29718101-Rexroth Demo System PSP-I01.1-01 IndraDrive M With SERCOS Interface

Industrial Electric Drives Linear Motion and Service Mobile
Hydraulics and Controls Assembly Technologies Pneumatics Automation Hydraulics
Rexroth Demo System

R911297181
PSP-I01.1-01 Edition 01
IndraDrive M with SERCOS Interface
Users Manual
About this Documentation PSP-I01.1-01-EN
Title Demo System

PSP-I01.1-01
IndraDrive M with SERCOS-Interface
Type of Documentation User Manual
Document Typecode DOK-SUPPL*-PSP01.1-KB01-EN-P
Internal File Reference Binder

Document Number, 120-2100-B345-01/EN PDM
Purpose of Documentation This documentation describes:

• Programming, parameter setting, setup of the demo system
• Handling
• Design and wiring
• Safety instructions
• Soft- and hardware requirements
Record of Revisions Description Release Notes

Date
DOK-SUPPL*-PSP01.1-KB01-EN-P 02/03 1st release
Copyright  2003 Bosch Rexroth AG

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 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 availability of the product.
Published by Bosch Rexroth AG

Bgm.-Dr.-Nebel-Str. 2 • D-97816 Lohr a. Main
Telephone +49 (0)93 52/40-0 • Tx 68 94 21 • Fax +49 (0)93 52/40-48 85
http://www.boschrexroth.com/
Dept. BRC/BMS3 (WKL), BRC/PDM2 (EGL)
Note This document has been printed on chlorine-free bleached paper.
DOK-SUPPL*-PSPI01.1-KB01-EN-P
PSP-I01.1-01-EN Inhaltsverzeichnis I
Inhaltsverzeichnis
1 Abbildungsverzeichnis 1-1
2 System description 2-1

2.1 Design........................................................................................................................................... 2-1
2.2 State of delivery ............................................................................................................................ 2-1
2.3 Dimensions and weight................................................................................................................. 2-1
2.4 Mains connection.......................................................................................................................... 2-1
3 General Instructions 3-1

3.1 Definition of Terms, Introduction................................................................................................... 3-1
Introduction .............................................................................................................................. 3-1
Areas of use and application ................................................................................................... 3-2
3.2 Improper use................................................................................................................................. 3-2
3.3 Functions and Operation modes .................................................................................................. 3-3
Main Operating Modes ............................................................................................................ 3-3
General Functions ................................................................................................................... 3-3
4 Safety Instructions for Electric Drives and Controls 4-1

4.1 Introduction ................................................................................................................................... 4-1
4.2 Explanations ................................................................................................................................. 4-1
4.3 Hazards by Improper Use............................................................................................................. 4-2
4.4 General Information ...................................................................................................................... 4-3
4.5 Protection Against Contact with Electrical Parts........................................................................... 4-5
4.6 Protection Against Electric Shock by Protective Low Voltage (PELV) ......................................... 4-6
4.7 Protection Against Dangerous Movements .................................................................................. 4-7
4.8 Protection Against Magnetic and Electromagnetic Fields During Operation and
Mounting ....................................................................................................................................... 4-9
4.9 Protection Against Contact with Hot Parts.................................................................................. 4-10
4.10 Protection During Handling and Mounting.................................................................................. 4-10
4.11 Battery Safety ............................................................................................................................. 4-11
4.12 Protection Against Pressurized Systems.................................................................................... 4-11
5 Start up Instructions for the demo system 5-1

5.1 Minimum requirements for start-up............................................................................................... 5-1
5.2 Installation Hardware .................................................................................................................... 5-3
5.3 Presettings .................................................................................................................................... 5-5
5.4 Analog command communication mode ...................................................................................... 5-8
5.5 SERCOS mode through SYSDA-box ......................................................................................... 5-11
II Inhaltsverzeichnis PSP-I01.1-01-EN
6 Extended parameter settings 6-1

6.1 Introduction ................................................................................................................................... 6-1
7 Attachment 7-1
7.1 Switchboard of the demo system ................................................................................................. 7-1
Description of the switchboard ................................................................................................ 7-2
7.2 Operating panel ............................................................................................................................ 7-3
Description of the operating panel........................................................................................... 7-4
7.3 Mounting plate motors .................................................................................................................. 7-6
Information for motor mounting plate or motor replacement ................................................... 7-6
8 Supplement 8-1
8.1 Internal Wiring of components ...................................................................................................... 8-1
8.2 Wiring power supply module HVE ................................................................................................ 8-2
8.3 Wiring control voltage drives......................................................................................................... 8-3
8.4 Rewiring for optional Mains voltages............................................................................................ 8-4
8.5 Rewiring of the internal transformer ............................................................................................. 8-5
8.6 Rewiring the internal 24V power supply module .......................................................................... 8-6
9 Service & Support 9-1

9.1 Helpdesk ....................................................................................................................................... 9-1
9.2 Service-Hotline ............................................................................................................................. 9-1
9.3 Internet.......................................................................................................................................... 9-1
9.4 Vor der Kontaktaufnahme... - Before contacting us... .................................................................. 9-2
10 Kundenbetreuungsstellen - Sales & Service Facilities 10-1
PSP-I01.1-01-EN Abbildungsverzeichnis 1-1
1 Abbildungsverzeichnis
Fig. 4-1: Hazard classification (according to ANSI Z535) 4-1
Abb. 5-1: 2-axis IndraDrive M demo system 5-1
Abb. 5-2: Schematic representation of the hardware installation 5-3
Abb. 5-3: Connection of the fiber optical cables (IKO). 5-4
Abb. 5-4: Status after Boot routine 5-5
Abb. 5-5: Menu selection 1 5-5
Abb. 5-7: Address selection dialog 5-6
Abb. 5-8: Address adjustment range x10 5-6
Abb. 5-9: Address adjustment range x1 5-6
Abb. 5-10: address selection dialog 5-7
Abb. 5-12: Status after Boot routine 5-8
Abb. 5-15: Address selection dialog 5-8
Abb. 5-16: Selection analog mode 5-9
Abb. 5-17: Set point command value 5-9
Abb. 5-18: Warning message E-Stop active "E8034" 5-9
Abb. 5-19: Ready for power On "bb" 5-9
Abb. 5-20: Drive ready "Ab" 5-10
Abb. 5-21: Drive Halt (drive stop) with torque 5-10
Abb. 5-22: Drive enable 5-10
Abb. 5-23: Information of Software version 5-12
Abb. 5-24: Select connection "Online using SERCANS" 5-12
Abb. 5-25: System overview 5-13
Abb. 5-26: System overview DriveTop 5-13
Abb. 5-27: Declare SERCANS Drive address 1 5-14
Abb. 5-28: Add SERCANS Drive address 2 5-14
Abb. 5-29: Load parameters 5-15
Abb. 5-30: Loading parameter file 5-15
Abb. 5-31: Status after parameter upload 5-16
Abb. 5-32: Activate operating mode 5-16
Abb. 5-33: Ready for power On 5-17
Abb. 5-34: Control and Power section ready for operation 5-17
Abb. 5-35: Virtual battery box selection 5-18
Abb. 5-36: Command generator selection 5-18
Abb. 5-37: Menu "virtual battery box adjustments" 5-19
Abb. 5-38: Enable drive 5-19
Abb. 5-39: Warning! Dangerous Axis Movements! 5-20
Abb. 5-40: Command profile ready to start 5-20
Abb. 5-41: Axis selection Drive 2 5-21
1-2 Abbildungsverzeichnis PSP-I01.1-01-EN
Abb. 7-1: Design of the switchboard, PSP-I01.1-01 7-1

Abb. 7-2: Operating panel 7-3
Abb. 7-3: Allocation table E1 - E5 7-4
Abb. 7-4: Allocation table E/A8 - E/A11 7-4
Abb. 7-5: Allocation table I/An+ - I/An- 7-4
Abb. 7-6: Zuweisungsliste An1 - An2 7-5
Abb. 7-7: mounting plate motors 7-6
Abb. 8-1: wiring internal components 8-1
Abb. 8-2: control voltage wiring HVE02.2 8-2
Abb. 8-3: control voltage wiring HMS02.* 8-3
Abb. 8-4: Rewiring of the internal transformer 8-5
Abb. 8-5: Rewiring the internal 24V power supply module 8-6
PSP-I01.1-01-EN System description 2-1
2 System description
2.1 Design
The demo system is designed for different purposes. These are:
• Training
• Help Desk and Troubleshooting
• Simulation of applications
• Programming and parameter settings
2.2 State of delivery

The demo system includes:
• Ready-made net cable for German wall sockets (3m)
• Set of fiber optical cables IKO 0985 (5m)
• This document
2.3 Dimensions and weight

• Height: 925 mm
• Width: 500 mm
• Depth: 450 mm
• Weight: 83 kg
2.4 Mains connection

In the state of delivery the demo system is prepared for an earthed TT-net
with 230 VAC (+-10%), 50-60 Hz; less than16Amps.
Note: When required the mains voltage can be modified to different

inputs like 115VAC. Refer to chapter Supplement-Rewiring for
required rewiring of the demo system.
2-2 System description PSP-I01.1-01-EN
PSP-I01.1-01-EN General Instructions 3-1
3 General Instructions
3.1 Definition of Terms, Introduction
Introduction
Read these instructions before the initial startup of the equipment in order
to eliminate the risk of bodily harm or material damage. Follow these sa-
fety instruction at all times.
The products of Bosch Rexroth Ltd. are designed and produced on actual
level of technology. Before delivery all products are checked for reliability
and operational safety.
The products are designed for designated purposes only. Bosch Rexroth
is not liable for damages resulting from failure to observe the warnings
provided in this documentation.
Warning: Improper use of this equipment, failure to follow the safe-

ty instructions in this document or tampering with the
product, including diabling of safety devices, may result
in material damge, bodily harm, electrial shock or even
death!.
Before use of Bosch Rexroth products the following prerequisites are full-
filled to guarantee a designated use of the products:
• Every user who works in any way with our products have to know the
related safety instructions and must know and understand the de-
signated use..
• In case of hardware products, the hardware must not be modified.
Software products not decompiled or source codes modified.
• Defective or non fail-safe parts must not used or mounted.
3-2 General Instructions PSP-I01.1-01-EN
Areas of use and application

The demo system PSP-I01.1-01 of Bosch Rexroth is designed for the use
in office and laboratory.
Note: The demo system PSP-I01.1-01 may used only used with ge-
nuine parts listed in that documentation. Additional parts are
not allowed.
Use only the specificated configuration and combination with
the Soft- and Firmware listed in this document.
The demo system must not be used under different conditions as descri-
bed in the respective application manual, mounting- or installation guide
e.g. temperature, protection class, humidity, EMC..
3.2 Improper use

• Do not attempt the demo system if It is exposed to improper am-
bient conditions. It is not allowed to use under water, extreme tem-
perature conditions (condensation) or temperature higher than 55
degrees Celsius.
• In applications who are not explicit released by Bosch Rexroth it is
absolutely required to read the Safety instructions. Only personal
who are trained and qualified for the use and operation of the
equipment may work on this equipment or within its proximity.
• The persons are qualified if they have sufficient knowledge of the
assembly, installation and operation of the equipment as well as an
understanding of all warnings and precautionary measures noted in
these instructions.
• Furthermore, they must be trained, instructed and qualified to
switch electrical circuits and equipment on and off in accordance
with technical safety regulations, to ground them and to mark them
according to the requirements of safe work practices. They must
have adequate safety equipment and be trained in first aid
PSP-I01.1-01-EN General Instructions 3-3
3.3 Functions and Operation modes
Main Operating Modes

