TK1 Aw02 en P - 032006

TransKit1
Single/Dual Axis Solution

Application Description
DOK-CONTRL-WZM*TK1-AW02-EN-P
TransKit1 Table of Content 1-2
Title TransKit1
Single/Dual Axis Solution
Type of Documentation Application description
Document Type code DOK-CONTRL-WZM*TK1-AW02-EN-P
Internal file reference Document number, 03-2006-02/EN
Purpose of Documentation This documentation describes pre-engineered single/dual axis motion

solutions for Powertrain applications. Specifically, TRANS-01 connector
compatible configuration is available.
Record of Revisions Description Release Notes

Date
DOK-CONTRL-WZM*TK1-AW01-EN-P April, 04 First issue
DOK-CONTRL-WZM*TK1-AW02-EN-P March, 06 Release
Copyright © Rexroth Indramat GmbH, 2003

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).
Publisher Bosch Rexroth Corporation

5150 Prairie Stone Parkway • Hoffman Estates, IL 60192
Telephone +01 847 645 3600 • Fax +01 847 645 6201
http://www.boschrexroth-us.com/
Dep. BRC/SIM/USA
Note All rights are reserved with respect to the content of this documentation
and the availability of the product.
Table of Contents
1 Introduction 1-1
1.1 Goals ............................................................................................................................. 1-1
1.2 Content .......................................................................................................................... 1-4
2 Important Usage Directions 2-1

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

3.1 Introduction .................................................................................................................... 3-1
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
3-8
3.9 Protection Against Contact with Hot Parts...................................................................... 3-9
3.10 Protection During Handling and Mounting...................................................................... 3-9
3.11 Battery Safety .............................................................................................................. 3-10
3.12 Protection Against Pressurized Systems...................................................................... 3-10
4 Trans-01 retrofitting check list 4-1

4.1 Ambient conditions......................................................................................................... 4-1
4.2 Control topology ............................................................................................................. 4-1
4.3 TRANS-01 control parameters ....................................................................................... 4-4
4.4 I/O-configuration............................................................................................................. 4-4
4.5 NC Program ................................................................................................................... 4-5
4.6 Quotation content........................................................................................................... 4-6
5 Frequently Asked Questions 5-1

Analog command interface (±10V), is it supported? ................................................................................ 5-1
Trans-01, how compatible is the TransKit1?............................................................................................ 5-1
MAC (Indramat) motors, can they be reused? ......................................................................................... 5-1
MAC motor power cable, can it be reused? ............................................................................................. 5-1
MAC motor tachometer and feeback cable, can it be reused?................................................................. 5-1
Axes, how many with the ControlBoxD? .................................................................................................. 5-1
Fieldbus interfaces, are they available?................................................................................................... 5-1
115VAC IO, is it available? ...................................................................................................................... 5-2

G-code programming, is it used?............................................................................................................. 5-2
NC-programs, can it be done at the BTV06? ........................................................................................... 5-2
Auxiliary functions, do they work different with the ControlBoxD?............................................................ 5-2
Reverse program, is it available?............................................................................................................. 5-2
Axes / Stations, can I simultaneously run two independent axes / stations?............................................ 5-2
Adapter plates, are they required when replacing a MAC motor with MHD or MKD?............................... 5-2
Display of BTV06 is dark, why? ............................................................................................................... 5-3
Fuses, are there some in the ControlBoxC and ControlBoxD of the TransKit1? ...................................... 5-3
Heat exchanger, is it required? ................................................................................................................ 5-3
Cable 04-0101 (TRANS-01-DSC NC-cable) , can it be reused? .............................................................. 5-3
Cable 04-0900 (Control cable), can it be reused?.................................................................................... 5-3
Cable 03-0400/03-0401 (Position feedback cable), can it be reused? ..................................................... 5-3
Cable 03-0100/03-0101 (MAC Motor feedback cable), can it be reused?................................................ 5-3
Cable 01-0300 (DSC01 power cable), can it be reused? ......................................................................... 5-4
Cable 01-0520 (DSC03 power cable), can it be reused? ......................................................................... 5-4
Cable 01-0400 (TRANS power cable), can it be reused? ........................................................................ 5-4
MAC motor, can the feedback (encoder) be upgraded for use with DURADRIVE? ................................. 5-4
MAC motor brake control, does it change?.............................................................................................. 5-4
MAC motor blower control, does it change? ............................................................................................ 5-5
24VDC external control voltage, is it required ? ....................................................................................... 5-5
Battery for memory backup, is it used with the TransKit1? ...................................................................... 5-5
ControlBoxD, can I order it from Bosch Rexroth? .................................................................................... 5-5
Drive / motor selection, who can help? .................................................................................................... 5-5
Networking the ControlBoxD ?................................................................................................................. 5-5
Drives that can be controlled with ControlBoxD? ..................................................................................... 5-6
Are the DURADRIVE addresses changeable? ........................................................................................ 5-6
PC communication, how is it setup in the ControlBoxD (TRANS200 inside)?.......................................... 5-6
LHA and/or LZH, is it supported?............................................................................................................. 5-6
TAM panel, does it connect to the ControlBox? ....................................................................................... 5-6
TAM panel, is there a compatible programming tool?.............................................................................. 5-6
Trans-01M, what would I use for retrofit?................................................................................................. 5-7
Programmable limit switches (Waypoints) ? ............................................................................................ 5-7
“Spindle function”, is it available with the ControlBoxD of TransKit1? ...................................................... 5-7
“Adaptive Depth function”, is it possible with the ControlBoxD of TransKit1?........................................... 5-7
“Adaptive Feed function”, is it possible with the ControlBoxD of TransKit1? ............................................ 5-7
“Tapping function”, is it possible with the ControlBoxD of TransKit1? ...................................................... 5-7
“PIM function”, is it possible with the ControlBoxD of TransKit1?............................................................. 5-8
6 TransKit1 Configurations 6-1

6.1 Type Code and ordering ................................................................................................ 6-1
Items to order .......................................................................................................................................... 6-1
Valid type codes/configurations ............................................................................................................... 6-1
ControlBoxD Type Code.......................................................................................................................... 6-2
TransKit1 – TK1 - Type Code .................................................................................................................. 6-3
6.2 Basic TransKit1 elements............................................................................................... 6-4
6.3 Ratings of TransKit1 elements ....................................................................................... 6-6

Ratings – DURADRIVE amplifier ............................................................................................................. 6-6
Ratings – ControlBoxD (discrete IO)........................................................................................................ 6-7
6.4 TransKit1 – Components ............................................................................................... 6-8
TransKit1 – Mounting Frame ................................................................................................................... 6-9
6.5 DURADRIVE Amplifier (with TK1) ................................................................................ 6-12
6.6 ControlBoxD components ............................................................................................ 6-17
ControlBoxD connections & cables........................................................................................................ 6-17
Terminal Block X50 of ControlBoxD ...................................................................................................... 6-18
Heat Exchanger (Optional) .................................................................................................................... 6-19
Internal 24VDC power supply ................................................................................................................ 6-20
ControlBoxD spare parts references...................................................................................................... 6-22
7 Interface Descriptions 7-1

7.1 Connector ST.3 – Control supply voltage....................................................................... 7-1
7.2 Connector St.1 – Interface Control Cable....................................................................... 7-1
Power supply ( see drawings BE2000: sheets 01/12 and 09/12) ............................................................ 7-3
Power control functions ( see drawings BE2000: sheets 03/12 to 09/12) ................................................ 7-4
NC control functions ................................................................................................................................ 7-8
Auxiliary functions.................................................................................................................................. 7-21
Axis #1 functions ................................................................................................................................... 7-32
Axis #2 functions ................................................................................................................................... 7-39
Spare wires of the connector St.1.......................................................................................................... 7-43
7.3 Connector RX and TX – SERCOS fiber optic............................................................... 7-44
7.4 Connector X54 and X55 – DURADRIVE interlock cable .............................................. 7-45
Overview ............................................................................................................................................... 7-45
Connector X54 – Drive #1 Interlock Cable............................................................................................ 7-46
Connector X55 – Drive #2 Interlock Cable............................................................................................ 7-47
7.5 PIM Function – External Tool Correction...................................................................... 7-48
7.6 Connector X10 – Serial port for programming .............................................................. 7-48
Technical data ....................................................................................................................................... 7-48
Choosing the RS232C or RS485 cable.................................................................................................. 7-50
RS232C/RS485 at TRANS200 in ControlBoxD ..................................................................................... 7-51
7.7 Connector X20 – Ethernet port for programming.......................................................... 7-52
Ethernet networking overview................................................................................................................ 7-52
Setup of Ethernet Converter .................................................................................................................. 7-53
PC – TRANS200 System Configurator setup ........................................................................................ 7-56
8 NC setup 8-1
8.1 TRANS200..................................................................................................................... 8-1
TRANS200 - Training ............................................................................................................................. 8-1
TRANS200 - Documentation ................................................................................................................... 8-1
TRANS200 - WinTrans software............................................................................................................. 8-2
TRANS200 – Parameter adaptation ........................................................................................................ 8-2
TRANS200 - NC-programming ................................................................................................................ 8-3
9 Operation 9-1
9.1 ControlBoxD - BTV06 HMI button description ................................................................ 9-1
9.2 BTV06 HMI - screen description .................................................................................... 9-4
10 Cables and Accessories 10-1

10.1 Selection List of Connectors and Ready-Made Cables ................................................ 10-1
10.2 Accessories.................................................................................................................. 10-3
11 Index 1
TransKit1 Introduction 1-1
1 Introduction
1.1 Goals
A large installed base of transfer machines exists and is an important
base for high volume production, especially in automotive Powertrain.
Such transfer machines installed from early 1980 to 2000 have many
single or dual axis slides performing cyclical movements around the
clock. In many cases retrofitting the existing electro-mechanical feed or
older analog servo and control systems with programmable digital servo
systems provide higher productivity while keeping investment low.
Also the first generation analog single axis NC systems such as the
“TRANS-01 NC and DSC servo drives” have performed close to 20
years of service. Many components of these systems are no longer
available in the market and spare parts become difficult to source.
To make the retrofit of these systems faster and easier, Bosch Rexroth
now provides a scalable and cost effective digital upgrade TransKit1.
Note: Due to the variety of applications, the solutions described here
will still require machine specific alterations that must be
implemented by knowledgeable integration personnel.
Target application areas are:
- Electro-mechanical single and dual axes feed packs (non servo)
- TRANS-01 – DSC systems (fixture mount) using discrete 24VDC
IO connection
- Any other single and dual axes servo feed system
Transfer control In the past mainly centralized PLC control architectures have been
architectures applied with transfer machines as shown below.
Centralized PLC control

The Indramat TRANS-01 and DSC drive platform was mostly used in
machines with centralized PLC control. Discrete 24VDC (and some
115VAC) wiring was used to communicate with the TRANS-01 controller
and DSC fixture mount servo drive.
Central PLC for total

machine control
Remote Remote Remote

I/O I/O I/O
Digital I/O‘s Digital I/O‘s Digital I/O‘s
PIM
MAC Motor MAC Motor MAC Motor

TRANS-01 TRANS-01 TRANS-01
DSC drive DSC drive DSC drive
Fig. 1-1: Centralized transfer control architecture
Distributed PLC control More recent machines eventually are also controlled with distributed PLC
systems. This architecture allows faster integration, startup and ease of
use and reuse of engineering. The TRANS-01 was also applied here.
Fig. 1-2: Distributed transfer PLC control architecture
TRANS-01/DSC retrofit
architecture
The TransKit1 employs digital intelligent controllers that satisfy the same
architectures. Existing discrete wiring is utilized to connect to the existing
PLC IO system. The ControlBox contains NC functionality with simple
NC-programming. Digital intelligent drives are connected via SERCOS
fiber optic link providing precision and extended diagnostics. These
drives can run a variety of servo motors (rotary, spindle, linear, torque)
employing also absolute feedback measuring systems that reduce wiring.
All programs and parameters are programmed via PC-based Windows™
WinTrans software. The data of up to 32 TransKit1 systems can be
networked and managed from the central machine PC.
Fig. 1-3: TRANS-01 / DSC retrofit architecture
The TransKit1 utilizes the TRANS200 NC controller with the discrete I/O
communication to the PLC. It also provides HMI choices that display
status and offer Offset, tool data and variable modifications.
Even though the TransKit1 described here is suitable for most
applications, Bosch Rexroth recommends TRANS200 NC controllers with
Fieldbus connection to the PLC if the PLC is retrofitted as well.
The TRANS200 controller offers Interbus, Profibus, DeviceNet and
ControlNet interface slave modules. The Fieldbus connection will reduce
wiring costs, increases diagnostics to the machine HMI.
1.2 Content
The information provided in this document does describe the functionality
of the single/dual axis retrofit solution. This document does not replace
the documentation of the specific Bosch Rexroth products (TRANS200,
BTV06, RECO02 IO, PPC-R, DURADRIVE HDC) used for the retrofit
TransKit1. It merely describes the pre-engineered solutions and how they
can be applied.
The TransKit1 permits the following axis combinations based on
parameter settings and installed DURADRIVE amplifiers:
Motion DURADRIVE DURADRIVE
(possible interpolation) Axis #01 (left) Axis #02 (right)
-- Linear axis --
-- Rotary axis --
Linear, circular Linear axis Linear axis
Linear Linear axis Rotary axis
Time Rotary axis Rotary axis
Linear, feed/rev (tapping) Linear axis Spindle axis
-- Rotary axis Spindle axis
Note: It is the integrators responsibility to review relevant product

documentation referenced in this document in order to
achieve a comprehensive understanding of the products
involved. This applies especially to the NC-programming and
functioning of the interface signals since they differ from the
TRANS-01.
The following sections provide safety information for applying electrical

equipment, TransKit1 component description, interface information and
integration and programming software guidelines.
Standard Bosch Rexroth warranty to components and standard terms
apply. Warranty is voided if modifications to the wiring and/or I/O
Configuration are performed.
TransKit1 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.
Areas of Use and Application

Products made by Bosch Rexroth and used for TransKit1 are 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.
TransKit1 Important Usage Directions 2-2
The motion control and drive system may only be operated under the
assembly, installation and ambient conditions as described in this and
respective product documents (temperature, system of protection,
humidity, EMC requirements, etc.) and in the position specified.
2.2 Inappropriate Use

Using the products 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".
TransKit1 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
• If Bosch Rexroth has not specifically released them for that intended
purpose. Please note the specifications outlined in the general Safety
Guidelines!
• If modifications are made to the inside of the TransKit1 and wiring
between the TransKit1 and the DURADRIVE amplifier without the
specific approval of Bosch Rexroth.
TransKit1 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)
3.3 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
safety to 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 tested higher-
level monitoring device or measures integrated in the
installation. Unintended machine motion is possible if monitoring
Danger 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 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!
CAUTION Danger of burns!
⇒ After switching the equipment off, wait at least ten
(10) minutes to allow it to cool down before touching
it.
⇒ Do not touch hot parts of the equipment, such as
housings with integrated heat sinks and resistors.
Danger of burns!
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).
CAUTION
Observe the operation instructions of the respective
manufacturer.
Before disassembling pressurized systems, release
pressure and drain off the fluid or gas.
Use suitable protective clothing (for example safety
glasses, safety shoes and safety gloves)
Remove any fluid that has leaked out onto the floor
immediately.
Note: Environmental protection and disposal! The media used in the

operation of the pressurized system equipment may not be
environmentally compatible. Media that are damaging the
environment must be disposed separately from normal waste.
Observe the legal requirements in the country of installation.
TransKit1 Trans-01 retrofitting check list 4-1
4 Trans-01 retrofitting check list

The following checklist should be used as a planning guide for better
preparation of a retrofit. While it covers the major areas of the retrofit it
may not consider peculiarities of every installation.
It is strongly recommended that the retrofitter visit the installation and
review not only information on paper but also verify information on-site.
It is possible that the field modifications made to many installations were
never recorded properly.
4.1 Ambient conditions

Do the overall ControlBoxD dimensions, mounting dimensions and
connector locations satisfy the ambient conditions at the machine?
Yes No
Next Plan for modifications at
the machine to mount the
ControlBoxD.
Do the overall dimensions of the selected TransKit1 satisfy the machine

conditions?
Yes No
the machine to mount the
TransKit1 frame.
Is protection class IP65 sufficient for this application?

Yes No
the machine to provide
IP65 environment.
Will the Control be exposed to fluids other than water and/or water/oil
emulsion (max. 5% oil)?
Yes No
The ControlBox, cabling, Next
Motors and DURADRIVE are
rated IP65 and for normal
coolant composition (water
plus 5% oil). If in doubt contact
Bosch Rexroth representative.
4.2 Control topology

Which parts of the machine shall be replaced?
Drive amplifier with motors
Motion control (NC-control)
PLC-hardware
Which control topology is available?
Supervisory logic is working with PLC
Supervisory logic is working with contactor / relay
One overall PLC, one PLC for each TRANS-01
One overall PLC, one remote IO for each TRANS-01
Which kind of PC communication network is installed in the machine with

TRANS-01?
RS422-coupling via LCA
RS485 network
Ethernet network
no network
Which interface to the ControlBoxD of the TransKit1 should be applied?
INTERBUS
Profibus
DeviceNet
ControlNet
Discrete 24 VDC I/O-interface
Other: ________________________________________
NOTE: The ControlBoxD of the TransKit1 is only supporting discrete
24VDC IO. Check with Bosch Rexroth for a TransKit with
Fieldbus connection.
Which supplementary TRANS-01 equipment is or should be integrated at

the machine?
PIM (Positions-Interface-Module) for external BCD tool length

correction input
Additional position encoder (adaptive depth)
Adaptive feed
Type code of the existing TRANS-01 control system:

Hardware: TRANS01.___ / ___ / ___ ___ ___
Firmware: TR___ ___ - ___ ___ ___ . ___ ___ ___
Type code of the drive amplifier and motor:

Motor: MAC_____ ___ - ___- 0 - ___ ___
Drive amplifier: _______________________
If applicable: Type code / make of the PLC

______________________________________
PLC logic scan time:
Before retrofit: ________ms After retrofit: ________ms
Are there custom-made special installations or functions to be conserved?

