After firmware download has been completed, close "Firmware Man
agement" window.
2. Put machine into ready-for-operation status
Put machine into ready-for-operation status again according to machine
manufacturer's instructions.
Check functions of drive.
3. Check safety technology parameters (only when safety technology has
been activated in the drive)
In the case of a firmware release update, the safety technology parame
ters are retained. With safety technology activated, the following steps are
additionally required:
Check whether the correct safety technology parameter settings for
drive are still available!
To do this, check the following points:

10.6.3

Data in parameter "P03205, Safety technology device identifier"

Status of safety technology via parameter "P03207, Safety

technology password level" (in the case of active and locked safety
technology, level is 2)

Change counter of safety technology memory (parameter "P03201,

Change counter of safety technology memory")

Operating hours at last change of memory (parameter "P03202,

Operating hours at last change of memory")

Firmware Version Upgrade

General Information
When firmware in a drive controller is replaced by firmware of a more recent
version,
this
is
called
firmware
version
upgrade
(e.g.,
FWAINDRV*MPH06V10D5 replaced by FWAINDRV*MPH-07V02D5).
Before carrying out the firmware version upgrade, you must save
all parameters (e.g., with "IndraWorks"). After firmware replace
ment, the parameters must be restored, because the command
"C07_1 Load defaults procedure command" is carried out automat
ically. After the desired parameter file was loaded, the drive con
troller is ready for operation again.
The described sequences of the firmware version upgrade depend on the con
figuration of the control section and the firmware used. The basically recom
mended sequence of the firmware version upgrade is illustrated in the scheme
below:

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CSH0x.x
CDB0x.x
CSB0x.xC
CSB0x.xN
Active memo
ry

Fig.10-13:

ADVANCED single-axis control section

BASIC double-axis control section
BASIC single-axis control section (configurable)
BASIC single-axis control section (not configurable)
"Programming module" operation of MMC (see P04065)

Schematic Sequence of Firmware Version Upgrade

The actions to be taken which are marked with dark background in

this figure are described in the paragraphs below.

Save Parameter Values

Before firmware upgrade, all application-specific parameter values must be
saved on a data carrier. The parameter backup can be carried out by means
of:

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Commissioning software "IndraWorks Ds/D/MLD"

Saving parameter values on external data carrier

- or

Control master
Saving parameter values on master-side data carrier
Saving the parameters on the MMC available in the drive is without
effect, as this backup will be deleted during the firmware upgrade!

Loading New Firmware to MMC

Requirements

Loading Firmware to MMC

The following requirements must have been fulfilled for loading firmware to the
MMC of the drive:

New firmware available (ibf file)

PC with MMC reader

MMC with old firmware in drive

The following steps are required for loading the firmware to the MMC:
1. Switch drive off and remove MMC.
2. Plug MMC into MMC reader and open folder "Firmware" on MMC.
3. Delete old firmware (e.g., FWA-INDRV*-MPH-06V10-D5.ibf).
4. Copy new firmware (e.g., FWA-INDRV*-MPH-07V02-D5.ibf) to folder
"Firmware".
Note: Only one firmware file may be stored in the folder "Firmware" on the
MMC. With several firmware files, the message "MMC not correct" ap
pears on the display of the drive after the booting process.
5. Remove MMC from MMC reader after writing process has been comple
ted.

Variant 1: Version Upgrade With MMC (With Safety Technology)

Selection Criterion

Firmware Upgrade With MMC

(With Safety Technology)

The following requirements should have been fulfilled in order that carrying out
the firmware version upgrade with MMC makes sense (with safety technology):

Controller has not been equipped with BASIC single-axis control section.

Optional slot for safety technology has been equipped with the optional
module "Safe Motion" (S2).

Current parameter setting of axis was saved.

Carrying out the firmware version upgrade with MMC requires the following
steps (with safety technology):
1. Load firmware
Switch drive off!
Plug MMC with new firmware into corresponding slot at controller.
Restart drive with MMC plugged!
After drive has been booted, the following message appears:

"Firmware update?"

Acknowledge this message by pressing "Enter" key of control panel. By

doing this, firmware is loaded from plugged MMC to controller.
One of the following messages will be displayed, depending on the oper
ating status of the drive:

"Load Param from MMC" or "Load new param?"

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"Activate new MMC?"

"F2120 MMC: Defective or missing, replace"

Switch off drive, remove MMC (if drive was operated without MMC plug
ged) and restart drive!
2. Put drive into ready-for-operation status
After the drive has been restarted, the error message "F8201" is gen
erated (F8201 Safety command for basic initialization incorrect).
Clear all present error messages and start execution of "C07_2 Load
defaults procedure command (load defaults procedure for safety technol
ogy)"!
As the number of parameters to be buffered has changed, "C07_1 Load
defaults parameter command (loading basic parameters)" must be acti
vated subsequently. All buffered parameters are thereby set to their
default values.
3. Load parameter values
Load parameter file which was saved.
Switch off drive and start it again so that the parameterization becomes
active.
4. Entire commissioning of integrated safety technology
Switch drive to operating mode (communication phase 4).
The error message "F3152 Incorrect backup of safety technology data"
appears, as the safety technology parameter set between firmware ver
sions 02, 03, 04 and 05 has changed.
Clear error message.
Activate command "synchronize and store safety technology IDN".
(C3000 Synchronize and store safety technology IDN)
Activate safety technology by inputting safety technology password
(P03206, Safety technology password).
Carry out new acceptance test.
See sections "Activating the Safety Technology" and "Acceptance
Test" in the separate documentation "Integrated Safety Technology
According to IEC61508" (DOK-INDRV*-SI2-**VRS**-AW**-EN-P; part
no. R911327664)
#

Dangerous movements possible! Danger to life, risk of injury, seri

ous injury or property damage!
DANGER

In order to ensure correct functioning and to prevent personal damage, a

complete acceptance test must be carried out after a firmware version
upgrade for drive controllers with the optional module for safety technology
(S2).
Make safety technology parameter backup, compile acceptance test
protocol and add it to safety-relevant documentation of machine.
5. Put machine into ready-for-operation status
Put machine into ready-for-operation status again according to machine
manufacturer's instructions.
Check functions of drive.

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Variant 2: Version Upgrade With MMC (Without Safety Technology)

Selection Criterion

Firmware Upgrade With MMC

(Without Safety Technology)

The following requirements should have been fulfilled in order that carrying out
the firmware version upgrade with MMC makes sense (without safety technol
ogy):

Controller has not been equipped with BASIC single-axis control section
of type CSB0x.xN.

Optional slot for safety technology has not been equipped with the optional
module "Safe Motion" (S2).

Current parameter setting of axis was saved.

Carrying out the firmware version upgrade with MMC requires the following
steps (without safety technology):
1. Load firmware
Switch drive off!
Plug MMC with new firmware into corresponding slot at controller.
Restart drive with MMC plugged!
After drive has been booted, the following message appears:

"Firmware update?"

Acknowledge this message by pressing "Enter" key of control panel. By

doing this, firmware is loaded from plugged MMC to controller.
One of the following messages will be displayed, depending on the oper
ating status of the drive:

"Load Param from MMC" or "Load new param.?"

"Activate new MMC?"

"F2120 MMC: Defective or missing, replace"

Switch off drive, remove MMC (if drive was operated without MMC plug
ged) and restart drive!
2. Put drive into ready-for-operation status
As number of parameters to be buffered has changed, "PL" appears on
display (in case errors are present, remove them first). If you now press
"Esc" key, all buffered parameters are set to their default values. During
this time, message "C07 Load default parameters" appears on display. If
errors are present, they first have to be removed and the command C07_1
must then be manually activated!
3. Load parameter values
Load parameter file which was saved.
Switch off drive and start it again so that the parameterization becomes
active.
4. Put machine into ready-for-operation status
Put machine into ready-for-operation status again according to machine
manufacturer's instructions.
Check functions of drive.

Variant 3: Version Upgrade With "IndraWorks Ds/D/MLD"

Selection Criterion

The following requirements should have been fulfilled in order that carrying out
the firmware version upgrade with "IndraWorks Ds/D/MLD" makes sense:

Controller has been equipped with BASIC single-axis control section.

Current parameter setting of axis was saved.

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Handling, Diagnostic and Service Functions

Firmware Upgrade With
"IndraWorks Ds/D/MLD"

Carrying out the firmware version upgrade with "IndraWorks Ds/D/MLD" re

quires the following steps:
1. Load firmware
Call "IndraWorks".
Load project for corresponding axis or create new project. To do this,
address axis via a serial connection.
Switch project "online".
Select/highlight controller and call "Firmware Management" in context
menu.
A new window opens and firmware currently available in drive is displayed
on its right side. On left side of window, firmware available in current firm
ware directory is displayed.
Highlight new firmware (*.ibf file) on left side and start firmware down
load via "Download" button.
Firmware download runs automatically and all required firmware compo
nents are loaded to drive.
After firmware download has been completed, close "Firmware Man
agement" window.
2. Put drive into ready-for-operation status
Switch project "offline" and then "online" again.
After project has been switched online, a message signals that
"IndraWorks" could not establish communication to drive via serial inter
face, as drive-internal settings for serial communication were reset.
Reconfigure communication via button "Search for devices".
As firmware in drive no longer complies with version stored in project,
a corresponding message is displayed. To adjust firmware version in proj
ect, first select option "Repair" and then options "Delete existing drive from
project" and "Add new drive to project".
As number of parameters to be buffered has changed, "PL" appears on
display (in case errors are present, remove them first). If you now press
"Esc" key, all buffered parameters are set to their default values. During
this time, message "C07 Load default parameters" appears on display.
If errors are present, they first have to be removed and the command
C07_1 must then be manually started!
3. Load parameter values
Load parameter file which was saved.
4. Put machine into ready-for-operation status
Put machine into ready-for-operation status again according to machine
manufacturer's instructions.
Check functions of drive.

10.6.4

Possible Problems During Firmware Replacement

Problematic Situations

Firmware replacement is carried out incompletely, if one of the following situa

tions occurs during the sequence of firmware replacement:

24V supply of control section is switched off

Connection to drive is interrupted (e.g., defective interface cable)

Software crashes

The drive controller then possibly is no longer operable, because the firmware
contained in the components is no longer compatible.

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If there isn't any valid firmware available in the control section in this case, the
loader is started. The drive display signals "LOADER". The loader only allows
updating the firmware of the control section. Optional modules, such as "Safe
Motion" (S2) or "cross communication" (CCD), cannot be programmed in this
state. This must be done, after successful firmware replacement in the control
section, in a second run according to the descriptions of the firmware replace
ment variants.
In this situation, replacement of the control section firmware is only supported
by "IndraWorks".
Upon successful firmware replacement in the control section, a re
start has to be carried out. Then all available components have to
be updated, too.
Requirements for Loading the Firm
ware

Firmware Replacement in Control

Section in the Case of Error

The following requirements must have been fulfilled for loading firmware to the
drive:

Serial connection to drive available

Drive display signals "LOADER"

The following steps are required for loading the firmware to the control section
in the case of error:
1. Call "IndraWorks Ds/D/MLD".
2. In menu, call firmware management under "Tools Drive Firmware
Management".
3. Select device and COM interface.
A new window opens and firmware available in current firmware directory
is displayed on its left side.
4. Highlight new firmware (*.ibf file) on left side and start firmware download
via "Download" button.
Firmware download runs automatically and all required firmware compo
nents are loaded to drive.
5. After firmware download has been completed, close "Firmware Manage
ment" window.
6. Restart drive!
If the drive has not been equipped with any optional modules, such as "Safe
Motion" (S2) or "cross communication" (CCD), continue following the instruc
tions for release update or version upgrade! Otherwise, carry out the release
update or version upgrade again to program the optional modules.

10.7

Notes on How to Replace the Devices

10.7.1

Replacing the Supply Unit

General Information
The concept of Rexroth supply units includes safe, quick and uncomplicated
replacement of devices. This allows reducing production downtimes, caused
by failures of these devices, to a minimum.
Failures in the supply unit are displayed by means of diagnostic messages.
According to the diagnostic error message, the measure "replacing the supply
unit" can be indicated.

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See documentation "Troubleshooting Guide" (description of diagnostic

messages)
Immediately after having replaced the device, the drive is operational again,
because it is not required to repeat the adjustment of the drive to the machine.

How to Replace the Supply Unit

Procure Replacement Device

Identify device to be replaced by means of type plate; procure supply unit of

same type from Bosch Rexroth!
See also documentation of the respective Supply Unit

Fill Out Fault Report

In the documentation of the respective supply unit, you can find a fault report
form to be copied. Please copy this fault report, fill it out carefully and completely
and enclose it with the defective device! The fault report filled out completely
supports quick handling of repair and helps recognizing application-related fail
ure causes.

Replace Supply Unit

De-energize drive system; wait for DC bus to discharge; then replace defective
supply unit!

DANGER

Live conductor bars (higher than 50 V), even if mains voltage switched
off!
Electric shock when touching!
Wait for the DC bus (L+/L-) to discharge; before touching the conductor bar,
check whether below 50 V!
For notes on how to dismount and mount the supply unit, see documen
tation of the respective Supply Unit

Put Drive System Into Operation

Again

10.7.2

Put machine into operation again according to machine manufacturer's instruc

tions!

Replacing the Controller

Overview
A controller of the IndraDrive range consists of the components power section
and control section (incl. firmware). The control section can be configured with
additional components (encoder interface, optional safety technology mod
ule,...). In the case of a defect, it is basically possible to replace one of the two
components (control section or power section). As control section and power
section are firmly connected and one of the two components may only be re
placed by Rexroth service engineers or especially trained users, the para
graphs below describe how to replace the complete controller as regards safety
technology. The mounting and dismounting of the entire drive controller is de
scribed in the Project Planning Manual for the power section.

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Only applies to Rexroth service engineers or especially trained
users: The replacement of a defective power section does not re
quire any specific handling due to integrated safety technology; i.e.
it is not necessary to repeat safety technology commissioning and
acceptance test.
When a controller is replaced for which the control section has been
configured with the option "Safe Torque Off" (L2), this does not re
quire any specific measure, i.e. the additional measures only apply
to the use of the option "Safe Motion" (S2)!
When you replace the controller, you should not carry out the firm
ware version upgrade, as otherwise it is necessary to repeat the
safety technology acceptance test!
When replacing a controller with activated safety technology, observe that
safety technology is not active for controllers in their condition as supplied:

The status of "P03207, Safety technology password level" is zero and

"INDRASAVE" has been entered in "P03206, Safety technology

password".
A controller supplied for replacement which already was in opera
tion has to be put in its condition as supplied before it is used (see
documentation "Integrated Safety Technology", index entry "Safety
technology Deactivating").

The figure below illustrates the basically required individual steps.

Fig.10-14:

General Sequence of Controller Replacement

Replacing the Controller Without Stationarily Plugged MMC

1. Save Parameter Values
Before dismounting the defective device, save the drive parameter values,
if possible.

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When the controller is to be replaced by means of the MMC, make sure
before starting the replacement that the MMC folder "Firmware" contains
the firmware required for the drive (e.g., FWA-INDRV*-MPH-07V02D5.IBF).
If saving the parameter values before replacing the device should
be impossible due to a total breakdown of the device, only the pa
rameter values backed up after initial commissioning can be loaded
when the parameter values are loaded later on (see index entry
"Load parameter values in case of total breakdown of device")!
1. Switch drive off and on again
2. Switch to parameter mode (PM or P2)
The parameter values of the defective device are saved via the control
panel of the controller with MMC temporarily plugged ("hot plug").
If the MMC does not remain stationarily (permanently) plugged in
the device, it may be temporarily plugged in the switched-on device
after the booting phase and removed again ("hot plug" or
"hot unplug").
3. Go to service menu
By simultaneously pressing "Esc" and "Enter" keys for at least 8 sec
onds, you can call up extended displays; subsequently pressing "Up" key
(twice) activates service menu.
Select submenu "device replace" by means of arrow keys and activate it
with "Enter" key.
Active parameter values [according to "S00192, IDN-list of all backup
operation data" and "P00195, IDN list of retain data (replacement of
devices)"] and PLC retain data are copied from controller-internal memory
to an MMC temporarily plugged in controller.
Activate command "save Data?"

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Fig.10-15:

Activating Commands "save Data?" and "restore Data?" When

Replacing Controller via Control Panel

2. Replace Controller
1. Open main switch
2. Make sure main switch cannot be switched on again
3. Make sure drive controller is completely de-energized
#

Lethal electric shock caused by live parts with more than 50 V!

WARNING

Before working on live parts: De-energize the installation and secure the
power switch against unintentional or unauthorized re-energization.
Wait at least 30 minutes after switching off the supply voltages to allow
discharging. To shorten the waiting time until voltage has fallen below 50
V, you can use a discharging device (see chapter "Appendix").
Check whether voltages have fallen below 50 V before touching live parts!
4. Remove touch guard and separate connection lines from drive control
ler
5. Unscrew screws on top and bottom of housing
6. Take drive controller out of drive system
7. Mount new drive controller
8. Connect new drive controller as specified in machine circuit diagram
9. Mount touch guard
3. Put Controller Into Ready-For-Operation Status Again
Put machine into ready-for-operation status again according to machine
manufacturer's instructions.
4. Load Firmware and Parameter Values via MMC

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When firmware and drive parameters are to be transmitted via MMC to
the replacement controller, you have to make sure that the MMC folder
"Firmware" contains the firmware required for the drive and the MMC fold
er "Parameters" contains the parameters saved before the device was
replaced.
1. Disconnect replacement controller from control voltage
2. Put MMC into replacement controller
3. Supply device with control voltage again
4. Depending on previous configuration of replacement device, message
"Firmware-Update?" can appear during booting phase.
Acknowledge this message by pressing "Enter" key of control panel. By
doing this, firmware is loaded from plugged MMC to controller.
If the message "Firmware-Update?" is not displayed, the firmware
update must be started via the display.
"3. Service" "Firmware update" "FWA update"
5. Then one of the messages below can be displayed:

"Load new param.?"

"Load Par from MMC?"

Acknowledge the respective message by pressing "Enter" key of control

panel. Drive parameters are now loaded from MMC to volatile memory of
device; the message "Load new safety?" then possibly appears.
Also acknowledge this message by pressing "Enter" key of control pan
el. Safety technology parameters are now loaded from MMC to memory
of optional safety technology module.
6. Switch to parameter mode (PM or P2)
The step below depends on the utilized firmware version:
7. Go to service menu
By simultaneously pressing "Esc" and "Enter" keys for at least 8 sec
onds, you can call up extended displays; subsequently pressing "Up" key
(twice) activates service menu.
Select submenu "device replace" by means of arrow keys and activate it
with "Enter" key.
Store PLC retain data and parameters from MMC to internal, non-vol
atile memory of controller via control panel by activating command
"restore Data?" (storing according to parameters "S00192, IDN-list of all
backup operation data" and "P00195, IDN list of retain data (replacement
of devices)"). After parameter loading processes have been completed,
drive waits for further actions of control master.
If safety technology is to be activated in the replacement device (in
accordance with replaced device), the drive after loading the safety
technology parameters has to be switched to operating mode (OM)
or communication phase (P4) before it is switched off!
8. Switch controller off
9. Remove MMC from device
10. Switch controller on again
11. Message "Load new param.?" can then be displayed. Acknowledge
this message by pressing "Enter" key of control panel. Drive parameters

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are now loaded from the non-volatile memory ("flash") to volatile memory
(RAM) of device. From now on, device behaves like device without MMC
plugged.
5. Put Machine Into Ready-For-Operation Status
1. Put machine into ready-for-operation status again according to machine
manufacturer's instructions.
2. Check functions of drive.
6. Check Safety Technology Parameters
Completing the process, you must check with activated safety technology
whether the correct safety technology parameters have been loaded for
the drive; to do this, check data in "P03205, Safety technology device
identifier" (machine type, unit, drive for .. axis/spindle) and compile a pro
tocol with the contents listed below and add it to safety-relevant docu
mentation of the machine:

Drive controller replaced on (date)

Change counter of safety technology memory (P03201) is at (val

ue)

Operating hours at last change of memory (P03202) is at (value)

(Date), (name), (signature)

Replacing the Controller With Stationarily Plugged MMC

1. Save Parameter Values
When the firmware characteristic IndraMotion MLD (firmware type code:
FWAINDRV*MPH07VRSD51***ML) is activated and the controller to
be replaced is configured in one of the following optional modules, the
retain data of the drive PLC must be stored on the MMC before
disassembling the defective device.

Module
digital
I/O
(control
CSH01.**********MD1**SNNFW)

section

type

code:

Module digital I/O and SSI encoder interface (control section type
code: CSH01.**********MD2**SNNFW)
If saving the PLC retain data before replacing the device should be
impossible due to a total breakdown of the device, the parameter
values and retain data backed up after initial commissioning must
be loaded when the parameter values are loaded later on (see index
entry "Load parameter values in case of total breakdown of
device")!

1. Switch drive off and on again

2. Switch to parameter mode (PM or P2)
3. Switch drive to service menu via display
By simultaneously pressing "Esc" and "Enter" keys for at least 8 sec
onds, you can call up extended displays; subsequently pressing "Up" key
(twice) activates service menu.
4. Select submenu "device replace" by means of arrow keys and activate
it with "Enter" key.
5. Activate command "save Data?"
The active PLC retain data are copied from the controller-internal mem
ory to the MMC plugged in the controller.

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Fig.10-16:

Activating Commands "save Data?" and "restore Data?" When

Replacing Controller via Control Panel

6. Disconnect controller from control voltage (this automatically saves pa

rameter values).
7. Remove MMC from controller
2. Replace Controller
1. Open main switch
2. Make sure main switch cannot be switched on again
3. Make sure drive controller is completely de-energized
#

Lethal electric shock caused by live parts with more than 50 V!

WARNING

Before working on live parts: De-energize the installation and secure the
power switch against unintentional or unauthorized re-energization.
Wait at least 30 minutes after switching off the supply voltages to allow
discharging. To shorten the waiting time until voltage has fallen below 50
V, you can use a discharging device (see chapter "Appendix").
Check whether voltages have fallen below 50 V before touching live parts!
4. Remove touch guard and separate connection lines from drive control
ler
5. Unscrew screws on top and bottom of housing
6. Take drive controller out of drive system
7. Mount new drive controller
8. Connect new drive controller as specified in machine circuit diagram
9. Mount touch guard
3. Put Controller Into Ready-For-Operation Status Again

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Handling, Diagnostic and Service Functions

Put machine into ready-for-operation status again according to machine
manufacturer's instructions.
4. Load Firmware and Parameter Values via MMC
When firmware and drive parameters are to be transmitted via MMC to
the replacement controller, you have to make sure that the MMC folder
"Firmware" contains the firmware required for the drive and the MMC fold
er "Parameters" contains the parameters saved before the device was
replaced.
1. Disconnect replacement controller from control voltage
2. Put MMC into replacement controller
3. Supply device with control voltage again
4. Depending on previous configuration of replacement device, message
"Firmware-Update?" can appear during booting phase.
Acknowledge this message by pressing "Enter" key of control panel. By
doing this, firmware is loaded from plugged MMC to controller.
If the message "Firmware-Update?" is not displayed, the firmware
update must be started via the display:
"3. Service" "Firmware update" "FWA update"
5. Then one of the messages below can be displayed:

"Load new param.?"