• Torque control
• Velocity control
• Position control
• Drive-internal interpolation
• Jog mode
• Position block mode
General Functions
Controller functions • Extensive diagnostic options
• Base parameter loding
• Current limitation
• Speed limitation
• Excessive Position limitation
• Drive internal Failure reaction:
• Drive lock function
• Drive Halt function
• Automatical homing
• Analog I/O's
• Oscilloscope function
Warnings Many areas are monitored in connection with operating modes and para-
meter settings. A warning will be generated if a state is detected that al-
lows a proper operation for the being, but will eventually generate an error
and thereby lead to a shutdown of the drive if this state continues.
Operational modes Given drive controllers without command communications interface or if

the command communications is not active (command communications
could be SERCOS), then the drive switches automatically into operating-
mode after the control voltage is switched on.
If the command communication is active, then the drive controller does
not automatically switch into operating mode after the control voltage is
switched on. Only the command communications master can switch bet-
ween parametrization modes and operating modes.
Parametrization surfaces that communicate with the drive controller via
the RS232/485 can switch from parametrization and operating mode as
long as the drive is not in control mode and command communications is
not active. Commsioning Guidelines: For commissioning drive controllers,
the parametrization interface DriveTop can be used.
Errors Errors: Many areas are monitored in connection with operating modes
and parameter settings. An error message is generated if a condition is
encountered which no longer allows proper operation
Backup & Restore To save the data of the axis, all important and changeable parameters of
the axis are stored in the list S-0-0192, IDN-List of backup operation data.
By saving the parameters listed there with the control or parametrization
surface, you can obtain a complete data backup of this axis after the first
setup (Backup&Restore-function).
3-4 General Instructions PSP-I01.1-01-EN
Parameter Buffer Mode The drive controller is capable of storing data that is transmitted via the
user data channel (e.g., service channel) either temporarily or perma-
nently.
Firmware Update with the Dolfi Firmware updates for a drive controler via the serial interface are avai-
Program lable with the program DOLFI. The program can be ordered from Bosch
Rexroth with part number: SWA-DOL*PC-INB-01VRS-MS-C1,44-COPY
or material number 279804.
Overview of SERCOS The basic features of the SERCOS interface are:
Communication
• Cyclicyl data exchange command and feedback values with exact time
intervals
• Synchronization of measurement point and command value input
• Overall synchronization of all drives connected to the control
• Minimum cycle time 0.5 ms / maximum cycle time 65 ms
• Baud rate selectable, either 2 or 4 MBaud
• Service channel for settings and diagnostics
• Data transfer through fiber optic ring
• Configuration of the telegram contents
• SERCOS compatibility class C, Granularity 1, i.e., a multiple of
1000 µsec can be programmed as cycle time.
The features of the interface are mentioned here briefly. More detailed
information is included in the SERCOS interface specification.
Startup for the SERCOS To start the interface you have to:
Interface
• connect the fiber optic cable
• set the drive address
• check the distortion indicator
• set the transmission rate
• set the transmission power
Adjustments of the SERCOS All settings can be done with switches on the front plate of the interface
Interface
Command Communications with If the SERCOS interface is not active then the analog interface can be
Analog Interface used in both of these units as well.
Note: In case of any technical problem please call the Bosch Rex-
roth Dept. BRC/BMS3 (+49 9352 40-4295) or by Email: wer-
ner.klein@boschrexroth.de
PSP-I01.1-01-EN Safety Instructions for Electric Drives and Controls 4-1
4 Safety Instructions for Electric Drives and Controls
4.1 Introduction
Read these instructions before the initial startup of the equipment in order
to eliminate the risk of bodily harm or material damage. Follow these
safety instructions at all times.
Do not attempt to install or start up this equipment without first reading all
documentation provided with the product. Read and understand these
safety instructions and all user documentation of the equipment prior to
working with the equipment at any time. If you do not have the user
documentation for your equipment, contact your local Rexroth Indramat
representative to send this documentation immediately to the person or
persons responsible for the safe operation of this equipment.
If the equipment is resold, rented or transferred or passed on to others,
then these safety instructions must be delivered with the equipment.
Improper use of this equipment, failure to follow

the safety instructions in this document or
tampering with the product, including disabling
WARNING of safety devices, may result in material
damage, bodily harm, electric shock or even
death!
4.2 Explanations
The safety instructions describe the following degrees of hazard
seriousness in compliance with ANSI Z535. The degree of hazard
seriousness informs about the consequences resulting from non-
compliance with the safety instructions.
Warning symbol with signal Degree of hazard seriousness according
word to ANSI
Death or severe bodily harm will occur.
DANGER
Death or severe bodily harm may occur.
WARNING
Bodily harm or material damage may occur.
CAUTION
Fig. 4-1: Hazard classification (according to ANSI Z535)
4-2 Safety Instructions for Electric Drives and Controls PSP-I01.1-01-EN
4.3 Hazards by Improper Use
High voltage and high discharge current!

Danger to life or severe bodily harm by electric
shock!
DANGER
Dangerous movements! Danger to life, severe

bodily harm or material damage by
unintentional motor movements!
DANGER
High electrical voltage due to wrong

connections! Danger to life or bodily harm by
electric shock!
WARNING
Health hazard for persons with heart

pacemakers, metal implants and hearing aids in
proximity to electrical equipment!
WARNING
Surface of machine housing could be extremely

hot! Danger of injury! Danger of burns!
CAUTION
Risk of injury due to improper handling! Bodily

harm caused by crushing, shearing, cutting and
mechanical shock or incorrect handling of
CAUTION pressurized systems!
Risk of injury due to incorrect handling of

batteries!
CAUTION
4.4 General Information

• Bosch Rexroth is not liable for damages resulting from failure to
observe the warnings provided in this documentation.
• Read the operating, maintenance and safety instructions in your
language before starting up the machine. If you find that you cannot
completely understand the documentation for your product, please ask
your supplier to clarify.
• Proper and correct transport, storage, assembly and installation as
well as care in operation and maintenance are prerequisites for
optimal and safe operation of this equipment.
• Only persons who are trained and qualified for the use and operation
of the equipment may work on this equipment or within its proximity.
• The persons are qualified if they have sufficient knowledge of the
assembly, installation and operation of the equipment as well as
an understanding of all warnings and precautionary measures
noted in these instructions.
• Furthermore, they must be trained, instructed and qualified to
switch electrical circuits and equipment on and off in accordance
with technical safety regulations, to ground them and to mark them
according to the requirements of safe work practices. They must
have adequate safety equipment and be trained in first aid.
• Only use spare parts and accessories approved by the manufacturer.
• Follow all safety regulations and requirements for the specific
application as practiced in the country of use.
• The equipment is designed for installation in industrial machinery.
• The ambient conditions given in the product documentation must be
observed.
• Use only safety features and applications that are clearly and explicitly
approved in the Project Planning Manual.
For example, the following areas of use are not permitted: construction
cranes, elevators used for people or freight, devices and vehicles to
transport people, medical applications, refinery plants, transport of
hazardous goods, nuclear applications, applications sensitive to high
frequency, mining, food processing, control of protection equipment
(also in a machine).
• The information given in the documentation of the product 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
documentation with regard to the use of the components,
• make sure that his application complies with the applicable safety
regulations and standards and carry out the required measures,
modifications and complements.
• Startup of the delivered components is only permitted once it is sure
that the machine or installation in which they are installed complies
with the national regulations, safety specifications and standards of the
application.
• Operation is only permitted if the national EMC regulations for the

application are met.
The instructions for installation in accordance with EMC requirements
can be found in the documentation "EMC in Drive and Control
Systems".
The machine or installation manufacturer is responsible for
compliance with the limiting values as prescribed in the national
regulations.
• Technical data, connections and operational conditions are specified in
the product documentation and must be followed at all times.
4.5 Protection Against Contact with Electrical Parts
Note: This section refers to equipment and drive components with

voltages above 50 Volts.
Touching live parts with voltages of 50 Volts and more with bare hands or
conductive tools or touching ungrounded housings can be dangerous and
cause electric shock. In order to operate electrical equipment, certain
parts must unavoidably have dangerous voltages applied to them.
High electrical voltage! Danger to life, severe

bodily harm by electric shock!
⇒ Only those trained and qualified to work with or on
DANGER electrical equipment are permitted to operate, maintain
or repair this equipment.
⇒ Follow general construction and safety regulations when
working on high voltage installations.
⇒ Before switching on power the ground wire must be
permanently connected to all electrical units according
to the connection diagram.
⇒ Do not operate electrical equipment at any time, even
for brief measurements or tests, if the ground wire is not
permanently connected to the points of the components
provided for this purpose.
⇒ Before working with electrical parts with voltage higher
than 50 V, the equipment must be disconnected from
the mains voltage or power supply. Make sure the
equipment cannot be switched on again unintended.
⇒ The following should be observed with electrical drive
and filter components:
⇒ Wait five (5) minutes after switching off power to allow
capacitors to discharge before beginning to work.
Measure the voltage on the capacitors before beginning
to work to make sure that the equipment is safe to
touch.
⇒ Never touch the electrical connection points of a
component while power is turned on.
⇒ Install the covers and guards provided with the
equipment properly before switching the equipment on.
Prevent contact with live parts at any time.
⇒ A residual-current-operated protective device (RCD)
must not be used on electric drives! Indirect contact
must be prevented by other means, for example, by an
overcurrent protective device.
⇒ Electrical components with exposed live parts and
uncovered high voltage terminals must be installed in a
protective housing, for example, in a control cabinet.
To be observed with electrical drive and filter components:
High electrical voltage on the housing!