Which?
______________________________________
Do you plan to retrofit the single axis controller TRANS-01?

Yes No
Choose the ControlBoxD as Next
described in this document.
Do you plan to retrofit the DSC drive amplifier?

Yes No
Choose one or two Next
DURADRIVE amplifiers as The TransKit1 does not
offered with the TransKit1. support analog (10V) drive
interface (DSC, TDM, etc.)
Do you plan to retrofit the MAC servo motor?

Yes No
Choose a MHD or MKD motor Contact you Bosch Rexroth
with DURADRIVE based on Electric Drives and
required performance. Contact Controls representative for
your local Bosch Rexroth information on how to
representative for help in refurbish a MAC motor that
selecting the proper motor- it can be used with the
drive combination and cables. DURADRIVE (and other
digital intelligent drives).
Do you want to order a pre-wired and mounted TransKit1 that comes

ready for installation with frame of super-structure?
Yes No
Review the type code for Next
TransKit1 and check the
overall dimensions.
Do you want to replace 2 TRANS-01 systems on a station with one

TransKit1 (provides one motion process)?
Yes No
Solution 1: Next
Order a TransKit1 for each
TRANS-01.
Solution 2:
Order TransKit1 with 2
DURADRIVEs. Plan for using
only one Control Cable with
St.1. Modify PLC logic

accordingly. Create NC-
program controlling two axes.
4.3 TRANS-01 control parameters

Is a TRANS-01 parameter list available?– Please keep for reference!
Yes No
Keep for future reference. Obtain the parameters from
the TRANS-01 to be
retrofitted.
Is the existing parameter list complete, and is it identical with the

parameters in the TRANS-01 system?
Yes No
Keep for future reference. Obtain the parameters from
the TRANS-01 to be
retrofitted.
Are oscilloscope records (taken during the machining cycle of a

workpiece!) for precise determination respective drive/motor
dimensioning and cycle time(s)?
Yes No
Keep for future reference. Make the oscilloscope
recording. The following
signals give information
about the current
dimensioning: motor
current and speed. This is
also very useful for the
cost-effective sizing /
selection of the new drives.
Are the calculations of the presently existing machine documented?

Yes No
Keep for future reference. Try to obtain all mechanical
information that permit
proper amplifier/motor
sizing, minimizing cost and
uncertainty.
4.4 I/O-configuration
Is there up to date information about the interface signals used with the
TRANS-01 application?
Overview of interface signals
interface table of the PLC
current diagram of the supervisory/station PLC logic
further signals:
Yes No
Compare with the interface Try to obtain all above

layout of the connector St.1 information so upfront
wiring changes and logic
changes can be planned
and prepared.
Are any extra signals to be considered in this system?

Yes No
Document the signals and Next
compare with connector St.1
Establish an overview of switching signals or M-functions for control of

specific functions (BCD-signals, M-functions) available with the Trans-01
and required after the retrofit.
Yes No
M-functions work different Next
with the ControlBoxD of the
TransKit1. Compare the
functioning of auxiliary
functions on connector St.1.
NOTE: The TransKit1 does not
support BCD signals.
Which key functions are influencing the existing NC-program(s)?

Yes No
Record and compare them with Next
the NC-program control signals
of connector St.1
4.5 NC Program
Is any programming sheet available for the TRANS-01 NC program to be
translated to the TRANS200 based NC-program?
Yes No
Review the sheet and compare Obtain the NC-program of
with the TRANS200 NC- the TRANS-01.
commands (see NC-Instruction
documentation).
Is the NC program available in ASCII format?

Yes No
Review the sheet and compare Obtain the NC-program of
with the TRANS200 NC- the TRANS-01.
commands (see NC-Instruction
documentation).
Is tool length correction used with TRANS-01?

Yes No
Note (save) the tool offset Next
value of the tools to be used.
Use a respective D-correction
for tool length (and radius)

correction in the TRANS200.
Is a process diagram available clearly explaining the flow of the NC

program?
Yes No
Assure it informs which Review the machining flow
configured signals are of the station/machine and
necessary and how they confirm the desired flow
become effective in the after the retrofit.
presently applied system logic
for TRANS-01! Eventually a
signal flow diagram or graphic
is useful as well.
4.6 Quotation content

What is included in the retrofit quote/offer?
A TransKit1 solution (ControlBoxD and DURADRIVE(s) mounted
on frame and pre-wired)
Selected individual components of TransKit1
Selected individual motors and cables
Creating and updating wiring and cabinet diagrams
Re-creating the NC program(s)
Designing new I/O-configuration to the PLC I/O
Creating a different parameter list
Designing custom HMI for the BTV06/BTC06 HMI
Other: ________________________________________
TransKit1 Frequently Asked Questions 5-1
5 Frequently Asked Questions

Analog command interface (±10V), is it
supported?
The ControlBoxD of the TransKit1 does not provide a 10V analog
command interface. The ControlBoxD uses the digital fiber optic
SERCOS interface and intelligent drives.
Trans-01, how compatible is the TransKit1?

The ControlBoxD provides discrete IO at connector St.1 and 115VAC
control voltage power connector.
Since the ControlBoxD is capable of controlling up to 2 axes, the signals
on connector St.1 are not 100% compatible to the Trans01 (in function
and pin location).
SERCOS fiber optic cable is used to connect digital intelligent drives such
as DURADRIVE (or Ecodrive DKC02.3) .
MAC (Indramat) motors, can they be reused?

It is recommended to replace the MAC motor with the equivalent MHD
and MKD servo motors.
MAC motor power cable, can it be reused?

The DURADRIVE and DKC drives can operate at 3x220VAC supply
voltage resulting in the same motor voltage as with the Indramat DSC
drives.
However, the MHD and MKD motors are rated for higher voltage and
therefore have different connectors. Adaptor cables must be used.
MAC motor tachometer and feeback cable, can it

be reused?
Not directly, in some cases a cable adapter can be employed allowing the
use of the existing tachometer and feedback cable.
Axes, how many with the ControlBoxD?

The TRANS200 motion controller included in the ControlBoxD can
simultaneously control 4 servo and 3 spindle axes. But as configured and
wired in the ControlBoxD and TransKit1, up to 2 digital intelligent drives
can be operated.
Fieldbus interfaces, are they available?

The ControlBoxD is configured for discrete IO connection.
You may also ask your Bosch Rexroth sales contact if another
ControlBoxF and TransKit2 version is available.
If not, the user can design another solution since the integrated
TRANS200 controller permits the use of Interbus, Profibus, ControlNet or
DeviceNet interfaces.
115VAC IO, is it available?

No, the ControlBoxD of the TransKit1 is configured for discrete 24VDC
IO. If old Trans-01 systems were connected to 115VAC signals a
converter was used. You can either re-apply these converters or design
such a solution using respective 115VAC compatible IO and wiring.
G-code programming, is it used?

Yes, the ControlBoxD of the TransKit1 uses RS274-D based G-code
programming with functional extensions. The command set is more
powerful than the set of the TRANS-01 and therefore has differences that
must be observed.
NC-programs, can it be done at the BTV06?

G-code NC-programs and cycles must be programmed via the Windows
software WinTrans (Version 23VRS) running on a PC (with Windows
NT4.0, Windows2000 or Windows XP).
NC-variables, Offsets and tool data can be entered at the local HMI
BTV06 or the portable HMI BTC06.
Auxiliary functions, do they work different with

the ControlBoxD?
Yes, the auxiliary functions in the ControlBoxD work different than in the
TRANS-01. ControBoxD offers also more functionality and 2 axes
connection. This require careful review of available M-functions and how
they work. The integrator must observe the differences outlined in the
interface section of this documentation.
Reverse program, is it available?

In comparison to the one reverse program block of the TRANS-01, the
TRANS200 allows the programming of many reverse vectors. Refer to
the “TRANS200 NC Programming Instructions”
DOK-TRA200-NC**PRO*V22-AW01-EN-P
Axes / Stations, can I simultaneously run two

independent axes / stations?
The TRANS200 contained in the ControlBoxD can operate multiple axes
in one NC channel/process but these axes interpolate when programmed
in the same NC-block. Multi-process control is possible with the MTC200
CNC.
Adapter plates, are they required when replacing

a MAC motor with MHD or MKD?
Yes, in some cases it may be necessary since the motor performance
and size may differ. Check the overall space and compare frame sizes,
motor shaft diameter and pilot-hole diameters. Additionally, motor power

cable and motor feedback cable must be replaced. The tachometer cable
of the MAC motor is no longer required.
Display of BTV06 is dark, why?

The BTV06 is equipped with a screen backlight saver to maximum
backlight life. Press any button and the backlight will come on. Refer to
Options menu of the BTV06 for setup of the backlight timer.
Note: It is also possible that the 24VDC external or 115VAC (24V
internal) are missing or the internal circuit breakers are tripped.
Fuses, are there some in the ControlBoxC and

ControlBoxD of the TransKit1?
The ControlBoxD contains two circuit breakers mounted on the terminal
strip. See chapter 5 for more information.
Heat exchanger, is it required?

The ControlBoxD is designed to work without heat exchanger up to an
ambient temperature of 42°C. Mechanically the ControlBoxD is prepared
for installation of a McLean heat exchanger (refer to section 4 for
installation information).
Cable 04-0101 (TRANS-01-DSC NC-cable) , can it

be reused?
No, this cable is obsolete. The TransKit1 provides a new cable to connect
the DURADRIVE to the ControlBox.
Cable 04-0900 (Control cable), can it be reused?

Yes, the cable can be reused. However, observe the St.1 connector
signal functions and wiring as described in this documentation.
Cable 03-0400/03-0401 (Position feedback cable),

can it be reused?
No, this cable cannot be used as is since it does not provide the
conductors and shielding required for sinusoidal motor feedback systems.
With the TransKit1, digital intelligent DURADRIVE amplifiers are used
requiring a direct connection of the motor / slide position feedback cable
to connector X4 / X8.
Cable 03-0100/03-0101 (MAC Motor feedback

cable), can it be reused?
This cable is no longer required.
New digital intelligent drives such as the DURADRIVE no longer use
Tachometer and BLC commutation signals. These drives use intelligent
motors, meaning the commutation angle is stored in the motor feedback.
Cable 01-0300 (DSC01 power cable), can it be

reused?
Yes, but…
- the connector at the DSC side must be replaced with the
respective connector that matches the DURADRIVE X13 socket
- the control voltage (pin E, F,G) are no longer used and must not
be connected
- the cable can only be used with 3x220VAC, also for the
DURADRIVE
- the DURADRIVE/Motor selection must be based on 3x220VAC
supply voltage
Cable 01-0520 (DSC03 power cable), can it be

reused?
Yes, but…
- the connector at the DSC side must be replaced with the
respective connector that matches the DURADRIVE X13 socket
- the control voltage (pin E, F,G) are no longer used and must not
be connected
- the cable can only be used with 3x220VAC, also for the
DURADRIVE
- the DURADRIVE/Motor selection must be based on 3x220VAC
supply voltage
Cable 01-0400 (TRANS power cable), can it be

reused?
Yes, but…
- the cable provides the 115V AC to the ControlBoxD. The 220V
AC supply is no longer supported.
- the cable is only necessary if the ControlBoxD is equipped with
internal power supply and/or the heat exchanger.
- If the TransKit1 is applied as a new application (not a TRANS01
retrofit) and the 115V supply is necessary, the IKL0221 cable
should be ordered. (Mat. No. 212126)
MAC motor, can the feedback (encoder) be

upgraded for use with DURADRIVE?
Not in the field. Check with Bosch Rexroth engineering providing your
motor type code asking for motor upgrading.
MAC motor brake control, does it change?

Yes brake control changes. As with DSC drives, digital intelligent drives
such as the DuraDrive directly control and monitor the brake current. The
brake wires for the integrated motor brake (24VDC) are contained in the
Bosch Rexroth supplied motor power cable (connector X5 of the

DuraDrive).
MAC motor blower control, does it change?

Yes, the blower of a MAC motor is supplied directly to the blower. If
installing new motors, e.g., MHD and MKD with blower, then observe
blower voltage and connection.
24VDC external control voltage, is it required ?

Yes, the ControlBoxD of the TransKit1 ships without an internal 24VDC
supply unless specified in the type code. Normally the 24VDC is supplied
via the control cable on connector St.1 as it did for the Trans-01.
Note: In case the external 24VDC supply does not meet the specification
24VDC +/-10% or has too much noise (spikes, dips) causing errors, an
optional 24VDC supply can be installed in ControlBoxD. (The internal
wiring is already prepared.) It will require the external 115V AC supply
through the connector ST3. Observe the wiring directions explained in
chapter 6.6.
Battery for memory backup, is it used with the

TransKit1?
No, the TRANS200 motion controller and DURADRIVE use FlashCard
technology without battery backup.
The TRANS200 firmware and control data are stored on a removable
PCMCIA card and the drive firmware and parameter data is stored on a
removable programming module.
Note: Do not remove these cards while control voltage is on.
ControlBoxD, can I order it from Bosch Rexroth?

Yes, contact your sales representative requesting ControlBoxD. You may
also order the required cables separately.
Drive / motor selection, who can help?

Contact your local sales representative or contact inside sales support at
your regional Bosch Rexroth office.
Networking the ControlBoxD ?

Yes, the ControlBoxD provides at the bottom a 15pin Sub-D
communications connector X10 that is IP65 rated. This connector permits
RS232 (single point) and RS485 (multiple points) networking.
As an option, the ControlBoxD can be equipped with Ethernet
communication hardware and IP65 rated connection X20. Refer to
chapter 7.7 for more details.
Drives that can be controlled with ControlBoxD?

The ControlBoxD connectors X1 and X2 and internal interlocking are pre-
configured for cables that directly connect to the DURADRIVE (HDC
amplifiers), permitting the simple installation of a TransKit1.
However, using the same connectors at the ControlBoxD, the customer
(OEM, integrator) can create his own design for proper interlocks and
cables (no ready solution from BRC). The following drives using
SERCOS can be operated:
- DIAX02 servo drives (latest firmware)
- DIAX03 servo drives (latest firmware)
- DIAX04 (HDD, HDS) servo/spindle drives (latest firmware)
- DKR spindle vector drives (latest firmware)
- DKC servo drives (latest firmware)
Are the DURADRIVE addresses changeable?

NO! As shipped from Bosch Rexroth, the default drive addresses are
- “01” for the left drive amplifier
- “02” for the right amplifier
selected with the switches S2 and S3 at the DURADRIVE programming
modules. The TRANS200 I/O configuration requires that the addresses
remain unchanged.
Note: Addresses changes take effect at control voltage power on.
PC communication, how is it setup in the

ControlBoxD (TRANS200 inside)?
When shipped from Bosch Rexroth the PC communication settings for
the internal TRANS200 controller are setup as described in section 7.6.
LHA and/or LZH, is it supported?

No, these old networking solutions were exclusively used with Trans-01
and are not compatible with the ConrolBoxD / TransKit1.
TAM panel, does it connect to the ControlBox?

No, the TAM was exclusively used with Trans-01.
TAM panel, is there a compatible programming

tool?
No, the TRANS200 motion controller in the ControlBoxD is programmed
with PC-based software. NC-variables, Offsets and Tool Data can be
modified via the local HMI BTV06 Also the diagnostics can be viewed
there. Additionally, all ControlBoxD units (up to 32) can be networked to
a single PC, e.g., at the head station.
Trans-01M, what would I use for retrofit?

The TRANS-01M is a modular unit typically installed in the machine
control enclosure. A TRANS200 can be used in its place using a similar
interconnection to the PLC as is used with the ControlBoxD of the
TransKit1. Also, other digital intelligent drives with SERCOS such as
Ecodrive (DKC02.3) for panel installation could be used in place of the
DURADRIVE.
Programmable limit switches (Waypoints) ?

