Rexroth VisualMotion 10 - Project Planning Manual

Industrial Electric Drives Linear Motion and Service Mobile
Hydraulics and Controls Assembly Technologies Pneumatics Automation Hydraulics
Rexroth IndraControl VCP 20

Rexroth VisualMotion 10 R911306326
Edition 01
Multi-Axis Machine Control
Project Planning Manual

About this Documentation Rexroth VisualMotion 10 Project Planning
Title Rexroth VisualMotion 10

Multi-Axis Machine Control
Type of Documentation Project Planning Manual
Document Typecode DOK-VISMOT-VM*-10VRS**-PR01-EN-P
Internal File Reference Document Number, 120-2300-B322-01/EN

Part of Box Set, 20-10V-EN (MN R911306370)
Purpose of Documentation This documentation describes …

• the controls and components used with the VisualMotion 10 multi-axis
machine control system with Integrated PLC functionality (IndraLogic)
and optional interfaces, such as Encoder Interface Card, Ethernet,
Fieldbus, Option Card PLS, Link Ring.
Record of Revisions Description Release Notes

Date
DOK-VISMOT-VM*-10VRS**-PR01-EN-P 08/2004 Initial release
Copyright  2004 Bosch Rexroth AG

Copying this document, giving it to others and the use or communication
of the contents thereof without express authority, are forbidden. Offenders
are liable for the payment of damages. All rights are reserved in the event
of the grant of a patent or the registration of a utility model or design
(DIN 34-1).
Validity The specified data is for product description purposes only and may not
be deemed to be guaranteed unless expressly confirmed in the contract.
All rights are reserved with respect to the content of this documentation
and the availability of the product.
Published by Bosch Rexroth AG

Bgm.-Dr.-Nebel-Str. 2 • D-97816 Lohr a. Main
Tel.: +49 (0)93 52/40-0 • Fax: +49 (0)93 52/40-48 85 • Telex: 68 94 21
Bosch Rexroth Corporation • Electric Drives and Controls
5150 Prairie Stone Parkway • Hoffman Estates, IL 60192 • USA
Tel.: 847-645-3600 • Fax: 847-645-6201
http://www.boschrexroth.com/
Dept. ESG4 (DPJ)
Note This document has been printed on chlorine-free bleached paper..
DOK-VISMOT-VM*-10VRS**-PR01-EN-P
Rexroth VisualMotion 10 Project Planning Table of Contents I
Table of Contents
1 Rexroth VisualMotion 10 Overview 1-1
1.1 System Overview........................................................................................................................... 1-1
1.2 PPC-R Control Overview ............................................................................................................... 1-1
PPC-R Components ................................................................................................................ 1-2
PPC-R PLC Support................................................................................................................ 1-2
PPC-R Optional Interface Support .......................................................................................... 1-2
Drive I/O Support ..................................................................................................................... 1-3
1.3 PPC-P11.1 Control Overview ........................................................................................................ 1-3
GMP 10 Firmware Features .................................................................................................... 1-4
PPC-P11.1 Components ......................................................................................................... 1-4
PPC-P11.1 Optional Interface Support ................................................................................... 1-4
Drive I/O Support ..................................................................................................................... 1-4
1.4 Rexroth Digital Drive Families ....................................................................................................... 1-5
Rexroth IndraDrive Digital Drives ............................................................................................ 1-5
Rexroth Diax 04 Digital Drives................................................................................................. 1-6
Rexroth EcoDrive Digital Drive Family .................................................................................... 1-7
1.5 Supporting Documentation ............................................................................................................ 1-9
Additional VisualMotion Documentation for GPP/GMP 10 Firmware...................................... 1-9
IndraLogic Documentation....................................................................................................... 1-9
Rexroth Inline I/O Modules ...................................................................................................... 1-9
RECO02.2 SERCOS I/O Modules......................................................................................... 1-10
IndraDrive Digital Drive Documentation ................................................................................ 1-10
Diax 04 Digital Drive Documentation for SSE Firmware ....................................................... 1-10
Diax 04 Digital Drive Documentation for ELS Firmware........................................................ 1-10
EcoDrive 03 Digital Drive Documentation for SMT02 Firmware ........................................... 1-10
EcoDrive 03 Digital Drive Documentation for SGP01 Firmware ........................................... 1-11
EcoDrive Cs Digital Drive Documentation for MGP01 Firmware ......................................... 1-11
Windows Help System for Drives .......................................................................................... 1-11
Control and Drive Systems Electronic Documentation.......................................................... 1-12
2 Important Usage Directions 2-1

2.1 Appropriate Use ............................................................................................................................. 2-1
Introduction .............................................................................................................................. 2-1
Areas of Use and Application .................................................................................................. 2-2
2.2 Inappropriate Use .......................................................................................................................... 2-2
3 Safety Instructions for Electric Drives and Controls 3-1

3.1 Introduction .................................................................................................................................... 3-1
II Table of Contents Rexroth VisualMotion 10 Project Planning
3.2 Explanations .................................................................................................................................. 3-1

3.3 Hazards by Improper Use.............................................................................................................. 3-2
3.4 General Information ....................................................................................................................... 3-3
3.5 Protection Against Contact with Electrical Parts............................................................................ 3-5
3.6 Protection Against Electric Shock by Protective Low Voltage (PELV) .......................................... 3-6
3.7 Protection Against Dangerous Movements ................................................................................... 3-7
3.8 Protection Against Magnetic and Electromagnetic Fields During Operation and Mounting.......... 3-9
3.9 Protection Against Contact with Hot Parts................................................................................... 3-10
3.10 Protection During Handling and Mounting................................................................................... 3-10
3.11 Battery Safety .............................................................................................................................. 3-11
3.12 Protection Against Pressurized Systems..................................................................................... 3-11
3.13 Protection Against Unwanted Network Access ........................................................................... 3-12
4 VisualMotion Control System 4-1

4.1 PPC-R22.1 Overview..................................................................................................................... 4-1
Installing the PPC-R22.1 and Reco 02 I/O Modules ............................................................... 4-2
PPC-R22.1 Hardware.............................................................................................................. 4-3
PPC-R22.1 Specifications ....................................................................................................... 4-4
Supply Voltage, Digital I/O and Watchdog .............................................................................. 4-5
Optional EtherNet Onboard ..................................................................................................... 4-8
4.2 PPC-P11.1 (PCI-Version) Overview............................................................................................ 4-10
PPC-P11.1 Hardware ............................................................................................................ 4-10
PCI Hardware Requirements................................................................................................. 4-11
Soft/Slot PLC Interface to PPC-P11.1 ................................................................................... 4-11
PPC-P11.1 Specifications ..................................................................................................... 4-12
Supply Voltage, Digital I/O..................................................................................................... 4-13
Installation Guidelines for PPC-P11.1 ................................................................................... 4-14
4.3 Serial Communication.................................................................................................................. 4-15
Serial Interface Pin Assignment ............................................................................................ 4-16
4.4 PPC Diagnostic Displays ............................................................................................................. 4-17
Control Status and Settings on H1 Display ........................................................................... 4-17
Error Codes ........................................................................................................................... 4-17
4.5 Compact Flash Memory Cards .................................................................................................... 4-18
Control Data on Compact Flash ............................................................................................ 4-18
Control Data on NVRam........................................................................................................ 4-18
NVRam and Compact Flash Backup Commands ................................................................. 4-18
4.6 System Grounding ....................................................................................................................... 4-20
5 System I/O Modules 5-1

5.1 PPC-R22.1 Motion Control System ............................................................................................... 5-1
5.2 Supported I/O Devices................................................................................................................... 5-2
Rexroth Inline I/O Hardware .................................................................................................... 5-2
Rexroth Reco 02 I/O Modules ................................................................................................. 5-5
Diax I/O Module ....................................................................................................................... 5-9
EcoDrive EMD I/O Module ...................................................................................................... 5-9
5.3 Configuring I/O Modules .............................................................................................................. 5-10
Rexroth VisualMotion 10 Project Planning Table of Contents III
Sercos I/O Configuration Limits............................................................................................. 5-10

Accessing Rexroth Inline I/O Modules .................................................................................. 5-10
Accessing Reco 02 I/O Modules ........................................................................................... 5-11
Diax Digital I/O Modules ........................................................................................................ 5-16
Diax Analog Input I/O Module................................................................................................ 5-17
Configuring EMD I/O Modules for DKC22.3.......................................................................... 5-18
6 Fieldbus Interfaces 6-1

6.1 Profibus-DP Fieldbus Master and Slave Interfaces....................................................................... 6-2
Pin Assignment of Connector X70 and X75 ............................................................................ 6-2
Profibus Diagnostics ................................................................................................................ 6-2
Profibus Specifications ............................................................................................................ 6-3
6.2 DeviceNet Fieldbus Master and Slave Interfaces.......................................................................... 6-4
Pin Assignment of Connector X80 and X85 ............................................................................ 6-4
DeviceNet Diagnostics ............................................................................................................ 6-4
DeviceNet Specifications......................................................................................................... 6-5
6.3 ControlNet Fieldbus Slave Interface.............................................................................................. 6-6
Channel A ControlNet Interface............................................................................................... 6-6
Channel B ControlNet Interface............................................................................................... 6-6
ControlNet Network Access Port ............................................................................................. 6-6
ControlNet Diagnostics............................................................................................................ 6-7
ControlNet Specifications ........................................................................................................ 6-8
6.4 Interbus Fieldbus Slave Interface .................................................................................................. 6-9
Pin Assignment of Connector X65........................................................................................... 6-9
Pin Assignment of Connector X66........................................................................................... 6-9
Interbus Diagnostics .............................................................................................................. 6-10
Interbus Specifications .......................................................................................................... 6-11
7 Encoder Interface, Option Card PLS, and Link Ring 7-1

7.1 Encoder Interface Card (MEC) ...................................................................................................... 7-1
Encoder Interface Card Specifications .................................................................................... 7-2
7.2 Option Card PLS for PPC-R22.1 and PPC-P11.1 ......................................................................... 7-4
Connecting Supply Voltage ..................................................................................................... 7-5
Option Card PLS Specifications .............................................................................................. 7-6
7.3 DAQ03 for PPC-R22.1 and PPC-P11.1 ........................................................................................ 7-7
DAQ03 Diagnostics ................................................................................................................. 7-8
DAQ03 Specifications.............................................................................................................. 7-8
Cable Connections for DAQ03 ................................................................................................ 7-9
8 VisualMotion Human Machine Interfaces 8-1

8.1 Overview ........................................................................................................................................ 8-1
8.2 Rexroth IndraControl VCP Terminals ............................................................................................ 8-1
VCP Features .......................................................................................................................... 8-2
8.3 Rexroth IndraControl VEP Embedded Terminals.......................................................................... 8-3
VEP Features .......................................................................................................................... 8-3
8.4 BTC06............................................................................................................................................ 8-4
IV Table of Contents Rexroth VisualMotion 10 Project Planning
BTC06 Specifications .............................................................................................................. 8-4

Standard Features ................................................................................................................... 8-6
Optional Features .................................................................................................................... 8-6
Safety Concept ........................................................................................................................ 8-6
Enclosure Dimensions ............................................................................................................. 8-7
BTC06 Accessories ................................................................................................................. 8-8
BTC06 Connections ................................................................................................................. 8-9
Enclosure Connection from BTC to Control .......................................................................... 8-10
BTC06 to PPC-R22.1 Connections ....................................................................................... 8-11
9 Fiber Optic Cable(LWL) 9-1

9.1 Data Transmission Ring Structure................................................................................................. 9-1
Fiber Optic Transmission Path Installation.............................................................................. 9-1
Fiber Optic Cable Types.......................................................................................................... 9-2
Fiber Optic Cable Accessories ................................................................................................ 9-2
9.2 Project Planning Notes .................................................................................................................. 9-3
Maximum Transmission Length............................................................................................... 9-3
Technical Data......................................................................................................................... 9-4
General Safety Guidelines....................................................................................................... 9-4
Handling................................................................................................................................... 9-5
9.3 System Setup................................................................................................................................. 9-6
Preparations ............................................................................................................................ 9-6
Sercos Drive Address Settings................................................................................................ 9-6
Changing the Sercos Baudrate ............................................................................................... 9-8
Setting the Optic Transmitter Output Power............................................................................ 9-9
10 Hardware and Firmware Configurations 10-1

10.1 PPC-R Hardware and Firmware .................................................................................................. 10-1
PPC-R22.1 Hardware Configurations ................................................................................... 10-1
10.2 PPC-P11.1 Hardware and Firmware ........................................................................................... 10-8
PPC-P11.1 Hardware Configurations.................................................................................... 10-8
10.3 Upgrading Control Firmware...................................................................................................... 10-10
Bootloader Firmware on Controls........................................................................................ 10-10
Dolfi Software ...................................................................................................................... 10-10
10.4 HMI Hardware and Firmware..................................................................................................... 10-11
VCP Small Operator Terminals ........................................................................................... 10-11
BTC06.2 Hardware .............................................................................................................. 10-13
BTC06 Firmware.................................................................................................................. 10-13
11 Typecodes 11-1
11.1 Typecode Description .................................................................................................................. 11-1
PPC-R22.1 Typecode............................................................................................................ 11-1
PPC-P11.1 Typecode............................................................................................................ 11-2
VCP02 Typecode................................................................................................................... 11-3
VCP05 Typecode................................................................................................................... 11-3
VCP08 Typecode................................................................................................................... 11-4
Rexroth VisualMotion 10 Project Planning Table of Contents V
VCP20 Typecode................................................................................................................... 11-4

VCP25 Typecode................................................................................................................... 11-5
BTC06.2 Typecode................................................................................................................ 11-6
BTZ01.1 Typecode ................................................................................................................ 11-7
12 Index 12-1
13 Service & Support 13-1

13.1 Helpdesk ...................................................................................................................................... 13-1
13.2 Service-Hotline............................................................................................................................. 13-1
13.3 Internet......................................................................................................................................... 13-1
13.4 Vor der Kontaktaufnahme... - Before contacting us... ................................................................. 13-1
13.5 Kundenbetreuungsstellen - Sales & Service Facilities ................................................................ 13-2
VI Table of Contents Rexroth VisualMotion 10 Project Planning
Rexroth VisualMotion 10 Project Planning Rexroth VisualMotion 10 Overview 1-1
1 Rexroth VisualMotion 10 Overview
1.1 System Overview

VisualMotion is a programmable multi-axis motion and logic control
system capable of controlling up to 40 intelligent digital drives from Bosch
Rexroth. The PC software used for programming and commissioning of
motion and logic is VisualMotion Toolkit.
VisualMotion 10 supports the following hardware and firmware versions:
• PPC-R22.1 using GPP 10 firmware
• PPC-P11.1 using GMP 10 firmware
1.2 PPC-R Control Overview

The PPC-R is a stand-alone multi-axis motion and logic control. It has the
Reco 02 form factor, a form factor used by Bosch Rexroth for motion
controls, PLCs and I/O modules. These devices share the LocalReco 02
back-plane bus for data exchange.
It is recommended to use the VisualMotion motion/logic control with
Rexroth IndraDrive, Diax 04, and EcoDrive 03 digital servo drives. The
communication between control and digital servo drives is performed
using the SERCOS interface, the international standard for real-time
communication for digital servo drives.
VisualMotion GPP 10 firmware can provide multi-axis coordinated or non-
coordinated motion control with tightly integrated logic control functions. It
supports a variety of applications, from general motion control to
sophisticated multiple master electronic line shafting (ELS) and robotics.
PPCR22_Overview.FH7
Fig. 1-1: PPC-R Motion Control
1-2 Rexroth VisualMotion 10 Overview Rexroth VisualMotion 10 Project Planning
PPC-R Components
The VisualMotion PPC-R control system is comprised of the following
components:
• Rexroth PPC-R22.1 (three expansion slots) with an optional
onboard EtherNet connection
Note: Onboard EtherNet supports both standard TCP/IP and

EtherNet/IP slave fieldbus communication.
• Rexroth Reco 02 I/O modules (Local and SERCOS)

• Rexroth Inline I/O modules
• Diax 04 and EcoDrive 03 I/O modules
• Rexroth VisualMotion Toolkit (VMT) software program for motion
control programming, parametrization, system diagnostics and
motion control management.
• DDE and OPC servers communicate via the SCP using the SIS
protocol between Windows programs and the control.
• Up to 40 intelligent digital drives can be connected to one control
over SERCOS
– Rexroth IndraDrive (using MPx02 firmware with ELS05
support) drives and motors
– Rexroth Diax 04 (using SSE03 or ELS05 firmware) drives and
motors
– Rexroth EcoDrive 03 (using SMT02, SGP01, SGP03 or SGP20
firmware) drives and motors
– Rexroth EcoDrive Cs (using MPG01 firmware) drives and
motors
• HMI interfaces (BTC06, BTV04, BTV05, BTV06)
PPC-R PLC Support

The Rexroth IndraLogic PLC software is integrated into VisualMotion
Toolkit for support of PLC logic programming. Refer to chapter 7 in the
VisualMotion 10 Functional Description for details.
PPC-R Optional Interface Support

The PPC-R control supports the following optional interfaces:
Fieldbus Slave Interfaces

• Profibus-DP (32 words max.)
• Interbus (16 words max.)
• DeviceNet (32 words max.)
• ControlNet (32 words max.)
• EtherNet/IP (32 words max.)
Fieldbus Master Interfaces

• Profibus-DP (32 words max.)
• DeviceNet (32 words max.)
Additional Interfaces
• Option Card Programmable Limit Switch (16 or 32 outputs)
• Link Ring for master/slave interfacing of VisualMotion controls
• Master Encoder Card (MEC)
Drive I/O Support

Rexroth digital drives support the following I/O devices:
• Dea x.1M (x = 4, 5, 6, 8, 9, and 10) I/O cards for Diax 04 digital
drives
• EMD I/O module using the EcoX interface for DKC22.3 digital
drives using SGP20 firmware
Note: VisualMotion does not support the I/O functionality in Rexroth

IndraDrive digital drives.
1.3 PPC-P11.1 Control Overview

The PPC-P11.1 (PCI-version) is a PC-based stand-alone multi-axis
motion and logic control. The GMP 10 firmware used with the PPC-P11.1
is designed to work as a complete motion and logic control solution.
Just like the PPC-R, the PPC-P11.1 supports Rexroth IndraDrive, Diax
04 and EcoDrive 03 digital servo drives. Communication between the
control and digital servo drives is performed via the SERCOS interface.
ppc_pci.tif
Fig. 1-2: PPC-P11.1 Motion Control
GMP 10 Firmware Features

All firmware functionality supported in GPP 10 will also be supported in
GMP 10 with the following restriction:
• VisualMotion fieldbus slave interfaces are not supported
• Ethernet interface is not supported
PPC-P11.1 Components
The VisualMotion PPC-P11.1 control system is composed of the following
components:
• Rexroth PPC-P11.1 control using GMP 10 firmware
• Optional Rexroth SercosReco 02 I/O modules
• Rexroth Inline I/O modules
• Diax 04 and EcoDrive 03 I/O modules
• Rexroth VisualMotion Toolkit (VMT) software program for motion
control programming, parametrization, system diagnostics and
motion control management.
• DDE and OPC servers communicate via the SCP using the SIS
protocol between Windows programs and the control.
• Up to 40 intelligent digital drives can be connected to one control
over SERCOS
– Rexroth IndraDrive (using MPx02 firmware with ELS05
support) drives and motors
– Rexroth Diax 04 (using SSE03 or ELS05 firmware) drives and
motors
– Rexroth EcoDrive 03 (using SMT02, SGP01, SGP03 or SGP20
firmware) drives and motors
– Rexroth EcoDrive Cs (using MPG01 firmware) drives and
motors
• HMI interfaces (BTC06, BTV04, BTV05, BTV06)
PPC-P11.1 Optional Interface Support

The PPC-P11.1 supports the following optional interfaces:
• second Serial interface
• Up to 2 Option Card Programmable Limit Switch
with 16 outputs each
• Link Ring for master/slave interfacing of VisualMotion controls
• Master Encoder Card (MEC)
Drive I/O Support

Rexroth digital drives support the following I/O devices:
• Dea x.1M (x = 4, 5, 6, 8, 9, and 10) I/O cards for Diax 04 digital
drives
• EMD I/O module using the EcoX interface for DKC22.3 digital
drives using SGP20 firmware

1.4 Rexroth Digital Drive Families

Rexroth digital drive families are comprised of power supplies, drive
controllers and their associated motors. The IndraDrive, Diax 04, and
EcoDrive 03 digital drive families are fully capable of using the functions
available in the VisualMotion.
Rexroth IndraDrive Digital Drives

Rexroth IndraDrive provides integrated safety technology conforming to
EN 954-1, category 3. They offer a wide range of power from 1 kW to
110 kW. They are available as IndraDrive C (compact converters) and
IndraDrive M (modular inverters). VisualMotion GPP 10 and GMP 10
firmware support the following IndraDrive firmware:
IndraDrive Firmware Description

FWA-INDRV*-MPH-02VRS-MS-1-AXC-NN closed-loop with servo
FWA-INDRV*-MPH-02VRS-MS-1-SNC-NN closed-loop with synchronization
FWA-INDRV*-MPH-02VRS-MS-1-AXC-ML closed-loop with servo and PLC
FWA-INDRV*-MPH-02VRS-MS-1-SNC-ML closed-loop with synchronization
and PLC
Table 1-1: VisualMotion 10 Supported IndraDrive Firmware
Refer to the relevant Rexroth IndraDrive documentation for safety

technology, ratings, and output power details.
IndraDrive C Compact Converters

The IndraDrive C digital drive family incorporates a power supply section
with a drive controller in one package. The following compact converters
are available:
• HCS02.1-W0012
• HCS02.1-W0028
• HCS02.1-W0054
• HCS02.1-W0070
• HCS03.1-W0070
• HCS03.1-W0100
• HCS03.1-W0150
• HCS03.1-W0210
• HCS03.1-W0350
IndraDrive M Modular Power Supplies

IndraDrive power supply units of the HMV line support the power and
control voltage of the HMD line. IndraDrive power supplies requires a
mains voltage of 3 x 380 … 480 V.
The HMV01.1E power supply uses a bleeder resistor to absorb
regenerative power that is fed back from the attached digital drive
controllers. The following HMV01.1E power supplies are available:
• HMV01.1E-W0030
• HMV01.1E-W0075
• HMV01.1E-W0120
The HMV01.1R power supply uses current regeneration to regenerate

power that is fed back from the attached digital drive controllers. The
following HMV01.1R power supplies are available:
• HMV01.1R-W0018
• HMV01.1R-W0045
• HMV01.1R-W0065
IndraDrive M Modular Inverters

IndraDrive modular inverters using MPx02 firmware are supported by
GPP 10 and GMP 10 firmware.
• HMD01.1N-W0020
• HMD01.1N-W0036
• HMS01.1N-W0020
• HMS01.1N-W0036
• HMS01.1N-W0054
• HMS01.1N-W0070
• HMS01.1N-W0150
• HMS01.1N-W0210
Motors used with IndraDrive

IndraDrive digital drive controllers are capable of operating all rotating and
linear motors of the MSK, MLF, MBT, MAD, and LSF.
IndraDrive.jpg
Fig. 1-3: Motors used with IndraDrive
Rexroth Diax 04 Digital Drives

The modular concept in the Rexroth Diax 04 digital drive family enables a
flexible combination of digital drive controllers to one power supply unit.
Power supplies and digital drive controllers are combined based on their
power requirements. Refer to the relevant Rexroth Digital Drive
documentation.
Diax 04 Power Supplies

Power supply units of the HV* line support the power and control voltage
of Rexroth digital drive controllers of the HD* line. Diax 04 power supplies
require a mains voltage of 3 x AC 380 ... 480 V.
HVE Power Supply

The HVE power supply uses a bleeder resistor to absorb regenerative
power that is fed back from the attached digital drive controllers. The
following HVE power supplies are available:
• HVE02.2
• HVE03.2
• HVE04.2
HVR Power Supply

