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REXROTH SYNAX200 Project Planning Manual

REXROTH SYNAX200 Project Planning Manual

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

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  • Page 1 SYNAX200 Decentralized System for the Synchronization of Machine Axes Project Planning Manual: Version 07 DOK-SYNAX*-SY*-07VRS**-PR01-EN-P...
  • Page 2 Date DOK-SYNAX*-SY*-07VRS**-PR01-EN-P 05.00 Version 07VRS  2000 Rexroth Indramat GmbH Copyright 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).

  • Page 3: Table Of Contents

    SYNAX200 Contents Contents Determing Drive and System Configurations General............................1-1 Important Directions for Use Appropriate Use ..........................2-1 Introduction ..........................2-1 Areas of Use and Application....................2-2 Inappropriate Use........................... 2-2 Safety Instructions for Electric Servo Drives and Controls Introduction............................. 3-1 Explanations...........................
  • Page 4 Contents SYNAX200 Power supply..........................4-9 Digital inputs and outputs......................4-9 EMC ............................4-10 Interfaces ..........................4-10 Connecting the Power Supply...................... 4-11 Connecting Inputs and Outputs ....................4-11 Connector Pin Assignments......................4-12 X1 (11-way Phoenix female connector)................. 4-12 PROG / COM interface (X10, X16) ..................4-12 BT bus (X15) ..........................
  • Page 5 Drive Configuration DIAX04 Based on Basic Configuration HS45 ..........7-15 7.10 Example ............................7-17 Motion Control Configuration ....................7-17 Drive Configuration ........................ 7-18 Set-Up SYNAX200 Ring Data Transmission via Fibre-Optics Cable ..................8-1 Optical Transmission Ring Structure ..................8-1 Constructing the Transmission Path..................8-2 Types of Fibre-Optics Cables ....................
  • Page 6 Contents SYNAX200 10.2 Connecting the PPC........................10-1 10.3 RS485 Link........................... 10-2 11 Appendix 11-1 11.1 Dimensional Sheets, Terminal Diagrams RECO ................. 11-1 Mounting Dimensions Module Carrier RMB02.2-02 .............. 11-1 Mounting Dimensions Module Carrier RMB02.2-04 .............. 11-2 PPC-R01.2 and PPC-R02.2....................11-3 DAQ03.1R..........................

  • Page 7: Determing Drive And System Configurations General

    Determing Drive and System Configurations Determing Drive and System Configurations General SYNAX200 systems are built of up to 40 digital intelligent drives of the DIAX03 (DKR), DIAX04 and ECODRIVE03 drive family, a motion control PPC-R, one LWL connection between these components meeting...
  • Page 8 Determing Drive and System Configurations SYNAX200 DIAX03 220 V Steuer- Netz/Mains Motor spannung Aux. N L K DIGITAL COMPACT CONTROLLER DKR 4 220 V Netz/Mains Motor Steuerspannung Aux. DIGITAL COMPACT CONTROLLER DKR DIGITAL COMPACT CONTROLLER DKR DKR 2.1 DKR 3.1 DKR 4.1...
  • Page 9 SYNAX200 Determing Drive and System Configurations Fig. 1-3: Rotary motors Fig. 1-4: Linear motors DOK-SYNAX*-SY*-07VRS**-PR01-EN-P...
  • Page 10 Fieldbus slave interfaces are available for the fieldbusses Profibus (DPS), Fieldbus module Interbus (IBS) and DeviceNet (DNS). Note: The SYNAX200 system is adapted to the hardware on the machine in two steps: • First the drive concept in terms of the motor is determined.
  • Page 11 Fig. 1-5: PPC configurations e.g. SPS PPC link and/or ARCNET coupling card e.g. SPS Profibus slave circuit e.g. SPS Interbus slave circuit e.g. SPS DeviceNet slave circuit SY7PR081.FH7 Fig. 1-6: Functional assignment of the PPC option modules with SYNAX200- system configuration DOK-SYNAX*-SY*-07VRS**-PR01-EN-P...
  • Page 12 Determing Drive and System Configurations SYNAX200 Motors All rotary and linear motors which belong to the product line MKD, MKE, MHD, 2AD, 1MB, MBW, MBS, LAF and LSF can always be used. Drive Controller Digital drive controllers of the type DIAX03 (DKR) and DIAX04 can be adapted to meet numerous application requirements by using various plug-in modules.
  • Page 13 MHD, MKD feedback interface EnDat/SSI EnDat encoder interface high-resolution motor feedback or master axis master axis encoder GDS 1.1 encoder interface SY7PR048.FH7 Fig. 1-7: Functional assignment of the drive plug-in modules with SYNAX200 system configuration DOK-SYNAX*-SY*-07VRS**-PR01-EN-P...
  • Page 14 Determing Drive and System Configurations SYNAX200 DOK-SYNAX*-SY*-07VRS**-PR01-EN-P...

  • Page 15: Important Directions For Use

    The user alone carries all responsibility of the risks. Before using Rexroth Indramat products, make sure that all the pre- requisites for appropriate use of the products are satisfied: • Personnel that in any way, shape or form uses our products must first read and understand the relevant safety instructions and be familiar with appropriate use.

  • Page 16: Areas Of Use And Application

    The motion control solution SYNAX200 has been developed for use in single or multiple-axis drives and control tasks. Typical applications of SYNAX200 are: •...

  • Page 17: Safety Instructions For Electric Servo Drives And Controls

    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.

  • Page 18: Hazards By Inappropriate Use

    Safety Instructions for Electric Servo Drives and Controls SYNAX200 Hazards by Inappropriate Use High voltage and high discharge current! Danger to life, risk of severe electrical shock and risk of injury! DANGER Dangerous movements! Danger to life and risk of injury or equipment damage by unintentional...

  • Page 19: General Information

    Safety Instructions for Electric Servo Drives and Controls General Information • Rexroth Indramat GmbH is not liable for damages resulting from failure to observe the warnings given in these documentation. • Order operating, maintenance and safety instructions in your language before starting up the machine.

  • Page 20: Protection Against Contact With Electrical Parts

    Safety Instructions for Electric Servo Drives and Controls SYNAX200 Protection Against Contact with Electrical Parts Note: This section refers to equipment with voltages above 50 Volts. Making contact with parts conducting voltages above 50 Volts could be dangerous to personnel and cause an electrical shock. When operating electrical equipment, it is unavoidable that some parts of the unit conduct dangerous voltages.
  • Page 21 SYNAX200 Safety Instructions for Electric Servo Drives and Controls To be observed with electrical drives, power supplies, and filter components: High electrical voltage! High leakage current! Danger to life, danger of injury and bodily harm from electrical shock! ⇒ Before switching on power for electrical units, all...

  • Page 22: Protection By Protective Low Voltage (Pelv) Against Electrical Shock

    Safety Instructions for Electric Servo Drives and Controls SYNAX200 Protection by Protective Low Voltage (PELV) Against Electrical Shock All connections and terminals with voltages between 5 and 50 Volts on INDRAMAT products are protective low voltages designed in accordance with the following standards on contact safety: •...
  • Page 23 SYNAX200 Safety Instructions for Electric Servo Drives and Controls Dangerous movements! Danger to life and risk of injury or equipment damage! ⇒ Personnel protection must be secured for the above listed reason by means of superordinate monitors or DANGER measures.

  • Page 24: Protection Against Magnetic And Electromagnetic Fields During Operations And Mounting

    Safety Instructions for Electric Servo Drives and Controls SYNAX200 ⇒ 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 ⇒...

  • Page 25: Protection Against Contact With Hot Parts

    SYNAX200 Safety Instructions for Electric Servo Drives and Controls Protection Against Contact with Hot Parts Housing surfaces could be extremely hot! Danger of injury! Danger of burns! ⇒ Do not touch surfaces near the source of heat! Danger of burns! CAUTION ⇒...