"activate new MMC?"

Acknowledge the respective message by pressing "Enter" key of control

panel. Drive parameters are now loaded from MMC to volatile memory of
device; the message "Load new safety?" then possibly appears.
Also acknowledge this message by pressing "Enter" key of control pan
el. Safety technology parameters are now loaded from MMC to memory
of optional safety technology module.
After parameter loading process has been completed, drive waits for fur
ther actions of control master.
If safety technology is to be activated in the replacement device (in
accordance with replaced device), the drive after loading the safety
technology parameters has to be switched to operating mode (OM)
or communication phase (P4) before it is switched off!
5. Put Machine Into Ready-For-Operation Status
1. Put machine into ready-for-operation status again according to machine
manufacturer's instructions.
2. Check functions of drive.
6. Check Safety Technology Parameters
Completing the process, you must check with activated safety technology
whether the correct safety technology parameters have been loaded for
the drive; to do this, check data in "P03205, Safety technology device
identifier" (machine type, unit, drive for .. axis/spindle) and compile a pro
tocol with the contents listed below and add it to safety-relevant docu
mentation of the machine:

Drive controller replaced on (date)

Change counter of safety technology memory (P03201) is at (val

ue)

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Operating hours at last change of memory (P03202) is at (value)

(Date), (name), (signature)

Replacing the Controller Without MMC

The execution of a controller replacement without MMC only makes
sense if the controller is equipped with a BASIC single-axis control
section.
If the controller is equipped with another control section, it cannot
be ensured that after the replacement of the device all parameter
ized device functions are available again when carrying out the
process described below. Therefore, for such controllers, replace
ment is only recommended with MMC.
1. Save Parameter Values
Before dismounting the defective device, save the drive parameter values,
if possible.
If saving the parameter values before replacing the device should
be impossible due to a total breakdown of the device, only the pa
rameter values backed up after initial commissioning can be loaded
when the parameter values are loaded later on (see index entry
"Load parameter values in case of total breakdown of device")!
1. Switch drive off and on again
2. Switch to parameter mode (PM or P2)
3. Saving parameter values of defective device can take place via com
missioning tool "IndraWorks Ds/D/MLD" or control master:

Commissioning tool "IndraWorks Ds/D/MLD":

By selecting the respective menu item, the parameter values ac
cording to the list parameters S00192 and P00195 are stored on
an external data carrier (hard disk, floppy disk or the like) [serial
communication with the controller or via SYSDA/SERCOS interface].

Control master:
The parameter values according to the list parameters S00192 and
P00195 are stored on a master-side data carrier by the control
master.

2. Replace Controller
1. Open main switch
2. Make sure main switch cannot be switched on again
3. Make sure drive controller is completely de-energized
#

Lethal electric shock caused by live parts with more than 50 V!

WARNING

Before working on live parts: De-energize the installation and secure the
power switch against unintentional or unauthorized re-energization.
Wait at least 30 minutes after switching off the supply voltages to allow
discharging. To shorten the waiting time until voltage has fallen below 50
V, you can use a discharging device (see chapter "Appendix").
Check whether voltages have fallen below 50 V before touching live parts!

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Handling, Diagnostic and Service Functions

4. Remove touch guard and separate connection lines from drive control
ler
5. Unscrew screws on top and bottom of housing
6. Take drive controller out of drive system
7. Mount new drive controller
8. Connect new drive controller as specified in machine circuit diagram
9. Mount touch guard
3. Put Controller Into Ready-For-Operation Status Again
Put machine into ready-for-operation status again according to machine
manufacturer's instructions.
4. Load Firmware and Parameter Values
When firmware and drive parameters are to be transmitted to the replaced
controller, the required firmware and a parameter backup of the respective
axis must be available.
1. Supply controller with control voltage
2. Depending on previous configuration of replacement device, one of the
following messages can appear during booting phase:

"F2120 MMC: Defective or missing, replace"

Acknowledge this message by pressing "Esc" key of control panel.

"Load new param.?"

Acknowledge this message by pressing "Enter" key of control pan
el.

3. By selecting respective menu item in "IndraWorks Ds/D/MLD", firmware

stored on an external data carrier (hard disk, floppy disk or the like) is
loaded to controller (serial communication with controller).
4. Loading parameter values can take place via commissioning tool
"IndraWorks Ds/D/MLD" or control master:

Commissioning tool "IndraWorks Ds/D/MLD"

By selecting the respective menu item, the parameter values stored
on an external data carrier (hard disk, floppy disk or the like), imme
diately before the device was replaced, according to list parameters
S00192 and P00195 are loaded to the controller (serial commu
nication with the controller or via SYSDA/SERCOS interface). With
safety technology available, further actions are required (see index
entry "Replacing the controller without stationarily plugged MMC").

Control master
The axis-specific parameter values saved before having replaced the
device can also be loaded via the control master. The parameter
values saved immediately before the replacement of the device on
a master-side data carrier (according to list parameters S00192 and
P00195) are loaded to the controller by the control master. With
safety technology available, further actions are required (see index
entry "Replacing the controller without stationarily plugged MMC").

5. Put Machine Into Ready-For-Operation Status

1. Put machine into ready-for-operation status again according to machine
manufacturer's instructions.
2. Check functions of drive.

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Possible Problems During Controller Replacement

The paragraphs below give a brief description of critical problems and their
recommended handling.
Load Parameter Values in Case of
Total Breakdown of Device

If it should have been impossible to save the parameter values according to the
list parameters S00192 and P00195 immediately before replacing the device
(total breakdown of device), the parameter values saved after initial commis
sioning have to be loaded.
In the case of drives with absolute value encoder and modulo for
mat, the position data reference has to be established again after
having loaded the parameter values saved after initial commission
ing, even if the actual position values are signaled to be valid via
the parameter "S00403, Position feedback value status"!

The parameter values saved after initial commissioning are not gener
ally suited for reestablishing the operatability of the drive after replace
ment of devices!

WARNING

Before setting drive enable, check actual position values and active target
position and, if necessary, PLC retain data!

10.8

Enabling of Functional Packages

10.8.1

Brief Description
The scope of functionality of the IndraDrive firmware can be scaled by the user.
This allows adjusting the scope of firmware functions to the respective require
ments and, if necessary, reducing its complexity.
The drive functionality is scaled by licensing (enabling) optional expansion
packages that are available in addition to the standard base package of the
respective IndraDrive firmware.
In the case of drives of double-axis design (firmware variant MPD),
it is only possible to enable the same functional packages for both
axes. In case the enabling for drive 1 is changed, the enabling for
drive 2 is automatically changed, too.
See also "Overview of Functions/Functional Packages"
Features

Pertinent Parameters

Pertinent Diagnostic Messages

Display of activated functional packages in "P02004, Active functional

packages"

Firmware type designation in "S00030, Manufacturer version" dynami

cally adjusted to the active functional packages displayed in P02004

Functional packages activated/deactivated via parameter

Count of operating hours counter at last change of access enable is stored

S00030, Manufacturer version

P02002, Oper. hours of contr. sect. at change of functional packages

P02003, Selection of functional packages

P02004, Active functional packages

C0202 Parameter limit error (->S-0-0423)

C0299 Configuration changed. Restart

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Handling, Diagnostic and Service Functions

10.9

Extended Diagnostic Possibilities

10.9.1

Monitoring Function

Brief Description
The so-called "monitor function" implemented in the drive is for in
ternal use only, or can be used as an extended possibility of
diagnosis in the case of error.
The monitoring function provides the following options:

Displaying memory ranges

Changing storage locations

Writing/reading EEPROM memory cells (controller and encoder)

Adjusting analog measured values

Displaying internal system states

Executing several test routines for software and hardware

Using the monitor function requires a VT100 terminal, an ANSI ter
minal or a corresponding emulation. It is recommended to have a
132-column display.

Pertinent Parameters

10.9.2

P04021, Baud rate RS-232/485

P04025, Drive address of master communication

P04095, RS-232/485 Parity

Logbook Function

Brief Description
A logbook function is realized in the drive firmware in order to obtain a detailed
diagnostic error message in the case of error. The information provided by the
logbook function allows reproducing the internal firmware sequence, if required.
Pertinent Parameters

10.9.3

P00478, Logbook event

P00479, Logbook time stamp

Patch Function

Brief Description
The patch function can be used for reading and writing any storage location (or
internal variable) as a data object via the master communication, the analog
output or the oscilloscope function.
In conjunction with the analog output or the oscilloscope function, this func
tionality can be used for locating errors.
The PLC patch function serves for diagnosis of internal signal states and inter
nal data of the PLC by developers and instructed users.
When using the patch display in the oscilloscope you have to take
into account that first the patch address and then the oscilloscope
signal is assigned. This must be repeated after every change in the
patch address.

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As it is a function for exclusive use by the development staff, the
patch display parameters P00485 and P00491 write-protected
with the master password.
The configuration parameters of the patch function are not stored
in the flash, but are lost when the drive is switched off.
Pertinent Parameters

General patch functions:

P00480, Patch function 1, source pointer

P00481, Patch function 1, attribute

P00482, Patch function 1, bit maskP

P00483, Patch function 1, exponent

P00485, Patch function 1, display

P00486, Patch function 2, source pointer

P00487, Patch function 2, attribute

P00488, Patch function 2, bit mask

P00489, Patch function 2, exponent

P00491, Patch function 2, display

PLC Patch function:

P00492, PLC patch function 1, data source

P00493, PLC patch function 1, display

P00494, PLC patch function 2, data source

P00495, PLC patch function 2, display

P00496, PLC patch function 3, data source

P00497, PLC patch function 3, display

P00498, PLC patch function 4, data source

P00499, PLC patch function 4, display

10.10

Oscilloscope Function

10.10.1

Brief Description
The oscilloscope function can be used to record drive-internal and external
signals and status variables (parameter contents). This function can be effec
tively used both for initial commissioning and debugging. Its functionality can
be compared to that of a 4channel oscilloscope.
The total scope of the oscilloscope function is divided into the following function
blocks:

Recording measured values

It is possible to record 4 channels at the same time, the signals being
selected by configuration of signal selection lists (IDN lists).

Configuration (basic settings)

The control/status block determines the basic functions (start/stop, time
resolution, size of memory, operating mode). The current status (status
diagram) of the oscilloscope is continuously transmitted to the master.

Trigger function
Besides extensive trigger functions, the drive provides the possibility of
triggering at different signals and events in the drive.

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Handling, Diagnostic and Service Functions

Features

The oscilloscope function is characterized by the following features:

Recording measured values

4 channels, each with a maximum of 8192 measured values

Time resolution to be freely selected in steps of the position loop

clock (see "Performance Data")

Signal selection by indicating the IDN of the respective parameter

Configuration (basic settings)

Pertinent Parameters

4-channel display in "IndraWorks Ds/D/MLD"

More than 100 different measuring and trigger signals (cf. P00149)

Expanded oscilloscope function using patch function

Trigger function

Trigger signal selection by indicating the parameter IDN

Internal trigger or external trigger

External trigger with trigger offset determination for synchronizing

multiple-axis measurements

Unit of trigger level adjusting to trigger signal selection

Possibility of triggering at internal memory contents with patch signal

Control/status:

P00028, Oscilloscope: control word

P00029, Oscilloscope: status word

P00031, Oscilloscope: time resolution

P00032, Oscilloscope: size of memory

P00149, Oscilloscope: signal selection list

P00150, Oscilloscope: number of valid measured values

Measuring channels:

P00021, Oscilloscope: list of measured values 1

P00022, Oscilloscope: list of measured values 2

P00023, Oscilloscope: signal selection 1

P00024, Oscilloscope: signal selection 2

P00145, Oscilloscope: list of measured values 3

P00146, Oscilloscope: list of measured values 4

P00147, Oscilloscope: signal selection 3

P00148, Oscilloscope: signal selection 4

Trigger function:

P00025, Oscilloscope: trigger mask

P00026, Oscilloscope: trigger signal selection

P00027, Oscilloscope: trigger level

P00030, Oscilloscope: trigger edge

P00033, Oscilloscope: number of measured values after trigger event

P00035, Oscilloscope: control offset

P00036, Oscilloscope: external trigger signal

P00037, Oscilloscope: internal trigger signal

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Engineering/Diagnostic Interfaces

11

Engineering/Diagnostic Interfaces

11.1

Serial Communication

11.1.1

Overview of Serial Communication

General Information
The serial interface of the drive controller is used as a universal medium of
communication for different services. It can be used for master communication
(in addition to SERCOS), for reading and writing parameters, for replacing the
firmware, for locating errors and for other services. The physical standard used
is RS232 (with accessory HAS05.1-005 "RS232/RS485 converter", RS485 is
possible, too).
Two protocols are supported for serial communication:

ASCII-based protocol

SIS protocol (Rexroth-standard serial binary protocol)

The protocol is automatically recognized by the drive!

The following functions are made possible via the serial interface:

Reading and writing parameters via terminal or commissioning tool in par

allel with the existing master communication

Connecting a control terminal (BTV04)

Firmware update with "IndraWorks Ds/D/MLD"

The maximum baud rate is 115 kB.

Pertinent Parameters

P04021, Baud rate RS-232/485

P04022, Drive address of serial interface

P04050, Answer delay RS-232/485

P04095, RS-232/485 Parity

Interface Mode
The serial interface can optionally be operated in one of the following modes:

RS232 Mode

RS485 Mode
Communication via RS485 is only possible in conjunction with an
external RS232/RS485 converter (e.g. with accessory module
HAS05.1-005 by Bosch Rexroth).
Depending on the mode, it is necessary to use different cables (see
corresponding "Project Planning Manual").

Transmission Protocols
Two different protocols are supported on the drive side:

ASCII protocol

SIS protocol

When switching on the 24 V supply voltage, automatic protocol detection is

activated when receiving signals via the serial interface.
A soon as either

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a valid ASCII start sequence

- or

a valid SIS telegram

was received, the drive internally switches to the respective kind of protocol.
Properties of ASCII Protocol

Transmission rates 9600 and 19200 baud

8-bit ASCII protocol

No parity bit

One stop bit

There isn't any telegram frame used, but the transmitted ASCII
signs are converted and interpreted. It is only necessary to comply
with a certain order.

Properties of SIS Protocol

11.1.2

Binary protocol

Checksum test (higher Hamming distance D)

all telegrams are identified by an unequivocal start character ("0x02")

Defined structure of the telegram frame

It is possible to activate motions (e.g. jogging)

Functional Principle Independent of Protocol

Basic State After Applying the Control Voltage

After the control voltage has been switched on, the serial communication in the
drive is in the "passive mode". Communication is impossible in the passive
mode.
Determining the Protocol

In order to establish the serial communication with the drive, it is necessary to

determine the kind of communication (protocol) by

a CHANGE DRIVE command (in the case of ASCII protocol)

- or

a valid SIS telegram (in the case of SIS protocol).

Setting the Drive Address

The drive address of the serial interface is set by writing data to parameter
"P04022, Drive address of serial interface".
This can be done, for example, by means of the standard control panel or the
"IndraWorks Ds/D/MLD" commissioning tool.
Exception: If the value "256" (default value) was entered in parameter P04022,
the device address set in parameter "P04025, Drive address of master
communication" is used for serial communication.
RS232 Mode

In this mode, it is not obligatory to set the drive address, because only one node
is connected (peer-to-peer connection).
When communicating via the SIS protocol, the address "128" is
provided for peer-to-peer communication. Independent of the set
ting in parameter P04022, the address "128" is always valid.

RS485 Mode

In the case of communication via RS485 bus, it is obligatory to set the drive
address, because each bus node is addressed via a specific bus address.

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Engineering/Diagnostic Interfaces
In order to avoid access conflicts, each drive address may be as
signed only once.

Communication Via RS232 Interface

The RS232 interface is particularly intended to be used for connecting a PC
with installed "IndraWorks Ds/D/MLD" commissioning tool.
Features

Transmission rates from 9600 to 115,200 baud

Max. transmission distance 15 m

ASCII protocol or SIS protocol (8-bit each)

Parity bit according to parameter "P04095, RS-232/485 Parity"

One stop bit

Fig.11-1:

Communication Via RS232 Interface (Example: "IndraWorks Ds/D/

MLD")

Communication Via RS485 Interface

General Information
The communication via the RS485 interface allows realizing a serial bus with
the following data:
Features

It is possible to connect up to 31 drives with one bus master

Transmission rates from 9600 to 115,200 baud

Max. transmission distance 500 m

Semi-duplex operation via 2-wire line

ASCII protocol or SIS protocol (8-bit each)

Parity bit according to parameter "P04095, RS-232/485 Parity"

One stop bit

Communication via RS485 is only possible in conjunction with an
external RS232/485 converter.

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Operating Several Drives With "IndraWorks Ds/D/MLD"

Advantages for Application

Commissioning several drive controllers without plugging the interface

cable into a different connection (central parameterization and diagnosis
connection)

Realizing a central PC-based visualization unit

Fig.11-2:

Operating Several Drives With "IndraWorks Ds/D/MLD"

Using "IndraWorks Ds/D/MLD" via the RS485 interface is only pos

sible as of version 05.

Parameterization and Diagnosis Via PLC

Advantages for Application

Parameters can be changed via PLC (e.g. adjustment of positioning

blocks)

Extended diagnostic possibilities for the PLC by reading in the error code

Fig.11-3:

Parameterization and Diagnosis Via PLC

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Engineering/Diagnostic Interfaces

Parameterization and Diagnosis of Drive Groups by an Operator Unit

Advantages for Application

Realizing a central visualization unit

Fig.11-4:

Parameterization and Diagnosis of Drive Groups by an Operator Unit

11.2

TCP/IP Communication

11.2.1

Brief Description
The section "TCP/IP Communication" describes all information re
quired for standard Ethernet communication. Apart from TCP/IP
communication, communication via UDP/IP is possible, too.
To avoid confusion with the master communication "Ethernet/IP in
terface" the description "Ethernet communication" is not used in this
connection.
It is possible to communicate with an IndraDrive controller via standard Ethernet
telegrams. These Ethernet telegrams contain TCP/IP or UDP/IP telegrams for
application-side connection. For communication with the device, the CSMA/CD
access method is applied. As connection options, a variety of interfaces are
available, such as the Engineering Port of the control section CSH01.2 or a free
port of a SERCOS III interface (master or slave).
For SERCOS III, in addition to the time-controlled transmission of SERCOStype Ethernet telegrams (MDT and AT), an NRT channel (NonRealTime or IP
channel) exists, for which telegrams are sent in a specially reserved time slot.
Therefore, for SERCOS III, another option for asynchronous data transmission
is available in addition to the existing service channel, that is very well suitable
for large amounts of data due to the maximum lengths of useful data of approx.
1500 bytes.
Possible Applications

With the utilization of the Ethernet communication in the drive, different appli
cation options are available, which are summarized in the following table.

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Connection

Server application

Possible client applications

SIS protocol

Parameterization via SIS-based parameter services, integra Addressed client-sidedly via SCP in
ted in TCP
IndraWorks

Com-Server

Access to parameters and PLC variables for HMI connection VCP / VEP

3S-TCP

Programming/debugging/boot program download for IL run

time

1. IL programming environment
2. See 3S Gateway for OPC Server

3S-UDP

Cyclic exchange of network variables between Codesys-based controls

FTP server

FTP server for uploading (writing to target device) and down FTP client program on the master comput
loading (reading from target device) of files of the MMC
er, engineering PC, ...

Fig.11-5:
Pertinent Parameters

Pertinent Diagnostic Messages

Overview of the Possible Applications

S01019, Master comm. engineering over IP: MAC address

S01020, Master comm. engineering over IP: IP address

S01021, Master comm. engineering over IP: Network mask

S01022, Master comm. engineering over IP: Gateway address

P01044, Master comm. engineering over IP: Status IP communication

P01530, Engineering: MAC address

P01531, Engineering: IP address

P01532, Engineering: Network mask

P01533, Engineering: Gateway address

P01534, C6100 Command Activate IP settings

P01544, Engineering: Status IP communication

P01640, CCD: MAC address

P01641, CCD: IP address

P01642, CCD: network mask

P01643, CCD: gateway address

P01644, CCD: status IP communication

C6101 Incorrect IP settings

F2190 Incorrect Ethernet configuration

11.3

SIS Ethernet Parameter Channel

11.3.1

Parameter Structure
All parameters of the drive controller are stored in a uniform parameter struc
ture. Each parameter consists of 7 elements. The table below describes the
individual elements and the possibilities of access. The following sections will
also refer to the parameter structure below.
Element No.

Data block element

Possibility of access

IDN

read

Name

read

Attribute

read

Unit

read

Min. input value

read

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Element No.

Data block element

Possibility of access

Max. input value

read

Operating data

read / write

Fig.11-6:

11.3.2

Parameter Structure

Telegram Structure, Telegram Scope

Basic Telegram Structure

In principle, a SIS telegram is devided into 3 blocks:

Telegramm header

Useful data header

Useful data
Telegramm header

Fig.11-7:

11.3.3

Useful data header

Useful data

Structure of a SIS Telegram

Communication via SIS Protocol

Addressing a Drive
In the case of communication with SIS protocols we distinguish between com
mand telegrams and reaction telegrams, according to the direction of trans
mission. A node can only be addressed under its address (see Program
Module) when a specific telegram format (frame) is observed.
Read Access

When the reading of a parameter is started in a command telegram, a check is

run in the drive to determine whether a sequential telegram is required. In this
case, bit 2 (current/last transmission) is kept at "0" in the control byte of the
reaction telegram until the last reaction telegram is sent. In the last reaction
telegram, bit 2 is set to "1".
The sending of a sequential reaction telegram is activated by the repeated
sending of the unchanged command telegram.

Sequential Telegram Access

When the writing or reading of a parameter with sequential telegrams was star
ted in the drive, it is necessary to complete or cancel this process before another
service with sequential telegrams can be started. If another service was started
nevertheless, the "0x800C unauthorized access" error code is sent in the re
action telegram. The service with sequential telegram started before can then
be normally processed or cancelled with the next command telegram.