The HVR power supply uses current regeneration to regenerate power
that is fed back from the attached digital drive controllers. The following
HVR power supplies are available:
• HVR02.2
• HVR03.2
Diax 04 Digital Drive Controllers

The following digital drive controllers are part of the Diax 04 drive family.
HDD Controllers
The HDD02.2 is a dual axes digital drive controller with two slots for plug-
in cards (one per axis) and a continuous drive output of up to
approximately 8 kW.
HDS Controllers
The HDS digital drive controller is designed with three slots (HDS02.2) or
four slots (HDS03/04) for plug-in cards. The following HDS drives are
available:
• HDS02.2
• HDS03.2
• HDS04.2
• HDS05.2
Rexroth EcoDrive Digital Drive Family

The EcoDrive digital drive family incorporates a power supply section with
a drive controller in one package. The DKC digital drive controller
requires additional components to output the mechanical power listed
above. Refer to the relevant Rexroth EcoDrive 03 documentation.
EcoDrive 03 Digital Drive Controllers

The following DKC digital drive controllers using SGP or SMT firmware
are supported by GPP 10 and GMP 10 firmware.
• DKC02.3-016
• DKC02.3-040 or DKC22.3-040
• DKC02.3-100 or DKC22.3-100
• DKC02.3-200 or DKC22.3-200
Motors used with Diax 04 and EcoDrive 03

All Diax 04 and EcoDrive 03 digital drive controllers are capable of
operating all rotating and linear motors of the MHE, MKD, MKD, 2AD,
1MB, MBS, MBW, ADF, LAF and LSF series.
MOTORS.FH7
Fig. 1-4: Motors used with Diax 04 and EcoDrive 03
EcoDrive Cs Digital Drive Controllers

The following DKC digital drive controllers using MGP firmware are
supported by GPP 10 and GMP 10 firmware:
• DKC02.3-004
• DKC02.3-008
• DKC02.3-012
• DKC02.3-018
Refer to the EcoDrive Cs Project Planning manual for mechanical output

power.
Larger units like the

DKC02.3-018 will have
a heatsink mounted to
the left of the unit.
ECO3_DKCs.jpg
Fig. 1-5: EcoDrive Cs Digital Drive Controllers
Motors used with EcoDrive Cs

Each MSM motor is combined with a DKC02.3 EcoDrive Cs controller.
Refer to the EcoDrive Cs Project Planning manual for drive - motor
combinations.
MSM040B
MSM030C
MSM030B
MSM020B
ECO3_MSM.jpg
Fig. 1-6: Motor used with EcoDrive Cs
1.5 Supporting Documentation

The information in this manual is intended for users and programmers of
the Rexroth VisualMotion control. In addition to this manual, the following
supporting documentation is available:
Additional VisualMotion Documentation for GPP/GMP 10 Firmware
Type of Manual Typecode Material Number

Box Set 20-10V-EN DOK-VISMOT-VM*-10VRS**-2001-EN-P R911306370
Functional Description (2 volume set) DOK-VISMOT-VM*-10VRS**-FK01-EN-P R911306325
Troubleshooting Guide DOK-VISMOT-VM*-109VRS**-WA01-EN-P R911306327
Table 1-2: Additional VisualMotion Documentation
IndraLogic Documentation

PLC Programming with Rexroth
DOK-CONTRL-IL**PRO*V01-AW01-EN-P R911305036
IndraLogic 1.0
Table 1-3: IndraLogic Documentation
Rexroth Inline I/O Modules

Rexroth Inline Overall View DOK-CONTRL-R-IL*INLINE-KB02-EN-P R911292649
Digital I/O Terminals DOK-CONTRL-R-IL*DIO***-FK03-EN-P R911289589
Analog I/O Terminals DOK-CONTRL-R-IL*AIO***-FK02-EN-P R911289591
Table 1-4: RECO02.2 Module Documentation
RECO02.2 SERCOS I/O Modules

Configuration DOK-CONTRL-RECO02.2**-PR01-EN-P R911283915
Table 1-5: RECO02.2 Module Documentation
IndraDrive Digital Drive Documentation

Functional Description DOK-INDRV*-MP*-02VRS**-FK01-EN-P R911299225
Parameter Description DOK-INDRV*-GEN-**VRS**-PA01-EN-P R911297317
Troubleshooting DOK-INDRV*-GEN-**VRS**-WA01-EN-P R911297319
Integrated Safety Technology DOK-INDRV*-SI*-**VRS**-FK02-EN-P R911297838
Table 1-6: IndraDrive MP*02 Documentation
Diax 04 Digital Drive Documentation for SSE Firmware

Functional Description DOK-DIAX04-SSE-03VRS**-FK01-EN-P R911284050
Parameter Description DOK-DIAX04-SSE-03VRS**-PA01-EN-P R911284051
Troubleshooting DOK-DIAX04-SSE-03VRS**-WA01-EN-P R911284052
Drive Configurations DOK-DIAX04-SSE-03VRS**-IF02-EN-P R911284045
Firmware Version Notes DOK-DIAX04-SSE-03VRS**-FV01-EN-P R911284044
Table 1-7: Diax 04 SSE03 Documentation
Diax 04 Digital Drive Documentation for ELS Firmware

Functional Description DOK-DIAX04-ELS-05VRS**-FKB1-EN-P R911276260
Troubleshooting DOK-DIAX04-ELS-05VRS**-WAR1-EN-P R911276258
Drive Configurations DOK-DIAX04-ELS-05VRS**-IF02-EN-P R911276256
Firmware Version Notes DOK-DIAX04-ELS-05VRS**-FVN1-EN-P R911276254
Table 1-8: Diax 04 ELS05 Documentation
EcoDrive 03 Digital Drive Documentation for SMT02 Firmware

Project Planning DOK-ECODR3-DKC**.3****-PR05-EN-P R911280107
Functional Description DOK-ECODR3-SMT-02VRS**-FK01-EN-P R911285846
Parameter Description DOK-ECODR3-SMT-02VRS**-PA01-EN-P R911285850
Troubleshooting DOK-ECODR3-SMT-02VRS**-WA01-EN-P R911285852
Firmware Version Notes DOK-ECODR3-SMT-02VRS**-FV01-EN-P R911285851
Table 1-9: EcoDrive 03 SMT01 Documentation
EcoDrive 03 Digital Drive Documentation for SGP01 Firmware

Functional Description DOK-ECODR3-SGP-01VRS**-FKB1-EN-P R911279095
Parameter Description DOK-ECODR3-SGP-01VRS**-PAR1-EN-P R911283218
Troubleshooting DOK-ECODR3-SGP-01VRS**-WAR1-EN-P R911279096
Firmware Version Notes DOK-ECODR3-SGP-01VRS**-FVN1-EN-P R911280282
Table 1-10: EcoDrive 03 SGP01 Documentation

Functional Description DOK-ECODR3-SGP-03VRS**-FKB1-EN-P R911295671
Parameter Description DOK-ECODR3-SGP-03VRS**-PAR1-EN-P R911295673
Troubleshooting DOK-ECODR3-SGP-03VRS**-WAR1-EN-P R911295675
Firmware Version Notes DOK-ECODR3-SGP-03VRS**-FVN1-EN-P R911295677

Functional Description DOK-DRIVE*-SGP-20VRS**-FK01-EN-P R911289469
Parameter Description DOK-DRIVE*-SGP-20VRS**-PA01-EN-P R911289471
Troubleshooting DOK-DRIVE*-SGP-20VRS**-WA01-EN-P R911289472
Firmware Version Notes DOK-DRIVE*-SGP-20VRS**-FV02-EN-P R911289470
EcoDrive Cs Digital Drive Documentation for MGP01 Firmware

Project Planning DOK-ECODR3-DKC**.3-CS*-PR01-EN-P R911295758
Functional Description DOK-DRIVE*-MGP-01VRS**-FK01-EN-P R911296549
Parameter Description DOK-DRIVE*-MGP-01VRS**-PA01-EN-P R911296551
Troubleshooting DOK-DRIVE*-MGP-01VRS**-WA01-EN-P R911296553
Firmware Version Notes DOK-DRIVE*-MGP-01VRS**-FV01-EN-P R911296555
Windows Help System for Drives

Windows help systems for all of Bosch Rexroth's digital drives are
available on CD-ROM:
Description Typecode Material Number

DRIVEHELP - Help files for drives DOK-GENERL-DRIVEHELP**-GN07-MS-D0600 R911282411
Table 1-14: DRIVEHELP CD-ROM
Control and Drive Systems Electronic Documentation

The documents referred in this manual are available on Bosch Rexroth's
documentation CD-ROM. This CD-ROM contains the current control and
drive systems documentation for products sold by Bosch Rexroth.
Electronic Documentation for Control
DOK-GENERL-CONTR*DRIVE-GN13-EN-D0650 R911281883
and Drive Systems
Table 1-15: Documentation CD-ROM
Rexroth VisualMotion 10 Project Planning Important Usage Directions 2-1
2 Important Usage Directions
2.1 Appropriate Use
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.
Note: Bosch Rexroth, as manufacturer, is not liable for any damages

resulting from inappropriate use. In such cases, the guarantee
and the right to payment of damages resulting from
inappropriate use are forfeited. The user alone carries all
responsibility of the risks.
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.
2-2 Important Usage Directions Rexroth VisualMotion 10 Project Planning
Areas of Use and Application

VisualMotion made by Bosch Rexroth is designed for the control of servo
drives.
Control and monitoring of the drive system may require additional sensors
and actors.
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.
The motion control and every drive controller has to be parameterized/

programmed before starting it up, making it possible for the motor to
execute the specific functions of an application.
VisualMotion, the motion control solution, has been developed for use in
single or multiple axis drives and control tasks.
Typical applications of VisualMotion are:
• motion control in general automation,
• handling and assembly systems,
• packaging and foodstuff machines,
• printing and paper converting machines and
• textile machines.
The motion control and drive system may only be operated under the
assembly, installation and ambient conditions as described in this
document (temperature, system of protection, humidity, EMC
requirements, etc.) and in the position specified.
2.2 Inappropriate Use

Using VisualMotion components outside of the above referenced areas of
application or under operating conditions other than those described in
this document and in specified technical data is defined as “inappropriate
use".
VisualMotion components may not be used if
• they are subject to operating conditions that do not meet the
specified ambient conditions in this document. This includes, for
example, operation under water, in the case of extreme
temperature fluctuations or extremely high maximum
temperatures or if
• Bosch Rexroth has not specifically released them for that
intended purpose. Please note the specifications outlined in the
general Safety Guidelines!
Rexroth VisualMotion 10 Project Planning Safety Instructions for Electric Drives and Controls 3-1
3 Safety Instructions for Electric Drives and Controls
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.
Improper use of this equipment, failure to follow

the safety instructions in this document or
tampering with the product, including disabling
WARNING of safety devices, may result in material
damage, bodily harm, electric shock or even
death!
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
Death or severe bodily harm will occur.
DANGER
Death or severe bodily harm may occur.
WARNING
Bodily harm or material damage may occur.
CAUTION
Fig. 3-1: Hazard classification (according to ANSI Z535)
3-2 Safety Instructions for Electric Drives and Controls Rexroth VisualMotion 10 Project Planning
3.3 Hazards by Improper Use
High voltage and high discharge current!

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

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

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

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

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

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

batteries!
CAUTION
3.4 General Information

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

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

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

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

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

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

Dangerous movements can be caused by faulty control of the connected
motors. Some common examples are:
• improper or wrong wiring of cable connections
• incorrect operation of the equipment components
• wrong input of parameters before operation
• malfunction of sensors, encoders and monitoring device
• defective components
• software or firmware errors
Dangerous movements can occur immediately after equipment is
switched on or even after an unspecified time of trouble-free operation.
The monitoring in the drive components will normally be sufficient to avoid
faulty operation in the connected drives. Regarding personal safety,
especially the danger of bodily injury and material damage, this alone
cannot be relied upon to ensure complete safety. Until the integrated
monitoring functions become effective, it must be assumed in any case
that faulty drive movements will occur. The extent of faulty drive
movements depends upon the type of control and the state of operation.
Dangerous movements! Danger to life, risk of

injury, severe bodily harm or material damage!
⇒ Secure personal safety by means of qualified and
DANGER tested higher-level monitoring device or measures
integrated in the installation. Unintended machine
motion is possible if monitoring device are disabled,
bypassed or not activated.
⇒ Pay attention to unintended machine motion or other

malfunction in any case of operation.
⇒ Keep free and clear of the machine’s range of

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

master switch and secure the switch against
reconnection for:
- maintenance and repair work
- cleaning of equipment
- long periods of discontinued equipment use
⇒ Prevent the operation of high-frequency, remote
control and radio equipment near electronics circuits
and supply leads. If the use of such equipment
cannot be avoided, verify the system and the
installation for possible malfunctions in all possible
positions of normal use before initial startup. If
necessary, perform a special electromagnetic
compatibility (EMC) test on the installation.
3.8 Protection Against Magnetic and Electromagnetic Fields

During Operation and Mounting
Magnetic and electromagnetic fields generated near current-carrying
conductors and permanent magnets in motors represent a serious health
hazard to persons with heart pacemakers, metal implants and hearing
aids.
Health hazard for persons with heart

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

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

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

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

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

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

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

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

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

operation of the pressurized system equipment may not be
environmentally compatible. Media that are damaging the
environment must be disposed separately from normal waste.
Observe the legal requirements in the country of installation.
3.13 Protection Against Unwanted Network Access

The VisualMotion PPC-R22.1 control can be equipped with an optional
EtherNet connection that allows the control to be accessed over a
network. The PPC-P11.1 control can also be accessed over a network
via DCOM.
The assignment of an IP address and Internet security against unwanted
access is the sole responsibility of the customer's Information Technology
department.
Control data is not encrypted, nor do we have access or security levels for
it. It is recommended to isolate the control's network by using a router as
well as a hardware firewall for any portion of the network accessible to an
Internet connection.
Rexroth VisualMotion 10 Project Planning VisualMotion Control System 4-1
4 VisualMotion Control System
4.1 PPC-R22.1 Overview

The PPC-R22.1 control can be used with VisualMotion’s GPP 10 firmware
and is designed to plug directly into the Reco 02 rack from Bosch
Rexroth. The Reco 02 rack can hold the PPC-R22.1 along with Reco 02
I/O modules, allowing communication along the Reco 02 back-plane bus.
PPC_R_list.FH7
Fig. 4-1: PPC-R22.1
Note: VisualMotion GPP 10 firmware will only support the

PPC-R22.1 double width control hardware.
4-2 VisualMotion Control System Rexroth VisualMotion 10 Project Planning
Installing the PPC-R22.1 and Reco 02 I/O Modules

The PPC-R22.1 control should be mounted in a vertical upright position
as shown in the figure below. Allow adequate clearance above and below
the control to prove sufficient room for heat dissipation. The control must
be installed in slot 00 of the first RMB rack for proper communication
between Local Reco 02 I/O modules. Afterwards Reco 02 I/O modules
should be installed in the next available slot to the right of the PPC-R22.1.
PPCR22_Reco.FH7
Fig. 4-2: PPC-R and Reco Rack Dimensions
PPC-R22.1 Hardware
Note: Refer to chapter 10 for a complete listing of available

configurations for the PPC-R22.1 motion/logic control.
• Double slot width versions with onboard EtherNet support

– PPC-R22.1, with three expansion slots
Note: The same EtherNet hardware is used for both EtherNet/IP

fieldbus and standard EtherNet TCP/IP networking
communication. When enabled as an EtherNet/IP salve
fieldbus interface in VisualMotion 10 using GPP 10 firmware,
standard TCP/IP communication between VisualMotion Toolkit
over the same network is possible.
• Fieldbus slave interface cards

(only one slave interface card can be used at one time)
– Profibus fieldbus slave interface
– Interbus fieldbus slave interface
– DeviceNet fieldbus slave interface
– ControlNet fieldbus slave interface
– Onboard EtherNet/IP fieldbus slave interface
• Fieldbus master interface cards
(only one master interface card can be used at one time)
– Profibus fieldbus master interface
– DeviceNet fieldbus master interface
• Additional interfaces
– Option Card Programmable Limit Switch
– Link Ring (DAQ03)
– Encoder Interface Card (MEC)
• 4-digit alphanumeric display (H1)
• 32 MB compact flash memory card (U1)
• Sercos Interface (2, 4, 8 or 16 MBaud)
• Two serial interface ports available with a software selectable baud
rate of 9600 to 115200 (Default: 9600)
– PPC-R22.1: X10 and X16
Note: The standard RS-232 interface cable used for connecting to

VisualMotion Toolkit, via a 9 pin PC COM port, is the IKB0005.
PPC-R22.1 Specifications
PPC_R22_Dim.FH7
Fig. 4-3: PPC-R22.1 Dimensions [mm]
General Specifications for PPC-R22.1

2
Permissible cable cross section for incoming power: Up to 1.5 mm
Mounting style: Using RMB02.2 racks on TS 35x27x15 DIN rails
Protection rating: IP20, DIN VDE 0470, EN 60529
Humidity: 5 – 78 %, no condensation (operating)
5 – 95 %, no condensation (transport)
DIN 40 040 Class F
Atmospheric pressure: 860 … 1080 hPa, 1500 m (operating)
660 … 1080 hPa, 3500 m (transport)
Ambient operating temperature: 0 … 45 °C (32 … 113 °F), DIN 40 040 Class KV
Storage and transport temperature: –25 … 70 °C (-13 … 158 °F)
Weight: 1.3 kg (2.87 lbs.)
Supply Voltages for PPC-R22.1

Nominal value: 24 VDC
Permissible ripples: 4 Vpp within the permissible voltage range
Permissible voltage range: 19.2 … 30 VDC, including ripples
Maximum current consumption:
PPC-R22.1 1.2 A (+ supply voltage for I/O modules up to 2.6 A)
Digital Input and Output Rating for PPC-R22.1
Digital Input: Current draw, isolated

Vi,Low = 0V …5V: Vi,High = 15V …30V
Delay type: 50 µs
Digital Output: Current rating = 0.5 A, isolated
Response (delay) time = 500 µs max.
Internal Clock for PPC-R22.1
Internal clock: No battery backup.

A Real-time clock that maintains accurate time of A capacitor provides power for up to 3 days
diagnostic logs during a power down condition.
EMC
Noise emission to EN 55022: Class of an industry environment
Noise immunity to IEC 1000-4-2 (ESD): Judgement criterion B
Noise immunity to IEC 1000-4-4 (Burst): Judgement criterion B
Noise immunity to IEC 1000-5-5 (Surge): Judgement criterion B
Serial Interfaces for PPC-R22.1

Programming port (X10): RS-232 (D-sub, 15pin, female)
RS-485 (D-sub, 15pin, female)
Communication port (X16): RS-232 / RS-422 / RS-485 (D-sub, 15pin, female)
Supply Voltage, Digital I/O and Watchdog

Power is supplied to the PPC-R22.1 through the X1 Phoenix connector.
X1 Pin Assignment on PPC-R22.1
Pin Signal Description

1 Digital Output 1 (Q1)
2 Digital Output 2 (Q2)
3 Digital Input 1 (I1)
6 24 V external
7 GND external
8 BB relay (Watchdog)
9 BB relay (Watchdog)
10 24 V (control supply voltage)
11 GND
Table 4-1: X1 Pin Assignment
Power Supply Voltage for PPC-R22.1

Faultless operation of the PPC-R22.1 requires the supply voltage to fulfill
the following criteria:
• The supply voltage must never drop below +20VDC. If this occurs, a
POWER-FAIL signal will become active and shutdown the
motion/logic.
Note: The power supply unit used with the PPC-R22.1 should be a
switching power supply with an inrush current as high as 20 A.
Do not connect another PPC-R22.1 unit to the same supply
voltage. The high inrush current may cause the supply voltage
to breakdown and activate the POWER-FAIL signal.
PPC_R_power.FH7
Fig. 4-4: PPC-R22.1 Power Supply Voltage
Digital Input / Output Supply Voltage for PPC-R22.1
PPC_R_IO.FH7
Fig. 4-5: Digital Input / Output Supply Voltage
Note: The digital inputs and outputs found on connector X1 of the

PPC-R22.1 are not functional unless 24V are supplied to pins
6 and 7. Digital inputs I1, I2 and I3 are mapped the bits 1, 2,
and 3 of register 44. Digital outputs Q1 and Q2 are mapped
the bits 1 and 2 of register 45.
Bb Watchdog Contact
The Bb contact on connector X1 is provided as an signal to an external
device or circuitry that the control is no longer in operating mode (Sercos
phase 4). The Bb contact opens and closes under the following
conditions:
Bb Contact Opens:
• Reboot of control from either bootloader, downloading a project, or
from a runtime system reboot command.
• Control is place in pROBE
• Clear flash memory command C-0-0996
• Switch from Sercos phase 4 to Sercos phase 2
• Task watchdog (internal) error
Bb Contact Closes:
• Successful initialization into Sercos phase 4
Optional EtherNet Onboard

The PPC-R22.1 can be ordered with an optional 10/100 MBaud EtherNet
interface residing onboard. The connection is located on the bottom of
the control. This EtherNet connection can be used for standard TCP/IP
networking communication and/or as an EtherNet/IP fieldbus slave
interface.
The TCP/IP stack enables the EtherNet interface to transmit data over a
network or Internet and communicate with VisualMotion Toolkit via the
DDE or OPC servers.
EtherNet/IP is an open network using the standard EtherNet IEEE 802.3,
TCP/IP protocol, and CIP (Control and Information Protocol), the same
real-time I/O and information protocol used by DeviceNet and ControlNet.
Note: When using EtherNet/IP in a VisualMotion 10 system, no other

fieldbus slave interface card (i.e., Profibus, DeviceNet,
ControlNet, Interbus) can be installed.
EtherNet Network Access Port

The EtherNet network access port is used to connect to a LAN by using a
standard RJ-45 cable.
EtherNet Network Security

The assignment of an IP address and Internet security against unwanted
access is the sole responsibility of the customer's Information Technology
department. Control data is not encrypted, nor do we have access or
security levels for it. It is recommended to isolate the control's network by
using a router as well as a hardware firewall for any portion of the network
accessible to an Internet connection.
EtherNet Diagnostics
The EtherNet interface has a green LED (H3) located above the compact
flash memory card. It allow diagnosis of the communication between the
EtherNet interface and the control.
EtherNet and EtherNet/IP Specifications

Hardware
Description Description
Performance - max. baud
10/100 MBaud
rate
Full Duplex support YES
Auto negotiation support YES
Operating Temperature 0 – 55 °C (32 – 131 °F)
Table 4-2: EtherNet and EtherNet/IP Hardware
EtherNet Firmware
Description Details
Slave type TCP/IP Server
Message type TCP/IP message using SIS
Port address 5001
Table 4-3: EtherNet Firmware
EtherNet/IP Firmware
Description Details
Slave type Level 2 I/O server
Message types TCP/IP Msg for VisualMotion (9 sockets),
TCP port address 5001
Polled I/O (1 socket), UDP port address 44818
Explicit Msg (2 sockets), TCP port address 44818
Polled I/O Capacity 64 bytes input / 64 bytes output
Request Packet Interval 5ms
minimum
Table 4-4: EtherNet/IP Firmware
Note: An EtherNet/IP configuration file (*.eds) is available in the

VisualMotion 10 installation CD.
Certification
Description Details
Certification CE Marked
Table 4-5: EtherNet Certification
4.2 PPC-P11.1 (PCI-Version) Overview

The PPC-P11.1 control can be used with VisualMotion's GMP 10
firmware and is designed to plug directly into a PC's PCI slot. The card
supports the "plug-and-play" feature, so memory allocation on the host
PC is assigned dynamically. No jumper settings are required for memory
allocation. A second optional interface card is available containing digital
inputs, digital outputs, and a communication port.
PPC_P_list.FH7
Fig. 4-6: PPC-P11.1 Control
PPC-P11.1 Hardware
Note: Refer to section 10.2 for a complete listing of available

configurations for the PPC-P11.1 motion/logic.
• PC bus connection
– PCI, 32-bit @ 33Mhz
• Supported interfaces (optional with additional front faceplate)
– Option Card Programmable Limit Switch (NSW01)
• 1-digit 7-segment display
• I/O Support
– Drive-based
– Sercos Reco 02
• 32 Mb compact flash memory card (U1)
• Sercos interface for up to 40 drives