  • Page 26: 3.11 Battery Safety

    3-10 Safety Instructions for Electric Servo Drives and Controls SYNAX200 3.11 Battery Safety Batteries contain reactive chemicals in a solid housing. Inappropriate handling may result in injuries or equipment damage. Risk of injury through incorrect handling! ⇒ Do not attempt to reactivate discharged batteries by heating or other methods (danger of explosion and corrosion).

  • Page 27: Ppc Motion Control Configuration

    SYNAX200 PPC Motion Control Configuration PPC Motion Control Configuration Brief Description PPC-R01.2 PPC-R02.2 Key for display switchover RECO RECO 8888 8888 or other usage Slot for the PC card-compatible firmware module Reset key S2 Distortion display H2 for SERCOS interface...

  • Page 28: Installation Dimensions

    PPC Motion Control Configuration SYNAX200 Installation Dimensions PPC-R01.2 and PPC-R02.2 PPC-R01.2 PPC-R02.2 41,5 83,7 126,5 RECO RECO 8888 8888 RESET RESET DIST DIST 24V e 24V e 0V e 0V e PPC-R01.2 PPC-R02.2 Bemaßung.FH7 Fig. 4-2: Dimensioned drawing PPC-R01.2 and PPC-R02.2...

  • Page 29: Installation Dimensions Of Module Carrier Rmb02.2-02

    SYNAX200 PPC Motion Control Configuration ca. 183 56,5 Mounting rail TS 35 x 27 x 15 54,5 ca. 235 ca. 300 Bemaßung_Einbau.FH7 Fig. 4-3: Installation dimensions of PPC-R01.2 and PPC-R02.2 Installation dimensions of module carrier RMB02.2-02 54.5 Screw for locking...

  • Page 30: Installation Dimensions Of Module Carrier Rmb02.2-04

    PPC Motion Control Configuration SYNAX200 Installation dimensions of module carrier RMB02.2-04 Screw for locking the subrack on the tophat rail 54,5 Tophat rail TS 35 x 27 x15 RMB02.2-04_Maß.FH7 Fig. 4-5: Module carrier RMB02.2-04 RMB02.2-04+02-04_Maß.FH7 Fig. 4-6: Side-by-side installation of several RMB02.2-04 module carriers...

  • Page 31: Installation Instructions

    SYNAX200 PPC Motion Control Configuration Installation Instructions The module carriers must first be installed before the PPC-R units can be installed. These module carriers are equipped with the PPC-R unit and, according to the requirements, with the related I/O modules (RECO02 modules).

  • Page 32: Grounding

    PPC Motion Control Configuration SYNAX200 Grounding Grounding the controller and screening the electronic components requires a grounding cable of at least 6mm² to be laid between the grounding stud of the controller to the central grounding point of the machine. The other devices of the machine must be grounded in a star- shaped configuration (see Fig.

  • Page 33: Slot Addressing Of The Module Carriers

    SYNAX200 PPC Motion Control Configuration Slot Addressing of the Module Carriers A maximum of 4 module carriers RMB02.2-04 can be installed side by side. To be able to address the module carriers, there is a DIP switch on the bus board of the module carriers. Depending on the module carrier, the switch must be set to the corresponding module carrier number (module carrier address 00-03, see diagram below).

  • Page 34: Combination Options Module Carrier - Ppc - I/O Module

    PPC Motion Control Configuration SYNAX200 Combination Options Module Carrier - PPC - I/O Module Structure Remark one module carrier RMB02.2-02 1 x PPC-R01.2 without I/O 1 x PPC-R02.2 without I/O RECO RECO 8888 RECO RECO 8888 8888 8888 2 x PPC-R01.2...

  • Page 35: Specifications

    SYNAX200 PPC Motion Control Configuration Specifications General Information Cable cross section of 0.75 mm² to 1.5 mm² Power supply feeder: Attachment in the control cabinet: with RMB02.2 module carrier on DIN rail TS 35 x 27 x 15 Protection rating:...

  • Page 36: Emc

    4-10 PPC Motion Control Configuration SYNAX200 Emitted interference to EN 55022 Class A (industrial environment) Noise immunity to EN 61000-4-2 (ESD) Rating criterion B Noise immunity to EN 61000-4-4 (burst) Rating criterion B Noise immunity to EN 61000-5-5 (surge) Rating criterion B Fig.

  • Page 37: Connecting The Power Supply

    4-11 SYNAX200 PPC Motion Control Configuration Connecting the Power Supply Note: Connector and modules may only be inserted or removed when the power is switched off. PPC-R Dig. output 1 Dig. output 2 Dig. input 1 Dig. input 2 Dig. input 3...

  • Page 38: Connector Pin Assignments

    4-12 PPC Motion Control Configuration SYNAX200 Connector Pin Assignments X1 (11-way Phoenix female connector) Signal name Digital output 1 (Q1) Digital output 2 (Q2) Digital input 1 (I1) Digital input 2 (I1) Digital input 3 (I1) 24V external voltage External GND...

  • Page 39: Bt Bus (X15)

    4-13 SYNAX200 PPC Motion Control Configuration BT bus (X15) Signal name Signal name TxD+ RxD+ TxD- RxD- Fig. 4-20: Connector pin assignments BT-BUS X15 DOK-SYNAX*-SY*-07VRS**-PR01-EN-P...

  • Page 40: 4.10 Motion Control Configuration When Using The Ppc-R

    4-14 PPC Motion Control Configuration SYNAX200 4.10 Motion Control Configuration when Using the PPC-R DAQ03 2nd serial on slot plate Configuration designation PPC-R01.2N-P1N-NN-FW PPC-R01.2N-P1N-S1-FW PPC-R01.2N-P1N-P2-FW PPC-R01.2N-P1N-B4-FW PPC-R01.2N-P1N-V2-FW PPC-R01.2N-P1N-Q1-FW PPC-R02.2N-P1N-NN-NN-NN-FW PPC-R02.2N-P1N-NN-P2-NN-FW PPC-R02.2N-P1N-Q1-P2-NN-FW PPC-R02.2N-P1N-B2-NN-NN-FW PPC-R02.2N-P1N-Q1-B2-NN-FW PPC-R02.2N-P1N-V2-NN-NN-FW PPC-R02.2N-P1N-Q1-V2-NN-FW PPC-R02.2N-P1N-Q1-NN-NN-FW Fig. 4-21: Coonfiguration selection when using the PPC-R...

  • Page 41: Determining Basic Drive Configuration

    SYNAX200 Determining Basic Drive Configuration Determining Basic Drive Configuration Procedure The drive configuration choices (motor, drive amplifier, drive-related plug- in cards) conform to the power requirements and the precision requirements of the respective drive task. To determine the drive configuration or to specify the hardware...

  • Page 42: B) Selecting The Suitable Motor/Controller Combinations

    Determining Basic Drive Configuration SYNAX200 b) Selecting the Suitable Motor/Controller Combinations The selection lists must be used. The following figure offers a rough orientation. rated output [KW] SY7PR003.FH7 Fig. 5-2: Power range of different lines of motors Once motor type and encoder arrangement are fixed, a suitable basic drive configuration is selected using the subsections below.
  • Page 43 SYNAX200 Determining Basic Drive Configuration Illustration: Determining the Hardware Configuration Labelling 1. Determining the Tab.: A necessary plug-in Motor feedback interface: modules Motor Dig. servo Sine Sprocket EnDat feedback type: feedback Resolver feedback feedback 1.1 Selection of motor- motor feedback...