High leakage current! Danger to life, danger of
injury by electric shock!
DANGER ⇒ Connect the electrical equipment, the housings of all
electrical units and motors permanently with the safety
conductor at the ground points before power is
switched on. Look at the connection diagram. This is
even necessary for brief tests.
⇒ Connect the safety conductor of the electrical
equipment always permanently and firmly to the
supply mains. Leakage current exceeds 3.5 mA in
normal operation.
⇒ Use a copper conductor with at least 10 mm² cross
section over its entire course for this safety conductor
connection!
⇒ Prior to startups, even for brief tests, always connect
the protective conductor or connect with ground wire.
Otherwise, high voltages can occur on the housing
that lead to electric shock.
4.6 Protection Against Electric Shock by Protective Low

Voltage (PELV)
All connections and terminals with voltages between 0 and 50 Volts on
Rexroth Indramat products are protective low voltages designed in
accordance with international standards on electrical safety.
High electrical voltage due to wrong

connections! Danger to life, bodily harm by
electric shock!
WARNING ⇒ Only connect equipment, electrical components and
cables of the protective low voltage type (PELV =
Protective Extra Low Voltage) to all terminals and
clamps with voltages of 0 to 50 Volts.
⇒ Only electrical circuits may be connected which are
safely isolated against high voltage circuits. Safe
isolation is achieved, for example, with an isolating
transformer, an opto-electronic coupler or when
battery-operated.
4.7 Protection Against Dangerous Movements

Dangerous movements can be caused by faulty control of the connected
motors. Some common examples are:
• improper or wrong wiring of cable connections
• incorrect operation of the equipment components
• wrong input of parameters before operation
• malfunction of sensors, encoders and monitoring devices
• defective components
• software or firmware errors
Dangerous movements can occur immediately after equipment is
switched on or even after an unspecified time of trouble-free operation.
The monitoring in the drive components will normally be sufficient to avoid
faulty operation in the connected drives. Regarding personal safety,
especially the danger of bodily injury and material 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 depends upon the type of control and the state of operation.
Dangerous movements! Danger to life, risk of

injury, severe bodily harm or material damage!
⇒ Ensure personal safety by means of qualified and
DANGER tested higher-level monitoring devices or measures
integrated in the installation. Unintended machine
motion is possible if monitoring devices are disabled,
bypassed or not activated.
⇒ Pay attention to unintended machine motion or other
malfunction in any mode of operation.
⇒ Keep free and clear of the machine’s range of motion

and moving parts. Possible measures to prevent
people from accidentally entering the machine’s range
of motion:
- use safety fences
- use safety guards
- use protective coverings
- install light curtains or light barriers
⇒ Fences and coverings must be strong enough to
resist maximum possible momentum, especially if
there is a possibility of loose parts flying off.
⇒ Mount the emergency stop switch in the immediate
reach of the operator. Verify that the emergency stop
works before startup. Don’t operate the machine if the
emergency stop is not working.
⇒ Isolate the drive power connection by means of an
emergency stop circuit or use a starting lockout to
prevent unintentional start.
⇒ Make sure that the drives are brought to a safe
standstill before accessing or entering the danger
zone. Safe standstill can be achieved by switching off
the power supply contactor or by safe mechanical
locking of moving parts.
⇒ 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
- ensuring sufficient equilibration of the vertical axes
The standard equipment motor brake or an external
brake controlled directly by the drive controller are
not sufficient to guarantee personal safety!
⇒ Disconnect electrical power to the equipment using a

master switch and secure the switch against
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 equipment near electronics circuits
and supply leads. If the use of such equipment cannot
be avoided, verify the system and the installation for
possible malfunctions in all possible positions of
normal use before initial startup. If necessary, perform
a special electromagnetic compatibility (EMC) test on
the installation.
4.8 Protection Against Magnetic and Electromagnetic Fields

During Operation and Mounting
Magnetic and electromagnetic fields generated near current-carrying
conductors and permanent magnets in motors represent a serious health
hazard 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 electrical equipment!
WARNING ⇒ Persons with heart pacemakers, hearing aids and
metal implants are not permitted to enter the following
areas:
- Areas in which electrical equipment and parts are
mounted, being operated or started up.
- Areas in which parts of motors with permanent
magnets are being stored, operated, repaired or
mounted.
⇒ If it is necessary for a person with a heart pacemaker
to enter such an area, then a doctor must be
consulted prior to doing so. Heart pacemakers that
are already implanted or will be implanted in the
future, have a considerable variation in their electrical
noise immunity. Therefore there are no rules with
general validity.
⇒ Persons with hearing aids, metal implants or metal
pieces must consult a doctor before they enter the
areas described above. Otherwise, health hazards will
occur.
4.9 Protection Against Contact with Hot Parts
Housing surfaces could be extremely hot!

Danger of injury! Danger of burns!
⇒ Do not touch housing surfaces near sources of heat!
CAUTION Danger of burns!
⇒ After switching the equipment off, wait at least ten (10)
minutes to allow it to cool down before touching it.
⇒ Do not touch hot parts of the equipment, such as
housings with integrated heat sinks and resistors.
Danger of burns!
4.10 Protection During Handling and Mounting

Under certain conditions, incorrect handling and mounting of parts and
components may cause injuries.
Risk of injury by incorrect handling! Bodily

harm caused by crushing, shearing, cutting and
mechanical shock!
CAUTION ⇒ Observe general installation and safety instructions
with regard to handling and mounting.
⇒ Use appropriate mounting and transport equipment.
⇒ Take precautions to avoid pinching and crushing.
⇒ Use only appropriate tools. If specified by the product
documentation, special tools must be used.
⇒ Use lifting devices and tools correctly and safely.
⇒ For safe protection wear appropriate protective
clothing, e.g. safety glasses, safety shoes and safety
gloves.
⇒ Never stand under suspended loads.
⇒ Clean up liquids from the floor immediately to prevent
slipping.
4.11 Battery Safety

Batteries contain reactive chemicals in a solid housing. Inappropriate
handling may result in injuries or material damage.
Risk of injury by incorrect handling!

⇒ Do not attempt to reactivate discharged batteries by
heating or other methods (danger of explosion and
cauterization).
CAUTION
⇒ Never charge non-chargeable batteries (danger of
leakage and explosion).
⇒ Never throw batteries into a fire.
⇒ Do not dismantle batteries.
⇒ Do not damage electrical components installed in the
equipment.
Note: Be aware of environmental protection and disposal! The

batteries contained in the product should be considered as
hazardous material for land, air and sea transport in the sense
of the legal requirements (danger of explosion). Dispose
batteries separately from other waste. Observe the legal
requirements in the country of installation.
4.12 Protection Against Pressurized Systems

Certain motors and drive controllers, corresponding to the information in
the respective Project Planning Manual, must be provided with
pressurized media, such as compressed air, hydraulic oil, cooling fluid
and cooling lubricant supplied by external systems. Incorrect handling of
the supply and connections of pressurized systems can lead to injuries or
accidents. In these cases, improper handling of external supply systems,
supply lines or connections can cause injuries or material damage.
Danger of injury by incorrect handling of

pressurized systems !
⇒ Do not attempt to disassemble, to open or to cut a
CAUTION pressurized system (danger of explosion).
⇒ Observe the operation instructions of the respective
manufacturer.
⇒ Before disassembling pressurized systems, release
pressure and drain off the fluid or gas.
⇒ Use suitable protective clothing (for example safety
glasses, safety shoes and safety gloves)
⇒ Remove any fluid that has leaked out onto the floor
immediately.
Note: Environmental protection and disposal! The media used in the

operation of the pressurized system equipment may not be
environmentally compatible. Media that are damaging the
environment must be disposed separately from normal waste.
Observe the legal requirements in the country of installation.
Notes
PSP-I01.1-01-EN Start up Instructions for the demo system 5-1
5 Start up Instructions for the demo system
5.1 Minimum requirements for start-up
Abb. 5-1: 2-axis IndraDrive M demo system
Soft- and Hardware IndraDrive M 2-axis demo system with SERCOS Command Communi-
requirements cation Interface.
Standard PC oder Laptop.
Minimum requirements:
• Intel 486 PC (Pentium 166 or faster recommended)
• Microsoft Windows 95, Microsoft Windows 98, Microsoft Windows ME,
Microsoft Windows NT 4.0, Microsoft Windows 2000 or Microsoft
Windows XP.
• installed Software DriveTop 15VRS or higher recommended.
• minimum 32 MByte RAM Memory
• minimum 60 MByte Hard disk Memory
• use small fronts for the screen in the control panel
• Start-up tool SYSDA02.X
The Start-up tool SYSDA02.X contents a SERCOS-Master unit for the
Communication with the drives of the demo system.
In the state of delivery no additional adjustments have to be done for
SYSDA02.x
Note: The Start-up tool, Type: SYSDA02.2 can be ordered sepera-

tely with the part number 287218.
The following start-up is based on Software DriveTop 16VRS. In other

DriveTop versions the display representation can be slightly different from
this documentation.
5-2 Start up Instructions for the demo system PSP-I01.1-01-EN
Note: The Software DriveTop 16VRS is not inluded with the demo
system. DriveTop can be ordered seperately with the part
number 287218.
Ready-made Parameter set The demo system needs to be programmed with a parameter set.
Note: The above mentioned Software DriveTop 16VRS includes

ready-made parameter sets for demo systems.
Additional Documentation Additional documentation concerning the products in the demo system is
available:
• DOCU CD-Rom (part number: 281882)
• Online Help system for the drive firmware
• Paper documentation
• HVE + HVR Application manual (part number: 280604)
• HMS Project planning description (part number: ******)
• MHD Project planning description (part number: 272177)
5.2 Installation Hardware

Mains connection Press the Emergency switch (Not Aus) on the IndraDrive demo system
and turn the main switch into position "0 (OFF)" to be sure there is no
voltage activated.
Connect the enclosed net cable at the demo system with 1 x AC 230 V ±
10% (earthed TT net); 50-60 Hz; 16 amps via a safety contact electrical
outlet. When use of divergent mains voltage the internal transformer and
the input of the 24V power supply need to be rewired. see chapter: Supp-
lement-Rewiring (Modification for other net input voltages.
PC or
Laptop
Connector
RS 232
Cable SYSDA02.X
8
RxD TxD
Rexroth
Indramat
Start-up tool
SYSDA 02
SYSDA02
IKO 0985
IKO 0985
Fiber optical cables
Demo system
Rexroth
Indramat
HAUPTSCHALTER MAIN SWITCH

ÖFFNEN IN OPEN IN
PSP-I01.1-01
0-STELLUNG OFF-POSITION
NOT
O POWER
OFF
ON
AUS
control voltage
Bb Bb
I1 Cam 1 I1 Cam 1
I2 Cam 2 I2 Cam 2
I3 Limit + I3 Limit +
I4 Limit - I4 Limit -
I5 Ref I5 Ref
I/O 8 E-Stop I/O 8 E-Stop
I/O 9 I/O 9
I/O10 AH I/O10 AH
I/O11 RF I/O11 RF
8.8.
analog value analog value
0 90 0 90
10 10
30 20
30 20
80 70
80 70
1 P-1 1 P-1
60 60
50 40 50 40
- + - + Esc Esc
Enter Enter
HMS01.1 HMS01.1
An 1 GND An 1 GND
An 1 GND An 1 GND
+24VDC
/max.1A Fuse
F3/4A
0V +24 V 0V
control
Output: 24VDC / 1A DC
voltage 24VDC
HVE02.2
DANGER! GEFAHR!
High Voltage. Danger to life. Hohe Spannung. Lebensgefahr.
Withdraw the mains plug Vor dem Öffnen des Gehäuses
before opening the housing! Netzstecker ziehen!
Connect the ground connection Schutzleiter fest ans Netz
permanently to the mains! anscließen!
P S P - I 0 1 . 1 - 0 1-NN Read and follow operating Bedienungsanleitung lesen
00284608-00100 instructions. und beachten.
WARNING! WARNUNG!
Danger from moving parts. Danger from moving parts.
Operate only with protective Betrieb nur bei geschlossener
screen closed! Schutzabdeckung zulässig!
0 0
315 45 315 45
270 90 270 90
Connector
225 135 225 135
180 180
Demo system
Abb. 5-2: Schematic representation of the hardware installation
SYSDA box connection Connect one fiber optical cables IKO0985 with the SYSDA box terminal
TxD and the other end with the Drive controller HMS (axis 1) terminal
X20RX. Connect the the second fiber optical cable with RxD at the SYS-
DA box and the other end with X20TX at the Drive controller HMS (axis 2)
8
SercTop
RxD TxD
RS232 Start-up tool

