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DOK-CONTRL-WZM*TK1-AW02-EN-P
TransKit1 Table of Content 1-2
Title TransKit1
Single/Dual Axis Solution
Note All rights are reserved with respect to the content of this documentation
and the availability of the product.
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TransKit1 Table of Content 1-3
Table of Contents
1 Introduction 1-1
1.1 Goals ............................................................................................................................. 1-1
1.2 Content .......................................................................................................................... 1-4
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TransKit1 Table of Content 1-4
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TransKit1 Table of Content 1-5
8 NC setup 8-1
8.1 TRANS200..................................................................................................................... 8-1
TRANS200 - Training ............................................................................................................................. 8-1
TRANS200 - Documentation ................................................................................................................... 8-1
TRANS200 - WinTrans software............................................................................................................. 8-2
TRANS200 – Parameter adaptation ........................................................................................................ 8-2
TRANS200 - NC-programming ................................................................................................................ 8-3
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TransKit1 Table of Content 1-6
9 Operation 9-1
9.1 ControlBoxD - BTV06 HMI button description ................................................................ 9-1
9.2 BTV06 HMI - screen description .................................................................................... 9-4
11 Index 1
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TransKit1 Introduction 1-1
1 Introduction
1.1 Goals
A large installed base of transfer machines exists and is an important
base for high volume production, especially in automotive Powertrain.
Such transfer machines installed from early 1980 to 2000 have many
single or dual axis slides performing cyclical movements around the
clock. In many cases retrofitting the existing electro-mechanical feed or
older analog servo and control systems with programmable digital servo
systems provide higher productivity while keeping investment low.
Also the first generation analog single axis NC systems such as the
“TRANS-01 NC and DSC servo drives” have performed close to 20
years of service. Many components of these systems are no longer
available in the market and spare parts become difficult to source.
To make the retrofit of these systems faster and easier, Bosch Rexroth
now provides a scalable and cost effective digital upgrade TransKit1.
Note: Due to the variety of applications, the solutions described here
will still require machine specific alterations that must be
implemented by knowledgeable integration personnel.
Target application areas are:
- Electro-mechanical single and dual axes feed packs (non servo)
- TRANS-01 – DSC systems (fixture mount) using discrete 24VDC
IO connection
- Any other single and dual axes servo feed system
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TransKit1 Introduction 1-2
Transfer control In the past mainly centralized PLC control architectures have been
architectures applied with transfer machines as shown below.
PIM
Distributed PLC control More recent machines eventually are also controlled with distributed PLC
systems. This architecture allows faster integration, startup and ease of
use and reuse of engineering. The TRANS-01 was also applied here.
TRANS-01/DSC retrofit
architecture
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TransKit1 Introduction 1-3
The TransKit1 employs digital intelligent controllers that satisfy the same
architectures. Existing discrete wiring is utilized to connect to the existing
PLC IO system. The ControlBox contains NC functionality with simple
NC-programming. Digital intelligent drives are connected via SERCOS
fiber optic link providing precision and extended diagnostics. These
drives can run a variety of servo motors (rotary, spindle, linear, torque)
employing also absolute feedback measuring systems that reduce wiring.
All programs and parameters are programmed via PC-based Windows™
WinTrans software. The data of up to 32 TransKit1 systems can be
networked and managed from the central machine PC.
The TransKit1 utilizes the TRANS200 NC controller with the discrete I/O
communication to the PLC. It also provides HMI choices that display
status and offer Offset, tool data and variable modifications.
Even though the TransKit1 described here is suitable for most
applications, Bosch Rexroth recommends TRANS200 NC controllers with
Fieldbus connection to the PLC if the PLC is retrofitted as well.
The TRANS200 controller offers Interbus, Profibus, DeviceNet and
ControlNet interface slave modules. The Fieldbus connection will reduce
wiring costs, increases diagnostics to the machine HMI.
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TransKit1 Introduction 1-4
1.2 Content
The information provided in this document does describe the functionality
of the single/dual axis retrofit solution. This document does not replace
the documentation of the specific Bosch Rexroth products (TRANS200,
BTV06, RECO02 IO, PPC-R, DURADRIVE HDC) used for the retrofit
TransKit1. It merely describes the pre-engineered solutions and how they
can be applied.
The TransKit1 permits the following axis combinations based on
parameter settings and installed DURADRIVE amplifiers:
Motion DURADRIVE DURADRIVE
(possible interpolation) Axis #01 (left) Axis #02 (right)
-- Linear axis --
-- Rotary axis --
Linear, circular Linear axis Linear axis
Linear Linear axis Rotary axis
Time Rotary axis Rotary axis
Linear, feed/rev (tapping) Linear axis Spindle axis
-- Rotary axis Spindle axis
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TransKit1 Important Usage Directions 2-1
Introduction
Bosch Rexroth products represent state-of-the-art developments and
manufacturing. They are tested prior to delivery to ensure operating
safety and reliability.
The products may only be used in the manner that is defined as
appropriate. If they are used in an inappropriate manner, then situations
can develop that may lead to property damage or injury to personnel.
Before using Bosch Rexroth products, make sure that all the pre-
requisites for appropriate use of the products are satisfied:
• Personnel that in any way, shape or form uses our products must first
read and understand the relevant safety instructions and be familiar
with appropriate use.
• If the product takes the form of hardware, then they must remain in
their original state, in other words, no structural changes are
permitted. It is not permitted to decompile software products or alter
source codes.
• Do not mount damaged or faulty products or use them in operation.
• Make sure that the products have been installed in the manner
described in the relevant documentation.
Note: The components may only be used with the accessories and
parts specified in this document. If a component has not been
specifically named, then it may not be either mounted or
connected. The same applies to cables and lines.
Operation is only permitted in the specified configurations and
combinations of components using the software and firmware
as specified in the relevant function descriptions.
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TransKit1 Important Usage Directions 2-2
The motion control and drive system may only be operated under the
assembly, installation and ambient conditions as described in this and
respective product documents (temperature, system of protection,
humidity, EMC requirements, etc.) and in the position specified.
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TransKit1 Safety Instructions for Electric Drives and Controls 3-1
3.1 Introduction
Read these instructions before the initial startup of the equipment and
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 Bosch Rexroth
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, transferred, or passed on to others,
then these safety instructions must be delivered with the equipment.
3.2 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
DANGER
WARNING
CAUTION
Fig. 3-1: Hazard classification (according to ANSI Z535)
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TransKit1 Safety Instructions for Electric Drives and Controls 3-2
CAUTION
CAUTION
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TransKit1 Safety Instructions for Electric Drives and Controls 3-3
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TransKit1 Safety Instructions for Electric Drives and Controls 3-4
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TransKit1 Safety Instructions for Electric Drives and Controls 3-5
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.
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TransKit1 Safety Instructions for Electric Drives and Controls 3-6
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TransKit1 Safety Instructions for Electric Drives and Controls 3-7
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TransKit1 Safety Instructions for Electric Drives and Controls 3-8
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TransKit1 Safety Instructions for Electric Drives and Controls 3-9
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TransKit1 Safety Instructions for Electric Drives and Controls 3-10
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TransKit1 Safety Instructions for Electric Drives and Controls 3-11
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TransKit1 Trans-01 retrofitting check list 4-1
Will the Control be exposed to fluids other than water and/or water/oil
emulsion (max. 5% oil)?
Yes No
The ControlBox, cabling, Next
Motors and DURADRIVE are
rated IP65 and for normal
coolant composition (water
plus 5% oil). If in doubt contact
Bosch Rexroth representative.