• Two serial interface ports available with a software selectable baud
rate of 9600 to 115200 (Default: 9600)
– One serial interface port on main front faceplate
nd
– 2 serial interface is only available with the SUP-E01-PPC-P11
Note: The standard RS-232 interface cable used for connecting to

VisualMotion Toolkit, via a 9 pin PC COM port, is the IKB0005.
• Additional interfaces
– Option Card Programmable Limit Switch
– Encoder Interface Card (MEC)
• 32 MB compact flash memory card (U1)
• Sercos Interface (8 or 16 MBaud)
PCI Hardware Requirements

The following requirements should be met to ensure proper operation of
the PPC-P11.1 control card.
• PC with PCI Specification 2.2 (PCI Specification 2.1 also works if the
PC is capable of providing the proper 1400 mA current for the 3.3V)
• 3.3V and 5V supplies are required to operate the PPC-P11.1. If there
are PC104 cards on-board, the 12V supply is also required (provided
on the PCI bus)
• Dimensions: Short board with fixed height: Length 6.875 in (175 mm);
Height 4,2 in (107 mm)
• In systems with a shared ISA/PCI slot, only one card can be used
(either an ISA or the PPC-P11.1 card)
• 1 PC serial port is required for communication using DOLFI and
VisualMotion
Soft/Slot PLC Interface to PPC-P11.1

The following hardware and software requirements are used when
combining the PPC-P11.1 with a Soft or Slot PLC card.
Hardware Requirements:
• Intel based Pentium Processor with 2 available PCI-Slots
• Bosch Rexroth PPC-P11.1 motion card with GMP09vRS firmware
• Slot PLC and associated hardware / cabling (Not required for soft PLC
interface)
Software Requirements:
• Windows NT 4.0; SP6 minimum
• VisualMotion 09vRS
• PLC programming and communications software or Soft PLC
programming and tool package
• Recommended: VenturCom RTX Version 4.3.2 Run-Time
Environment
PPC-P11.1 Specifications
General Specifications for PPC-P11.1
Mounting style: Standard PC PCI bus "short card"

Humidity: 5 – 78 %, no condensation (operating)
5 – 95 %, no condensation (transport)
DIN 40 040 Class F
Atmospheric pressure: 860 … 1080 hPa, 1500 m
Ambient operating temperature: 0 … 45 °C (32 … 113 °F), DIN 40 040 Class KV
Storage and transport temperature: –20 … 70 °C (-4 … 158 °F)
Supply Voltage for PPC-P11.1
Power requirements: 3.3V @ 1400 mA **

+5V @ 450 mA
+12V @ 0 mA *
* 12 V supply is routed to PC104 expansion connector. 0 mA are present when no PC104 boards are connected.
** If insufficient current is provided to the PPC-P11.1, the H1 (7 segment) LED may either display nothing or a small
dot. If this occurs, verify that the PC's motherboard provides the proper voltages and currents.
Bb Contacts and Digital I/O for PPC-P11.1
Bb contacts: U = 24V , Imax = 150 mA

Digital Input (Q1, Q2): Current draw, isolated
Vi,Low = 0V …5V: Vi,High = 15V …30V
Digital Output ( I1, I2, I3 ): Current rating = 0.5 A, isolated
Response (delay) time = 400 µs max.
Serial Interfaces for PPC-P11.1
Programming port (X10): RS-232 / RS-485 (D-sub, 15 pin, female)

Communication port (X16): RS-232 / RS-485 (D-sub, 15 pin, female)
Supply Voltage, Digital I/O

Power for the PPC-P11.1 is supplied over the PCI bus.
X5 Pin Assignment on PPC-P11.1

1 Bb relay (Watchdog)
2 Bb relay (Watchdog)
X4 Pin Assignment on SUP-E01-PPC-P11

4 Digital Output (Q1)
5 Digital Output (Q2)
6 24V external
7 GND external
Digital Input / Output Supply Voltage for PPC-P11.1
PPC_P_IO.FH7
Fig. 4-7: Digital Input / Output Supply Voltage
Note: The digital inputs and outputs found on connector X4 of the

SUP-E01-PPC-P11 are not functional unless 24V are supplied
to pins 6 and 7. Digital inputs I1, I2 and I3 are mapped the bits
1, 2, and 3 of register 44. Digital outputs Q1 and Q2 are
mapped the bits 1 and 2 of register 45.
Installation Guidelines for PPC-P11.1

The PC board on the PPC-P11.1 is mounted to the right of the front
faceplate, when viewed from inside the PC (standard PCI mounting).
Optional interface cards from Bosch Rexroth have a small board mounted
to the left of the front faceplate (standard ISA mounting). Refer to Fig. 4-8
for details.
board_mount.FH7
Fig. 4-8: PC Board mounts to Front Faceplate
When installing the PPC-P11.1 with optional interfaces, such as Link Ring
and/or Option Card PLS, the optional interfaces are installed to the left of
the PPC-P11.1 (viewed from inside PC). The optional interfaces are
installed to the left to allow connection of the PC104 card (from each
interface) to the PPC-P11.1.
Note: Only one PPC-P11.1 card can be installed in a PC. Only one
PCI bus address is supported for the PPC-P11.1.
Improper installation of PCI and ISA cards in the

PC can cause unwanted contact between
boards!
CAUTION ⇒ Install cards to allow sufficient space between
adjacent boards.
Recommended Installation
When installing a PCI card, such as a fieldbus interface card for a soft
PLC, in conjunction with the PPC-P11.1 and optional interfaces, the PCI
card should be installed to the right of the PPC-P11.1 (refer to Fig. 4-9).
This configuration allows sufficient space between the PPC-P11.1 and
PCI cards.
Note: If no optional interface cards are installed with the PPC-P11.1,

then the PCI card can be installed either to the left or the right
of the PPC-P11.1.
mount_ppcp.FH7
Fig. 4-9: Recommended Installation of PPC-P11.1 Configurations
4.3 Serial Communication

Two serial port interfaces are available on the PPC-R22.1. The PPC-
P11.1 card has one serial interface with a second serial interface
available on an optional secondary faceplate.
Note: Refer to chapter 10 for a complete listing of available

configuration for both the PPC-R22.1 and PPC-P11.1.
Each serial port can be setup using VisualMotion Toolkit. Both ports
always operate with 8 bit, 1 stop bit and no parity. Select
Tools ⇒ Control Settings, click on X10 or X16 and configure each port
as follows:
Baud rate options: 9600 to 115200 Baudrate options: 9600 to 115200
Mode options: Mode options: Type:

RS232 (default) RS232 (default) Off
RS422 RS422 Standard Host
RS485 RS485 Teach Pendant
Reserved
Password Protection: IndraLogic
Disable SysLibCom
Read/Write
Read only Password Protection:
Disable
Read/Write
Read only
PPC_R_serial.tif
Fig. 4-10: VisualMotion Toolkit communication settings
Serial Interface Pin Assignment

The two interface ports, PROG (X10) and COM (X16) have the following
pin assignments.
Pin Signal Pin Signal

1 Protected Ground – not used 9 Transmit Data + for RS422
2 Transmit Data for RS232 10 Ground
3 Receive Data for RS232 11 Transmit Data – for RS422
4 RS485+ / Receive Data + for RS422 12 +5V
5 RS485- / Receive Data – for RS422 13 Request To Send
6 Data Set Ready 14 Clear To Send
7 Signal Ground 15 Data Terminal Ready
8 Data Carrier Detect
Table 4-8: Pin Assignment for PROG Interface X10 and COM Interface X16.
4.4 PPC Diagnostic Displays

The PPC-R22.1’s 4-digit alphanumeric matrix display (H1) alternates
between motion and Integrated PLC diagnostic messages. Motion
related diagnostic message are stored in control parameters C-0-0122,
while Integrated PLC diagnostic message are stored in C-0-1612.
The PPC-P11.1's single-digit 7-segment alphanumeric LED displays one
digit at a time. The display will flash the diagnostic code for motion, flash
a "P", then flash the Integrated PLC diagnostic code.
Control Status and Settings on H1 Display

The PPC-R H1 display provides additional control status and settings that
can be retrieved by pressing the S1 push button on the control. The
following table list all of the available displays:
# of Times
pressing S1 Description Parameter
0 Motion and Integrated PLC status C-0-0122 & C-0-1612
messages
1 Firmware version C-0-0100
2 NVRam backup status Register 21, bit 16
(valid or NOT valid)
3 X10 programming port mode C-0-0013
(RS232, RS422, RS485)
4 X10 programming port baud rate C-0-0003
(9600, 19.2K, 38.4K, 57.6K, 115.2K)
5 X16 programming port mode C-0-0014
(RS232, RS422, RS485)
6 X16 programming port baud rate C-0-0004
(9600, 19.2K, 38.4K, 57.6K, 115.2K)
7 IP Address C-0-0400
8 Control Address C-0-0002
Table 4-9: Control Status and Settings on H1 Display
Error Codes
When an error is encountered by the PPC, the display automatically
displays an “E“, indicating an error, followed by the corresponding 3 digit
diagnostic code. The PPC-R22.1 will display the error type following the
code. The PPC-P11.1 will only display the code.
Code Error Type

E200 – E399 Warning
E400 – E999 Shutdown Error
PF Power Failure
.. Probe
Table 4-10: Error Codes
Refer to the VisualMotion 10 Troubleshooting Guide for a complete listing

of error codes and messages.
4.5 Compact Flash Memory Cards

All data necessary to operate the control is stored on the PFM01.1
compact flash memory card and on the onboard NVRam memory. The
NVRam is a non-volatile memory chip mounted on the hardware.
Control Data on Compact Flash

The following control data is stored on the compact flash memory card:
Firmware:
• GPP 10 firmware for the PPC-R22.1, or
• GMP 10 firmware for the PPC-P11.1
File system:
• VisualMotion user programs
• Cams, points, event and zone tables
• Option Card PLS parameter lists
• Program variables
• I/O configurations (Local, Sercos RECO and drive-based)
Control Data on NVRam

The following control data is stored on the NVRam memory:
File System Allocation Table:
• logical mapping of file system data
Currently Active Program Data:
• program variables
System Parameters:
• control, task, and axis
NVRam and Compact Flash Backup Commands

In the event that control hardware must be replace, the contents of
NVRam (non-volatile data) and compact flash must be valid in order to
ensure portability of control data to the new hardware. VisualMotion
provides backup commands for both the NVRam and compact flash.
These backup commands can be preformed by writing directly to the
parameters listed in the following sections or from VisualMotion Toolkit
under menu selection Commission ⇒
Archive ⇒
Other…
NVRam Backup
The following parameters are used to backup the contents of the NVRam
to the compact flash:
Parameter Description
C-0-0170 NVRam backup command
C-0-0171 NVRam backup status
Table 4-11: NVRam Backup Parameters
Note: NVRam restore functionality is not required. During power up,

the NVRam is restored automatically from flash if a difference
is detected between the current NVRam content and the
backup copy in flash.
Compact Flash Backup

For controls using a 32 MB or greater compact flash card, the following
parameters divide the compact flash memory into two equal parts and
creates a complete backup of the compact flash including the NVRam.
C-0-0172 Compact flash backup command
C-0-0173 Compact flash backup status
Table 4-12: Compact Flash Backup Parameters
Compact Flash Restore

The following parameters are used to restore the contents of a compact
flash backup:
C-0-0174 Compact flash restore command
C-0-0175 Compact flash restore status
Table 4-13: Compact Flash Restore Parameters
4.6 System Grounding

Each electronic component within an enclosure (controls, drives, etc.)
should be grounded individually to a central grounding point on the
machine as per Fig. 4-11. To ensure proper grounding of control system,
use a ground wire of at least 10 mm² (8 American Wire Gauge). Voltage
supply grounding should also be performed in the same manner.
sys_ground.FH7
Fig. 4-11: System Grounding
Rexroth VisualMotion 10 Project Planning System I/O Modules 5-1
5 System I/O Modules
5.1 PPC-R22.1 Motion Control System

When a PPC-R22.1 is used as a stand-alone control, it is installed in the
left most slot of an RMB rack. This slot is identified as slot 00. The
device installed in slot 00, in this case the PPC-R22.1, controls all
backplane communication of installed LocalReco 02 I/O modules.
LocalReco 02 modules are defined as I/O modules that are installed
either on the same RMB rack as the control or as I/O modules installed in
an adjacent RMB rack. Two adjacent RMB racks communicate via the
local bus connection created between two racks, up to a maximum of 4
RMB racks.
In addition to LocalReco I/O modules, the PPC-R22.1 can also
communicate, via Sercos, with Rexroth Inline, SercosReco racks, and
drive I/O cards.
PPC_motion system.FH7
Fig. 5-1: PPC-R22.1 Motion Control Configuration
5-2 System I/O Modules Rexroth VisualMotion 10 Project Planning
5.2 Supported I/O Devices
Sercos Inline I/O Hardware

Sercos Inline is a Sercos based I/O module system that provides the user
with greater flexibility in I/O configurations. Rexroth Inline modules are
stacked on to a Sercos coupler (R-IL-SE-BK). A maximum of six (6)
Sercos couplers can be on the Sercos ring. Each Sercos coupler can
hold a maximum of 40 Rexroth Inline modules as long as the total number
of bytes per Sercos coupler does not exceed 32 bytes for input data and
32 bytes for output data.
Refer to Sercos I/O Configuration Limits on page 5-10 for details.
The following arrangements are strongly recommended for optimal
performance:
• I/O module blocks should be attached to the Inline Sercos coupler
sequentially from left to right in the following order: Analog Outputs,
Digital Outputs, Analog Inputs, Digital Inputs.
• I/O modules should be arranged depending on the data length, i.e.
modules with the larger data length should be placed in the first slot
position, modules with the lowest data length in last slot position.
Refer to the Rexroth Inline Overall View manual DOK-CONTRL-R-

IL*INLINE-KB02-EN-P (MN R911292649) and the Sercos Terminal and
Module Supply project planning manual, DOK-CONTRL-R-IL-SEBK**-
PR01-EN-P for details.
Rexroth Inline I/O Update Calculation

The I/O update rate for Rexroth Inline I/O configurations is slower than it
is for SercosReco I/O modules. As a general rule, the update time for
Rexroth Inline I/O configurations can be calculated using the following
formula:
Update Time = (2 * Sercos Update Rate) + Max[ (Total Bytes / 2), 6 ]
If the calculation (Total Bytes / 2) is less than 6, then use 6 bytes as a

Max value.
Fig. 5-2: Rexroth Inline I/O Update Calculation
Update Time = time (in ms) for a signal change to a given Inline IO
update module to reach the actual VisualMotion register for which it is
defined.
Sercos Update Rate = value (in ms) of the Sercos Update as defined in
C-0-0099.
Total Bytes = total number of data bytes (for both input and output
direction) used within the Sercos Inline module.
Note: Additional time could also be considered for individual module

behavior (A->D conversion for analog modules, latency delays,
etc.). However, in most cases the bulk of the Update Time
calculation is taken in to account in the formula mentioned
above.
For example:
With an Inline I/O configuration using 2 bytes of input and 2 bytes of
output and a Sercos update rate of 2 ms, an Update Rate of 10 ms or
more can be expected. With additional I/O, inclusion of analog modules,
etc. this time will increase.
In contrast, the Sercos Reco IO (RMK) has a considerably faster update
time. In the same scenario, the update time would be 4ms for the RMK
system.
Refer to the relevant Rexroth Inline Terminal functional description for
details.
Rexroth Inline Digital I/O Modules

The following tables list the available digital modules supported in
VisualMotion 10:
Digital Module Description Material Number

R-IL-SE-BK Sercos coupler - use with supply connector R911296696
R-IB IL SCN-PWR IN-CP (MN R911289328)
R-IB IL 24 DI 2 2 bit - 24V digital input R911289286
R-IB IL 24 DI 32/HD 32 bit - 24V digital input R911297188
R-IB IL 24 DO 2-2A 2 bit - 24V digital output R911289294
R-IB IL 24 DO 4 4 bit - 24V digital output R911289295
R-IB IL 24/230 DOR1/W 1 digital output / 230 VAC / relay R911289301
R-IB IL 24/230 DOR4/W 4 digital outputs / 230 VAC / relay R911289302
R-IB IL 24 EDI 2-DES 2 digital inputs / 2 monitoring inputs / 24 VDC R911289292
Table 5-1: Rexroth Inline Digital Modules
RecoInlineDig.tif
Fig. 5-3: Rexroth Inline Digital Modules
Refer to the Rexroth Inline Digital I/O Terminal functional description,

DOK-CONTRL-R-IL*DIO***-FK03-EN-P (MN R911289589) for details.
Rexroth Inline Analog I/O Modules

The following tables list the available analog modules supported in
VisualMotion 10:
Analog Module Description Material Number

R-IB IL 24 AI 2/SF 4 byte input / 4 byte output 24V analog input R911289306
R-IB IL TEMP 2 RTD 4 byte input / 4 byte output analog input R911289305
R-IB IL 24 AO 1/SF 2 byte input 24V analog output R911289303
R-IB IL 24 AO 2/U/BP 4 byte input / 4 byte output 24V R911289381
Table 5-2: Rexroth Inline Analog Modules
RecoInlineAna.tif
Fig. 5-4: Rexroth Inline Analog Modules
Refer to the Rexroth Inline Analog Terminals functional description,

DOK-CONTRL-R-IL*AIO***-FK02-EN-P (MN 911289591) for details.
Rexroth Inline Fieldbus Couplers

The following tables list the available fieldbus couplers supported in
VisualMotion 10 that can be used with the Rexroth Inline I/O modules:
Fieldbus Coupler Description Material Number

R-IL PB BK Profibus coupler R911289283
use with supply connector R-IB IL SCN-PWR IN-CP (MN R911289328)
R-IL DN BK DeviceNet coupler R911289284
use with supply connector R-IB IL SCN-PWR IN-CP (MN R911289328)
Table 5-3: Rexroth Inline Fieldbus Couplers
Refer to the Design and Installation of Reco Inline Module family in

Profibus DP manual, DOK-CONTRL-R-IL*PBSSYS-AW02-EN-P
(MN R911289597) for details.
Rexroth Reco 02 I/O Modules

Reco 02 defines a form factor for controllers and I/O modules from Bosch
Rexroth. Reco I/O modules are installed directly in a RMB four slot rack
unit and provide I/O data to the PPC-R22.1 controller via the RMB’s back-
plane.
A maximum of four RMB racks can be connected and mounted side by
side. Each rack contains an addressing DIP switch for configuring the
order of installation as illustrated in Fig. 5-8.
Refer to the Rexroth Reco 02 Configuration manual for details.
A control system is composed of:
• a Reco 02 RMB base rack unit
• PPC-R22.1 controls using GPP firmware
• and a combination of RME, RMA I/O and RMC modules
LocalReco 02 I/O Station

The PPC-R22.1 control is physically installed into a RMB02.2 rack
designed to hold the control along with Reco 02 I/O modules. RMB02.2
racks are a 4 slotted mounting platform that provide power and backplane
communication to installed modules. The control can use up to 2 slots
(PPC-R22.1) leaving the remaining slots available for I/O modules. The
I/O modules that plug into the same rack as that of the control are
identified as LocalReco 02 I/O modules. Any additional RMB02.2 rack
(maximum of 4) containing I/O modules connected directly to the control's
rack is also identified as LocalReco 02 I/O modules. LocalReco 02 I/O
modules are automatically detected by the control and identified in control
parameter C-0-2013 (I/O Configuration List). The assignment of registers
for LocalReco I/O modules is done using the I/O Setup Tool.
local_reco.FH7
Fig. 5-5: LocalReco 02 I/O Station
SercosReco I/O Station

A SercosReco I/O station is a RMB rack configured with a Sercos RMK
I/O Controller and up to 3 Reco 02 I/O modules connected to the control
via a Sercos ring. Up to 3 additional RMB racks can be configured and
connected to the RMB containing the RMK Sercos coupler. A maximum
of 6 Sercos couplers can be on the Sercos ring. Each Sercos coupler
can hold a maximum of 15 Reco 02 I/O modules.
REC
X X X X X X X
1 I*.3.0 1 I*.3.0 1 1 Q*.3.0 1 Q*.3.0
8
2 I*.3.1 2 I*.3.1 2 Q*.3.1 2 Q*.3.1
3 3 2 Q*.1.0 3 3
H I*.3.2 I*.3.2 Q*.3.2 Q*.3.2
4 I*.3.3 4 I*.3.3 3 4 Q*.3.3 4 Q*.3.3
DIA 5 I*.3.4 5 I*.3.4 4 Q*.1.1 5 Q*.3.4 5 Q*.3.4
1 I*.1.0 6 I*.3.5 6 I*.3.5 1 Q*.1.0 6 Q*.3.5 6 Q*.3.5
5
2 3 2 3
2 I*.1.1 7 I*.3.6 7 I*.3.6 2 Q*.1.1 7 Q*.3.6 7 Q*.3.6
I*.3.7 I*.3.7 6
0 1
0 1
8 8 Q*.1.2 8 8
4
Q*.3.7 Q*.3.7
5 6
5 6
9
3 Q*.1.2
9
8 7 8 7
3 I*.1.2 9 0V 9 0V 7 9 +U 9 +U
DEVICE- 4 I*.1.3 4 Q*.1.3 10 0V 10 0V
8 Q*.1.3
5 I*.1.4 5 Q*.1.4
X X 9 X X
6 I*.1.5 6 Q*.1.5
MO 1 I*.2.0 1 I*.2.0 1 Q*.1.4
1 Q*.2.0 1 Q*.2.0
7 I*.1.6 2 I*.2.1 2 I*.2.1 7 Q*.1.6 2 Q*.2.1 2 Q*.2.1
1 3 3
8 I*.1.7 3 I*.2.2 3 I*.2.2 8 Q*.1.7 Q*.2.2 Q*.2.2
< 15
1 4 I*.2.3 4 I*.2.3 1 Q*.1.5 4 Q*.2.3 4 Q*.2.3
15 - 30 9 0V 9 +U
5 I*.2.4 5 I*.2.4 5 Q*.2.4 5 Q*.2.4
2
> 30 1
1 0V
3
1 +U 6 Q*.2.5 6 Q*.2.5
4
GLA 6 I*.2.5 6 I*.2.5 1 Q*.1.6 7 Q*.2.6 7 Q*.2.6