SYSDA 02.2
Rexroth
Bosch Group
SYSDA 02
Fiber optical cables

IKO 0985
Rexroth
Indramat

ÖFFNEN IN OPEN IN
N OT
O POWER
OFF
ON
AUS
control voltage
Bb Bb
I1 Cam 1 I1 Cam 1
I2 Cam 2 I2 Cam 2
I5 Ref I5 Ref

X20TX
X20TX
I/O 9 I/O 9
I/O10 AH I/O10 AH
8.8.
X21RX
X21RX
I/O11 RF I/O11 RF
0 90 0 90
10 10
30 20
30 20
80 70
80 70
1 P-1 1 P-1
60 60
50 40 50 40
- + - + Esc Esc
Enter Enter
HMS01.1 HMS01.1
An 1 GND An 1 GND
An 1 GND An 1 GND
+24VDC
/max.1A Fuse
F3/4A
0V +24 V 0V
control
Output: 24VDC / 1A DC
voltage 24VDC
HVE02.2
DANGER! GEFAHR!
P S P - D 0 4 . 2 - 0 4 -NN-*** Read and follow operating Bedienungsanleitung lesen
00284608-00100 instructions. und beachten.
WARNING! WARNUNG!
Abb. 5-3: Connection of the fiber optical cables (IKO).
5.3 Presettings
Function overview of drive The following functions can be executed by the Diagnose module:
diagnose module
• Adjustment Drive adress
• Adjustment SERCOS Transmit power
• SERCOS Autodetect Field bus transfer
• Position reference
• Failure history
• Base parameter load
• Adjustment Analog inputs
Adjustment drive address This procedure is needed for the SERCOS-Master to identify the Drive
controller modules.
The required procedure is described in the following chapter.
Note: For the adjustment of the drive controller address, the SYSDA
box is not required.
Switch-On Demo system Check if the emergency switch and the fuse on the back plane of the de-
mo system are switched on. Turn the main switch to "1" (ON) to supply
the power supply module HVE. The fans of the power supply module HVE
and the drive controllers HMS are running. The diagnose display H1 at
the power supply module HVE gets the message "23" (Drive failure) or
already "bb" (Ready for power On). The diagnose modules of both drives
display the boot routine and finally following status:
1 P-1
Esc Enter
Abb. 5-4: Status after Boot routine
The following steps must be carried out completely for both drive control-
lers:
• press push-button "Enter" 1x
Dialog change: Menu selection
1 . E r. A n z
Esc Enter
Abb. 5-5: Menu selection 1
• Press push button "", 1x

Dialog change: Comand
2.Comand
Esc Enter
• Press push button "Enter" 1x

Dialog change: Address selection dialog. Alternately the following indicati-
on appears
2.1 Adr. Adr. 1

Esc Enter Esc Enter
Abb. 5-7: Address selection dialog

.Dialog change: Address adjustment range x10
2.1.1 11
Esc Enter
Abb. 5-8: Address adjustment range x10
The adjustment range of the decade is represented by a blinking digit in

the display.
• Press push button "" oder ""if necessary until the indication is
without number
• Press push button "Enter"
Dialog change: Address adjustment range x1.
2.1.2 11
Esc Enter
Abb. 5-9: Address adjustment range x1
The adjustment range of the one decade is represented by a blinking digit

in the display.
• Press push button "" or "" if necessary press until "1" at the left
drive or 2 appear at the right drive.
• Press push button "Enter"
Dialog change: The following indication alternately seems address selec-
tion dialog.
2.1 Adr. Adr. 1

Esc Enter Esc Enter
Abb. 5-10: address selection dialog
• Press push button "Esc"

Dialog change: Comand.
2.Comand
Esc Enter
Result: The Drive on the left side has got the address 1, the right hand
side drive has got the address 2.
5.4 Analog command communication mode

Driving the drives in analog mode some additional adjustments are requi-
red. All two-way switches of the operating panel have to be in middle po-
sition (no contact).The following instructions must be carried out on both
drive controllers.
Define analog mode

Note: If the display already shows the status "Command" skip the
next 3 work steps!
The diagnose modules of both drive controllers display the following re-
port after the Boot routine.
1 P-1
Esc Enter
Abb. 5-12: Status after Boot routine

Dialog change: Menu selection
1 . E r. A n z
Esc Enter
• Press push button "" 1x

Dialog change: Comand
2.Comand
Esc Enter

Dialog change: Address selection dialog. The following indication alter-
nately appears.
2.1 Adr. Adr. 1

Esc Enter Esc Enter
Abb. 5-15: Address selection dialog
The display of the left drive controller shows address 1 and the display of
the right drive controller shows address "2".
• Press push button "", 2x
Dialog change: Selection analog mode
2.3 Anlg
Esc Enter
Abb. 5-16: Selection analog mode

Dialog change: Set point command value
V- R e g ? 10V / N m a x
Esc Enter Esc Enter
Abb. 5-17: Set point command value
• press push button "Enter" 1x

Dialog change: Warning message E-Stop active "E8034".
In addition to the warning message the drive address is displayed on the
left side of the respective drive. The status "Ready for power on" is also
confirmed by the green LED on top of the operating panel. The display H1
of the HVE module changes to "23".
1 E8034
Esc Enter
Abb. 5-18: Warning message E-Stop active "E8034"
The warning message "E8034" indicates the active E-Stop status.

• Move switch "E-Stop" (I/O 8) at the operating panel to the right po-
sition
Dialog change: Ready for power On "bb" for the respective Drive control-
ler.
1 bb
Esc Enter
Abb. 5-19: Ready for power On "bb"
Switch Power On Prerequisite for Power On is the status "bb" for the Drive controller and
the power supply module.
• Release emergency switch
• Press push button "Power ON"
Dialog change: Drive ready "Ab" for the respective Drive controller
1 Ab
Esc Enter
Abb. 5-20: Drive ready "Ab"
The display shows on the left side the address of the respective drive
controller and on the right side the drive status. The status changes from
"bb" to "Lb" Drive ready during Power On.
Run the drives The following requirments must be fulfilled to run the drives: At the opera-
ting panel of the demo system there is a potentiometers and a switch for
the direction of speed command for the respective drive. No set point is
given in the middle position. (The Motor has got torque) Negativ (-) means
CCR in direction of the motor rotary table
Note: For the protection against dangerous movements both poten-

tiometers have to be set into zero position (turn counter clock-
wise) and both switches have to be in middle position.
• Move switch drive stop (I/O11) at the operating panel into right po-
sition
Dialog change: Drive Halt (of the respective drive controller).
1 AH
Esc Enter
Abb. 5-21: Drive Halt (drive stop) with torque
The left side of the display shows the respective drive address. The right
side shows the drive status "AH" Drive Halt.
• Move switch drive enable (I/O10) at the operating panel into right
position
Dialog change: Drive enable (The respective drive controllers).
1 AF
Esc Enter
Abb. 5-22: Drive enable
The left side of the display shows the respective drive address. The right
side shows the drive status "AF" Drive enable.
• Move the set point switch into right position (+)
• Turn the potentiometer to increase/degrease the speed
The drive follows the current set point and the selected direction of rotati-
on.
5.5 SERCOS mode through SYSDA-box

In this chapter the handling of the IndraDrive demo with SERCOS com-
munication and Setup tool SYSDA 02.2 system is described.
Note: Prerequisite for the setup is: The proper installation of the de-
mo system, loaded parameter set, preadjusted drive addres-
ses and the demo system must be switched on. Refer to
chapter: "Installation of hardware or "xxx".
Start DriveTop For the communication with the IndraDrive demo system the software
DriveTop is needed. Drivetop Version 16 isn't contained in the scope of
supply of the demo system and can be ordered separately with the part
number 295178.
The following functions can be carried out with Drivetop:
• Backup/Restore Drive parameter sets
• Carry out simple commissioning and editing drive parameters
• Indication of the diagnosis and status reports
• Executing drive commands
• Failure history (log book) and delete faults
• Adjusting communication parameters
Note: Software DriveTop from version 15 VRS can be used.

This documentation was made with DriveTop 16 VRS.
Use of another software version can have a divergent repre-
sentation of menu operation and dialogs.
• Start DriveTop Software

Information about DriveTop Software version
Abb. 5-23: Information of Software version
Dialog change: automatically

• select connection "Online using SERCANS"
• confirm the Command box with "OK"
Abb. 5-24: Select connection "Online using SERCANS"
Dialog change: System overview DriveTop
Abb. 5-25: System overview
• select menu: Setup SERCANS basic configuration System o-

verview
• change to menu: "System overview" (SERCANS configuration)
Abb. 5-26: System overview DriveTop
Dialog change: Declare SERCANS Drive address 1
• Declare SERCANS Drive address 1
Abb. 5-27: Declare SERCANS Drive address 1
Dialog: Declare SERCANS Drive address 2

• overwrite selected drive adress (row 2) number with the value 2 in
the content input window
• confirm the switch box "Change"
• confirm the switch box "Save list"
• confirm the switch box "Exit"
Abb. 5-28: Add SERCANS Drive address 2
Load parameter file For an easy setup and simple trial of the drives it is required to load the
parameter set into the demo system
Note: In the delivery state of the demo system a parameter set has
been loaded already.In each case it is recommended to save
the current file for later use. The parameter set is enclosed in
DriveTop or can be ordered by email:
elmar.glassen@boschrexroth.de
Menu selection: File Load

• change the path of the backup file into the path of the respective
setup file
• adjust the loading options like in the previous dialog "load parame-
ters"
• confirm of the switch box "OK"
Abb. 5-29: Load parameters
Dialog change: Loading parameter file.
Abb. 5-30: Loading parameter file
Dialog change: After the loading event the dialog is automatically carried
into the DriveTop-System Overview
Abb. 5-31: Status after parameter upload
Switch to operating mode Menu selection: Extras Operating mode
Abb. 5-32: Activate operating mode
Dialog change: Ready for power On
Abb. 5-33: Ready for power On
Switch Power On • Press push button "Power On"

The supply module changes the indication at the display "H1" from "bb" to
"Lb" and gives also a confirmation by the LED of the Power-On switch.
The indications of the drive controllers changing from "bb" to "Ab".
Dialog change: Control and Power section ready for operation
Abb. 5-34: Control and Power section ready for operation
Activate command generator Menu selection: Extras Virtual battery box Virtual battery box selecti-
on....
Abb. 5-35: Virtual battery box selection
Dialog change: Command generator selection

• activate the option button "configured"
Abb. 5-36: Command generator selection
Note: The combination of various firmware releases of the SYSDA

box and the software DriveTop can diplay different notes or
require to shift the SERCOS mode. In that case confirm the
dialogs with "Close" or "OK".
Dialog change: System Overview.

• Menu selection: Extras virtual battery box Virtual battery box
adjustments....
Abb. 5-37: Menu "virtual battery box adjustments"
Dialog change: Command generator

Drive enable • Select the switch box "Enable"
Abb. 5-38: Enable drive
Dialog change: Warning! Dangerous Axis Movements!
Note: Read the following warning notes in the dialogue. The measu-
res of the safety instruction have to be noticed!
• select switch box "OK"
Abb. 5-39: Warning! Dangerous Axis Movements!
Note: An additional dialog "Drives OFF" occurs after the confirmation

"Dangerous Axis Movements!". This dialog "Drives OFF"
works as a virtual Emergency stop and shutdown the Drive e-
nable.
An active command profile will be interupted instantly.
Dialog change: Command profile ready to start.