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TransKit1 Trans-01 retrofitting check list 4-2
PLC-hardware
Which control topology is available?
RS485 network
Ethernet network
no network
INTERBUS
Profibus
DeviceNet
ControlNet
Other: ________________________________________
NOTE: The ControlBoxD of the TransKit1 is only supporting discrete
24VDC IO. Check with Bosch Rexroth for a TransKit with
Fieldbus connection.
Adaptive feed
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TransKit1 Trans-01 retrofitting check list 4-3
______________________________________
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TransKit1 Trans-01 retrofitting check list 4-4
4.4 I/O-configuration
Is there up to date information about the interface signals used with the
TRANS-01 application?
Overview of interface signals
interface table of the PLC
current diagram of the supervisory/station PLC logic
further signals:
Yes No
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TransKit1 Trans-01 retrofitting check list 4-5
4.5 NC Program
Is any programming sheet available for the TRANS-01 NC program to be
translated to the TRANS200 based NC-program?
Yes No
Review the sheet and compare Obtain the NC-program of
with the TRANS200 NC- the TRANS-01.
commands (see NC-Instruction
documentation).
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TransKit1 Trans-01 retrofitting check list 4-6
Other: ________________________________________
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TransKit1 Frequently Asked Questions 5-1
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TransKit1 Frequently Asked Questions 5-2
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TransKit1 Frequently Asked Questions 5-3
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TransKit1 Frequently Asked Questions 5-4
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TransKit1 Frequently Asked Questions 5-5
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TransKit1 Frequently Asked Questions 5-6
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TransKit1 Frequently Asked Questions 5-7
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TransKit1 Frequently Asked Questions 5-8
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TransKit1 TransKit1 Configurations 6-1
6 TransKit1 Configurations
Items to order
A complete retrofit of Trans-01 and DSC requires:
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TransKit1 TransKit1 Configurations 6-2
ControlBox Version
BTV06 HMI..................... V
24VDC Supply 2)
No internal 24VDC supply........ NN
Int. 24VDC/5A supply (1 axis)... 05
Int. 24VDC/10A supply (2 axes).. 10
Model 2)
IP65, 42°C ambient temp. ........... NN
IP65, 45°C ambient temp. ........... HE
(includes a heat exchanger and user
must consider DURADRIVE de-rating)
Motion Control 1)
NC motion (TRANS200).................. T2
PC Communication
Serial RS232C & RS485 networking port.... S
Ethernet networking port................. E
PLC Communication
Discrete IO (24VDC)........................ IO
1)
Motion programming software:
T2 – WinTrans software is used for programming and drive setup.
Each PC running the software requires a license of:
- 1 x SWA-TRA200-T11-23VRS-MS-CD650 (CD and installation docu)
Further licenses can be purchased as
- SWL-TRA200-T11-23VRS-MS-COPY (single seat license without
CD)
This software permits the user to network up to 32 ControlBox systems
to a single PC running the WinTrans software.
2)
10A internal 24VDC power supply:
-10- The heat exchanger option –HE- must be installed. The heat
exchanger must also be installed if the ControlBoxD is equipped in the
field with a 10A power supply.
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TransKit1 TransKit1 Configurations 6-3
Use this type code to order the pre-configured TransKit1 that provides up
to 2 axes and the ControlBoxD with digital IO for communication to the
machine (e.g., supervisory PLC) similar to the old Indramat Trans-01
controller, all mounted an pre-wired on the frame..
The ControlBoxD (CBD-…) must be ordered as a separate item.
c ControlBox
Order via separate code .... CBD-…
DURADRIVE axis 1
No drive .........................NNNN
040A .............................HDC4
100A .............................HDC1
200A .............................HDC2
DURADRIVE axis 2
No drive ..............................NNNN
040A ..................................HDC4
100A ..................................HDC1
200A ..................................HDC2
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TransKit1 TransKit1 Configurations 6-4
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TransKit1 TransKit1 Configurations 6-5
amplifiers mounted on a frame for quick and easy installation, e.g. at the
transfer station.
Discrete 24VDC IO is used to connect to the supervisory PLC controller
using TRANS-01 compatible connectors.
Note: The solutions described here do NOT provide a 100%
compatible replacement of TRANS-01-DSC drive and MAC
motor system. The integrator must perform modifications to
the existing machine wiring hardware and software. For
detailed information refer to section7.
ControlBox…
with interface to
discrete IO
BTV06.Optional
display for
diagnostics, and
data entry
DURADrive
amplifier
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TransKit1 TransKit1 Configurations 6-6
DURADRIVE
amplifier
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TransKit1 TransKit1 Configurations 6-7
TransKit1 The 24VDC control supply voltage for the ControlBoxD and DURADRIVE
Supply Voltage Rating amplifier(s) can be supplied via connector St.1 unless an internal supply
is ordered/installed. The following provides an overview about the power
requirements:
TransKit1 The TransKit1 contains 24VDC external inputs that represent the
External Inputs interface to the supervisory PLC. Below you find the principle connection
diagram of the external inputs (refer to section 7 for detailed interface
signal description).
Note:
Each input represents a maximum (sinking) load of 10mA.
The integrator must check that the connected discrete PLC
output will operate with loads less than 10mA.
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TransKit1 TransKit1 Configurations 6-8
TransKit1 The solid state 24VDC outputs (sourcing) of the ControlBoxD are
External Outputs supplied by the 24V external (St.1:C16, #2) wire. Each TransKit1 output
is short circuit proof with a short circuit current of 0.5A
Note: With the old Trans-01 each output was limited to 150mA per
output – max. of 2.4A.
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TransKit1 TransKit1 Configurations 6-9
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TransKit1 TransKit1 Configurations 6-10
The sections are joined in the middle to allow compact shipment and
quick installation at the machine.
This also permits the mounting individually or as stacked arrangement.
Cables between ControlBox and DURADRIVE are 1.5m long and
accommodate several mounting locations.
• Individual • Stacked
Due to the specific machine conditions, the OEM or integrator will have to
provide brackets to securely mount the frame to the machine. These
brackets can be attached with mounting bolts using the aluminum slots.
Note: The final mounting location and method must assure that the
temperature; vibration and protection rating of the enclosure
and DURADRIVE are not exceeded. A minimum of 8
mounting brackets for Individual (horizontal) arrangement or
six for the stacked vertical arrangement must be used.
Brackets should be distributed equally on each side so the
aluminum frame and weight are supported properly.
Mounting gusset Mounting gussets for 45x45 frame (PN 3842523561) are available if they
fit the installation of the frame to the machine structure (indicated yellow
in Fig. 5.2.1). A minimum of 6 gussets per frame should be used if the
frame is mounted as one piece. Four (4) gussets must be used per frame
section if mounted as two sections.
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TransKit1 TransKit1 Configurations 6-11
DURADRIVE mounting For secure mounting of the DURADRIVE, 10mm T-blocks (galvanized
steel) and spring (spring steel) elements are inserted into the slot of the
mounting rails. Only this type of mounting will assure that the T-block
(nut) remains in the preset position.
Universal Mounting Mounting Mounting M6: Mounting screw / M8: Mounting screw / End caps
configuration: Rail 1 Rail 2 Rail 3 10mm T-block with spring 10mm T-block with spring for 45*45
(for 40A drives) (100/200A drives) profile
One or Two drives 480 mm 480 mm 480 mm 3 pcs/per drive M6 T- 3 pcs/per drive M8 T- 10pcs
-- any size Block (Part no. 613748) Block (Part no. 613746)
3 pcs/per drive Spring 3 pcs/per drive Spring
(Part no. 613747) (Part no. 613747)
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TransKit1 TransKit1 Configurations 6-12
For drive and motor sizing and selection information and requirements
Drive / Motor Sizing
refer to the ”Selection Data” (DOK-DRIVE*-SERVO*WZM**-AU02-MS) or
contact your Bosch Rexroth representative.