LWL 7 I*.2.6 7 I*.2.6 1 0V
8 I*.2.7 8 I*.2.7 1 8 Q*.2.7 8 Q*.2.7
1 0V
SERC 9 0V 9 0V 1 Q*.1.7 9 +U 9 +U
10 0V 10 0V
X R X X X X X2 X X
1 I*.1.0 1 I*.1.0 1 1 Q*.1.0 1 Q*.1.0
2 I*.1.1 2 I*.1.1 2 Q*.1.1 2 Q*.1.1
2 Q*.0.0
3 I*.1.2 3 I*.1.2 3 Q*.1.2 3 Q*.1.2
4 I*.1.3 4 I*.1.3 3 4 Q*.1.3 4 Q*.1.3
5 I*.1.4 5 I*.1.4 4 Q*.0.1 5 Q*.1.4 5 Q*.1.4
1 I*.0.0 6 I*.1.5 6 I*.1.5 1 Q*.0.0 6 Q*.1.5 6 Q*.1.5
5
2 I*.0.1 7 I*.1.6 7 I*.1.6 2 Q*.0.1 7 Q*.1.6 7 Q*.1.6
8 I*.1.7 8 I*.1.7 6 Q*.0.2 8 Q*.1.7 8 Q*.1.7
X T 3 I*.0.2 9 9 3 Q*.0.2
0V 0V 7 9 +U 9 +U
4 I*.0.3 4 Q*.0.3 1 0V 1 0V
8 Q*.0.3
5 I*.0.4 5 Q*.0.4
X X 9 X X
6 I*.0.5 1 I*.0.0 1 I*.0.0 6 Q*.0.5 1 Q*.0.0 1 Q*.0.0
1 Q*.0.4
7 I*.0.6 2 I*.0.1 2 I*.0.1 7 Q*.0.6 2 Q*.0.1 2 Q*.0.1
3 I*.0.2 3 I*.0.2 1
8 I*.0.7 8 Q*.0.7 3 Q*.0.2 3 Q*.0.2
4 I*.0.3 4 I*.0.3 1 Q*.0.5 4 Q*.0.3 4 Q*.0.3
9 0V 5 5 9 +U Q*.0.4 Q*.0.4
I*.0.4 I*.0.4 1 5 5
1 +24VD 1 0V 6 I*.0.5 6 I*.0.5 1 +U 6 Q*.0.5 6 Q*.0.5
1 Q*.0.6
2 0V 7 I*.0.6 7 I*.0.6 1 0V 7 Q*.0.6 7 Q*.0.6
8 I*.0.7 8 I*.0.7 1 8 Q*.0.7 8 Q*.0.7
3 0V 1 0V
9 0V 9 0V 1 Q*.0.7 9 +U 9 +U
4 1 0V 1 0V
RMK02.2-LWL-SER RME02.2-16-DC024 RME02.2-32-DC024 RME02.2-32-DC024 RMA02.2-16-AC230- RMA02.2-16-DC024- RMA02.2-32-DC024- RMA02.2-32-DC024-
RMK RECO RECO

SERCOS Modules Modules
Unit
remote_reco.FH7
Fig. 5-6: Sercos I/O Stations
Reco 02 I/O Hardware

Reco 02 I/O modules can be combined in any order beginning with the
next available adjacent slot next to the PPC-R22.1.
Description Type Details Material

Number
RMB02.2-04 Base rack, 4 slots accommodates up to 4 modules R911278846
RME02.2-16-DC024 Input module 2 x 8 inputs, 24 VDC R911280936
RME02.2-32-DC024 Input module 4 x 8 inputs, 24 VDC R911280937
RME02.2-32-AC115 Input module 2 x 8 inputs, 115 VAC R911280938
RMA02.2-16-DC024-200 Output module 2 x 8 outputs, 24 VDC, 2A R911280930
RMA02.2-32-DC024-050 Output module 4 x 8 outputs, 24 VDC, 500mA R911280931
RMA02.2-16-AC230-200 Output module 2 x 8 outputs, 230 VDC, 2A R911280929
RMA02.2-16-RE230-200 Output module 2 x 8 relay outputs, 230 VAC, 2A R911280928
RMC02.2-2E-1A Analog module analog module 2 x inputs, 1 x output R911280945
Table 5-4: Reco 02 I/O Module Overview
Reco Sercos Coupling Unit

Reco 02 I/O modules can be used remotely to the PPC-R22.1. In this
case, a Sercos coupling RMK unit is necessary. The remote Reco 02
rack is then connected via the Sercos ring to the PPC-R22.1.
Description Type Details Material

Number
RMK02.2-LWL-SER-FW Sercos coupling unit Sercos Interface R911280946
Table 5-5: Remote Sercos Coupling Unit
Mounting the Reco RMB Base Rack

The RMB02.2-04 base racks can be mounted onto a TS 35x27x15 DIN
rail, and secured with a set screw. If necessary, the RMB racks can be
mounted directly onto a mounting panel within the cabinet using the holes
provided in the racks.
4 x RMB02.2-04
with a total of 16 module slots for
accommodating the PPC-R and
different RECO02 I/O modules
Word Art
Fig. 5-7: RMB02.2-04 Maximum Configuration
RMB02.2 Rack Slot Addressing

A DIP switch on the rack’s bus board enables up to four (4) RMB02.2-04
racks to be addressed individually. Each rack must have its own unique
address. Number of racks used in a given application should be
addressed as shown in Fig. 5-8.
RMB02.2_Address.FH7
Fig. 5-8: Setting the Reco Rack Addresses
Note: The PPC-R22.1 must be installed in slot 00 of base rack 1.
Diax I/O Module

Diax 03/04 digital drives can hold up to 3 I/O modules. VisualMotion
supports both the digital Dea modules and analog Dae and Drf modules.
Diax_IO.FH7
Fig. 5-9: Diax I/O Modules
EcoDrive EMD I/O Module

EcoDrive 03 digital drives using SGP20 firmware support the EMD I/O
module using the Eco-X bus system.
EMD_Input_Output.FH7
Fig. 5-10: EMD I/O Module
5.3 Configuring I/O Modules

VisualMotion 10 separates the configuring of I/O modules depending on
the level of communication. LocalReco I/O modules are installed in the
same RMB rack as the control and communicate via the rack's
backplane. For this reason, the configuration of such modules is
performed using IndraLogic. On the other hand, SercosReco I/O,
Rexroth Inline, and drive I/O modules all communicate via the Sercos ring
and are configured using VisualMotion Toolkits I/O Setup tool.
Sercos I/O Configuration Limits

The VisualMotion system supports a maximum of 40 Sercos devices,
including both drives and I/O devices. The use of Sercos I/O devices
reduces the number of drives allowed on the Sercos ring.
The maximum number of Sercos and Drive I/O that can be configured for
one control is 240 inputs and 240 outputs.
SercosReco and Inline Limits A total of 6 Sercos I/O devices of type RMK and/or R-IL-SE-BK can be
configured for a VisualMotion control. The following table lists the
maximum number of modules that can be configured for each Sercos I/O
device:
Sercos I/O Device I/O Type Max. Number per Device

RMK Reco 02 15 Modules
R-IL-SE-BK Rexroth Inline 40 Modules *
* 40 modules are possible if the total I/O length is not greater than 32 bytes in
each direction.
Table 5-6: Sercos I/O Limits
Drive I/O Limits The following table lists the maximum number of Sercos I/O cards that
can be configured for a Rexroth digital drive:
Drive Type I/O Type Max. Number of I/O Modules

Diax 04 Dea I/O Cards Up to 3 I/O cards per drive
EcoDrive 03 EcoX I/O Up to 2 Inputs and 2 Outputs per drive
Table 5-7: Drive I/O Limits
Accessing Rexroth Inline I/O Modules

Rexroth Inline I/O modules are accessed via user defined VisualMotion
registers. The assignment of registers is performed using the I/O Setup
tool. Rexroth Inline modules should only be assembled while the Rexroth
Inline Sercos coupler is powered down.
Note: A valid Rexroth Inline configuration can only be detected and

displayed in the I/O Setup tool when the Sercos coupler,
attached to the Rexroth Inline modules, is connected to the
Sercos ring and VisualMotion Toolkit is in online mode.
VisualMotion register bits are assigned to the Rexroth Inline signal input
row (non-colored row), from left to right. The following figure shows an
example of the register bit order for an 8 bit digital module.
Example Register Assignment to Rexroth Inline Module
D08.FH7
Fig. 5-11: Rexroth Inline Bit Order
Refer to the I/O Setup Tool in chapter 7 of the VisualMotion 10 Functional

Description manual for details.
Accessing Reco 02 I/O Modules

Local Reco 02 I/O modules are addressed in the I/O image of IndraLogic.
SercosReco 02 I/O modules are assigned to VisualMotion registers. The
labeling of Reco 02 modules is illustrated in Fig. 5-12.
Note: This section only covers the accessing of SercosReco 02 I/O

modules. For accessing Local Reco, refer to Configuring
Local Reco 02 I/O modules with IndraLogic in chapter 7 of the
VisualMotion 10 Functional Description.
reco_label.FH7
Fig. 5-12: Reco 02 Bit Label
Reco 02 16-Bit I/O Modules

The RME02.2-16 (Input) and RMA02.2-16 (Output) modules each use 1
VisualMotion register for accessing their respective 16 bits. The lower 8
VisualMotion register bits are assigned to the lower connector X2 (Byte 0)
and the upper 8 bits are assigned to the upper connector X1 (Byte 1).
Reco 02 32-Bit I/O Modules

The RME02.2-32 (Input) and RMA02.2-32 (Output) modules each use 2
VisualMotion registers for accessing their respective 32 bits. The first
VisualMotion register (n) is assigned to the lower two connectors (X3 and
X4). The second adjacent VisualMotion register (n+1) is assigned to the
upper two connectors (X1 and X2). Bit distribution of each register is
similar to that of the 16-bit input module.
Note: A VisualMotion register is equivalent to 2 Bytes or 1 Word.

Each Reco 02 module connector is identified as a Byte. Reco
02 module connectors begin at Byte 0 (lowest connector) up to
Byte 3 (in the case of a 32-bit module with 4 connectors).
The bits on a Reco 02 module are labeled from 0-7 for the
lower Byte and 0-7 for the upper Byte. VisualMotion assigns
bit numbers 1-8 for the lower Byte and 9-16 for the upper Byte.
Fig. 5-13 illustrates the labeling structure of a Reco 02 Input or Output

module and the relationship to VisualMotion assigned register bits.
VisualMotion n Register Definition

This section makes mention of a (n) register and a (n + 1) register.
During the configuration of Reco 02 I/O modules, a slot number is used to
identify the module as well as the register number that will be assigned to
the inputs or outputs, if applicable.
The Number assigned to the input or output is considered the (n) register.
The (n + 1) register is the next adjacent register number assigned to 32-
Bit Reco 02 modules. 16-Bit modules only use one register (n).
For example,
If register 400 is assigned to the inputs of a Reco 02 I/O module, register
401 is the (n + 1) register.
RECO02 16-Bit RECO02 32-Bit

I/O Module I/O Module
VisualMotion Register (n + 1)
Upper Byte Access
RECO Bit VisualMotion Bit
X1 X1 Designation Designation
VisualMotion Register (n) I=Input / Q=Output 1 I*.3.0 3.0 09
Upper Byte Access 2 I*.3.1 3.1 10
Byte (0,1,2 or 3)
3 I*.3.2 3.2 11
RECO Bit VisualMotion Bit Bit (0-7) 4 I*.3.3
Designation Designation 3.3 12
5 I*.3.4 3.4 13
1.0 09 1 Q*.1.0 6 I*.3.5 3.5 14
1.1 10 2 Q*.1.1 7 I*.3.6 3.6 15
8 I*.3.7
1.2 11 3 Q*.1.2 3.7 16
9 0VL
1.3 12 4 Q*.1.3 Lower Byte Access
5 Q*.1.4 RECO Bit VisualMotion Bit
1.4 13 X2 Designation Designation
1.5 14 6 Q*.1.5 1 I*.2.0 2.0 01
1.6 15 7 Q*.1.6 2 I*.2.1 2.1 02
8 Q*.1.7 3 I*.2.2 2.2 03
1.7 16
4 I*.2.3
9 +U 5 I*.2.4
2.3 04
2.4 05
10 +U 6 I*.2.5
2.5 06
11 0V 7 I*.2.6
8 I*.2.7 2.6 07
12 0V 2.7 08
VisualMotion Register (n) 9 0VL
Upper Byte Access
RECO Bit VisualMotion Bit X3
X2
Designation Designation
VisualMotion Register (n) 1 I*.1.0
1.0 09 2 I*.1.1
Lower Byte Access 1.1 10 3 I*.1.2
RECO Bit VisualMotion Bit 1.2 11 4 I*.1.3
Designation Designation 1.3 12 5 I*.1.4
0.0 01 1 Q*.0.0 1.4 13 6 I*.1.5
2 Q*.0.1 1.5 14 7 I*.1.6
0.1 02 1.6 15 8 I*.1.7
3 Q*.0.2
0.2 03 1.7 16 9 0VL
0.3 04 4 Q*.0.3
Lower Byte Access
5 Q*.0.4
0.4 05 RECO Bit VisualMotion Bit X4
0.5 06 6 Q*.0.5 Designation Designation 1 I*.0.0
0.6 07 7 Q*.0.6 0.0 01 2 I*.0.1
8 Q*.0.7 0.1 02 3 I*.0.2
0.7 08 0.2 03 4 I*.0.3
9 +U 5 I*.0.4
0.3 04
10 +U 0.4 05 6 I*.0.5
11 0V 0.5 06 7 I*.0.6
0.6 07 8 I*.0.7
12 0V
0.7 08 9 0VL
RMA02.2-16-DC024-200 RME02.2-32-DC024
Reco 02_16_32.FH7 / Word Art
Fig. 5-13: Reco 02 Digital Input and Output Module Bit Access
RMC02.2-2E Analog Input and Output Module

The RMC02.2 analog Reco 02 module uses 2 VisualMotion registers for
accessing the X1 and X2 input connectors and 1 VisualMotion register for
accessing the X3 output connector. A second VisualMotion register is
used for scaling the output value of X3. The first (n) VisualMotion input
register is assigned to the upper X1 connector. The second (n + 1)
adjacent VisualMotion input register is assigned to the center X2
connector. For output, the lower X3 connector is assigned to the first (n)
VisualMotion output register. The second (n + 1) adjacent VisualMotion
output register is reserved for the output scaling of connector X3. Refer
to the Sercos I/O Unit Reco 02.2 configuration manual for details.
Note: The scaling for the output is done in VisualMotion Toolkit's I/O
Setup Tool when configuring an analog Reco 02 module.
RECO02 Analog
I/O Module
UANALOG
X1
1 IA CONST
The first VisualMotion
input register (n) is
2 IIN
assigned to X1
3 U IIN
4 UI +
5 UI -
6 GND A
7 GND A
8
ANALOG-INPUT 1
X2
1 IA CONST The second VisualMotion
2 IIN input register (n + 1) is
3 U IIN assigned to X2
4 UIN +
5 UIN -
6 GND A
7 GND A
8
ANALOG-INPUT 2
X3
1 IO 0-20mA The first VisualMotion
2 UO ±10V output register (n) is
3 GND A assigned to X3
4 GND A
5
The second VisualMotion
ANALOG-OUTPUT 1 output register (n + 1) is
reserved for scaling of the
RMC02.2-2E-1A
outputs
RMC02_2.FH7 / Word Art
Fig. 5-14: Reco 02 Analog Input and Output Module Bit Access
Reco I/O Error Reaction Bits

Bits 6 and 7 of control parameter C-0-0010 (System Options) are used to
specify how VisualMotion responds to errors reported by Reco I/O
modules. The bit settings are as follows:
Bit 6 Bit 7 Reaction

0 0 Ignore
1 0 Warning
x 1 Fatal Error (default)
Table 5-8: Reco I/O Error Reaction Bits (C-0-0010)
Note: All power connectors on Reco 02 output modules must be

connected to a 24V supply or a “24V Missing” error message
will be displayed in the I/O Setup Tool.
A Generate Fatal Error setting will not allow motion to start
unless each 24V supply is satisfied.
Ignore
The control ignores any errors reported by the Reco I/O modules. This
reaction is selected if the user program is to handle Reco I/O errors. In
this case, the User I/O Configuration tool would be used to map the Reco
I/O modules 32-bit status words to a VisualMotion register, where the
user program can monitor them.
Note: This reaction provides default backwards compatibility to older

versions of GPP firmware that are not capable of directly
responding to Reco I/O errors.
Warning
The control responds to errors reported by the Reco I/O modules by
generating a "215 Reco I/O Failure" warning. This reaction is selected if
the user is to be notified of any Reco I/O errors, while still allowing the
user program to continue executing.
Fatal Error
The control responds to errors reported by the Reco I/O modules by
generating a "544 Reco I/O Failure" error, stopping program execution
and motion. This is the system’s default reaction. This reaction is
selected if the application requires program execution and motion to be
stopped as soon as a Reco I/O error is detected.
Diax Digital I/O Modules

Diax 03/04 digital drives can hold up to 3 Dea I/O modules. The Dea 4.1,
5.1 and 6.1 each requires 1 register for 16 inputs and the 1 register for 15
outputs. The Dea 8.1, 9.1 and 10.1 each requires 2 registers for 32
inputs and 2 registers for 24 outputs. The pin-out for each module is
illustrated in Fig. 5-15.

dea_4_8.FH7
Fig. 5-15: Dea Digital Drive I/O Modules
The following table is an example using registers 405 and 453 as the
assigned registers for the Dea 4.1, 5.1 or 6.1 inputs and outputs.
Register Bits Dea04 Pin-out

405 (Input) 01 - 15 01 - 15
453 (Output) 16 - 31 16 -31
Table 5-9: Dea 04 Digital I/O Pin-out
The following table is an example using registers 406, 407, 454 and 455
as the assigned registers for the Dea 8.1, 9.1 or 10.1 inputs and outputs.
Register Bits Dea08 Pin-out

406 (Input) 01 - 11 01 - 11
406 (Input) 12 - 16 22 - 26
407 (Input) 01 - 06 27 - 32
407 (Input) 07 - 16 43 - 52
454 (Output) 01 - 08 12 - 19
454 (Output) 09 - 16 33 - 40
455 (Output) 01 - 08 53 - 60
Table 5-10: Dea 08 Digital I/O Pin-out
Diax Analog Input I/O Module

Bosch Rexroth digital drives of the Diax 03/04 families can be configured
to hold an analog input module to receive input from a feedback device
for use in a VisualMotion user program. Allowable analog input modules
are…
• Dae 02.1 14-bit analog inputs
dae2_1.FH7
Fig. 5-16: Dae 02.1 Analog Input Module
Configuring EMD I/O Modules for DKC22.3

The EMD module is an expansion I/O module that interfaces with the
DKC22.3 using the EcoX bus system. EcoX communication can be used
by a DKC22.3 drive with an SGP20 module and the appropriate cable.
Within each EcoX bus system, a master drive can have up to two EMD
I/O modules with 16 digital inputs and outputs per module. Additional
master drives, with up to two EMD I/O modules per drive, can be
connected through the Sercos ring, as shown in Fig. 5-17.
System_EMD.FH7
Fig. 5-17: System Configuration with EMD I/O Module
Configuring VisualMotion for EMD I/O Devices with EcoX

Communication
To configure VisualMotion Toolkit for EMD modules:
1. Open the I/O Configuration window by selecting I/O Setup… from the
Commission menu in VisualMotion Toolkit.
2. Highlight I/O Configuration and select Add Sercos Device from the
Edit menu to open the Add Sercos Device window.
3. Select EcoDrive With Eco-X IO Module device type.
4. Accept the Default device type, DKC 22.3 EcoDrive 03, and select a
Sercos address for the drive in the Drive Setup window.
5. Add an I/O module by highlighting the new drive in the I/O
Configuration window and selecting Add I/O Module from the Edit
menu.
6. Select Digital for the drive type (EMD 16 – 16 inputs/16 outputs @

24 VDC will appear in the drop-down window) and select Inputs or
Outputs.
Add_IO_Module.tif
Fig. 5-18: Add I/O Module Window
7. Select the slot number (1 or 2, according to the type of bus

connection) for the EMD I/O module.
Config_EMD.tif
Fig. 5-19: Assigning Registers for EMD Module
8. Assign register numbers to the input and output registers of the EMD
I/O module.
The input and output registers assigned by VisualMotion, coincide with
the inputs and outputs in the gray row on the EMD I/O module, as shown
in Fig. 5-20. The 16 bits of each register are labeled 1 through 16 below
each register in the row.
EMD_Input_Output.FH7
Fig. 5-20: Inputs and outputs on EMD I/O Module
Configuring Drives for Torque Following Mode with

EcoX Communication
For drives configured in torque following mode, EcoX bus can be used
between the master and slave drives. Previously, an analog connection
was used for communication between the master and slave drives.
Torque_Following_Analog.FH7
Fig. 5-21: Drives in Torque Following Mode with Analog Connection
A digital connection, the EcoX bus connection, can now be used in place
of the analog connection between the master and slave drives for greater
following accuracy. With EcoX bus communication, slave drives can only
receive signals sent by the master drive while the master drive can send
and receive signals from the slave drives. Up to three slave drives can be
connected to the master drive through the EcoX bus.
Torque_Following_EcoX.FH7
Fig. 5-22: Drives in Torque Following Mode with EcoX Connection
The drives are configured for EcoX communication using DriveTop IE

(Integrated Edition), the drive configuration tool in VisualMotion Toolkit.
When configuring the drives for torque following mode, the system must
be in parameter mode as configuration changes are not possible in
runtime. To configure the drives:
1. Launch DriveTop by selecting Drive Overview from the Commission
menu in VisualMotion Toolkit while your project is online.
2. In the Drives window, double-click the drive table or click the
Overview button to launch DriveTop.
3. In the DriveTop window, select Drive Functions ⇒
Special/optional
drive functions ⇒
EcoX – Cross communication…
4. Configure the master drive in the configuration window for the drive
by selecting the number of slaves. Maintain the default setting (0) in
the IO-Module field, VisualMotion will apply the correct settings.
5. Select Torque/Force command for the command value and change
the drive number to the next drive.
DriveTop_setup_master.tif
Fig. 5-23: Digital I/O Assignment for Mater Drive
6. Configure the slave drives by selecting Slave in the Assignment

window.
DriveTop_setup_slave.tif
Fig. 5-24: Digital I/O Assignment for Slave Drive
7. Maintain the default settings for Synchronization (unchecked) and

IO-Module (0).
8. Select Torque/Force command for the command value.
9. Click Next> to apply the settings.
Rexroth VisualMotion 10 Project Planning Fieldbus Interfaces 6-1
6 Fieldbus Interfaces
The PPC-R22.1 and PPC-P11.1 can be ordered with a fieldbus slave
interface, or a fieldbus master interface, or both. Only one fieldbus
interface of each type can be installed in a control at one time. The
mapping list for the slave interface is scanned every 4 ms. The fieldbus
master interface is scanned at the current Integrated PLC I/O image
update rate. Data is sent and received via the fieldbus board's dual port
RAM.
The following fieldbus slave interfaces are available:
• Profibus slave interface
• DeviceNet slave interface
• ControlNet slave interface
• Interbus fieldbus slave interface
Note: EtherNet/IP fieldbus slave interface is available with the

optional onboard EtherNet connection. Refer to the PPC-R
Overview in section 4.1 for details.
The following fieldbus master interfaces are available:

• Profibus master interface
• DeviceNet master interface
The fieldbus interface are installed in an expansion slot of the PPC-R22.1

or mounted next to the PPC-P11.1 via the PC104 interface.
Note: Fieldbus slave interface is controlled via the motion portion of

the control firmware. Fieldbus master interface is controlled via
the Integrated PLC.
6-2 Fieldbus Interfaces Rexroth VisualMotion 10 Project Planning
6.1 Profibus-DP Fieldbus Master and Slave Interfaces
Profibus_card.FH7
Fig. 6-1: Front Panel of DPM01 and DPS01 Profibus-DP Interface
Pin Assignment of Connector X70 and X75
Pin Signal Function

1 --- not used
2 --- not used
3 RS485+ Receive / Transmit Data Plus
4 CNTR-P Repeater Control Signal
5 Ground 0V
6 +5V Repeater Supply
7 --- not used
8 RS485- Receive / Transmit Data Minus
9 Ground 0V
Table 6-1: Pin Assignment of Connector X70 and X75
Profibus Diagnostics
The Profibus interface has 4 LEDs on the front panel. They allow
diagnosis of the bus status and communications between the Profibus
interface and the PPC-R22.1.
LED Color code

Ready Yellow
Run Green
Status Yellow
Error Red
Table 6-2: Designation and Color of LEDs for Profibus Interface
LED State Meaning