Supported Services and Subservices

SIS serv
ice
0x00

0x01

Description
Node identification

Data transmission
canceled

Subservi
ces

Subservices description

Notes

0x01

Reading SIS version

Subservice is implemented but not active

0x02

Reading firmware version Supplies content of S00030

0x03

Reading controller type

Supplies content of S00140

0x04

Reading supported baud

rates

9600 baud, 19200 baud, 38400 baud,

57600 baud, 115200 baud

None

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SIS serv
ice
0x02

0x03

Description
Flash operations

Initialization of the SIS

communication

Subservi
ces

Subservices description

Notes

0x90

Shutdown

Switches drive firmware to the loading mode

0x91

Reboot

Causes restart

0x92

Read flash

Reads content of the flash

0x93

Find header

Supplies header address of the first IBF mod

ule

0x94

Erase flash

Deletes content of the flash

0x96

Program flash

Programs content of the flash

0x97

Build checksum

Supplies CRC32 checksum of the indicated

IBF module

0x9F

Error reset in the slave

Clears error in loading mode

0xA0

Read configuration

Supplies configuration table

0xA2

Read header

Reads header of the corresponding module

0xA5

Write file information

Generates corresponding file

0xA6

Write file data

Writes content to the opened file

0x01

Determining TrS

Initializes max. reaction time in the slave

0x02

Determining TzA

Initializes max. character interval on the bus

0x03

Determining Tmas

Subservice is implemented but not active

0x07

Determining the baud rate Initializes the baud rate of the serial transmis
sion

0x08

Time-controlled baud rate Allows temporary change of the baud rate

test

0xFF

Accepting the determined Activates the values initialized with the subser
values
vices 0x01, 0x02 and 0x07

0x10

Reading parameter

None

0x10 = 0x80

0x11

Reading list segment

None

Segment information in byte

0x1E

Writing list segment

None

Segment information in byte

0x1F

Writing parameter

None

0x1F = 0x8F

0x80

Reading parameter

None

0x80 = 0x10

0x81

Reading list segment

None

Segment information in word

0x8E

Writing list segment

None

Segment information in word

0x8F

Writing parameter

None

0x8F = 0x1F

Fig.11-8:

Supported Services and Subservices

11.4

File Handling by FTP via Ethernet

11.4.1

Brief Description
Base package of all firmware variants in open-loop and closedloop characteristic

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Engineering/Diagnostic Interfaces
Via an integrated FTP server, IndraDrive devices with Ethernet communication
can access the data of the MMC programming module by means of FTP con
nection. This allows reading or writing data/directories on the MMC.

Fig.11-9:
Features

Schematic Illustration of FTP File Handling

The FTP server of an IndraDrive device has the following features:

Two kinds of login to the FTP server:

Anonymous login (read-only data access)

User login (read and write access to data)

A maximum of 2 simultaneous connections

Effective transmission rate depends on communication port used and

processor load
The transmission rate at the Engineering Port of CSH01.2, for example,
is approx. 20 kbyte/s for download (STOR command) and 50 kbyte/s for
upload (RETR command). If both FTP connections are active at the same
time, the transmission rate is distributed accordingly.

Hardware Requirements

Pertinent Parameters

The following hardware requirements must have been fulfilled:

Use a control section with Ethernet communication (e.g. CSH01.2C or

CSH01.1C-S3)

Plug MMC before booting

S01020, Master comm. engineering over IP: IP address

P04070, Parameter storage configuration

Additional for the utilization of a CSH01.2 control section:

P01531, Engineering: IP address

P01641, CCD: IP address

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Commissioning

12

Commissioning

12.1

Commissioning Motors

12.1.1

Checking the Installation/Assembly

Checking the Assembly

Check the assembly of the IndraDrive controllers and supply units as well
as motors with regard to correct implementation, according to the data con
tained in respective Project Planning Manual.

Checking the Installation

Check the wiring of control cabinet and machine with regard to correct
implementation, according to the data contained in the Project Planning Manual
and the recommendations in the documentation "Electromagnetic Compatibility
(EMC) in Drive and Control Systems".

12.1.2

Initial Commissioning/Serial Commissioning

Brief Description
The drive can be commissioned after assembly and installation have been cor
rectly implemented.
Initial Commissioning

The initial commissioning of a drive differs from the commissioning of other

identical drives (serial commissioning).
The initial commissioning is carried out in the following steps:

Establishing the operatability of the drive (including the required measur

ing systems)

Adjusting the drive behavior to the requirements of the application

Adjusting the master communication interface between master and drive

Integrating drive functionalities in the machine processes

In each of the mentioned steps, values of relevant parameters are adjusted to

the requirements. The result of the initial commissioning is a drive the behavior
of which is exactly adjusted to the axis. By storing the values of the initial com
missioning in the form of a parameter set the drive behavior can be reproduced.
Serial Commissioning

For the commissioning of other identical axis drives on machines of the same
type, the set of parameter values determined during the initial commissioning
is loaded to the respective controller (serial commissioning). This allows

exactly reproducing the drive behavior

- and
Possibilities of Commissioning

reducing the effort for further commissioning to a little adjustment work

and, if necessary, search and elimination of assembly/installation errors.

As a matter of principle, commissioning can be carried out by means of

the "IndraWorks Ds/D/MLD" commissioning tool by Bosch Rexroth con

nected to the drive via SERCOS interface or via a serial interface,via
Ethernet or a field bus.

the control panel of the controller and digital and analog input signals,

a control unit connected to the drive via a master communication interface.

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Two-Step Commissioning

It is basically recommended to always carry out both the initial commissioning

and the serial commissioning in two steps:

1st objective: Initial Start of the Motor

2nd objective: Providing drive functions for the machine axis

Fig.12-1:

Two-Step Drive Commissioning (Schematic)

In the first step, the two-step procedure ensures the operatability of the drive
(1st objective during initial commissioning and serial commissioning). In the
second step, the drive functions required for the machine axis and the drive's
advantageous properties are individually adjusted to the machine axis in a rea
sonable order (2nd objective during initial commissioning) or the expected
functional principle is checked (2nd objective during serial commissioning).
As a matter of principle, it is advantageous to establish the operat
ability of a drive independent of a higher-level control system. The
drive should therefore first be commissioned as a self-contained
unit via "IndraWorks Ds/D/MLD" or in the "easy startup" mode!
See following sections:
- "Initial start in the "easy startup" mode"
- "Initial Start With the Commissioning Tool"

Notes on Commissioning
Initial Start of the Motor

See "Initial Start in Easy Startup Mode"

See "Initial Start With the Commissioning Tool"

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Providing Drive Functions
Initial Commissioning

See "Commissioning Machine Axes"

After initial commissioning has been carried out the defined application-specific
parameter values have to be saved. The saved parameter values allow repro
ducing the drive behavior required at the respective machine axis.
For saving the parameter values the drive provides parameter lists
supporting the complete storage of the relevant parameter values.
By reloading the saved parameter values the initial status after initial commis
sioning can be established again for the axis drive!
See also "Parameters, Basics: Loading, Storing and Saving Parameters"

Reestablishing the Original Status

CAUTION

Attention:For drives with absolute encoders, it is necessary to reestablish the

original status after initial commissioning!

Possible property damage for drives with absolute encoders caused by

incorrect actual position value after repeated loading of parameter val
ues saved according to S00192!
? Save parameter values by means of accordingly modified IDN list of param
eter S-0-0270 (see below)
For drives with absolute value encoder and modulo scaling it is recommended
to determine the parameter set for saving the parameter values after initial
commissioning by means of a list of "S-0-0270, IDN-list of selected backup
operation data" modified by the customer so that there cannot occur any actual
position value error when the saved parameter values are loaded to the same
axis drive again.
This is only possible via a control master. MMC and
"IndraWorks Ds/D/MLD" only work with the content of the list pa
rameter S-0-0192!
In its initial status, the content of the list parameter S-0-0270 first corresponds
to the list parameter S-0-019 and should be modified as follows:

Remove the IDNs P-0-0177 and P-0-0178

These parameters contain information on the current position data of the ab

solute encoders at the time of parameter backup. If the current data of P-0-0177
and P-0-0178 during the loading of the saved parameter values were overwrit
ten with data referring to a different axis position current at the time of parameter
backup, the actual position values would then correspond to the other axis po
sition! The actual position values would remain valid (S-0-0403, Position
feedback value status) because it still is the same absolute value encoder.
The incorrect actual position value generated in this case cannot
be detected on the drive side because otherwise unjustified errors
would be generated in service cases when devices are replaced!
See also "Notes on How to Replace the Devices"
The list of S-0-0270 modified as described can also be used for
saving and loading the parameter values of axes with relative meas
uring systems, because the parameters P-0-0177 and P-0-0178 in
this case do not contain relevant information!

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The content, possibly modified, of the list parameter S-0-0270 is
contained in parameter S-0-0192, too! This means that when the
backup is made via parameter S-0-0192, the content of parameter
S-0-0270 can be read from the stored list, in order to load only these
individually selected parameter values!
Serial Commissioning

The serial commissioning of axis drives of machines of the same type is sup
ported by the application-specific parameter set of the respective axis drive
saved after initial commissioning.
During serial commissioning the saved parameter sets are loaded to the con
trollers of the respective axis drives of other machines of the same type. This
allows easily reproducing the behavior of the drives of a "model machine"!
After the application-specific parameter set of an axis drive has been loaded
only some more adjustments are required:

Setting the drive address (see "Basic Functions of Master Communication:

Setting the Axis Address")

"Establishing position data reference" for axes with measuring systems

that can be evaluated in absolute form (see "Establishing Position Data
Reference: Establishing Position Data Reference for Absolute Measuring
Systems")

See also "Parameters, Basics: Loading, Storing and Saving Parameters"

12.2

Initial Start in "Easy Startup" Mode

12.2.1

Brief Description
The so-called ""easy startup" mode" allows moving the drive without connected
or active control unit (or master communication master) or external command
value box. When using a Rexroth motor with encoder data memory, this is also
possible without using a commissioning PC, because all motor and controller
parameters are stored in the encoder data memory.
The easy startup mode is therefore particularly suited for initial
commissioning of individual axes, as well as for maintaining an
emergency mode when the control unit has failed.
Features

Activation of the "easy startup" mode is possible in two ways:

By activating the command parameter "P04085, Command

Activate easy startup mode" via serial interface or digital input

Via control panel of controller (pressing the corresponding keys in a

certain order triggers activation of P04085)

Automatic deactivation of master communication interface (see P04077,

S00134) and activation of "P00120, Control word easy startup"

Activation of drive enable (P00120, bit 15) via:

The digital input assigned to drive enable (different according to

hardware design, see default assignment under "Automatic Config
uration of the Inputs")

Serial interface when configuration of digital inputs for "easy start

up" mode made before was removed

Drive moves in "velocity control" mode with a parameterizable velocity

command value (see P01206) without external command value box

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Commissioning

Selection of travel direction (positive/negative) via digital input signals (see

parameter "P01200, Control word 1 velocity control")

Fig.12-2:
Hardware Requirements

Activating the Easy Startup Mode, Overview

Control sections BASIC SERCOS, BASIC PROFIBUS, BASIC UNIVERSAL

and ADVANCED
For using the easy startup mode, the digital inputs and outputs (X31, X32) must
be connected as follows:

Connect 24V/0V power supply to respective terminal connectors

X31/4: +24 V for activating drive enable

X32/7 and X32/8: 0V/+24V for activating positive or negative rotational

direction
or X31/3 and X31/7 for control of motor potentiometer

Control sections BASIC UNIVERSAL double-axis

For using the "easy startup" mode, the digital inputs and outputs (X33, X34)
must be connected as follows:

Axis 1:

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Connect 24V/0V power supply to respective terminal connectors

X33/1: +24 V for activating drive enable

X33/2 and X33/3: 0V/+24V for activating positive or negative rota

tional direction
or X33/4 and X33/5 for control of motor potentiometer

Axis 2:

Connect 24V/0V power supply to respective terminal connectors

X34/1: +24 V for activating drive enable

X34/2 and X34/3: 0V/+24V for activating positive or negative rota

tional direction
or X34/4 and X34/5 for control of motor potentiometer

Control sections BASIC OPENLOOP and BASIC ANALOG

For drives with these control sections, the "easy startup" mode actually is not
required, because these drives can easily be moved with an analog command
value (see "Analog Interface").
IndraDrive Mi
For using the "easy startup" mode, the digital inputs and outputs (X37, X38)
must be connected as follows:

Pertinent Parameters

Pertinent Diagnostic Messages

12.2.2

Connect 24V/0V power supply to respective terminal connectors

X37/2: +24 V for activating drive enable

X37/4 and X38/4: 0V/+24V for activating positive or negative rotational

direction

S00032, Primary mode of operation

S00091, Bipolar velocity limit value

P00120, Control word easy startup

P00300, Digital I/Os, assignment list

P00301, Digital I/Os, bit numbers

P00302, Digital I/Os, direction

P01200, Control word 1 velocity control

P01206, Memory of velocity command values

P04085, Command Activate easy startup mode

P04086, Master communication status

When the "easy startup" mode is used, additional simple diagnostic texts ap
pear on the display of the control panel in "light writing":

When the "easy startup" mode has been activated, the display changes
between the drive address and the message "CM" (Commissioning
Mode).

During commissioning, the relevant messages appear on the display (see

fig. "Activating the "Easy Startup " Mode Via the Control Panel").

Functional Description
Requirements

The following requirements and conditions must have been fulfilled for using
the "easy startup" mode:

The wiring of the drive is complete and correct.

There shouldn't any master communication have been activated.

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Commissioning
Attention: The "easy startup" mode switches off any possibly active master
communication!

The controller must be supplied with control voltage and it must be pos
sible to switch power on.

There mustn't any error message be present.

For Rexroth motors with encoder data memory, there is no commissioning PC

required; otherwise the motor parameters have to be set during commissioning,
if necessary with a PC.
General Information on How to Ac
tivate the Easy Startup Mode

The "easy startup" mode can be activated both in the parameter mode (phase 2)
and in the operating mode (phase 4), by activating "P04085, Command
Activate easy startup mode".
If the drive already is in the "easy startup" mode and this mode is
activated again, the display reads "easymode active"!
The "easy startup" mode can be activated in the following ways:

Via the control panel of the controller

Via a digital input

Via the serial interface

By activating the "P04085, Command Activate easy startup
mode" , the drive automatically switches to the parameter mode and
configures the "velocity control" mode with values from the memory
of fixed command values (P01206).

Activation Via Control Panel

The figure below illustrates how the easy startup mode is activated via the con
trol panel of the IndraDrive controllers:

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Fig.12-3:

Activating the Easy Startup Mode Via the Control Panel

See also "Control Panels of the IndraDrive Controllers"

Activation Via Digital Input

If the "easy startup" mode is activated via a digital input, bit 0 of parameter
P04085 has to be assigned to a digital input.
See "Digital Inputs/Outputs"

Activation Via Serial Interface

If the "easy startup" mode is activated via the serial interface, parameter
P04085 has to be written via SIS telegrams.
See "Serial Communication"
"P04085, Command Activate easy startup mode" can also be di
rectly written via the master communication (e.g. SERCOS or field
bus), but in this way the master would deactivate itself!

Acknowledging the Active "Easy

Startup" Mode

The active "easy startup" mode is acknowledged by:

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Automatic Configuration of the In

puts

Set bit 8 in "P04085, Command Activate easy startup mode"

Changing the display on the control panel between "CM" (Commissioning

Mode) and the drive address

For automatic configuration of the inputs, the following actions are carried out:

Deactivation of master communication interface and activation of drive

enable in parameter "P00120, Control word easy startup"

Setting of operation mode "velocity control" with values from memory of

fixed command values (P01206)

Assignment of the command velocity selected via the control panel (in
percent) of "S00091, Bipolar velocity limit value" to element 1 or 2 of
"P01206, Memory of velocity command values" (with positive sign to el
ement 1, with negative sign to element 2).

Assignment of allocation of inputs

The actual configuration of the inputs/outputs depends on the avail
able digital inputs of the control section (see tables below).
The automatic configuration of the inputs/outputs for the "easy
startup" mode takes place in volatile form, i.e. any I/O configuration
existing before is reestablished when the command is completed.
This is not the case, if the I/O configuration was specifically (man
ually) changed with the command being active.

IndraDrive single-axis control sections (CSB, CSH)

Connection

Signal

Function

I/O assignment

X31.3

I_1

Motor potentiometer, ramp +

P01200, Control word 1 velocity control (bit 8)

X31.4

I_2

Drive enable

P00120, Control word easy startup (bit 15)

X31.7

I_5

Motor potentiometer, ramp

P01200, Control word 1 velocity control (bit 9)

X32.7

I/O_9

Selection of memory of fixed com P01200, Control word 1 velocity control (bit 0)
mand values

X32.8

I/O_10

Selection of memory of fixed com P01200, Control word 1 velocity control (bit 1)
mand values

Fig.12-4:

Automatic I/O Configuration for Easy Startup Mode With Single-Axis

Control Sections

IndraDrive double-axis control sections (CDB)

Connection

Signal

Axis

Function

I/O assignment

X33.4

I_15

Motor potentiometer, ramp +

P01200, Control word 1 velocity control (bit 8)

X33.1

I_12

Drive enable

P00120, Control word easy startup (bit 15)

X33.5

I_16

Motor potentiometer, ramp

P01200, Control word 1 velocity control (bit 9)

X33.2

I_13

Selection of memory of fixed

command values

P01200, Control word 1 velocity control (bit 0)

X33.3

I_14

Selection of memory of fixed

command values

P01200, Control word 1 velocity control (bit 1)

X34.4

I_21

Motor potentiometer, ramp +

P01200, Control word 1 velocity control (bit 8)

X34.1

I_18

Drive enable

P00120, Control word easy startup (bit 15)

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IndraDrive double-axis control sections (CDB)
Connection

Signal

Axis

Function

I/O assignment

X34.5

I_22

Motor potentiometer, ramp

P01200, Control word 1 velocity control (bit 9)

X34.2

I_19

Selection of memory of fixed

command values

P01200, Control word 1 velocity control (bit 0)

X34.3

I_20

Selection of memory of fixed

command values

P01200, Control word 1 velocity control (bit 1)

Fig.12-5:

Automatic I/O Configuration for Easy Startup Mode With Double-Axis

Control Sections

IndraDrive Mi (KSM)
Connection

Signal

Function

I/O assignment

X37.2

I/O_3

Drive enable

P00120, Control word easy startup (bit 15)

X37.4

I/O_1

Selection of memory of fixed com P01200, Control word 1 velocity control (bit 0)
mand values

X38.4

I/O_2

Selection of memory of fixed com P01200, Control word 1 velocity control (bit 1)
mand values

Fig.12-6:

Automatic I/O Configuration for Easy Startup Mode With IndraDrive Mi

IndraDrive Mi (motor-integrated inverter drive) only has a limited

number of digital inputs/outputs (4 inputs/outputs), it has no analog
input and no control panel!
See also "Optional Modules for Control Sections" in the separate docu
mentation "Control Sections for Drive Controllers; Project Planning Manual"
"Load Basic Parameters" With In
valid Parameter Settings

After activating the "easy startup" mode, the drive normally is ready for opera
tion ("bb" or "Ab" communication phase 4). When the drive stops in commu
nication phase 3 due to invalid parameter values, valid basic parameter values
can be loaded via the control panel.
See also "Control Panels of the IndraDrive Controllers"

Controlling the Drive

According to master communication or setting of the device control, different

control words take effect. Internally, however, all relevant control bits are always
displayed in "P00116, Device control: control word".

Fig.12-7:

Controlling the Drive in the "Easy Startup" Mode

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In the case of temporary control of the PLC, bit 14 (drive enable) is
nevertheless taken from "S00134, Master control word" for
SERCOS interface! Only in the case of stand-alone "Motion Con
trol" does the PLC also control bit 14. In the case of field buses,
bit 14 is activated internally.
See also "Profile Types (With Field Bus Interfaces)"
The control parameter "P00120, Control word easy startup" active in the "easy
startup" mode can be changed or influenced in the following ways:

Via digital inputs, if they were accordingly configured before

Via the serial interface by direct writing of P00120

In this case, the parameter has to be actively written at least every 2 s,
otherwise the drive will automatically clear drive enable!

Terminating the "Easy Startup"

Mode

The "easy startup" mode can only be terminated by switching the controller off!
After the "easy startup" mode was terminated, the controller is in its initial status
again and all configurations specifically made for this mode were undone.
After successful command execution, the drive is automatically switched to the
operating mode again, if it had been in phase 4 before the start of the command!
If required, the "easy startup" mode has to be activated again.

12.2.3

Notes on Commissioning
Invalid Commands

The commands for backup of working memory ("P00120, Control word easy
startup" and "C2400 Selectively backup working memory procedure
command") should not be triggered in "easy startup" mode, because otherwise
the settings of the "easy startup" mode will be stored in the non-volatile memory
and will be active again after the drive is switched on the next time!

Initial Commissioning

In the "easy startup" mode, initial commissioning of Rexroth motors with en

coder data memory is easily done without commissioning tool, because the
required parameter settings for motor control and motor encoder are automat
ically made via the command "load defaults procedure - load controller param
eters".
For "load defaults procedure" see "Default Settings in the Motor Encoder Data
Memory" in "Drive Control: Overview".
Initial commissioning of Rexroth motors without encoder data memory or of
third-party motors is only possible in the "easy startup" mode in conjunction with
a commissioning tool "IndraWorks Ds/D/MLD" in order to load or enter the val
ues for motor control parameters and motor encoder parameters. For synchro
nous motors with absolute measuring system, the commutation offset only has
to be determined at initial commissioning. For synchronous motors with relative
measuring system, the commutation offset is automatically determined every
time drive enable is set for the first time after transition "PM OM".
If for synchronous motors the commutation offset can only be determined by
supplying current, this is only possible in the operating status "Ab" with "active
easy startup" mode!
See "Initial Start With the Commissioning Tool"

Danger of property damage during initial start in "easy startup" mode

caused by incorrect parameter values!
CAUTION

For motors without encoder data memory, the required motor and controller
parameters have to be checked before initial start in "easy startup" mode!

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Commissioning
Recommissioning

In "easy startup" mode, recommissioning (after initial commissioning having

been carried out) of drives is possible without any problem, because the correct
values of motor control parameters and motor encoder parameters are already
available in the drive.
Only the commutation setting of synchronous motors with relative measuring
system is automatically determined again every time drive enable is set for the
first time after transition "PM OM"!

Property damage caused by errors when controlling motors!

The digital input signals have to be applied with due caution!

CAUTION
The figure below summarizes the commissioning sequence with "easy start
up" mode:

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Commissioning

1)

Fig.12-8:

See assignment tables for the different hardware designs under "Auto
matic Configuration of the Inputs"

Commissioning Sequence With Easy Startup Mode

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Commissioning

12.3

Initial Start with the Commissioning Tool

12.3.1

Brief Description

Establishing the Operatability of the

Drive

After complete and correct assembly and wiring of the drive or the drives it is
advisable to establish the operatability. With drives of the IndraDrive family this
is very easily done by means of initial start in "easy startup" mode (velocitycontrolled operation, master communication master not required) in conjunction
with the Rexroth "IndraWorks Ds/D/MLD" commissioning tool. With older drive
families and connections via the SERCOS interface this is possible by means
of the Rexroth "DriveTop" commissioning tool and the Rexroth-SERCOS-Mas
ter SYSDA02.2.
According to the available equipment, the initial commissioning of the motor is
supported as follows:

Available Commissioning Tools

If there is no commissioning tool (e.g. PC) available, Rexroth motors with

encoder data memory can be easily commissioned in "easy startup"mode.
The motor parameters and motor control parameters of these motors are
automatically loaded from the data memory to the controller by switching
control voltage on.

IndraDrive: If a PC with Rexroth commissioning tool is available, the motor

parameters and motor control parameters of motors without encoder data
memory can be loaded from the internal database of the commissioning
tool to the controller via the serial interface. This allows initial commis
sioning in "easy startup" mode for these motors, too.