Drive Interface The DURADRIVE uses the SERCOS digital fiber optic interface to
connect to the ControlBox. The DURADRIVE must have “SE01” defined
in the type code and use the SMT-02VRS firmware as defined below:
Drive parameter setup WinTrans software contains the DriveTop tool to configure, tune and
troubleshoot the DURADRIVE using the SERCOS fiber optic link. This
convenient method eliminates the need of laptop PC connection to X2
(cable IKB0006) of the DURADRIVE.
Drive parameter The details of drive parameters and their function are described in the
description functional description of the drive firmware or the help systems for that
firmware (if installed on the PC that contains DriveTop). Typically the
firmware version SMT 02VRS is used:
Functional Description SMT 02
(285849; DOC-ECODR3-SMT-02VRS**-FK01-EN-P)
Parameter Description SMT 02
(285850; DOC-ECODR3-SMT-02VRS**-PA01-EN-P)
Troubleshooting SMT 02
(285852; DOC-ECODR3-SMT-02VRS**-WA01-EN-P)
Firmware Version Notes
(285851; DOC-ECODR3-SMT-02VRS**-FV01-EN-P)
The DURADRIVE design requires that a blower unit LECH-xxxN is
installed. In the case of the 100 A and 200 A drive controllers, the blower
must always be connected. The drive cannot be enabled and powered
up if the LECH-xxxN is disconnected (X14) and the drive H1 diagnostic
LED shows the error F217 “Blower not connected”
For ease of use and maintenance, the blower can be removed and
replaced during drive operation if the drive is powered up already. During
this time the drive shows the warning E217 “Blower running too slow”.
Unless the drive shat off with the respective error because the unit or
bleeder overheated since the blower was not running, the warning goes
away once the blower is re-connected.
Note: Although it is not recommended, the 40 A DURADRIVE can be
run without the blower.
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TransKit1 TransKit1 Configurations 6-13
X14:
Blower connection
DURADRIVE control The control cables and motor feedback cable are routed into the Control
cable installation signals. The 24VDC supply, the SERCOS fiber optic cable and the
position feedback cables are installed via the cable bushing assembly of
the DURADRIVE. Observe the installation instructions below when
removing cables, e.g., during drive replacement.
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TransKit1 TransKit1 Configurations 6-14
Control Voltage The DURADRIVE electronics and blower are conveniently supplied from
the ControlBoxD with 24VDC via the control cable.
Note: The 0V DC line of the ControlBoxD and DURADRIVE are
connected to the housing ground. This means that the 0V DC
potential of external supply systems must be connected with
the 0V DC line of the ControlBoxD! This must also be
considered when connecting switches and wiring directly to
the DURADRIVE!
Feedback/Encoder The motor feedback cables are directly connected to the DURADRIVE.
connection Connector X4 (encoder 1 at motor) and X8 (encoder 2) are located
behind the plastic cover. Follow the cable installation instructions below:
Both connectors employ different feedback interfaces based on the cable
used.
Note: Feedback cable 03-0400 of MAC motors cannot directly be
used with the DURADRIVE. Consult Bosch Rexroth sales and
engineering for further information.
DURADRIVE bottom The motor power and DURADRIVE main supply connectors are located
connections at the bottom of the DURADRIVE.
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TransKit1 TransKit1 Configurations 6-15
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TransKit1 TransKit1 Configurations 6-16
Drive Mains Voltage The DURADRIVE supply voltage (3 x 220 .. 3 x 480 VAC) is directly
connection connected via connector X13 of the DURADRIVE located at the drive
bottom.
The cable and connector for this connection is not provided with the
TransKit1 and must be ordered separately.
Note: The used cable must be rated according to the chosen supply
voltage. Also the temperature sensor and brake wires must be
shielded according to Bosch Rexroth specifications. It is
recommended to use only original Bosch Rexroth cables
suitable for the DURADRIVE.
Motor Power The motor power cable gets connected to connector X5 from the bottom
connection at the DURADRIVE.
The cable and connector for this connection is not provided with the
TransKit1 and must be ordered separately.
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TransKit1 TransKit1 Configurations 6-17
PPC-R / Trans200
UDS-10-01 IND5007
Serial<->
Ethernet
24V
DC
BTV06 HMI
=
IKB0015
RKO0101
RKO0101 IKL0221
IND5008 / IND5009
IKS0580
Ethernet CAT5
IND3048 IND3048
The above figure shows the location and connection of the different
cables. Cables are available and described in section 10.
St.3 – Supply voltage for int. 24VDC and heat exchanger (115VAC)
St.1 – Machine 64 pin connector (discrete 24VDC)
X20 – Ethernet connector (CAT5)
X53 – Serial interface port (RS232 / RS485)
X54 – Drive 1 interlocking (discrete 24 VDC)
X55 – Drive 2 interlocking (discrete 24 VDC)
TX – SERCOS drive interface output (transmitter) – fiber optic
RX – SERCOS drive interface input (receiver) – fiber optic
See chapter 7 for detailed description of the connections and signals.
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TransKit1 TransKit1 Configurations 6-18
St.1
X55 TX
+
Fig. 6-6.2: ControlBoxD connectors (bottom view)
Remove jumper if
internal 24VDC
supply installed.
The terminal block X50 uses multi-point terminal with cage clamp
technology providing reliable connections and measuring points for
troubleshooting.
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TransKit1 TransKit1 Configurations 6-19
Additionally some terminals contain relais (K1, K2, K3, K4, K5, K6) and
circuit breakers (F1 and F2) as indicated in the figure above and
described in further detail in the sections below.
The cutout is prepared for the McLean heat exchanger XR2016-001. This
permits the installation in the field if necessary.
The heat exchanger requires 115VAC supply voltage provided via St.3 of
the ControlBoxD.
Installation instructions Step 1: Switch control voltage power off by turning off the circuit breaker
CB1 and disconnecting St.3
Step 2: Clean off the left side of the ControlBox using soapy water.
Step 3: Remove the cover plate.
Step 4: Clean sheet metal area where the seal is applied.
Step 5: Position the heat exchanger and the flat seal properly.
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TransKit1 TransKit1 Configurations 6-20
Step 6: Fasten the heat exchanger with the screws provided or screws of
the cover plate. Make sure the seal is properly located on clean
surface and the bolts are tightened as per manufacturer
installation description.
Step 6: Strip the wires and connect the 115VAC fan supply wires to the
terminals X50:2BH/X50:3BH (115VAC) and X50:4BH (GND).
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TransKit1 TransKit1 Configurations 6-21
Installation instructions Step 1: Switch off circuit breaker CB1 and disconnect control voltage
power off by disconnecting ST.3
Step 2: Assure that in the machine control panel the 24V Internal control
wire of St.1 (D16) is disconnected from the 24V External wire of
St.1 (C16). Connection of the wires can result in overloading of
the internal or external 24VDC power supplies!
Note: The internal 24VDC power supply of 5A (10A) is only
rated to supply the internal ControlBox devices and the
electronics and blower of up to two (2) DURADRIVE. Do
not draw any power externally from the wire 24V Internal
if the optional power supply is installed.
Step 3: Snap the optional internal power supply on the DIN-rail to the
right of the PPC-R controller rack.