  • Page 44: Rotary Axes

    Determining Basic Drive Configuration SYNAX200 Rotary Axes Drive with Step-Down Gear and Indirect Position Detection • Precision is determined with gear error Features: (generally four angle minutes) • encoder is integrated into motor • motor encoder with singleturn or multiturn absolute encoder Usable Motors DKR: •...
  • Page 45 SYNAX200 Determining Basic Drive Configuration Usable Motors DIAX04: • MHD • MKD • MKE • 2AD with HSF • ADF with HSF • MBW • 1MB Basic Drive Configuration HS12 (DIAX04): MHD, MKE, MKD, U1 (DSS) 2AD with HSF, ADF with HSF,...

  • Page 46: Drive With Step-Down Gears And Direct Incremental Position Detection

    Determining Basic Drive Configuration SYNAX200 Drive with Step-Down Gears and Direct Incremental Position Detection • Precision determined by gear error Feature: (generally four angle minutes) • encoder is integrated into motor • motor encoder single-turn encoder • load angle directly detected via incremental external encoder •...
  • Page 47 SYNAX200 Determining Basic Drive Configuration Usable Motors DIAX04: • MHD • MKD • MKE • 2AD with HSF • ADF with HSF Basic Drive Configuration HS32 (DIAX04): MHD, MKD, MKE, U1 (DSS) 2AD with HSF, ADF with HSF: U2 (DLF)

  • Page 48: Drive With Step-Down Gear And Direct Absolute Position Detection

    Determining Basic Drive Configuration SYNAX200 Drive with Step-Down Gear and Direct Absolute Position Detection • Precision is determined by gear error Feature: (generally four angle minutes) • encoder is integrated into motor • motor encoder multiturn absolute encoder • load angle directly detected via absolute external encoder •...
  • Page 49 SYNAX200 Determining Basic Drive Configuration Usable Motors DIAX04: • MHD • MKD • MKE • 2AD with HSF • ADF with HSF Basic Drive Configuration HS45 (DIAX04): MHD, MKD, MKE U1 (DSS) 2AD with HSF, ADF with HSF: U2 (DAG)

  • Page 50: Drive With Indirect Position Detection

    5-10 Determining Basic Drive Configuration SYNAX200 Drive with Indirect Position Detection • no gear between motor and cylinder Features: • high level of precision can be achieved • encoder is integrated into motor Usable Motors DKR: • 1MB Basic Drive Configuration BE37 (DKR):...
  • Page 51 5-11 SYNAX200 Determining Basic Drive Configuration Usable Motors DIAX04: • 1MB Basic Drive Configuration HS37 (DIAX04): 1MB: U1 (DSS) U2 (DZF) DANG High oltage. Danger of electrical shock. Do not touch electrical connec tions 5 minutes after switching Read and follow Instructions for Electrical Drives"...

  • Page 52: Drive With Direct Incremental Position Detection

    5-12 Determining Basic Drive Configuration SYNAX200 Drive with Direct Incremental Position Detection • no gear between motor and cylinder Features: • high level of precision can be achieved • load angle directly determined via incremental external encoder • gear error statically compensated •...
  • Page 53 5-13 SYNAX200 Determining Basic Drive Configuration Basic Drive Configuration BE32 (DKR): MBS: external incremental encoder with sine output e.g., Heidenhain DIGITAL COMPACT CONTROLLER ROD 481 DKR 4 ERN 180 ERN 680 RON 285 IKS 374 IKS 349 U2 (DLF) U1 (DSS) SY7PR007.FH7...

  • Page 54: Drive With Direct Absolute Position Detection

    5-14 Determining Basic Drive Configuration SYNAX200 Basic Drive Configuration HS32 (DIAX04): MHD, MKD, MKE, MBS: U1 (DSS) U2 (DLF) IKS4383 IKS374 external incremental encoder with sine output e.g., Heidenhain ROD 481 DANG High oltage. Danger of electrical shock. Do not touch electrical connec tions...
  • Page 55 5-15 SYNAX200 Determining Basic Drive Configuration Basic Drive Configuration BE45 (DKR): MBW, 2AD, ADF, 1MB: DIGITAL COMPACT CONTROLLER EnDat encoder DKR 4 e.g., Heidenhain EnDat U2 (DAG) U1 (DSS) SY7PR0051.FH7 Fig. 5-17: Drive with MBW, 2AD, ADF or 1MB motor with direct absolute position...
  • Page 56 5-16 Determining Basic Drive Configuration SYNAX200 Usable Motors DIAX04: • MBW (without motor encoder) • 1MB (without motor encoder) • 2AD (without motor encoder) • ADF (without motor encoder) • MHD (only in connection with motor encoder) • MKD (only in connection with motor encoder) •...

  • Page 57: Linear Axes

    5-17 SYNAX200 Determining Basic Drive Configuration Linear Axes Drive with Indirect Position Detection • accuracy determined by spindle and gear errors Features: • encoder is integrated into motor • motor encoder either with singleturn or multiturn absolute encoder Usable Motors DKR: •...
  • Page 58 5-18 Determining Basic Drive Configuration SYNAX200 Usable Motors DIAX04: • MHD • MKD • MKE • 2AD with HSF • ADF with HSF Basic Drive Configuration HS12 (DIAX04): MHD, MKD, MKE, 2AD with HSF, scale input U1 (DSS) ADF with HSF neg.

  • Page 59: Drive With Direct Incremental Position Detection

    5-19 SYNAX200 Determining Basic Drive Configuration Drive with Direct Incremental Position Detection • motor encoder with either singleturn or multiturn absolute encoder Features: • load position directly detected via incremental external encoder • gear error statically compensated Usable Motors DKR: •...
  • Page 60 5-20 Determining Basic Drive Configuration SYNAX200 Usable Motors DIAX04: • MHD • MKD • MKE • 2AD with HSF • ADF with HSF Basic Drive Configuration BE32 (DIAX04): MHD, MKD, MKE, 2AD with HSF, U1 (DSS) scale input ADF with HSF U2 (DLF) neg.

  • Page 61: Drive With Direct Absolute Position Detection

    5-21 SYNAX200 Determining Basic Drive Configuration Drive with Direct Absolute Position Detection • gearwheel encoder as motor encoder Features: • load position directly detected via absolute external encoder • gear error statically compensated Usable Motors DKR: • 2AD with gearwheel encoder •...
  • Page 62 5-22 Determining Basic Drive Configuration SYNAX200 Usable Motors DIAX04: • 2AD with gearwheel encoder • 1MB with gearwheel encoder Basic Drive Configuration HS45 (DIAX04): 1MB, 2AD: U1 (DSS) U2 (DLF) scale input U3 (DAG) neg. travel range limit switch pos. travel range limit switch...

  • Page 63: Drive With Linear Motor And Incremental Position Detection

    5-23 SYNAX200 Determining Basic Drive Configuration Drive with Linear Motor and Incremental Position Detection • incremental position detection via external linear scale with sinusoidal Features: output • Direct Drive • highest possible degree of static and dynamic precision • high achievable acceleration of up to 100 m/s²...
  • Page 64 5-24 Determining Basic Drive Configuration SYNAX200 Usable Motors DIAX04: • LAF • LAR • LSF Basic Drive Configuration HS32 (DIAX04): LAR, LAF, LSF: U1 (DSS) U2 (DLF) DANG High oltage. Danger of electrical shock. Do not touch electrical connec tions...

  • Page 65: Drive With Linear Motor And Absolute Position Detection

    5-25 SYNAX200 Determining Basic Drive Configuration Drive with Linear Motor and Absolute Position Detection • absolute position detection via external linear scale with EnDat Features: interface • DirectDrive • highest possible degree of static and dynamic precision • high achievable acceleration of up to 100 m/s²...
  • Page 66 5-26 Determining Basic Drive Configuration SYNAX200 Usable Motors DIAX04: • LAF • LAR • LSF Basic Drive Configuration HS45 (DIAX04): LAR, LAF, LSF: U1 (DSS) U2 (DAG) DANG High oltage. Danger of electrical shock. Do not touch electrical connec tions...