Enable command for Drive 1
• select switchbox "Change"
Abb. 5-40: Command profile ready to start
Drive 1 is active with the preadjusted command profile. The command

profile can be variated with the settings of velocity, dwell time, position1
and position 2.
Enable command for Drive 2 • Interrupt command generator for drive 2 with switchbox "Stop".
• Confirm the switchbox "Change"
Dialog change: Axis selection Drive 2

• Highlight the input "Selection" Drive 2
• confirm the switchbox "Close"
• confirm again the switchbox "Start" after the automatical change
into the menu Command generator
Abb. 5-41: Axis selection Drive 2
Drive 2 is active with the preadjusted command profile. The command

profile can be variated with the settings of velocity, dwell time, position1
and position 2.
Shutdown demo system • press the red switchbox "Drives OFF" to disable all axis
• finish the Software Drivetop (Menu selection: File Exit
• press the Emergency Stop at the demo system
• switch off the main switch
PSP-I01.1-01-EN Extended parameter settings 6-1
6 Extended parameter settings
6.1 Introduction
To be continued with release of firmware version MTH02VRS
6-2 Extended parameter settings PSP-I01.1-01-EN
PSP-I01.1-01-EN Attachment 7-1
7 Attachment
7.1 Switchboard of the demo system
Indra
Rexroth Drive

ÖFFNEN IN OPEN IN
NOT
O POWER
OFF
ON
1. Switch
AUS Power ON
control voltage 2. Emergency stop

Bb Bb
I1 Cam 1 I1 Cam 1
3. Main switch
I2 Cam 2 I2 Cam 2
I5 Ref I5 Ref
I/O 9 I/O 9
drive drive
I/O 10 I/O 10
enable enable
drive drive
I/O 11 I/O 11
analog value
stop
analog value
stop
4. control panel
0 9 0 9
10 0 10 0
30 20
30 20
80 70
80 70
0 60 0 60
50 4 50 4
- + - +
analog output analog output
An1 GND An1 GND
An2 GND An2 GND
+24VDC
Fuse
F3/4A
0VDC
0VDC +24VDC control
voltage
Output: 24VDC / 1A 24VDC
5. Power supply
consumer devices
DANGER! GEFAHR!
Read and follow operating Bedienungsanleitung lesen
PSP-D04.2.-02-NN-** instructions. und beachten.
00284607-00100
WARNING! WARNUNG!
Abb. 7-1: Design of the switchboard, PSP-I01.1-01
7-2 Attachment PSP-I01.1-01-EN
Description of the switchboard

1. Main switch
The main switch enables the power supply for the internal components
and the multicontact socket.
2. Emergency Stop
The operation of the Emergency stop switch disables the power contactor
in the power supply module HVE. Result: The DC-bus-voltage will be di-
scharged and the motors come to a standstill.
High voltage and high discharge current! Dan-

ger to life or severe bodily harm by electric
shock!
DANGER ⇒ At the terminal connector (HVE) are still approx.
500V connected.
⇒ The discharge time of the DC-bus is bigger than 5
min.
3. Power ON switch
The Power On switch activates the Mains contactor in the HVE-module.
After pressing Power-On the DC-bus voltage is connected to the drive
modules.
4. Operating panel
Different machine conditions like travel limits, position reference etc. can
be simulated with the switches. Programmable outputs can be used for
separate drive status signals. 2 analog inputs per axis can simulate exter-
nal reference voltages or setpoints e.g. analog command communication
via 2 potentiometers. 2 analog outputs can forward voltages for external
use.
Note: In the state of delivery the I/O's are already programmed and
predefined.
5. 24 VDC output - For external consumers -

External 24V-consumers can be connected up to max. 1A.
Note: An overload can disturb the overall function of the demo sys-
tem!
7.2 Operating panel
control voltage
Bb Bb
I1 Cam 1 I1 Cam 1
I2 Cam 2 I2 Cam 2
I5 Ref I5 Ref
I/O 9 I/O 9
drive drive
I/O10 I/O10
enable enable
drive drive
I/O11 I/O11
stop stop
0 9 0 9
10 0 10 0
30 20
30 20
80 70
80 70
60 0 60 0
50 4 50 4
- + - +
analog output analog output
An1 GND An1 GND
An2 GND An2 GND
+24VDC
Fuse
F3/4A
0VDC
0VDC +24VDC control
voltage
Output: 24VDC / 1A 24VDC
Abb. 7-2: Operating panel
Description of the operating panel

In this chapter the function and design of the operating panel is described.
control voltage Status 24VDC internal power supply - control voltage -
Bb The green LED confirm the ready signal of the respective drive.
Inputs I1 - I5
Label Defaultassignment Default-IDN
I1 - Cam 1 Cam probe switch 1 S-0-0401
I2 - Cam 2 Cam probe switch 2 S-0-0402
I3 - Limit + Travel limit switch pos. P-0-0422
I4 - Limit - Travel limit switch neg. P-0-0422
I5 - Ref. Reference switch S-0-0400
Abb. 7-3: Allocation table E1 - E5
The Acknowledge of the Inputs I1-I5 is selectable via 2-way switches. On

the left position it is a push-button function; on the right position it is a
permanent confirmation. The respective LED confirm a "1" status.
Bidirectional In-/Outputs I/O8 -
I/O11 Label Defaultassignment Default-IDN
P-0-0223
I/O8 - EStop EStop
I/O9 n.c.
I/O10 - drive enable Drive enable P-0-4028
I/O11 - drive stop Drive Halt P-0-4028
Abb. 7-4: Allocation table E/A8 - E/A11
I/O8 - I/O11 used as Inputs The Acknowledge of the Inputs I8-I11 is selectable via 2-way switches.
On the left position it is a push-button function; on the right position it is a
I/O8 - I/O11 used as Outputs The Acknowledge of the Outputs O1-O5 is selectable via 2-way switches.
On the left position it is a push-button function; on the right position it is a
Analog inputs
I6/An+ - Analog-In (+) Setpoint potentiometer P-0-0213
I7/An- - Analog-In (-) Setpoint potentiometer P-0-0213
Abb. 7-5: Allocation table I/An+ - I/An-
The analog setpoint can be given with the potentiometer. The respective
switch controls the direction of the motor. "+" means clockwise turn in
direction to the rotaty table motor; "-" counterclockwise turn of motor.
Analog outputs
An1 Analogausgan 1 P-0-0427
An2 Analogausgang 2 P-0-0427
Abb. 7-6: Zuweisungsliste An1 - An2
24VDC Output Via this output external consumers can be supplied. The current is limited
to max. 1 A..
Fuse 24VDC The fuse F3 (4A) limit the current for the overall 24V supply. The OK-
status is also displayed via the LED Control voltage on top of the opera-
ting panel.
7.3 Mounting plate motors
1. optical initiator switch
0 0
315 45 2. rotary table motor 3. rotary table motor 315 45
Axis 1 Axis 2
270 90 270 90
225 135 225 135

180 180
Abb. 7-7: mounting plate motors
Information for motor mounting plate or motor replacement
Dangerous movements! Danger to life, severe

bodily harm or material damage by uninten-
tional motor movements
DANGER ⇒ The protection against dangerous movements is
made via a transparent plastic cover. Don't use the
Demo system without this protection cover.
6. Initiator switch
The optical intitiator switch simulates a reference switch of a linear axis..
7. Motor rotary table Axis 1
The motor rotary table is mounted on a motor MHD041B-144.NG0-KN
with a Single-Turn-Feedback.
8. Motor rotary table Axis 2
The motor rotary table is mounted on a motor MHD041B-144.PG0-KN
with a Multi-Turn-Feedback.
PSP-I01.1-01-EN Supplement 8-1
8 Supplement
8.1 Internal Wiring of components
Note: The schematics display the state of delivery!
X 20 F3/ 4A
PE
3
4
5
6
control panel
1 L1
3 L2
5 L3
F2
10-16A
X1
2
1
V+
V-
L.1
N.1
Z1 Last / Load T2 DC 24 V
AC 230
BGR-LK
NFE02.1 NTM01.1 control panel
line filter -230-008
Netz / Line
-024-04
I >> I >> I >>
X2
N
L
2
1
L
2 T1
4 T2
6 T3
X 20
7
8
S1
Main
0
110V
115V
127V
220V
230V
240V
switch 2 4 6 F1/10A
mounting plate Switch board
1 3
3x32A T1
mounting plate Backplane
ETT 1,0kVA/S
BV 31375
1 3 5 2 4 500V
0
X 20 X 20 X 20 X 20
PE
PE
PE
PE
PE
PE
10
12
13
14
15
11
1
ext. earthing connection backplane
HMS01.1N HMS01.1N
mounting plate transformer
-W0036 -W0036
PE
L1
N
HVE02.2-W018N X1 X1 X1 X1
out in out in
+24V
0V
L+
2
2,5 mm
L1 N PE L-
2 U V W
2,5 mm
single phase
power supply
1 x 230 VAC
50 - 60 Hz
3x1,5mm2
2
unlabeled wires 1,5 mm
Abb. 8-1: wiring internal components
Note: The multicontact socket, the circuit breaker Q1 and the auto-
matic breaker F1 are mounted on the back side of the demo
system. The circuit breaker current is adjusted to 10 Amps.
8-2 Supplement PSP-I01.1-01-EN
8.2 Wiring power supply module HVE
X3
1 rd
ZKS
2 bu
ZKS
3 bn
OFF
LK-operating panel
2
1
4 ye X15
OFF
5 pk Bb Axis 1
ON
temp contact K2
6 vt Transformer B
ON
q
A
Bb Axis 2
Power K1
4 X1 Emergency stop 2
ON
3 X2 1
X4
HVE02.2-W018N
1
+15VM
2
0VM
3
-15VM
4
Ground
5 gn
+24VL
6 gy
0VL
7
EL out
8
9
EL in
10
X6
K1 1
2 bk
K1 3 2
0,5 mm
4
K1 5
Abb. 8-2: control voltage wiring HVE02.2