The ControlBoxD of the TransKit1 provides 2 waypoint signals for Axis #1
via the connector St.1. No waypoints are available over St.1 for Axis #2.
“Spindle function”, is it available with the

ControlBoxD of TransKit1?
Yes, but only Axis #02 can be used to operate a spindle motor.
Note: The DURADRIVE can only control spindle motors with compatible
feedback system and power.
Since the TransKit1 uses IP65 rated DURADRIVE amplifiers, it does not
permit spindle motor operation without feedback.
“Adaptive Depth function”, is it possible with the

Yes, adaptive depth is possible by connecting the encoder directly to the
drive of Axis #1. For detailed information refer to the manuals:
- NC Programming Instructions (DOK-TRA200-NC**PRO*V22-AW01-EN-P)
- Description of Parameters (DOC-CONTRL-PAR*DES*V22-AW01-EN-P)
“Adaptive Feed function”, is it possible with the

Yes, adaptive feed is possible. For detailed information refer to the
manuals:
“Tapping function”, is it possible with the

Yes, tapping is possible as long as Axis #01 is a linear axis (slide) onto
which a digitally controlled spindle motor (Axis #02) is mounted.
Note: The specific mechanical requirements for floating (compression
and/or tension) and rigid tapping (only with direct drive motor-spindle
systems) must be observed.
For detailed information refer to the manuals:
“PIM function”, is it possible with the

No. The PIM option was not implemented in the ControlBoxD of

TransKit1.
TransKit1 TransKit1 Configurations 6-1
6 TransKit1 Configurations
6.1 Type Code and ordering
Items to order
A complete retrofit of Trans-01 and DSC requires:
c CBD-x-xx-xx-T2-IO ;Configuration of the ControlBoxD for discrete IO

interface similar to Trans-01 (St.1)
d TK1-CBD-xxxx-xxxx ;Complete assembly of ControlBoxD with frame,
interconnect cables and DURADRIVE amplifier(s)
e MHD, MKD, etc. ;Motors (servo and/or spindle) as needed
f IKG…,IKS…, IKL.. ;Cables: Motor power, motor

DURADRIVE supply cable etc.
feedback,
Valid type codes/configurations

ControlBoxD TK1 configuration
CBD-*-NN-NN-T2-*-IO TK1-CBD-****-****
CBD-*-HE-NN-T2-*-IO TK1-CBD-****-****
CBD-*-NN-05-T2-*-IO TK1-CBD-****-NNNN
CBD-*-HE-05-T2-*-IO TK1-CBD-****-NNNN
CBD-*-HE-10-T2-*-IO TK1-CBD-****-****
ControlBoxD Type Code

The specifics of the ControlBoxD must be is specified with the following
type code.
Note: If only the ControlBoxD is ordered, the interconnecting cables
must be ordered separately like the drives, motors and their
cables.
Type Code: CBD-V-NN-NN-T2-S-IO
ControlBox Version
BTV06 HMI..................... V
24VDC Supply 2)
No internal 24VDC supply........ NN
Int. 24VDC/5A supply (1 axis)... 05
Int. 24VDC/10A supply (2 axes).. 10
Model 2)
IP65, 42°C ambient temp. ........... NN
IP65, 45°C ambient temp. ........... HE
(includes a heat exchanger and user
must consider DURADRIVE de-rating)
Motion Control 1)
NC motion (TRANS200).................. T2
PC Communication
Serial RS232C & RS485 networking port.... S
Ethernet networking port................. E
PLC Communication
Discrete IO (24VDC)........................ IO
1)
Motion programming software:
T2 – WinTrans software is used for programming and drive setup.
Each PC running the software requires a license of:
- 1 x SWA-TRA200-T11-23VRS-MS-CD650 (CD and installation docu)
Further licenses can be purchased as
- SWL-TRA200-T11-23VRS-MS-COPY (single seat license without
CD)
This software permits the user to network up to 32 ControlBox systems
to a single PC running the WinTrans software.
2)
10A internal 24VDC power supply:
-10- The heat exchanger option –HE- must be installed. The heat
exchanger must also be installed if the ControlBoxD is equipped in the
field with a 10A power supply.
TransKit1 – TK1 - Type Code
Use this type code to order the pre-configured TransKit1 that provides up
to 2 axes and the ControlBoxD with digital IO for communication to the
machine (e.g., supervisory PLC) similar to the old Indramat Trans-01
controller, all mounted an pre-wired on the frame..
The ControlBoxD (CBD-…) must be ordered as a separate item.
Type Code: TK1-CBD-HDC1-NNNN
c ControlBox
Order via separate code .... CBD-…
DURADRIVE axis 1
No drive .........................NNNN
040A .............................HDC4
100A .............................HDC1
200A .............................HDC2
DURADRIVE axis 2
No drive ..............................NNNN
040A ..................................HDC4
100A ..................................HDC1
200A ..................................HDC2
Note: The firmware SMT 02VRS is included with the defined

DURADRIVEs.
6.2 Basic TransKit1 elements
The following sections provide an overview about the components and

configurations of the TransKit1 available from Bosch Rexroth USA.
Note: The information in this document applies only to the
configurations sold as a complete Bosch Rexroth solution with
a valid Bosch Rexroth serial number – attached to the upper
left corner of the front panel.
Front View Left View

Fig. 6-1: TransKit1: ControlBoxD + Frame + 40A DURADRIVE
A configuration typically consists of a ControlBoxD (SCE-20EL

1612LPSP; RAL 5010) and one or two IP65 rated DURADRIVE
amplifiers mounted on a frame for quick and easy installation, e.g. at the
transfer station.
Discrete 24VDC IO is used to connect to the supervisory PLC controller
using TRANS-01 compatible connectors.
Note: The solutions described here do NOT provide a 100%
compatible replacement of TRANS-01-DSC drive and MAC
motor system. The integrator must perform modifications to
the existing machine wiring hardware and software. For
detailed information refer to section7.
ControlBoxD can be equipped with optional BTV06 HMI for the

diagnostics and data entry.
A single axis system consists of the following major components that are
delivered completely assembled and tested ready for installation:
ControlBox…
with interface to
discrete IO
BTV06.Optional
display for
diagnostics, and
data entry
DURADrive
amplifier
Fig 6-1: TransKit1 example
6.3 Ratings of TransKit1 elements
Ratings – DURADRIVE amplifier

The TransKit1 is rated for a maximum of 42°C ambient temperature
unless the optional heat exchanger is installed which brings the maximum
ambient temperature to 47°C.
However, at above 45°C the power of the DURADRIVE is de-rated as
described in the product documentation “Project Planning Manual
DURADRIVE” (DOK-DURADR-HDC01.1****-PR02-EN-P; 288285).
DURADRIVE
amplifier
Note: The DURADRIVE amplifier electronics are IP65 protected but

to assure long-term trouble free operation any direct coolant
exposure and wash down is not permitted. A bleeder resistor
is integrated into the heat sink as well, requiring cleaning
depending on the environmental conditions.
Ratings – ControlBoxD (discrete IO)

ControlBoxD
Designation Symb Unit ControlBox
ol
Permissible ambient °C +42°C/110°F w/o heat
temperature operation exchanger
+47°C/116°F w. heat
exchanger
Permissible ambient °C -25…+70°C
temperature storage
Protection rating IP65 IP65 only if all enclosure
openings are properly closed!
Air pressure 86..106kPa (operation)
70…106kPa (storage)
Vibration Like DURADRIVE
Installation altitude Like DURADRIVE
TransKit1 The 24VDC control supply voltage for the ControlBoxD and DURADRIVE
Supply Voltage Rating amplifier(s) can be supplied via connector St.1 unless an internal supply
is ordered/installed. The following provides an overview about the power
requirements:
TransKit1 Supply voltage regulated 24VDC ± 10%

Supply Voltage
ControlBox Axis 1 Axis 2 Total

TransKit1
Electronics Drive Motor Drive Motor
Supply Current
(excl. electronics brake electronics brake
outputs)
0.8A 2A 1.5..2A -- -- 4.8AMIN
0.8A 2A 2A 2A 2A 8.8AMIN
Note: If the externally supplied control voltage of 24VDC cannot

meet the above requirements (e.g., excessive spikes, noise), an optional
24VDC supply kit is available for installation into the ControlBox. If such
an installation occurs the 24Vinternal (St.1:D16, #64) and 24V external
(St.1:C16, #2) wires provided via connector St.1 must be separated at
the control cable end in the machine electrical enclosure.
TransKit1 The TransKit1 contains 24VDC external inputs that represent the
External Inputs interface to the supervisory PLC. Below you find the principle connection
diagram of the external inputs (refer to section 7 for detailed interface
signal description).
Note:
Each input represents a maximum (sinking) load of 10mA.
The integrator must check that the connected discrete PLC
output will operate with loads less than 10mA.
TransKit1 The solid state 24VDC outputs (sourcing) of the ControlBoxD are
External Outputs supplied by the 24V external (St.1:C16, #2) wire. Each TransKit1 output
is short circuit proof with a short circuit current of 0.5A
Note: With the old Trans-01 each output was limited to 150mA per
output – max. of 2.4A.
+UL - 24VDC external ± 10%
Note: The user must install surge suppression devices parallel to

inductive loads.
6.4 TransKit1 – Components

The following sections describe the major components of the TransKit1.
TransKit1 – Mounting Frame
Fig. 6-2.1: Mounting frame (front and side view)
The ControlBoxD and DURADRIVE(s) used with the TransKit1 are

mounted on a frame made with extruded aluminum if ordered according
to the type code. This frame has two sections, the top with the
ControlBoxD and the bottom with one or two DURADRIVE amplifier(s).
The sections are joined in the middle to allow compact shipment and
quick installation at the machine.
This also permits the mounting individually or as stacked arrangement.
Cables between ControlBox and DURADRIVE are 1.5m long and
accommodate several mounting locations.
• Individual • Stacked
Frame connection for

flexible mounting
and shipping
Fig. 6-3.2: Mounting arrangements (horizontal or vertical)
Due to the specific machine conditions, the OEM or integrator will have to
provide brackets to securely mount the frame to the machine. These
brackets can be attached with mounting bolts using the aluminum slots.
Note: The final mounting location and method must assure that the
temperature; vibration and protection rating of the enclosure
and DURADRIVE are not exceeded. A minimum of 8
mounting brackets for Individual (horizontal) arrangement or
six for the stacked vertical arrangement must be used.
Brackets should be distributed equally on each side so the
aluminum frame and weight are supported properly.
Accessories Optional accessories available from Bosch Rexroth Linear Systems

(Refer to “40/50 Aluminum Structural Framing Catalog” for furtherdetails).
Mounting gusset Mounting gussets for 45x45 frame (PN 3842523561) are available if they
fit the installation of the frame to the machine structure (indicated yellow
in Fig. 5.2.1). A minimum of 6 gussets per frame should be used if the
frame is mounted as one piece. Four (4) gussets must be used per frame
section if mounted as two sections.
DURADRIVE mounting For secure mounting of the DURADRIVE, 10mm T-blocks (galvanized
steel) and spring (spring steel) elements are inserted into the slot of the
mounting rails. Only this type of mounting will assure that the T-block
(nut) remains in the preset position.
Fig. 6-4.2 T-blocks for DURADRIVE mounting
Universal Mounting Mounting Mounting M6: Mounting screw / M8: Mounting screw / End caps
configuration: Rail 1 Rail 2 Rail 3 10mm T-block with spring 10mm T-block with spring for 45*45
(for 40A drives) (100/200A drives) profile
One or Two drives 480 mm 480 mm 480 mm 3 pcs/per drive M6 T- 3 pcs/per drive M8 T- 10pcs
-- any size Block (Part no. 613748) Block (Part no. 613746)
3 pcs/per drive Spring 3 pcs/per drive Spring
(Part no. 613747) (Part no. 613747)
Fig. 6-5.3 T-block and spring part numbers
Note: The T-block requires different screw sizes depending on the

installed DURADRIVE.
♦ M6 for HDC01.1-A040N-SE01-01-FW (40 A drive)
♦ M8 for HDC01.1-A100N-SE01-01-FW (100A drive) and
HDC01.1-A200N-SE01-01-FW (200A drive)
The used steel screw must have a lock washer and be in the
range of 10mm … 15mm maximum.
6.5 DURADRIVE Amplifier (with TK1)
For drive and motor sizing and selection information and requirements
Drive / Motor Sizing
refer to the ”Selection Data” (DOK-DRIVE*-SERVO*WZM**-AU02-MS) or
contact your Bosch Rexroth representative.
Note: Especially when supplying the DURADRIVE with 3-phase

220VAC voltage speed and power sizing must be reviewed
with the respective motor.
The “Project Planning Manual DURADRIVE” (DOK-DURADR-

HDC01.1****-PR02-EN-P; 288285) provides information for mains
connection, startup and maintenance.
Drive Interface The DURADRIVE uses the SERCOS digital fiber optic interface to
connect to the ControlBox. The DURADRIVE must have “SE01” defined
in the type code and use the SMT-02VRS firmware as defined below:
- HDC01.1-AxxxN-SE01-01-FW (where xxx = 040, 100 or 200)

- FWA-ECODR3-SMT-02VRS-MS
If the drive is replaced for any reason the programming module

(containing the firmware and parameters) must be retained and the
device-typical interface card of the new DURADRIVE must match.
Drive parameter setup WinTrans software contains the DriveTop tool to configure, tune and
troubleshoot the DURADRIVE using the SERCOS fiber optic link. This
convenient method eliminates the need of laptop PC connection to X2
(cable IKB0006) of the DURADRIVE.
Drive parameter The details of drive parameters and their function are described in the
description functional description of the drive firmware or the help systems for that
firmware (if installed on the PC that contains DriveTop). Typically the
firmware version SMT 02VRS is used:
Functional Description SMT 02
(285849; DOC-ECODR3-SMT-02VRS**-FK01-EN-P)
Parameter Description SMT 02
(285850; DOC-ECODR3-SMT-02VRS**-PA01-EN-P)
Troubleshooting SMT 02
(285852; DOC-ECODR3-SMT-02VRS**-WA01-EN-P)
Firmware Version Notes
(285851; DOC-ECODR3-SMT-02VRS**-FV01-EN-P)
The DURADRIVE design requires that a blower unit LECH-xxxN is
installed. In the case of the 100 A and 200 A drive controllers, the blower
must always be connected. The drive cannot be enabled and powered
up if the LECH-xxxN is disconnected (X14) and the drive H1 diagnostic
LED shows the error F217 “Blower not connected”
For ease of use and maintenance, the blower can be removed and
replaced during drive operation if the drive is powered up already. During
this time the drive shows the warning E217 “Blower running too slow”.
Unless the drive shat off with the respective error because the unit or
bleeder overheated since the blower was not running, the warning goes
away once the blower is re-connected.
Note: Although it is not recommended, the 40 A DURADRIVE can be
run without the blower.
X14:
Blower connection
Fig. 6-1.1: DURADRIVE connection locations
DURADRIVE control The control cables and motor feedback cable are routed into the Control
cable installation signals. The 24VDC supply, the SERCOS fiber optic cable and the
position feedback cables are installed via the cable bushing assembly of
the DURADRIVE. Observe the installation instructions below when
removing cables, e.g., during drive replacement.
Control Voltage The DURADRIVE electronics and blower are conveniently supplied from
the ControlBoxD with 24VDC via the control cable.
Note: The 0V DC line of the ControlBoxD and DURADRIVE are
connected to the housing ground. This means that the 0V DC
potential of external supply systems must be connected with
the 0V DC line of the ControlBoxD! This must also be
considered when connecting switches and wiring directly to
the DURADRIVE!
Feedback/Encoder The motor feedback cables are directly connected to the DURADRIVE.
connection Connector X4 (encoder 1 at motor) and X8 (encoder 2) are located
behind the plastic cover. Follow the cable installation instructions below:
Both connectors employ different feedback interfaces based on the cable
used.
Note: Feedback cable 03-0400 of MAC motors cannot directly be
used with the DURADRIVE. Consult Bosch Rexroth sales and
engineering for further information.
DURADRIVE bottom The motor power and DURADRIVE main supply connectors are located
connections at the bottom of the DURADRIVE.
Fig. 6-1.2: Power and motor power connectors HDC01.1-A040N
Fig. 6-1.3: Power and motor power connectors HDC01.1-A100/200N
Drive Mains Voltage The DURADRIVE supply voltage (3 x 220 .. 3 x 480 VAC) is directly
connection connected via connector X13 of the DURADRIVE located at the drive
bottom.
The cable and connector for this connection is not provided with the
TransKit1 and must be ordered separately.
Fig. 6-1.4: DURADRIVE main supply connector X13
Note: The used cable must be rated according to the chosen supply
voltage. Also the temperature sensor and brake wires must be
shielded according to Bosch Rexroth specifications. It is
recommended to use only original Bosch Rexroth cables
suitable for the DURADRIVE.
Motor Power The motor power cable gets connected to connector X5 from the bottom
connection at the DURADRIVE.
The cable and connector for this connection is not provided with the
TransKit1 and must be ordered separately.
6.6 ControlBoxD components
ControlBoxD connections & cables

All connections to the ControlBoxD are performed with connectors
assuring fast and reliable installation. Connectors labeled with “St.x”
permit the use of existing TRANS-01 cables. Other connectors starting
“Xx” provide new /different connectivity.
PPC-R / Trans200
UDS-10-01 IND5007
Serial<->
Ethernet
24V
DC
BTV06 HMI
=
IKB0015
Ethernet CAT5 X50

RS232 or RS485
IKO0982
TX RX X53 X20 X54 X55 St.1 St.3
RKO0101
RKO0101 IKL0221
IND5008 / IND5009
IKS0580
Ethernet CAT5
IND3048 IND3048
Fig. 6-6.1: ControlBoxD connection layout
The above figure shows the location and connection of the different
cables. Cables are available and described in section 10.
St.3 – Supply voltage for int. 24VDC and heat exchanger (115VAC)
St.1 – Machine 64 pin connector (discrete 24VDC)
X20 – Ethernet connector (CAT5)
X53 – Serial interface port (RS232 / RS485)
X54 – Drive 1 interlocking (discrete 24 VDC)
X55 – Drive 2 interlocking (discrete 24 VDC)
TX – SERCOS drive interface output (transmitter) – fiber optic
RX – SERCOS drive interface input (receiver) – fiber optic
See chapter 7 for detailed description of the connections and signals.
St.1
X55 TX
St.3 X20 X10 X54 RX
+
Fig. 6-6.2: ControlBoxD connectors (bottom view)
Terminal Block X50 of ControlBoxD

Inside the ControlBoxD, the terminal block marked X50 is used for
discrete wiring. Each terminal uses cage-clamp technology and provides
multiple connection points that are identified as follows:
F1 (115VAC 2/4A) F2 (24VDC 6/10A)
Remove jumper if
internal 24VDC
supply installed.
Fig. 6-6.3: ControlBoxD connectors (bottom view)
The terminal block X50 uses multi-point terminal with cage clamp
technology providing reliable connections and measuring points for
troubleshooting.
Additionally some terminals contain relais (K1, K2, K3, K4, K5, K6) and
circuit breakers (F1 and F2) as indicated in the figure above and
described in further detail in the sections below.
Heat Exchanger (Optional)

The ControlBoxD is prepared for installation of a heat exchanger on the
left side. This heat exchanger is required if an internal 24VDC power
supply greater than 5A is used to permit the maximum specified ambient
temperature.
ControlBoxD with heat exchanger ControlBoxD w/o heat exchanger
The cutout is prepared for the McLean heat exchanger XR2016-001. This
permits the installation in the field if necessary.
Note: The specified heat exchanger has separated air circulation

between the inside and outside, preventing inside
contamination. Special care must be applied to install the seal
when installing the heat exchanger or plate. It is not permitted
to blow or suck outside air into the ControlBoxD or install
another heat exchanger model. Such modification will void
warranty.
The heat exchanger requires 115VAC supply voltage provided via St.3 of
the ControlBoxD.
Installation instructions Step 1: Switch control voltage power off by turning off the circuit breaker
CB1 and disconnecting St.3
Step 2: Clean off the left side of the ControlBox using soapy water.
Step 3: Remove the cover plate.
Step 4: Clean sheet metal area where the seal is applied.
Step 5: Position the heat exchanger and the flat seal properly.
Step 6: Fasten the heat exchanger with the screws provided or screws of
the cover plate. Make sure the seal is properly located on clean
surface and the bolts are tightened as per manufacturer
installation description.
Step 6: Strip the wires and connect the 115VAC fan supply wires to the
terminals X50:2BH/X50:3BH (115VAC) and X50:4BH (GND).
Fig. 6-6.4: Heat exchanger connections
Step 7: Connect the 115VAC supply cable to connector St.3 of the