  • Page 67: Determining The Control-Related Plug-In Cards

    SYNAX200 Determining the Control-Related Plug-In Cards Determining the Control-Related Plug-In Cards Determining Parallel I/Os DEA04 or DEA08 parallel I/O cards can be inserted into DKR and HDS controllers. Binary signals can be exchanged with this card between the PPC and a PLC.

  • Page 68: Combination Options Of The External I/O (Drive Internal)

    Determining the Control-Related Plug-In Cards SYNAX200 Combination Options of the External I/O (Drive Internal) In addition to the RECO I/O modules the following I/O variants are available drive internal: • drive plug-in card DEA04 • drive plug-in card DEA08 These can be used for the following functions: •...

  • Page 69: Determining The Master Axis

    SYNAX200 Determining the Control-Related Plug-In Cards Determining the Master Axis If it is necessary that the slave drive of the electronic gears has reference to a real master axis, then a master axis encoder must be mounted to this master axis.
  • Page 70 Determining the Control-Related Plug-In Cards SYNAX200 EnDat/SSI Encoder It is also possible to connect a real master axis using an EnDat/SSI encoder. In this case use encoder interface DAG. DIAX03, DIAX04 EnDat/SSI encoder master axis position in the slot of a DKR/HDS SY7PR034.FH7...
  • Page 71 SYNAX200 Determining the Control-Related Plug-In Cards Incremental Encoder with Sinusoidal Signals 1Vss It is also possible to connect a real master axis using an incremental encoder with sinousoidal signals 1Vss. Note: Use only encoders with binary line numbers (2 In this case use encoder interface DLF.

  • Page 72: Determining Analog Inputs

    Determining the Control-Related Plug-In Cards SYNAX200 Determining Analog Inputs Two analog signals per drive can be detected via the analog interface DAE. Analog signals are read by the drive and transmitted via the SERCOS LWL ring to the PPC. The PPC processes and allocates the analog signals (e.g., actual values of the tension control).

  • Page 73: Incremental Encoder Emulation

    SYNAX200 Determining the Control-Related Plug-In Cards Incremental Encoder Emulation The master axis position can be generated as an incremental signal via DIAX03, DIAX04 the incremental encoder emulation interface DAE. The DAE card can be placed in any drive in the fibre-optics ring for this purpose.

  • Page 74: Encoder Branching Dga 01.2 For Encoders With Sinusoidal Voltage Signals 1Vss

    Determining the Control-Related Plug-In Cards SYNAX200 Encoder Branching DGA 01.2 for Encoders with Sinusoidal Voltage Signals 1Vss General U1 (DSS) U2 (DLF) e.g., external register control IKS4383 external incremental encoder with sine output e.g., Heidenhain ROD 481 ERN 180 DANG High oltage.

  • Page 75: Terminal Diagram

    SYNAX200 Determining the Control-Related Plug-In Cards Terminal Diagram measuring sytem, e.g., LIF181, LS186, LS468 from Heidenhain max. processing frequency f max = 400 kHz max. cable length: 30 m INS0488 4 10 12 9 INS0701 INS0493 A+ A- B+ B- R+ R-...

  • Page 76: Technical Data

    6-10 Determining the Control-Related Plug-In Cards SYNAX200 Technical Data External Measuring System DC +5 V ( ± 5%) Supply voltage for external Output voltage X1/12: measuring system max. output load X1/12: 150 mA Approximately sinusoidal signals Signal form Signal voltage:...
  • Page 77 6-11 SYNAX200 Determining the Control-Related Plug-In Cards Diverting Measuring System Signals to Four Connection The signals from the measuring system are diverted to connections X2, X3, X4 and X5. The DGA01.2 receives ist power via terminal X2. DGA01.2 supply DC +8 V ( ± 5%)
  • Page 78 6-12 Determining the Control-Related Plug-In Cards SYNAX200 DOK-SYNAX*-SY*-07VRS**-PR01-EN-P...

  • Page 79: Drive Configurations

    SYNAX200 Drive Configurations Drive Configurations General Informations The control related plug-in cards are now distributed to the free slots in the basic configuration. Possible configurations are listed below. The HDS02.1 controller is limited in its configuration to a DSS card plus two additional cards.
  • Page 80 Drive Configurations SYNAX200 Configuration 01.2M 04.2M 08.1M 01.1M 02.1M 01.1M 01.1M 02.1M 01.1M 02.1M 03.1M designation: BE09-01-FW BE10-01-FW BE12-01-FW BE23-01-FW BE25-01-FW BE30-01-FW BE47-01-FW BE54-01-FW BE56-01-FW BE59-01-FW BE60-01-FW BE73-01-FW BE76-01-FW BE78-00-FW BE79-01-FW BE80-01-FW BE84-01-FW BE86-01-FW BE91-01-FW BE92-01-FW BE94-01-FW BE99-01-FW BT08-01-FW BT10-01-FW...

  • Page 81: Drive Configurations Diax03 Based On Basic Configuration Be32

    SYNAX200 Drive Configurations Drive Configurations DIAX03 Based on Basic Configuration BE32 01.2M 04.2M 08.1M 01.1M 02.1M 01.1M 01.1M 02.1M 01.1M 02.1M 03.1M Features: analog inputs digitla input/output ext. measurement system with Heidenhain square-wave encoder ext. measurement system with DSF encoder (1) ext.
  • Page 82 Drive Configurations SYNAX200 Configuration 01.2M 04.2M 08.1M 01.1M 02.1M 01.1M 01.1M 02.1M 01.1M 02.1M 03.1M designation: BE08-01-FW BE28-01-FW BE32-01-FW BE33-01-FW BE55-01-FW BE57-01-FW BE58-01-FW BE62-01-FW BE68-01-FW BT01-01-FW BT02-01-FW BT03-01-FW BT04-01-FW BT05-01-FW BT06-01-FW BT07-01-FW BT54-01-FW BT57-01-FW BT58-01-FW BT66-01-FW Fig. 7-4: Drive configuration based on basic configuration BE32...

  • Page 83: Drive Configuration Diax03 Based On Basic Configuration Be37

    SYNAX200 Drive Configurations Drive Configuration DIAX03 Based on Basic Configuration BE37 01.2M 04.2M 08.1M 01.1M 02.1M 01.1M 01.1M 02.1M 01.1M 02.1M 03.1M Features: analog input didgital input/output ext. measurement system with Heidenhain square-wave encoder ext. measurement system with DSF encoder (1) ext.
  • Page 84 Drive Configurations SYNAX200 Configuration 01.2M 04.2M 08.1M 01.1M 02.1M 01.1M 01.1M 02.1M 01.1M 02.1M 03.1M designation: BE02-02-FW BE03-02-FW BE04-02-FW BE19-01-FW BE22-01-FW BE26-01-FW BE27-01-FW BE32-01-FW BE37-01-FW BE38-01-FW BE63-01-FW BE65-01-FW BE67-01-FW BE70-01-FW BE72-02-FW BE88-01-FW BE89-01-FW BE90-01-FW BT55-01-FW BT59-01-FW BT60-01-FW BT61-01-FW BT62-01-FW BT63-01-FW Fig.

  • Page 85: Drive Configuration Diax03 Based On Basic Configuration Be45

    SYNAX200 Drive Configurations Drive Configuration DIAX03 Based on Basic Configuration BE45 01.2M 04.2M 08.1M 01.1M 02.1M 01.1M 01.1M 02.1M 01.1M 02.1M 03.1M Features analog inputs digital input/output ext. measurement system with Heidenhain sine encoder ext. measurement system with Heidenhain square-wave encoder ext.
  • Page 86 Drive Configurations SYNAX200 Configuration 01.2M 04.2M 08.1M 01.1M 02.1M 01.1M 01.1M 02.1M 01.1M 02.1M 03.1M designation: BE02-02-FW BE03-02-FW BE04-02-FW BE45-01-FW BE66-01-FW BE72-02-FW BE74-02-FW BE83-00-FW BE87-01-FW BE90-01-FW BE93-01-FW BT01-01-FW BT02-01-FW BT03-01-FW BT09-01-FW BT11-01-FW BT12-01-FW BT14-01-FW BT18-01-FW BT24-01-FW BT51-01-FW BT58-01-FW BT63-01-FW BT64-01-FW BT65-01-FW Fig.