bodily harm by electrical shock!
⇒ For the use with a single phase connection the pha-
DANGER se monitoring has been deactivated!
⇒ In case of a three phase connection there is no
monitoring for the power connection..
8.3 Wiring control voltage drives
X3 / HVE
rd 1 J X1
1
bu 2 1 +24VE
2
Axis 1 PTC
2 0VE Axis 2
HMS01.1N- X15 C950 HMS01.1N-
K1 K2
W0036 X2 W0036
1 +24V
2 0V
H1
R1
contr. voltage 2K49
X3
CSH01.1 H2 H12 1
+24V
CSH01.1
R2 R12 2
0V
bb 2K49 2K49 bb
X31 X4 X11 X31
H3 S1 S11 H13
1 vt 1 R3 R13 1 vt 1
Rel1 Rel1
2 pk 2 2K49 2K49 2 pk 2
Rel2 Rel2
3 bk 3 3 bk 3
I 1/3a 0 0 I 1/3a
4 rd 4 4 rd 4
I 2/4a S2 S12 I 2/4a
5 bu 5 H4 H14 5 bu 5
I 3/5a R4 R14 I 3/5a
6 wh 6 6 wh 6
I 4/6a 2K49 2K49 I 4/6a
7 bn 7 7 bn 7
I 5/7a I 5/7a
8 gn 8 0 0 8 gn 8
+24VE gr gr +24VE
9 S3 S13 9
0VE H5 H15 0VE
R5 R15
1 2K49 2K49 1
2 2
0 0
X5 H6 S4 S14 H16 X12
R6 R16
2K49 2K49
0 0
H7 S5 S15 H17
R7 R17
2K49 2K49
0 0
H8 S6 S16 H18
R8 R18
2K49 2K49
X32 X6 X13 X32
0 0
1 wh/bu 1 1 wh/bu 1
An1 An1
2 wh/pk 2 H9 S7 S17 H19 2 wh/pk 2
An2 An2
3 wh/gr 3 R9 R19 3 wh/gr 3
GND 2K49 2K49 GND
4 wh/gn 4 4 wh/gn 4
I 6/IAn+ I 6/IAn+
5 wh/bn 5 0 0 5 wh/bn 5
I 7/IAn- I 7/IAn-
6 wh/ye 6 6 wh/ye 6
I/O 8* H10 S8 S18 H20 I/O 8*
7 wh/rd wh/rd 7
I/O 9* R10 R20 I/O 9*
8 wh/bk 2K49 2K49 wh/bk 8
I/O 10* bn/gn bn/gn I/O 10*
9 9
I/O 11* X7 0 0 X14 I/O 11*
1
H11 S9 S19 H21 1
2 R11 R21 2
3 2K49 2K49 3
4 4
0 0
S10 S20
+ +
R22 R23
475R 0 0 475R
- -
+15V +24V
IC1 DC
-15V
DC 24 V
GND +- 15V 0V
X8 X9 X10
1
2
3
4
1
2
3
4
5
6
7
8
1
2
3
4
5
6
7
8
rd
pk
bl
ye
wh/ye
wh
gn
gr
rd
pk
bl
ye
wh/ye
wh
gn
gr
bn
bu
bk
1K
1K
Initiator (optical)
+24VE
+24VE
0VE
0VE
E+
E+
E+
E+
E-
E-
E-
E-
An1 An2 An1 An2

socket socket socket socket socket
X4 X4
IKS 4042 Motor- Motor- IKS 4042

Feed- Feed-
back back
X6 IKG 4120 IKG 4120 X6
E E
TM+ 1 1 TM+
H H
TM- 2 2 TM-
G PTC PTC G
Br+ 3 3 Br+
Br- 4 F F 4 Br-
U U
X5 X5
A1
A2
A
B M M A
B
A1
A2
A3 C 3 3 C A3
D D
Abb. 8-3: control voltage wiring HMS02.*
8.4 Rewiring for optional Mains voltages

bodily harm by electrical shock!
⇒ The rewiring of the demo system for persons who
DANGER are qualified and have sufficient knowledge of the
assembly, installation and operation of the equip-
ment as well as an understanding of all warnings and
precautionary measures noted in these instructions.
Only those trained and qualified to work with or on
electrical equipment are permitted to operate, main-
tain or repair this equipment
⇒ Furthermore, they must be trained, instructed and
qualified to switch electrical circuits and equipment
on and off in accordance with technical safety regu-
lations, to ground them and to mark them according
to the requirements of safe work practices. They
must have adequate safety equipment and be
trained in first aid!
⇒ The output voltage of the multicontact socket is e-
qual to the input voltage! It is absolutely required to
modify in case of rewiring the sign "Supply Voltage"
with the new values.
⇒ Disconnect the mains plug and check if the system
has been discharged.
⇒ Remove the plate on the left side of the demo sys-
tem.
To be continued..
8.5 Rewiring of the internal transformer
Single phase connection 110V/AC Single phase connection 115V/AC
sec connection
sec connection
sec connection
sec connection
q contact
q contact
q contact
q contact
127V
220V
230V
240V
500V
127V
220V
230V
240V
500V
110V
115V
110V
115V
0V
0V
0V
0V
a
b
a
b
Emergency X10 / 11 Emergency X10 / 11
stop 2 X10 / 12 stop 2 X10 / 12
HVE X3/4 HVE X3/4
mains connection mains connection
110V / AC 115V / AC
Single phase connection 127V/AC Single phase connection 220V/AC

sec connection
sec connection
sec connection
sec connection
q contact
q contact
q contact
q contact
127V
220V
230V
240V
500V
127V
220V
230V
240V
500V
110V
115V
110V
115V
0V
0V
0V
0V
a
b
a
b

stop 2 X10 / 12 stop 2 X10 / 12
HVE X3/4 HVE X3/4
127V / AC 220V / AC
State of delivery Single phase connection 240V/AC

Single phase connection 230V/AC
sec connection
sec connection
sec connection
sec connection
q contact
q contact
q contact
q contact
127V
220V
230V
240V
500V
127V
220V
230V
240V
500V
110V
115V
110V
115V
0V
0V
0V
0V
a
b
a
b

stop 2 X10 / 12 stop 2 X10 / 12
HVE X3/4 HVE X3/4
230V / AC 240V / AC
Abb. 8-4: Rewiring of the internal transformer
8.6 Rewiring the internal 24V power supply module
Attention! Attention!
Do not use bridge! Bridge required!
FG CAUTION
FG CAUTION
N
N
L
L
FG
FG
FG
FG
-S
-V
-S
-V
+S +V -V
+V -V
+V +V -V
+S +V -V
+V -V
UN 170 - 265VAC UN 85 - 132VAC +V +V -V
Abb. 8-5: Rewiring the internal 24V power supply module
PSP-I01.1-01-EN Service & Support 9-1
9 Service & Support
9.1 Helpdesk
Unser Kundendienst-Helpdesk im Hauptwerk Lohr Our service helpdesk at our headquarters in Lohr am
am Main steht Ihnen mit Rat und Tat zur Seite. Main, Germany can assist you in all kinds of inquiries.
Sie erreichen uns Contact us
- telefonisch - by phone: 49 (0) 9352 40 50 60

über Service Call Entry Center Mo-Fr 07:00-18:00
- via Service Call Entry Center Mo-Fr 7:00 am - 6:00 pm
- per Fax - by fax: +49 (0) 9352 40 49 41
- per e-Mail - by e-mail: service@boschrexroth.de
9.2 Service-Hotline
Außerhalb der Helpdesk-Zeiten ist der Service After helpdesk hours, contact our service
direkt ansprechbar unter department directly at
+49 (0) 171 333 88 26

oder - or +49 (0) 172 660 04 06
9.3 Internet
Unter www.boschrexroth.de finden Sie At www.boschrexroth.de you may find

ergänzende Hinweise zu Service, Reparatur und additional notes about service, repairs and training
Training sowie die aktuellen Adressen *) unserer in the Internet, as well as the actual addresses *) of
auf den folgenden Seiten aufgeführten Vertriebs- our sales- and service facilities figuring on the
und Servicebüros. following pages.
Verkaufsniederlassungen sales agencies
Niederlassungen mit Kundendienst offices providing service
Außerhalb Deutschlands nehmen Sie bitte zuerst Kontakt mit Please contact our sales / service office in your area first.
unserem für Sie nächstgelegenen Ansprechpartner auf.
*) Data in the present documentation may have become
*) Die Angaben in der vorliegenden Dokumentation können obsolete since printing.
seit Drucklegung überholt sein.
9-2 Service & Support PSP-I01.1-01-EN
9.4 Vor der Kontaktaufnahme... - Before

contacting us...
Wir können Ihnen schnell und effizient helfen wenn For quick and efficient help, please have the
Sie folgende Informationen bereithalten: following information ready:
detaillierte Beschreibung der Störung und der 1. Detailed description of the failure and
Umstände. circumstances.
Angaben auf dem Typenschild der betreffenden 2. Information on the type plate of the affected
Produkte, insbesondere Typenschlüssel und products, especially type codes and serial
Seriennummern. numbers.
Tel.-/Faxnummern und e-Mail-Adresse, unter 3. Your phone/fax numbers and e-mail address,
denen Sie für Rückfragen zu erreichen sind. so we can contact you in case of questions.
PSP-I01.1-01-EN Kundenbetreuungsstellen - Sales & Service Facilities 10-1
10 Kundenbetreuungsstellen - Sales & Service

Facilities
Deutschland – Germany vom Ausland: (0) nach Landeskennziffer weglassen!
from abroad: don’t dial (0) after country code!
Vertriebsgebiet Mitte
Germany Centre SERVICE SERVICE SERVICE
Rexroth Indramat GmbH CALL ENTRY CENTER HOTLINE ERSATZTEILE / SPARES
Bgm.-Dr.-Nebel-Str. 2 / Postf. 1357 MO – FR MO – FR verlängerte Ansprechzeit
97816 Lohr am Main / 97803 Lohr von 07:00 - 18:00 Uhr von 17:00 - 07:00 Uhr - extended office time -
from 5 pm - 7 am ♦ nur an Werktagen
Kompetenz-Zentrum Europa from 7 am – 6 pm + SA / SO - only on working days -
Tel.: +49 (0)9352 40-0 ♦ von 07:00 - 18:00 Uhr
Tel. +49 (0) 9352 40 50 60 Tel.: +49 (0)172 660 04 06 - from 7 am - 6 pm -
Fax: +49 (0)9352 40-4885
service@boschrexroth.de oder / or
Tel.: +49 (0)171 333 88 26 Tel. +49 (0) 9352 40 42 22
Vertriebsgebiet Süd Vertriebsgebiet West Gebiet Südwest Gebiet Südwest
Germany South Germany West Germany South-West Germany South-West
Rexroth Indramat GmbH Bosch Rexroth AG Bosch Rexroth AG Bosch Rexroth AG
Landshuter Allee 8-10 Regionalzentrum West Service-Regionalzentrum Süd-West Regionalzentrum Südwest
80637 München Borsigstrasse 15 Siemensstr.1 Ringstrasse 70 / Postfach 1144
40880 Ratingen 70736 Fellbach 70736 Fellbach / 70701 Fellbach
Tel.: +49 (0)89 127 14-0 Tel.: +49 (0)2102 409-0 Tel.: +49 (0)711 51046–0 Tel.: +49 (0)711 57 61–100
Fax: +49 (0)89 127 14-490 Fax: +49 (0)2102 409-406 Fax: +49 (0)711 51046–248 Fax: +49 (0)711 57 61–125
Vertriebsgebiet Nord Vertriebsgebiet Mitte Vertriebsgebiet Ost Vertriebsgebiet Ost

Germany North Germany Centre Germany East Germany East
Bosch Rexroth AG Bosch Rexroth AG Bosch Rexroth AG Bosch Rexroth AG
Walsroder Str. 93 Regionalzentrum Mitte Beckerstraße 31 Regionalzentrum Ost
30853 Langenhagen Waldecker Straße 13 09120 Chemnitz Walter-Köhn-Str. 4d
Tel.: +49 (0) 511 72 66 57-0 64546 Mörfelden-Walldorf 04356 Leipzig
Service: +49 (0) 511 72 66 57-256
Fax: +49 (0) 511 72 66 57-93 Tel.: +49 (0) 61 05 702-3
Service: +49 (0) 511 72 66 57-95 Fax: +49 (0) 61 05 702-444 Tel.: +49 (0)371 35 55-0 Tel.: +49 (0)341 25 61-0
Fax: +49 (0)371 35 55-333 Fax: +49 (0)341 25 61-111
10-2 Kundenbetreuungsstellen - Sales & Service Facilities PSP-I01.1-01-EN
Europa (West) - Europe (West)

vom Ausland: (0) nach Landeskennziffer weglassen, Italien: 0 nach Landeskennziffer mitwählen
from abroad: don’t dial (0) after country code, Italy: dial 0 after country code
Austria - Österreich Austria – Österreich Belgium - Belgien Denmark - Dänemark