ControlBox.
Step 8: Turn on the circuit breaker CB1.
Step 9: Confirm airflow of both fans – inside and outside circuit.
Step 10: Close the ControlBox.
Internal 24VDC power supply

Normally, the user supplies 24VDC via the St.1 connector by connecting
the wires
- Internal 24VDC and External 24VDC
- Internal 0VDC and External 0VDC
to the same 24VDC power supply in the machine control panel.
In situations where no such 24VDC power supply is available or if the

24VDC supplied to the ControlBoxD do not meet the required quality, an
optional 24VDC power supply can be installed into ControlBoxD.
If installed, this optional power supply will only supply the internal controls
(TRANS200, BTV06) as well as the DURADRIVE electronics and blower.
The optically isolated inputs and outputs connected to connector St.1
remain supplied by the external 24VDC and external 0VDC.
Depending on the machines grounding situation, the 0VDC internal and

0VDC external can be connected, e.g., if the 0VDC of the machine panel
power supply is connected to GND.
The ControlBox is prepared for connection of the Phoenix 24VDC power
supply using pre-wired green connectors.
Fig. 6-6.5: Internal 24VDC power supply connections
Installation instructions Step 1: Switch off circuit breaker CB1 and disconnect control voltage
power off by disconnecting ST.3
Step 2: Assure that in the machine control panel the 24V Internal control
wire of St.1 (D16) is disconnected from the 24V External wire of
St.1 (C16). Connection of the wires can result in overloading of
the internal or external 24VDC power supplies!
Note: The internal 24VDC power supply of 5A (10A) is only
rated to supply the internal ControlBox devices and the
electronics and blower of up to two (2) DURADRIVE. Do
not draw any power externally from the wire 24V Internal
if the optional power supply is installed.
Step 3: Snap the optional internal power supply on the DIN-rail to the
right of the PPC-R controller rack.
Step 4: Connect the pre-wired green connectors.
Step 5: Confirm that Step 2 was performed on the machine panel side.
Step 6: Connect the 115VAC supply cable to connector St.3 of the
ControlBox and turn on circuit breaker CB1.
Step 7: Make sure circuit breaker CB2 is on.
Step 8: Confirm that 24VDC is supplied to the TRANS200 (H1 indicator
must display changing characters ending at “b”), the BTV06 and
DURADRIVEs (H1 indicator must come on and end at “Bb” and
Fan must operate). This may take about a minute.
Step 10: Close the ControlBox.
ControlBoxD spare parts references
The following list provides basic spare component information at the time
of document creation. Suppliers and models may change without notice
and components may differ in the actual ControlBox purchased.
BRC = Bosch Rexroth Electric Drives and Controls
BRL = Bosch Rexroth Linear Motion and Assembly Technologies
TK1 7/30/2003
Components Type Qty Supplier Supplier Part No
Enclosure
BSC2-20EL1612LP-M Enclosure 1 Saginaw Control Engineering BSC2-20EL1612LP-M
SCE-20P16 Sub Panel 1 Saginaw Control Engineering SCE-20P16
Connector socket 115 VAC MSE 300 1 LOHR #218539
Plug, terminated HD 64 Terminated Plug # 1-64 1 Lapp USA #11.2700
Pin, HD MC #20-16 AWG, Dia 1.6mm Pin 64 Lapp USA #11.2210
Base, HBE 24 With Double Levers Base, HBE 24 1 Lapp USA #10.1020
Connector interconnect Duradrive 1 CONN INS0222/L01 1 LOHR #279499
Connector interconnect Duradrive 2 CONN INS0222/L01 1 LOHR #279499
Dust Cover Cap 1 LOHR #218589
Chain, for dust cover cap 1 LOHR 216664
Screw, for dust cover cap 4 screws per cap 4 LOHR 274033
Complete terminal strip w fuses Din Rail Assy 1 Phoenix Proposal # E03-0328
115/220 VAC - 24VDC 5A supply 1 Phoenix #2938581
115/220 VAC - 24VDC 10A supply (For double axes units) 0 Phoenix
Panel Mount Base VS-15-SD 1 Steiner Electric 1887099
Contact Plug, protective cover Q-PROT9/11 1 Steiner Electric 1670235
CP-HCC4 1 Steiner Electric 1600027
ZBN18 1 Steiner Electric 2809128
Heat Exchanger {Optional} 0 McClean XR2016-001
Screw, for BTV06 6
Screw, for connectors (power, 64 pin) M4 Torx - self tapping 6
Screw, for connectors (network) M3 Torx - self tapping 4
Screw, for connectors (drives) M2.5 Torx - self tapping 8
Mounting Frame
Profile Profile 45 X 45 H -/-, L=680 2 BRL 3842990520/680
Profile Profile 45 x 45 H -/-, L=480 3 BRL 3842990520/480
Gusset Gusset 45 x 45 W/Fastnr 10-10MM 16 BRL 3842523561
End Cap End Cap ESD 45 x 45 & 45 X 45 BLK 10 BRL 3842517058
Connection Link Connection Link 10MM L=180MM 4 BRL 3842528746
Spring Clip, T-Block,Swivel 3.842.529.300 6 BRL
Spring Clip, T-Block,Swivel 3.842.529.299 6 BRL
Screw, for mounting Drive (100A, 200A) 6
Flat washer 6
Spring washer 6
Screw, for mounting Drive (40A) 6
Flat washer 6
Spring washer 6
Control system
NC-card PPC-R01.2N-N-S1-FW 1 BRC 11285236
Firmware FWA-PPCR0*-T01-23VRS-NN-XXXXXX 1 BRC 11291836
Small HMI BTV06.1HN-RS-FW 1 BRC 11285948
Firmware FWA-BTV06*-DOL-01VRS-EN 1 BRC 11285306
Software SWA-BTV06*-T21-23VRS-MS-C1,44 1 BRC 11295762
Control rack RMB02.2-04 1 BRC 11278846
Input card RME02.2-32-DC024 1 BRC 11280937
Output card RMA02.2-32-DC024-050 1 BRC 11280931
2 mm fiber optic cable CABLE ASSEMBLY IKO0982/000.5 2 BRC 11260580
Serial communication cable CABLE ASSEMBLY IKB0015 1 BRC 11282870
Connector socket CONN INS0222/L01 2 BRC 11279499
Fiber optic bulk-head connector CONN FIB-OPT BLKHD 01 UNS IP65 2 BRC 11252524
TransKit1 Interface Descriptions 7-1
7 Interface Descriptions
7.1 Connector ST.3 – Control supply

voltage
This connector supplies 115VAC (only) to the control box for the optional heat
exchanger and internal 24VDC (optional) power supply, supplying the internal
electronics of control box and DuraDrives.
St.3 ControlBox
GND
N
115VAC ±10% 115VAC
60Hz L1 60Hz
TransKit power
cable 01-0400
Fig. 7-1.2: Connector ST.3
Note: If using the existing TRANS-01 supply voltage connector,

make sure you check that the supplied voltage is 115VAC.
Higher voltage will result in damage of the heat exchanger.
7.2 Connector St.1 – Interface Control

Cable
The IO configuration between the connector St.1 and the TRANS200 is
provided by Rexroth Indramat as described here.
Fig. 7-2.1: ControlBoxD – Default TRANS200 IO configuration
Note: If the IO configuration of the TRANS200 does not match the

configuration shown in the above figure then the description
for St.1 in this documentation may no longer apply resulting in
support difficulty! Contact the integrator for the specific
functionality and help.
This section describes the most important TRANS200 signal.
More datils can be obtained from the documentation
“Application Manual TRANS200 - Interface Description”
(DOK-TRA200-SPS*COM*V22-AW01-EN-P).
This section describes the signals for the connector St.1. St.1 is used to
connect the discrete IO functionality to the ControlBox. The connector is
compatible to the TRANS-01 St.1 connector, however, there are signal
and functional differences that must be considered.
Note: The user must review each of the signals contained in the
connector St.1 since they differ in functionality when
compared with the original Trans-01 controller.
Note: The description of signals in this manual refers to the status of

the signals at the time of the factory set-up and start-up. We
guarantee the described functionality of the control assuming
the proper in the field application. Any change in signal
configuration as well as change of status of the static interface
signals made afterwards, can cause the control malfunction
and can disable the functionality of the BTV06 HMI. Therefore
the configuration changes in the TK1 made afterwards will
automatically void the system warranty..
Power supply ( see drawings BE2000: sheets 01/12 and 09/12)
Connector St.1:A16 – 0V internal

Signal 0V of supply voltage reference for internal components (TRANS200, BTV06
or BTA10 & BTC06, DURADRIVE electronics with Blower, circulation
blower).
Function If no internal power supply is installed then “0V internal” and “0V external”
description must be connected in the machine control panel.
TRANS-01 note Identical to the TRANS-01 wiring.
Connector St.1:B16 – 0V external

Signal 0V of supply voltage reference for external components (RME inputs and
RMA outputs).
description must be connected in the machine control panel.
Connector St.1:C16 – 24V DC external

Signal 24V DC supply voltage for external components (RMA outputs).
description must be connected in the machine control panel. Then the external supply
voltage also supplies the internal components.
The external 24VDC must be fused externally.
Connector St.1:D16 – 24V DC internal

Signal 24V DC supply voltage for internal components (TRANS200, BTV06 ,
DURADRIVE electronics with Blower, circulation blower).
description must be connected in the machine control panel. Then the external supply
voltage also supplies the internal components.
The circuit breaker Q2 6A or 10A (depending on the power supply size and
number of connected drives) must be installed if the internal power supply is
used.
Wiring See diagram below.
Power control functions ( see drawings BE2000: sheets

03/12 to 09/12)
Connector St.1:A14 – Power enable

Signal PCPOWEN = 0: Power enablement blocked by the PLC
PCPOWEN = 1: Power enablement released by the PLC
Function The PLC uses this signal to indicate to the NC that the power may be
description switched on.
This signal is provided in the event that the PLC itself assumes the
evaluation of conditions for the power logic, including diagnosis ("Power
logic Version 2"). The PLC then just passes on to the NC the information
"Drives are ready for input power" in order to guarantee that the NC carries
out the minimum diagnosis.
If the PLC does not assume the evaluation of the conditions for inputting
power, or if this diagnostic option is to be omitted, the PLC program must
assign a logical '1' to the control signal.
TRANS-01 note It was original signal ‘Safety Limit’. This signal is no longer used via cable
04-0900 since if need be, all travel limit switches are wired directly to the
drive amplifiers (DURADRIVE). In general it is recommended to use motors
with multi-turn absolute feedback and software travel limits.
Wiring
St.1 Control Cable
Slot 1 X4
04-0900
%I1.0.0 1
#7 A14 PCPOWEN #7
0V X50:33 B16 #1
Connector St.1:C1 – Ready for power on

Signal PSPOWEN = 0: No power enabling signal from the NC
PSPOWEN = 1: Power enabling signal from the NC
The signal is valid in all modes.
Function The NC employs this signal to tell the PLC that all conditions for power
description activation have been fulfilled for this station.
The 'power enabled' signal is only issued if the following conditions are
fulfilled:
♦ There is no NC error pending for the process to prevent power
from being switched on (PSERROR=0)
♦ The 24 V supply for the process is OK (PCEXT24=1) (TransKit
sets this signal statically HI)
♦ The station EMERGENCY STOP button has not been pressed
(PCESTAT=1)
♦ There is no EMERGENCY STOP condition for the system
(PCEMACH=1) (TransKit sets this signal statically HI).
♦ None of the three possible guards is open (PCESTP1=1,
PCESTP2=1, PCESTP3=1) (TransKit sets these signals
statically HI).
♦ No limit switch for this process has been actuated (all
AxCOTRVL=1, x= axis number) (TransKit sets these signals
statically HI).
♦ The power supply unit is ready for operation (PCBBSUP=1)

(TransKit sets this signal statically HI).
♦ There is no excessively high temperature at the power supply
unit (PCTPSUP=1) (TransKit sets this signal statically HI).
The 'power enabled' signal is not output if one of the above-mentioned
conditions are not satisfied. The NC station diagnosis will then display the
first missing condition
TRANS-01 note It was original TRANS-01 signal “Main Contactor Control”.
Wiring
Slot 2 X4 Control Cable
St.1 04-0900
%Q2.0.0 1
#9 C1 PSPOWEN #9
X50
32
C16 #2
24V
33 #1
0V B16
Connector St.1:B10 – Power ON

Signal PCPOWON = 0: No power request
PCPOWON = 1: Power request via PLC
Function The PLC employs this control signal for requesting the NC to activate the
description power for the station. The power request will be ignored as long as the
NC does not issue the 'power enabled' (PSPOWEN) status signal.
Otherwise, the NC issues the 'power on' (PSPOWON) signal to
acknowledge the 'power request'. The power ON request signal can be
activated by pressing the relevant button at the machine or station. In
automatic mode, the power request signal may be supplied by central power
activation at the plant's main control panel.
If power activation should depend on additional external conditions, those
conditions must logically be linked with the power request.
TRANS-01 note It was the original signal “Enable”. The signal function is different now. It is
powering up the drives connected to the ControlBox.
Wiring
St.1 Control Cable
Slot 1 X4
X50 04-0900
%I1.0.1 2 10
#17 B10 PCPOWON #17
\
K2 & K3
0V X50:33 B16 #1
Connector St.1:D12 – Drive DC-Bus voltage ready

Signal PCUDRDY = 0: Drive DC-Bus voltage not available
PCUDRDY = 1: Drive DC-Bus voltage available
Active in all modes
Function tells the motion controller whether or not the DC bus voltage has been built
description up.
This signal is reported by the 'UD contact' of the drive power supply unit.
The controls internal power interlocking checks for this signal to have status
“1” in order to allow motion.
The user must read the 'UD contact' of both drives into the PLC and AND
them before outputting them as the PCUDRDY signal.
Note: If only one drive installed, then the drive’s 'UD contact' can directly be
wired to the PCUDRDY signal.
TRANS-01 note This wire was not used with TRANS-01.

Wiring
Control Cable
X3 St.1
04-0900 Machine Enclosure
Slot 1 %I1.1.6 7 With PLC
#24 D12 PCUDRDY #24
X50
33 0V B16 #1
PLC Logic
UD1 UD2 QUD
X50
17 A4 #54
UD1 ;PLC input
18 B4 #55 UD2 ;PLC input
X54 3 4 X55 3 4
DURADRIVE #1 DURADRIVE #2
Red/ Wht Red/ Wht
Blk Blk
Interlock Interlock
cable cable
IND3048 IND3048
Connector St.1:D3 – Power is on

Signal PSPOWER = 0: Power has not yet been switched on
PSPOWER = 1: Power is on
Function The NC employs this signal to report that all signals are present that must
description be reported after power activation. If, in addition, all the general enabling
signals exist, the NC will be able to execute programs for the station in
question or the axes may be moved manually.
The 'Power is ON' signal is only issued if the following conditions exist:
 The NC reports 'power ON' to the PLC (PSPOWON=1)
 The main contactor is closed (PCPWRDY=1)
 The DC bus voltage is available (PCUDRDY=1)
 The main spindle is operational (PCBBMSP=1) and
 Power enabled is OK (PSPOWEN=1)
The 'Power is ON' signal is not issued if one of the above conditions is not
satisfied. In this case, the NC station diagnosis shows the first missing
condition in the list.
TRANS-01 note It was the orginal signal “Power Interrupt”. Note: The signal meaning is
different – it is no fault. The tag at the indicator or meaning in the PLC
program needs modification.
Wiring
St.1 04-0900
%Q2.0.1
2 D3 PSPOWER
#21 #21
X50
32
C16 #2
24V
33 #1
0V B16
Connector Internal signal: Emergency Stop at Station

Signal PCESTAT = 0 Emergency Stop chain opened at the station (PB)
PCESTAT = 10 Emergency Stop chain closed at the station (PB)
Function This signals informs NC if the Emergency Chain has been broken on the
description station by activation of the Emergency Stop button. At delivery The
terminals X50.13 and A50.14 are jumpered, since no Emergrncy Stop
pushbutton is mounted on the ControlBox. This would supply the PCESTAT
and EM.STOP input of both drives with 24V through the NO contact of the
Emergency Stop relay K1.
If local Emergency Stop button is necessary on the ControlBox it can be
added during the machine integration. The pushbutton has to be properly
mounted to maintain the IP65 status of the ControlBox.
TRANS-01 note This signal is not transferred to the PLC.
Wiring
NC control functions
Note: The signals listed here influence the operation of the motion
and provide status feedback.
Connector St.1:A3 – Ready to start

Signal PSREADY = 0: Not ready to start
PSREADY = 1: Ready to start
The signal is effective in all modes.
Note: Depending on the settings of the two parameters 'reverse program
execution required' and 'reference required', executing a reverse program
and/or the axis reference is not necessary for starting the advance program.
Function The 'ready to start' signal indicates that a process is ready to be started.
description Depending on the setting of the 'reverse program execution required'
parameter, a process is first ready to be started after a reverse program has
been executed. In this reverse program, reference dimension must be
established for all axes that belong to the process.
The 'ready to start' signal is set when the reverse program is terminated with
the 'jump with stop' (BST) or 'program end with reset' (RET) command.
The 'ready-to-start' condition is also established when a forward program
has been correctly executed. In this case, the forward program must be
terminated by a 'jump with stop' (BST) or 'program end with reset' (RET)
command.
The 'ready to start' signal is cleared when an advance or reverse program is
active (PSACTIV).
Any type of jogging movement (single axis homing, jogging) cancels the
'ready to start' signal.
Successful completion of the reverse program permits the 'ready to start'
signal to be re-established.
Single-axis homing of all axes does not permit the 'ready to start' signal to
be established.
TRANS-01 note It was the original signal “Ready”. The wiring can remain the same if the
described functionality above is acceptable.
Wiring
St.1 04-0900
%Q2.0.5
6 A3 PSREADY
#18 #18
X50
32
C16 #2
24V
33 #1
0V B16
Connector St.1:B3 – NC-program active

Signal PSACTIV = 0: No NC program being executed
PSACTIV = 1: NC program being executed
Function The 'NC program active' signal shows that an NC program is being
description executed. Distinction between advance and reverse program is not made
here.
The 'NC program active' signal is retained when an NC program is stopped
by a stop command.
The 'NC program active' signal is cleared when a 'jump with stop' (BST) or
'program end with reset' (RET) block is executed in the program.
Unlike the 'NC block active' signal, the 'NC program active' signal is retained
after each NC block in single block mode.
Any type of jogging movement (single axis homing, jogging) cancels the 'NC
program active' signal.