  • Page 87: Drive Configuration Diax04 Based On Basic Configuration Hs12

    SYNAX200 Drive Configurations Drive Configuration DIAX04 Based on Basic Configuration HS12 01.2M 04.2M 08.1M 01.1M 02.1M 01.1M 01.1M 02.1M 01.1M 02.1M 03.1M Features analog input incremental feedback emulation digital input/output ext. measurement system with Heidenhain sine encoder ext. measurement system with...
  • Page 88 7-10 Drive Configurations SYNAX200 Configuration 01.2M 04.2M 08.1M 01.1M 02.1M 01.1M 01.1M 02.1M 01.1M 02.1M 03.1M designation: HS09-01-FW HS10-01-FW HS12-01-FW HS23-01-FW HS25-01-FW HS30-01-FW HS47-01-FW HS54-01-FW HS56-01-FW HS59-01-FW HS60-01-FW HS73-01-FW HS76-01-FW HS78-01-FW HS79-01-FW HS80-01-FW HS84-01-FW HS86-01-FW HS91-01-FW HS92-01-FW HS94-01-FW HS99-01-FW HT08-01-FW...

  • Page 89: Drive Configuration Diax04 Based On Basic Configuration Hs32

    7-11 SYNAX200 Drive Configurations Drive Configuration DIAX04 Based on Basic Configuration HS32 01.2M 04.2M 08.1M 01.1M 02.1M 01.1M 01.1M 02.1M 01.1M 02.1M 03.1M Features: analog input digital input/output ext. measurement system with Heidenhain square-wave encoder ext. measurement system with DSF encoder (1) ext.
  • Page 90 7-12 Drive Configurations SYNAX200 Configuration 01.2M 04.2M 08.1M 01.1M 02.1M 01.1M 01.1M 02.1M 01.1M 02.1M 03.1M designation: HS08-01-FW HS28-01-FW HS32-01-FW HS33-01-FW HS55-01-FW HS57-01-FW HS58-01-FW HS62-01-FW HS68-01-FW HT01-01-FW HT02-01-FW HT03-01-FW HT04-01-FW HT05-01-FW HT06-01-FW HT07-01-FW HT33-01-FW HT36-01-FW HT37-01-FW HT45-01-FW Fig. 7-12: Drive configuration based on basic configuration HS32...

  • Page 91: Drive Configuration Diax04 Based On Basic Configuration Hs37

    7-13 SYNAX200 Drive Configurations Drive Configuration DIAX04 Based on Basic Configuration HS37 01.2M 04.2M 08.1M 01.1M 02.1M 01.1M 01.1M 02.1M 01.1M 02.1M 03.1M Features: analog input digital input/output ext. measurement system with Heidenhain square-wave encoder ext. measurement system with DSF encoder (1) ext.
  • Page 92 7-14 Drive Configurations SYNAX200 Configuration 01.2M 04.2M 08.1M 01.1M 02.1M 01.1M 01.1M 02.1M 01.1M 02.1M 03.1M designation: HS02-02-FW HS03-02-FW HS04-02-FW HS19-01-FW HS22-01-FW HS26-01-FW HS27-01-FW HS36-01-FW HS37-01-FW HS38-01-FW HS63-01-FW HS65-01-FW HS67-01-FW HS70-01-FW HS72-02-FW HS88-01-FW HS89-01-FW HS90-01-FW HT34-01-FW HT38-01-FW HT39-01-FW HT40-01-FW HT41-01-FW Fig.

  • Page 93: Drive Configuration Diax04 Based On Basic Configuration Hs45

    7-15 SYNAX200 Drive Configurations Drive Configuration DIAX04 Based on Basic Configuration HS45 01.2M 04.2M 08.1M 01.1M 02.1M 01.1M 01.1M 02.1M 01.1M 02.1M 03.1M Features analog input digital input/output ext. measurement system with Heidenhain sine encoder ext. measurement system with Heidenhain square-wave encoder ext.
  • Page 94 7-16 Drive Configurations SYNAX200 Configuration 01.2M 04.2M 08.1M 01.1M 02.1M 01.1M 01.1M 02.1M 01.1M 02.1M 03.1M designation: HS02-02-FW HS03-02-FW HS04-02-FW HS45-01-FW HS66-01-FW HS72-02-FW HS72-02-FW HS74-02-FW HS74-02-FW HS81-01-FW HS87-01-FW HS90-01-FW HS93-01-FW HT01-01-FW HT02-01-FW HT03-01-FW HT09-01-FW HT11-01-FW HT12-01-FW HT14-01-FW HT18-01-FW HT24-01-FW HT30-01-FW...

  • Page 95: 7.10 Example

    7-17 SYNAX200 Drive Configurations 7.10 Example The rotary press and folding machine of the plant shown in Fig. 7-17 should be equipped with the SYNAX200 system. phase encoder DANG DANG DANG High Danger of electrical shock. oltage. High Danger of electrical shock.

  • Page 96: Drive Configuration

    7-18 Drive Configurations SYNAX200 Drive Configuration The following equipment is needed for all three drives and is always based on both precision and power requirements: Axis Drive controller Motor rotary die-cut HDS03.2-W075 anvil zylinder HDS03.2-W075 folding drive HDS04.2-W200 Fig. 7-18: Drive equipment The result is the basic drive configuration HS12-01 on section 7.6.
  • Page 97 5 minutes after switching Read and follow Read and follow Read and follow Instructions for Electrical Drives" Instructions for Electrical Drives" Instructions for Electrical Drives" manual, manual, manual, DOK-GENERL-DRIVE******-SVS... DOK-GENERL-DRIVE******-SVS... DOK-GENERL-DRIVE******-SVS... rotary folder die-cut SY7PR109.FH7 Fig. 7-20: System configuration for equipping SYNAX200 DOK-SYNAX*-SY*-07VRS**-PR01-EN-P...
  • Page 98 7-20 Drive Configurations SYNAX200 DOK-SYNAX*-SY*-07VRS**-PR01-EN-P...

  • Page 99: Set-Up Synax200 Ring

    SYNAX200 Set-Up SYNAX200 Ring Set-Up SYNAX200 Ring Data Transmission via Fibre-Optics Cable Optical Transmission Ring Structure The connection between the motion control (PPC) and the digital drives is conducted with help of fibre-optics cables (LWL). A ring structure as defined in SERCOS interface (IEC 61491 or EN SERCOS interface (IEC 61491 or 61491) is used.

  • Page 100: Constructing The Transmission Path

    Set-Up SYNAX200 Ring SYNAX200 Constructing the Transmission Path A transmission path starts at a transmitter output and ends at a receiver input. The transmission path is made up of fibre-optics cables and fibre-optics Fibre-optics cable isolating cable leadthroughs. These serve as, for example, coupling units for wall points leadthroughs.

  • Page 101: Fibre-Optics Cable Accessories

    SYNAX200 Set-Up SYNAX200 Ring Glass fibre-optics cable for internal and external control cabinet use with Glass fibre-optics cable 3 mm reinforced casing. The diameter of this fibre-optics cable equals 3 mm. LWL cable ø 3,0 mm connector protective cap SY6PR025.FH7 Fig.

  • Page 102: Project Planning Notes

    Set-Up SYNAX200 Ring SYNAX200 Project Planning Notes General Notes Note the following when planning the project: The length of the transmission path is limited. Isolating points decrease The length of the transmission the maximum length of a fibre-optics cable stretch.