Bosch Rexroth GmbH Bosch Rexroth GmbH Bosch Rexroth AG BEC A/S
Bereich Indramat Gesch.ber. Rexroth Indramat Electric Drives & Controls Zinkvej 6
Stachegasse 13 Industriepark 18 Industrielaan 8 8900 Randers
1120 Wien 4061 Pasching 1740 Ternat
Tel.: +43 (0)1 985 25 40 Tel.: +43 (0)7221 605-0 Tel.: +32 (0)2 5830719 Tel.: +45 (0)87 11 90 60
Fax: +43 (0)1 985 25 40-93 Fax: +43 (0)7221 605-21 - service: +32 (0)2 5830717 Fax: +45 (0)87 11 90 61
Fax: +32 (0)2 5830731
indramat@boschrexroth.be
Great Britain – Großbritannien Finland - Finnland France - Frankreich France - Frankreich

Bosch Rexroth Ltd. Bosch Rexroth Oy Bosch Rexroth S.A. Bosch Rexroth S.A.
Rexroth Indramat Division Rexroth Indramat division Division Rexroth Indramat Division Rexroth Indramat
Broadway Lane, South Cerney Ansatie 6 Avenue de la Trentaine ZI de Thibaud, 20 bd. Thibaud
Cirencester, Glos GL7 5UH 017 40 Vantaa (BP. 74) (BP. 1751)
77503 Chelles Cedex 31084 Toulouse
Tel.: +44 (0)1285 863000 Tel.: +358 (0)9 84 91-11 Tel.: +33 (0)164 72-70 00 Tel.: +33 (0)5 61 43 61 87
Fax: +44 (0)1285 863030 Fax: +358 (0)9 84 91-13 60 Fax: +33 (0)164 72-63 00 Fax: +33 (0)5 61 43 94 12
sales@boschrexroth.co.uk Hotline: +33 (0)608 33 43 28
service@boschrexroth.co.uk
France - Frankreich Italy - Italien Italy - Italien Italy - Italien

Bosch Rexroth S.A. Bosch Rexroth S.p.A. Bosch Rexroth S.p.A. Bosch Rexroth S.p.A.
Division Rexroth Indramat Via G. Di Vittoria, 1 Via Paolo Veronesi, 250 Via del Progresso, 16 (Zona Ind.)
91, Bd. Irène Joliot-Curie 20063 Cernusco S/N.MI 10148 Torino 35020 Padova
69634 Vénissieux – Cedex
Tel.: +33 (0)4 78 78 53 65 Tel.: +39 02 92 365 1 Tel.: +39 011 224 88 11 Tel.: +39 049 8 70 13 70
Fax: +33 (0)4 78 78 53 62 +39 02 92 365 326 Fax: +39 011 224 88 30 Fax: +39 049 8 70 13 77
Fax: +39 02 92 365 500
+39 02 92 365 516378
Italy - Italien Italy - Italien Netherlands – Niederlande/Holland Netherlands - Niederlande/Holland
Bosch Rexroth S.p.A. Bosch Rexroth S.p.A. Bosch Rexroth B.V. Bosch Rexroth Services B.V.
Via Mascia, 1 Viale Oriani, 38/A Kruisbroeksestraat 1 Technical Services
80053 Castellamare di Stabia NA 40137 Bologna (P.O. Box 32) Kruisbroeksestraat 1
5281 RV Boxtel (P.O. Box 32)
Tel.: +39 081 8 71 57 00 Tel.: +39 051 34 14 14 Tel.: +31 (0)411 65 19 51 5281 RV Boxtel
Fax: +39 081 8 71 68 85 Fax: +39 051 34 14 22 Fax: +31 (0)411 65 14 83 Tel.: +31 (0)411 65 19 51
www.boschrexroth.nl Fax: +31 (0)411 67 78 14
services@boschrexroth.nl
Norway - Norwegen Spain - Spanien Spain – Spanien Sweden - Schweden

Bosch Rexroth AS Bosch Rexroth S.A. Goimendi S.A. Rexroth Mecman Svenska AB
Rexroth Indramat Division Divisiòn Rexroth Indramat División Rexroth Indramat Rexroth Indramat Division
Berghagan 1 or: Box 3007 Centro Industrial Santiga Parque Empresarial Zuatzu - Varuvägen 7
1405 Ski-Langhus 1402 Ski Obradors s/n C/ Francisco Grandmontagne no.2 (Service: Konsumentvägen 4, Älfsjö)
08130 Santa Perpetua de Mogoda 20018 San Sebastian 125 81 Stockholm
Barcelona
Tel.: +47 (0)64 86 41 00 Tel.: +34 9 37 47 94 00 Tel.: +34 9 43 31 84 21 Tel.: +46 (0)8 727 92 00
Fax: +47 (0)64 86 90 62 Fax: +34 9 37 47 94 01 - service: +34 9 43 31 84 56 Fax: +46 (0)8 647 32 77
jul.ruud@rexroth.no Fax: +34 9 43 31 84 27
- service: +34 9 43 31 84 60
sat.indramat@goimendi.es
Sweden - Schweden Switzerland West - Schweiz West Switzerland East - Schweiz Ost
Rexroth Mecman Svenska AB Bosch Rexroth Suisse SA Bosch Rexroth Schweiz AG
Indramat Support Département Rexroth Indramat Geschäftsbereich Indramat
Ekvändan 7 Rue du village 1 Hemrietstrasse 2
254 67 Helsingborg 1020 Renens 8863 Buttikon
Tel.: +46 (0) 42 38 88 -50 Tel.: +41 (0)21 632 84 20 Tel. +41 (0) 55 46 46 111
Fax: +46 (0) 42 38 88 -74 Fax: +41 (0)21 632 84 21 Fax +41 (0) 55 46 46 222
Europa (Ost) - Europe (East)

vom Ausland: (0) nach Landeskennziffer weglassen
from abroad: don’t dial (0) after country code
Czech Republic - Tschechien Czech Republic - Tschechien Hungary - Ungarn Poland – Polen
Bosch -Rexroth, spol.s.r.o. DEL a.s. Bosch Rexroth Kft. Bosch Rexroth Sp.zo.o.
Hviezdoslavova 5 Strojírenská 38 Angol utca 34 ul. Staszica 1
627 00 Brno 591 01 Zdar nad Sázavou 1149 Budapest 05-800 Pruszków
Tel.: +420 (0)5 48 126 358 Tel.: +420 566 64 3144 Tel.: +36 (1) 422 3200 Tel.: +48 22 738 18 00
Fax: +420 (0)5 48 126 112 Fax: +420 566 62 1657 Fax: +36 (1) 422 3201 – service: +48 22 738 18 46
Fax: +48 22 758 87 35
– service: +48 22 738 18 42
Poland – Polen Romania - Rumänien Romania - Rumänien Russia - Russland

Bosch Rexroth Sp.zo.o. East Electric S.R.L. Bosch Rexroth Sp.zo.o. Bosch Rexroth OOO
Biuro Poznan B-dul Basarabie, nr.250, sector 3 Str. Drobety nr. 4-10, app. 14 Wjatskaja ul. 27/15
ul. Dabrowskiego 81/85 73429 Bucuresti 70258 Bucuresti, Sector 2 127015 Moskau
60-529 Poznan Tel./Fax:: +40 (0)21 255 35 07 Tel.: +40 (0)1 210 48 25 Tel.: +7-095-785 74 78
Tel.: +48 061 847 64 62 /-63 +40 (0)21 255 77 13 +40 (0)1 210 29 50 +7-095 785 74 79
Fax: +48 061 847 64 02 Fax: +40 (0)21 725 61 21 Fax: +40 (0)1 210 29 52 Fax: +7 095 785 74 77
est@mb.roknet.ro laura.kanina@boschrexroth.ru
Russia - Russland Turkey - Türkei Slowenia - Slowenien

ELMIS Bosch Rexroth Otomasyon DOMEL
10, Internationalnaya San & Tic. A..S. Otoki 21
246640 Gomel, Belarus Fevzi Cakmak Cad No. 3 64 228 Zelezniki
Tel.: +375/ 232 53 42 70 34630 Sefaköy Istanbul Tel.: +386 5 5117 152
+375/ 232 53 21 69 Tel.: +90 212 541 60 70 Fax: +386 5 5117 225
Fax: +375/ 232 53 37 69 Fax: +90 212 599 34 07 brane.ozebek@domel.si
elmis_ltd@yahoo.com
Africa, Asia, Australia – incl. Pacific Rim
Australia - Australien Australia - Australien China China

AIMS - Australian Industrial Bosch Rexroth Pty. Ltd. Shanghai Bosch Rexroth Shanghai Bosch Rexroth
Machinery Services Pty. Ltd. No. 7, Endeavour Way Hydraulics & Automation Ltd. Hydraulics & Automation Ltd.
28 Westside Drive Braeside Victoria, 31 95 Waigaoqiao, Free Trade Zone 4/f, Marine Tower
Laverton North Vic 3026 Melbourne No.122, Fu Te Dong Yi Road No.1, Pudong Avenue
Melbourne Shanghai 200131 - P.R.China Shanghai 200120 - P.R.China
Tel.: +61 3 93 243 321 Tel.: +61 3 95 80 39 33 Tel.: +86 21 58 66 30 30 Tel: +86 21 68 86 15 88
Fax: +61 3 93 243 329 Fax: +61 3 95 80 17 33 Fax: +86 21 58 66 55 23 Fax: +86 21 58 40 65 77
Hotline: +61 4 19 369 195 mel@rexroth.com.au richard.yang_sh@boschrexroth.com.cn
terryobrien@aimservices.com.au gf.zhu_sh@boschrexroth.com.cn
China China China China

Bosch Rexroth China Ltd. Bosch Rexroth China Ltd. Bosch Rexroth (China) Ltd. Melchers GmbH
15/F China World Trade Center Guangzhou Repres. Office A-5F., 123 Lian Shan Street BRC-SE, Tightening & Press-fit
1, Jianguomenwai Avenue Room 1014-1016, Metro Plaza, Sha He Kou District 13 Floor Est Ocean Centre
Beijing 100004, P.R.China Tian He District, 183 Tian He Bei Rd Dalian 116 023, P.R.China No.588 Yanan Rd. East
Guangzhou 510075, P.R.China 65 Yanan Rd. West
Tel.: +86 10 65 05 03 80 Shanghai 200001
Fax: +86 10 65 05 03 79 Tel.: +86 20 8755-0030 Tel.: +86 411 46 78 930 Tel.: +86 21 6352 8848
+86 20 8755-0011 Fax: +86 411 46 78 932 Fax: +86 21 6351 3138
Fax: +86 20 8755-2387
Hongkong India - Indien India - Indien India - Indien