EcoDrive/Diax: If a PC with the "DriveTop" commissioning tool (ver

sion 16VRS) and SYSDA02.2 is available, drives with SERCOS interface
can be conveniently commissioned and moved via command values of
SYSDA02.2.

Bosch Rexroth provides the following commissioning tools (software) for drives:

EcoDrive/Diax: DriveTop (version 16VRS)

IndraDrive: IndraWorks Ds/D/MLD

DriveTop

"DriveTop" is a tool for parameterizing and commissioning drives. It supports

the Rexroth SERCOS master SYSDA02.2 by means of which it is possible to
move drives with SERCOS interface. The communication with the drive or with
SYSDA02.2 is established via the serial interface RS232/RS485.

IndraWorks Ds/D/MLD

"IndraWorks Ds/D/MLD" is a component of the software range "IndraWorks",

which supports parameterization and commissioning of control units and drives
by Bosch Rexroth. "IndraWorks Ds/D/MLD" has been designed for interaction
with the SERCOS master SYSDA02.2. The communication with the drive is
established via the serial interface RS232/RS485.
The commissioning tools "DriveTop" and "IndraWorks Ds/D/MLD" provide the
following possibilities and advantages:

The functions and features made available by the drive are structurally
visualized, the respective parameter values are displayed in their func
tional context.

Parameter values can be directly changed and thereby adjusted to the

respective requirements.

The parameter values available in the drive can be saved drive-externally

as a group (parameter set), e.g. on the PC hard disk, and can be reloaded
from the hard disk.

Diagnostic messages and operating status messages are displayed in

clearly arranged form.

For the purpose of commissioning, commands can be started.

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Commissioning

By means of the "easy startup" mode IndraDrive drives or, in conjunction

with SYSDA02.2, all drives can be commissioned and travelled.

12.4

Commissioning Machine Axes

12.4.1

Procedure for Commissioning

The drive supports different commissioning procedures. The type of commis
sioning depends on the existing machine components (control, drive control
lers, motor, mechanical system). Commissioning is made using one of the
commissioning tools available.

Commissioning Procedure

Fig.12-9:

12.4.2

Overview of Procedures for Commissioning

Real Operation

In real operation all necessary components are available. The parameterization

of the drive controller is made online; then commissioning of the axis system
can be made in setting-up mode. The commissioning of the machine is made
by means of a control.

Offline Simulation

The offline simulation does not require any machine component. The parame
terization of the drive controller is made offline. The parameters are applied to
the drive controller during transition to real operation. The parameterization for
a drive-internal control (MLKD) can also be made offline, as well as creation of
motion programs.

Simulation Mode

In simulation mode only the drive controller is required, parameterization is

made online. With the axis simulation the velocity and actual position values
are simulated, the drive can be operated in velocity- and position-controlled
operation modes. A subordinate control can thus test its motion programs even
without motor or mechanical system.

Commissioning Real Operation

Brief Description
Before commissioning machine axis-specific functions it is useful to make sure
that the drive, consisting of controller, motor and motor encoder, is operational.
The best way to do this is the initial start of the drive with the PC-based com

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Commissioning
missioning tool "IndraWorks Ds/D/MLD" by Bosch Rexroth (see "Initial Start
With the Commissioning Tool").
The commissioning of machine axis-specific functions should also be carried
out via "IndraWorks Ds/D/MLD", if possible. The advantage is that the correct
sequence of an axis-specific function can be configured and ensured inde
pendent of the control unit. Further commissioning of the drive, with widely
complete configuration, is then easier for the control unit.

Schematic Sequence
Commissioning procedure as a sequence of steps:

Fig.12-10:

Steps of Machine Axis-Related Commissioning

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Commissioning

12.4.3

Simulation Mode

Brief Description
Contained in base package of variants MPH, MPC, MPB and MPD in open-loop
and closed-loop characteristic.
The "simulation mode" function is available for function check of controls. It
enables the control to perform a program test without axis motion. To do so,
the drive only needs one drive control section, the power supply, motor and
encoder are not used. In operating mode, the drive is thus directly ready for
enable"AB"
The function is realized via the command "Parking axis". In this process the
function "permanently parked axis" is activated via parameter "P00399,
Configuration of simulation mode". The command and thus the axis simulation
is automatically started at transition to the operating mode.
Pertinent Parameters

P00399, Configuration of simulation mode

P00612, Set absolute position control

S00139, C1600 Parking axis procedure command

S00147, Homing parameter

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Notes on Application

13

Notes on Application

13.1

Functions

13.1.1

Compatible New Functions and Functional Modifications

System Overview
HCS04.2 Supported
Devices of type HCS04.2 are supported.

Distributed Drive Controller Supported

The distributed drive controller "KMS01.2-B" of the "IndraDrive Mi" product
range is supported.

MultiEthernet Interface "ET" Supported

IndraDrive controllers can be operated with a MultiEthernet interface (optional
module "ET"). SERCOS III, EtherCAT, PROFINET, EtherNet/IPTM protocols
are supported.

CSH01.3 Supported by MPC-06 and MPC-07

The new control section variant CSH01.3 (high-performance control section for
MLD/CCD applications, including SERCOS III master interface and standard
Ethernet interface) is supported.

Brake Current Monitoring

As of MPx06, the brake current can be monitored with the additional device
"HAS05.1-010-NHN-NN" and activation of the function via "P-0-0525", bit 12.

Change in Functional Packages

As of the firmware derivates MPB-06, MPC-06 and MPH-06 (not MPD-06), pa
rameter set switching with 8 sets is also contained in the functional packages
"Servo function" and "Synchronization", but only the groups controller param
eters/application parameters can be switched (see"P02216, Parameter set
switching, configuration").

Master Communication
Quantity of Cyclic Data With SERCOS III
Number of configurable IDNs extended for SERCOS IIIconnections:

62bytes / 15IDNs 52bytes / 16IDNs

28bytes / 11IDNs 28bytes / 12IDNs

SERCOS III: Unequal Cycle Times Supported

It is possible to set consumer cycle times (in connection instance 0 or 1) of N
times the producer cycle time (in connection instance 0 or 1). The drive then
interpolates in the consumer cycle time. The behavior of the function corre
sponds to that which was possible in SERCOS II by Tncyc = N*Tscyc.

SERCOS III Redundancy Function in Slave Supported

The redundancy function in the slave ensures that the search for a valid tele
gram with consumer data (process data/command values) always takes place,
independent of the port. In the case of a ring interruption the double ring is split
into 2 lines. In the case of a ring recovery the topology is changed vice versa.
To ensure that this functions without errors, bus master and bus slave must be
able to handle both, the respective topology states and the transitions.

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Notes on Application

EtherCAT
Conversion EtherCAT according to profile "Servo over Ethercat" (SoE) via Mul
tiEthernet interface "ET".
"Ethernet over Ethercat" (EoE) is not supported! "Engineering over IP" is not
supported!

PROFINET RT
Conversion PROFINET RT via MultiEthernet interface "ET".
"Engineering over IP" is not supported!

Ethernet/IP
Conversion Ethernet/IP via MultiEthernet interface "ET".
"Engineering over IP" is not supported!

SERCOS III/SCPV1.1.2 Conversion SMP

The SERCOS Messaging Protocol (SMP) was defined to allow transmission,
independent of the SERCOS timing, of messages of any length between two
SERCOS nodes. The SMP protocol stack was implemented according to the
current SMP specification. With IndraDrive, it is required as a transport layer
for Safety Messages.

Motor, Mechanical Axis System, Measuring Systems

Parameter for Output Frequency
"P-0-0580, Motor frequency" shows the electric output frequency of the con
troller. It is displayed without decimal place and sign.

Maximum Initialization Velocity of HIPERFACE Encoders Too Low

The maximum velocity during the initialization of the HIPERFACE encoder can
now be 100 rpm (was 50 rpm).

HIPERFACE Encoder "TTK70" Supported

The linear encoder "TTK70" with HIPERFACE interface by SICK-STEGMANN
is supported.

Optimization of Encoder Replacement Monitoring and Reestablishment

of Reference After Encoder Errors
The encoder replacement monitoring and reestablishment of reference after
encoder errors was optimized.
Application 1: Encoders are replaced for a check and put back again.
With modulo axes, the installation reference was always deleted, even if the
actual position and the reference could be reestablished with the original en
coder.
Application 2: Reestablishment of reference after encoder errors.
For modulo axes with absolute encoder and encoder memory, the actual po
sition is generated from the encoder position and the offset from the encoder
memory, if the modulo range fits integrally in the absolute range. In this case,
the reference is reestablished after encoder replacement or encoder errors.
In the case of non-integral relations, the encoder can only be replaced in the
parameter mode. The actual position cannot be reestablished after an encoder
error.

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Notes on Application

Absolute Value Monitoring HIPERFACE Encoder

The digital transmission of the absolute position of the encoder was only used
for initialization. In cyclic operation, the position was only evaluated in incre
mental form.
Now, additional absolute encoder monitoring takes place by comparing the in
crementally determined position to the digitally transmitted position of the
encoder in motor standstill. In the case of error, the warning E2074 is output. If
the monitor falsely triggers, the monitor can be switched off in the feedback type
parameter (S00277, S00115).

Cyclic Reference Mark Evaluation

The reference mark of an encoder can be continuously determined when bit 9
has been set in the position feedback type parameter of the corresponding en
coder. The marker position is previously displayed in parameter S00440/
S00441 and can be monitored accordingly.

Absolute Encoder Without Absolute Monitoring and Reference

The absolute position of the encoder is also used for the start value when the
absolute encoder function has been switched off. It can then be used in a control
unit for homing.

Homing Without Drive Enable

An incremental encoder can now be homed without drive enable, if movement
is not required (homing without home switch and without reference mark).

Drive Control
Improved Torque Display for Synchronous Motors
The temperature dependance and the saturation dependance of the torque/
force constant had not been taken into account. Activate the correction in
"P00556, Config word of axis controller", bit 11.
To display the torque-current characteristic, the following parameters were im
plemented:

Sx0533, Nominal torque/force of motor

Sx0534, Maximum torque/force of motor

P00448, Temperature-dependent torque/force coefficient

P00449, Speed-dependent torque/force coefficient

P00450, Current torque/force constant

Commutation Offset With Mechanically Adjusted Encoders (as of

MPx07)
Only as of MPx07V06
Third-party motors with fixed commutation offset, i.e. the same mechanical an
gle of stator to encoder (rotor), are supported. The commutation offset is only
stored as a parameter in the drive and not additionally in the encoder memory.

Commutation Synchronous Motor With Encoder Gear

For selected gear ratios and encoders, one-time commutation at commission
ing is also possible with encoder gear. The extension is only allowed for rotary
encoders.

Load Display for the Motor Temperature Model

For thermal protection of the motor, the drive firmware calculates a thermal load
of the motor by means of the motor current. The parameter "P00446, Thermal

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Notes on Application
motor load" now displays the percentage-based load with relation to the con
tinuous current of the motor.

Automatic Determination of Load Due to Weight

The parameter "S00163, Weight counterbalance" had to be parameterized
and could not be automatically determined. When drive enable is switched off,
the current torque is to be written to parameter S00163. The value is not stor
ed. When drive enable is switched on, the speed loop I-component is initialized
with this value. The function is activated via bit 12 of "P00556, Config word of
axis controller".
After having switched to the operating mode, the parameterized value takes
effect the first time drive enable is switched on.

FXC for Synchronous Motor

The flux-controlled motor operation available for asynchronous motors can be
used for synchronous motors, too.
For synchronous motors, the FXC method works with the output of a velocityproportional frequency and the output of a voltage pointer, which in absolute
value and phase angle results in a not directly load-dependent generated cur
rent.
For synchronous motors, the torque is generated by the "load angle". Its value
is proportional to the load. When it remains smaller than 90 electrically, the
actual velocity value follows the velocity command value without deviation.
When the load causes a load angle greater than 90 electrically, the synchro
nous motor stops abruptly.
For synchronous motors, the magnetic flux already exists in the air gap due to
the permanent magnets. However, a command value for the total motor current
is preset when the motor is in no-load operation. The impulse load stability is
improved with increased no-load current, the no-load loss, however, is in
creased.
The no-load current is set in "P00602, FXC: Minimum no-load current". In this
parameter, both a negative and a positive minimum value can be entered for
the flux-generating current (wattless current). This minimum value is intended
for the no-load operation of synchronous motors and exclusively takes effect
with synchronous motors when the entered value is positive. When a negative
value is entered, a minimum no-load current of 1/10 INominal applies, but the
absolute value of P00602 takes effect in the current at standstill under eval
uation with P00532 as holding current in standstill. Thus current at standstill
= P00532*|P00602|
Properties of the control method

No positioning possible

Mere velocity-controlled operation for spindle applications

Drive stiffness starts with low output frequencies (approx. 2% of the fre
quency for maximum velocity)

No overload capacity of the drive

Torque jumps only allowed up to approx. 90% of the nominal torque.

These impulse loads must be limited by application measures. If this is not
done, the current of the motor can no longer be maintained at an efficient
and stable level.

Display Parameter for Mechanical Power / Energy

The calculation for the parameter S00382 was improved.

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Notes on Application
Additionally, the new parameter "P00851, Short-time energy counter" was
implemented. This parameter displays the energy consumption of the drive with
a resolution of 1 Ws.
The mechanical power of the motor is displayed in "P00447, Motor shaft
power". The power is calculated from the data "speed" and "torque/force con
stant". Only in conjunction with the improved torque display for synchronous
motors does the calculation provide good results.
P00447 = n[1/min]/60*2Pi *Md[Nm] rotary motors
P00447 = V[mm/min]* M[N] linear motors

Short Circuit of the Motor Phases via Output Stage

For certain F8xxx errors, the motor can be decelerated more quickly if the motor
phases are short-circuited. The short-circuit braking must be activated in
"P00119, Best possible deceleration", bit 8.

Synchronous PWM
Extension of control for high-speed motors up to a motor output frequency of
2600Hz. The PWM is generated synchronously to the rotor speed and no longer
synchronously to the velocity loop clock.

Velocity-Dependent Switching of PWM Frequency

To increase the amplifier continuous current at low speeds while simultaneously
improving the sinusoidal converter output voltage at high speeds, it is possible
to automatically switch to the double PWM frequency at high speeds.
Control section

Low performance

Standard
ance

perform High performance

(switching frequen
(switching frequen cy)
cy)
CSH

16kHz8kHz
(<800Hz)12kHz6
kHz(<600Hz)
8kHz4
(<400Hz)

8kHz4
kHz (<400Hz)

Rotor-synchronous
PWM
CDB

CSB

12kHz6
kHz(<600Hz)

8kHz4
(<400Hz)

8kHz4
(<400Hz)

16kHz8kHz
(<800Hz)
kHz

Rotor-synchronous
PWM
-

kHz -

kHz (12 and 16 kHz not

available)

(16 kHz not availa

ble)

PWM Frequency Switchable With Parameter Set

"P00001, Switching frequency of the power output stage" will be included in
the group of parameters with switchable parameter set. The switching frequen
cy is assigned to the group of motor parameters. This forces switching to PM
during parameter set switching.

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Notes on Application

Maximum Model Deviation When Initializing the Operation Mode

The max. model deviation (P-0-0098) is no longer deleted in the case of a
change of operation mode, but only when the axis is initialized (switching pa
rameter mode operating mode).

HIPERFACE Encoder "DME5000" Supported

The HIPERFACE encoder "DME5000" by SICK-STEGMANN is supported; it
can be operated at the ENS interface (universal HIPERFACE encoder).

Interpolating Correction Changes

The temperature value for axis error correction of the temperature expansion
is much more filtered.
The temperature value is smoothed with a PT1 filter of the time constant 1s.

Operation Modes
Linear Interpolation for Velocity Command Value (Average Value Filter)
The previously used VZ1 filter for the velocity command value is not suited for
the application servo operation with position control in the control unit.
Via "P01214, Control word 2 velocity control", bit 11, you can select whether
the previously used VZ1 filter or an average value filter takes effect.

Average Value Filter With Constant Filter Order in Interpolation Modes

The filter order of the average value filter in interpolation mode is calculated
from acceleration and jerk and can change during the motion of an axis, par
ticularly when the acceleration is cyclically set.
When the filter order is changed, the filter every time is set to the current ve
locity; this can cause problems, particularly when the axis is in acceleration or
deceleration.
Setting the filter to const. velocity distorts the position profile.
A function of constant filter order was implemented. The filter order is set via
a parameter (P00641) and can be kept constant for the complete position
profile.

"Drive Halt" Optimization

Troubleshooting for

unwanted position profile at "Drive Halt" with average value filter.

selection of control mode cannot be freely selected at "Drive Halt".

no operational stop possible (no switching of internal operation mode)

"Drive Halt" as quick stop (individual operation mode) is decelerated with 2nd
order interpolator from acceleration and jerk, no more average value filter! At
tention: The jerk limit value (S00193) takes effect with quick stop
Control mode (velocity-controlled or position-controlled) selected via parameter
("P00558, Drive Halt configuration")
Configuration of an operational stop for operation modes with internal command
value generation (e.g. positioning)

System-Wide Terms for the Synchronous Operation Modes

The names of parameters, diagnostic messages and terms belonging to the
topic "synchronous operation modes" were harmonized system-wide.

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Notes on Application

Single-Step Synchronization of Secondary Master

The single-step synchronization of the secondary master is required to allow
synchronization in a defined master axis range. Identical implementation as for
real axis with 5th order polynomial.

Optimization of Synchronization
The existing single-step synchronization implemented with a 5th order polyno
mial is time-optimized, but has no limitation regarding the acceleration and
velocity. The synchronization process is master-axis-synchronous and, partic
ularly for real master axes which often change their motion state, it cannot be
predicted which accelerations and velocities occur.
A new synchronization method by means of interpolator is made available for
the position synchronization modes.

Synchronization and Desynchronization of the Virtual Master Axis (as

of MPx07)
Available with MPx07V06.
For the real axis, the single-step synchronization is selected in parameter
"P00155, Synchronization mode", for the virtual axis in parameter "P00919,
Synchronization mode, secondary master".
Both parameters are extended by the bit 9 (distance optimization).
When bit 9 has been set with single-step synchronization selected (bit 6 ="1"),
the required synchronization distance is optimized.
Distance optimization is only possible with modulo axes.
The added synchronization profile is good when there is no reversal point in the
position curve. In this case, there won't be any maximum in the velocity curve
(overshooting) and no change of the acceleration sign.
For desynchronization, the function block "MX_MoveAbsolut" can be used.
To have the slave axis immediately start decelerating when moving to the target
position, the input value for the deceleration, before calling "MX_MoveAbso
lut", must be calculated such that it is smaller than a preset maximum value and
the braking distance corresponds to the residual path up to the target position.
For this purpose, it might be necessary to increase the residual path by one or
more modulo ranges.
A function block is created in which the calculation is carried out. This function
block is processed before "MX_MoveAbsolut".

Position Command Value Delay (as of MPx07)

For master-slave systems (CCD), the position command value of the master is
transmitted to the slave. Due to the transmission and processing time in the
slave, the command value takes effect in the slave later than in the master. To
achieve direct linking, the position command values in the controller should be
the same for both axes.
To achieve time-synchronous control, the position command value in the mas
ter can be transmitted to the controller with a delay (P00456, max. 32 position
clocks).
The slave is controlled with the position command value generator (P00457)
which is without delay. The delay in the slave is compensated in the master by
delaying the position command value controller (P00434).

CCD System Mode for SERCOS II (as of MPx07)

Available as of MPx07V04

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Notes on Application
As implemented for PROFIBUS-DP and DeviceNet with cyclic and acyclic ac
cess, the CCD system mode is also possible for SERCOS II master communi
cation in the CCD master.
This means that the axes of the CCD slaves and the axis in the CCD master
are to behave with the higher-level master communication (master communi
cation in the CCD master) in such a way as if they were a multi-axis device with
up to 8 axes. Each of these slaves (axes) can be addressed in the master
communication dialect of the master communication of the CCD master. In
particular, the following aspects must be considered in greater detail:

Addressing

Parameter channel (acyclic channel)

Real-time data (cyclic channel)

Communication state machine

Timing / synchronization

Error handling

Profiles / profile interpretation (control word / status word)

Additionally, SERCOS III slaves (I/Os, encoders) can be connected to the

SERCOS III interface of the CCD master. These, however, are not visible in the
higher-level master communication.

Extended Axis Functions

Correction of Torque/Force Constant
For IndraDrive devices, the current load of the motor is determined and dis
played on the drive side. The load can be limited by means of the controller.
The unit of the load display and load limit value input can be selected:

Percentage-based, with relation to the continuous motor current or nom

inal motor current

Physically, values in "Nm" (rotary) or "N" (linear)

The load of the motor is determined by means of the measured motor current;
with physical scaling, the controller determines the motor torque or force by
using the currently flowing current for calculating the motor-type-specific torque
or force constant.
If torque/force precision up to approx. +/- 5% is required (e.g., for load limitation)
due to the mechanical axis system or process technology, the controller pro
vides the "correction of torque/force constant". In this case, the motor-typespecific value is corrected depending on the current motor current, the motor
temperature and the average speed.
Due to the downward compatibility of the firmware and possibly un
available parameter values (e.g., for third-party motors), this cor
rection must be separately activated!

Integrated Safety Technology

With MPx06, the integrated safety technology according to EN 954 is still avail
able.
Compared to MPx05, the functions are unchanged.

Integrated Safety Technology: Maximum Value for "Time Interval for

Dynamization of Safety Function Selection" Increased
To avoid hazards, it was agreed upon in the safety concept to carry out dy
namization only in a certain area of the workspace, because changes in

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and Controls

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Notes on Application
selection are impossible during dynamization. The maximum time was in
creased to 6 hours.

Integrated Safety Technology: Minimum Pulse Width of Dynamization

Signal in Safety Technology Channel 2 is Monitored for Excessively
High Value
Monitoring of minimum pulse width of dynamization signal set to 26 ms. Data
in Functional and Application Description is 30ms. A tolerance of 4 ms was
taken into account due to signal jitter.

Measuring Wheel Mode Without Loss of Reference

When switching between motor encoder and measuring wheel encoder took
place, the reference of the measuring wheel encoder and of the motor encoder
always got lost. This cannot be used for some applications. For this reason,
absolute positioning of the drive was no longer possible, because the operation
modes and MLD query the position status. Repeated homing is not accepted.
The loss of reference after encoder switching is quite right, unless the position
data reference to the machine is maintained by other measures. If measures
with regard to the application are ensured which guarantee the position data
reference to the machine in spite of switching in the measuring wheel mode,
the setting in parameter "P00185, Control word of encoder 2 (optional
encoder)", bit 5, can be activated.

Measuring Wheel Mode Without Automatic Initialization of the Measur

ing Wheel Position
Loss of measuring wheel position when switching to velocity control
In parameter "P00185, Control word of encoder 2 (optional encoder)", bit 6, it
is possible to set the behavior for the cases in which the drive is switched to
velocity control or drive enable is switched off.
Bit 6 equal "1" switches off the automatic initialization of the actual position
value of the measuring wheel encoder. The measuring wheel position is only
initialized with regard to the measuring wheel encoder when control is activated.
(S00520, bit 0 switched from "0" to "1")

Optional Device Functions

2MB Data Memory for MPC Supported
With MPx06, the data memory management of MLD was extended. Up to 2MB
of data memory are now available with MPC06 and MPC07 for the "global"
segment. For all other variants the size remains the same. All derivates can
nevertheless still be operated with the same target.