  • Page 103: General Safety Guidelines

    SYNAX200 Set-Up SYNAX200 Ring General Safety Guidelines High-energy light Risk of blindness and eye injury ⇒ Do not look into the light (transmitter output or fiber optic cable end) DANGER Error during mounting or when handling fiber optic cable components could be mechanically damaged ⇒...

  • Page 104: Set-Up

    Set-Up SYNAX200 Ring SYNAX200 Routing and Mounting When routing and mounting the fibre-optics cables, please note that the specific load data do not damage the fibre-optics cables. The minimum bend radius may not be exceeded (e.g., when routing Bend radius around corners).
  • Page 105 SYNAX200 Set-Up SYNAX200 Ring H3 ERR distortion display H3 ERR X10 fibre-optic transmitter for SERCOS interface X11 fibre-optic receiver for SERCOS interface DANG High oltage. Danger of electrical shock. Do not touch electrical connec tions 5 minutes after switching Read and follow Instructions for Electrical Drives"...

  • Page 106: Setting Drive Address

    Setting Drive Address The address is set at every drive (see Fig. 8-13 or Fig. 8-14). It must be unique in each SYNAX200 ring. There may not be two drives with the same address. Permitted addresses lie within the range of [1..40].

  • Page 107: Use Of Distortion Display

    SYNAX200 Set-Up SYNAX200 Ring The causes could be: • incorrectly set drive addresses • incorrectly parametrized parameters C-0-0002 or C-0-0086 • incorrectly set transmission rates • incorrectly set output power • defective fibre-optics cable. Use of Distortion Display A distortion display (see Fig. 8-12: "H2", Fig. 8-13: "H3 ERR" or Fig. 8-14: "H20") lights up in the following cases:...
  • Page 108 8-10 Set-Up SYNAX200 Ring SYNAX200 The transmission rate is set with the help of switch S20,1 on the front ECODRIVE03 (DKC02.3) panel. For a transmission rate of 2 MBit/s the switch must be set to ’OFF’ (=in front). Distortion display...

  • Page 109: Setting The Optic Output Power

    8-11 SYNAX200 Set-Up SYNAX200 Ring Setting the Optic Output Power The output power of the PPC is parametrized using the parameters "fibre- optics cable (LWL) length" (C-0-0007). If plastic fibre-optics cables are used, then the length of the fibre-optics cable connected to the transmission output is set here.
  • Page 110 8-12 Set-Up SYNAX200 Ring SYNAX200 DOK-SYNAX*-SY*-07VRS**-PR01-EN-P...

  • Page 111: Ppc Link

    PPC plug-in card DAQ. All DAQ boards are connected with a fibre-optics cable (LWL) ring thereby creating the PPC link. Communications within the PPC link implements, as does the SYNAX200 ring, a fibre-optics cable ring. The PPC link can be built on a simple or double LWL ring.

  • Page 112: Ppc Link With Simple Ring

    PPC Link SYNAX200 PPC Link with Simple Ring drive drive drive PPC-R + SYNAX ring 1 RECO 8888 RESET DIST 24Ve drive drive drive PPC-R02.2 PPC-R + RECO SYNAX ring 2 8888 link ring RESET DIST drive drive drive 24Ve PPC-R02.2...

  • Page 113: Ppc Link With Double Ring

    SYNAX200 PPC Link PPC Link With Double Ring drive drive drive PPC-R + SYNAX ring 1 8888 RECO primary ring RESET DIST 24Ve drive drive drive PPC-R02.2 secondary ring PPC-R + RECO SYNAX ring 2 8888 RESET DIST drive drive...

  • Page 114: Configuration Example With Ppc

    PPC Link SYNAX200 Configuration Example with PPC With an eye towards increased machine availability PPC motion controls can become an own 24V electronic storage. So they can be supported as with master system UPS = uninterruptable power source. ARCNET link ring...

  • Page 115: Commissioning

    SYNAX200 PPC Link Commissioning First the PPC link and the fibre-optics lengths are parametrized via SynTop and the PPCs are brought into operating mode. The active PPC link is displayed on displays H11 or H12 at each PPC using the parametrized PPC link. (Precisely one link master and several link slaves).
  • Page 116 PPC Link SYNAX200 DOK-SYNAX*-SY*-07VRS**-PR01-EN-P...

  • Page 117: Set-Up Interfaces

    10-1 SYNAX200 Set-Up Interfaces Set-Up Interfaces 10.1 General Information The PC set-up software SynTop is connected to the PPC by means of a serial interface. This uses the PPC interface X10 or X16. The choice of the interface can be made using a parameter. The interface X10 is galvanic seperated and therefore it should be used preferably.

  • Page 118: 10.3 Rs485 Link

    10-2 Set-Up Interfaces SYNAX200 10.3 RS485 Link SynTop can communicate with many PPCs using an RS485 link. RS485 further SYNAX rings RECO RECO 8888 8888 PPC + master axis link RS232 SynTop PPC-R02.2 PPC-R02.2 SY7PR059.FH7 Fig. 10-3: RS485 link of SynTop to multiple PPCs This necessitates couplers from RS485 to RS232 for the connection of the PC to the RS485 link.
  • Page 119 10-3 SYNAX200 Set-Up Interfaces The cable from interface module to PC is constructed as follows: Cable converter <->PC RS232 cable from PC to converter PSM-EG.: D-Sub PC side: D-subminiature 9-pin, bushing 9-pin, bushing connector connector housing housing SY7PR060.FH7 Fig. 10-4: RS232 cable from PC to converter...
  • Page 120 10-4 Set-Up Interfaces SYNAX200 RS485 cable between PSM-EG and PPC PSM-EG.: D-subminiature PPC: D-subminiature 9-pin, pins 15-pin, pins RS485- D(A) D(A) RS485+ D(B) D(B) D(A) D(B) connector connetor housing housing D(A) and D(B) D-sub15 bushing twisted in pairs to the next PPC SY7PR062.FH7...

  • Page 121: Appendix

    11-1 SYNAX200 Appendix Appendix 11.1 Dimensional Sheets, Terminal Diagrams RECO Mounting Dimensions Module Carrier RMB02.2-02 54.5 Screw for locking the subrack on the tophat rail Tophat rail TS35 x27 x15 Fig. 11-1: Module carrier RMB02.2-02 DOK-SYNAX*-SY*-07VRS**-PR01-EN-P...

  • Page 122: Mounting Dimensions Module Carrier Rmb02.2-04

    11-2 Appendix SYNAX200 Mounting Dimensions Module Carrier RMB02.2-04 Screw for locking the subrack on the tophat rail 54,5 Tophat rail TS 35 x 27 x15 Fig. 11-2: Module carrier RMB02.2-04 Fig. 11-3: Side-by-side installation of several RMB02.2-04 module carrier DOK-SYNAX*-SY*-07VRS**-PR01-EN-P...

  • Page 123: Ppc-R01.2 And Ppc-R02.2

    11-3 SYNAX200 Appendix PPC-R01.2 and PPC-R02.2 PPC-R01.2 PPC-R02.2 41,5 83,7 126,5 RECO RECO 8888 8888 RESET RESET DIST DIST 24Ve 24Ve PPC-R01.2 PPC-R02.2 Bemaßung.FH7 Fig. 11-4: Dimensioanl sheet PPC-R01.2 and PPC-R02.2 ca. 183 56,5 Mounting rail TS 35 x 27 x 15 54,5 ca.

  • Page 124: Daq03.1R

    11-4 Appendix SYNAX200 DAQ03.1R DAQ03.1R H11,H12,H17,H18 M S S P SY7PR103.FH7 Fig. 11-6: DAQ03.1R DOK-SYNAX*-SY*-07VRS**-PR01-EN-P...