Step 4: Connect the pre-wired green connectors.
Step 5: Confirm that Step 2 was performed on the machine panel side.
Step 6: Connect the 115VAC supply cable to connector St.3 of the
ControlBox and turn on circuit breaker CB1.
Step 7: Make sure circuit breaker CB2 is on.
Step 8: Confirm that 24VDC is supplied to the TRANS200 (H1 indicator
must display changing characters ending at “b”), the BTV06 and
DURADRIVEs (H1 indicator must come on and end at “Bb” and
Fan must operate). This may take about a minute.
Step 10: Close the ControlBox.
DOK-CONTRL-WZM*TK1-AW02-EN-P
TransKit1 TransKit1 Configurations 6-22
The following list provides basic spare component information at the time
of document creation. Suppliers and models may change without notice
and components may differ in the actual ControlBox purchased.
BRC = Bosch Rexroth Electric Drives and Controls
BRL = Bosch Rexroth Linear Motion and Assembly Technologies
TK1 7/30/2003
Components Type Qty Supplier Supplier Part No
Enclosure
BSC2-20EL1612LP-M Enclosure 1 Saginaw Control Engineering BSC2-20EL1612LP-M
SCE-20P16 Sub Panel 1 Saginaw Control Engineering SCE-20P16
Connector socket 115 VAC MSE 300 1 LOHR #218539
Plug, terminated HD 64 Terminated Plug # 1-64 1 Lapp USA #11.2700
Pin, HD MC #20-16 AWG, Dia 1.6mm Pin 64 Lapp USA #11.2210
Base, HBE 24 With Double Levers Base, HBE 24 1 Lapp USA #10.1020
Connector interconnect Duradrive 1 CONN INS0222/L01 1 LOHR #279499
Connector interconnect Duradrive 2 CONN INS0222/L01 1 LOHR #279499
Dust Cover Cap 1 LOHR #218589
Chain, for dust cover cap 1 LOHR 216664
Screw, for dust cover cap 4 screws per cap 4 LOHR 274033
Complete terminal strip w fuses Din Rail Assy 1 Phoenix Proposal # E03-0328
115/220 VAC - 24VDC 5A supply 1 Phoenix #2938581
115/220 VAC - 24VDC 10A supply (For double axes units) 0 Phoenix
Panel Mount Base VS-15-SD 1 Steiner Electric 1887099
Contact Plug, protective cover Q-PROT9/11 1 Steiner Electric 1670235
CP-HCC4 1 Steiner Electric 1600027
ZBN18 1 Steiner Electric 2809128
Heat Exchanger {Optional} 0 McClean XR2016-001
Screw, for BTV06 6
Screw, for connectors (power, 64 pin) M4 Torx - self tapping 6
Screw, for connectors (network) M3 Torx - self tapping 4
Screw, for connectors (drives) M2.5 Torx - self tapping 8
Mounting Frame
Profile Profile 45 X 45 H -/-, L=680 2 BRL 3842990520/680
Profile Profile 45 X 45 H -/-, L=950 2 BRL 3842990520/950
Profile Profile 45 x 45 H -/-, L=480 3 BRL 3842990520/480
Profile Profile 45 X 45 H -/-, L=310 2 BRL 3842990520/310
Gusset Gusset 45 x 45 W/Fastnr 10-10MM 16 BRL 3842523561
End Cap End Cap ESD 45 x 45 & 45 X 45 BLK 10 BRL 3842517058
Connection Link Connection Link 10MM L=180MM 4 BRL 3842528746
Spring Clip, T-Block,Swivel 3.842.529.300 6 BRL
Spring Clip, T-Block,Swivel 3.842.529.299 6 BRL
Screw, for mounting Drive (100A, 200A) 6
Flat washer 6
Spring washer 6
Screw, for mounting Drive (40A) 6
Flat washer 6
Spring washer 6
Control system
NC-card PPC-R01.2N-N-S1-FW 1 BRC 11285236
Firmware FWA-PPCR0*-T01-23VRS-NN-XXXXXX 1 BRC 11291836
Small HMI BTV06.1HN-RS-FW 1 BRC 11285948
Firmware FWA-BTV06*-DOL-01VRS-EN 1 BRC 11285306
Software SWA-BTV06*-T21-23VRS-MS-C1,44 1 BRC 11295762
Control rack RMB02.2-04 1 BRC 11278846
Input card RME02.2-32-DC024 1 BRC 11280937
Output card RMA02.2-32-DC024-050 1 BRC 11280931
2 mm fiber optic cable CABLE ASSEMBLY IKO0982/000.5 2 BRC 11260580
Serial communication cable CABLE ASSEMBLY IKB0015 1 BRC 11282870
Connector socket CONN INS0222/L01 2 BRC 11279499
Fiber optic bulk-head connector CONN FIB-OPT BLKHD 01 UNS IP65 2 BRC 11252524
DOK-CONTRL-WZM*TK1-AW02-EN-P
TransKit1 Interface Descriptions 7-1
7 Interface Descriptions
St.3 ControlBox
GND
N
115VAC ±10% 115VAC
60Hz L1 60Hz
TransKit power
cable 01-0400
DOK-CONTRL-WZM*TK1-AW02-EN-P
TransKit1 Interface Descriptions 7-2
This section describes the signals for the connector St.1. St.1 is used to
connect the discrete IO functionality to the ControlBox. The connector is
compatible to the TRANS-01 St.1 connector, however, there are signal
and functional differences that must be considered.
Note: The user must review each of the signals contained in the
connector St.1 since they differ in functionality when
compared with the original Trans-01 controller.
DOK-CONTRL-WZM*TK1-AW02-EN-P
TransKit1 Interface Descriptions 7-3
DOK-CONTRL-WZM*TK1-AW02-EN-P
TransKit1 Interface Descriptions 7-4
0V X50:33 B16 #1
DOK-CONTRL-WZM*TK1-AW02-EN-P
TransKit1 Interface Descriptions 7-5
X50
32
C16 #2
24V
33 #1
0V B16
Wiring
St.1 Control Cable
Slot 1 X4
X50 04-0900
%I1.0.1 2 10
#17 B10 PCPOWON #17
\
K2 & K3
0V X50:33 B16 #1
DOK-CONTRL-WZM*TK1-AW02-EN-P
TransKit1 Interface Descriptions 7-6
The user must read the 'UD contact' of both drives into the PLC and AND
them before outputting them as the PCUDRDY signal.
Note: If only one drive installed, then the drive’s 'UD contact' can directly be
wired to the PCUDRDY signal.
X50
33 0V B16 #1
PLC Logic
UD1 UD2 QUD
X50
17 A4 #54
UD1 ;PLC input
18 B4 #55 UD2 ;PLC input
X54 3 4 X55 3 4
DURADRIVE #1 DURADRIVE #2
Red/ Wht Red/ Wht
Blk Blk
Interlock Interlock
cable cable
IND3048 IND3048
DOK-CONTRL-WZM*TK1-AW02-EN-P
TransKit1 Interface Descriptions 7-7
X50
32
C16 #2
24V
33 #1
0V B16
DOK-CONTRL-WZM*TK1-AW02-EN-P
TransKit1 Interface Descriptions 7-8
NC control functions
Note: The signals listed here influence the operation of the motion
and provide status feedback.
X50
32
C16 #2
24V
33 #1
0V B16
DOK-CONTRL-WZM*TK1-AW02-EN-P
TransKit1 Interface Descriptions 7-9
TRANS-01 note It was the original signal “Run”. The wiring can remain the same if the
described functionality above is acceptable.