Bosch Rexroth (China) Ltd. Bosch Rexroth (India) Ltd. Bosch Rexroth (India) Ltd. Bosch Rexroth (India) Ltd.
6th Floor, Rexroth Indramat Division Rexroth Indramat Division 1st Floor, S-10
Yeung Yiu Chung No.6 Ind Bldg. Plot. A-58, TTC Industrial Area Plot. 96, Phase III Green Park ext. Market
19 Cheung Shun Street Thane Turbhe Midc Road Peenya Industrial Area New Delhi – 110016
Cheung Sha Wan, Mahape Village Bangalore - 560058
Kowloon, Hongkong Navi Mumbai - 400 701
Tel.: +852 22 62 51 00 Tel.: +91 22 7 61 46 22 Tel.: +91 80 41 70 211 Tel.: +91 1 16 56 68 88
Fax: +852 27 41 33 44 Fax: +91 22 7 68 15 31 Fax: +91 80 83 94 345 Fax: +91 1 16 56 68 87
alexis.siu@boschrexroth.com.hk mohanvelu.t@boschrexroth.co.in
Indonesia - Indonesien Japan Japan Korea

PT. Rexroth Wijayakusuma Bosch Rexroth Automation Corp. Bosch Rexroth Automation Corp. Bosch Rexroth-Korea Ltd.
Building # 202, Cilandak Service Center Japan Rexroth Indramat Division Electric Drives and Controls
Commercial Estate Yutakagaoka 1810, Meito-ku, 1F, I.R. Building Bongwoo Bldg. 7FL, 31-7, 1Ga
Jl. Cilandak KKO, Jakarta 12560 NAGOYA 465-0035, Japan Nakamachidai 4-26-44, Tsuzuki-ku Jangchoong-dong, Jung-gu
YOKOHAMA 224-0041, Japan Seoul, 100-391
Tel.: +81 52 777 88 41 Tel.: +81 45 942 72 10 Tel.: +82 234 061 813
Tel.: +62 21 7891169 (5 lines) +81 52 777 88 53 Fax: +81 45 942 03 41 Fax: +82 222 641 295
Fax: +62 21 7891170 - 71 +81 52 777 88 79
Fax: +81 52 777 89 01
Korea Malaysia Singapore - Singapur South Africa - Südafrika

Bosch Rexroth-Korea Ltd. Bosch Rexroth Sdn.Bhd. Bosch Rexroth Pte Ltd TECTRA Automation (Pty) Ltd.
1515-14 Dadae-Dong, Saha-Ku 11, Jalan U8/82, Seksyen U8 15D Tuas Road 71 Watt Street, Meadowdale
Rexroth Indramat Division 40150 Shah Alam Singapore 638520 Edenvale 1609
Pusan Metropolitan City, 604-050 Selangor, Malaysia
Tel.: +60 3 78 44 80 00 Tel.: +65 68 61 87 33 Tel.: +27 11 971 94 00
Tel.: +82 51 26 00 741 Fax: +60 3 78 45 48 00 Fax: +65 68 61 18 25 Fax: +27 11 971 94 40
Fax: +82 51 26 00 747 hockhwa@hotmail.com sanjay.nemade Hotline: +27 82 903 29 23
gyhan@rexrothkorea.co.kr rexroth1@tm.net.my @boschrexroth.com.sg georgv@tectra.co.za
Taiwan Thailand
Rexroth Uchida Co., Ltd. NC Advance Technology Co. Ltd.
No.17, Alley 24, Lane 737 59/76 Moo 9
Cheng Bei 1 Rd., Yungkang Ramintra road 34
Tainan Hsien Tharang, Bangkhen,
Tel.: +886 6 25 36 565 Bangkok 10230
Fax: +886 6 25 34 754 Tel.: +66 2 943 70 62
indra.charlie@msa.hinet.net +66 2 943 71 21
Fax: +66 2 509 23 62
sonkawin@hotmail.com
Nordamerika – North America

USA USA Central Region - Mitte USA Southeast Region - Südwest USA SERVICE-HOTLINE
Headquarters - Hauptniederlassung
Bosch Rexroth Corporation Bosch Rexroth Corporation
Bosch Rexroth Corporation Rexroth Indramat Division Rexroth Indramat Division
- 7 days x 24hrs -
Rexroth Indramat Division Central Region Technical Center Southeastern Technical Center
5150 Prairie Stone Parkway 1701 Harmon Road 3625 Swiftwater Park Drive
Hoffman Estates, IL 60192-3707 Auburn Hills, MI 48326 Suwanee, Georgia 30124
+1-800-860-1055
Tel.: +1 847 6 45 36 00 Tel.: +1 248 3 93 33 30 Tel.: +1 770 9 32 32 00
Fax: +1 847 6 45 62 01 Fax: +1 248 3 93 29 06 Fax: +1 770 9 32 19 03
servicebrc@boschrexroth-us.com
repairbrc@boschrexroth-us.com
USA East Region – Ost USA Northeast Region – Nordost USA West Region – West
Bosch Rexroth Corporation Bosch Rexroth Corporation Bosch Rexroth Corporation

Rexroth Indramat Division Rexroth Indramat Division 7901 Stoneridge Drive, Suite 220
Charlotte Regional Sales Office Northeastern Technical Center Pleasant Hill, California 94588
14001 South Lakes Drive 99 Rainbow Road
Charlotte, North Carolina 28273 East Granby, Connecticut 06026
Tel.: +1 704 5 83 97 62 Tel.: +1 860 8 44 83 77 Tel.: +1 925 227 10 84
+1 704 5 83 14 86 Fax: +1 860 8 44 85 95 Fax: +1 925 227 10 81
Canada East - Kanada Ost Canada West - Kanada West Mexico Mexico
Bosch Rexroth Canada Corporation Bosch Rexroth Canada Corporation Bosch Rexroth Mexico S.A. de C.V. Bosch Rexroth S.A. de C.V.
Burlington Division 5345 Goring St. Calle Neptuno 72 Calle Argentina No 3913
3426 Mainway Drive Burnaby, British Columbia Unidad Ind. Vallejo Fracc. las Torres
Burlington, Ontario Canada V7J 1R1 07700 Mexico, D.F. 64930 Monterrey, N.L.
Canada L7M 1A8
Tel.: +1 905 335 55 11 Tel. +1 604 205-5777 Tel.: +52 5 754 17 11 Tel.: +52 8 333 88 34...36
Fax: +1 905 335-41 84 Fax +1 604 205-6944 +52 5 754 36 84 +52 8 349 80 91...93
michael.moro@boschrexroth.ca david.gunby@boschrexroth.ca +52 5 754 12 60 Fax: +52 8 346 78 71
Fax: +52 5 754 50 73 mario.quiroga@boschrexroth.com.mx
+52 5 752 59 43
mariofelipe.hernandez@boschrexroth.com.m
x
Südamerika – South America

Argentina - Argentinien Argentina - Argentinien Brazil - Brasilien Brazil - Brasilien
Bosch Rexroth S.A.I.C. NAKASE Bosch Rexroth Ltda. Bosch Rexroth Ltda.
"The Drive & Control Company" Servicio Tecnico CNC Av. Tégula, 888 R. Dr.Humberto Pinheiro Vieira, 100
Acassusso 48 41/47 Calle 49, No. 5764/66 Ponte Alta, Atibaia SP Distrito Industrial [Caixa Postal 1273]
1605 Munro B1653AOX Villa Balester CEP 12942-440 89220-390 Joinville - SC
Provincia de Buenos Aires Provincia de Buenos Aires
Tel.: +54 11 4756 01 40 Tel.: +54 11 4768 36 43 Tel.: +55 11 4414 56 92 Tel./Fax: +55 47 473 58 33
Fax: +54 11 4756 01 36 Fax: +54 11 4768 24 13 +55 11 4414 56 84 Mobil: +55 47 9974 6645
victor.jabif@boschrexroth.com.ar nakase@usa.net Fax sales: +55 11 4414 57 07 prochnow@zaz.com.br
nakase@nakase.com Fax serv.: +55 11 4414 56 86
gerencia@nakase.com (Service) alexandre.wittwer@rexroth.com.br
Columbia - Kolumbien
Reflutec de Colombia Ltda.

Calle 37 No. 22-31
Santafé de Bogotá, D.C.
Colombia
Tel.: +57 1 368 82 67
+57 1 368 02 59
Fax: +57 1 268 97 37
reflutec@neutel.com.co
reflutec@007mundo.com
Bosch Rexroth AG
Electric Drives and Controls
P.O. Box 13 57
97803 Lohr, Germany
Bgm.-Dr.-Nebel-Str. 2
97816 Lohr, Germany
Phone +49 93 52-40-0
Fax +49 93 52-40-48 85
www.boschrexroth.com
Printed in Germany
R911297181 DOK-SUPPL*-PSPI01.1-01-KB01-EN-P

29718101-Rexroth Demo System PSP-I01.1-01 IndraDrive M With SERCOS Interface

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29718101-Rexroth Demo System PSP-I01.1-01 IndraDrive M With SERCOS Interface

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Copyright:

Available Formats

Industrial Electric Drives Linear Motion and Service Mobile

Hydraulics and Controls Assembly Technologies Pneumatics Automation Hydraulics

Rexroth Demo System

IndraDrive M with SERCOS Interface

Title Demo System

Document Typecode DOK-SUPPL*-PSP01.1-KB01-EN-P

Internal File Reference Binder

Purpose of Documentation This documentation describes:

Record of Revisions Description Release Notes

Copyright  2003 Bosch Rexroth AG

Published by Bosch Rexroth AG

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

2 System description 2-1

3 General Instructions 3-1

4 Safety Instructions for Electric Drives and Controls 4-1

5 Start up Instructions for the demo system 5-1

6 Extended parameter settings 6-1

9 Service & Support 9-1

10 Kundenbetreuungsstellen - Sales & Service Facilities 10-1

Abb. 7-1: Design of the switchboard, PSP-I01.1-01 7-1

2.2 State of delivery

2.3 Dimensions and weight

2.4 Mains connection

Note: When required the mains voltage can be modified to different

3.1 Definition of Terms, Introduction

Warning: Improper use of this equipment, failure to follow the safe-

Areas of use and application

3.2 Improper use

3.3 Functions and Operation modes

Main Operating Modes

Operational modes Given drive controllers without command communications interface or if

4 Safety Instructions for Electric Drives and Controls

Improper use of this equipment, failure to follow

Death or severe bodily harm will occur.

Death or severe bodily harm may occur.

Bodily harm or material damage may occur.

4.3 Hazards by Improper Use

High voltage and high discharge current!

Dangerous movements! Danger to life, severe

High electrical voltage due to wrong

Health hazard for persons with heart

Surface of machine housing could be extremely

Risk of injury due to improper handling! Bodily

Risk of injury due to incorrect handling of

4.4 General Information

• Operation is only permitted if the national EMC regulations for the

4.5 Protection Against Contact with Electrical Parts

Note: This section refers to equipment and drive components with

High electrical voltage! Danger to life, severe

To be observed with electrical drive and filter components:

High electrical voltage on the housing!

4.6 Protection Against Electric Shock by Protective Low

High electrical voltage due to wrong

4.7 Protection Against Dangerous Movements

Dangerous movements! Danger to life, risk of

⇒ Keep free and clear of the machine’s range of motion

⇒ Disconnect electrical power to the equipment using a

4.8 Protection Against Magnetic and Electromagnetic Fields

Health hazard for persons with heart

4.9 Protection Against Contact with Hot Parts

Housing surfaces could be extremely hot!

4.10 Protection During Handling and Mounting

Risk of injury by incorrect handling! Bodily

4.11 Battery Safety