  • Page 125: Profibus Interface Dps01

    11-5 SYNAX200 Appendix Profibus Interface DPS01 PROFIBUS-DP Slave module X75 PROFIBUS interface (slave) X79 PROFIBUS diagnosis interface RS232 C (project planning interface) DP-SLAVE SY7PR105.FH7 Fig. 11-7:Profibus interface DPS01 DOK-SYNAX*-SY*-07VRS**-PR01-EN-P...

  • Page 126: Interbus Interface Ibs03

    11-6 Appendix SYNAX200 INTERBUS Interface IBS03 INTERBUS module X65 INTERBUS interface (in coming) (slave) X66 INTERBUS interface (out going) IBS-SLAVE SY7PR106.FH7 Fig. 11-8: INTERBUS interface IBS03 DOK-SYNAX*-SY*-07VRS**-PR01-EN-P...

  • Page 127: Devicenet Interface Dns03

    11-7 SYNAX200 Appendix DeviceNet Interface DNS03 X85 DeviceNet interface (slave) X89 DeviceNet diagnosis interface RS232 C (project planning interface) DN-SLAVE SY7PR104.FH7 Fig. 11-9: DeviceNet interface DNS03 DOK-SYNAX*-SY*-07VRS**-PR01-EN-P...

  • Page 128: Rme02.2-16-Dc024 Input Module

    11-8 Appendix SYNAX200 RME02.2-16-DC024 Input Module Brief Description The digital 24 VDC input modules are designed for connecting digital control signals that are produced by pushbuttons, limit switches or electronic proximity switches. The 16 inputs are arranged in 2 isolated potential groups.
  • Page 129 11-9 SYNAX200 Appendix Pin Assignments Specifiactions: I*.1.0 I*.0.0 I*.1.1 I*.0.1 - Low: -10V ... +8V I*.1.2 I*.0.2 - High: +17 ... +30V - Input current I High < 10mA I*.1.3 I*.0.3 - Power loss Pv ca. 4W I*.1.4 I*.0.4 - Weight ca. 290g I*.1.5...

  • Page 130: Rme02.2-32-Dc024 Input Module

    11-10 Appendix SYNAX200 RME02.2-32-DC024 Input Module Brief Description The digital 24 VDC input modules are designed for connecting digital control signals that are produced by pushbuttons, limit switches or electronic proximity switches. The 32 inputs are arranged in 4 isolated potential groups.
  • Page 131 11-11 SYNAX200 Appendix Pin Assignments Specifications: I*.3.0 I*.2.0 I*.1.0 I*.0.0 I*.3.1 I*.2.1 I*.1.1 I*.0.1 - Low: -10V ... +8V - High: +17 ... +30V I*.3.2 I*.2.2 I*.1.2 I*.0.2 - Input current I High < 10mA I*.3.3 I*.2.3 I*.1.3 I*.0.3 - Power loss ca. 2,5W I*.3.4...

  • Page 132: Rme02.2-16-Ac115 Input Module

    11-12 Appendix SYNAX200 RME02.2-16-AC115 Input Module Brief Description AC sources of a maximum rating of 120VAC / 60Hz can directly be connected to the digital 115VAC input modules. The 16 AC inputs are arranged in 2 isolated potential groups. Mounting Dimensions total installation depth incl.
  • Page 133 11-13 SYNAX200 Appendix Pin Assignments Specifications: I*.1.0 I*.0.0 I*.1.1 I*.0.1 - Low: < 35V AC - High: 85 ... 138V AC I*.1.2 I*.0.2 - Input current I High < 15mA I*.1.3 I*.0.3 - Power loss Pv ca. 3W - Weight ca. 300g I*.1.4...

  • Page 134: Rma02.2-16-Dc024-200 Output Module

    11-14 Appendix SYNAX200 RMA02.2-16-DC024-200 Output Module Brief Description The digital 24VDC output modules are designed for the connection of digital actuators, such as solenoid valves, contactors, or indicator lights. The 16 outputs are FET transitor switches (active 1 switching) that are arranged in 2 isolated groups of 8 outputs each.
  • Page 135 11-15 SYNAX200 Appendix Pin Assignments Specifications: Q*.1.0 Q*.0.0 - FET - output switch for 24V DC Q*.1.1 Q*.0.1 - output current I L = 2A per output Q*.1.2 Q*.0.2 - internal current limitation Q*.1.3 Q*.0.3 - short-circuit-proof Q*.1.4 Q*.0.4 - 2 isolated blocks Q*.1.5...

  • Page 136: Rma02.2-32-Dc024-050 Output Module

    11-16 Appendix SYNAX200 RMA02.2-32-DC024-050 Output Module Brief Description The digital 24VDC output modules are designed for the connection of digital actuators, such as solenoid valves, contactors, or indicator lights. The 32 outputs are FET transitor switches (active 1 switching) that are arranged in 4 isolated groups of 8 outputs each.
  • Page 137 11-17 SYNAX200 Appendix Pin Assignments Q*.3.0 Q*.2.0 Q*.1.0 Q*.0.0 Q*.3.1 Q*.2.1 Q*.1.1 Q*.0.1 Specifications: Q*.3.2 Q*.2.2 Q*.1.2 Q*.0.2 - FET - output switch for 24V DC Q*.3.3 Q*.2.3 Q*.1.3 Q*.0.3 - output current I = 0.5A per output Q*.3.4 Q*.2.4 Q*.1.4 Q*.0.4 - internal current limitation Q*.3.5 Q*.2.5 Q*.1.5 Q*.0.5...

  • Page 138: Rma02.2-16-Ac230-200 Output Module

    11-18 Appendix SYNAX200 RMA02.2-16-AC230-200 Output Module Brief Description The digital AC output modules are designed for the connection of digital actuators that operate on the mains voltage. The 16 active 1 switching outputs are arranged in 2 isolated groups of 8 outputs each. Each 230V AC output is able to source up to 2A.
  • Page 139 11-19 SYNAX200 Appendix Pin Assignments Q*.1.0 Q*.0.0 Q*.1.1 Q*.0.1 Q*.1.2 Q*.0.2 Specifications: Q*.1.3 Q*.0.3 - Switching voltage: Q*.1.4 Q*.0.4 = 12 ... 275Vrms AC / 10 ... 440Hz - Switching current: Q*.1.5 Q*.0.5 max = 2A Q*.1.6 Q*.0.6 = 5mA - Power loss Pv ca.

  • Page 140: Rma02.2-16-Re230-200 Output Module

    11-20 Appendix SYNAX200 RMA02.2-16-RE230-200 Output Module Brief description The digital relay output modules are designed as floating switching contacts for AC and DC. The 16 active 1 switching outputs are arranged in 2 isolated groups of 8 outputs each. Depending on the load, the maximum switching capacity of each output is between 50W and 200W.
  • Page 141 11-21 SYNAX200 Appendix Pin Assignments +U od. L1 Q*.1.0 Q*.0.0 0V od. N +U od. L1 Q*.1.1 Q*.0.1 0V od. N Q*.1.2 Q*.0.2 Q*.1.3 Q*.0.3 Specifications: Q*.1.4 Q*.0.4 - switching voltage: U max = 230V eff - switching power: P max = 50W ...

  • Page 142: 11.2 Dimensional Sheet, Terminal Diagrams Drives

    11-22 Appendix SYNAX200 11.2 Dimensional Sheet, Terminal Diagrams Drives SERCOS interface DSS02.1M distortion display (see section 8.3 "Commissioning") H3 ERR FSMA connector 2,2 ø INS0420/F02 6,0 ø INS0425/F02 fiber-optic interface transmitter fiber-optic interface receiver reference switch pos. travel range limit switch neg.