Wiring
Slot 2 X4 Control Cable
St.1 04-0900
%Q2.0.6
7
#19 B3 PSACTIV #19
X50
32
C16 #2
24V
33 #1
0V B16
0V X50:33 B16 #1
DOK-CONTRL-WZM*TK1-AW02-EN-P
TransKit1 Interface Descriptions 7-10
TRANS-01 note It was the original signal “Fault”. Can remain as wired.
Wiring
Slot 2 X4 %I1.0.3 Control Cable
St.1 04-0900
%Q2.0.3
4 A2 PSERROR
#22 #22
X50
32
C16 #2
24V
33 #1
0V B16
Control Reset:
A stopped NC program can be aborted by a 'Control-Reset' input. A running
spindle is stopped by 'Control reset' (exception: see AxCSPRST with x=axis
number of spindle). (TransKit1 sets the AxCSPRST by default to 1:”Control
reset does not influence the spindle”).
Programmed reverse vectors are cleared. The '.HOME' base reverse vector
is therefore called when a reverse program is initiated. This executes the
base reverse program. Complicated return movements that permit program-
controlled establishment of the readiness to start by programming reverse
vectors are not performed.
The operator must perform those movements in 'Setup' mode through jog
movements. Once it has been ensured that the base reverse program can
be executed without interference, the operator may trigger a start of the
reverse program and initiate the base reverse program.
The following signals and actions are also influenced by a 'Control reset':
The 'NC block active' (PSACTIV) status signal is reset
DOK-CONTRL-WZM*TK1-AW02-EN-P
TransKit1 Interface Descriptions 7-11
X50
32 C16
24V #2
0V 33 B16 #1
0V X50:33 B16 #1
DOK-CONTRL-WZM*TK1-AW02-EN-P
TransKit1 Interface Descriptions 7-12
'Manual' mode'
'Manual’ mode permits NC programs to be executed and axes to be moved
by jog commands.
DOK-CONTRL-WZM*TK1-AW02-EN-P
TransKit1 Interface Descriptions 7-13
TRANS-01 note It was the original signal “Auto”. The signal functioning is similar but the
signal level is reversed. In Trans-01 HI status indicated AUTO mode, while
here it indicates MANUAL.
Wiring
St.1 Control Cable
Slot 1 X4
04-0900
%I1.0.2 3
#23 B10 PCMODE1 #23
0V X50:33 B16 #1
DOK-CONTRL-WZM*TK1-AW02-EN-P
TransKit1 Interface Descriptions 7-14
Jog movements can only be continued after the process enable signal has
been re-applied.
TRANS-01 note It was the original signal “Forward Enable”. The signal functioning is similar
but motion execution will require an edge at PCADV or PCREV.
Wiring
St.1 Control Cable
Slot 1 X3
04-0900
%I1.1.5 6
#60 A12 PCENABL #60
0V X50:33 B16 #1
DOK-CONTRL-WZM*TK1-AW02-EN-P
TransKit1 Interface Descriptions 7-15
Error
Process enabling signal removed
Stop
Changing modes
single step mode, and
Starting a reverse program
TRANS-01 note It was the original signal “Start”. The signal functioning is similar.
Wiring
DOK-CONTRL-WZM*TK1-AW02-EN-P
TransKit1 Interface Descriptions 7-16
'Setup' mode
A positive edge of the 'start of reverse program' signal starts the reverse
program.
Unlike in 'Automatic' mode, the NC monitors the 'start reverse program'
signal in the other modes after the program has been started. The reverse
program is executed as long as the signal is applied. When the signal is
removed, active movements are decelerated along a ramp, and program
execution is interrupted. Program execution is resumed (restart) when the
signal is re-applied.
The following conditions interrupt a reverse program:
Power shutdown – Error - Process enabling signal removed - Stop
single step mode, and Changing modes
TRANS-01 note It was the original signal “Homing”. The signal functioning is similar.
Wiring
3 Control Cable
K4 X50 St.1 04-0900
32
24V C16 #2
0V 33 B16 #1
4
Outputs Q4 Output on when R1 (reverse) is
pressed and MAN mode active
13
24V K6 Supply BTV06 outputs when
MAN mode selected
0V 14 K4
Slot 1 %I1.0.6 X4
PCREV
#15 D10 #15
7 K6
Wiring
DOK-CONTRL-WZM*TK1-AW02-EN-P
TransKit1 Interface Descriptions 7-17
0V X50:33 B16 #1
0V X50:33 B16 #1
DOK-CONTRL-WZM*TK1-AW02-EN-P
TransKit1 Interface Descriptions 7-18
0V X50:33 B16 #1
0V X50:33 B16 #1
DOK-CONTRL-WZM*TK1-AW02-EN-P
TransKit1 Interface Descriptions 7-19
0V X50:33 B16 #1
X50
32
C16 #2
24V
X50:33 #1
0V B16
DOK-CONTRL-WZM*TK1-AW02-EN-P
TransKit1 Interface Descriptions 7-20
TRANS-01 note It was the original signal “Excessive Thrust”. The wiring can remain if the
described functionality above is acceptable.
Wiring
Slot 2 X3 Control Cable
St.1 04-0900
%Q2.1.1
2 D2 P2EXCTH
#59 #59
X50
32
C16 #2
24V
33 #1
0V B16
DOK-CONTRL-WZM*TK1-AW02-EN-P
TransKit1 Interface Descriptions 7-21
Auxiliary functions
Note: The auxiliary functions work differently than with the Trans-01.
By default, the auxiliary functions
o are output at the end of the NC-block
o must be acknowledged at the end of the NC-block to
continue motion program execution.
DOK-CONTRL-WZM*TK1-AW02-EN-P
TransKit1 Interface Descriptions 7-22
X50
32
C16 #2
24V
33 #1
0V B16
DOK-CONTRL-WZM*TK1-AW02-EN-P
TransKit1 Interface Descriptions 7-23
X50
32
C16 #2
24V
33 #1
0V B16
X50
32
C16 #2
24V
33 #1
0V B16
DOK-CONTRL-WZM*TK1-AW02-EN-P
TransKit1 Interface Descriptions 7-24
is different and the number of the auxiliary function changes. The TransKit1
does not monitor the state of the acknowledge signal.
Wiring
Slot 2 X1 Control Cable
St.1 04-0900
%Q2.3.3
4 D7 PSAUX405
#34 #34
X50
32
C16 #2
24V
33 #1
0V B16
X50
32
C16 #2
24V
33 #1
0V B16
DOK-CONTRL-WZM*TK1-AW02-EN-P
TransKit1 Interface Descriptions 7-25
X50
32
C16 #2
24V
33 #1
0V B16
X50
32
C16 #2
24V
33 #1
0V B16
DOK-CONTRL-WZM*TK1-AW02-EN-P
TransKit1 Interface Descriptions 7-26
X50
32
C16 #2
24V
33 #1
0V B16
X50
32
C16 #2
24V24V
33 #1
0V B16
DOK-CONTRL-WZM*TK1-AW02-EN-P
TransKit1 Interface Descriptions 7-27
X50
32
C16 #2
24V
33 #1
0V B16
0V X50:33 B16 #1
DOK-CONTRL-WZM*TK1-AW02-EN-P
TransKit1 Interface Descriptions 7-28
changes. The TransKit1 does not monitor the state of the acknowledge
signal.