READY (yellow) On Hardware O.K.
Flashing (continuous) Initial configuration O.K.
Flashing (irregular) Hardware or system O.K.
Off Hardware defective
RUN (green) On fieldbus communication is active
Flashing (continuous) Ready for fieldbus
communications
Flashing (irregular) Parameterization error
STATUS (yellow) On Bus token active
ERROR (red) On Internal error
Table 6-3: LED Diagnostics for Profibus Interface
Profibus Specifications
Hardware
Description Details
Performance – Max. Baudrate 9.6 KBaud- 12 MBaud RS-485
optically isolated
Connector Type Standard 9 pin Profibus D-sub
Table 6-4: Profibus Hardware
Software
Description Details
Master or Slave Type Profibus DP only
I/O Capacity 64 bytes input / 64 bytes output
Table 6-5: Profibus Software
Note: A Profibus slave configuration file (*.gsd) and master file

(*.gmd) are available in the VisualMotion 10 installation CD.
Certifications
Description Details
Certifications Profibus NutzerOrganisaton
Profibus Trade Organization
CE Marked
Table 6-6: Profibus Certifications
6.2 DeviceNet Fieldbus Master and Slave Interfaces
devicenet_card.FH7
Fig. 6-2: Front Panel of DNS03 DeviceNet Slave Interface
Pin Assignment of Connector X80 and X85
Pin Signal Function

1 V- 0V
2 CAN_L Differential low signal
3 Shield/Drain Shield connection
4 CAN_H Differential high signal
5 V+ +24 V Interface supply (Maximum 30 V)
Table 6-7: Pin Assignment of Connector X85
DeviceNet Diagnostics
The DeviceNet interface has 4 LEDs on the front panel. They allow
diagnosis of the bus status and communications between the DeviceNet
interface and the PPC-R22.1.
LED Color code

Ready Yellow
Run Green
Network Status White / Red / Green
Module Status White / Red / Green
Table 6-8: Designation and Color of LEDs for DeviceNet interface
LED State Meaning

READY (yellow) On Hardware O.K.
RUN (green) On fieldbus communication is active
Flashing (continuous) Ready for fieldbus
communications
Flashing (irregular) Parameterization error
NET * RED on Critical link failure
(Network Status) RED flashing Connection timeout
GREEN on On-line, link O.K.
GREEN flashing On-line, not connected
White Device not power from DeviceNet
master, Baudrate error
MODUL * RED on Unrecoverable error
(Module Status) RED flashing Minor fault
GREEN on Normal operation
GREEN flashing Configuration failure
White Device not power from
DeviceNet, Baudrate error
* NET and MODUL LED's are based on the DeviceNet specification.
Table 6-9: LED Diagnostics for DeviceNet
DeviceNet Specifications
Hardware
Description Details
Performance – max. baud rate 500 KBaud optically isolated
Transceiver Information 100mA @ 24 V
Connector type 5 pin "Open Style" terminal block
Table 6-10: DeviceNet Hardware
Software
Description Details
Master and Slave type Group 2 only server
Message types Polled I/O, Explicit
Table 6-11: DeviceNet Software
Note: A DeviceNet configuration file (*.eds) is available in the

Certification
Description Details
Certification Open DeviceNet Vendor Association
CE Marked
Table 6-12: DeviceNet Certification
6.3 ControlNet Fieldbus Slave Interface
controlnet_card.EPS
Fig. 6-3: Front Panel of the CNS01 ControlNet Slave Interface
Channel A ControlNet Interface

A standard quad shield coax RG-6 cable, using a BNC coaxial connector,
is used to connect the ControlNet slave (Ch_A) to the ControlNet network
(Ch_A) via a passive tap.
Channel B ControlNet Interface

A standard quad shield coax RG-6 cable, using a BNC coaxial connector,
is used to connect the ControlNet slave (Ch_B) to the ControlNet network
(Ch_B) via a passive tap.
Note: Either Ch_A or Ch_B can be used to create the ControlNet

network path. To create a Redundant Parallel network path,
both Ch_A and Ch_B are connected to the independent
network.
ControlNet Network Access Port

The Network Access Port (NAP) can be used to connect to a Laptop
(using a PCMCIA ControlNet Interface card) or an equivalent device for
configuration and diagnostics on the ControlNet network. A standard 8-
pin RJ-45 connector using shield cable is used.
ControlNet Diagnostics
The ControlNet interface has 4 LEDs on the front panel. They allow
diagnosis of the bus status and communications between the ControlNet
slave interface and the PPC-R22.1.
LED Color code

RDY Yellow
RUN Green
Ch_A Clear
Ch_B Clear
Table 6-13: Designation and Color of LEDs for ControlNet
LED State Meaning

RDY On Hardware O.K.
no firmware loaded
Flashing (irregular) Hardware or system error
RUN On fieldbus communication with master
is active
Flashing (continuous) Communication stopped
Flashing (irregular) Missing or faulty configuration
Off No communication
Ch_A * Both off Reset or no power
and Ch_B Both red Failed link interface
(Redundant Alternating red / green Self test
Option)
Alternating red / off Bad node configuration
Both green Normal operation
Ch_A Both off Channel disabled
or Ch_B Flashing red / green Invalid link configuration
Flashing red / off Link fault or no MAC frames
received
Flashing green / off Temporary channel error or listen
only
On green Normal operation
* C_A and Ch_B LED's are based on the ControlNet Specification.
Table 6-14: LED Diagnostics for ControlNet Interface
ControlNet Specifications
The fieldbus slave card is designed based on the ControlNet
specification, Rev. 2.0, March 1998.
Hardware
Description Details
Performance – max. baud rate 5 MBaud fixed
Connector type BNC RG-6 connector (Ch_A and Ch_B
8-pin RJ-45 connector (NAP)
Redundant configuration According to ControlNet specs.
supported = yes
NAP port supported = yes According to ControlNet specs.
Table 6-15: ControlNet Hardware
Software
Description Details
Slave type Adapter, messaging
Message types Polled I/O, Explicit
Table 6-16: ControlNet Software
Note: A ControlNet configuration file (*.eds) is available in the

Certification
Description Details
Certification ControlNet International
CE Marked
Table 6-17: ControlNet Certification
6.4 Interbus Fieldbus Slave Interface
Interbus_card.FH7
Fig. 6-4: Front Panel of the IBS03 Interbus Slave Interface
Pin Assignment of Connector X65
Pin Signal Function

1 DO 2 RS 485 (Out)
2 DI 2 RS 485 (In)
3 GND 2 reference ground
4 --- not used
5 +5V
6 /DO 2 RS 485 (Out)
7 /DI 2 RS 485 (In)
8 --- not used
9 RBST remote bus control
Table 6-18: Pin assignment of Connector X65 (outgoing bus)
Pin Assignment of Connector X66
Pin Signal Function

1 DO 1 RS 485 (Out)
2 DI 1 RS 485 (In)
3 GND 1 reference ground
4 --- not used
5 --- not used
6 /DO 1 RS 485 (Out)
7 /DI 1 RS 485 (In)
8 --- not used
9 --- not used
Table 6-19: Pin assignment of Connector X66 (incoming bus)
Interbus Diagnostics
The Interbus interface has 8 LEDs on the front panel. They allow
diagnosis of the bus status and communications between the Interbus
slave interface and the PPC-R22.1.
LED Color code

RDY Yellow
RUN Green
TR Green
UL Green
RC Yellow
BA Green
RD Red
Table 6-20: Designation and Color of LEDs for Interbus
LED State Meaning

RDY On Hardware O.K.
no firmware loaded
RUN On fieldbus communication with master
is active
Flashing (continuous) Communication stopped
Flashing (irregular) Missing configuration
Off No communication
TR On PCP communication O.K.
Off No PCP communication
UL On Bus power supply O.K.
Off Power supply low
RC On No error from incoming remote bus
Off No connection to device
BA On Active data telegram
Off No data exchange on Interbus
RD On Outgoing remote bus interface
switched off
Off Outgoing remote bus interface
switched on
Table 6-21: LED Diagnostics for Interbus Interface
Interbus Specifications
Hardware
Description Details
Performance – max. baud rate 500 Kbaud (X65) optically isolated
(X66) non-isolated
Connector type Standard 9 pin D-sub
X65 - female connector
X66 - male connector
Table 6-22: Interbus Hardware
Software
Description Details
Card type Interbus slave with Generation 4 and
Loop support
Message types PD (Process Data)
PCP (Peripheral Communication
Protocol)
Max. length of PD channel up to 32 bytes input / 32 bytes output
Length of PCP channel Configurable via fieldbus Mapper tool
(OFF or ON at 2 words)
Table 6-23: Interbus Software
Certification
Description Details
Certification CE Marked
Table 6-24: Interbus Certification
Rexroth VisualMotion 10 Project Planning Encoder Interface, Option Card PLS, and Link Ring 7-1
7 Encoder Interface, Option Card PLS, and Link Ring

VisualMotion 10 supports the following optional interfaces for the
PPC-R22.1 and the PPC-P11.1:
• Encoder Interface Card (MEC)
• Option Card PLS (NSW01)
• Link Ring (DAQ03)
7.1 Encoder Interface Card (MEC)

The Encoder Interface Card (MEC) is used to provide a real master input
to an ELS System. It is not intended to provide a secondary feedback
device for a drive that supports only one primary feedback.
The following two cards are available for the PPC-R22.1 and PPC-P11.1:
• 2 encoder input interface
– EnDat encoders
– 1 V peak-to-peak Sinusoidal encoders only
Note: GPP 10 and GMP 10 firmware only support the presence of

one encoder interface card.
MEC_Endat.FH7
Fig. 7-1: Encoder Interface Card (MEC)
The following VisualMotion features support the encoder interface card as

a source of data:
• ELS System
• Position Monitoring Group
• Slip Monitoring
• Rotary Events
• Programmable Limit Switch
7-2 Encoder Interface, Option Card PLS, and Link Ring Rexroth VisualMotion 10 Project Planning
The MEC card uses standard Rexroth cable assemblies for EnDat and
1 Vpp encoders. The following table lists some example of Bosch
Rexroth encoders and the cable assemblies used:
Encoder Cable Assembly

ROC413 (EnDat) IKS4001 *
ROD486 (1 Vpp) IKS4002 *
Table 7-1: Encoder Types
* Cable assembly may vary based on drive type. Refer to the relevant
digital drive documentation for details.
Encoder Interface Card Specifications

Supply Voltage X10
Description Details
Input voltage 24 VDC, -15%+20% , EN61131-2
Current range: 0.15 A to 0.3 A
Table 7-2: X10 Power Supply
1 Vpp (SinCos) Encoder Signals
Amplitude Typical: 1Vpp

Min: 0,6Vpp
Max: 1,2Vpp with 120 Ohm termination
resistance
Reference Voltage 2.7 V
Maximum Input Frequency 200 kHz
Output Voltage +5 VDC ± 0.1 V
Maximum Output Current 300 mADC
Sensing Yes
Table 7-3: 1 Volt Peal-to-Peak Encoder Signals
EnDat Encoder Signals
Level RS485
Differential Output Voltage Min: 1.5 V
Max: 5 V
Differential Input Voltage Threshold:
Min: -0.2 V
Max: +0.2 V
Input Hysteresis 70 mV
Clock Frequency Min: 100 kHz
Max: 2 MHz
Termination Resistance 120 Ohm
Output Voltage +5 VDC ± 0.1 V
Maximum Output Current 300 mADC
Sensing Yes
Table 7-4: EnDat Encoder Signals
X81 and X82 Pin Assignment
Pin Signal Type Signal Description

1 Voltage 5 V Sense
2 Voltage 0 V Sense
3 IN (analog) Not used
4 IN (analog) Not used
5 IN (analog) Cosine -
6 IN (analog) Cosine +
7 IN (analog) Sine +
8 IN (analog) Sine -
9 BIDIR (485) EnDatD +
10 0V
11 OUT (485) EnDatClk +
12 5V
13 OUT (485) EnDatClk -
14 0V
15 BIDIR (485) EnDatD -
Table 7-5: X81 and X82 Pin Assignment (15 pin female Dsub)
Note: Refer to chapter 10, Hardware and Firmware Configurations

for ordering information.
7.2 Option Card PLS for PPC-R22.1 and PPC-P11.1

The Option Card PLS (NSW01) is the PPC-R22.1 and PPC-P11.1
programmable limit switch interface. Up to two Option Card PLSs,
containing 16 outputs each for a total of 32 outputs, can be ordered for
each control.
Each Option Card PLS features the following:
• 16 outputs per card
• 2 mini-phoenix connectors with 8 outputs each (X6 and X7)
• LED indicator for each output
Note:
• Current draw per output is 250 mA @ 24V
• PLS outputs updated every 250 µs
Note: The maximum current draw of each output is limited to about

500 mA. However, the sum of all 8 output currents per
connector (X6 or X7) should not exceed 2 amps.
NSW01_card.FH7
Fig. 7-2: Option Card PLS

Connecting Supply Voltage

Each connector on the Option Card PLS (X6 and X7) requires a 24V input
for the outputs to function. The label on the Option Card PLC identifies
the 24V and 0V connections. Refer to Fig. 7-2 for details. The 24V LED
indicator will be lit when power is applied.
X6 and X7 Pin Assignment
Phoenix Connector Label on X6 Label on X7 Signal

Numbering for X6 Description
and X7
10 1 9 Digital Output
2 24V 24V 24 V
1 0V 0V Ground
Table 7-6: X6 and X7 Pin Assignment
Option Card PLS Power Supply Voltage
Card_PLS_power.FH7
Fig. 7-3: Option Card PLS Power Supply Voltage
Damage due to component overload!

⇒ Exceeding the maximum current draw of the Option
Card PLS can cause damage to the internal
CAUTION components.
Option Card PLS Specifications

Hardware
Description Details
Protection rating IP 20, EN 60529
Relative humidity 5 - 85 %, no condensation (operating)
5 - 95 %, no condensation (transport)
Atmospheric pressure 860 - 1060 hPa
Ambient operating 0 … 45 °C (32 … 113 °F)
temperature
Storage and transportation -25 … 70 °C (-13 … 158 °F)
temperature
Power Supply
Description Details
Input voltage 24 VDC, -15%+20% , EN61131-2
Maximum current The maximum input current per 8 outputs (X6 or
X7) should be limited to 2 Amps.
7.3 DAQ03 for PPC-R22.1 and PPC-P11.1

The DAQ03 card is the PPC-R22.1 and PPC-P11.1 interface to a Link
Ring, a fiber optic loop of controls sharing master position data. Each
PPC-R22.1 and PPC-P11.1 in a Link Ring must be ordered with a DAQ03
card.
The DAQ03 has two pairs of transmit and receive terminals for the fiber
optic cables that connect the controls in the Link Ring. Only one pair, the
primary ring, is required to form a Link Ring. The second pair forms a
secondary ring which provides redundancy.
DAQ03_card.FH7
Fig. 7-4: DAQ03 Card

When participating in a Link Ring, the jumpers on the control’s DAQ03

board should be set as follows (regardless of firmware type):
• Jumpers J2 and J4 (only) should be set.
DAQ03 cards are shipped with jumper J4 set to enable operation of the
ARCNET connector which is not used by GPP or GMP. Therefore, it is
not necessary to change the J4 setting.
DAQ03 Diagnostics
The DAQ03 faceplate has four LEDs that indicate the status of the Link
Ring cables.
LED Indication
H11 (M) DAQ03 is set as Link Ring master
H12 (S) DAQ03 is set as Link Ring slave
H17 (S) An error has occurred in the secondary ring
H18 (P) An error has occurred in the primary ring
Table 7-7: DAQ03 LEDs
DAQ03 Specifications
Hardware
Condition Rating
Relative humidity 5-85%, no condensation (operating)
5-95%, no condensation (transport)
Atmospheric pressure 86-106 hPa
Ambient operating temperature 0 - 45 °C
Storage and transportation -25 - +70 °C
temperature
Table 7-8: Hardware Specifications for DAQ03
Power Supply
Type Rating
Input voltage 5V
Maximum Current 700mA
Table 7-9: Power Supply Specifications for DAQ03
Cable Connections for DAQ03

Single Ring
A single ring uses only the primary receive and transmit connections on
the DAQ03 cards, see Fig. 7-6.
single_link_ring.FH7
Fig. 7-5: Single Link Ring
single_link_conn.FH7
Fig. 7-6: DAQ03 Connection for Single Link Ring
Double Ring
The primary and secondary rings in a double ring are identical except that
they transmit signals in opposite directions and the secondary ring
transmits only diagnostic signals when the primary ring is active.
double_link_ring.FH7
Fig. 7-7: Double Link Ring

The primary and secondary loops are connected in a different order from
each other. One transmitting from the Link Ring Master to node 2, the
other transmitting from the Link Ring Master to the last node in the series.
For example, in Fig. 7-8, the primary Link Ring transmits a signal from the
Link Ring Master to node 3 while the secondary ring transmits from the
Link Ring Master to node 2.
double_link_conn.FH7
Fig. 7-8: DAQ03 Connection for Double Link Ring
Rexroth VisualMotion 10 Project Planning VisualMotion Human Machine Interfaces 8-1
8 VisualMotion Human Machine Interfaces
8.1 Overview
Rexroth IndraControl VCP, VEP and BTC Human Machine Interface units
are used to interface with the control, providing the operator with a wide
variety of functionality. The operator can view and modify parameters, jog
axes, and interface with machine operations.
8.2 Rexroth IndraControl VCP Terminals

The VCP small operator terminals provide textual and/or graphical user
interface to the machine. They provide ease of use and convenience to
the user. The parametrization and visualization of the VCP small operator
terminals is done using the VI-Composer software.
They are available in the following types:
Operator Terminal Display Type Application Memory

VCP 02 Text-based - 4 x 20 character display
256 kB flash
VCP 05 Text-based - 4 x 20 character display
256 kB flash
VCP 08 Graphic-based - 4 x 20 character display
256 kB flash
VCP 20 Graphic-based - 16 x 40 character display
768 kB flash
VCP 25 Graphical Touch-screen
320 x 240 pixel resolution, 256 color 3 MB compact flash
Table 8-1: VCP Small Operator Terminals
VCPfront.jpg
Fig. 8-1: VCP Series Front View
8-2 VisualMotion Human Machine Interfaces Rexroth VisualMotion 10 Project Planning
VCP Features
Enclosure, Control and Display Elements
• Front panel interface with keys
– VCP 02 has 4 function keys and 7 system keys
• Front panel touch-screen interface without keys
– VCP 25
• Protection Class
– VCP 02, 25: IP65 aluminum front panel
– VCP 05, 08, 20: IP54 aluminum front panel
Communication Interface
All VCP terminals support RS232 and RS485 serial interfaces or Profibus
DP fieldbus.
VCP Documentation
Rexroth IndraControl VCP terminals are outlined in more detail
(dimensions and specifications) in the following documents:
• Rexroth IndraControl VCP 02
DOK-SUPPL*-VCP02******-PR01-EN-P
8.3 Rexroth IndraControl VEP Embedded Terminals

The VEP embedded terminals provide graphical user interface to the
machine. These terminals are configured with WinStudio runtime and the
IndraLogic (CoDeSys) Windows CE OPC server. The OPC server is
configured via an *.ini file. VEP terminals are not programming terminals.
They are intended for supporting the runtime of an HMI system (mainly
WinStudio).
They are available in the following types:
Operator Terminal Display Type Application Memory

VEP 30 Graphic-based – 8.4" Touch-screen 64 MB/ 128 MB Compact Flash
800 x 600 pixel, SVGA
VEP 40 Graphic-based – 12.1" Touch-screen 64 MB/ 128 MB Compact Flash
800 x 600 pixel, SVGA
Table 8-2: VEP Embedded Terminals
VEP30_40.jpg
Fig. 8-1: VEP Front View
VEP Features
Enclosure, Control and Display Elements
• Front panel touch-screen interface with virtual keyboard
– VEP 30
– VEP 40
• Protection Class
– VEP 30, 40: IP65 aluminum front panel, IP20 back panel
Communication Interface
• All VEP terminals support RS232 serial interface or EtherNet
• 2 PC104 plug-in slots
8.4 BTC06
The BTC06 is a portable, compact interface that allows a user the
flexibility of movement for a better perspective of the function being
performed. An RS422/485 combination interface allows connection of the
BTC06 to the Rexroth VisualMotion control (PPC-R22.1).
BTC06_front.FH7
Fig. 8-2: BTC06 Front Face
BTC06 Specifications
Basic BTC06 Unit
Basic BTC06 Unit

Supply voltage 24 V (20 to 30 V) DC
Power consumption max. 400 mA
Display LCD 240 x 128 pixel, b/w, full graphics
function
LED, backlit
visible area 108 x 58 mm (4.25" x 2.25")
Keyboard Polyester film with 48 keys
Enclosure material Polycarbonate
Protection IP 65 (Main connection cable plugged in,
RS-232 connector provided with protective
cap)
Temperature range 0 to +55°C (Operation) (32 to 131 °F)
-20 to +70°C (Storage) (-4 to 158 °F)
Weight approx. 1.3 Kg (2.9 lbs.)
Table 8-3: Electrical Data
Emergency Stop Switch
Emergency Stop
Switch elements Twist release with two floating
normally closed contacts,
electrically isolated
Rated voltage 24 V DC / 42 V AC
Rated current 2 A DC / 3 A AC
Operating cycles > 100,000
Table 8-4: Emergency Stop Switch Data
Live-Man Switch
Live-Man switch
Three position switch Position 1 – Off
Position 2 – Live-Man
Position 3 - Panic
Switch elements Two floating N.O. contacts,
electrically isolated
Rated voltage 24 V DC / 42 V AC
Rated current 2 A DC / 3 A AC
Operating cycles > 200,000 for Live-Man range
> 100,000 for Panic position
Control category 4 in accordance with EN954-1
Table 8-5: Live-Man Switch Data
Note: TÜV/BG certified integrated safety circuitry, category 4, according

to EN954-1, ensure that the live-man switch will not be activated after a
panic event when returning over position 2 to position 1.
Handwheel
The handwheel option has the following characteristics:
• Internal 16 bit absolute counter (in conjunction with Screen Manager
software).
• A two-place relative counter from -99 to +99.
• Display reset by pressing the handwheel for an extended period
(about two seconds).
Hardware Components
• 1 Mbyte Flash
• 256 Kbytes SRAM
• RS-232 programming interface for downloading firmware and for
programming of custom displays
• Communications interface in accordance with Indramat standard, i.e.
bus-capable RS485 and RS422
BG Test Certifications
• EN 60204 Part 1: "Safety of Machinery - Electrical Equipment of
Industrial Machinery; Part 1: General Requirements"
• EN 775: "Industrial Robots Safety"
• EN 418: "Safety of Machinery - Emergency Shut-Off Equipment,
Functional Aspects, Design Guidelines"
• Integrated Safety Circuitry, Category 4, according to EN954-1 for Live-
Man Switches
Standard Features
Emergency Shut-Off
The emergency stop button is designed to shut-off the system operation
in any mode (stop category 0). For category 1 emergency stop functions,
appropriate measures must be taken in addition to the electronic safety
equipment (DIN EN 60204-1). The emergency stop button is a dual-
circuit switch.
Live-Man Switch
The live-man switch is activated with the holding hand. Enclosure and
shape of the live-man switch have been ergonomically optimized for right-
hand and left-hand operation.
The live-man switch directly affects the post-connected system (drive
amplifier, SPS/PLC, robot). It is designed to allow hazardous machine
movement only upon intentional activation of the operator, when the
operator has to work within the hazardous zone of the machine.
The BTC06 interface cable includes the power supply line for the device,
the connection cable for the emergency stop button, and the live-man
switch as well as the data cables for data transfers between the BTC06
and the controller.
When the user disconnects the connector, the emergency stop circuit and
the live-man circuit will be interrupted.
Optional Features
The BTC06 may be equipped with an optional 4-bit override switch and a
16-bit handwheel.
Feedrate Override
Used with Screen Manager version of VT-100 software or custom Screen
manager screens
Handwheel
Used with custom Screen Manager screens
Safety Concept
If the BTC06 is equipped with the appropriate optional features
(emergency stop and live-man switch), it can be used for operation with
industrial drive and robot controllers. It includes a dual-circuit 3-position,
live-man switch. Both circuits are electrically isolated and operate
redundantly. It is important that the subsequent control interprets the
switch in accordance with the machine-specific or system-specific
standards and rules.
If appropriate interlocks with the safety contacts of the drive or robot
control are provided, hazardous movements in certain modes (e.g.,
manual or test mode) can only be activated if the live-man switch is held
in the center (= enabled) position. If this switch is not depressed, or if it is
pressed all the way down to the panic position, any movement will be
stopped immediately. The return from the panic position is activated
electrically, whereby the switch returns to the non-activated position. To
start a new movement, enter a command and re-activate the live-man
switch.
The live-man switch of the BTC06 provides integrated safety circuitry. A post-
connected control must be used to ensure compliance with machine-specific
or system-specific standards and rules. It must be linked to the control in a
way that meets the safety requirements for the power circuits in accordance
with EN775, EN60204, EN954-1, EN1088, VDI2853, and VDI2854.
Enclosure Dimensions
Outer Dimensions
BTC06_dim.FH7
Fig. 8-3: BTC06 Enclosure Dimensions
Rear View
BTC06_back.FH7
Fig. 8-4: Rear View –BTC06
BTC06 Accessories
SUP-M01-BTC06 Wall-Mounting Bracket
BTC06_mount.TIF
Fig. 8-5: Wall Mounting Bracket
The mounting bracket is provided to attach the BTC06 to a wall or to a

machine part. When fastened at the proper height, the display can be
read and the device can be operated without removing it from the bracket.
The user can mount the two-piece wall bracket so that the live-man switch
is enabled when the device is inserted into the bracket. However, this
mounting method should be used only if the device is mounted outside of
a hazardous zone. In this case, the system must have provisions in

accordance with DIN EN 775 to ensure that no persons are present within
the room that is equipped with protective safety features.
BTC06 Connections
RS422/485 Main Connection
This 17 pin circular connection is used for RS422/485 communications to
the BTC06. Table 8-6 contains a pin-out of the necessary connections to
the BTC06 for communications as well as machine interfacing.
BTC06_main_conn.FH7
Fig. 8-6: BTC06 Main Connection
Pin Assignment
1 0V
2 + 24 V
3 Live-man switch 1 in
4 Live-man switch2 in
5 Live-man switch1 out
6 Live-man switch2 out
7 E-STOP 1 in
8 E-STOP 2 in
9 E-STOP 1 out
10 RS422 TxD- RS485 -
11 RS422 TxD+ RS485 +
12 RS422 RxD-
13 RS422 RxD+
14 Signal Ground
15
16 E-STOP 2 out
17 Not used
Table 8-6: Pin-out of the 17-Pin Connector
RS232 Firmware Download and Projecting Interface
BTC06_rs232.FH7
Fig. 8-7: RS232 Interface
Pin Assignment
1 not used
2 TxD
3 RxD
4 Signal Ground
Table 8-7: Pin-out of the RS232 Interface
IKB0010 PC Connection Cable