New Bit Access "Axis_Interrupted" for the Axis Data Structure "AxisDa
ta"
In IndraDrive, there are higher-level drive functions which can interrupt motion
command triggering by a higher-level PLC, but cannot abort the command trig
gering. For example, see the functions "Safe Stop 2", "quick stop with probe
detection", etc.
When the active motion function block (DiscreteMotion, Continuous or Syn
chronizedMotion) on the MLD target detects that motion command triggering
was interrupted by a subordinate drive function, the function block aborts its
processing with "CommandAborted"=TRUE.
After the drive function has been terminated, the motion function block remains
in the status "CommandAborted" and all operation modes become active again
(DiscreteMotion modes do not move to the last target position, ContinuousMo
tion and SynchronizedMotion modes follow the command value input again).

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Rexroth IndraDrive | Release Notes

Notes on Application
The bit access is intended to help detect interruptions in motion command trig
gering so that the desired reaction to an interruption can be carried out after
wards.

"MX_INT_fReadPosSIChan2" for Safety-Relevant Use

The function block "MX_INT_fReadPosSIChan2" provides the original position
of P-0-3280 by means of direct access to the actual position value of channel
2. The axis is transmitted to the function as a parameter. As the function has
only one output and the internal implementation is mere memory access, there
is no error output. When the axis is invalid, the position "0" is returned.

Extended Control of SetPositionControlMode via S-0-0346, Bit 4

The function block "MB_SetPositionControlMode" was extended by a "Move
AbsUseCmdPos" input; with this input, it is possible to configure whether the
function block "MC_MoveAbsolute" sets bit 4 of S-0-0346 to "0" or "1" at the
next call (MoveAbsUseCmdPos:=TRUE dedicated point is the interpolator
command position).

Additional Signal Selection Parameters for Master Axis Format Con

verter
When the additional package "IndraMotion MLD" has been enabled in the drive,
the parameters "P-0-1270, PLC Global Register A0" to "P-0-1277, PLC Global
Register A7" are available as signal selection parameters for the master axis
format converter.
The "PLC Global Register parameters" can be used as target parameters for
the configuration of the freely programmable CCD process data.
Example: "P-0-0052, Actual position value of measuring encoder" of the CCD
slave axis x is transmitted via the free process data to the parameter "P-0-1270,
PLC Global Register A0". The parameter P-0-1270 can then be used as input
parameter for the master axis format converter. The measuring encoder posi
tion of the slave axis x can thus be made available as master axis position for
all axes in the CCD ring.

PLC Registers as Data Memories

The parameters P-0-1370 to P-0-1385 are now available in the base package,
too. The registers are intended to be used as data memories, so that machine
data or a version identifier for the current parameter data set, for example, can
be written to the drive.

AxisInterface Function Block

The AxisInterface function block is available in version 06V02 as a high-per
formance firmware implementation.

Configuration Bit for Storage Location of PLC Retain Data

Depending on the available control section configuration (MMC, MD1, MD2 or
CSH01.3), the retain data were stored in different memories. Even if the avail
able MMC was used as active parameter memory, the commands C5500 and
C5400 had to be used when replacing devices to save all retain data on the
MMC.
In parameter "P-0-1367, PLC Global Register A0", the storage location of the
retain data can now be selected by means of bit 9:

Bit 9="0": It is always the retain data of the active storage medium (on
board retain data or MMC) which are used.

Bit 9="1": The retain data on MD1, MD2, HPC03 or HPC04 are used.

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Release Notes | Rexroth IndraDrive

Electric Drives | Bosch Rexroth AG

and Controls

469/505

Notes on Application

Synchronized Data Exchange Between Tasks

For synchronized data exchange between tasks, the library "SysLibSem.lib"
with the corresponding resource management was made available.

"MB_Command" in "MX_PLCopen.lib"
The IEC function block "MB_Command" was included in "MX_PLCopen.lib".

Motion Task in Synchronism With CCD Acts as Motion Task in Syn

chronism With Master Communication Without MLD-M System Mode
Up to now, the motion task in synchronism with master communication and the
motion task in synchronism with CCD had been strictly separated (see de
scription "Task System of MLD"). For turnkey solutions with MLD for 1-8 real
axes, 2 PLC projects were therefore required.
As of MPx06, motion tasks in synchronism with CCD behave like motion tasks
in synchronism with master communication, if the axis in which the PLC project
is loaded does not have activated master communication of SERCOS III mas
ter.

MB_ChangeCamData
The function block "MB_ChangeCamData" supports loading of cam profiles to
the drive parameters intended for this purpose.

CCD-/MLD-M Adjustments for SERCOS III, V1.12

Within the scope of SERCOS III-V1.1.2 introduction for IndraDrive with
SERCOS slave interface in MPx06, several items of the master interface were
adjusted and added in the CCD-/MLD-M function:

Adjustments to new control word/status word structures

New display parameter for IP address implementation

Topology parameterization and monitoring, as well as diagnostic support

(see also actual topology display), are supported

Redundancy in the case of double ring topology is supported

Direct CC connections according to V1.1.2 by means of distributed con

figuration

Adjustments in connection configuration

MLD-M interface adjustments

MLD-M System Mode With 9 Slave Axes

Maximum number of slave axes in MLD-M system mode increased to 9 slave
axes (like in CCD system mode and basic mode).

Size of Code Memory CSH01.3 Increased (as of MPx07)

Available as of MPC-07V04
Size of program memory increased
The program size of MPC07 (with CSH1.3) was increased from 2 MB to 4 MB.
Size of project memory increased
As of MPC-07V04 or MPC06V10: The size of the project or symbol memory is
increased, too, so that, for example, a maximum of 8000 symbols is possible
instead of 4000 symbols (increase from 1MB to 2MB symbol project memory)
Effectiveness
The extension takes effect together with the target of MPx07. MPC06V10 also
benefits from the extension of the project memory.

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Rexroth IndraDrive | Release Notes

Notes on Application

Internal Command Value Box for Sensorless Operation

The command value box for the velocity-controlled drive can be use with sen
sorless control "U/f" or "FXC", too. With position-controlled command value box,
the switching encoder1 or 2, or lagless/with lag error can be triggered via the
parameter "S00520, Control word of axis controller".

P-0-4076 is to be Smaller Than CCD Cycle Time

The parameter "P04076, Field bus: cycle time (Tcyc)" had overwritten the
parameter S00001 and thereby changed the CCD cycle time, as well as the
cycle time of command value processing in the drive. This was not supposed
to happen with PROFIBUS-DP, only with synchronous master communication,
such as CANopen.

Maximum Value of P-0-0329 Increased

The maximum value of 50 ms of "P00329, Smoothing of actual position value
3 of measuring encoder" is not sufficient for certain applications. The maximum
value of P00329 now is 1000 ms.

CCD Axis or Basic Profile Also for SERCOS II

Also implemented as of 05V14!
In the CCD basic mode and CCD system mode, acyclic access to parameters
of remote axes up to now had not been allowed. This applied to all parameter
function blocks, which as a matter of principle could access remote axes, and
the function block "MX_Command".

Master Adjust for the Virtual Axis

In the secondary master mode it is necessary to offset the secondary master
as compared to the primary master. An additive master axis position for the
secondary master is implemented.
The offset can also be achieved with MLD-M by means of the function block
"MB_Phasing".

Compensation of a Probe Dead Time

For each edge of a probe there is a parameter which can compensate a known
dead time.

Handling, Diagnostic and Service Functions

Direct Voltage Input Also for U/f Operation
The function block "MX_INT_DIREKTESPGVORGABE" can also be used for
U/f operation, to operate an induction furnace, for example.

Parameter Set Switching: Changes in the Parameter Groups

The following changes were made for parameter set switching:

"S00446, Ramp reference velocity for acceleration data" is no longer

switchable

"S00222, Spindle positioning speed" was moved from the group "load
gear parameters" to the group "application parameters".

Long Storage Times With Command "Load Basic Parameters"

The time for the execution of the command "load basic parameters" was re
duced.
The command is only signaled to have been completed after the parameters
were stored.

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Release Notes | Rexroth IndraDrive

Electric Drives | Bosch Rexroth AG

and Controls

471/505

Notes on Application

Automatic Loading of Factory Settings

After firmware upgrade, the factory settings are automatically loaded for the
motor-integrated converter (IndraDrive Mi), because there is no control panel
available to confirm the message "PL Load default parameters". It is still nec
essary to enable the functional package.

Extension SERCOS III GDP

Implementation of the required minimum function "GDP Basic" for successful
conformity check of IndraDrive with SERCOS III. The following parameters
were implemented:

S01300.x.3, Vendor Code

S01300.x.5, Vendor Device ID

S01301, List of GDP classes

S01302.x.1, FSP Type

In this context, a SERCOS III device data sheet (SDDML format) is made avail
able for IndraDrive with MPx06 or MPx07 firmware. This is used, among other
things, to configure the connection of the drive to the PLC via a PLC with
SERCOS III interface with the PLC's I/O configurator.

Improvement/Extension Standard Display

For the standard display, another menu branch "easy menu" was implemented
to set the Multi-Ethernet protocol, the IP addresses and the drive address.

Display for Whether Errors Can be Cleared (Status Bit for Error of High
est Priority)
"S01045, SERCOS III: Device Status (S-Dev)", bit 1, displays whether the
current error displayed in "S00390, Diagnostic message number" can be
cleared, i.e. the error situation is currently no longer present.
These errors cannot be cleared by "S00099, C0500 Reset class 1
diagnostics", when the error situation is currently present. This means that the
command "clear error" is executed. The command "S00099, C0500 Reset
class 1 diagnostics" is nevertheless not acknowledged with error, the error bit
in "S01045, SERCOS III: Device Status (S-Dev)", bit 7, remains 1.

WebServer Implementation
Only for MPC
For service cases at OEM (machine manufacturer) or end user (operating com
pany of the machine), an integrated end user service tool is made available on
the basis of an integrated web server and corresponding web applications
which are delivered on the MMC.

Easy Startup Mode for any Operation Mode

The easy startup mode was only possible with the secondary PLC operation
modes. In many cases, it is advantageous to work in the operation modes 0 to
7; therefore, the operation modes 0 to 7 can be parameterized when bit 12 has
been deactivated in "P00120, Control word easy startup".

Quicker Data Handling With MMC

For FTP transfer of a file from the FTP client to the MMC, the data for the MMC
write function are not transmitted in sectors (512 bytes). This requires contin
uous reading processes from the MMC to put these partial sectors and the
existing data together.

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Rexroth IndraDrive | Release Notes

Notes on Application
The data flow from the FTP client is buffered until there are enough write data
with a quantization of 512 bytes. This procedure allows replacing the corre
sponding sectors on the MMC without preceding reading processes.

FWA-Based Drive Parameter Restore and Backup Function

Only for MPC
A backup data directory on the MMC allows updating and saving an installation
configuration of an MLD application; this is done by using standard file services
(FTP, http) and thus without implementing specific protocols and without knowl
edge of the storage locations of the specific data.
In addition, the drive monitors whether the operating data of the drives existing
in an MLD/CCD system are consistent as compared to the backup data; for
example, this allows easily restoring the operating data in case a device is re
placed.

Interfaces Support UTF-8 Format

Generally, texts are no longer internally displayed in the SERCOS ASCII for
mat, but in the UTF-8 format. 40 characters are still available for a parameter
of the "string" type. This means that less text can be displayed when such
characters are used which require more than 1 character (e.g., ).
Via IndraWorks Engineering, the texts are displayed in the UTF-8 format.
For SERCOS II, PROFIBUS, DeviceNet and CANopen, the texts are converted
to SERCOS ASCII.
With MLD, the texts are still converted to ANSI code.

Simulation Mode ("Motion Without Movement")

It is possible to move the axis in a simulation mode; i.e. the actual position value
is simulated on the basis of the position command value. There is no motor
required for the simulation mode. The simulation mode is activated via
"P00399, Configuration of simulation mode", bit 0="1". When switching to the
operation mode, the axis is switched to the status permanently parked axis. The
SafeMotion goes to the safely parked axis state.

EIDNs Supported
As of MPx06, all parameter numbers are displayed as 32-bit values (EIDNs).
The syntax for EIDNs is according to this pattern:
< IDN>.<SI>.<SE>

IDN: 4096 IDNs each are possible in the parameter ranges S and P.

S/P: As before, we distinguish standard IDNs and product-specific

IDNs.

PS: There can be up to 8 parameter sets for each parameter.

SI: Identical types of structure elements can be indexed via "SI". The range
of values is from 0 to 255. This allows, for example, indexing several com
munication channels of the same structure.

SE: To address the individual structure elements of an ident number.

SE 0..127 are predefined (like S parameters before),

SE 128..255 are manufacturer-specific (like P parameters before).

Thus, 16bit IDNs can also be mapped as 32bit IDNs. The ident number
"S00001" in 16bit syntax is equivalent to "S00001.0.0" in EIDN syntax. This
ensures the compatibility with the world of 16bit IDNs.

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Release Notes | Rexroth IndraDrive

Electric Drives | Bosch Rexroth AG

and Controls

473/505

Notes on Application
Cyclic operation with 16bit field buses at EIDN IndraDrive is possible. In im
portant cases, alias parameters for EIDNs have been created as 16bit IDNs
(e.g., P04089.0.1 alias P03210).

13.1.2

Incompatible Functional Modifications

System Overview
MPC06 and MPC07 no Longer Support CSH01.2
As of MPH06V08, CSH01.2C is no longer supported.
The control section type CSH01.2C is replaced by CSH01.3C which is of clearly
higher performance and equipped with the hardware-side measures for con
version according to safety technology standard.

Master Communication
Change in Communication Profile According to SERCOS III V1.1.2
Incompatible changes as compared to SERCOS III communication profile V1.0.
The SERCOS communication profile was changed from V1.0 to V1.1.2. The
following modifications and extensions were implemented:

Extension and detailing of definition for synchronous connections

Detailing and modification of synchronization function

Redefinition / revision of interface/slave description

Redefinition / revision of function and version description

Redefinition / revision of SERCOS III diagnosis parameters

Logical separation of application, connection and communication layers

Redefinition / extension of connection configuration

Redefinition / extension of topology status

Modifications in drive control word

Modifications in drive status word

Redefinition / extension of timing parameters

Implementation of remote address assignment

Together with the implementation of SERCOS V1.1, the parameter model was
extended from 2byte to 4byte IDN addressing (implementation of EIDN spec
ification).

Ethernet/IP
Ethernet/IP via standard engineering interface (like for MPH05 with CSH1.2) is
no longer supported!

Master Communication Switch-Off

The master communication cannot be switched off any more in P04088, bits
14 and 15.
Master communication is now switched off together with the protocol selection
for master communication in P04089.0.1.

Drive Control
PWM Frequency Switching Depending on Load
Within the scope of PWM frequency switching depending on velocity, the acti
vation of the switching depending on load was changed, too.

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Rexroth IndraDrive | Release Notes

Notes on Application
Activation no longer takes place in parameter P00556, but in P00045, Con
trol word of current controller.
The possibilities of PWM switching were extended. Switching from
16kHz8kHz and 8kHz4 kHz is additionally available.

Operation Modes
CCD Adjusted to SCP V1.1.2
The CCD communication was adjusted to SERCOS III V1.1.2. Always use the
same firmware version in master and slave.
This concerns the following aspects:

Modified/new control words/status words (S-/C-Dev, C-Con, S-/C-Res)

Parameterization of MDT/AT connections via connection parameter

S01050 SI = 0/1

Connection 0/1 existing

Ring recovery / redundancy in CCD master supported

Slave IP addresses made available for HMI (end user tool)

It should be possible to operate SERCOS III slaves with new hardware

(MPx16) at the CCD master with MPx06

Extended Axis Functions

Integrated Safety Technology
The integrated safety technology was certified for MPx07 according to the
IEC 61508 standard.
Operating MPx07 with the integrated safety technology requires special control
sections with the safety technology option "L2" or "S2".

Integrated Safety Technology

(Conversion According to Safety
Technology Standard)

CSH01.1. S2..

CSH01.1. L2..

CSH01.3. S2..

CSH01.3. L2..

CDB01.1. S2..

CDB01.1. L2..

Names of parameters and diagnostic messages were adjusted to the new terms
of the safety functions.
Parameter verification was implemented.
The acceptance test was adjusted to the requirements of IEC 61508.
To comply with the standard, a risk assessment of motors and encoders must
be made.

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Release Notes | Rexroth IndraDrive

Electric Drives | Bosch Rexroth AG

and Controls

475/505

Notes on Application
Up to MPx06

As of MPx07
The integrated safety technology is stateof-the-art for safety-relevant control units
in the field of high-dynamic drives.

The integrated safety technology is state-

of-the-art for safety-relevant control units
of category 3 according to EN 9541 in the
field of high-dynamic drives.

Name of the safety function up to MPx06

"Safe Motion": Category 3 PL d ac

cording to EN ISO 13849-1 and SIL
2 according to EN 62061
"Safe Torque Off": Category 3 PL d/
e according to EN ISO 13849-1 and
SIL 2/SIL 3 according to EN 62061

Name of the safety function as of MPx07 (IEC 61508)

Safety related starting lockout

AS

Safe torque off

STO

Safety related drive interlock

ASP

Safe stop 1 (Emergency stop)

SS1 ES

Safety related standstill

SH

Safe stop 1

SS1

Safety related operational stop

SBH

Safe stop 2

SS2

Safety related maximum speed

Safe maximum speed

SMS

Safety related reduced speed

SG

Safely-limited speed

SLS

Safety related limited increment

SM

Safely-limited increment

SLI

Safety related direction of motion

SD

Safe direction

SDI

Safety related limited absolute position

SL

Safely-monitored position

SMP

Safety related limited absolute end position

Safely-limited position

SLP

Safety related end position, positive

Safely-limited position, positive

Safety related end position, negative

Safely-limited position, negative

Safety related homing procedure

Safe homing procedure

Safety related braking and holding system

Safe braking and holding system

SBS

Safety related monitored deceleration

Safely-monitored deceleration

SMD

Communication via safety bus

Safe communication

SCO

Safety related control of a door locking device

Safe door locking

SDL

Safety related diagnostic outputs

Safe diagnostic outputs

Safety related inputs/outputs

Safe inputs/outputs

Safety related parking axis

Safe parking axis

Axis in stand-alone form

Single-axis acknowledgment

Safety related braked standstill

SGH

Safe stop 1 (braked)

SS1 B

Safe stop 1 (braked Emergency stop)

SS1 BES

Fig.13-1:

Safety Functions

SIO

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Bosch Rexroth AG | Electric Drives

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Rexroth IndraDrive | Release Notes

Notes on Application

Name of the optional safety technology modules up to MPx06

Name of the optional safety technology modules as of MPx07

(IEC 61508)

Safety technology I/O

S1

Safe Motion

S2

Starting lockout

L1

Safe Torque Off

L2

Fig.13-2:

Optional Safety Technology Modules

Name of the safety states / displays up to MPx06

Name of the safety states / displays as of MPx07 (IEC 61508)

Normal operation

NO

Normal operation

NO

Special mode

SO

Special mode

SM

Special mode "safety related halt"

Special mode "safe standstill"

Starting lockout

AS

Safe torque off

STO

Drive interlock

ASP

Safe stop 1 (Emergency stop)

SS1 ES

Safety related standstill

SH

Safe stop 1

SS1

Safety related operational stop

SBH

Safe stop 2

SS2

Special mode "safety related motion"

SBB

Special mode "safe motion"

SMM

Fig.13-3:

Safety States / Displays

Name of the safety inputs as of MPx07 (IEC 61508)

Name of the safety inputs up to MPx06

Mode selector

BA

Mode selector

MS

Enabling control

ZT

Enabling control

EC

Drive interlock

ASP

SS1 (Emergency stop) switch

ES

Home switch

REF

Home switch

REF

Safety switch

S1/S2

Safety switch

S1/S2

Fig.13-4:

Safety Inputs
Name of the hardware inputs as of MPx07 (IEC 61508)

Name of the hardware inputs up to MPx06

Supply for acknowledgment

ASQ

Supply for acknowledgment

STO Q

Acknowledgment

ASQ1

Acknowledgment

STO Q1

Inverted acknowledgment

ASQ2

Inverted acknowledgment

STO Q2

Control signal starting lockout assignment A

AS A

Control signal Safe torque off assignment A

STO A

Control signal starting lockout assignment B

AS B

Control signal Safe torque off assignment B

STO B

Inverted control signal starting lockout

AS n

Inverted control signal Safe torque off

STO n

Fig.13-5:

Hardware Inputs

13.2

New or Modified Parameters

13.2.1

New Parameters
The following new parameters were implemented in firmware version MPx07:

P-0-0399, Configuration of simulation mode

P-0-0446, Thermal motor load

P-0-0447, Motor shaft power

P-0-0448, Temperature-dependent torque/force coefficient

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and Controls

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Notes on Application

P-0-0449, Speed-dependent torque/force coefficient

P-0-0450, Current torque/force constant

P-0-0456, Position command value delay

P-0-0457, Position command value generator

P-0-0552, Input holding brake current monitoring

P-0-0558, Drive Halt configuration

P-0-0580, Motor frequency

P-0-0602, FXC: Minimum no-load current

P-0-0641, Interpolation cmd value average value filter time constant

P-0-0665, C6500 Kommando Parameter auf MMC sichern

P-0-0666, C6600 Kommando Parameter von MMC wiederherstellen

P-0-0668, MMC backup function configuration

P-0-0669, MMC backup function status

P-0-0817, Amplifier temperature 3

P-0-0851, Short-time energy counter

P-0-0928, Additive master axis position, secondary master

P-0-0929, Change velocity of add. master axis posit., secondary master

P-0-0930, Change accel. of add. master axis posit., secondary master

P-0-0931, Synchronous position, secondary master

P-0-0932, Synchronization range, secondary master

P-0-1610.0.21, CCD: Slave addresses at end of line

P-0-1610.0.3, CCD: Actual topology

P-0-1610.0.30, CCD: Diagnostic message text

P-0-1610.0.31, CCD: Diagnosis code

P-0-1620.0.21, CCD: Command Close ring

P-0-1620.0.3, CCD: Command topology

P-0-1621.0.1, CCD: Slave address in high level network

P-0-1621.0.10, CCD: Master comm. C5200 Comm. phase 4 transition

check

P-0-1621.0.11, CCD: Mater comm. master control word

P-0-1621.0.12, CCD: Master comm. drive status

P-0-1621.0.13, CCD: S2 Allocation of real-time control bit 1

P-0-1621.0.14, CCD: S2 Allocation of real-time control bit 2

P-0-1621.0.15, CCD: S2 Allocation of real-time status bit 1

P-0-1621.0.16, CCD: S2 Allocation of real-time status bit 2

P-0-1621.0.17, CCD: S2 Bit number allocation of real-time control bit 1

P-0-1621.0.18, CCD: S2 Bit number allocation of real-time control bit 2

P-0-1621.0.19, CCD: S2 Bit number allocation of real-time status bit 1

P-0-1621.0.2, CCD: S2 AT Transmission starting time (T1)