Wiring
St.1 Control Cable
Slot 1 X1
04-0900
%I1.3.1 2
#40 C8 PCACKN401 #40
0V X50:33 B16 #1
0V X50:33 B16 #1
DOK-CONTRL-WZM*TK1-AW02-EN-P
TransKit1 Interface Descriptions 7-29
0V X50:33 B16 #1
0V X50:33 B16 #1
DOK-CONTRL-WZM*TK1-AW02-EN-P
TransKit1 Interface Descriptions 7-30
0V X50:33 B16 #1
0V X50:33 B16 #1
DOK-CONTRL-WZM*TK1-AW02-EN-P
TransKit1 Interface Descriptions 7-31
0V X50:33 B16 #1
0V X50:33 B16 #1
DOK-CONTRL-WZM*TK1-AW02-EN-P
TransKit1 Interface Descriptions 7-32
0V X50:33 B16 #1
Axis #1 functions
Axis #1 can be a servo axis. Additional signals for functions such as
touch probing, and way points are provided.
Note: Axis #1 must not be used as spindle axis since respective
signals are not available via connector St.1.
X54 HDC01.1-AxxxN-SE01-01-FW
Slot 1 X2 Bb
%I1.2.0 1
Interlock Cable
IND3048 1.5m ON1
ON1
X11
Violet 7 On3
10 Yellow 8 On4
15 1 Pink 0V
\
910
9 Green +24Vpro
K2:14 11
6 ZKS1
0V
2
DOK-CONTRL-WZM*TK1-AW02-EN-P
TransKit1 Interface Descriptions 7-33
X50
32
C16 #2
24V
33 #1
0V B16
DOK-CONTRL-WZM*TK1-AW02-EN-P
TransKit1 Interface Descriptions 7-34
Control Cable
X50 St.1 04-0900
21 #12 B14 #12
Home LS
20 #11 C14 #11
Pos. OT LS
19 #10 #10
D14 Neg. OT LS
X50
0V 33 #1
X54 5 6 7 11
X3 1 2 3 X1 3
DURADRIVE Axis 1
HDC01.1-AxxxN-SE01-01-FW
DOK-CONTRL-WZM*TK1-AW02-EN-P
TransKit1 Interface Descriptions 7-35
2. Drive setup:
The user must configure (edge selection, arming, etc.) for the Probe 1 input
using the AXD NC-command, e.g. via the subroutine or reverse (HOME)
program. (See blocks N003 to N005 in the attached example. )
Note:
The probe used must have a deflection in the direction of probing.
The distance of deflection must be large enough so that the motion
can be stopped after signal recognition without damaging the probe.
If probe will not trigger in the expected area, program should stop
(See block N0010 in the attached example) and message can be
issued.
TRANS-01 note This functionality did NOT exist with the Trans-01.
Caution: The original signal of St.1:C12 was “Reverse”. This signal is not
used anymore. Reverse program execution is triggered through the input
St.1:D10 Æ PCREV described before.
Wiring
DOK-CONTRL-WZM*TK1-AW02-EN-P
TransKit1 Interface Descriptions 7-36
X50 0V B16 0V
32
X54 11 4
Blue Wht
DURADRIVE
Axis #1
HDC01.1-AxxxN-SE01-01-FW
X50
32
C16 #2
24V
X50:33 #1
0V B16
DOK-CONTRL-WZM*TK1-AW02-EN-P
TransKit1 Interface Descriptions 7-37
Note: The NC always outputs the waypoints, even if the axis has not yet
been homed. TRANS200 stores the axis positions when the controller is
switched off, and restores them when it is switched on. It can therefore be
assumed that, even without homing, the positions may be employed for
performing rough monitoring activities using the waypoints. Obviously, this is
not true after the machine has been manually manipulated or after new
parameters have been loaded. The absolute validity of the waypoints can
only be assured by including the 'axis homed' signal (AxSHOMED).
Note: Although the TRANS200 permits to use up to 8 waypoints, the
TransKit limits them to only two: ‘Waypoint 0’ and ‘Waypoint 1’.
TRANS-01 note This function did not exist in the Trans-01.
Caution: The original signal of St.1:D4 was “BCD 10*23”.. This function is
no longer available since the TransKit1 does not support BCD outputs.
Wiring
X50
32
C16 #2
24V
33 #1
0V B16
DOK-CONTRL-WZM*TK1-AW02-EN-P
TransKit1 Interface Descriptions 7-38
Note: The NC always outputs the waypoints, even if the axis has not yet
been homed. TRANS200 stores the axis positions when the controller is
switched off, and restores them when it is switched on. It can therefore be
assumed that, even without homing, the positions may be employed for
performing rough monitoring activities using the waypoints. Obviously, this is
not true after the machine has been manually manipulated or after new
parameters have been loaded. The absolute validity of the waypoints can
only be assured by including the 'axis homed' signal (AxSHOMED).
Note: Although the TRANS200 permits to use up to 8 waypoints, the
TransKit limits them to only two: ‘Waypoint 0’ and ‘Waypoint 1’.
TRANS-01 note This function did not exist in the Trans-01.
Caution: The original signal of St.1:A5 was “BCD 1*20”. This function is no
longer available since the TransKit1 does not support BCD outputs.
Wiring
X50
32
C16 #2
24V
33 #1
0V B16
DOK-CONTRL-WZM*TK1-AW02-EN-P
TransKit1 Interface Descriptions 7-39
Axis #2 functions
Axis 2 can be a servo axis or a spindle axis.
Note: If spindle axis functionality is required, Axis #2 must be used
as the spindle axis since respective signals are provided via
St.1.
X55 HDC01.1-AxxxN-SE01-01-FW
Slot 1 X2
%I1.2.1 2
Interlock Cable
IND3048 1.5m
X11
Violet 7
Bb
10 Yellow 8
Bb
16
1 Pink 9 ON1
\
10 ON1
K2:14 9 Green
On4
12
6 0V
+24Vpro
2
ZKS1
\
3
ZKS1
4
0V
5
DOK-CONTRL-WZM*TK1-AW02-EN-P
TransKit1 Interface Descriptions 7-40
TRANS-01 note Caution: It was the original signal “+/- 15 OK”. Wiring in the machine
control panel must be modified!
Wiring
Slot 2 X2 Control Cable
St.1 04-0900
%Q2.2.1
2 D1 A2SHOMED
#8 #8
X50
32
C16 #2
24V
33 #1
0V B16
DOK-CONTRL-WZM*TK1-AW02-EN-P
TransKit1 Interface Descriptions 7-41
Control Cable
04-0900
X50 St.1
#61 25 A15 #61
Home LS
#63 24 #63
B15 Pos. OT LS
23
#62 C15 #62 Neg. OT LS
X50
0V 33 #1
X55 5 6 7 11
X3 1 2 3 X1 3
DURADRIVE Axis 2
HDC01.1-AxxxN-SE01-01-FW
Note: The signal is only valid for digital main spindle drives.
TRANS-01 note This signal did not exist with the TRANS01.
Caution: The original signal of St.1:B2 was “Brake release”. This function
is no longer necessary since the motor brake is directly controlled from the
DURADRIVE. If this signal was previously used, control cabinet has to be
rewired.
Wiring
DOK-CONTRL-WZM*TK1-AW02-EN-P
TransKit1 Interface Descriptions 7-42
X50
32
C16 #2
24V
33 #1
0V B16
Note: The signal is only valid for digital main spindle drives.
TRANS-01 note Caution: It was signal “BCD output 1*21”. This function is no longer
available since the TransKit1 does not support BCD output.
Wiring
X50
32
C16 #2
24V
33 #1
0V B16
Note: The 'AxSN_MIN' signal does not fulfill the personal safety
requirements. The signal is only valid for digital main spindle drives.