Setting the 'clear error' signal in the PLC program without a pending process
error clears the 'NC program active' signal (Control Reset).
TRANS-01 note It was the original signal “Run”. The wiring can remain the same if the
Wiring
St.1 04-0900
%Q2.0.6
7
#19 B3 PSACTIV #19
X50
32
C16 #2
24V
33 #1
0V B16
Connector St.1:D13 – Program Stop

Signal PCSTOP = 0: No program stop
PCSTOP = 1: Program stop
Program stop has an effect in all modes.
Function The 'program stop' signal interrupts program execution for this process.
description Axis movements are decelerated along a ramp, and program preparation is
interrupted. The stopped process can be continued by starting an advance
or a reverse program. The 'program stop' signal has to be cleared first
however.
Jog movements are not influenced by setting the 'program stop' signal.
TRANS-01 note It was the original signal ‘Tool Change’. This signal is no longer used and if
need be, a conditional jump can be programmed in the PLC to move the
axes to a tool change position.
Wiring
St.1 Control Cable
Slot 1 X4
04-0900
%I1.0.7 8
#26 D13 PCSTOP #26
0V X50:33 B16 #1
Connector St.1:A2 – Error active

Signal PSERROR = 0: No error
PSERROR = 1: Error
The signal has an effect in all modes.
Function The NC uses the 'error' signal to notify the PLC of a process error. The clear
description error text is displayed in the diagnosis overview of the user interface.
The error number can be read from the PLC by means of the multiplex
channel (cf. Field bus documentation). A pending error must be cleared by
setting the 'clear error' signal in the PLC program. The 'PSERROR' error
signal is set again if the error condition is still active even after the error has
been cleared. An NC program cannot be executed as long as an error
status is pending.
TRANS-01 note It was the original signal “Fault”. Can remain as wired.
Wiring
Slot 2 X4 %I1.0.3 Control Cable
St.1 04-0900
%Q2.0.3
4 A2 PSERROR
#22 #22
X50
32
C16 #2
24V
33 #1
0V B16
Connector St.1:A10 – Clear error / Control Reset

Signal PCCLEAR = '0' - No action
PCCLEAR = '1' - Clear error / Control reset
Depending on whether or not there is an error pending (PSERROR = 1), the
signal has two different effects:
 PSERROR=0, PCCLEAR=1: Control reset
 PSERROR=1, PCCLEAR=1: Pending error is deleted
Connector Slot 2 RMA X4:5 – Clear error / Control Reset from BTV06
Signal BSDAT06 = '0' - No action
BSDAT06 = '1' - Clear error / Control reset Æ sets PCCLEAR =1
Depending on whether or not there is an error pending (PSERROR = 1), the
signal has two different effects:
 PSERROR=0, PCCLEAR=1: Control reset
 PSERROR=1, PCCLEAR=1: Pending error is deleted
Function Clear error:
description A pending error is cleared upon the rising edge of the 'clear error' signal.
The NC clears the 'error' signal to indicate that the error has been cleared.
The 'error' signal is set again and the error is indicated again if the error still
exists. Once an error has been successfully cleared, the advance program
interrupted by the error cannot be restarted. The only exception is if the
'reverse program execution required' process parameter has also been set
to 'no' and if the axes have measuring reference. If a start is to be possible
without measuring reference, the 'reference required' process parameter
must also be set to 'no'. When a reverse program is initiated, program
segments with reverse vectors will be processed first, followed by the base
reverse program (starting from the jump label '.HOME').
Control Reset:
A stopped NC program can be aborted by a 'Control-Reset' input. A running
spindle is stopped by 'Control reset' (exception: see AxCSPRST with x=axis
number of spindle). (TransKit1 sets the AxCSPRST by default to 1:”Control
reset does not influence the spindle”).
Programmed reverse vectors are cleared. The '.HOME' base reverse vector
is therefore called when a reverse program is initiated. This executes the
base reverse program. Complicated return movements that permit program-
controlled establishment of the readiness to start by programming reverse
vectors are not performed.
The operator must perform those movements in 'Setup' mode through jog
movements. Once it has been ensured that the base reverse program can
be executed without interference, the operator may trigger a start of the
reverse program and initiate the base reverse program.
The following signals and actions are also influenced by a 'Control reset':
 The 'NC block active' (PSACTIV) status signal is reset
 The 'reverse program active' (PSREV) status signal is reset

 The 'program stopped' (PSSTOP) status signal is reset
 The 'control voltage interruption' (PSPOWIN) status signal is reset
 pending M functions are aborted
 an unconditional stop (M00) is terminated
 a conditional stop (M001) is terminated
 M3 spindle CCW rotation is aborted (exception: see AxCSPRST)
 M4 spindle CW rotation is aborted (exception: see AxCSPRST)
 The ‘PSREADY’ signal is set to '1' if the 'homing required' parameter has
been set to 'no'
 messages that have been generated in the NC program are cleared
 the NC block 'N0001' appears in the position display for the currently
selected NC program
 Zero offsets are switched off
 the upper limit of the override value is set to 100%
 G codes are set according to their default values
 Internal couplings are deactivated (e.g., tapping)
 event monitoring is de-activated
 Process acceleration is set to 100%
 the 'travel to dead stop' state is reset
 a pending AXD-command from the NC is aborted
 spindle '1' is used as reference spindle
 the D corrections are de-activated
TRANS-01 note It was the original signal “Restart”. The signal function is now different and is
used to reset the error in the TransKit1.
Wiring

St.1 04-0900
%Q2.0.4 5 BSDAT06
X50
32 C16
24V #2
0V 33 B16 #1
Diodes in the terminal

Slot 1 X4 St.1
%I1.0.4 5
X50:11 A10 PCCLEAR #16
#16
0V X50:33 B16 #1
Connector St.1:C10 – Automatic/Manual mode

Signal PCMODE1 = 0: Automatic mode
PCMODE1 = 1: Manual Mode
With the TransKit1 the signal PCMODE0 is not used and has the status “0”.
Function ‘Automatic' mode:
description 'Automatic mode' permits only NC programs to be executed. Moving axes
by jog commands is not possible.
Advance program:
1. The NC advance program is started by a 'start advance program'

(PCADV) signal.
2. The 'Program active' (PSACTIV) signal indicates the NC advance
program is being executed. The 'Reverse program active' (PSREV) signal
remains cleared while an advance program is being executed. The 'ready to
start' (PSREADY) signal is canceled when the advance program execution
starts.
3. In 'automatic mode', one impulse is sufficient for starting the NC advance
program. The start signal may be cleared once the NC program execution
has started. The NC program will be completed even if the advance
program start signal is no longer applied.
4. The 'Program active' (PSACTIV) signal is cleared when the NC advance
program is completed. At the same time, the subsequent NC advance
program will have the 'ready to start' (PSREADY) signal assigned.
Reverse program:
1. The NC reverse program is started by a 'start reverse program' (PCREV)
signal.
2. The 'program active' (PSACTIV) and 'reverse program active' (PSREV)
signals indicate the NC reverse program is being executed. The 'ready to
start' (PSREADY) signal is canceled at the same time.
3. In 'Automatic' mode, one impulse is sufficient for starting the NC reverse
program. The start signal may be cleared once the NC program execution
has started. The NC program will be completed even if the reverse program
start signal is no longer applied.
4. The 'program active' (PSACTIV) and 'reverse program active' (PSREV)
signals are cleared when the NC reverse program is completed. An NC
advance program will have the 'ready to start' (PSREADY) signal assigned if
reference exists for all the axes after the reverse program has been
executed.
'Manual' mode'
'Manual’ mode permits NC programs to be executed and axes to be moved
by jog commands.
NC-program operation is the same as in ‘semi-automatic’ mode, explained

below.
Advance program:
1. The NC advance program is started by a 'start advance program'
(PCADV) signal.
2. The 'Program active' (PSACTIV) signal indicates the NC advance
program is being executed. The 'Reverse program active' (PSREV) signal
remains cleared while an advance program is being executed. The 'ready to
start' (PSREADY) signal is canceled when the advance program starts to be
executed.
3. In 'semi-automatic' mode, the NC advance program is executed as long
as the advance program start signal is applied.
4. The axes and NC program will be stopped immediately if the start
advance signal is removed while the NC advance program is being
executed. The interruption is indicated by the 'program stopped' (PSSTOP)
signal.
5. A new start advance program signal permits the NC advance program to
be resumed from the point of interruption.
6. Restarting the advance program clears the 'program stopped' (PSSTOP)
signal.
7. The 'program active' signal is cleared when the NC advance program is
completed. At the same time, the 'ready to start' signal will be assigned for a
new advance program.
8. The start signal may be cleared when the advance program is completed.
Reverse program:
1. The NC reverse program is started by a 'start reverse program' (PCREV)
signal.
2. The 'program active (PSACTIV) and 'reverse program active' (PSREV)
signals indicate the NC reverse program is being executed. The 'ready to

start' signal (PSREADY) is canceled at the same time.
3. In 'semi-automatic' mode, the NC reverse program is executed as long as
the reverse program start signal is applied.
4. The axes and NC program will be stopped immediately if the start reverse
program signal is removed while the NC reverse program is being executed.
The interruption is indicated by the 'program stopped' (PSSTOP) signal.
5. A new start reverse program signal permits the NC reverse program to be
resumed from the point of interruption.
6. Restarting the reverse program clears the 'program stopped' (PSSTOP)
signal.
7. The 'program active' signal is cleared when the NC reverse program is
completed. At the same time, the 'ready to start' signal will be assigned for
an advance program start.
8. The start signal may be cleared when the reverse program is completed.
TransKit1 Note1: Through the BTV06 setup configuration it is possible to
enable the NC program execution in Manual Mode using the BTV06 L1 and
R1 buttons.
TransKit1 Note2: All the status signals disussed above with the exception of
PSRUN and PSREV are available through the standard output assignment.
TRANS-01 note It was the original signal “Auto”. The signal functioning is similar but the
signal level is reversed. In Trans-01 HI status indicated AUTO mode, while
here it indicates MANUAL.
Wiring
St.1 Control Cable
Slot 1 X4
04-0900
%I1.0.2 3
#23 B10 PCMODE1 #23
0V X50:33 B16 #1
Connector St.1:A12 – Enable

Signal PCENABL = 0: No process enable signal
PCENABL = 1: Process enable signal available
The process enable signal has an effect in all modes.
Function The 'process enable' signal is required for moving an axis or for executing
description an NC program. Power remains ON when the process enable signal is
removed.
An immediate stop is initiated for the process if the process enable signal is
removed while an NC program is running. Axis movements are decelerated
along a ramp curve, and program execution is interrupted.
The NC program can only be restarted after the process enable signal has
been applied. The 'start advance program' signal (PCADV) can be used for
restarting an interrupted advance program.
The 'start reverse program' signal (PCREV) can be used for restarting an
interrupted reverse program.
If the process enable signal is removed during a jog movement (single axis
homing, jogging), the jog process is interrupted and axis movement is
decelerated along a ramp.
Jog movements can only be continued after the process enable signal has
been re-applied.
TRANS-01 note It was the original signal “Forward Enable”. The signal functioning is similar
but motion execution will require an edge at PCADV or PCREV.
Wiring
St.1 Control Cable
Slot 1 X3
04-0900
%I1.1.5 6
#60 A12 PCENABL #60
0V X50:33 B16 #1
Connector St.1:B12 – Advance program (Start)

NOTE: By default this external signal is active only in the AUTO mode. It is
possible to change the BTV06 setup this way, that the program ADV and
REV can be run in MAN mode through the L1 and R1 buttons
respectively.
Signal PCADV = 0: No advance program start
PCADV = 1: Advance program start
This control signal has different meanings in the different modes.
Function Requirements for the start of the advance program:
description  Power present
 No error
 Process enabling signal issued
 No reverse program active, and
 Ready to start
'Automatic' mode
A positive edge of the 'Start of advance program' (PCADV) signal starts
the advance program when the ready to start signal (PSREADY=1) has
been issued. The 'start of advance program' signal can be removed when
the advance program is processed.
The restart of an interrupted advance program from the currently active
block number is also triggered by a positive edge of the 'start of advance
program' signal.
'Manual' mode
The positive edge of the 'start of advance program' signal (PCADV) starts
the advance program. Unlike in 'Automatic' mode, the NC monitors the 'start
advance program' signal in the other modes after the program has been
started. The advance program is executed as long as the signal is applied.
When the signal is removed, active movements are decelerated along a
ramp, and program execution is interrupted.
A new advance program start restarts program execution.
The following conditions interrupt an advance program:
 Power shutdown
 Error
 Process enabling signal removed
 Stop
 Changing modes
 single step mode, and
 Starting a reverse program
TRANS-01 note It was the original signal “Start”. The signal functioning is similar.
Wiring
PSMODE1 MAN mode selected

Slot 2 %Q2.0.2 X4
Control Cable
3 St.1
K4 X50 04-0900
32 C16 #2
24V
#1
0V 33 B16
3 Output on when L1 (advance) is

Outputs Q3 pressed and MAN mode active
13 K5 Supply BTV06 outputs when

K4 MAN mode selected
24V
0V 14
Slot 1 %I1.0.5 X4 PCADV

#14 B12 #14
6 K5
Connector St.1:D10 – Reverse (homing) program start

NOTE: By default this external signal is active only in the AUTO mode. It is
possible to change the BTV06 setup this way, that the program ADV and
REV can be run in MAN mode through the L1 / R1 buttons respectively.
Signal PCREV = 0: No reverse program start
PCREV = 1: Reverse program start
Function Requirements for the start of the reverse program:
description  Power present - No error condition exists, and Process enabling
signal issued
This control signal has different meanings in the different modes.
'Automatic' mode
A positive edge of the 'start of reverse program' (PCREV) signal starts the
reverse program. A reverse program start may also be initiated while an
advance program is being executed or stopped.
The 'start of reverse program' signal may be removed when the reverse
program is processed. The restart of an interrupted reverse program from
the currently active block number is triggered by a positive edge of the 'start
of reverse program' signal.
'Setup' mode
A positive edge of the 'start of reverse program' signal starts the reverse
program.
Unlike in 'Automatic' mode, the NC monitors the 'start reverse program'
signal in the other modes after the program has been started. The reverse
program is executed as long as the signal is applied. When the signal is
removed, active movements are decelerated along a ramp, and program
execution is interrupted. Program execution is resumed (restart) when the
signal is re-applied.
The following conditions interrupt a reverse program:
 Power shutdown – Error - Process enabling signal removed - Stop
 single step mode, and Changing modes
TRANS-01 note It was the original signal “Homing”. The signal functioning is similar.
Wiring
Slot 2 %Q2.0.2 X4 PSMODE1 MAN mode selected
3 Control Cable
K4 X50 St.1 04-0900
32
24V C16 #2
0V 33 B16 #1
4
Outputs Q4 Output on when R1 (reverse) is
pressed and MAN mode active
13
24V K6 Supply BTV06 outputs when
MAN mode selected
0V 14 K4
Slot 1 %I1.0.6 X4
PCREV
#15 D10 #15
7 K6
Connector St.1:A11 – Branching conditions 20

Signal PCCOND0 = 0: Condition bit 20 inactive
PCCOND0 = 1: Condition bit 20 active
The branching conditions have an effect in all modes.
Function Applying a bit combination to the inputs PCCONDn (n = 0 to 3 for TransKit)
description satisfies the condition with the corresponding number in the NC program.
The condition can be queried in the NC program by means of the allocated
NC commands (BES / BEV).
The number of the condition is assigned to the inputs as a binary value. The
weight of each input follows directly from n to 2^n.
TRANS-01 note It was the original signal “Conditional Jump Input 20”. The signal functioning
is similar but uses NC-events in the NC-program.
Wiring
St.1 Control Cable

Slot 1 X3
04-0900
%I1.1.0 1
#30 A11 PCCOND0 #30
0V X50:33 B16 #1
Connector St.1:B11 – Branching conditions 21

Wiring
St.1 Control Cable
Slot 1 X3
04-0900
%I1.1.1 2
#29 B11 PCCOND1 #29
0V X50:33 B16 #1
Connector St.1:C11 – Branching conditions 22

Wiring
St.1 Control Cable

Slot 1 X3
04-0900
%I1.1.2 3
#28 C11 PCCOND2 #28
0V X50:33 B16 #1
Connector St.1:D11 – Branching conditions 23

Wiring
St.1 Control Cable
Slot 1 X3
04-0900
%I1.1.3 4
#27 D11 PCCOND3 #27
0V X50:33 B16 #1
Connector St.1:C13 – Asynchronous condition (Event)

Signal PCEVENT = 0: Asynchronous condition deleted
PCEVENT = 1: Asynchronous condition set
Function The PCEVENT signal interrupts any NC program that is running. All moving
description axes are stopped as quickly as possible. Then a block is started that has
been previously defined by means of program control commands (BEV).
The NC program is continued with this block.
TRANS-01 note It was the original signal ‘Spindle Enable Manual Mode’. This signal is no
longer used since the TRANS200 will control the spindle enable.
Wiring
St.1 Control Cable

Slot 1 X3
04-0900
%I1.1.4 5
#49 C13 PCEVENT #49
0V X50:33 B16 #1
Connector St.1:C2 – Thrust missing