P-0-1621.0.20, CCD: S2 Bit number allocation of real-time status bit 2

P-0-1621.0.21, CCD: Master comm. IDN-list of invalid operation data for

CP2

P-0-1621.0.23, CCD: Master comm. diagnosis

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Bosch Rexroth AG | Electric Drives

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Rexroth IndraDrive | Release Notes

Notes on Application

P-0-1621.0.3, CCD: S2 Position of data record in MDT

P-0-1621.0.4, CCD: SERCOS Telegram type parameter

P-0-1621.0.5, CCD: Master comm. configuration list of AT

P-0-1621.0.6, CCD: Master comm. configuration list of MDT

P-0-1621.0.7, CCD: S2 Slave arrangement (SLKN)

P-0-1621.0.8, CCD: S2 Mask class 3 diagnostics

P-0-1621.0.9, CCD: Master comm. C0100 Comm. phase 3 transition

check

P-0-1630.0.1, CCD: Slave IP address

P-0-1630.0.2, CCD: Device status word (S-Dev)

P-0-1630.0.20, CCD: Resource-Status (S-Res)

P-0-1630.0.3, CCD: Connection-Control #0 (C-Con)

P-0-1645.0.1, CCD connection: Configuration

P-0-1645.0.10, CCD connection: Producer cycle time

P-0-1645.0.11, CCD connection: Allowed losses of producer data

P-0-1645.0.12, CCD connection: Error counter data losses

P-0-1645.0.2, CCD connection: Connection number

P-0-1645.0.20, CCD connection: IDN allocation of real-time bits

P-0-1645.0.21, CCD connection: Bit number allocation of real-time bits

P-0-1645.0.3, CCD connection: Telegram assignment

P-0-1645.0.4, CCD connection: Max. length of connection

P-0-1645.0.5, CCD connection: Current connection length

P-0-1645.0.6, CCD connection: Configuration list

P-0-1645.0.8, CCD connection: Connection control (C-Con)

P-0-1660.0.2, CCD: Device control word (C-Res)

P-0-1660.0.20, CDD: Resource-Control (C-Res)

P-0-1660.0.3, CCD: Conection-Control #1 (C-Con)

P-0-1820, CCD: Command value data container 1, Master 2Byte

P-0-1821, CCD: Command value data container 1, Slave 1 2Byte

P-0-1822, CCD: Command value data container 1, Slave 2 2Byte

P-0-1823, CCD: Command value data container 1, Slave 3 2Byte

P-0-1824, CCD: Command value data container 1, Slave 4 2Byte

P-0-1825, CCD: Command value data container 1, Slave 5 2Byte

P-0-1826, CCD: Command value data container 1, Slave 6 2Byte

P-0-1827, CCD: Command value data container 1, Slave 7 2Byte

P-0-1828, CCD: Command value data container 1, Slave 8 2Byte

P-0-1829, CCD: Command value data container 1, Slave 9 2Byte

P-0-1830, CCD: Command value data container 2, Master 2Byte

P-0-1831, CCD: Command value data container 2, Slave 1 2Byte

P-0-1832, CCD: Command value data container 2, Slave 2 2Byte

P-0-1833, CCD: Command value data container 2, Slave 3 2Byte

P-0-1834, CCD: Command value data container 2, Slave 4 2Byte

P-0-1835, CCD: Command value data container 2, Slave 5 2Byte

Courtesy of CMA/Flodyne/Hydradyne Motion Control Hydraulic Pneumatic Electrical Mechanical (800) 426-5480 www.cmafh.com

Release Notes | Rexroth IndraDrive

Electric Drives | Bosch Rexroth AG

and Controls

479/505

Notes on Application

P-0-1836, CCD: Command value data container 2, Slave 6 2Byte

P-0-1837, CCD: Command value data container 2, Slave 7 2Byte

P-0-1838, CCD: Command value data container 2, Slave 8 2Byte

P-0-1839, CCD: Command value data container 2, Slave 9 2Byte

P-0-1840, CCD: Command value data container 3, Master 2Byte

P-0-1841, CCD: Command value data container 3, Slave 1 2Byte

P-0-1842, CCD: Command value data container 3, Slave 2 2Byte

P-0-1850, CCD: Command value data container 4, Master 2Byte

P-0-1851, CCD: Command value data container 4, Slave 1 2Byte

P-0-1852, CCD: Command value data container 4, Slave 2 2Byte

P-0-1853, CCD: Command value data container 4, Slave 3 2Byte

P-0-1854, CCD: Command value data container 4, Slave 4 2Byte

P-0-1855, CCD: Command value data container 4, Slave 5 2Byte

P-0-1856, CCD: Command value data container 4, Slave 6 2Byte

P-0-1857, CCD: Command value data container 4, Slave 7 2Byte

P-0-1858, CCD: Command value data container 4, Slave 8 2Byte

P-0-1859, CCD: Command value data container 4, Slave 9 2Byte

P-0-1860, CCD: Actual value data container 1, Master 2Byte

P-0-1861, CCD: Actual value data container 1, Slave 1 2Byte

P-0-1862, CCD: Actual value data container 1, Slave 2 2Byte

P-0-1863, CCD: Actual value data container 1, Slave 3 2Byte

P-0-1864, CCD: Actual value data container 1, Slave 4 2Byte

P-0-1865, CCD: Actual value data container 1, Slave 5 2Byte

P-0-1866, CCD: Actual value data container 1, Slave 6 2Byte

P-0-1867, CCD: Actual value data container 1, Slave 7 2Byte

P-0-1868, CCD: Actual value data container 1, Slave 8 2Byte

P-0-1869, CCD: Actual value data container 1, Slave 9 2Byte

P-0-1870, CCD: Actual value data container 2, Master 2Byte

P-0-1871, CCD: Actual value data container 2, Slave 1 2Byte

P-0-1872, CCD: Actual value data container 2, Slave 2 2Byte

P-0-1873, CCD: Actual value data container 2, Slave 3 2Byte

P-0-1874, CCD: Actual value data container 2, Slave 4 2Byte

P-0-1875, CCD: Actual value data container 2, Slave 5 2Byte

P-0-1876, CCD: Actual value data container 2, Slave 6 2Byte

P-0-1877, CCD: Actual value data container 2, Slave 7 2Byte

P-0-1878, CCD: Actual value data container 2, Slave 8 2Byte

P-0-1879, CCD: Actual value data container 2, Slave 9 2Byte

P-0-1880, CCD: Actual value data container 3, Master 2Byte

P-0-1881, CCD: Actual value data container 3, Slave 1 2Byte

P-0-1882, CCD: Actual value data container 3, Slave 2 2Byte

P-0-1883, CCD: Actual value data container 3, Slave 3 2Byte

P-0-1884, CCD: Actual value data container 3, Slave 4 2Byte

P-0-1885, CCD: Actual value data container 3, Slave 5 2Byte

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Bosch Rexroth AG | Electric Drives

and Controls

Rexroth IndraDrive | Release Notes

Notes on Application

P-0-1886, CCD: Actual value data container 3, Slave 6 2Byte

P-0-1887, CCD: Actual value data container 3, Slave 7 2Byte

P-0-1888, CCD: Actual value data container 3, Slave 8 2Byte

P-0-1889, CCD: Actual value data container 3, Slave 9 2Byte

P-0-1890, CCD: Actual value data container 4, Master 2Byte

P-0-1891, CCD: Actual value data container 4, Slave 1 2Byte

P-0-1892, CCD: Actual value data container 4, Slave 2 2Byte

P-0-1893, CCD: Actual value data container 4, Slave 3 2Byte

P-0-1894, CCD: Actual value data container 4, Slave 4 2Byte

P-0-1895, CCD: Actual value data container 4, Slave 5 2Byte

P-0-1896, CCD: Actual value data container 4, Slave 6 2Byte

P-0-1897, CCD: Actual value data container 4, Slave 7 2Byte

P-0-1898, CCD: Actual value data container 4, Slave 8 2Byte

P-0-1899, CCD: Actual value data container 4, Slave 9 2Byte

P-0-2300, List of 32-bit IDNs

P-0-2301, List of 16-bit alias IDNs

P-0-3055, Maximum motor torque/force, encoder memory

P-0-3056, Nominal motor torque/force, encoder memory

P-0-3057, Speed-dependent torque/force coefficient, encoder memory

P-0-3058, Temperature-dependent torque/force coefficient, enc. memory

P-0-3333, Code word for tests

P-0-4056, Thermal coefficients HCS04

P-0-4089.0.1, Master communication: Protocol

P-0-4089.0.10, Master communication: MAC address device

P-0-4089.0.11, Master communication: MAC address Port1

P-0-4089.0.12, Master communication: MAC address Port2

P-0-4089.0.127, Master communication: Master debugging

P-0-4089.0.13, Master communication: IP address

P-0-4089.0.14, Master communication: Network mask

P-0-4089.0.15, Master communication: Gateway address

P-0-4089.0.2, Master communication: Device name

S-0-0440, Marker position feedback 1

S-0-0441, Marker position feedback 2

S-0-0442, Counter marker position feedback 1

S-0-0443, Counter marker position feedback 2

S-0-0524, Dead time compensation, positive edge, probe 1

S-0-0525, Dead time compensation, negative edge, probe 1

S-0-0526, Dead time compensation, positive edge, probe 2

S-0-0527, Dead time compensation, negative edge, probe 2

S-0-0533, Nominal torque/force of motor

S-0-0534, Maximum torque/force of motor

S-0-1000, SERCOS III: SCP Type & Version

S-0-1027.0.1, SERCOS III: Requested MTU

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Electric Drives | Bosch Rexroth AG

and Controls

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Notes on Application

13.2.2

S-0-1027.0.2, SERCOS III: Effective MTU

S-0-1035, SERCOS III: Error counter Port1 & Port2

S-0-1041, SERCOS III: AT Command value valid time (t9)

S-0-1044, SERCOS III: Device Control (C-Dev)

S-0-1045, SERCOS III: Device Status (S-Dev)

S-0-1046, SERCOS III: List of SERCOS addresses in device

S-0-1050.0.1, SIII-Connection: Connection setup

S-0-1050.0.10, SIII-Connection: Producer cycle time

S-0-1050.0.11, SIII-Connection: Allowed data losses

S-0-1050.0.12, SIII-Connection: Error counter data losses

S-0-1050.0.2, SIII-Connection: Connection number

S-0-1050.0.20, SIII-Connection: IDN allocation of real-time bit

S-0-1050.0.21, SIII-Connection: Bit allocation of real-time bit

S-0-1050.0.3, SIII-Connection: Telegram assignment

S-0-1050.0.4, SIII-Connection: Max. length of connection

S-0-1050.0.5, SIII-Connection: Current length of connection

S-0-1050.0.6, SIII-Connection: Configuration list

S-0-1050.0.8, SIII-Connection: Connection control (C-Con)

S-0-1051, SIII-Connection: Image of connection setups

S-0-1100.0.1, Diagnostic counter sent SMP fragments

S-0-1100.0.2, Diagnostic counter received SMP fragments

S-0-1100.0.3, Diagnostic counter dropped SMP fragments

S-0-1101.0.1, SMP Container Data

S-0-1101.0.2, List of session identifiers

S-0-1101.0.3, List of session priorities

S-0-1300.0.3, Vendor Code

S-0-1300.0.5, Vendor Device ID

S-0-1301, List of GDP classes

S-0-1302.0.1, FSP Type

Modified Parameters
The following parameters were extended or modified in firmware version
MPx07:

P-0-0001, Switching frequency of the power output stage

P-0-0045, Control word of current controller

P-0-0072, Cam table 1

P-0-0073, Cam distance 2

P-0-0086, Configuration word synchronous operation modes

P-0-0088, Control word synchronization modes

P-0-0089, Status word synchronization modes

P-0-0092, Cam table 2

P-0-0093, Cam distance

P-0-0094, Cam switch angle

P-0-0119, Best possible deceleration

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Bosch Rexroth AG | Electric Drives

and Controls

Rexroth IndraDrive | Release Notes

Notes on Application

P-0-0120, Control word easy startup

P-0-0144, Cam distance switch angle

P-0-0159, Slave drive feed travel

P-0-0185, Control word of encoder 2 (optional encoder)

P-0-0227, Cam table, access angle

P-0-0328, Type of position encoder for measuring encoder

P-0-0522, Control word for commutation setting

P-0-0542, C2000 Command Release holding brake

P-0-0543, C3800 Command Apply holding brake

P-0-0544, C3900 Command Holding brake resurfacing

P-0-0545, Test torque for releasing holding system

P-0-0546, Starting torque for releasing holding system

P-0-0549, Oper. hours control sec. at last succ. holding system check

P-0-0550, Time interval holding system check

P-0-0556, Config word of axis controller

P-0-0691, Additive position command value, process loop

P-0-0700, MotionProfile, master axis switching position

P-0-0701, Motion step 1, slave axis initial position

P-0-0702, MotionProfile, diagnosis, set 0

P-0-0703, Number of motion steps, set 0

P-0-0704, Master axis velocity, set 0

P-0-0705, List of master axis initial positions, set 0

P-0-0706, List of motion laws, set 0

P-0-0707, List of distances, set 0

P-0-0708, List of slave axis velocities, set 0

P-0-0709, MotionProfile, diagnosis, set 1

P-0-0710, Number of motion steps, set 1

P-0-0711, Master axis velocity, set 1

P-0-0712, List of master axis initial positions, set 1

P-0-0713, List of motion laws, set 1

P-0-0714, List of distances, set 1

P-0-0715, List of slave axis velocities, set 1

P-0-0754, Command value cycle

P-0-0755, Gear reduction

P-0-0780, Cam table 3

P-0-0781, Cam table 4

P-0-0782, Cam table 5

P-0-0783, Cam table 6

P-0-0784, Cam table 7

P-0-0785, Cam table 8

P-0-1044, Master comm. engineering over IP: Status IP communication

P-0-1139, Cogging torque compensation adaption factor

P-0-1222, Velocity command filter

Courtesy of CMA/Flodyne/Hydradyne Motion Control Hydraulic Pneumatic Electrical Mechanical (800) 426-5480 www.cmafh.com

Release Notes | Rexroth IndraDrive

Electric Drives | Bosch Rexroth AG

and Controls

483/505

Notes on Application

P-0-1316, PLC Global Register G16

P-0-1317, PLC Global Register G17

P-0-1318, PLC Global Register G18

P-0-1319, PLC Global Register G19

P-0-1320, PLC Global Register G20

P-0-1321, PLC Global Register G21

P-0-1322, PLC Global Register G22

P-0-1323, PLC Global Register G23

P-0-1324, PLC Global Register G24

P-0-1325, PLC Global Register G25

P-0-1326, PLC Global Register G26

P-0-1327, PLC Global Register G27

P-0-1328, PLC Global Register G28

P-0-1329, PLC Global Register G29

P-0-1330, PLC Global Register G30

P-0-1331, PLC Global Register G31

P-0-1367, PLC configuration

P-0-1530, Engineering: MAC address

P-0-1531, Engineering: IP address

P-0-1532, Engineering: Network mask

P-0-1533, Engineering: Gateway address

P-0-1544, Engineering: Status IP communication

P-0-1629, CCD: configuration compact I/Os

P-0-1651, CCD: master control word, slave 1

P-0-1652, CCD: master control word, slave 2

P-0-1653, CCD: master control word, slave 3

P-0-1654, CCD: master control word, slave 4

P-0-1655, CCD: master control word, slave 5

P-0-1656, CCD: drive status word, slave 5

P-0-1657, CCD: master control word, slave 7

P-0-1658, CCD: master control word, slave 8

P-0-1659, CCD: master control word, slave 9

P-0-1661, CCD: drive status word, slave 1

P-0-1662, CCD: drive status word, slave 2

P-0-1663, CCD: drive status word, slave 3

P-0-1664, CCD: drive status word, slave 4

P-0-1665, CCD: drive status word, slave 5

P-0-1666, CCD: drive status word, slave 6

P-0-1667, CCD: drive status word, slave 7

P-0-1668, CCD: drive status word, slave 8

P-0-1669, CCD: drive status word, slave 9

P-0-1730, CCD: Command value data container 1, Master 4Byte

P-0-1731, CCD: Command value data container 1, Slave 1 4Byte

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Bosch Rexroth AG | Electric Drives

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Rexroth IndraDrive | Release Notes

Notes on Application

P-0-1732, CCD: Command value data container 1, Slave 2 4Byte

P-0-1733, CCD: Command value data container 1, Slave 3 4Byte

P-0-1734, CCD: Command value data container 1, Slave 4 4Byte

P-0-1735, CCD: Command value data container 1, Slave 5 4Byte

P-0-1736, CCD: Command value data container 1, Slave 6 4Byte

P-0-1737, CCD: Command value data container 1, Slave 7 4Byte

P-0-1738, CCD: Command value data container 1, Slave 8 4Byte

P-0-1739, CCD: Command value data container 1, Slave 9 4Byte

P-0-1740, CCD: Command value data container 2, Master 4Byte

P-0-1741, CCD: Command value data container 2, Slave 1 4Byte

P-0-1742, CCD: Command value data container 2, Slave 2 4Byte

P-0-1743, CCD: Command value data container 2, Slave 3 4Byte

P-0-1744, CCD: Command value data container 2, Slave 4 4Byte

P-0-1745, CCD: Command value data container 2, Slave 5 4Byte

P-0-1746, CCD: Command value data container 2, Slave 6 4Byte

P-0-1747, CCD: Command value data container 2, Slave 7 4Byte

P-0-1748, CCD: Command value data container 2, Slave 8 4Byte

P-0-1749, CCD: Command value data container 2, Slave 9 4Byte

P-0-1750, CCD: Command value data container 3, Master 4Byte

P-0-1751, CCD: Command value data container 3, Slave 1 4Byte

P-0-1752, CCD: Command value data container 3, Slave 2 4Byte

P-0-1753, CCD: Command value data container 3, Slave 3 4Byte

P-0-1754, CCD: Command value data container 3, Slave 4 4Byte

P-0-1755, CCD: Command value data container 3, Slave 5 4Byte

P-0-1756, CCD: Command value data container 3, Slave 6 4Byte

P-0-1757, CCD: Command value data container 3, Slave 7 4Byte

P-0-1758, CCD: Command value data container 3, Slave 8 4Byte

P-0-1759, CCD: Command value data container 3, Slave 9 4Byte

P-0-1760, CCD: Command value data container 4, Master 4Byte

P-0-1761, CCD: Command value data container 4, Slave 1 4Byte

P-0-1762, CCD: Command value data container 4, Slave 2 4Byte

P-0-1763, CCD: Command value data container 4, Slave 3 4Byte

P-0-1764, CCD: Command value data container 4, Slave 4 4Byte

P-0-1765, CCD: Command value data container 4, Slave 5 4Byte

P-0-1766, CCD: Command value data container 4, Slave 6 4Byte

P-0-1767, CCD: Command value data container 4, Slave 7 4Byte

P-0-1768, CCD: Command value data container 4, Slave 8 4Byte

P-0-1769, CCD: Command value data container 4, Slave 9 4Byte

P-0-1770, CCD: Actual value data container 1, Master 4Byte

P-0-1771, CCD: Actual value data container 1, Slave 1 4Byte

P-0-1772, CCD: Actual value data container 1, Slave 2 4Byte

P-0-1773, CCD: Actual value data container 1, Slave 3 4Byte

P-0-1774, CCD: Actual value data container 1, Slave 4 4Byte

Courtesy of CMA/Flodyne/Hydradyne Motion Control Hydraulic Pneumatic Electrical Mechanical (800) 426-5480 www.cmafh.com

Release Notes | Rexroth IndraDrive

Electric Drives | Bosch Rexroth AG

and Controls

485/505

Notes on Application

P-0-1775, CCD: Actual value data container 1, Slave 5 4Byte

P-0-1776, CCD: Actual value data container 1, Slave 6 4Byte

P-0-1777, CCD: Actual value data container 1, Slave 7 4Byte

P-0-1778, CCD: Actual value data container 1, Slave 8 4Byte

P-0-1779, CCD: Actual value data container 1, Slave 9 4Byte

P-0-1780, CCD: Actual value data container 2, Master 4Byte

P-0-1781, CCD: Actual value data container 2, Slave 1 4Byte

P-0-1782, CCD: Actual value data container 2, Slave 2 4Byte

P-0-1783, CCD: Actual value data container 2, Slave 3 4Byte

P-0-1784, CCD: Actual value data container 2, Slave 4 4Byte

P-0-1785, CCD: Actual value data container 2, Slave 5 4Byte

P-0-1786, CCD: Actual value data container 2, Slave 6 4Byte

P-0-1787, CCD: Actual value data container 2, Slave 7 4Byte

P-0-1788, CCD: Actual value data container 2, Slave 8 4Byte

P-0-1789, CCD: Actual value data container 2, Slave 9 4Byte

P-0-1790, CCD: Actual value data container 3, Master 4Byte

P-0-1791, CCD: Actual value data container 3, Slave 1 4Byte

P-0-1792, CCD: Actual value data container 3, Slave 2 4Byte

P-0-1793, CCD: Actual value data container 3, Slave 3 4Byte

P-0-1794, CCD: Actual value data container 3, Slave 4 4Byte

P-0-1795, CCD: Actual value data container 3, Slave 5 4Byte

P-0-1796, CCD: Actual value data container 3, Slave 6 4Byte

P-0-1797, CCD: Actual value data container 3, Slave 7 4Byte

P-0-1798, CCD: Actual value data container 3, Slave 8 4Byte

P-0-1799, CCD: Actual value data container 3, Slave 9 4Byte

P-0-1800, CCD: Actual value data container 4, Master 4Byte

P-0-1801, CCD: Actual value data container 4, Slave 1 4Byte

P-0-1802, CCD: Actual value data container 4, Slave 2 4Byte

P-0-1803, CCD: Actual value data container 4, Slave 3 4Byte

P-0-1804, CCD: Actual value data container 4, Slave 4 4Byte

P-0-1805, CCD: Actual value data container 4, Slave 5 4Byte

P-0-1806, CCD: Actual value data container 4, Slave 6 4Byte

P-0-1807, CCD: Actual value data container 4, Slave 7 4Byte

P-0-1808, CCD: Actual value data container 4, Slave 8 4Byte

P-0-1809, CCD: Actual value data container 4, Slave 9 4Byte

P-0-1843, CCD: Command value data container 3, Slave 3 2Byte

P-0-1844, CCD: Command value data container 3, Slave 4 2Byte

P-0-1845, CCD: Command value data container 3, Slave 5 2Byte

P-0-1846, CCD: Command value data container 3, Slave 6 2Byte

P-0-1847, CCD: Command value data container 3, Slave 7 2Byte

P-0-1848, CCD: Command value data container 3, Slave 8 2Byte

P-0-1849, CCD: Command value data container 3, Slave 9 2Byte

P-0-2216, Parameter set switching, configuration

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Bosch Rexroth AG | Electric Drives