TRANS-01 note Caution: It was signal “Brake Control 2”. The motor brake is directly
controlled by the DURADRIVE. If this signal was previously used, control
cabinet has to be rewired.
Wiring
DOK-CONTRL-WZM*TK1-AW02-EN-P
TransKit1 Interface Descriptions 7-43
X50
32
C16 #2
24V
33 #1
0V B16
DOK-CONTRL-WZM*TK1-AW02-EN-P
TransKit1 Interface Descriptions 7-44
TX of ControlBox The cable from TX (transmit) of the ControlBox represents the SERCOS
light output that connects to “X21 RX” of the first DURADRIVE.
RX of ControlBox From the first DURADRIVE connector “X20 TX” another fiber optic cable
is connected back to RX (receive) of the ControlBox, unless a second
DURADRIVE is installed. If latter, the cable returns from “X20 TX“ of the
second DURADRIVE. Both drives are connected between “X20 TX” and
“X21 RX” with a third SERCOS cable.
DOK-CONTRL-WZM*TK1-AW02-EN-P
TransKit1 Interface Descriptions 7-45
Overview
Hardware interlocking signals are connected to the ControlBoxC and
ControlBoxD via connectors X54 (DURADRIVE #1 left) and X55
(DURADRIVE #2 right).
X54 X55
DOK-CONTRL-WZM*TK1-AW02-EN-P
TransKit1 Interface Descriptions 7-46
Note: The “Local E-stop” can be added in the field if necessary. The
modification should be done in such way, that the IP65
enclosure rating is maintained.
Please contact Bosch Rexroth if for any reason the user must
make modification to this wiring.
Interlock Cable
IND3048 1.5m
HDC01.1-AxxxN-SE01-01-FW
X54
X1
ControlBoxD X50 3 DURADRIVE #1
White 1.0 0VDC
0V #83 11
X3
21 #12 5 Blue/Blk 1 Home LS
+ O.T. LS
20 #10 6 Yel/Blk 2
19 #11 7 3 - O.T. LS
Green/Blk
22 4 Red 4 Probe 1
\
3 UD OK
17 Red/Blk 11
2 E-Stop
14 Black 6
PCESTAT %I1.1.7 ----------------------------
Local Jumper if
E-Stop Æ X11
K1 no E-stop Bb
Violet 7
11 14 13 10
15 Yellow 8 Bb
A1CREADY %I1.2.0 ---------------------------
1 9 ON1
Pink
PCPOWON St.1:B10------- K2:14 9 Green
10
K2 ON1
X50:10
K2:11 8 Brown 11
On3
12
On4
6
0V
2
+24Vpro
3 ZKS1
\
4 ZKS1
5 0V
DOK-CONTRL-WZM*TK1-AW02-EN-P
TransKit1 Interface Descriptions 7-47
The TransKit1 uses a single cable per drive for interlocking. The cable
has a connector at the ControlBox and is connected to X1, X3 and X11 in
the DURADRIVE as shown below.
For details on limit switch connection refer to St.1 connector details.
The signal UD is providing feedback to the ControlBox if the drive is
powered up.
For further details on DURADRIVE functions, please refer to
Project Planning Manual
DURADRIVE
Drive Controllers with degree of protection IP 65
DOK-DURADR-HDC01.1****-PR02-EN-P; 288285
Note: The “Local E-stop” can be added in the field if necessary.
The modification should be done in such way, that the IP65
enclosure rating is maintained.
Please contact Bosch Rexroth if for any reason the user must
make modification to this wiring.
Interlock Cable
IND3048 1.5m
HDC01.1-AxxxN-SE01-01-FW
X55
X1
ControlBoxD X50 3 DURADRIVE #2
White 1.0 0VDC
0V #83 11
X3
25 #12 5 Blue/Blk 1 Home LS
+ O.T. LS
24 #10 6 Yel/Blk 2
23 #11 7 3 - O.T. LS
Green/Blk
26 4 Red 4 Probe 1
\
3 UD OK
18 Red/Blk 11
2 E-Stop
14 Black 6
PCESTAT %I1.1.7 ----------------------------
Local
E-Stop Æ Jumper if X11
K1 no E-stop Violet 7 Bb
11 14 13 10
16 Yellow 8 Bb
A2CREADY %I1.2.1 ---------------------------
1 9 ON1
Pink
PCPOWON St.1:B10 ------ 9 Green
10
K3:14 ON1
K3
X50:10 8 Brown 11
K3:11 On3
12
On4
6
0V
2
+24Vpro
3 ZKS1
\
4 ZKS1
5 0V
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TransKit1 Interface Descriptions 7-48
In the final revision of the TransKit1 the PIM function has not been
implemented. The signals PSAUX420 and PSAUX421 together with
appropriate acknowledgements PCACKN420 and PCACKN421 were
freed to be used as regular auxiliary functions.
Technical data
Behind a dust cover, the 15pin Sup-D connector X53 provides a serial
interface programming port. The type of connection (RS232C or RS485)
is chosen with the cable using the Bosch Rexroth SIS setup.
X53 as RS232C For a single point RS232 connection use cable IND5009(613220).
Note: The ControlBoxD internal connection between X53 socket and
TRANS200 programming port X10 is made with either universal serial
cable without termination AE1103 (613198) for RS232 communication, or
AE1107 (613337) cable for RS485 configuration. The later includes
termination resistors on the control side. Both cables are included in the
ControlBoxD delivery, so the change can be done in the field.
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TransKit1 Interface Descriptions 7-49
For RS485 communication the first and last connector must contain a
terminator circuit as shown below:
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TransKit1 Interface Descriptions 7-50
DOK-CONTRL-WZM*TK1-AW02-EN-P
TransKit1 Interface Descriptions 7-51
To modify these settings, press S1 (see figure below) and follow the
menu instructions for modifying the serial communication settings.
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TransKit1 Interface Descriptions 7-52
DOK-CONTRL-WZM*TK1-AW02-EN-P
TransKit1 Interface Descriptions 7-53
SWITCH Address
10/100 selection via
Ethernet S1 and H1
UDS-10
IND5007 cable The complete cable IND5007/000.6 is used to connect the DB25 serial
port of the Lantronix UDS 10-01 converter to the PROG port (X10) of the
PPC-R card (Trans200).
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TransKit1 Interface Descriptions 7-54
Ethernet – Serial converter The Lantronix UDS-10-01 “Serial-Ethernet” device server must be
setup programmed by the user. The following steps must be performed on the
PC that is used with WinTrans software and that is connected to
Ethernet:
Step 1 Install the Device Installer software provided with the TransKit1 or
ControlBox.
Step 2 Connect the PC (with active Ethernet TCP/IP setup) and the ControlBox
(of the TransKit1) via Ethernet cables to an Ethernet Switch (HUB). Then
start the “DeviceInstaller …” program on the PC. (You can also use
crossed Ethernet cable to connect to single device w/o hub.)
Press the search button (left large icon) to find connected UDS-10
devices. After the scan all available UDS-10 devices appear showing
their default address.
Note: It may be necessary to perform this setup one UDS-10 at a
time to prevent duplicate IP addresses in the network.
Step 3 Select the desired device and click the IP address button. Enter the
desired unique IP address of the UDS-10. This address must match the
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TransKit1 Interface Descriptions 7-55
Select the PC-network class the same like in other UDS-10 and the
machine PC (BTV). Press the „Set IP Address“ button to activate the IP
address in the UDS-10. To check that the UDS-10 device contains the
new IP address, press the Ping button and check that the UDS-10 is
responding. If the device is responding, document the IP-address for the
ControlBox of the TransKit1.