Signal PSTHMIS = 0: The machining torque has not exceeded the pre-selected
minimum machining torque (parameter B00.065) during machining.
PSTHMIS = 1: The machining torque has exceeded the pre-selected
minimum machining torque (parameter B00.065) during machining.
Function The 'PSTHMIS' signal indicates that the minimum machining torque
description (parameter B00.065) has not been exceeded during machining with an
active "adaptive feed control" function.
The 'PSTHMIS' signal is set, if the minimum machining torque (Parameter
B00.065) is not exceeded when the "adaptive feed control" (G25) function is
shut down.
The 'PSTHMIS' signal is reset, as soon as:
 the “adaptive feed control" function is switched on (G26),
 the program processing has been completed (RET / BST),
 any "control reset" has been cleared.
The following are possible reasons why the minimum machining torque has
not been exceeded:
 missing work piece
 Tool breakage
 incorrect correction data (D corrections)
 faulty zero offsets
TRANS-01 note It was the original signal “Thrust missing”. The wiring can remain if the
Wiring
St.1 04-0900
%Q2.1.0
1 C2
#58 #58
X50
32
C16 #2
24V
X50:33 #1
0V B16
Connector St.1:D2 – Excessive Thrust

Signal PSEXCTH = 0: The current feed reduction does not exceed the maximum
feed reduction (parameter B00.067).
PSEXCTH = 1: The current feed reduction does exceed the maximum feed
reduction (parameter B00.067).
Function The 'PSEXCTH' signal indicates that the maximum feed reduction
description (Parameter B00.067) has been exceeded during machining with an active
"adaptive feed control" function.
The 'PSEXCTH' signal is set, as soon as the current feed reduction

exceeds the "maximum feed reduction" (Parameter B00.067) limit value.
The 'PSEXCTH' signal is reset, as soon as the current feed reduction falls
short of the "maximum feed reduction" (Parameter B00.067) limit value.
Note: The NC continues machining even if the current feed
reduction exceeds the "maximum speed reduction" (parameter
B00.067) limit value. Not until the current feed reduction
 reaches 100% for more than 20 ms (axis standstill) and
 the value of the "maximum feed reduction" (Parameter B00.067)
limit value is less than 100%, does TRANS200 stop the machining
process and generate error message "100% feed reduction @ axis".
The following are possible reasons why the maximum feed reduction has
been exceeded:
 sluggish mechanical system
 worn-out tool
 coolant supply interrupted
TRANS-01 note It was the original signal “Excessive Thrust”. The wiring can remain if the
Wiring
St.1 04-0900
%Q2.1.1
2 D2 P2EXCTH
#59 #59
X50
32
C16 #2
24V
33 #1
0V B16
Auxiliary functions
Note: The auxiliary functions work differently than with the Trans-01.
By default, the auxiliary functions
o are output at the end of the NC-block
o must be acknowledged at the end of the NC-block to
continue motion program execution.
Based on the machine function to be initiated by an auxiliary

functions such as
o clamp/unclamp,
o coolant on/off,
o full depth,
o position reached,
o …
the status of the auxiliary functions must be stored (set/reset
or latched/unlatched) in the machine PLC program if the
function must be retained after their acknowledgement.
Below a simplified example on how the state if auxiliary

function signals from the Trans200 in the ControlBoxD can
be stored in the PLC logic. Additional conditions and
interlocks maybe required depending on the specific function
to be achieved and situation.
Fig. 7-1.4: Auxiliary function in PLC program
Connector St.1:A7 – Auxiliary function output 400

Signal PSAUX400 = 0: No signaling
PSAUX400 = 1: NC signaling active
Function In the NC program, the PSAUX400 signal can be set by executing NC
description auxiliary functions (M400 or MQ400), see separate description. All signaling
must be acknowledged via the allocated PCACKN400 signal. The NC
program is either interrupted until the acknowledgement is received (M400)
or the NC program can request the acknowledgment later (by means of
MW400 if NC-program ahead contained MQ400). Renewed signaling via the
same output signal is only possible following an acknowledgment.
Note: PSAUX400 and PSAUX401 belong to the same group. It means that
their use in the NC block is mutually exclusive.
TRANS-01 note It was the original signal “Auxiliary Function output 0”. The signal functioning
is different and the number of the auxiliary function changes. The TransKit1
does not monitor the state of the acknowledge signal.
Wiring
St.1 04-0900
%Q2.3.0
1 A7 PSAUX400
#31 #31
X50
32
C16 #2
24V
33 #1
0V B16
Connector St.1:B7 – Auxiliary function output 401

Wiring

St.1 04-0900
%Q2.3.1
2 B7 PSAUX401
#32 #32
X50
32
C16 #2
24V
33 #1
0V B16
Connector St.1:C7 – Auxiliary function output 404

Wiring
St.1 04-0900
%Q2.3.2
3 C7 PSAUX404
#33 #33
X50
32
C16 #2
24V
33 #1
0V B16
Connector St.1:D7 – Auxiliary function output 405

Wiring
St.1 04-0900
%Q2.3.3
4 D7 PSAUX405
#34 #34
X50
32
C16 #2
24V
33 #1
0V B16
Connector St.1:A6 – Auxiliary function output 408

Wiring
St.1 04-0900
%Q2.3.4
5 A6 PSAUX408
#35 #35
X50
32
C16 #2
24V
33 #1
0V B16
Connector St.1:B6 – Auxiliary function output 409


Wiring
St.1 04-0900
%Q2.3.5
6 B6 PSAUX409
#36 #36
X50
32
C16 #2
24V
33 #1
0V B16

Wiring
St.1 04-0900
%Q2.3.6
7 C6 PSAUX412
#37 #37
X50
32
C16 #2
24V
33 #1
0V B16


Wiring
St.1 04-0900
%Q2.3.7
8 D6 PSAUX413
#38 #38
X50
32
C16 #2
24V
33 #1
0V B16

their use in the NC block is mutually exclusive. (Functions were intended to
be used with PIM option, which is not implemented.)
TRANS-01 note It was the original signal “BCD 10*4”. This function is no longer available
since the TransKit1 does not support BCD output.
Wiring
St.1 04-0900
%Q2.2.6
7 C5 PSAUX420
#52 #52
X50
32
C16 #2
24V24V
33 #1
0V B16


their use in the NC block is mutually exclusive. (Functions were intended to
be used with PIM option, which is not implemented.)
TRANS-01 note It was the original signal “BCD 10*8”. This function is no longer available
since the TransKit1 does not support BCD output.
Wiring
St.1 04-0900
%Q2.2.7
8 D6 PSAUX421
#53 #53
X50
32
C16 #2
24V
33 #1
0V B16
Connector St.1:D8 – Auxiliary function 400 acknowledge

Signal PCACKN400 = 0: No acknowledgement
PCACKN400 = 1: NC signal is acknowledged
Function Signals generated in the NC program by M400 or MQ400 has to be
description acknowledged via the allocated control signals PCACKN400. Only as a
result of the acknowledgment can the NC cancel the relevant output signal
(PSAUX400), see separate description.
TRANS-01 note It was the original signal “Auxiliary Function output 0 acknowledge”. The
signal functioning is different and the number of the auxiliary function
changes. The TransKit1 does not monitor the state of the acknowledge
signal.
Wiring
St.1 Control Cable
Slot 1 X1
04-0900
%I1.3.0 1
#39 D8 PCACKN400 #39
0V X50:33 B16 #1
Connector St.1:C8 – Auxiliary function 401 acknowledge

signal.
Wiring
St.1 Control Cable
Slot 1 X1
04-0900
%I1.3.1 2
#40 C8 PCACKN401 #40
0V X50:33 B16 #1
Connector St.1:B8 – Auxiliary function 404 acknowledge

signal.
Wiring
St.1 Control Cable
Slot 1 X1
04-0900
%I1.3.2 3
#41 B8 PCACKN404 #41
0V X50:33 B16 #1
Connector St.1:A8 – Auxiliary function 405 acknowledge

signal.
Wiring
St.1 Control Cable

Slot 1 X1
04-0900
%I1.3.3 4
#42 A8 PCACKN405 #42
0V X50:33 B16 #1
Connector St.1:D9 – Auxiliary function 408cknowledge

description acknowledged via the allocated control signals PCACKN408 Only as a
signal.
Wiring
St.1 Control Cable
Slot 1 X1
04-0900
%I1.3.4 5
#43 D9 PCACKN408 #43
0V X50:33 B16 #1
Connector St.1:C9 – Auxiliary function 409 acknowledge

signal.
Wiring
St.1 Control Cable

Slot 1 X1
04-0900
%I1.3.5 6
#44 C9 PCACKN409 #44
0V X50:33 B16 #1

Signal PCACKN412= 0: No acknowledgement
PCACKN412= 1: NC signal is acknowledged
signal.
Wiring
St.1 Control Cable
Slot 1 X1
04-0900
%I1.3.6 7
#45 B9 PCACKN412 #45
0V X50:33 B16 #1

signal.
Wiring
St.1 Control Cable

Slot 1 X1
04-0900
%I1.3.7 8
#46 A9 PCACKN413 #46
0V X50:33 B16 #1

Signal PCACKN420= 0: No acknowledgement
PCACKN420= 1: NC signal is acknowledged
TRANS-01 note The signal was not assigned in the original TRANS-01.
Wiring
St.1 Control Cable
Slot 1 X1
04-0900
%I1.2.6 7
#47 A13 PCACKN420 #47
0V X50:33 B16 #1

TRANS-01 note The signal was not assigned in the original TRANS-01.
Wiring
St.1 Control Cable

Slot 1 X1
04-0900
%I1.2.7 8
#48 B13 PCACKN421 #48
0V X50:33 B16 #1
Axis #1 functions
Axis #1 can be a servo axis. Additional signals for functions such as
touch probing, and way points are provided.
Note: Axis #1 must not be used as spindle axis since respective
signals are not available via connector St.1.
Connector X54:1; X54:10 – Axis #1 drive ready

Signal A1READY = 0: Drive not ready for power on
A1READY = 1: Drive ready for power on
Function The signal indicates when the DURADRIVE is ready for switching the 3-
description phase main power on.
When ready, the drive shows “Bb” on the display and the Bb contact closes.
See also “Connector X54 – Drive #1 Interlock Cable” for further details.
TRANS-01 note N/A
Wiring
X54 HDC01.1-AxxxN-SE01-01-FW
ControlBoxD X50 White 1.0 X1 DURADRIVE #1

0V 11 3 0VDC
12 Blue 1.0
24V #83 1 24VDCBb
Slot 1 X2 Bb
%I1.2.0 1
Interlock Cable
IND3048 1.5m ON1
ON1
X11
Violet 7 On3
10 Yellow 8 On4
15 1 Pink 0V
\
910
9 Green +24Vpro
K2:14 11
K2:11 8 Brown ZKS1

12 \
6 ZKS1
0V
2
Connector St.1:C3 – Axis #1 is homed

Signal A1SHOMED = 0 : Axis #1 reference (home) not present
A1SHOMED = 1 : Axis #1 is homed
Function This signal tells the PLC whether or not the axis has been homed.
description With incremental position measuring systems, reference must be re-
established whenever the controller is switched on. This can be done
manually for each individual axis using the 'axis homing' signal (AxCHOME)
or be programmed via the valid NC reverse program.
Single-axis homing of all axes of a process does not make the NC program
of that process ready to start. The ready-to-start condition can only be
attained by executing a NC reverse program (see signal: 'Ready to start').
The 'axis is homed' signal is used as a validity signal for the waypoint
signals of that axis.
TRANS-01 note It was original signal “HOME”. Note: signal only reflects if Axis #1 is homed.
Wiring
St.1 04-0900
%Q2.2.0
1
#20 C3 A1SHOMED #20
X50
32
C16 #2
24V
33 #1
0V B16
Connector St.1:B14 – Axis 1 home switch

Signal Wire from the axis home switch (24VDC). The “0VDC External” wire of the
external power supply must be connected to GND and “0VDC Internal”.
Function The switch indicates to the drive that the home switch has reached the
description home switch cam/dog.
TRANS-01 note It was the original signal ‘Home Limit Switch’.
Connector St.1:C14 – Axis 1 positive overtravel switch

Function The switch indicates to the drive that the hardware overtravel switch has
description reached the switch cam/dog.
TRANS-01 note It was the original signal ‘- overtravel limit switch’. The limit switches are
now reversed.
Connector St.1:D14 – Axis 1 negative overtravel switch

TRANS-01 note It was the original signal ‘+ overtravel limit switch’. The limit switches are
now reversed.
Control Cable
X50 St.1 04-0900
21 #12 B14 #12
Home LS
20 #11 C14 #11
Pos. OT LS
19 #10 #10
D14 Neg. OT LS
X50
0V 33 #1
X54 5 6 7 11
Interlock Cable INK0209

Blue/ Yell/ Grn/ Wht
Complete cable IND3048
Blk Blk Blk
X3 1 2 3 X1 3
DURADRIVE Axis 1
HDC01.1-AxxxN-SE01-01-FW
Connector St.1:C12 – Axis #1 – Probe 1

Signal Probe 1 = depends on the active drive parameter configuration
Only effective if the Probe 1 functionality is activated in the digital
DURADRIVE amplifier.
Note: The Probe function is only available for Axis #1!
Function 1. Connections:
description The user must connect the external probe (switch type) to the St.1:C12.
The probe signal is routed to the high-speed probe input of the digital
DURADRIVE Æ Axis #1.
The user must also
- Connect the Probe signal in parallel to the St.1:C13 wire
representing the asynchronous event
- Activate the event monitoring
-
2. Drive setup:
The user must configure (edge selection, arming, etc.) for the Probe 1 input
using the AXD NC-command, e.g. via the subroutine or reverse (HOME)
program. (See blocks N003 to N005 in the attached example. )
Note:
The probe used must have a deflection in the direction of probing.
The distance of deflection must be large enough so that the motion
can be stopped after signal recognition without damaging the probe.
If probe will not trigger in the expected area, program should stop
(See block N0010 in the attached example) and message can be
issued.
Example probing subroutine:
TRANS-01 note This functionality did NOT exist with the Trans-01.
Caution: The original signal of St.1:C12 was “Reverse”. This signal is not
used anymore. Reverse program execution is triggered through the input
St.1:D10 Æ PCREV described before.
Wiring
St.1 Control Cable

ControlBoxD
04-0900
X50 #25 C12 Probe 1 #25

22
X50 0V B16 0V
32
X54 11 4
Blue Wht

DURADRIVE
Axis #1
Connector St.1:C4 – Axis #1 Real Time Status Bit

Signal A1SIDDS = 0: Axis 1 Real-Time status bit is OFF
A1SIDDS = 1: Axis 1 Real Time status bit is ON
Function This signal enables the PLC to read a real-time status bit in the drive via the
description NC.
The status that is read from the drive depends on the allocation of an ID
number to the real-time status bit in the SERCOS parameters. Please refer
to the ‘SERCOS Interface’ description for a list of the parameters that can
be allocated to a real-time bit and for an explanation of the procedure for
allocating a parameter to the real-time bit.
TRANS-01 note This function did not exist in the Trans-01.
The original signal of St.1:C04 was “BCD 10*22”. This function is no longer
available since the TransKit1 does not support BCD outputs.
Wiring

St.1 04-0900
%Q2.2.2
3 C4 A1SIDDS
#56 #56
X50
32
C16 #2
24V
X50:33 #1
0V B16
Connector St.1:D4 – Axis #1 Waypoint 0

Signal A1SWP0 = 0: The active axis position is less than the position defined for
the waypoint 0
A1SWP0 = 1: The active axis position is less than the position defined for
the waypoint 0
Function The TRANS200 permits up to 8 positions to be entered in the axis
description parameters of each axis. Each position (0 to 7) is allocated to a status
signal 'AxSWPn' (n = 0 - 7).
Independently of the NC program, the status of the individual signal

A1SWP0 shows whether the current axis position is less than or greater
than the position that is stored in the associated axis parameter A01.C025.
These waypoints permit working area protections to be programmed.
Note: The NC always outputs the waypoints, even if the axis has not yet
been homed. TRANS200 stores the axis positions when the controller is
switched off, and restores them when it is switched on. It can therefore be
assumed that, even without homing, the positions may be employed for
performing rough monitoring activities using the waypoints. Obviously, this is
not true after the machine has been manually manipulated or after new
parameters have been loaded. The absolute validity of the waypoints can
only be assured by including the 'axis homed' signal (AxSHOMED).
Note: Although the TRANS200 permits to use up to 8 waypoints, the
TransKit limits them to only two: ‘Waypoint 0’ and ‘Waypoint 1’.
Caution: The original signal of St.1:D4 was “BCD 10*23”.. This function is
no longer available since the TransKit1 does not support BCD outputs.
Wiring

St.1 04-0900
%Q2.2.3
4 D4 A1SWP0
#57 #57
X50
32
C16 #2
24V
33 #1
0V B16
Connector St.1:A5 – Axis #1 Waypoint 1

Signal A1SWP1 = 0: The active axis position is less than the position defined for
the waypoint 1
A1SWP1 = 1: The active axis position is less than the position defined for
the waypoint 1
Function The TRANS200 permits up to 8 positions to be entered in the axis
description parameters of each axis. Each position (0 to 7) is allocated to a status
signal 'AxSWPn' (n = 0 - 7).
Independently of the NC program, the status of the individual signal

A1SWP1 shows whether the current axis position is less than or greater
than the position that is stored in the associated axis parameter A01.C026.
These waypoints permit working area protections to be programmed.
Note: The NC always outputs the waypoints, even if the axis has not yet
been homed. TRANS200 stores the axis positions when the controller is
switched off, and restores them when it is switched on. It can therefore be
assumed that, even without homing, the positions may be employed for
performing rough monitoring activities using the waypoints. Obviously, this is
not true after the machine has been manually manipulated or after new
parameters have been loaded. The absolute validity of the waypoints can
only be assured by including the 'axis homed' signal (AxSHOMED).
Note: Although the TRANS200 permits to use up to 8 waypoints, the
TransKit limits them to only two: ‘Waypoint 0’ and ‘Waypoint 1’.
Caution: The original signal of St.1:A5 was “BCD 1*20”. This function is no
longer available since the TransKit1 does not support BCD outputs.
Wiring