The IKB0010 is a RS232 interface connection cable used to download
firmware to the BTC06 and for transferring Screen Manager programs.
Refer to Accessories for ordering information.
Note: The firmware for this device is supplied on diskette. Therefore, an

OEM needs this cable to load the firmware.
Enclosure Connection from BTC to Control

The following components are used for connecting the BTC06 to a
VisualMotion control (EMC compliant).
• IKS0188 connection cable
• INS0627 bulkhead connector
• IKB0015 serial cable is used for connecting to a PPC-R22.1
Refer to Accessories for ordering information.
The connections for the live-man switch and the emergency stop function
inside the control cabinet are wired via the two 6 pin Phoenix connectors
on the BTZ01.1 junction box.
BTZ01.1 Junction Box
BTZ01_box.FH7
Fig. 8-8: BTZ01.1 Junction Box
The junction box ensures that the connections for the live-man switch and
the emergency stop function can be accessed externally. The IKS0188
connection cable establishes the connection to the INS0627 bulkhead
connector. Inside the box, the individual functional units are
distributed/wired to the respective connectors on the front panel.
The live-man circuits and the emergency stop function as well as the
voltage supply are connected at a 12-pin Phoenix terminal. The
connection to the BTC06 is established through a 17-pin female circular
connector.
From the BTZ to the PPC-R22.1, the IKB0015 serial communication cable
is used. RS485 and RS422 ports are connected to the control in
accordance with Indramat standards.
Note: In order to establish communications between the BTC06 and

the control, the serial port on the control, to which the BTZ01.1
is connected, must be set to the same settings as that of the
BTC06.
BTC06 to PPC-R22.1 Connections

Using a BTZ01.1 (EMC Compliant)
BTZ01_emc.FH7
Fig. 8-9: BTC06 to PPC-R22.1 through a BTZ01.1
Optional Terminal Strip Connection
BTZ01_term_strip.FH7
Fig. 8-10: BTC06 to PPC-R22.1 Terminal Strip Connection
Rexroth VisualMotion 10 Project Planning Fiber Optic Cable(LWL) 9-1
9 Fiber Optic Cable(LWL)
9.1 Data Transmission Ring Structure

The communications between the all Sercos devices (control, Sercos I/O,
digital drives) is accomplished using the standard Sercos interface (IEC
1491) via fiber optic cables (LWL). A Sercos fiber optic ring structure is
illustrated in Fig. 9-1.
Fiber_optic_ring.FH7
Fig. 9-1: Fiber Optic Ring Structure
The Sercos ring starts and end at the control. The optical output (TX) of
the control is connected with the optical input (RX) of the first drive. It's
output is then connected to the input of the next Sercos I/O device or
drive until all Sercos devices are connected. The output of the final
Sercos device is connected to the input (RX) of the control, thus
completing the Sercos ring.
Fiber Optic Transmission Path Installation

A fiber optic transmission path starts at a transmitter output (TX) and
ends at a receiver input (RX).
Fiber Optic Cable Connection The transmission path is made up of fiber optic cables and fiber optic
Points cable bulkhead connectors. Bulkhead connectors are used as coupling
units between two fiber optic cables installed through a cabinet wall.
FSMA Connector Standard The connectors used on the fiber optic cable correspond to the FSMA
standards (IEC 874-2).
9-2 Fiber Optic Cable(LWL) Rexroth VisualMotion 10 Project Planning
Fiber Optic Cable Types

The fiber used in the fiber optic cable assemblies are constructed of
either plastic or glass. Plastic fiber optic cables can be used for
transmission lengths up to 50 m and glass fiber optic cables for lengths
up to 500 m.
IKO 0982 Plastic Fiber Optic Cable ( 2.2 mm )

The IKO 0982 fiber optic cable assembly has an outer diameter of 2.2
mm and is recommend for internal control cabinet connections.
IKO0982.FH7
Fig. 9-2: IKO 0982 Fiber Optic Cable Assembly
IKO 0985 Plastic Fiber Optic Cable (6.0 mm)

The IKO 0985 fiber optic cable assembly has an outer diameter of 6.0
mm and is recommended for both internal and external control cabinet
connections. This fiber optic cable assembly contains the smaller 2.2 mm
fiber optic cable within a red reinforced outer jacketing.
IKO0985.FH7
Fig. 9-3: IKO 0985 Fiber Optic Cable Assembly
IKO Glass Fiber Optic Cable

Glass fiber optic cable assemblies are recommended for both internal and
external control cabinet connections. Glass fiber optic cable assemblies
are available in two types:
• IKO 0001
glass fiber optic cable available in 50, 75 and 100 m lengths with an
outer diameter of 3 mm.
• 06-0986
glass fiber optic cable assembled only in the United States in
predetermined lengths with an outer diameter of 6 mm.
Fiber Optic Cable Accessories

The following accessories are available for fiber optic cables:
• fiber optic bulkhead connector
• FSMA fiber optic connector wrench
Fiber_bulkhead.FH7
Fig. 9-4: Fiber Optic Bulkhead Connector
FSMA_wrench.FH7
Fig. 9-5: FSMA Fiber Optic Connector Wrench
Note: The fiber optic connector wrench can be helpful when

installing fiber optic cable onto the EcoDrive 03 digital
controllers.
Description Material Number

Fiber Optic Bulkhead Connector 252524
Fiber Optic Connector Wrench 260285
Table 9-1: Fiber Optic Cable Accessories
9.2 Project Planning Notes

Before planning a project, make certain that you fully understand the
requirements and recommendation of Rexroth's fiber optic cable
assemblies. Note the following details:
Transmission Path Length The maximum length of fiber optic cables is limited by the amount of
attenuation (light loss) in the transmission path between fiber optic
transmitters.
Combining Fiber Optic Cable Bosch Rexroth does not recommended the combining of plastic and glass
Types fiber optic cable assemblies through a bulkhead connector.
Mechanical Limits Observe all mechanical limit values (e.g., bend radii, pulling tensions,
cross tension, bending cycles) when installing fiber optic cable
assemblies.
Temperature Limits Never exceed the temperature limit values for fiber optic cable
assemblies.
Maximum Transmission Length
Fiber Type Without Bulkhead 1 Bulkhead Connection 2 Bulkhead Connections

Plastic 50 m 40 m 30 m
Glass 500 m 400 m 300 m
Table 9-2: Maximum Transmission Length
Technical Data
Description IKO 0982 IKO 0985 IKO 0001 06-0986

Outer jacketing Polyamide (PA) Polyurethane (PUR) Polyurethane (PUR) Polyurethane (PUR)
Outer diameter 2.2 mm ± 0.07 mm 6.0 mm ± 0.2 mm 3.0 mm ± 0.07 mm 6.0 mm ± 0.2 mm
Bend radius (min.) 50 mm 80 mm 16 mm 47 mm
Bend radius in Not recommended 100 mm Not recommended Not recommended
cable track
installations (min.)
Pulling tension 150 N 150 N 330 N 330 N
resistance (one
time)
Pulling tension 100 N 100 N 245 N 245 N
resistance
(continuous)
Cross tension 450 N/cm 450 N/cm 1000 N/cm 1000 N/cm
resistance (crush)
Bending cycle >8,000 Cycles ± 90° >100,000 Cycles ± 90° >10,000 Cycles ± 90° >10,000 Cycles ± 90°
endurance
Temperature -40 °C .. +85 °C -20 °C .. +80 °C -40 °C .. +85 °C -40 °C .. +85 °C
(operating/storage)
Fiber core 1000 µm (Plastic) 1000 µm (Plastic) 200 µm (Glass) 400 µm (Glass)
diameter
Specific optic < 250 dB/km < 250 dB/km < 8 dB/km < 8 dB/km
attenuation
Table 9-3: Technical Data for Fiber Optic Cables
General Safety Guidelines
Eye injury due to high-energy light!

⇒ Do not look into the light (transmitter output or fiber
optic cable end).
DANGER
Damage to fiber optic components due to

handling and mounting!
⇒ Do not over tighten fiber optic cable connectors.
CAUTION
Damage to fiber optic cable due to handling and

mounting!
⇒ Mechanical and thermal limit values must be
CAUTION maintained.
Handling
Connecting the Fiber Optic Cables
Note the following transmitter locations when connecting fiber optic cable
in a Sercos ring.
Transmitter End Connections Fiber optic cable assemblies are connected to the transmitting end as
follows:
TX (PPC-R22.1)
X10 (DSS in Diax 04)
X20 (DKC*2.3)
X2 (RMK02.2-LWL-SER)
X82 (R-IL SE BK)
Receiver End Connections Fiber optic cable assemblies are connected to the receiver end as follows:
RX (PPC-R22.1)
X11 (DSS in Diax 04)
X21 (DKC*2.3)
X1 (RMK02.2-LWL-SER)
X81 (R-IL SE BK)
Storage
When storage fiber optic cable assemblies, please not that…
• the protective caps must be in place
• the mechanical limits values are not exceeded
• the temperature limit values are not exceeded
Routing and Mounting

When routing and mounting fiber optic cable assemblies, make certain
that all mechanical limits are not exceeded.
Bend Radius Do not exceed the minimum bending radius when routing around corners
or cable tracks.
Cross Tension Do not exceed the maximum cross tension (e.g., when routing around
corners). Do not expose fiber optic cables to excessive weight stress
from larger power cables. Avoid routing over sharp edges or pointy
uneven surfaces. Any cuts or punctures to the cable's outer jacketing can
cause interference.
Cable Twist Remove all the twist out of the fiber optic cables before routing them.
9.3 System Setup
Preparations
Make certain that all fiber optic cables are connected between transmitter
output (TX) and receivers (RX) and that the Sercos fiber optic ring
terminates back at the control.
PPC_fiber_conn.FH7
Fig. 9-6: Sercos Connections for PPC-R22.1
Sercos Drive Address Settings

In order to achieve proper Sercos device addressing, a unique number
must be assigned to each device that will be connected in the Sercos
ring. Diax 04, EcoDrive 03, and Reco 02 RMK Sercos device have rotary
selector switches S2 (low) and S3(high). The Reco Inline Sercos coupler
uses a DIP switch to set the Sercos device address. The allowable
address range in a VisualMotion system is between 01..40. Refer to the
following figure for the location to set the address.
DSS02_address.FH7
Fig. 9-7: Sercos Connections for DSS02.1M (Diax 04)
DKC02_address.FH7
Fig. 9-8: Sercos Connections for DKC*2.3
Any RMK02.2-LWL-SER (Sercos Reco 02 I/O stations) must also be

addressed in the Sercos ring to a unique number not used by any other
device.
RMK_address.FH7
Fig. 9-9: Sercos Connections for the RMK-LWL-SER
The Sercos device address number for the Reco Inline Sercos coupler is
set using a combination of DIP switches. The allowable range is 1-127.
Address 0 is not valid. The following table shows the value for each
individual switch when set to the "ON" position.
For example, switching SW7 and SW8 to ON will set the Sercos device
address to 3. If all the switches are ON, the address is set to 127.
Position SW2 SW3 SW4 SW5 SW6 SW7 SW8

ON 64 32 16 8 4 2 1
OFF 0 0 0 0 0 0 0
Table 9-4: Reco Inline Sercos coupler Sercos Address Setting
Changing the Sercos Baudrate

Bosch Rexroth sets a Sercos baudrate of 2 Mbits/s at time of production
for both the control and drives. This is to ensure that all devices will
initially communicate at the same rate.
Why Increase the Sercos Transmission Baudrate?

The Sercos transmission baudrate for a system can be increased for
applications using more than 8 axis. Some benefits for an increased
Sercos transmission baudrate are:
1. A higher number of cyclic Sercos drive telegrams (more data) can be
processed by the control at the same Sercos cycle time.
2. The same number of cyclic Sercos drive telegrams can be processed
by the control at a reduced Sercos cycle time.
Changing Sercos Baudrate on VisualMotion Controls

The Sercos baudrate can be changed on VisualMotion controls by setting
control parameter C-0-0010, bits 4 and 5 as follows:
Bit 5 Bit 4 Sercos Baudrate

0 0 2 Mbaud (default)
1 0 4 Mbaud
0 1 8 Mbaud
1 1 16 Mbaud
Table 9-5: Sercos Baudrate Bit Settings
The control must be in parameter mode to modify C-0-0010.
Note: When changing the Sercos baudrate, make sure that all the
Sercos devices on the same fiber optic ring have the same
Sercos baudrate.
Changing Sercos Baudrate on Rexroth Digital Drives

IndraDrive, EcoDrive Cs, and Rexroth IndraDrive, EcoDrive Cs digital drives, and Reco Inline Sercos
Sercos Reco Inline couplers automatically detect the Sercos baudrate from VisualMotion
controls and set their own Sercos baudrate to match. These drives
support a 2, 4, 8, or 16 Mbaud Sercos baudrate.
Diax 04 (DSS02.1M) The Sercos baudrate for Diax 04 drives is set via DIP switch S4 on the
DSS02.1M. For a Sercos baudrate of 2 Mbaud, set S4 to the OFF
position. Diax 04 digital drives only support a 2 or 4 Mbaud Sercos
baudrate.
DSS02.1M
DSS_baudrate_switch.FH7
Fig. 9-10: DIP Switches on DSS02.1M
EcoDrive 03 (DKC02.3) The Sercos baudrate for EcoDrive 03 digital drives is set on DIP switch
S20/1 on the SERCOS interface card. For a Sercos baudrate of 2
Mbaud, set S20/1 to the OFF position. EcoDrive 03 digital drives only
support a 2 or 4 Mbaud Sercos baudrate.
DKC02_baudrate_switch.FH7
Fig. 9-11: DIP Switches on DKC*2.3 SERCOS Interface
Note: The DKC22.3 using SGP20 firmware automatically detects the

proper baudrate.
Setting the Optic Transmitter Output Power

VisualMotion Controls The transmitter output power (TX) on the VisualMotion controls is set with
control parameter C-0-0020, Transmitter Fiber Optic Length. When using
plastic fiber optic cable assemblies, set this parameter to match the
length of the cable that is used between the control and the first drive's
receiver (RX). When using glass fiber optic cable assemblies, set this
parameter to 50m.
Diax 04 (DSS02.1M) The transmitter output power (TX) on the DSS02.1M is set via DIP
switches S5A and S5B.
EcoDrive 03 (DKC02.3) The transmitter output power (TX) on the DKC02.3 is set via DIP switches
S20/2 and S20/3.
SercosReco Inline The transmitter output power (TX) on the Rexroth SercosReco Inline is
set via the DIP switch settings on the Sercos coupler R-IL-SE-BK.
Plastic Fiber Optic Settings
Sercos Device 0 .. 15 m 15 m .. 30 m 30 m .. 50 m
Diax 04 S5A = OFF S5A = ON S5A = ON
S5B = OFF S5B = OFF S5B = ON
DKC02.3 S20/2 = OFF S20/2 = ON S20/2 = ON
S20/3 = OFF S20/3 = OFF S20/3 = ON
R-IL-SE-BK SW9 = OFF SW9 = OFF SW9 = ON
SW10 = OFF SW10 = ON SW10 = OFF
Table 9-6: Setting the Transmitter Output Power for Plastic Fiber Optic Cables
Glass Fiber Optic Settings
Sercos Device 0 .. 500 m

Diax 04 S5A = ON
S5B = ON
DKC02.3 S20/2 = ON
S20/3 = ON
R-IL-SE-BK SW9 = ON
SW10 = ON
Table 9-7: Setting the Transmitter Output Power for Glass Fiber Optic Cables
Rexroth VisualMotion 10 Project Planning Hardware and Firmware Configurations 10-1
10 Hardware and Firmware Configurations
10.1 PPC-R Hardware and Firmware

The PPC-R22.1 control is available as a double slot unit. Firmware must
be ordered separately for each hardware configuration using the
appropriate FWA typecode. The FWA typecode includes additional
firmware that might be required for interfaces that are part of the
configuration, such as fieldbus or EtherNet. Firmware typecodes are
listed for all FWA typecodes in the following sections.
PPC-R22.1 Hardware Configurations

The standard PPC-R22.1 hardware configuration comes equipped with
two serial ports (X10 and X16) and a 32 MB PFM flash memory card.
The Dolfi bootloader firmware (FWC-PPCPR*-BTL-02VRS-NN) is not
flashed to the PFM compact flash memory card but resides on-board the
hardware flash.
PPC-R22.1 without EtherNet using GPP 10 Firmware

The hardware configurations in the following table are ordered with GPP
10 firmware.
Expansion Slots Description Material

Hardware Typecode U2 U3 U4 Number
PPC-R22.1N-N-NN-NN-NN-FW Cover Cover Cover No expansion cards 1070170148
PPC-R22.1N-N-Q1-NN-NN-FW DAQ03 Cover Cover Link Ring cross communication 1070170281
Table 10-1: PPC-R22.1 without EtherNet using GPP 10 Firmware
The following table contains the FWA typecode ordered with each
hardware configuration listed above.
Firmware Typecode (FWA) Material Includes Description Location

Number
FWA-PPCR2*-GP*-10VRS-DO-XXXXXX R911306461 FWC-PFM01*-GP*-10VRS-MS GPP 10 firmware PFM memory
(Material number: R911306521) card
FWC-PPCPR*-BTL-02VRS-NN Bootloader Onboard Flash
(Material number: R911299771) firmware
Table 10-2: FWA-PPCR2*-GP*-10VRS-DO-XXXXXX Firmware
PPC-R22.1 with EtherNet using GPP 10 Firmware

10 and EtherNet firmware.
Hardware Expansion Slots Description Material

Typecode U2 U3 U4 Number
PPC-R22.1N-T-NN-NN-NN-FW Cover Cover Cover No expansion cards 1070170191
PPC-R22.1N-T-Q1-NN-NN-FW DAQ03 Cover Cover Link Ring cross communication 1070170287
PPC-R22.1N-T-G3-NN-NN-FW MEC Cover Cover EnDat Encoder Interface 1070170300
PPC-R22.1N-T-N-N1-N2-NN-FW NSW01 NSW01 Cover PLS interface with 32 outputs 1070170290
PPC-R22.1N-T-N-N1-N2-G3-FW NSW01 NSW01 MEC PLS interface with 32 outputs and 1070170301
EnDat Encoder Interface
Table 10-3: PPC-R22.1 with EtherNet using GPP 10 Firmware
10-2 Hardware and Firmware Configurations Rexroth VisualMotion 10 Project Planning

Number
FWA-PPCR2*-GP*-10VRS-DO-XXXXXX R911306461 FWC-PFM01*-GP*-10VRS-MS GPP 10 firmware PFM memory
Table 10-4: FWA-PPCR2*-GP*-10VRS-DO-XXXXXX Firmware
PPC-R22.1 without EtherNet using GPP 10 / Profibus

Slave Firmware
10 / Profibus slave firmware.

PPC-R22.1N-N-NN-P2-NN-FW Cover DPS01 Cover Profibus slave interface 1070170149
PPC-R22.1N-N-Q1-P2-NN-FW DAQ03 DPS01 Cover Link Ring cross communication 1070170151
and Profibus slave interface
PPC-R22.1N-N-N1-P2-NN-FW NSW01 DPS01 Cover PLS interface with 16 outputs 1070170283
PPC-R22.1N-N-N1-N2-P2-FW NSW01 NSW01 DPS01 PLS interface with 32 outputs 1070170280
Table 10-5: PPC-R22.1 without EtherNet using GPP 10 / Profibus Slave
Firmware

Number
FWA-PPCR2*-GP*-10VRS-DO-P2XXXX R911306462 FWC-PFM01*-GP*-10VRS-MS GPP 10 firmware PFM memory
FWC-DPS01*-PHP-02VRS-NN Profibus slave DPS01 card
Table 10-6: FWA-PPCR2*-GP*-10VRS-DO-P2XXXX Firmware
PPC-R22.1 with EtherNet using GPP 10 / Profibus Slave

Firmware
10 / Profibus slave firmware.
Configuration Expansion Slots Description Material

U2 U3 U4 Number
PPC-R22.1N-T-NN-P2-NN-FW Cover DPS01 Cover Profibus slave interface 1070170285
PPC-R22.1N-T-Q1-P2-NN-FW DAQ03 DPS01 Cover Link Ring cross communication 1070170288
PPC-R22.1N-T-N1-N2-P2-FW NSW01 NSW01 DPS01 PLS interface with 32 outputs 1070170293
PPC-R22.1N-T-Q1-P2-G1-FW DAQ03 DPS01 MEC Link Ring cross communication, 1070170302
Profibus slave interface, and
GDS/GDM Encoder Interface
Table 10-7: PPC-R22.1 using GPP 10 / Profibus Slave / EtherNet Firmware

Number
FWC-DPS01*-PHP-02VRS-NN Profibus slave DPS01 card
PPC-R22.1 without EtherNet using GPP 10 / Profibus

Master Firmware
10 / Profibus master firmware.