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Rexroth IndraDrive | Release Notes

Notes on Application

P-0-4071, Field bus: length of cyclic command value data channel

P-0-4088, Master communication: Drive configuration

S-0-0099, C0500 Reset class 1 diagnostics

S-0-0115, Position feedback 2 type

S-0-0138, Bipolar acceleration limit value

S-0-0148, C0600 Drive-controlled homing procedure command

S-0-0163, Weight counterbalance

S-0-0222, Spindle positioning speed

S-0-0277, Position feedback 1 type

S-0-0292, List of supported operation modes

S-0-0446, Ramp reference velocity for acceleration data

S-0-1019, Master comm. engineering over IP: MAC address

S-0-1020, Master comm. engineering over IP: IP address

S-0-1021, Master comm. engineering over IP: Network mask

S-0-1022, Master comm. engineering over IP: Gateway address

S-0-1024, C5300 SERCOS III: SYNC delay measuring procedure

command

Modified due to Adjustment of Documentation

P-0-0103, Time interval of forced dynamization

P-0-3210, Safety technology configuration

P-0-3211, Safety technology I/O configuration list, channel 2

P-0-3212, Safety technology control word, channel 1

P-0-3213, Safety technology operating status

P-0-3215, Selected safety technology operating status

P-0-3216, Active safety technology signals

P-0-3232, Standstill window for safe direction

P-0-3233, Velocity threshold for safe standstill

P-0-3234, Safe maximum speed

P-0-3239, Configuration of global safety technology functions

P-0-3240, Configuration of safe motion 1

P-0-3250, Configuration of safe motion 2

P-0-3260, Configuration of safe motion 3

P-0-3270, Configuration of safe motion 4

P-0-3282, Safely-monitored deceleration

P-0-3296, Safety technology field bus control word

P-0-3313, C5800 Command Apply redundant holding brake

P-0-3314, C5900 Command Resurfacing of redundant holding brake

Modified due to Name Adjustment for Conversion According to Safety Tech
nology Standard (IEC 61508)

P-0-0101, Configuration for STO selector

P-0-0102, Oper. hours power section at last activation of STO

P-0-0106, Operating status of STO

P-0-3219, Extended safety technology diagnosis

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Electric Drives | Bosch Rexroth AG

and Controls

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Notes on Application

P-0-3226, Delay Safely-monitored deceleration

P-0-3230, Monitoring window for safe stop 2

P-0-3235, Safely-limited position, positive

P-0-3236, Safely-limited position, negative

P-0-3241, Safely-monitored position 1, positive

P-0-3242, Safely-monitored position 1, negative

P-0-3244, Safely-limited speed 1

P-0-3251, Safely-monitored position 2, positive

P-0-3252, Safely-monitored position 2, negative

P-0-3254, Safely-limited speed 2

P-0-3264, Safely-limited speed 3

P-0-3274, Safely-limited speed 4

P-0-3302, SBS: Time interval brake check

P-0-3303, SBS: Nominal load

P-0-3304, SBS: Torque/force constant

P-0-3306, SBS: Delay time motor holding brake

P-0-3307, SBS: Safety technology - drive off delay time

P-0-3310, SBS: Travel range brake check

P-0-3311, SBS: Duration test torque injection brake check

P-0-3315, C6200 Comm. Enabling SM without valid brake status

Modified due to Implementation of EIDNs

P-0-0013, List of all IDNs not corresponding to default value

P-0-0023, Oscilloscope: signal selection 1

P-0-0024, Oscilloscope: signal selection 2

P-0-0026, Oscilloscope: trigger signal selection

P-0-0130, Position switch signal selection list

P-0-0131, Position switch signal selection

P-0-0147, Oscilloscope: signal selection 3

P-0-0148, Oscilloscope: signal selection 4

P-0-0149, Oscilloscope: signal selection list

P-0-0189, Debug output: IDN list of parameters last saved

P-0-0195, IDN list of retain data (replacement of devices)

P-0-0212, Analog input, list of assignable parameters

P-0-0213, Analog input, assignment A, target parameter

P-0-0236, Analog input, assignment B, target parameter

P-0-0300, Digital I/Os, assignment list

P-0-0301, Digital I/Os, bit numbers

P-0-0394, IDN groups: list

P-0-0395, Average value filter for display: signal selection

P-0-0396, Average value filter for display: signal selection list

P-0-0420, Analog output, assignment A, signal selection

P-0-0423, Analog output, assignment B, signal selection

P-0-0426, Analog output IDN list of assignable parameters

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Bosch Rexroth AG | Electric Drives

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Rexroth IndraDrive | Release Notes

Notes on Application

P-0-0681, Assignment IDN -> parallel output 1

P-0-0682, Assignment parallel input 1 -> IDN

P-0-0900, Encoder emulation signal selection list

P-0-0901, Encoder emulation signal selection

P-0-0915, Master axis format converter IDN list signal selection

P-0-0916, Master axis format converter signal selection

P-0-1151, Command value generator, list of possible target parameters

P-0-1152, Command value generator, target parameter assignment

P-0-1611, CCD: configuration list signal status word

P-0-1612, CCD: configuration list signal control word

P-0-1615, CCD: extrapolated cmd value IDN list signal selection

P-0-1616, CCD: extrapolated cmd value signal selection

P-0-1621, CCD: configuration list master communication cmd values

P-0-1622, CCD: configuration list master communication actual values

P-0-1623, CCD: configuration list master cmd values

P-0-1624, CCD: configuration list actual master values

P-0-1625, CCD: configuration list slave cmd values

P-0-1626, CCD: configuration list actual slave values

P-0-1627, CCD: configuration list master cmd values I/Os

P-0-1628, CCD: configuration list act. master values I/Os

P-0-3613, CANopen: List of the Event Parameters

P-0-4024, IDN list cyclic parameter display

P-0-4080, Field bus: config. list of cyclic actual value data ch.

P-0-4081, Field bus: config. list of cyclic command value data ch.

S-0-0016, Configuration list of AT

S-0-0017, IDN-list of all operation data

S-0-0018, IDN-list of operation data for CP2

S-0-0019, IDN-list of operation data for CP3

S-0-0021, IDN-list of invalid operation data for CP2

S-0-0022, IDN-list of invalid operation data for CP3

S-0-0024, Configuration list of MDT

S-0-0025, IDN-list of all procedure commands

S-0-0026, Configuration list for signal status word

S-0-0027, Configuration list for signal control word

S-0-0187, List of configurable data in the AT

S-0-0188, List of configurable data in the MDT

S-0-0192, IDN-list of all backup operation data

S-0-0219, IDN-list of parameter set

S-0-0270, IDN-list of selected backup operation data

S-0-0279, IDN-list of password-protected operation data

S-0-0301, Allocation of real-time control bit 1

S-0-0303, Allocation of real-time control bit 2

S-0-0305, Allocation of real-time status bit 1

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Release Notes | Rexroth IndraDrive

Electric Drives | Bosch Rexroth AG

and Controls

489/505

Notes on Application

13.2.3

S-0-0307, Allocation of real-time status bit 2

S-0-0327, IDN list of checksum parameter

S-0-0328, Assign list signal status word

S-0-0329, Assign list signal control word

S-0-0370, Data container A: configuration list command value-1

S-0-0371, Data container A: configuration list feedback value-1

S-0-0398, IDN-list of configurable data in signal status word

S-0-0399, IDN-list of configurable data in signal control word

S-0-0423, IDN-list of invalid data for parameterization levels

S-0-0426, Signal selection probe 1

S-0-0427, Signal selection probe 2

S-0-0428, Probe, IDN-list signal selection

S-0-0490, Data container A: configuration list command value 2

S-0-0491, Data container A: configuration list command value 3

S-0-0492, Data container A: configuration list command value 4

S-0-0493, Data container A: configuration list command value 5

S-0-0494, Data container A: configuration list command value 6

S-0-0495, Data container A: configuration list command value 7

S-0-0496, Data container A: configuration list command value 8

S-0-0500, Data container A: configuration list feedback value 2

S-0-0501, Data container A: configuration list feedback value 3

S-0-0502, Data container A: configuration list feedback value 4

S-0-0503, Data container A: configuration list feedback value 5

S-0-0504, Data container A: configuration list feedback value 6

S-0-0505, Data container A: configuration list feedback value 7

S-0-0506, Data container A: configuration list feedback value 8

No Longer Existing Parameters

Compared to the firmware version MPx05, all parameters still exist and none
of them were replaced by other parameters.

13.3

New, Modified or no Longer Existing Diagnostic Messages

13.3.1

New Diagnostic Messages

The following new diagnostic messages were implemented in firmware version
MPx07:

C0172 Delay measurement (S-0-1024) not carried out

C0173 Connections (number) not configurable

C0174 Connection configuration not allowed

C0175 Producer cycle time of a connection not correct

C5300 SERCOS III: Command SYNC delay measurement

C5301 SERCOS III: Delay measurement failed

C6500 Save parameters on MMC

C6501 Error when writing backup data (MMC)

C6502 Error when reading backup data (device)

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Bosch Rexroth AG | Electric Drives

and Controls

Rexroth IndraDrive | Release Notes

Notes on Application

C6503 Error when checking backup data (comparison)

C6600 Restore parameters from MMC

C6601 Error when reading backup data (MMC)

C6602 Error when writing backup data (device)

C6603 Error when updating comparative data (MMC)

C6604 Error when reading comparative data (device)

C6605 Warning, restoration incomplete (device)

C7100 CCD: Command Close ring

C7101 CCD: Impossible to close ring

E4007 SERCOS III: Consumer connection failed

E4016 CCD: Topology error

F8030 Safe stop 1 while drive enabled

F8830 Power section error

Booting Errors With MultiEthernet

XXX Upd: Copy firmware or logicware XXX from MMC to ET

ActLW Up: Copies active logicware within ET to address 0

E FIP nf: ET error: Flash Info Page not found

E FIP CS: ET error: Flash Info Page checksum incorrect

E Pge Sz: ET error: Flash geometry outside of defined size

E MMC op: ET error: MMC could not be opened for reading

E MMC cl: ET error: MMC could not be closed after reading

E Adress: ET error: Trying to read invalid address

E Length: ET error: Reading number greater than maximum file size

E ET SW: ET error: Error when copying from MMC to ET flash

E MMC cp: ET error: Error when copying from MMC

E HW nok: ET error: ET hardware signals not ready

E SW-VER: ET error: Active LW or FW not supported version

13.3.2

Modified Diagnostic Messages

The following diagnostic messages were extended or modified in firmware ver
sion MPx07:

A0010 Drive HALT

A0011 Safe torque off active

A0014 Safe stop 1 (Emergency stop) active

A0015 Safe stop 1 active

A0016 Safe stop 2 active

A0018 Special mode safe motion 1 active

A0019 Special mode safe motion 2 active

A0020 Special mode safe motion 3 active

A0021 Special mode safe motion 4 active

A0128 Cam, encoder 1, virtual master axis

A0129 Cam, encoder 2, virtual master axis

A0130 Cam, encoder 1, real master axis

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Release Notes | Rexroth IndraDrive

Electric Drives | Bosch Rexroth AG

and Controls

491/505

Notes on Application

A0131 Cam, encoder 2, real master axis

A0132 Cam, lagless, encoder 1, virt. master axis

A0133 Cam, lagless, encoder 2, virt. master axis

A0134 Cam, lagless, encoder 1, real master axis

A0135 Cam, lagless, encoder 2, real master axis

A0136 MotionProfile, encoder 1, virtual master axis

A0137 MotionProfile, encoder 2, virtual master axis

A0138 MotionProfile, encoder 2, real master axis

A0139 MotionProfile, encoder 1, real master axis

A0140 MotionProfile lagless, encoder 1, virtual master axis

A0141 MotionProfile lagless, encoder 2, virtual master axis

A0142 MotionProfile lagless, encoder 1, real master axis

A0143 MotionProfile lagless, encoder 2, real master axis

C0108 Time slot parameter > Sercos cycle time

C0109 Telegram offset unsuitable

C0170 Config. IDNs for connection not configurable

C0171 Maximum length for connections exceeded

C0255 Safety command for system init. incorrect

C0256 Safety technology configuration error

C0299 Configuration changed. Restart

C2103 Holding brake: Torque too low

C2109 SBS: Test torque invalid

C2903 Error when accessing the MMC

C3001 Synchronization and storage failed

C3701 Error when manually unlocking the safety door

C3900 Command Holding brake resurfacing

C3901 Resurfacing of holding brake only possible with drive enable

C3902 Error during resurfacing of holding brake

C4001 Error during safe homing procedure

C6100 Command Activate IP settings

C6200 Command Enabling SM without valid brake status

E2069 Holding brake torque too low

E3107 Safe reference missing

E3108 Safely-monitored deceleration exceeded

E4001 Double MST failure shutdown

E8027 Safe torque off while drive enabled

F2004 Error in MotionProfile

F2005 Cam table invalid

F2018 Device overtemperature shutdown

F2019 Motor overtemperature shutdown

F2021 Motor temperature monitor defective

F2022 Device temperature monitor defective

F2031 Encoder 1 error: Signal amplitude incorrect

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Bosch Rexroth AG | Electric Drives

and Controls

Rexroth IndraDrive | Release Notes

Notes on Application

F2033 External power supply X10 error

F2036 Excessive position feedback difference

F2040 Device overtemperature 2 shutdown

F2042 Encoder 2: Encoder signals incorrect

F2043 Measuring encoder: Encoder signals incorrect

F2044 External power supply X15 error

F2055 External power supply dig. I/O error

F2068 Brake error

F2087 Module group communication error

F2190 Incorrect Ethernet configuration

F2820 Braking resistor overload

F2821 Error in control of braking resistor

F2825 Switch-on threshold braking resistor too low

F2836 DC bus balancing monitor error

F3112 Safe reference missing

F3115 Brake check time interval exceeded

F3117 Actual position values validation error

F3122 SBS: System error

F3123 SBS: Brake check missing

F3130 Error when checking input signals

F3131 Error when checking acknowledgment signal

F3132 Error when checking diagnostic output signal

F3133 Error when checking interrupting circuits

F3134 Dynamization time interval incorrect

F3135 Dynamization pulse width incorrect

F3140 Safety parameters validation error

F3141 Selection validation error

F3142 Activation time of enabling control exceeded

F3143 Safety command for clearing errors incorrect

F3144 Incorrect safety configuration

F3145 Error when unlocking the safety door

F3146 System error channel 2

F3147 System error channel 1

F3150 Safety command for system start incorrect

F3151 Safety command for system halt incorrect

F3152 Incorrect backup of safety technology data

F3160 Communication error of safe communication

F4001 Sync telegram failure

F4002 RTD telegram failure

F4034 Emergency-Stop

F6034 Emergency-Stop

F7010 Safely-limited increment exceeded

F7011 Safely-monitored position, exceeded in pos. direction

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Release Notes | Rexroth IndraDrive

Electric Drives | Bosch Rexroth AG

and Controls

493/505

Notes on Application

13.3.3

F7012 Safely-monitored position, exceeded in neg. direction

F7013 Safely-limited speed exceeded

F7020 Safe maximum speed exceeded

F7021 Safely-limited position exceeded

F7030 Position window Safe stop 2 exceeded

F7050 Time for stopping process exceeded

F7051 Safely-monitored deceleration exceeded

F8018 Device overtemperature shutdown

F8027 Safe torque off while drive enabled

F8079 Velocity limit value exceeded

F8133 Error when checking interrupting circuits

F8134 SBS: Fatal error

F8135 SMD: Velocity exceeded

F8201 Safety command for basic initialization incorrect

No Longer Existing Diagnostic Messages

The following diagnostic messages no longer exist compared to the firmware
version MPx05 or were replaced by other diagnostic messages:

E2270 Analog input 1 or 2, wire break

F2270 Analog input 1 or 2, wire break

F8067 Synchronization PWM-Timer wrong

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Bosch Rexroth AG | Electric Drives
and Controls
Rexroth IndraDrive | Release Notes

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Release Notes | Rexroth IndraDrive

Electric Drives | Bosch Rexroth AG

and Controls

495/505

Service and Support

14

Service and Support

Our service helpdesk at our headquarters in Lohr, Germany and our worldwide
service will assist you with all kinds of enquiries. You can reach us around the
clock - even on weekend and on holidays.

Helpdesk
Phone

+49 (0) 9352 40 50 60

Fax

+49 (0) 9352 40 49 41

E-mail

[email protected]

Service Hotline
Worldwide
Outwith Germany please con
tact our sales/service office in
your area first.
For hotline numbers refer to
the sales office addresses on
the Internet.

http://www.boschrexroth.com
Internet
Preparing Information

You will also find additional notes regarding service, mainte

nance (e.g. delivery addresses) and training.

For quick and efficient help please have the following information ready:

Detailed description of the fault and the circumstances

Information on the type plate of the affected products, especially type co

des and serial numbers

Your phone, fax numbers and e-mail address so we can contact you in
case of questions.

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Bosch Rexroth AG | Electric Drives
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Rexroth IndraDrive | Release Notes

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Release Notes | Rexroth IndraDrive

Electric Drives | Bosch Rexroth AG

and Controls

497/505

Index

Index
A

Absolute encoder.............................................. 461

Absolute encoder emulation............................. 381
Absolute positioning.......................................... 265
Actual value adjustment (for position loop)....... 202
Actual value cycle..................................... 289, 306
Address setting
Overview ...................................................... 57
Via parameter access .................................. 58
Via standard control panel ........................... 57
Administration commands............................. 22, 59
Advanced performance....................................... 38
Analog inputs.................................................... 366
Analog interface................................................ 108
Analog outputs.................................................. 370
Analog outputs (Analog outputs)....................... 370
Appropriate use................................................... 43
Applications .................................................. 43
ASCII protocol
Properties ................................................... 432
Availability
Extended axis functions ............................. 329
Optional device functions ........................... 353
Axis address setting............................................ 57
Axis control
Position loop ............................................... 202
Velocity loop ............................................... 200
Axis control (closed-loop operation)
Overview .................................................... 166
Axis control (open-loop operation)
Overview .................................................... 166
Axis error correction.......................................... 337
Axis functions, extended................................... 329
Availability .................................................. 329
AxisInterface..................................................... 468
Axis simulation.................................................. 457

Basic functions of master communication........... 55

Basic functions of the synchronization modes. . 287
Basic performance.............................................. 38
Best possible deceleration................................ 332
Brief description ......................................... 332
Brake current monitoring................................... 459

Cam, electronic................................................. 318

CANopen interface............................................ 104
CCD (cross communication)............................. 353
CCD communication......................................... 474
Change of operation mode, drive-controlled..... 246
Changing the operation mode........................... 230
Checking the installation/assembly................... 441
Checksum of parameter values.................. 21, 388

Circuit board code............................................. 395

Classes of warnings............................................ 23
Clearing an error message................................. 24
Clock rates.......................................................... 38
Closed-loop axis control.................................... 196
Automatic setting ........................................ 198
Closed-loop axis control (closed-loop operation)
General information .................................... 196
Closed-loop operation (axis control)
Overview .................................................... 166
Code memory................................................... 469
Cogging torque compensation.......................... 338
Command change bit.......................................... 60
Command execution........................................... 59
Command processing......................................... 59
Commands.......................................................... 22
Command value acceptance............................ 230
Command value acknowledgment.................... 230
Command value addition for slave axis............ 305
Command value adjustment
In phase synchronization ................... 317, 327
In position control ....................................... 245
In torque/force control ................................ 233
In velocity control ....................................... 237
In velocity synchronization ......................... 311
With drive-controlled positioning ................ 252
With drive-internal interpolation .................. 250
With electronic cam .................................... 322
With positioning block mode ...................... 260
Command value box, drive-internal.................. 379
Command value cycle............................... 289, 306
Command value generator, drive-integrated.... 377
Command value limitation
In velocity control ....................................... 242
Commissioning
Checking the installation/assembly ............ 441
Easy startup mode ..................................... 444
Initial commissioning/serial commission
ing .............................................................. 441
Machine axes ............................................. 455
Motor .......................................................... 441
With commissioning tool ............................ 454
Commissioning tool, initial start with ............ 454
Communication phases...................................... 67
Communication via RS232 interface................. 433
Communication via RS485 interface................. 433
Communication with SIS protocol............. 436, 437
Commutation offset
Determined by saturation method .............. 209
Determined by sine-wave method .............. 210
Commutation setting......................................... 203
Basics ......................................................... 203
For Rexroth motors .................................... 208
Compensation functions................................... 336

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Bosch Rexroth AG | Electric Drives

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Rexroth IndraDrive | Release Notes

Index

...Compensation functions
Axis error correction ................................... 337
Cogging torque compensation ................... 338
Encoder error correction ............................ 337
Friction torque compensation ..................... 336
Configurations of the control section................... 26
Control, sensorless........................................... 470
Controller design............................................... 390
Controllers, overview.......................................... 24
Control loop features......................................... 196
Control loops
Features ..................................................... 170
Control loop structure................................ 167, 196
Control loop structure (figure)
With display parameters ............................. 169
With setting parameters ............................. 168
Control options (via master communication)....... 77
Control panels................................................... 401
Standard control panel ............................... 402
Control parameters........................................... 401
Control password.............................................. 390
Control section configurations............................. 26
Control section designs....................................... 26
Control sections, overview.................................. 26
Cross communication (CCD)............................ 353
CSH01.2C......................................................... 473
CSH01.3........................................................... 459
CSH01.3C......................................................... 473
Current and torque/force limitation.................... 211
Current control, field-oriented (FOC control)..... 178
Current limitation............................................... 215
Current loop...................................................... 234
Customer password.......................................... 390
Cycle times......................................................... 38
SERCOS III ................................................ 459

Data exchange
Synchronized ............................................. 469
Data storage....................................................... 20
Deceleration, best possible............................... 332
Defdb00063875................................................ 473
Defdb00064115................................................ 460
Defdb00077576................................................ 472
Defdb00077984................................................ 459
Defdb00078398................................................ 460
Defdb00078489................................................ 459
Defdb00078542................................................ 472
Defdb00079628................................................ 472
Defdb00080212................................................ 463
Defdb00080216................................................ 463
Defdb00080346................................................ 465
Defdb00080391................................................ 470
Defdb00080771................................................ 472
Defdb00081025................................................ 465
Defdb00081026................................................ 470