St.1 04-0900
%Q2.2.4
5 A5 A1SWP1
#50 #50
X50
32
C16 #2
24V
33 #1
0V B16
Connector St.1:A4 – Axis #1 Bus voltage OK

Signal UD_OK = 0: DC bus too low.
UD_OK = 1: DC bus above the minimum voltage.
This signal is effective in all modes
Function Once the minimum voltage in the power DC bus is reached, the drive
description controller is ready to output power and the UD output is set high.
The signal is the condition for system power up. For the safety reasons the
power can not be applied to the system until UD_OK = 1 in all connected
drives. When TransKit1 works with one drive only, the St1:A4 UD_OK can
be connected directly to the St1:D12 PCUDRDY. (see note on electrical
drawing BE2000 sheet 05/12). In described case there is no need to transfer
this signal to the PLC and back.
If TransKit1 has two drives connected, it is absolutely necessary to send
both signals UD_OK to the PLC. PLC is then responsible for issuing the
PCUDRDY back to the TransKit. (See: Drive DC-Bus voltage ready for
wiring diagram)
TRANS-01 note It was signal “BCD output 10*20”. This function is no longer available since
the TransKit1 does not support BCD output.
Wiring #54
Axis #2 functions
Axis 2 can be a servo axis or a spindle axis.
Note: If spindle axis functionality is required, Axis #2 must be used
as the spindle axis since respective signals are provided via
St.1.
Connector X55:1; X55:10 – Axis #2 drive ready

Signal A2READY = 0: Drive not ready for power on
A2READY = 1: Drive ready for power on
Function The signal indicates when the DURADRIVE is ready for switching the
description 3-phase main power on.
When ready, the drive shows “Bb” on the display and the Bb contact closes.
See also “Connector X55 – Drive #2 Interlock Cable” for further details.
TRANS-01 note N/A
Wiring
X55 HDC01.1-AxxxN-SE01-01-FW
ControlBoxD X50 White 1.0 X1 DURADRIVE #2

11 0VDC
0V 3
24V 12 Blue 1.0 24VDC
1
Slot 1 X2
%I1.2.1 2
Interlock Cable
IND3048 1.5m
X11
Violet 7
Bb
10 Yellow 8
Bb
16
1 Pink 9 ON1
\
10 ON1
K2:14 9 Green
K2:11 8 Brown 11 On3
On4
12
6 0V
+24Vpro
2
ZKS1
\
3
ZKS1
4
0V
5
Connector St.1:D1 – Axis #2 homed

Signal A2SHOMED = 0 : Axis #2 is not referenced (homed)
A2SHOMED = 1 : Axis #2 is referenced (homed)
Function The NC employs this signal to tell the PLC whether or not the axis has been
description homed. With incremental position measuring systems, reference must be
reestablished whenever the controller is switched on. This can be done
manually for each individual axis using the 'axis homing' signal (AxCHOME)
or be programmed via the valid NC reverse program.
Single-axis homing of all axes of a process does not make the NC program
of that process ready to start. The ready-to-start condition can only be
attained by executing an NC reverse program (see Process signals: 'Ready
to start').
TRANS-01 note Caution: It was the original signal “+/- 15 OK”. Wiring in the machine
control panel must be modified!
Wiring
St.1 04-0900
%Q2.2.1
2 D1 A2SHOMED
#8 #8
X50
32
C16 #2
24V
33 #1
0V B16
Connector St.1:A15 – Axis 2 home switch

Function The switch indicates to the drive that the home switch has reached the
description home switch cam/dog.
TRANS-01 note Did not exist with TRANS-01.
Connector St.1:B15 – Axis 2 positive overtravel switch

Signal Wire from the axis position limit switch (24VDC). The “0VDC External” wire
of the external power supply must be connected to GND and “0VDC
Internal”.
Connector St.1: C15 – Axis 2 negative overtravel switch

Signal Wire from the axis position limit switch (24VDC). The “0VDC External” wire
of the external power supply must be connected to GND and “0VDC
Internal”.
Control Cable
04-0900
X50 St.1
#61 25 A15 #61
Home LS
#63 24 #63
B15 Pos. OT LS
23
#62 C15 #62 Neg. OT LS
X50
0V 33 #1
X55 5 6 7 11

Blue/ Yell/ Grn/B Wht
Blk Blk lk
X3 1 2 3 X1 3
DURADRIVE Axis 2
Connector St.1:B2 – Axis #2 at commanded speed

Signal A2N_CMD = 0: Axis 2 (spindle) not at commanded speed
A2N_CMD = 1: Axis 2 (spindle) at commanded speed
Function The signal is set if the difference between the actual velocity value
description and the velocity command value is within a programmed velocity window.
List of the influencing SERCOS parameters:
Parameters SERCOS ident No.

Velocity window S-0-00157
Actual velocity value S-0-00040
Velocity command value S-0-00036
Note: The signal is only valid for digital main spindle drives.
TRANS-01 note This signal did not exist with the TRANS01.
Caution: The original signal of St.1:B2 was “Brake release”. This function
is no longer necessary since the motor brake is directly controlled from the
DURADRIVE. If this signal was previously used, control cabinet has to be
rewired.
Wiring

St.1 04-0900
%Q2.1.7
8
#13 B2 A2N_CMD #13
X50
32
C16 #2
24V
33 #1
0V B16
Connector St.1:B5 – Axis #2 spindle in position

Signal A2SINPOS = 0: Spindle not positioned
A2SINPOS = 1: Spindle has attained position
Function The ‘A2SINPOS’ signal is issued if, with respect to the position command
description value, the actual position value is within the positioning window after an
'Mx19' has been processed.
List of the related Axis #2 SERCOS parameters:

Positioning window S-0-00057
Position command value S-0-00047
Note: The signal is only valid for digital main spindle drives.
TRANS-01 note Caution: It was signal “BCD output 1*21”. This function is no longer
available since the TransKit1 does not support BCD output.
Wiring

St.1 04-0900
%Q2.2.5
6 B5 A2SINPOS
#51 #51
X50
32
C16 #2
24V
33 #1
0V B16
Connector St.1:B1 – Axis #2 Spindle speed Nmin attained

Signal A2SN_MIN = 0: Spindle speed Nmin not yet attained
A2SN_MIN = 1: Spindle speed Nmin attained
Function The signal is A2SN_MIN is set when the actual velocity value is inside the
description standstill window specified in the drive of axis #2.
List of the related Axis #2 SERCOS parameters:
Standstill window S-0-00124
Note: The 'AxSN_MIN' signal does not fulfill the personal safety
requirements. The signal is only valid for digital main spindle drives.
TRANS-01 note Caution: It was signal “Brake Control 2”. The motor brake is directly
controlled by the DURADRIVE. If this signal was previously used, control
cabinet has to be rewired.
Wiring

St.1 04-0900
%Q2.1.6
7 B1 A2SN_MIN
#3 #3
X50
32
C16 #2
24V
33 #1
0V B16
Connector St.1:B4 – Axis #2 Bus voltage OK

Signal UD_OK = 0: DC bus too low.
UD_OK = 1: DC bus above the minimum voltage.
Function Once the minimum voltage in the power DC bus is reached, the drive
description controller is ready to output power and the UD output is set high.
The signal is the condition for system power up. For the safety reasons the
power can not be applied to the system until UD_OK = 1 in all connected
drives. When TransKit1 works with one drive only, the St1:A4 UD_OK can
be connected directly to the St1:D12 PCUDRDY. (see note on electrical
drawing BE2000 sheet 05/12). In described case there is no need to transfer
this signal to the PLC and back.
If TransKit has two drives connected, it is absolutely necessary to send both
signals UD_OK to the PLC. PLC is then responsible for issuing the
PCUDRDY back to the TransKit1. (See: Drive DC-Bus voltage ready for
wiring diagram)
TRANS-01 note It was signal “BCD output 10*21”. This function is no longer available since
the TransKit1 does not support BCD output.
Wiring #55
Spare wires of the connector St.1
7.3 Connector RX and TX – SERCOS

fiber optic
These connectors are for the SERCOS fiber optic connection to the
DURADRIVE(s). These fiber optic cables (IKO0982 and IKO085) are pre-
installed when ordering a complete TransKit1 assembly.
Fig. 7-1.4: SERCOS drive interface cable wiring
TX of ControlBox The cable from TX (transmit) of the ControlBox represents the SERCOS
light output that connects to “X21 RX” of the first DURADRIVE.
RX of ControlBox From the first DURADRIVE connector “X20 TX” another fiber optic cable
is connected back to RX (receive) of the ControlBox, unless a second
DURADRIVE is installed. If latter, the cable returns from “X20 TX“ of the
second DURADRIVE. Both drives are connected between “X20 TX” and
“X21 RX” with a third SERCOS cable.
7.4 Connector X54 and X55 –

DURADRIVE interlock cable
Overview
Hardware interlocking signals are connected to the ControlBoxC and
ControlBoxD via connectors X54 (DURADRIVE #1 left) and X55
(DURADRIVE #2 right).
X54 X55
Fig. 7-1.5: DURADRIVE Interlock cable wiring
The one end of the interlock cable IND3048 connects to ControlBox

connector X54 or X55, and the other end to the Phoenix terminal blocks
that are inserted into the DURADRIVE connectors X1, X3 and X11.
Connector X54 – Drive #1 Interlock Cable

The TransKit1 uses a single cable per drive for interlocking. The cable
has a connector at the ControlBox and is connected to X1, X3 and X11 in
the DURADRIVE as shown below.
For details on limit switch connection refer to St.1 connector details.
The signal UD is providing feedback to the ControlBox if the drive is
powered up.
For further details on DURADRIVE functions, please refer to
Project Planning Manual
DURADRIVE
Drive Controllers with degree of protection IP 65
DOK-DURADR-HDC01.1****-PR02-EN-P; 288285
Note: The “Local E-stop” can be added in the field if necessary. The
modification should be done in such way, that the IP65
enclosure rating is maintained.
Please contact Bosch Rexroth if for any reason the user must
make modification to this wiring.
Interlock Cable
IND3048 1.5m
X54
X1
ControlBoxD X50 3 DURADRIVE #1
White 1.0 0VDC
0V #83 11
24V #101 12 Blue 1.0 1 24VDC
X3
21 #12 5 Blue/Blk 1 Home LS
+ O.T. LS
20 #10 6 Yel/Blk 2
19 #11 7 3 - O.T. LS
Green/Blk
22 4 Red 4 Probe 1
\
3 UD OK
17 Red/Blk 11
2 E-Stop
14 Black 6
PCESTAT %I1.1.7 ----------------------------
Local Jumper if
E-Stop Æ X11
K1 no E-stop Bb
Violet 7
11 14 13 10
15 Yellow 8 Bb
A1CREADY %I1.2.0 ---------------------------
1 9 ON1
Pink
PCPOWON St.1:B10------- K2:14 9 Green
10
K2 ON1
X50:10
K2:11 8 Brown 11
On3
12
On4
6
0V
2
+24Vpro
3 ZKS1
\
4 ZKS1
5 0V
Note: The jumpers (red) are directly installed on the DURADRIVE

connectors.
Fig. 7-1.6: Interlock cable wiring X54 - axis 1
Connector X55 – Drive #2 Interlock Cable
The TransKit1 uses a single cable per drive for interlocking. The cable
has a connector at the ControlBox and is connected to X1, X3 and X11 in
the DURADRIVE as shown below.
For details on limit switch connection refer to St.1 connector details.
The signal UD is providing feedback to the ControlBox if the drive is
powered up.
For further details on DURADRIVE functions, please refer to
Project Planning Manual
DURADRIVE
Drive Controllers with degree of protection IP 65
DOK-DURADR-HDC01.1****-PR02-EN-P; 288285
Note: The “Local E-stop” can be added in the field if necessary.
The modification should be done in such way, that the IP65
enclosure rating is maintained.
Please contact Bosch Rexroth if for any reason the user must
make modification to this wiring.
Interlock Cable
IND3048 1.5m
X55
X1
ControlBoxD X50 3 DURADRIVE #2
White 1.0 0VDC
0V #83 11
24V #101 12 Blue 1.0 1 24VDC
X3
25 #12 5 Blue/Blk 1 Home LS
+ O.T. LS
24 #10 6 Yel/Blk 2
23 #11 7 3 - O.T. LS
Green/Blk
26 4 Red 4 Probe 1
\
3 UD OK
18 Red/Blk 11
2 E-Stop
14 Black 6
PCESTAT %I1.1.7 ----------------------------
Local
E-Stop Æ Jumper if X11
K1 no E-stop Violet 7 Bb
11 14 13 10
16 Yellow 8 Bb
A2CREADY %I1.2.1 ---------------------------
1 9 ON1
Pink
PCPOWON St.1:B10 ------ 9 Green
10
K3:14 ON1
K3
X50:10 8 Brown 11
K3:11 On3
12
On4
6
0V
2
+24Vpro
3 ZKS1
\
4 ZKS1
5 0V
Note: The jumpers (red) are directly installed on the DURADRIVE

connectors.
Fig. 7-1.7: Interlock cable wiring X55 - axis #2
7.5 PIM Function – External Tool

Correction
In the final revision of the TransKit1 the PIM function has not been
implemented. The signals PSAUX420 and PSAUX421 together with
appropriate acknowledgements PCACKN420 and PCACKN421 were
freed to be used as regular auxiliary functions.
7.6 Connector X10 – Serial port for

programming
Technical data
Behind a dust cover, the 15pin Sup-D connector X53 provides a serial
interface programming port. The type of connection (RS232C or RS485)
is chosen with the cable using the Bosch Rexroth SIS setup.
X53 Serial Port pins
Fig. 7-1.8: X53 connector – serial interface pin assignment
X53 as RS232C For a single point RS232 connection use cable IND5009(613220).
Note: The ControlBoxD internal connection between X53 socket and
TRANS200 programming port X10 is made with either universal serial
cable without termination AE1103 (613198) for RS232 communication, or
AE1107 (613337) cable for RS485 configuration. The later includes
termination resistors on the control side. Both cables are included in the
ControlBoxD delivery, so the change can be done in the field.
Fig. 7-1.9: X53 connector – RS232C serial interface pin assignment
Fig. 7-1.10: X53 connector – RS232C serial connection to PC

X53 as RS485 The RS485 bus permits the daisy-chain connection of up to 32
ControlBox systems to a single PC for centralized programming,
monitoring and troubleshooting. A RS485 repeater should be used
between number 16 and 17 to strengthen (repeat) the signal.
The RS485 bus cable should be shielded and twisted in pairs. The cross-
section should be a minimum of 0.22mm², the surge impedance 100 –
120 Ohm. The shield is provided on both ends of the transmission link. If
ground-potential bonding currents may occur, one end is grounded
directly, the other end via a 15nF capacitor.
For RS485 communication the first and last connector must contain a
terminator circuit as shown below:
Fig. 7-1.11: X10 connector – RS485 termination
This is achieved with the ControlBoxD internal connection between X53

port and the TRANS200 programming port X10. The RS485 cable
AE1107 (613337) contains the terminating switch in the control side plug.
The switch has to be set into ON position to activate the termination.
Fig. 7-1.12: Example - RS485 Bus
Choosing the RS232C or RS485 cable

The internal serial communication of the ControlBoxD is wired for
RS232C from the factory. The user can convert to using RS485 by
selecting the mode in the PPC-R (Trans200) via S1 and replacing the
RS232 cable AE1103 (connected to X10 of TRANS200) with the RS485
cable AE1107 (contains the switch in one connector). Plug the RS485
connector (with the switch) into the X10 port at the PPC-R card and the
other end into the X53 plug at the bottom of the ControlBoxD.
Note: When switching to RS485 communication the termination

resistor must be activated at the cable connector plugged into
the LAST TRANS200 of the RS485 bus !
Note: The dust cover must be closed if no cable is connected to the

serial programming port of the ControlBoxD. Only IP65 rated
connectors must be used for permanent serial connection.
{Use cables IND5009 (613220) and IND5008 (613199)}
RS232C/RS485 at TRANS200 in ControlBoxD

The serial PC communication default settings are for RS232C:
TRANS200 X10 - “01”, controller address (TRANS200)
PC serial port settings - “38400” Baudrate
- Even parity
The serial PC communication default settings are for RS485:

- “01”, controller address (TRANS200)
- “38400” Baudrate
To modify these settings, press S1 (see figure below) and follow the
menu instructions for modifying the serial communication settings.
7-1.12: Modifying serial communication selection.
7.7 Connector X20 – Ethernet port for

programming
Ethernet networking overview

If the ControlBoxD is purchased with the Ethernet communication option,
the RJ45 connector X20 can be used for connection to the programming
PC running WinTrans software.
Fig. 7-1.14: Example – Laptop Ethernet connection
Fig. 7-1.15: Example – Ethernet Bus
Note: The dust cover must be closed if no cable is connected. Only

IP65 rated connectors must be used for permanent Ethernet
connection. Also a dummy RJ45 Ethernet plug must be
inserted into X20 if the dust cover remains open.
SWITCH Address
10/100 selection via
Ethernet S1 and H1
X20 X20 X20 IND5007 X20
UDS-10
Station: Machine Sta1L Sta1R Sta5L … Staxy c

Product: PC UDS-10 UDS-10 UDS-10 UDS-10 c
Ethernet setup
Address IP: 172.16.1.1 172.16.1.10 172.16.1.11 172.16.1.12 … 172.16.1.xx
Sub-net: 255.255.0.0 255.255.0.0 255.255.0.0 255.255.0.0 … 255.255.0.0
(Mode)/Port: - 5000 5001 5002 … 50xx
Baudrate: - 115200 115200 115200 115200
Flow: - 00 00 00 00
I/F Mode: - 4C 4C 4C 4C c
TRANS200 setup
Address: - 00 01 02 … xx
Serial: - RS232C RS23C RS232C RS232C
Baudrate: - 115200 115200 115200 115200
7-1.12: Example – ControlBoxD with Ethernet networking
IND5007 cable The complete cable IND5007/000.6 is used to connect the DB25 serial
port of the Lantronix UDS 10-01 converter to the PROG port (X10) of the
PPC-R card (Trans200).
Setup of Ethernet Converter