PPC-R22.1N-N-NN-P1-NN-FW Cover DPM01 Cover Profibus master interface 1070170307
PPC-R22.1N-N-Q1-P1-NN-FW DAQ03 DPM01 Cover Link Ring cross communication
and Profibus master interface
PPC-R22.1N-N-Q1-P1-N1-FW DAQ03 DPM01 NSW01 PLS interface with 16 outputs
PPC-R22.1N-N-N1-N2-P1-FW NSW01 NSW01 DPM01 PLS interface with 32 outputs
Table 10-9: PPC-R22.1 without EtherNet using GPP 10 / Profibus Master
Firmware

Number
FWC-DPM01*-PHP-02VRS-NN Profibus master DPM01 card
PPC-R22.1 with EtherNet using GPP 10 / Profibus Master

Firmware

U2 U3 U4 Number
PPC-R22.1N-T-NN-P1-NN-FW Cover DPM01 Cover Profibus master interface 1070170294
PPC-R22.1N-T-Q1-P1-NN-FW DAQ03 DPM01 Cover Link Ring cross communication 1070170296
PPC-R22.1N-T-N1-N2-P1-FW NSW01 NSW01 DPM01 PLS interface with 32 outputs 1070170298
PPC-R22.1N-T-G3-P1-NN-FW MEC DPM01 Cover EnDat Encoder Interface and 1070170303
Profibus master interface
PPC-R22.1N-T-N1-P1-G3-FW NSW01 DPM01 MEC PLS interface with 16 outputs, 1070170304
Profibus master interface, and
EnDat Encoder Interface
Table 10-11: PPC-R22.1 with EtherNet using GPP 10 / Profibus Master Firmware

Number
PPC-R22.1 without EtherNet using GPP 10 / DeviceNet

Slave Firmware
10 / DeviceNet slave firmware.

U2 U3 U4 Number
PPC-R22.1N-N-V2-NN-NN-FW DNS03 Cover Cover DeviceNet slave interface 1070170150
PPC-R22.1N-N-Q1-V2-NN-FW DAQ03 DNS03 Cover Link Ring cross communication 1070170282
and DeviceNet slave interface
PPC-R22.1N-N-N1-N2-V2-FW NSW01 NSW01 DNS03 PLS interface with 32 outputs 1070170284
Table 10-13: PPC-R22.1 without EtherNet using GPP 10 / DeviceNet Slave
Firmware

Number
FWA-PPCR2*-GP*-10VRS-DO-V2XXXX R911306463 FWC-PFM01*-GP*-10VRS-MS GPP 10 firmware PFM memory
FWC-DNS01*-PHV-01VRS-NN DeviceNet slave DNS03
(Material number: R911286688) firmware DeviceNet card
Table 10-14: FWA-PPCR2*-GP*-10VRS-DO-V2XXXX Firmware
PPC-R22.1 with EtherNet using GPP 10 / DeviceNet Slave

Firmware
10 / DeviceNet slave firmware.

U2 U3 U4 Number
PPC-R22.1N-T-V2-NN-NN-FW DNS03 Cover Cover DeviceNet slave interface 1070170286
PPC-R22.1N-T-Q1-V2-NN-FW DAQ03 DNS03 Cover Link Ring cross communication 1070170289
Table 10-15: PPC-R22.1 with EtherNet using GPP 10 / DeviceNet Slave
Firmware

Number
FWC-DNS01*-PHV-01VRS-NN DeviceNet slave DNS03
(Material number: R911286688) firmware DeviceNet card
PPC-R22.1 without EtherNet using GPP 10 / DeviceNet

Master Firmware
10 / DeviceNet master firmware.

U2 U3 U4 Number
PPC-R22.1N-N-V1-NN-NN-FW DNM03 Cover Cover DeviceNet master interface
PPC-R22.1N-N-Q1-V1-NN-FW DAQ03 DNM03 Cover Link Ring cross communication
and DeviceNet master interface
PPC-R22.1N-N-Q1-V1-N1-FW DAQ03 DNM03 NSW01 Link Ring cross communication,
DeviceNet master interface and
PLS interface with 16 outputs
PPC-R22.1N-N-V1-N1-N2-FW DNM03 NSW01 NSW01 DeviceNet master interface and
PLS interface with 32 outputs
Table 10-17: PPC-R22.1 without EtherNet using GPP 10 / DeviceNet Master
Firmware

Number
FWC-DNM03*-PHV-01VRS-NN DeviceNet DNM03 card
(Material number: R911291424) master firmware
PPC-R22.1 with EtherNet using GPP 10 / DeviceNet

Master Firmware

U2 U3 U4 Number
PPC-R22.1N-T-V1-NN-NN-FW DNM03 Cover Cover DeviceNet master interface 1070170295
PPC-R22.1N-T-Q1-V1-NN-FW DAQ03 DNM03 Cover Link Ring cross communication 1070170297
PPC-R22.1N-T-N1-N2-V1-FW NSW01 NSW01 DNM03 PLS interface with 32 outputs, 1070170299
Table 10-19: PPC-R22.1 with EtherNet using GPP 10 / DeviceNet Master
Firmware

Number
FWC-DNM03*-PHV-01VRS-NN DeviceNet DNM03 card
PPC-R22.1 with EtherNet using GPP 10 Interbus Slave

Firmware
The hardware configuration in the following table is ordered with GPP 10 /
Interbus slave firmware.

U2 U3 U4 Number
PPC-R22.1N-T-NN-B2-NN-FW Cover IBS03 Cover Interbus slave interface 1070170291
Table 10-21: PPC-R22.1 with EtherNet using GPP 10 / Interbus Slave Firmware
The following table contains the FWA typecode ordered with the hardware
configuration listed above.

Number
FWA-PPCR2*-GP*-10VRS-DO-B2XXXX R911306459 FWC-PFM01*-GP*-10VRS-MS GPP 10 firmware PFM memory
FWC-IBS03*-PHB-01VRS-NN Interbus slave IBS03 card
Table 10-22: FWA-PPCR2*-GP*-10VRS-DO-B2XXXX Firmware
PPC-R22.1 with EtherNet using GPP 10 / ControlNet

Slave Firmware
The hardware configuration in the following table is ordered with GPP 10 /
ControlNet slave firmware.

U2 U3 U4 Number
PPC-R22.1N-T-L2-NN-NN-FW CNS01 Cover Cover ControlNet slave interface and 1070170292
Table 10-23: PPC-R22.1 with EtherNet using GPP 10 / ControlNet Slave
Firmware
The following table contains the FWA typecode ordered with the hardware
configuration listed above.

Number
FWA-PPCR2*-GP*-10VRS-DO-L2XXXX R911306460 FWC-PFM01*-GP*-10VRS-MS GPP 10 firmware PFM memory
FWC-CNS01*-PHL-01VRS-NN ControlNet slave CNS01
(Material number: R911288991) firmware ControlNet
Table 10-24: FWA-PPCR2*-GP*-10VRS-DO-L2XXXX Firmware
10.2 PPC-P11.1 Hardware and Firmware

The PPC-P11.1 control is available with a 32 MB compact flash memory
card and optional interfaces on secondary front faceplates. Firmware
must be ordered separately for each hardware configuration using the
appropriate FWA typecode. The FWA typecode includes additional
firmware that might be required for optional interfaces that are part of the
configuration, such as Option Card PLS or Link Ring. Firmware
typecodes are listed for all FWA typecodes in the following sections.
PPC-P11.1 Hardware Configurations

The standard PPC-P11.1 hardware configuration comes equipped with
one serial programming port (X10) and a PFM compact flash memory
card. The Dolfi bootloader firmware (FWC-PPCPR*-BTL-02VRS-NN) is
not flashed to the PFM compact flash memory card but resides on-board
the hardware flash.
A second interface card containing a serial communication port (X16) and
digital inputs and outputs can be order as follows:
• SUP-E01-PPC-P11 Material Number: R911298775
Refer to section 4.2, PPC-P11.1 Overview for details.
PPC-P11.1 using GMP 10 Firmware

The hardware configurations in the following table are ordered with GMP
10 firmware.
Hardware PC Expansion Slots Description Material

st nd rd TH
Typecode 1 2 3 4 Number
PPC-P11.1N-N-NN-NN-NN-FW PPC-P Cover Cover Cover PPC-P11.1 only R911293533
PPC-P11.1N-N-N1-NN-NN-FW PPC-P NSW Cover Cover PPC-P11.1 and PLS interface R911296298
with 16 outputs
PPC-P11.1N-N-N1-N2-NN-FW PPC-P NSW NSW Cover PPC-P11.1 and PLS interface R911296299
with 32 outputs
PPC-P11.1N-N-Q1-NN-NN-FW PPC-P DAQ Cover Cover PPC-P11.1 and Link Ring cross R911296300
communication
PPC-P11.1N-N-N1-Q1-NN-FW PPC-P NSW DAQ Cover PPC-P11.1, PLS interface with R911296301
16 outputs and Link Ring cross
communication
Table 10-25: PPC-P11.1 using GMP 10 Firmware
hardware configurations listed above.

Number
FWA-PPCP11-GM*-10VRS-DO-XXXXXX R911306343 FWC-PFM01*-GM*-10VRS-DO GMP 10 PFM compact
(Material number: R911306342) firmware memory card
Table 10-26: FWA-PPCP11-GM*-10VRS-DO-XXXXXX Firmware
PPC-P11.1.1 using GMP 10 / Profibus Master Firmware


PPC-P11.1N-N-P1-NN-NN-FW DPM01 Cover Cover Profibus master interface R911296365
Table 10-27: PPC-P11.1 using GMP 10 / Profibus Master Firmware

Number
FWA-PPCP11-GM*-10VRS-DO-P1XXXX R911306344 FWC-PFM01*-GM*-10VRS-DO GMP 10 PFM compact
Table 10-28: FWA-PPCP11-GM*-10VRS-DO-P1XXXX Firmware
PPC-R22.1 using GMP 10 / DeviceNet Master Firmware


PPC-R22.1N-N-V1-NN-NN-FW DNM01 Cover Cover DeviceNet master interface R911296363
Table 10-29: PPC-P11.1 using GMP 10 / DeviceNet Master Firmware

Number
FWA-PPCP11-GM*-10VRS-DO-V1XXXX R911306352 FWC-PFM01*-GM*-10VRS-DO GMP 10 PFM compact
FWC-DNM03*-PHV-01VRS-NN DeviceNet DSM01 card
Table 10-30: FWA-PPCP11-GM*-10VRS-DO-V1XXXX Firmware
10.3 Upgrading Control Firmware

The upgrading of control firmware should only be performed by trained
personnel to ensure proper installation of the following firmware types:
• GPP 10 firmware (PPC-R22.1)
• GMP 10 firmware (PPC-P11.1)
• Bootloader firmware for PPC-R
Note: The PPC-P11.1 bootloader firmware is retrieved from the PC

board's on-board flash. The user never needs to upload
bootloader firmware to the PPC-P11.1. If new bootloader
firmware is required, contact Bosch Rexroth's Service
Department for assistance.
Bootloader Firmware on Controls

Bootloader firmware for the PPC-P11.1 resides on the PC board's
on-board flash. On power-up, the bootloader firmware is initialized from
the on-board flash. The control firmware on the PFM card is than
initialized and the control is ready for operation. If the PFM card does not
contain control firmware, the PPC-P11.1 remains in bootloader mode
awaiting the installation of GMP control firmware.
Upgrading flash bootloader firmware on PPC-

P11.1
⇒ The PPC-P11.1's on-board bootloader firmware can
CAUTION be upgrade using serial Dolfi software. However,
care must be taken not to turn power off or interrupt
the serial Dolfi communication. If this occurs, the
PPC-P11.1 may be rendered inoperable and must
then be sent to Bosch Rexroth's service department
for reinstallation of firmware.
Dolfi Software
Control firmware can be upgraded on a PFM card containing using the
following serial Dolfi software.
• Typecode: SWA-DOL*PC-INB-01VRS-MS
• Material Number: R911279804
Switching to Download Mode (DL)

To switch the PPC-R to download mode, cycle power to the control while
holding down the S1 button until the H1 display scrolls the bootloader
firmware version. Once released, the H1 display will read "DL". The
PPC-P11.1 does not have a S1 button and requires the use of control
parameter C-0-0994 to switch the control to download mode.
Note: To switch the control to standard operating mode, cycle power

without holding the S1 button.
To view the control's download mode settings, hold the S1 button for 2
seconds then release. Next, push the S1 button to scroll through the
following control's download mode settings.
Press S1 #
of Times H1 Display
0 M00: PPC Bootloader
1 M02: PSM01*-BTL02VRS (RS = current release)
2 M03: Device address = " # " ( # = control address)
3 M04: X10-Mode = 232
4 M05: X10-Baud = "current download baud rate"
5 M07: X16-Mode = 232
6 M08: X16-Baud = "current download baud rate"
Table 10-31: Bootloader Download Settings
Interrupting bootloader firmware upgrade will

render the PFM memory card inoperable.
⇒ When upgrading bootloader firmware of the same
CAUTION version, care must be taken not to turn power off or
interrupt the serial Dolfi communication. If this
occurs, the bootloader firmware must be reinstalled
using a compact flash hardware interface.
10.4 HMI Hardware and Firmware
VCP Small Operator Terminals

The VCP small operator terminal hardware is available in 5 different
models. Firmware must be ordered separately for each hardware
configuration using the appropriate FWA typecode.
VCP02 Serial or Profibus

The following VCP02 hardware configurations are available:
Hardware Typecode Description Material Number

VCP02.1BRN-RS-NN-FW Serial interface R911305253
VCP02.1BRN-PB-NN-FW Profibus interface R911305255
Table 10-32: VCP02 Hardware Configurations
Firmware Typecode (FWA) Description Material Number

FWA-VCP02*-SUE-01VRS-EN VCP02 firmware R911305254
Table 10-33: VCP02 Firmware Configuration


VCP05.1BSN-RS-NN-FW Serial interface R911305256
VCP05.1BSN-PB-NN-FW Profibus interface R911305257



VCP08.1BTN-RS-NN-FW Serial interface R911305259
VCP08.1BTN-PB-NN-FW Profibus interface R911305260



VCP20.1BUN-256RS-NN-FW Serial interface (256kB) R911305261
VCP20.1BUN-256PB-NN-FW Profibus interface (256kB) R911305263
VCP20.1BUN-768RS-NN-FW Serial interface (768kB) R911305265
VCP20.1BUN-768PB-NN-FW Profibus interface (768kB) R911305267



VCP25.1BVN-003RS-NN-FW Serial interface (3 MB) R911305268
VCP25.1BVN-003PB-NN-FW Profibus interface (3 MB) R911305269

VI Composer Software
The parametrization and visualization of the VCP small operator terminals
is done using the following VI-Composer software.
Software Typecode Material Number

SWA-VIC*PC-INB-01VRS-DO-CD0650-EN R911305266
Table 10-42: VI Composer Software
BTC06.2 Hardware
The BTC06.2 handheld unit comes equipped with a standard E-Stop
button and Liveman switch. Optional features can be ordered which
include a feedrate override switch and handwheel. The following
tables describe the available options along with typecodes and
material numbers.

BTC06 with 40 keys insert, handwheel, E-stop button, override BTC06.2A-F-EH3-FW R911285854
switch and live-man
BTC06 with 40 keys insert, E-stop button and live-man switch BTC06.2A-F-EN3-FW R911285855
BTC06 with 40 keys insert, E-stop button, override switch and BTC06.2A-F-EP3-FW R911285856
live-man
Table 10-43: BTC06.2 with Liveman and E-Stop
BTC06 Firmware
The BTC06 handheld unit can be ordered with any of the following
firmware configurations, depending on the following application.
• Teach Pendant VT100 Terminal
• Screen Manager Teach Pendant Interface
• Screen Manager Runtime
Firmware must be ordered separately for each hardware configuration
using the appropriate FWA and/or SWA typecodes.
VT100 Terminal Firmware

VT100 Terminal firmware is used to display screens that are generated by
the control firmware. This version uses control resources to provide
screens to the BTC06.
Firmware Typecode (FWB) Material Includes Description Location

Number
FWA-BTC06*-DOL-01VRS-EN R911280769 FWC-BTC06*-DOL-01VRS-EN Bootloader BTC06
SWA-BTC06*-VT-01VRS-MS-C1.44 R911280785 SWD-BTC06*-VT-01VRS-MS-C1.44 VT100 terminal BTC06
(Material number: R911280788) software
SWD-DOL*PC-INB-01VRS-MS-C1.44 Serial Dolfi PC
(Material number: R911279806) Software
Table 10-44: VT100 Terminal Firmware
Note: The feedrate override switch and handwheel are not supported
with the VT100 terminal firmware.
Screen Manager Teach Pendant Interface Firmware

The Screen Manager Teach Pendant Interface firmware displays the
same screens as the VT100 terminal with the following exceptions:
• No sequencer support
• Edit key is not supported
• Handwheel option is not supported.
• Pendant enable bit (reg. 1, bit 14) not supported
• Pendant status register (reg. 95-97) not supported
• Pendant password (C-0-0801, C-0-0802 and C-0-0807) not supported
• Control parameters C-0-0810 through C-0-0814 are not supported
Note: The Screen Manager Teach Pendant Interface firmware does

support the feedrate override switch.
The screens are generated on the BTC06 unit and not by the control.
This version frees up control resources. The BTC06 boots up into the
main screen. The communication settings on the BTC06 can be set by
the user. The baud rate and mode of the BTC06 must match the settings
of the PPC-R.
Note: PPC-R control parameter C-0-0012 must be set to ASCII

Host.
Firmware Typecode (FWB) Material Number Includes Description Location

FWA-BTC06*-VM*-02VRS-MS R911291480 FWC-BTC06*-DOL-01VRS-EN Bootloader firmware BTC06
(Material number: R911280770)
Table 10-45: Screen Manager Teach Pendant Interface Firmware
Screen Manager Runtime Firmware

The Screen Manager runtime firmware is used to display custom screens
created with the following Screen Manager PC software:
• SWA-SCM*PC-INB-03VRS-MS-C1.44 Material Number: R911289711
Firmware Typecode (FWB) Material Includes Description Location

Number
FWA-BTC06*-DOL-01VRS-EN R911280769 FWC-BTC06*-DOL-01VRS-EN Bootloader BTC06
SWA-BTC06*-SCM-02VRS-MS-C1.44 R911284172 SWD-BTC06*-SCM-02VRS-MS-C1.44 Screen Manager BTC06
(Material number: R911284434) runtime
SWD-DOL*PC-INB-01VRS-MS-C1.44 Serial Dolfi PC
(Material number: R911279806) Software
Table 10-46: Screen Manager Runtime Firmware
Note: The feedrate override and handwheel options can be

programmed for functionality using the Screen Manager PC
software and VisualMotion.
Rexroth VisualMotion 10 Project Planning Typecodes 11-1
11 Typecodes
11.1 Typecode Description
PPC-R22.1 Typecode
ppcr22_1_typecode.FH7
Fig. 11-1: PPC-R22.1 Typecode
11-2 Typecodes Rexroth VisualMotion 10 Project Planning
PPC-P11.1 Typecode
ppcp11_1_typecode.FH7
Fig. 11-2: PPC-P11.1 Typecode
VCP02 Typecode
vcp02_typecode.EPS
Fig. 11-3: VCP02 Typecode
VCP05 Typecode
vcp05_typecode.EPS
VCP08 Typecode
vcp08_typecode.EPS
VCP20 Typecode
vcp20_typecode.EPS
VCP25 Typecode
vcp25_typecode.EPS
BTC06.2 Typecode
btc06_typecode.FH7
Fig. 11-8: BTC06.2 Typecode
BTZ01.1 Typecode
btz01_1_typecode.FH7
Fig. 11-9: BTZ01.1 Typecode
Rexroth VisualMotion 10 Project Planning Index 12-1
12 Index
Technical Data .......................9-4
Fiber Optic Bulkhead..................9-2
0 Fiber Optic Cable .......................9-1
06-0986 ...................................... 9-2 Fieldbus
Interbus ..................................6-1
Firmware
B Basic GPP ..........................10-10
BTC06 ........................................ 8-4

Display ................................... 8-4 G
Emergency Shut-Off............... 8-6
Glass fiber optic cable ................9-2
Enclosure Dimensions ........... 8-7
Grounding
Flash ...................................... 8-5
System .................................4-20
Hardware and Firmware..... 10-13
Live-Man Switch ..................... 8-6
Main Connection .................... 8-9 H
Power consumption................ 8-4
Protection ............................... 8-4 Hardware Configurations
RS232 Interface ..................... 8-9 PPC-R02.2 ...........................10-1
Supply voltage........................ 8-4 HDD02.2 digital drive controller..1-7
Temperature range ................ 8-4 HDS digital drive controller.........1-7
Weight.................................... 8-4 HVE power supply...............1-5, 1-7
BTC06 to PPC-R Connection... 8-11 HVR power supply...............1-6, 1-7
BTC06 to PPC-R Terminal Strip
Connection ........................... 8-12
BTZ01.1 Junction Box.............. 8-10 I
I/O configuration limits..............5-10
C I/O modules .........................5-1, 5-6
Diax ........................................5-9
CNS01 ControlNet Slave Interface EMD...............................5-9, 5-18
............................................... 6-6 Reco 02 ..................................5-5
ControlNet Rexroth Inline .........................5-2
Diagnostics............................. 6-7 IBS03 Interbus Slave Interface...6-9
Specifications ......................... 6-8 IKB0010....................................8-10
IKO 0001 ....................................9-2
IKO 0982 ....................................9-2
D IKO 0985 ....................................9-2
DAE02.1................................... 5-17 Interbus
DAQ03 Expansion Card ............. 7-7 Diagnostics...........................6-10
DEA Digital Drive I/O Cards ..... 5-16 Specifications .......................6-11
DeviceNet................................... 6-4
Diagnostics............................. 6-4 L
Specifications ......................... 6-5
Transceiver Voltage ............... 6-5 Live-Man switch...................8-5, 8-6
DIAX04 digital drive.................... 1-7 Local Reco 02 I/O
DIAX04 Power Supplies ............. 1-6 Accessing .............................5-11
Double Link Ring...................... 7-10 Local RECO02 I/O station ..........5-5
Double Ring ............................. 7-10 LWL............................................9-1
DPS01 Profibus-DP Slave Interface
............................................... 6-2
Drive Address Settings............... 9-6 N
NSW01
E Hardware ................................7-6
Option Card PLS Specifications7-
ECODRIVE03 Digital Drive 6
Controllers.......................1-7, 1-8
EcoX Bus System .................... 5-18
Torque Following Mode........ 5-20 P
EMD I/O module......................... 5-9 panic position .............................8-7
Emergency Stop button.............. 8-6 Pin Assignment
Ethernet Interface....................... 4-8 X1 Power supply............4-5, 4-13
Ethernet/IP ................................. 4-8 PPC
Diagnostic Displays ..............4-17
F PPC-P11.1
Control..................................4-10
Fiber Optic Digital I/O Specs...................4-12
12-2 Index Rexroth VisualMotion 10 Project Planning
General Specifications ......... 4-12 Rexroth Inline .............................5-2

Hardware.............................. 4-10 Rexroth Inline I/O
Interfaces ............................. 4-12 Accessing .............................5-10
Supply Voltage ..................... 4-12 RMB02.2-02 ...............................5-7
PPC-R RMB02.2-04 ...............................5-8
Control.................................... 4-1
Digital I/O Specs. ..........4-5, 4-12
Digital Input / Output Supply S
Voltage ......................4-7, 4-13 Safety Concept...........................8-6
General Specifications ........... 4-4 Safety Instructions for Electric
Hardware................................ 4-3 Drives and Controls................3-1
Hardware and Firmware....... 10-1 Secondary Ring........................7-10
Maximum current consumption4- SERCOS
4 Baudrate.................................9-8
Motion Control System ........... 5-1 Transmitter Output Power ......9-9
Power Supply Voltage ............ 4-6 Sercos coupler ...........................5-2
PSM01.1 memory card......... 4-18 SercosReco 02 I/O modules
Supply Voltage ....................... 4-4 Accessing .............................5-11
Primary Ring .....................7-9, 7-10 Serial Communication ..............4-15
Profibus Single Ring .................................7-9
Diagnostics............................. 6-2 SUP-M01-BTC06 Wall-Mounting
Specifications ......................... 6-3 Bracket ...................................8-8
PSM01.1 memory card............. 4-18 Switch elements .........................8-5
R T
RECO 02 Hardware ................... 5-5 Typecode
Reco I/O Error Reaction........... 5-15 BTC06.2 ...............................11-6
RECO02 Bit Access BTZ01.1................................11-7
16-Bit I/O Modules................ 5-12
32-Bit I/O Modules................ 5-12
RMC02.2 Analog I/O Module 5-14 V
RECO02 I/O modules ................ 5-6
Remote Analog Input Drive Cards5- VisualMotion System Overview ..1-1
17
Remote I/O Station..................... 5-5
Rexroth VisualMotion 10 Project Planning Service & Support 13-1
13 Service & Support
13.1 Helpdesk
Unser Kundendienst-Helpdesk im Hauptwerk Lohr Our service helpdesk at our headquarters in Lohr am
am Main steht Ihnen mit Rat und Tat zur Seite. Main, Germany can assist you in all kinds of inquiries.
Sie erreichen uns Contact us
- telefonisch: +49 (0) 9352 40 50 60 - by phone: +49 (0) 9352 40 50 60

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

oder +49 (0) 172 660 04 06 or +49 (0) 172 660 04 06
13.3 Internet
Ergänzende Hinweise zu Service, Reparatur und Additional notes about service, repairs and training
Training sowie die aktuellen Adressen unserer as well as the actual addresses of our sales- and
Service- und Vertriebsbüros finden Sie unter service facilities are available on the Internet at
www.boschrexroth.com – einige Angaben in www.boschrexroth.com – some information
dieser Dokumentation können inzwischen überholt in this documentation may meanwhile be obsolete.
sein.
Please contact the sales & service offices in your
Außerhalb Deutschlands nehmen Sie bitte zuerst area first.
Kontakt mit Ihrem lokalen Ansprechpartner auf.
sales agencies
Verkaufsniederlassungen offices providing service
Niederlassungen mit Kundendienst
13.4 Vor der Kontaktaufnahme... - Before contacting us...