Defdb00081098................................................ 469
Defdb00082596................................................ 460
Defdb00084174................................................ 471
Defdb00084410................................................ 459
Defdb00085134................................................ 467
Defdb00085167................................................ 469
Defdb00085168................................................ 465
Defdb00085169........................................ 469, 474
Defdb00085431................................................ 469
Defdb00085628................................................ 469
Defdb00085701................................................ 459
Defdb00086146................................................ 459
Defdb00086666................................................ 469
Defdb00088095................................................ 459
Defdb00088099................................................ 463
Defdb00088102................................................ 463
Defdb00088105................................................ 462
Defdb00088126................................................ 472
Defdb00088129................................................ 468
Defdb00088801................................................ 461
Defdb00088803................................................ 461
Defdb00088977................................................ 471
Defdb00089079................................................ 464
Defdb00089522................................................ 470
Defdb00089851................................................ 467
Defdb00091223................................................ 471
Defdb00091374................................................ 471
Defdb00091445................................................ 461
Defdb00091499................................................ 462
Defdb00091713................................................ 459
Defdb00091774................................................ 468
Defdb00091883................................................ 470
Defdb00092036................................................ 468
Defdb00092653................................................ 461
Defdb00093136................................................ 459
Defdb00093170................................................ 461
Defdb00093194................................................ 468
Defdb00093745................................................ 471
Defdb00094052................................................ 467
Defdb00094125................................................ 460
Defdb00094869................................................ 470
Defdb00095897................................................ 464
Defdb00096309................................................ 468
Defdb00096440................................................ 470
Defdb00096443................................................ 468
Defdb00096587................................................ 461
Defdb00096589................................................ 464
Defdb00096764................................................ 467
Defdb00096832................................................ 460
Defdb00096847................................................ 459
Defdb00096861................................................ 471
Defdb00097379................................................ 465
Defdb00097902................................................ 470
Defdb00101695................................................ 467
Defdb00103108................................................ 471
Defdb00103439................................................ 464

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Release Notes | Rexroth IndraDrive

Electric Drives | Bosch Rexroth AG

and Controls

499/505

Index

Defdb00103652................................................ 462
Defdb00104289................................................ 460
Defdb00104638................................................ 464
Defdb00104663................................................ 466
Defdb00104719................................................ 464
Defdb00105084................................................ 470
Defdb00105277................................................ 461
Defdb00105289................................................ 461
Definitions of terms, general basic principles...... 20
Delay time, defined (for positioning block ad
vance)............................................................... 279
Detecting the marker position........................... 158
Determination of load due to weight................. 462
Determining the protocol................................... 432
Device configuration......................................... 390
Device control..................................................... 61
Device functions, optional................................. 353
Availability .................................................. 353
DeviceNet interface........................................... 105
Diagnosis.......................................................... 398
Diagnostic interfaces......................................... 431
Diagnostic messages
Modified ...................................................... 490
New ............................................................ 489
No longer existing ...................................... 493
Diagnostic messages of the drive..................... 398
Diagnostic possibilities, extended..................... 427
Diagnostic system............................................. 398
Digital inputs..................................................... 364
Digital inputs/outputs......................................... 364
Digital outputs................................................... 364
DME5000.......................................................... 464
Documentation
Overview ...................................................... 17
Reference documentations .......................... 17
Documentation, notes on how to use it............... 16
Drive address...................................................... 57
Drive control...................................................... 165
Basic principles and terms ......................... 165
Overview .................................................... 165
Principles .................................................... 166
Drive control commands............................... 22, 59
Drive-controlled change of operation mode...... 246
Drive-controlled homing procedure................... 153
Drive-controlled oscillation................................ 344
Drive-controlled positioning............................... 250
Block diagram ............................................ 251
Command value adjustment ...................... 252
Drive controller
Replace ...................................... 419, 422, 424
Drive controllers
Control sections ........................................... 26
Overview ...................................................... 24
Power sections ............................................. 25
Drive controllers, standard design...................... 24
Drive firmware, overview..................................... 19

Drive Halt.................................................. 330, 464

Drive-integrated PLC.......................................... 36
Drive-integrated PLC (Rexroth IndraMotion
MLD)................................................................. 360
Drive-internal interpolation................................ 248
Block diagram ............................................ 248
Command value adjustment ...................... 250
Drive profile......................................................... 93
DriveTop........................................................... 454
Dynamic synchronization of the slave axis....... 295

Easy startup mode............................................ 471

As local setting-up/emergency mode ........... 83
For initial start of the motor ........................ 444
Economy performance........................................ 38
EIDN................................................................. 472
Electronic cam
Command value adjustment ...................... 322
Electronic cam with real/virtual master axis...... 318
Emergency mode (when master communica
tion has failed)..................................................... 91
Enabling of functional packages....................... 426
Encoder emulation............................................ 380
Encoder error correction................................... 337
Encoder errors
Reestablishment of reference .................... 460
Encoder replacement monitoring...................... 460
Engineering/diagnostic interfaces..................... 431
Error classes............................................... 23, 331
Error corrections
Axis error correction ................................... 337
Encoder error correction ............................ 337
Quadrant error correction ........................... 338
Error memory...................................................... 24
Power section and control section ............. 398
Error reaction.................................................... 463
Error reactions.................................................. 331
Best possible deceleration ......................... 332
Drive error reactions ..................................... 24
MLD reaction .............................................. 335
NC reaction ................................................ 335
Overview .................................................... 331
Package reaction ....................................... 333
Errors.................................................................. 23
Drive error reactions ..................................... 24
Establishing position data reference
For absolute measuring systems ............... 149
For relative measuring systems ................. 150
Establishing the position data reference........... 147
Establishing the position data reference, gen
eral information................................................. 147
E-Stop function................................................. 335
EtherCAT.......................................................... 460
Ethernet/IP................................................ 460, 473
EtherNet/IPTM interface..................................... 124

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Rexroth IndraDrive | Release Notes

Index

Explanation of terms (for synchronization

modes).............................................................. 289
Extended axis functions.................................... 329
Availability .................................................. 329
Extended diagnostic possibilities...................... 427
Logbook function ........................................ 427
Monitoring function ..................................... 427
Patch function ............................................ 427

Fault report........................................................ 416

FEAT 1.49......................................................... 468
FEAT 1.50......................................................... 467
FEAT 1.51......................................................... 466
FEAT 2.5........................................................... 472
FEAT 2.77......................................................... 468
FEAT 2.79......................................................... 469
FEAT 2.81......................................................... 469
FEAT 2.82......................................................... 472
FEAT 2.87......................................................... 469
FEAT 2.89......................................................... 467
FEAT 2.90......................................................... 468
FEAT 2.91......................................................... 469
FEAT 3.44......................................................... 459
FEAT 3.45......................................................... 459
FEAT 3.46................................................. 459, 467
FEAT 3.52......................................................... 459
FEAT 4.102....................................................... 461
FEAT 4.103....................................................... 461
FEAT 4.104....................................................... 461
FEAT 4.105....................................................... 462
FEAT 4.106....................................................... 461
FEAT 4.111....................................................... 461
FEAT 4.115....................................................... 462
FEAT 4.120....................................................... 461
FEAT 4.122....................................................... 464
FEAT 4.69......................................................... 460
FEAT 4.72......................................................... 463
FEAT 4.75......................................................... 461
FEAT 4.84......................................................... 463
FEAT 4.86......................................................... 461
FEAT 4.87......................................................... 463
FEAT 4.90......................................................... 460
FEAT 4.93......................................................... 463
FEAT 4.95......................................................... 459
FEAT 4.96......................................................... 464
FEAT 4.98......................................................... 462
FEAT 5.31......................................................... 470
FEAT 5.49......................................................... 470
FEAT 5.68......................................................... 465
FEAT 5.71......................................................... 465
FEAT 5.73......................................................... 470
FEAT 5.74......................................................... 465
FEAT 5.76................................................. 469, 474
FEAT 5.78......................................................... 464
FEAT 5.80......................................................... 465

FEAT 5.83......................................................... 468

FEAT 5.86......................................................... 464
FEAT 5.88......................................................... 464
FEAT 5.91......................................................... 464
FEAT 5.93......................................................... 469
FEAT 6.35......................................................... 471
FEAT 6.39......................................................... 472
FEAT 6.40......................................................... 459
FEAT 6.41......................................................... 471
FEAT 6.44......................................................... 472
FEAT 6.45......................................................... 471
FEAT 6.46......................................................... 471
FEAT 6.53......................................................... 471
FEAT 6.56......................................................... 468
FEAT 7.12......................................................... 460
FEAT 7.17......................................................... 460
FEAT 7.22......................................................... 473
FEAT 7.26......................................................... 459
FEAT 7.35......................................................... 460
Field-oriented current control (FOC control)..... 178
Field-oriented current control with motor en
coder (FOC)...................................................... 172
Field weakening operation................................ 181
File handling by FTP (via Ethernet).................. 438
Fine interpolation
In velocity control ....................................... 242
Firmware
KMS01 ....................................................... 394
Firmware release update.................................. 405
Firmware replacement...................................... 404
Basic principles, terms ............................... 404
Possible problems ...................................... 414
Firmware types................................................... 32
Firmware update............................................... 404
Firmware upgrade............................................. 404
Firmware variants............................................... 19
Firmware version
IndraDrive Mi .............................................. 394
KMS01 ....................................................... 394
KSM01 ....................................................... 394
Firmware version upgrade................................ 409
Flux feedforward............................................... 184
Flux loop........................................................... 185
Flux model........................................................ 184
FOC control............................................... 172, 178
FOCsl control.................................................... 172
Force limitation.................................................. 213
Freely configurable mode................................... 98
Friction torque compensation............................ 336
FTP, file handling by ........................................ 438
Functional Description, notes on how to use it. . . 16
Functional packages........................................... 29
Additive functional packages ........................ 36
Alternative functional packages ................... 34
Base packages ............................................. 33
Enabling ..................................................... 426

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Electric Drives | Bosch Rexroth AG

and Controls

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Index

FXC................................................................... 462
FXC control............................................... 172, 185

Gear function, electronic................................... 294

Hall sensor box SHL......................................... 209

Handling, diagnostic and service functions....... 387
HAS05.1............................................................ 459
HCS04.2........................................................... 459
HIPERFACE
Absolute value monitoring .......................... 461
Homing...................................................... 150, 461
How to use this documentation........................... 16
How to use this documentation, notes................ 16

I/O mode (positioning and preset velocity).......... 94

IDN lists of parameters..................................... 389
Inappropriate use................................................ 44
Consequences, exclusion of liability ............ 43
Incremental encoder emulation......................... 380
IndraDrive profile type......................................... 98
IndraMotion MLD........................................ 36, 360
IndraWorks Ds/D/MLD...................................... 454
Initial commissioning......................................... 441
Initial start in easy startup mode....................... 444
Initial start with commissioning tool................... 454
Integrated safety technology....................... 37, 346
Interface mode.................................................. 431
Intermediate stop (for positioning block ad
vance)............................................................... 279
Interpolation modes
Filter order .................................................. 464

Jerk limitation
In velocity control ....................................... 241
Jogging............................................................. 257
Jog mode.................................................. 255, 257

Kinds of commands............................................ 22
Kinds of passwords, overview............................. 21
KMS01.2-B........................................................ 459

L2...................................................................... 348
Limitations......................................................... 210
Current and torque/force limitation ............. 211
Overview .................................................... 210
Position limitation ....................................... 221

...Limitations
Velocity limitation ....................................... 221
Limit switches.................................................... 221
Loading of parameter values, general................ 21
Load parameter values in case of total break
down of device.................................................. 426
Logbook function............................................... 427

Machine axes, commissioning.......................... 455

Machine commissioning.................................... 455
Mains connection.............................................. 224
Master axis........................................................ 289
Real master axis ........................................ 292
Virtual master axis ...................................... 292
Master axis adjustment..................................... 291
Master axis format converter............................ 468
Master axis generation...................................... 292
Master axis generator, virtual............................ 373
Master axis offset.............................................. 293
Master communication........................................ 55
Analog interface ......................................... 108
Basic functions ............................................. 55
CANopen interface ..................................... 104
Control words and status words ................... 69
DeviceNet interface .................................... 105
EtherNet/IPTM interface .............................. 124
Operating modes .......................................... 79
Overview ...................................................... 28
Parallel interface ........................................ 107
PROFIBUS-DP ................................... 101, 120
SERCOS III ................................................ 126
SERCOS interface ....................................... 99
Master password............................................... 390
MB_ChangeCamData....................................... 469
MB_Command.................................................. 469
MB_SetPositionControlMode............................ 468
Means of representation
Conventions of notation ............................... 15
Notations ...................................................... 15
Notes ............................................................ 15
Measuring encoder........................................... 385
Measuring systems........................................... 142
Absolute measuring systems ..................... 145
Arrangement .............................................. 159
Basics ......................................................... 142
Monitoring .................................................. 144
Relative measuring systems ...................... 146
Resolution .................................................. 142
Supported measuring systems ..................... 28
Measuring wheel mode............................. 339, 467
Mechanical axis system.................................... 159
Mechanical energy............................................ 462
Mechanical power............................................. 462
Memory of fixed command values.................... 238
MLD-M system mode........................................ 469

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Bosch Rexroth AG | Electric Drives

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Rexroth IndraDrive | Release Notes

Index

MLD reaction on error....................................... 335

MLD IndraMotion MLD.................................. 360
MMC.................................................................. 471
MMC (MultiMediaCard)..................................... 403
Model-based current control without motor
encoder (FXC, FOCsl)...................................... 172
Modulo limitation............................................... 293
Monitor commands....................................... 22, 59
Monitoring function............................................ 427
Monitoring functions
Measuring systems .................................... 144
Motor temperature ...................................... 132
MotionProfile..................................................... 323
Command value adjustment ...................... 327
MotionProfile with real/virtual master axis......... 323
Motor
Commissioning ........................................... 441
Commissioning motors ............................... 441
Motor control..................................................... 171
Automatic setting ........................................ 187
General information .................................... 171
Motor control frequency.................................... 176
Motor control method
Notes on selection of method ..................... 173
Motor control methods
Field-oriented current control with motor
encoder (FOC) ........................................... 172
Model-based current control without motor
encoder (FXC, FOCsl) ............................... 172
Overview .................................................... 171
Motor control parameters.................................. 190
Automatic setting ........................................ 187
Motor encoder, redundant................................. 341
Motor frequency................................................ 460
Motor holding brake.......................................... 140
Function check ........................................... 141
Operating behavior ..................................... 140
Motor operation, sensorless, flux-controlled..... 185
Motor parameters.............................................. 189
Automatic setting ........................................ 187
Motor parameter values, determining for thirdparty motors...................................................... 138
Motor potentiometer.......................................... 239
Motors
Basics ......................................................... 131
General information for operation with
IndraDrive ................................................... 131
Hardware data ............................................ 131
Rexroth housing motors ............................. 134
Rexroth kit motors ...................................... 135
Supported motors ......................................... 28
Temperature monitoring ............................. 132
Third-party motors ...................................... 137
Motor temperature model
Load display ............................................... 461
Motor temperature monitoring........................... 132

MultiEthernet..................................................... 115
MultiMediaCard................................................. 403
Multiplex channel................................................ 78
MX_INT_fReadPosSIChan2............................. 468

NC-controlled homing procedure...................... 155

NC reaction on error......................................... 335
Non-volatile data memories................................ 20
Notes on application......................................... 459

Open-loop axis control...................................... 195

Open-loop operation (axis control)
Overview .................................................... 166
Operating hours counter................................... 397
Operating mode............................................ 62, 68
Operating modes of master communication....... 79
Operation modes.............................................. 227
Basic principles ............................................ 22
Changing the operation mode .................... 230
Drive-controlled positioning ........................ 250
Drive-internal interpolation ......................... 248
Electronic cam with real/virtual master ax
is ................................................................. 318
General information .................................... 227
MotionProfile with real/virtual master axis . . 323
Operation mode handling ........................... 227
Phase synchronization with real/virtual
master axis ................................................. 313
Position control with cyclic command val
ue input ...................................................... 243
Positioning block mode .............................. 258
Selecting the operation mode .................... 227
Supported operation modes ....................... 227
Synchronization modes .............................. 287
Torque/force control ................................... 231
Velocity control ........................................... 234
Velocity synchronization with real/virtual
master axis ................................................. 309
Optional device functions.................................. 353
Availability .................................................. 353
Oscillation, drive-controlled............................... 344
Oscilloscope function........................................ 428
Overview of functions/functional packages......... 29

Package reaction on error................................. 333

Parallel interface............................................... 107
Parameter groups............................................. 470
Parameter handling, general............................... 20
Parameterization and diagnosis of drive
groups............................................................... 435
Parameterization and diagnosis via PLC.......... 434
Parameter mode........................................... 62, 68

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Release Notes | Rexroth IndraDrive

Electric Drives | Bosch Rexroth AG

and Controls

503/505

Index

Parameters
Basics ......................................................... 387
Definitions of terms ...................................... 20
Loading, storing and saving ....................... 387
Properties/features ..................................... 387
Parameters, new or modified............................ 476
Parameter set switching.................................... 343
Parking axis...................................................... 345
Password.................................................... 21, 389
Patch function
General patch function ............................... 427
PLC patch function ..................................... 427
PELV................................................................... 49
Performance data............................................... 38
Phase synchronization
Command value adjustment ...................... 317
Phase synchronization with real/virtual mas
ter axis.............................................................. 313
PLC patch function............................................ 427
PLC retain data................................................. 468
Position command value delay......................... 465
Position control
Block diagram ............................................ 243
Command value adjustment ...................... 245
Positioning block mode..................................... 258
Command value adjustment ...................... 260
Sequential block processing ...................... 276
Single-block processing ............................. 260
Positioning generator........................................ 257
Position limitation.............................................. 221
Position loop............................................. 202, 247
Position switch, programmable......................... 382
Position target interpreter.................................. 253
Positive stop...................................................... 341
Positive stop drive procedure............................ 341
Possibilities of filtering
In velocity control ....................................... 243
Possible device combinations........................... 224
Power sections, overview................................... 25
Power supply.................................................... 222
Probe dead time................................................ 470
Probe function................................................... 383
PROFIBUS-DP......................................... 101, 120
Profile types
Freely configurable mode ....................... 92, 98
I/O mode ...................................................... 92
I/O mode (positioning and preset velocity) ... 94
Overview ...................................................... 92
Profile types (with field bus interfaces)............... 92
PROFINET RT.................................................. 460
Protective extra-low voltage................................ 49
PWM frequency................................................ 473

Quadrant error correction.................................. 338

Ramp-function generator
In velocity control ....................................... 240
Real master axis............................................... 292
Redundancy function........................................ 459
Redundant motor encoder................................ 341
Reference documentations................................. 17
Reference mark................................................ 461
Relative positioning
Without residual path storage .................... 266
With residual path storage ......................... 269
Relative positioning block with residual path
storage after interrupting with jog mode............ 273
Release update................................................. 404
Replace
Drive controller ........................... 419, 422, 424
Replacement of devices.................................... 415
Fault report ................................................. 416
Replacing devices
Drive controller ........................................... 416
Supply unit ................................................. 415
Replacing the controller without stationarily
plugged MMC.................................................... 417
Resolution of measuring systems..................... 142
Restore and backup function............................ 472
Rexroth housing motors
With encoder data memory ........................ 134
Without encoder data memory ................... 135
Rexroth IndraMotion MLD................................. 360
Rexroth kit motors............................................. 135
Asynchronous ............................................ 136
Synchronous .............................................. 135
Rexroth motors................................................. 133
Basics ......................................................... 133
Rexroth housing motors ............................. 134
Rexroth kit motors ...................................... 135
Run-up stop...................................................... 241

Safe Motion....................................................... 346

Safety instructions for electric drives and con
trols..................................................................... 45
Safety technology, integrated..................... 37, 346
Saturation method............................................. 209
Scaling of physical data.................................... 162
Scaling the drive functionality............................. 29
Secondary master............................................. 465
Selecting the operation mode........................... 227
Sensorless motor operation, flux-controlled...... 185
Sequential block processing............................. 276
SERCOS II.................................................. 99, 470
CCD system mode ..................................... 465
SERCOS III............................................... 126, 471
SERCOS III V1.1.2........................................... 473
SERCOS III-V1.1.2........................................... 469
SERCOS interface.............................................. 99
Serial commissioning........................................ 441

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Bosch Rexroth AG | Electric Drives

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Rexroth IndraDrive | Release Notes

Index

Serial communication........................................ 431

Basic state .................................................. 432
Functional principle independent of proto
col ............................................................... 432
Overview .................................................... 431
Setting the drive address ........................... 432
Set/shift coordinate system procedure.............. 158
Set absolute measuring.................................... 149
Setting the axis address...................................... 57
Setting-up mode (easy startup mode)................. 83
Shifting the position data reference.................. 158
Signal control word............................................. 77
Signal status word............................................... 78
Simulation mode............................................... 472
Sine-wave method............................................ 210
Single-block processing.................................... 260
SIS protocol...................................................... 436
Addressing a drive ..................................... 437
Properties ................................................... 432
Supported services and subservices ......... 437
Telegram structure, telegram scope .......... 437
Slave axes, number.......................................... 469
Slave axis.......................................................... 289
Slave axis, dynamic synchronization................ 295
SMP specification............................................. 460
Spindle positioning............................................ 342
Stall current limit............................................... 185
State machine............................................... 61, 94
Device-internal ............................................. 62
Master communication ................................. 64
State-of-the-art.................................................... 43
Status classes................................................... 399
Status displays.................................................. 399
Storing of parameter values, general.................. 20
Supply unit
Replacing devices ...................................... 415
Support
see Service Hotline .................................... 495
Synchronization, absolute................................. 303
Synchronization, extended functions................ 306
Synchronization, relative................................... 302
Synchronization, relative/absolute.................... 302
Synchronization, single-step/double-step......... 299
Synchronization mode...................................... 296
Synchronization modes..................................... 287
Basic functions ........................................... 287
Synchronization of the slave axis, dynamic...... 295
Synchronous motor
Torque display ............................................ 461
System overview................................................. 15

TCP/IP communication..................................... 435

Third-party motors
Control, general information ....................... 137
Determining the motor parameter values ... 138
Hardware data ............................................ 138
Torque/force control.......................................... 181
Block diagram ............................................ 232
Command value adjustment ...................... 233
Torque/force limitation.............................. 211, 213
Transmission protocols of serial communica
tion.................................................................... 431
Travel range limit switches................................ 221
TTK70............................................................... 460

U/f control.......................................................... 177

Use
Appropriate use ............................................ 43
Inappropriate use ......................................... 44

Velocity command value

Inverting ..................................................... 239
Velocity control.................................................. 464
Block diagram ............................................ 234
Command value adjustment ...................... 237
Masking the command value ..................... 239
Velocity control loop.......................................... 242
Velocity limitation.............................................. 221
Velocity loop.............................................. 200, 242
Velocity synchronization
Command value adjustment ...................... 311
Velocity synchronization with real/virtual mas
ter axis.............................................................. 309
Version upgrade................................................ 404
Virtual master axis, external.............................. 292
Virtual master axis, internal............................... 292
Virtual master axis generator............................ 373
Voltage-controlled open-loop operation (U/f
control).............................................................. 177
Voltage input..................................................... 470
Voltage loop (with field-oriented current con
trol).................................................................... 184

Warnings............................................................. 23
WebServer........................................................ 471

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Release Notes | Rexroth IndraDrive

Notes

Electric Drives | Bosch Rexroth AG

and Controls
505/505

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Bosch Rexroth AG
Electric Drives and Controls
P.O. Box 13 57
97803 Lohr, Germany
Bgm.-Dr.-Nebel-Str. 2
97816 Lohr, Germany
Tel.
+49 (0)93 52-40-0
Fax
+49 (0)93 52-48 85
www.boschrexroth.com

R911330157

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