Repeat the Step 3 if the UDS-10 does not respond and assure that no
duplicate IP addresses are used and the chosen common Network Class.
Step 4 To confirm the serial port settings of the UDS-10, select the desired
device and click the configuration button (tools). Then click the “Telnet to
Device” to open the dialog.
After the dos-box opens press <Enter> to continue and the following
menu appears:
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TransKit1 Interface Descriptions 7-56
In the top the currently active serial port settings are listed. Press <1>
and <Enter> to modify the settings. Enter only data for:
Baudrate: 115200
I/F Mode: 4C ;for RS232C
Flow: 00
Port: <5xxxx> ;must match the “Mode” entry in the
System Configurator (see below)
Activate with 9 to save and press <Enter>. Close the Lantronix software
when all devices are done
.PC – TRANS200 System Configurator setup
If the TransKit1 (specifically its ControlBox) was ordered with the
Ethernet communication option the user must first enable the TCP/IP
before defining the TRANS200 systems in the System Configurator
software.
Step 1 After installing the WinTrans software on that PC, open the following file
System Configurator on the PC using Notepad (pure) text editor:
..:\Program Files\Indramat\MTGUI\BASICDATA\RESOURCE\SYSCON.INI
NOTE: Do not modify or delete any data in this file except what is
explained below.
Search for “[TRA200-R]” and add the string “,TCP” to V24 as shown
below. Then save the data and close the file.
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TransKit1 Interface Descriptions 7-57
Step 2 On the PC start the “System Configurator” and define one TRANS200
System Configurator control per TransKit1 ControlBox.
Double click the icon to start the System Configurator. Then enter a
new TRANS200 or select an existing TRANS200 that represents the
desired TRANS200 in the TransKit1 ControlBox.
Go through the wizard until the setup of the communication is prompted.
Either double-click “new” or the existing “CommAddr” for the device (not
used with another device).Now select “TCP” and enter the “Channel”
which is the <IP address> and “Mode” which is the <port> address of the
UDS-10 converter mounted in the ControlBox of the TransKit1.
To test the connection to the TRANS200 you must also match the
TRANS200 device address in the System Configurator setup and the
TRANS200 hardware (PPC-R) located in the ControlBox.
The Ping button can be used to verify the Ethernet IP connection if the
device address, Channel / IP address and Mode / Port are set identical.
DOK-CONTRL-WZM*TK1-AW02-EN-P
TransKit1 NC setup 8-1
8 NC setup
8.1 TRANS200
TRANS200 - Training
The user of the TransKit1 or ControlBoxC and ControlBoxD should attend
training courses offered by Bosch Rexroth for the TRANS200 motion
controller. Please contact Bosch Rexroth Electric Drives and Controls or
a representative for available training courses.
Note: Being unfamiliar with the TRANS200 control system may result in
potentially costly startup delays.
TRANS200 - Documentation
The user can obtain the latest Documentation CD from Bosch Rexroth or
purchase printed manuals via the BRC representative.
Hardware components:
Software:
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TransKit1 NC setup 8-2
Commissioning :
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TransKit1 NC setup 8-3
Note: The user will need to use the WinTrans software (on a PC) to
finalize
o the axis setup (e.g., axis name/meaning, axis type
linear/rotary, etc.)
o process definitions, feeds and speed
o D-correction setup
o auxiliary function setup
so they match the desired machine configuration. This setup
should occur during the preparation phase to minimized
delays during the startup.
TRANS200 - NC-programming
Compared to the single axis TRANS-01 controller, the multi-axis
TRANS200 has a more comprehensive G-code instruction set combined
with high-level commands. These commands are described in detail in
the documentation:
TRANS200
NC Programming Instructions Application Manual
DOK-TRA200-NC**PRO*V22-AW01-EN-P (PN 295379)
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TransKit1 NC setup 8-4
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TransKit1 Operation 9-1
9 Operation
L1 and R1 PB for
HMI screens MANual program control
MAN/ Indicator shows if manual operation mode was selected via the
JOG respective signal on connector St.1.
Light OFF Automatic mode active
The indicators “AXIS1+”, “AXIS1–“, “AXIS2+”, “AXIS2–“
and “RUN/ACTIVE” indicate axis movement and that the
NC program is active and running.
Light ON Manual mode active
This mode permits axis jogging via the PBs “AXIS1+”,
“AXIS1–“, “AXIS2+”, “AXIS2–“.
If activated in the setup of BTV06 HMI, NC program
execution is possible by pressing the PB “L1” (forward
execution) or PB “R1” (reverse program).
DOK-CONTRL-WZM*TK1-AW02-EN-P
TransKit1 Operation 9-2
AXIS1 AXIS1 Light OFF The respective axis is not moving in the positive or
+ – negative direction.
Light ON Axis is moving in respective direction.
AXIS2 AXIS2
+ – PB pressed Axis is jogged at preset speed when manual operation
mode is active.
PB pressed Displays the brief help for the active screen if the text
HELP “HELP” is shown in the upper left corner.
Main
PB pressed Calls the Main Menu screen “NC-Functions”.
Menu
PB pressed This key will cancel a function, exit windows and help
ESC screens.
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TransKit1 Operation 9-3
The numerals, cursor keys printed on the BLUE background are normally
active when the button is pressed.
The <Shift>-key (arrow to upper left) can be pressed and held while
pressing a button with characters printed on the GREEN background to
enter character information.
Specific characters are entered by pressing the button multiple times
while holding the <Shift>-key.
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TransKit1 Operation 9-4
Diagnostic
message
Screen
content
Soft-Key
description
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TransKit1 Operation 9-5
Main Menu
“NC-Functions”
The top line indicates that help information is available by pressing the
<HELP>-key. The active operating mode is displayed in the upper right
corner.
In the second line the currently active diagnostic message is displayed.
Axis position data can be displayed as Machine (M) or Program (P)
coordinates as selected in the SETup menu (<F8>). The screen shows
the commanded, actual and programmed end position,
The current and next NC-block are displayed in the block below,
providing the user with the NC-program information currently being
executed.
DOK-CONTRL-WZM*TK1-AW02-EN-P
TransKit1 Operation 9-6
DOK-CONTRL-WZM*TK1-AW02-EN-P
TransKit1 Operation 9-7
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TransKit1 Operation 9-8
DOK-CONTRL-WZM*TK1-AW02-EN-P
TransKit1 Operation 9-9
DOK-CONTRL-WZM*TK1-AW02-EN-P
TransKit1 Operation 9-10
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TransKit1 Operation 9-11
DOK-CONTRL-WZM*TK1-AW02-EN-P
TransKit1 Cables and Accessories 10-1
DOK-CONTRL-WZM*TK1-AW02-EN-P
TransKit1 Cables and Accessories 10-2
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TransKit1 Cables and Accessories 10-3
10.2 Accessories
The switch box PSS-T10 (PN 288679) and the ready-made cable
“IND3052“ (2 meter long) can be purchased for purpose of training,
engineering and debugging. The cable directly plugs into the St.1
connector of the ControlBoxD.
The switch box allows the insertion of label strips. The label strips for the
ControlBoxD connector St.1 are displayed below.
DOK-CONTRL-WZM*TK1-AW02-EN-P
TransKit1 Index 1
11 Index
DOK-CONTRL-WZM*TK1-AW02-EN-P
TransKit1 Index 2
DOK-CONTRL-WZM*TK1-AW02-EN-P
TransKit1 Index 3
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