Wir können Ihnen schnell und effizient helfen wenn For quick and efficient help, please have the
Sie folgende Informationen bereithalten: following information ready:
detaillierte Beschreibung der Störung und der 1. Detailed description of the failure and
Umstände. circumstances.
Angaben auf dem Typenschild der betreffenden 2. Information on the nameplate of the affected
Produkte, insbesondere Typenschlüssel und products, especially typecodes and serial
Seriennummern. numbers.
Tel.-/Faxnummern und e-Mail-Adresse, unter 3. Your phone/fax numbers and e-mail address,
denen Sie für Rückfragen zu erreichen sind. so we can contact you in case of questions.
13-2 Service & Support Rexroth VisualMotion 10 Project Planning
13.5 Kundenbetreuungsstellen - Sales & Service Facilities
Deutschland – Germany vom Ausland: (0) nach Landeskennziffer weglassen!

from abroad: don’t dial (0) after country code!
Vertriebsgebiet Mitte
Germany Centre SERVICE SERVICE SERVICE
Bosch Rexroth AG CALL ENTRY CENTER HOTLINE ERSATZTEILE / SPARES
Bgm.-Dr.-Nebel-Str. 2 MO – FR MO – FR verlängerte Ansprechzeit
97816 Lohr am Main von 07:00 - 18:00 Uhr von 17:00 - 07:00 Uhr - extended office time -
from 5 pm - 7 am ♦ nur an Werktagen
Kompetenz-Zentrum Europa from 7 am – 6 pm + SA / SO - only on working days -
Tel.: +49 (0)9352 40-0 ♦ von 07:00 - 18:00 Uhr
Tel. +49 (0) 9352 40 50 60 Tel.: +49 (0)172 660 04 06 - from 7 am - 6 pm -
Fax: +49 (0)9352 40-4885 oder / or
service@boschrexroth.de
Tel.: +49 (0)171 333 88 26 Tel. +49 (0) 9352 40 42 22
Vertriebsgebiet Süd Gebiet Südwest Vertriebsgebiet Ost Vertriebsgebiet Ost
Germany South Germany South-West Germany East Germany East
Bosch Rexroth AG Bosch Rexroth AG Bosch Rexroth AG Bosch Rexroth AG
Landshuter Allee 8-10 Vertrieb Deutschland – VD-BI Beckerstraße 31 Regionalzentrum Ost
80637 München Geschäftsbereich 09120 Chemnitz Walter-Köhn-Str. 4d
Tel.: +49 (0)89 127 14-0 Regionalzentrum Südwest 04356 Leipzig
Fax: +49 (0)89 127 14-490 Ringstrasse 70 / Postfach 1144
70736 Fellbach / 70701 Fellbach Tel.: +49 (0)341 25 61-0
Tel.: +49 (0)711 57 61–100 Tel.: +49 (0)371 35 55-0 Fax: +49 (0)341 25 61-111
Fax: +49 (0)711 57 61–125 Fax: +49 (0)371 35 55-333
Vertriebsgebiet West Vertriebsgebiet Mitte Vertriebsgebiet Nord Vertriebsgebiet Nord

Germany West Germany Centre Germany North Germany North
Bosch Rexroth AG Bosch Rexroth AG Bosch Rexroth AG Bosch Rexroth AG
Vertrieb Deutschland Regionalzentrum Mitte Walsroder Str. 93 Kieler Straße 212
Regionalzentrum West Waldecker Straße 13 30853 Langenhagen 22525 Hamburg
Borsigstrasse 15 64546 Mörfelden-Walldorf
40880 Ratingen Tel.: +49 (0) 511 72 66 57-0
Tel.: +49 (0)2102 409-0 Tel.: +49 (0) 61 05 702-3 Fax: +49 (0) 511 72 66 57-95 Tel.: +49 (0) 40 81 955 966
Fax: +49 (0)2102 409-406 Fax: +49 (0) 61 05 702-444 Fax: +49 (0) 40 85 418 978
Europa (West) - Europe (West)

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

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

Bosch Rexroth Ltd. Rexroth Mecman Oy Bosch Rexroth S.A. Bosch Rexroth S.A.
Broadway Lane, South Cerney Ansatie 6 Avenue de la Trentaine 1270, Avenue de Lardenne
Cirencester, Glos GL7 5UH 017 40 Vantaa BP. 74 31100 Toulouse
Tel.: +44 (0)1285 863000 Tel.: +358 (0)9 84 91-11 77503 CHELLES CEDEX Tel.: +33 (0)5 61 49 95 19
Fax: +44 (0)1285 863030 Fax: +358 (0)9 84 91-13 60 Tel.: +33 (0)164 72-70 00 Fax: +33 (0)5 61 31 00 41
sales@boschrexroth.co.uk Fax: +33 (0)164 72-63 00
service@boschrexroth.co.uk Hotline: +33 (0)608 33 43 28
France - Frankreich Italy - Italien Italy - Italien Italy - Italien

Bosch Rexroth S.A. Bosch Rexroth S.p.A. Bosch Rexroth S.p.A. Bosch Rexroth S.p.A.
91, Bd. Irène Joliot-Curie Via G. Di Vittoria, 1 Via Paolo Veronesi, 250 Via del Progresso, 16 (Zona Ind.)
69634 Vénissieux – Cedex 20063 Cernusco S/N.MI 10148 Torino 35020 Padova
Tel.: +33 (0)4 78 78 53 65 Tel.: +39 02 2 365 270 Tel.: +39 011 224 88 11 Tel.: +39 049 8 70 13 70
Fax: +33 (0)4 78 78 53 62 Fax: +39 02 700 408 252378 Fax: +39 011 220 48 04 Fax: +39 049 8 70 13 77
Italy - Italien Italy - Italien Netherlands - Niederlande/Holland Netherlands - Niederlande/Holland

Bosch Rexroth S.p.A. Bosch Rexroth S.p.A. Bosch Rexroth B.V. Bosch Rexroth Services B.V.
Via Mascia, 1 Viale Oriani, 38/A Kruisbroeksestraat 1 Kruisbroeksestraat 1
80053 Castellamare di Stabia NA 40137 Bologna (P.O. Box 32) (P.O. Box 32)
Tel.: +39 081 8 71 57 00 Tel.: +39 051 34 14 14 5281 RV Boxtel 5281 RV Boxtel
Fax: +39 081 8 71 68 85 Fax: +39 051 34 14 22 Tel.: +31 (0)411 65 19 51 Tel.: +31 (0)411 65 19 51
Fax: +31 (0)411 65 14 83 Fax: +31 (0)411 67 78 14
indramat@hydraudyne.nl
Norway - Norwegen Spain - Spanien Spain - Spanien Sweden - Schweden

Bosch Rexroth AS Bosch Rexroth S.A. Bosch Rexroth S.A. Rexroth Mecman Svenska AB
Berghagan 1 or: Box 3007 Centro Industrial Santiga Goimendi S.A. Varuvägen 7
1405 Ski-Langhus 1402 Ski Obradors s/n Parque Empresarial Zuatzu 125 81 Stockholm
Tel.: +47 (0)64 86 41 00 08130 Santa Perpetua de Mogoda C/ Francisco Grandmontagne no.2
Fax: +47 (0)64 86 90 62 Barcelona 20018 San Sebastian Tel.: +46 (0)8 727 92 00
jul.ruud@rexroth.no Tel.: +34 9 37 47 94 00 Tel.: +34 9 43 31 84 21 Fax: +46 (0)8 647 32 77
Fax: +34 9 37 47 94 01 - service: +34 9 43 31 84 56
Fax: +34 9 43 31 84 27
- service: +34 9 43 31 84 60
satindramat-goimendi@adegi.es
Sweden - Schweden Switzerland West - Schweiz West Switzerland East - Schweiz Ost
Rexroth Mecman Svenska AB Bosch Rexroth Suisse SA Bosch Rexroth Schweiz AG
Ekvändan 7 Rue du village 1 Hemrietstrasse 2
254 67 Helsingborg 1020 Renens 8863 Buttikon
Tel. +41 (0) 55 46 46 205
Tel.: +46 (0) 42 38 88 -50 Tel.: +41 (0)21 632 84 20 Fax +41 (0) 55 46 46 222
Fax: +46 (0) 42 38 88 -74 Fax: +41 (0)21 632 84 21
Europa (Ost) - Europe (East)

vom Ausland: (0) nach Landeskennziffer weglassen
from abroad: don’t dial (0) after country code
Czech Republic - Tschechien Czech Republic - Tschechien Hungary - Ungarn Poland – Polen
Bosch -Rexroth, spol.s.r.o. DEL a.s. Bosch Rexroth Kft. Bosch Rexroth Sp.zo.o.
Hviezdoslavova 5 Strojírenská 38 Angol utca 34 Biuro Poznan
627 00 Brno Zdar nad Sázavou 1149 Budapest ul. Dabrowskiego 81/85
591 01 Czech republic 60-529 Poznan
Tel.: +420 (0)5 48 126 358 Tel.: +420 616 64 3144 Tel.: +36 (1) 364 00 02 Tel.: +48 061 847 64 62 /-63
Fax: +420 (0)5 48 126 112 Fax: +420 616 216 57 Fax: +36 (1) 383 19 80 Fax: +48 061 847 64 02
Rumania - Rumänien Russia - Russland Russia - Russland Turkey - Türkei

Bosch Rexroth Sp.zo.o. Bosch Rexroth ELMIS Bosch Rexroth Otomasyon
Str. Drobety nr. 4-10, app. 14 Wolokolamskoje Chaussee 73 10, Internationalnaya Str. San & Tic. A..S.
70258 Bucuresti, Sector 2 Zimmer 406, 408 246640 Gomel, Belarus Fevzi Cakmak Cad No. 3
RUS – 123424 Moskau Tel.: +375/ 232 53 42 70 34630 Sefaköy Istanbul
Tel.: +40 (0)1 210 48 25 Tel.: +7 095/ 232 08 34 Fax: +375/ 232 53 37 69 Tel.: +90 212 541 60 70
+40 (0)1 210 29 50 +7 095/ 232 08 35 elmis_ltd@yahoo.com Fax: +90 212 599 34 07
Fax: +40 (0)1 210 29 52 Fax: +7 095/ 232 08 36
info.rex@rexroth.ru
Slowenia - Slowenien
DOMEL
Otoki 21
64 228 Zelezniki
Tel.: +386 5 5117 152
Fax: +386 5 5117 225
brane.ozebek@domel.si
Africa, Asia, Australia – incl. Pacific Rim

vom Ausland: (0) nach Landeskennziffer weglassen!
from abroad: don’t dial (0) after country code!
Australia - Australien Australia - Australien China China

AIMS - Australian Industrial Bosch Rexroth Pty. Ltd. Bosch Rexroth Ltd. Bosch Rexroth (China) Ltd.
Machinery Services Pty. Ltd. 15/F China World Trade Center
Unit 3/45 Horne ST No. 7, Endeavour Way Wai Gaoqiao Free Trade Zone 1, Jianguomenwai Avenue
Campbellfield , VIC 3061 Braeside Victoria, 31 95 No.122, Fu Te Dong Yi Road Beijing 100004, P.R.China
Melbourne Melbourne Shanghai 200131 - P.R.China
Tel.: +61 (0) 393 590 228 Tel.: +86 10 65 05 03 80
Fax: +61 (0) 393 590 286 Tel.: +86 21 58 66 30 30
Fax: +86 21 58 66 55 23 Fax: +86 10 65 05 03 79
Hotline: +61 (0) 419 369 195 Tel.: +61 (0)3 95 80 39 33
terryobrien@aimservices.com.au roger.shi_sh@boschrexroth.com.cn
Fax: +61 (0)3 95 80 17 33
mel@rexroth.com.au
China China Hongkong India - Indien

Bosch Rexroth (China) Ltd. Bosch Rexroth (Changzhou) Co.Ltd. Bosch Rexroth (China) Ltd. Bosch Rexroth (India) Ltd.
th
A-5F., 123 Lian Shan Street Guangzhou Repres. Office 6 Floor, Plot. A-58, TTC Industrial Area
Sha He Kou District Room 1014-1016, Metro Plaza, Yeung Yiu Chung No.6 Ind Bldg. Thane Turbhe Midc Road
Dalian 116 023, P.R.China Tian He District, 183 Tian He Bei Rd 19 Cheung Shun Street Mahape Village
Guangzhou 510075, P.R.China Cheung Sha Wan, Navi Mumbai - 400 701
Tel.: +86 411 46 78 930 Tel.: +86 20 8755-0030 Kowloon, Hongkong Tel.: +91 (0)22 7 61 46 22
Fax: +86 411 46 78 932 +86 20 8755-0011 Tel.: +852 22 62 51 00 Fax: +91 (0)22 7 68 15 31
Fax: +86 20 8755-2387 Fax: +852 27 41 33 44
alexis.siu@boschrexroth.com.hk
India - Indien Indonesia - Indonesien Japan Japan

Bosch Rexroth (India) Ltd. PT. Rexroth Wijayakusuma Bosch Rexroth Automation Corp. Bosch Rexroth Automation Corp.
Plot. 96, Phase III Building # 202, Cilandak Service Center Japan 1F, I.R. Building
Peenya Industrial Area Commercial Estate Yutakagaoka 1810, Meito-ku, Nakamachidai 4-26-44, Tsuzuki-ku
Bangalore - 560058 Jl. Cilandak KKO, Jakarta 12560 NAGOYA 465-0035, Japan YOKOHAMA 224-0041, Japan
Tel.: +91 (0)80 8 39 73 74 Tel.: +81 (0)52 777 88 41 Tel.: +81 (0)45 942 72 10
Fax: +91 (0)80 8 39 43 45 Tel.: +62 21 7891169 (5 lines) +81 (0)52 777 88 53 Fax: +81 (0)45 942 03 41
Fax: +62 21 7891170 - 71 +81 (0)52 777 88 79
Fax: +81 (0)52 777 89 01
Korea Malaysia Singapore - Singapur South Africa - Südafrika

Bosch Rexroth-Korea Ltd. Robert Bosch (SEA) Pte Ltd. TECTRA Automation (Pty) Ltd.
Bosch Rexroth Sdn.Bhd.
1515-14 Dadae-Dong, Saha-Ku Dept. RBSI-R/SAT 28 Banfield Road,Industria North
Pusan Metropolitan City, 604-050 Head Office 38-C Jalan Pemimpin RSA - Maraisburg 1700
Republic of South Korea No. 3, Block B, Jalan SS 13/5 Singapore 577180
Tel.: +82 (0)51 26 00 741 Subang Jaya Industrial Estate

Fax: +82 (0)51 26 00 747 47500 Petaling Jaya - Selangor Tel.: +65 35 05 470 Tel.: +27 (0)11 673 20 80
gyhan@rexrothkorea.co.kr Fax: +65 35 05 313 Fax: +27 (0)11 673 72 69
Tel.: +60 (0) 3 73 44 870 Hotline: +27 (0)82 903 29 23
Fax: +60 (0) 3 73 44 864 kenton.peh@sg.bosch.com georgv@tectra.co.za
hockhwa@hotmail.com
Taiwan Thailand
Rexroth Uchida Co., Ltd. NC Advance Technology Co. Ltd.
No.17, Lane 136, Cheng Bei 1 Rd.,
Yungkang, Tainan Hsien 59/76 Moo 9
Taiwan, R.O.C. Ramintra road 34
Tharang, Bangkhen,
Tel.: +886 (0)6 25 36 565 Bangkok 10230
Fax: +886 (0)6 25 34 754
indramat@mail.net.tw Tel.: +66 2 943 70 62
+66 2 943 71 21
Fax: +66 2 509 23 62
sonkawin@hotmail.com
Nordamerika – North America

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

Electric Drives and Controls Electric Drives and Controls 7901 Stoneridge Drive, Suite 220
Charlotte Regional Sales Office Northeastern Technical Center Pleasant Hill, California 94588
14001 South Lakes Drive 99 Rainbow Road
Charlotte, North Carolina 28273 East Granby, Connecticut 06026
Tel.: +1 704 5 83 97 62 Tel.: +1 860 8 44 83 77 Tel.: +1 925 227 10 84
+1 704 5 83 14 86 Fax: +1 860 8 44 85 95 Fax: +1 925 227 10 81
Canada East - Kanada Ost Canada West - Kanada West Mexico
Bosch Rexroth Canada Corporation Bosch Rexroth Canada Corporation Bosch Rexroth S.A. de C.V.
Burlington Division 5345 Goring St. Calle Neptuno 72
3426 Mainway Drive Burnaby, British Columbia Unidad Ind. Vallejo
Burlington, Ontario Canada V7J 1R1 MEX - 07700 Mexico, D.F.
Canada L7M 1A8
Tel.: +52 5 754 17 11
Tel.: +1 905 335 55 11 +52 5 754 36 84
Fax: +1 905 335-41 84 Tel. +1 604 205-5777 +52 5 754 12 60
michael.moro@boschrexroth.ca Fax +1 604 205-6944 Fax: +52 5 754 50 73
david.gunby@boschrexroth.ca +52 5 752 59 43
Südamerika – South America

Argentina - Argentinien Argentina - Argentinien Brazil - Brasilien Brazil - Brasilien
Bosch Rexroth S.A.I.C. NAKASE Bosch Rexroth Ltda. Bosch Rexroth Ltda.
"The Drive & Control Company" Servicio Tecnico CNC Av. Tégula, 888 R. Dr.Humberto Pinheiro Vieira, 100
Acassusso 48 41/47 Calle 49, No. 5764/66 Ponte Alta, Atibaia SP Distrito Industrial [Caixa Postal 1273]
1605 Munro 1653 Villa Balester CEP 12942-440 BR - 89220-390 Joinville - SC
Prov. Buenos Aires Prov. - Buenos Aires Tel.: +55 (0)11 4414 56 92 Tel./Fax: +55 (0)47 473 58 33
+55 (0)11 4414 56 84 Mobil: +55 (0)47 9974 6645
Tel.: +54 (0)11 4756 01 40 Tel.: +54 (0) 11 4768 36 43 Fax sales: +55 (0)11 4414 57 07 prochnow@zaz.com.br
Fax: +54 (0)11 4756 01 36 Fax: +54 (0) 11 4768 24 13 Fax serv.: +55 (0)11 4414 56 86
mannesmann@mannesmannsaic.com.ar nakase@usa.net alexandre.wittwer@rexroth.com.br
nakase@nakase.com
Columbia - Kolumbien
Reflutec de Colombia Ltda.
Calle 37 No. 22-31
Santafé de Bogotá, D.C.
Colombia
Tel.: +57 1 368 82 67

+57 1 368 02 59
Fax: +57 1 268 97 37
reflutec@inter.net. co
Bosch Rexroth AG
Electric Drives and Controls
P.O. Box 13 57
97803 Lohr, Germany
Bgm.-Dr.-Nebel-Str. 2
97816 Lohr, Germany
Phone +49 (0)93 52-40-50 60
Fax +49 (0)93 52-40-49 41
service.svc@boschrexroth.de
www.boschrexroth.com
Printed in Germany
R911306326 DOK-VISMOT-VM*-10VRS**-PR01-EN-P

Rexroth VisualMotion 10 - Project Planning Manual

Uploaded by

Copyright:

Available Formats

Rexroth VisualMotion 10 - Project Planning Manual

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Rexroth VisualMotion 10 - Project Planning Manual

Uploaded by

Copyright:

Available Formats

Industrial Electric Drives Linear Motion and Service Mobile

Hydraulics and Controls Assembly Technologies Pneumatics Automation Hydraulics

Rexroth IndraControl VCP 20

Project Planning Manual

Title Rexroth VisualMotion 10

Type of Documentation Project Planning Manual

Document Typecode DOK-VISMOT-VM*-10VRS**-PR01-EN-P

Internal File Reference Document Number, 120-2300-B322-01/EN

Purpose of Documentation This documentation describes …

Record of Revisions Description Release Notes

Copyright  2004 Bosch Rexroth AG

Published by Bosch Rexroth AG

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

2 Important Usage Directions 2-1

3 Safety Instructions for Electric Drives and Controls 3-1

3.2 Explanations .................................................................................................................................. 3-1

4 VisualMotion Control System 4-1

5 System I/O Modules 5-1

Sercos I/O Configuration Limits............................................................................................. 5-10

6 Fieldbus Interfaces 6-1

7 Encoder Interface, Option Card PLS, and Link Ring 7-1

8 VisualMotion Human Machine Interfaces 8-1

BTC06 Specifications .............................................................................................................. 8-4

9 Fiber Optic Cable(LWL) 9-1

10 Hardware and Firmware Configurations 10-1

VCP20 Typecode................................................................................................................... 11-4

13 Service & Support 13-1

1 Rexroth VisualMotion 10 Overview

1.1 System Overview

1.2 PPC-R Control Overview

Fig. 1-1: PPC-R Motion Control

Note: Onboard EtherNet supports both standard TCP/IP and

• Rexroth Reco 02 I/O modules (Local and SERCOS)

PPC-R PLC Support

PPC-R Optional Interface Support

Fieldbus Slave Interfaces

Fieldbus Master Interfaces

• Master Encoder Card (MEC)

Drive I/O Support

Note: VisualMotion does not support the I/O functionality in Rexroth

1.3 PPC-P11.1 Control Overview

Fig. 1-2: PPC-P11.1 Motion Control

GMP 10 Firmware Features

PPC-P11.1 Optional Interface Support

Drive I/O Support

Note: VisualMotion does not support the I/O functionality in Rexroth

1.4 Rexroth Digital Drive Families

Rexroth IndraDrive Digital Drives

IndraDrive Firmware Description

Table 1-1: VisualMotion 10 Supported IndraDrive Firmware

Refer to the relevant Rexroth IndraDrive documentation for safety

IndraDrive C Compact Converters

IndraDrive M Modular Power Supplies

The HMV01.1R power supply uses current regeneration to regenerate

IndraDrive M Modular Inverters

Motors used with IndraDrive

Fig. 1-3: Motors used with IndraDrive

Rexroth Diax 04 Digital Drives

Diax 04 Power Supplies