  • Page 143: Input / Output Interface Dea

    11-23 SYNAX200 Appendix Input / Output interface DEA DEA04.2M, DEA05.2M, DEA06.2M ready-made cable IKS4123 X17/X32/X33 IN 0 BKGN IN 1 GYPK IN 2 RDGN IN 3 BKYE IN 4 GNBU IN 5 RDBU IN 6 BNYE IN 7 BNGY inputs...
  • Page 144 11-24 Appendix SYNAX200 DEA08.1M, DEA09.1M, DEA10.1M ready-made cable IKS4186 X64 / X65 / X66 WH 0.16 mm In 0 BN 0.16 mm In 1 GN 0.16 mm In 2 YE 0.16 mm In 3 GY 0.16 mm In 4 PK 0.16 mm In 5 BU 0.16 mm...

  • Page 145: Encoder Interface Dag01.2M (Endat Or Ssi Interface)

    11-25 SYNAX200 Appendix Encoder interface DAG01.2M (EnDat or SSI interface) 4-pin plug-in screw clamp part no.: 254006 24 V ext. If an EnDat interface has 0 V ext. been selected then do not +U L Schirm connect voltage supply! 0V L...

  • Page 146: Analog Interface With Actual Position Value Output Dae02.1M

    11-26 Appendix SYNAX200 Analog interface with Actual Position Value Output DAE02.1M 14-pin plug-in, screw clamp, part no.: 274838 ± 10V analog input 1 temperature prewarning drive enable drive halt ± 10V analog input 2 DC +24V ext. DC 0V ext.

  • Page 147: Absolute Encoder Emulator Dsa01.1M

    11-27 SYNAX200 Appendix Absolute Encoder Emulator DSA01.1M absolute encoder emulator (SSI data format) 15-pin D-SUB. connector INS 0519/L01 (screw mounting) part no.: 263 365 cable (2x1,0 + 4x2x0,25)C type: INK 0448 DATA (+) DATA (+) DATA (-) DATA (-) BN 1 2 DC 0V ext.

  • Page 148: Position Interface For Square-Wave Signals Def01.1M

    11-28 Appendix SYNAX200 Position interface for Square-Wave Signals DEF01.1M type: INK0209 cable (2x1,0+4x2x0,25)C WH 1 2 DC 0V ext. BN 1 2 DC +5V ext. looking towards 15-pin D-SUB. front panel connector INS0439/C01 (screwed mounting) part no.: 252884 color coding applies to INDRAMAT cable type: INK0209 SY6PR075.FH7...

  • Page 149: Encoder Interface Dff01.1M

    11-29 SYNAX200 Appendix Encoder interface DFF01.1M encoder GDS 1.1 / GDM PRIOR_OUT not assigned shield connector INS0439/C01 part no.: 231715 IKS4374 DFF 01.1M, X18 BNWH PRIOR_IN looking towards front panel not assigned GNWH YEWH join shield to GYWH connector housing...

  • Page 150: High-Resolution Position Interface For Sinusoidal Signals Dlf01.1M

    11-30 Appendix SYNAX200 High-Resolution Position interface for Sinusoidal Signals DLF01.1M max. 50 m connector INS0616/C01 ready made cable IKS4384 connector INS0639/C01 41,5 GN 0,25 mm BN 0,25 mm BK 0,25 mm RD 0,25 mm GY 0,25 mm PK 0,25 mm...

  • Page 151: Gear Wheel Encoder Interface Dzf02.1M

    11-31 SYNAX200 Appendix Gear Wheel Encoder interface DZF02.1M 9pin plug-in connector INS0701/C01 ready-made cable IKS4314 9pin cable INK0209 15pin plug-in connector (colour coding applies D-Sub. INS0701/C01 INDRAMAT cable type: plug-in connector INK0209) INS0519/L01 PK 0,25 mm 2 GY 0,25 mm 2...

  • Page 152: Gear Wheel Encoder Interface Dzf03.1M

    11-32 Appendix SYNAX200 Gear Wheel Encoder interface DZF03.1M 9pin plug-in connector INS0701/C01 ready-made cable IKS4314 9pin cable INK0209 15pin plug-in connector (colour coding applies to D-Sub. INS0701/C01 INDRAMAT cable type: plug-in connector INK0209) INS0519/L01 PK 0,25 mm 2 GY 0,25 mm 2...

  • Page 153: Dimensional Sheet Dga01.2

    11-33 SYNAX200 Appendix Dimensional Sheet DGA01.2 (60) (60) Mb5040f1.fh7 Fig. 11-35: Dimensional sheet DGA01.2 DOK-SYNAX*-SY*-07VRS**-PR01-EN-P...

  • Page 154: List Of Connectors And Ready-Made Cable

    11-34 Appendix SYNAX200 List of Connectors and Ready-Made Cable Order designation for Mating connector of INDRAMAT cable Cable end ready-made cable the unit INS526 INS439 IKB0005 Part no.: 278 141, 2m INK572 Part no.: 278 144, 5m Part no.: 278 142, 10m Part no.: 278 143, 15m...
  • Page 155 11-35 SYNAX200 Appendix Connectors Y connector for ready-made INS0619/K01 cables with active Part no.: 279 583 termination INS0619/RS485 (15pin/pins) connector for ready-made INS0645/K01 cables with active Part no.: 282 040 termination INS0645/RS422 Profibus connector for ready- INS0540/K01 made cables with active Part no.: 279 538...

  • Page 156: 11.3 Supplementary Documentation

    Appendix SYNAX200 11.3 Supplementary Documentation This document contains dimensional sheets and terminal diagrams of plug-in modules related to SYNAX200. Supplementary documentation: • "DIAX03 Plug-in modules for digital intelligent drive controllers" (DOK-DIAX03-PLUG*IN*MOD-PR03-EN-P) • "DIAX04 Plug-in modules for digital intelligent drive controllers"...

  • Page 157: Index

    12-1 SYNAX200 Index Index 1MB 1-6 2AD 1-6 Absolute limits 4-9 AC voltage component 4-9 Analog input 1-6 Analog inputs 6-6 Appropriate use Introduction 2-1 Uses 2-2 ARCNET 4-14 ARCNET assembly 1-4 Atmospheric pressure 4-9 Attachment 4-9 Basic devices 1-4, 1-6...
  • Page 158 12-2 Index SYNAX200 Determining the master axis 6-3 Determining the motor/controller combination - illustration 5-2 DeviceNet 4-14 DeviceNet (DNS) 1-4 DFF encoder interface 6-3 DGA 01.2 6-8 DGA terminal diagram 6-9 DIAX03 1-6 DIAX04 1-6 Digital outputs 4-9 Digital inputs 4-9...
  • Page 159 12-3 SYNAX200 Index HS04 7-15 HS12 5-5, 5-18, 7-9 HS32 5-7, 5-13, 5-14, 5-16, 5-24, 7-11 HS37 5-11, 7-13 HS45 5-9, 5-16, 5-22, 5-26 I/O modules 4-1, 4-5 IBS03 11-6 IEC 61491 8-1 IEC 874-2 8-2 IKO0001 8-4 IKO0982 8-4...
  • Page 160 Serial Indramat Interface 4-1 Serial interface 4-10 Set-up SYNAX200 ring 8-1 Simple ring 9-1, 9-2 Slot address 4-7 SSI 6-4, 6-6 SSI emulation 6-6 Supply 4-9 SYNAX200 system configuration 1-5, 1-7 SynTop 10-1 System grounding 4-6 Temperature 4-9 Transmission rate 8-9 DOK-SYNAX*-SY*-07VRS**-PR01-EN-P...
  • Page 161 12-5 SYNAX200 Index Twisting of fibre-optics cable 8-6 Use See appropriate use and inappropriate use Watchdog relay 4-9 Weight 4-9 Wrench for FSMA connector 8-3 X1 4-12 X10 4-12 X15 4-13 X16 4-12 DOK-SYNAX*-SY*-07VRS**-PR01-EN-P...
  • Page 162 12-6 Index SYNAX200 DOK-SYNAX*-SY*-07VRS**-PR01-EN-P...
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