Ethernet – Serial converter
The Ethernet option is accomplished by use of the Lantronix UDS–10-01
hardware
device server. The input side the UDS 10–01 (factory default: 5001,
115200, 00, 4C) is connected to the Ethernet and the output to the PPC-
R card using a serial port X10 (factory default: RS232C, 115200, Even).
Fig. 7-1.13: Lantronix UDS 10-01 connections
Ethernet – Serial converter The Lantronix UDS-10-01 “Serial-Ethernet” device server must be
setup programmed by the user. The following steps must be performed on the
PC that is used with WinTrans software and that is connected to
Ethernet:
Step 1 Install the Device Installer software provided with the TransKit1 or
ControlBox.
Step 2 Connect the PC (with active Ethernet TCP/IP setup) and the ControlBox
(of the TransKit1) via Ethernet cables to an Ethernet Switch (HUB). Then
start the “DeviceInstaller …” program on the PC. (You can also use
crossed Ethernet cable to connect to single device w/o hub.)
Press the search button (left large icon) to find connected UDS-10
devices. After the scan all available UDS-10 devices appear showing
their default address.
Note: It may be necessary to perform this setup one UDS-10 at a
time to prevent duplicate IP addresses in the network.
Step 3 Select the desired device and click the IP address button. Enter the
desired unique IP address of the UDS-10. This address must match the
address entered in the “System Configurator software for the TRANS200

controller to which the UDS-10 is connected to.
Select the PC-network class the same like in other UDS-10 and the
machine PC (BTV). Press the „Set IP Address“ button to activate the IP
address in the UDS-10. To check that the UDS-10 device contains the
new IP address, press the Ping button and check that the UDS-10 is
responding. If the device is responding, document the IP-address for the
ControlBox of the TransKit1.
Repeat the Step 3 if the UDS-10 does not respond and assure that no
duplicate IP addresses are used and the chosen common Network Class.
Step 4 To confirm the serial port settings of the UDS-10, select the desired
device and click the configuration button (tools). Then click the “Telnet to
Device” to open the dialog.
After the dos-box opens press <Enter> to continue and the following
menu appears:
In the top the currently active serial port settings are listed. Press <1>
and <Enter> to modify the settings. Enter only data for:
Baudrate: 115200
I/F Mode: 4C ;for RS232C
Flow: 00
Port: <5xxxx> ;must match the “Mode” entry in the
System Configurator (see below)
Activate with 9 to save and press <Enter>. Close the Lantronix software
when all devices are done
.PC – TRANS200 System Configurator setup
If the TransKit1 (specifically its ControlBox) was ordered with the
Ethernet communication option the user must first enable the TCP/IP
before defining the TRANS200 systems in the System Configurator
software.
Step 1 After installing the WinTrans software on that PC, open the following file
System Configurator on the PC using Notepad (pure) text editor:
..:\Program Files\Indramat\MTGUI\BASICDATA\RESOURCE\SYSCON.INI
NOTE: Do not modify or delete any data in this file except what is
explained below.
Search for “[TRA200-R]” and add the string “,TCP” to V24 as shown
below. Then save the data and close the file.
Step 2 On the PC start the “System Configurator” and define one TRANS200
System Configurator control per TransKit1 ControlBox.
Double click the icon to start the System Configurator. Then enter a
new TRANS200 or select an existing TRANS200 that represents the
desired TRANS200 in the TransKit1 ControlBox.
Go through the wizard until the setup of the communication is prompted.
Either double-click “new” or the existing “CommAddr” for the device (not
used with another device).Now select “TCP” and enter the “Channel”
which is the <IP address> and “Mode” which is the <port> address of the
UDS-10 converter mounted in the ControlBox of the TransKit1.
To test the connection to the TRANS200 you must also match the
TRANS200 device address in the System Configurator setup and the
TRANS200 hardware (PPC-R) located in the ControlBox.
The Ping button can be used to verify the Ethernet IP connection if the
device address, Channel / IP address and Mode / Port are set identical.
Fig. 7-1.13: Example – Ethernet configuration of TRANS200 on PC side
TransKit1 NC setup 8-1
8 NC setup
8.1 TRANS200
TRANS200 - Training
The user of the TransKit1 or ControlBoxC and ControlBoxD should attend
training courses offered by Bosch Rexroth for the TRANS200 motion
controller. Please contact Bosch Rexroth Electric Drives and Controls or
a representative for available training courses.
Note: Being unfamiliar with the TRANS200 control system may result in
potentially costly startup delays.
TRANS200 - Documentation
The user can obtain the latest Documentation CD from Bosch Rexroth or
purchase printed manuals via the BRC representative.
Note: Even though the TRANS200 of the ControlBoxD uses version

23VRS software and firmware, the documentation of version
22VRS can also be used if no documentation for 23VRS is
available.
Hardware components:
Software:
Commissioning :
TRANS200 - WinTrans software

The user must purchase and use the WinTrans software
SWA-TRA200-T11-23VRS-MS-CD650 (PN 298491)
to commission the ControlBoxD of the TransKit1 solution. This software
must be installed on a PC (laptop or machine PC) and works under the
PC operating system Windows 2000 (SP2 or higher) or Windows XP (SP
2 or higher).
TRANS200 – Parameter adaptation

The TRANS200 used in the ControlBoxD is provided with default
parameter sets for single and dual axis configurations.
Parameter set and IO configuration are pre-loaded if the ControlBoxD is
ordered as a finished kit, or they can be loaded from the provided Floppy
Disk.
Note: The user will need to use the WinTrans software (on a PC) to
finalize
o the axis setup (e.g., axis name/meaning, axis type
linear/rotary, etc.)
o process definitions, feeds and speed
o D-correction setup
o auxiliary function setup
so they match the desired machine configuration. This setup
should occur during the preparation phase to minimized
delays during the startup.
Further documentation required for this process:

MTC200/TRANS200
Parameter Description Application Manual
DOK-CONTRL-PAR*DES*V22-AW01-EN-P
TRANS200 - NC-programming
Compared to the single axis TRANS-01 controller, the multi-axis
TRANS200 has a more comprehensive G-code instruction set combined
with high-level commands. These commands are described in detail in
the documentation:
TRANS200
NC Programming Instructions Application Manual
DOK-TRA200-NC**PRO*V22-AW01-EN-P (PN 295379)
Use the above documentation for creation of NC-programs.
Note: Application of the described NC-functions (G-codes, D-

corrections, Auxiliary functions, etc.) is limited by the interface
configuration (connector St.1) and axis configuration as well
as the setup in the parameter set.
The WinTrans software offers the beginner a NC-programming assistant

that provides clear text dialog for NC-block creation with integrated help.
TransKit1 Operation 9-1
9 Operation
The TransKit1 with ControlBoxD can be configured with a BTV06 HMI

that allows axis operation in manual machine mode. Diagnostic
information and help is available at any time.
The user can edit Zero Offsets, NC-variables, NC-Events and tool offset
data permitting fast and convenient process related optimization.
9.1 ControlBoxD - BTV06 HMI button

description
L1 and R1 PB for
HMI screens MANual program control
PB and LEDs for MANual operation

Numerical and
navigation
Softkey Text and Softkeys
Fig. 9-1: BTV06 HMI Overview
MAN/ Indicator shows if manual operation mode was selected via the
JOG respective signal on connector St.1.
Light OFF Automatic mode active
The indicators “AXIS1+”, “AXIS1–“, “AXIS2+”, “AXIS2–“
and “RUN/ACTIVE” indicate axis movement and that the
NC program is active and running.
Light ON Manual mode active
This mode permits axis jogging via the PBs “AXIS1+”,
“AXIS1–“, “AXIS2+”, “AXIS2–“.
If activated in the setup of BTV06 HMI, NC program
execution is possible by pressing the PB “L1” (forward
execution) or PB “R1” (reverse program).
AXIS1 AXIS1 Light OFF The respective axis is not moving in the positive or
+ – negative direction.
Light ON Axis is moving in respective direction.
AXIS2 AXIS2
+ – PB pressed Axis is jogged at preset speed when manual operation
mode is active.
RUN/ Light OFF` The NC program /. NC block is not active.

ACTIVE Light ON The NC program / NC block is active.
PB pressed No function
CLEAR Light OFF No error active.

ERROR Light ON Error active.
PB pressed Control Reset aborting the active NC program if NO
error is active.
Clear Error if an error is active.
PB pressed If manual mode active (MAN/JOG =ON) the NC program

L1 is executed (forward) while “L1” and “MAN/JOG” is
simultaneously pressed. (Can be disabled through the
BTV06 setup)
PB pressed If manual mode active (MAN/JOG =ON) the Reverse NC

R1 program is executed while “R1” and “MAN/JOG” is
simultaneously pressed. (Can be disabled through the
BTV06 setup)
F1 … F8 PB pressed Activates the menu described in the respective softkey

name that is displayed in the lowest line of the display.
PB pressed Displays the brief help for the active screen if the text
HELP “HELP” is shown in the upper left corner.
Main
PB pressed Calls the Main Menu screen “NC-Functions”.
Menu
PB pressed Used to scroll up/down through the screen if more

information is available than can be displayed. Also used
to page forward/backward through tables.
PB pressed This key will cancel a function, exit windows and help
ESC screens.
PB pressed This key is used to confirm prompts and conclude entries.

OK
The numerals, cursor keys printed on the BLUE background are normally
active when the button is pressed.
The <Shift>-key (arrow to upper left) can be pressed and held while
pressing a button with characters printed on the GREEN background to
enter character information.
Specific characters are entered by pressing the button multiple times
while holding the <Shift>-key.
9.2 BTV06 HMI - screen description

The BTV06 HMI of the ControlBoxD provides all necessary screens for
station operation. Special emphasis was put on minimizing the key
stokes to reach information. This section describes these screens.
Help is Screen Name Operation

Screen Areas
available Mode
Diagnostic
message
Screen
content
Soft-Key
description
Main Menu
“NC-Functions”
Fig 9-1A: NC-function screen – Automatic Mode
The “NC-Functions” screen is displayed at power up or when the Main

Menu
is pressed.
The top line indicates that help information is available by pressing the
<HELP>-key. The active operating mode is displayed in the upper right
corner.
In the second line the currently active diagnostic message is displayed.
Axis position data can be displayed as Machine (M) or Program (P)
coordinates as selected in the SETup menu (<F8>). The screen shows
the commanded, actual and programmed end position,
The current and next NC-block are displayed in the block below,
providing the user with the NC-program information currently being
executed.
Fig 9-1B: Help of NC-function screen – Automatic Mode
Fig 9-1C: NC-Status screen
Fig 9-1D: Help - NC-Status screen
Fig 9-1E: NC-function screen – Manual Mode
Fig 9-1F: NC-block / program display
Fig 9-1G: Help for NC-block / program display
Fig 9-1H: NC-variable list display
Fig 9-1J: Help for NC-variable list display
Fig 9-1K: Setup of NC-variable Lists
NC-Event Status display

The screen contains two separate windows:
• First one shows if the Asynchronous Event (EVENT 0) has been
activated
• Second one shows the number of currently active synchronous
events (1 to 15)
Additionally it is possible to assign short event description through the
modifications in the BTV06 event setup screen. The description will
display on the screen together with the event number.
Fig 9-1L: Help for NC-Event Status display
Fig 9-1M: Zero Offsets display
Fig 9-1N: Offsets display
Fig 9-1P: Setup of Offsets display
Fig 9-1Q: D-corrections (Tool corrections) screen
Fig 9-1R: Help for D-corrections (Tool corrections) display
Fig 9-1S: Setup D-corrections (Tool corrections) display
Fig 9-1T: TK1 Components display
Fig 9-1U: Setup - Axis configuration screen
TransKit1 Cables and Accessories 10-1
10 Cables and Accessories
10.1 Selection List of Connectors and

Ready-Made Cables
Ordering of ready made Connector Rexroth cable Connector
cables
AE1103-00 (PN 613198)

ControlBoxD – internal
RS232C cable
For connection between AE1103
connector PPC-R X10 and
X53 (IP67) in the housing.
Note: fixed length 0.6m (2
feet).
AE1107-00 (PN 613337)

RS485 cable for internal
15 1
ControlBox connection
INS0439/L01
between connector PPC-R X10
and X53 in the housing.
Switch should be set to "1" on
the first and the last unit in the
RS485 net.
If more than 16 units has to be
interconnected (32 units AE1107
maximum) the bus amplifier
must be used between device
16 and device 17.
Note: fixed length 0.6m (2
feet).
IND5008 (PN 613199)

ControlBoxD - RS485 cable
For external linking of
multiple ControlBox systems
via IP67 rated connector
plugging into X53 of the IND5008/xxx.x
ControlBox.
Note: Max. RS485 bus cable
length is 400m..
IND5009 (PN 613220)

ControlBoxD - RS232 cable
For connection of PC (using
15-pin D-sub connector) to
X53 of the ControlBox for
programming. IND5009/xxx.x
Note: Max. cable length is 15
m (45 feet).
Ordering of ready made Connector Rexroth cable Connector

cables
IND5007 (PN 613155)

Lantronix UDS 10-01 or 25 pin male
UDS 100-01 to PPC-R X10
(Trans200) . IND5007/000.6
Note: Standard length is
0.6m (2 Feet).
INS0439/L0
IND3048 (PN 612819)

ControlBoxD –
DURADRIVE (HDC)
interlocking cable. IND3048/001.5
Note: Standard length is
1.5m (5 feet).
IKB0015 (PN 613000)

ControlBoxD – IKB0015/000.6
conection between Trans200
X16 and BTV06 COM1
10.2 Accessories
The switch box PSS-T10 (PN 288679) and the ready-made cable
“IND3052“ (2 meter long) can be purchased for purpose of training,
engineering and debugging. The cable directly plugs into the St.1
connector of the ControlBoxD.
The switch box allows the insertion of label strips. The label strips for the
ControlBoxD connector St.1 are displayed below.
POWEN POWER N=CMD N<MIN A1 WP0 A1 WP1 LO-PIM HI-PIM
READY Act/Run A1 Ref A2 Ref Sp_Pos ThMis ThExc ERROR
Mc400 Mc401 Mc404 Mc405 Mc408 Mc409 Mc412 Mc413
PowEN PowON MAN. E-Stop CLR ADV REV STOP
Cond0 Cond1 Cond2 Cond3 Event Enable A1 HSw A1 -OT
A1 +OT Probe1 A1_UD A2 HSw A2 -OT A2 +OT PIM_LO PIM_HI
Ma400 Ma401 Ma404 Ma405 Ma408 Ma409 Ma412 Ma413
TransKit1 Index 1
11 Index
01—400.........................................................7-1 Branching conditions 23............................ 7-18

0V external ................................................. 7-3 BTV06 Clear Error...................................7-10
0V internal .................................................. 7-3 BTV06 Control Reset..............................7-10
24VDC external ......................................... 7-3 BTV06, buttons ............................................ 9-1
24VDC internal .......................................... 7-3 button, BTV06.............................................. 9-1
A1READY .................................................7-32 cable 01-0400 ............................................... 7-1
A1SHOMED .............................................7-33 Cable clamp of DURADRIVE ................6-13
A1SWP0 ...................................................7-37 cable IND5007 ........................................... 7-53
A1SWP1 ...................................................7-37 cables – ControlBoxD................................ 6-17
A2READY .................................................7-39 Cables – ready made .................................. 10-1
A2SHOMED .............................................7-40 Centralized PLC control .............................. 1-2
A2SIN_MIN ..............................................7-42 Checklist for retrofitting .............................. 4-1
A2SINPOS................................................7-42 Clear Error – BTV06 ...............................7-10
address, TRANS200 address ......................7-57 Clear error / Control Reset.....................7-10
address, TRANS200 in ControlBox...........7-53 connections – ControlBoxD....................... 6-17
Advance program (Start) .......................7-14 connector X20 ............................................ 7-52
Asynchronous condition (Event)...........7-18 connectors – ControlBoxD ........................ 6-18
Automatic/Manual mode ........................7-11 Control Reset – BTV06 ..........................7-10
Auxiliary function 400 acknowledge ....7-27 Control voltage DURADRIVE (24VDC)... 6-
Auxiliary function 401 acknowledge ....7-27 14
Auxiliary function 404 acknowledge ....7-28 DC Bus Voltage ready ....................7-6, 7-38
Auxiliary function 405 acknowledge ....7-28 Default IO configuration of TransKit1 ....7-2
Auxiliary function 408 acknowledge ....7-29 default, serial settings................................. 7-53
Auxiliary function 409 acknowledge ....7-29 DeviceInstaller software ............................ 7-54
Auxiliary function 412 acknowledge ...7-30, Distributed PLC control............................... 1-2
7-31 documentation, commissioning ................... 8-2
Auxiliary function 413 acknowledge ...7-30, documentation, hardware components ........ 8-1
7-31 documentation, more.................................... 8-1
Auxiliary function output 400.................7-22 documentation, software components ......... 8-1
Auxiliary function output 401.................7-22 Drive documentation ...............................6-12
Auxiliary function output 404 ....................7-23 DURADRIVE – mounting on frame ......... 6-11
Auxiliary function output 405.................7-23 DURADRIVE - parameters ....................... 6-12
Auxiliary function output 408.................7-24 DURADRIVE amplifier............................6-12
Auxiliary function output 409.................7-24 DURADRIVE Fan ....................................6-12
Auxiliary function output 412.......7-25, 7-26 E217 warning – Blower running too slow 6-
Auxiliary function output 413.......7-25, 7-26 12
auxiliary functions ......................................7-21 Enable........................................................7-13
auxiliary functions – PCL logic example...7-21 Error active .................................................7-9
Axis #1 drive ready .................................7-32 Ethernet ...................................................... 7-52
Axis #1 is homed .....................................7-33 Ethernet bus................................................ 7-52
Axis #2 drive ready .................................7-39 Ethernet example........................................ 7-53
Axis #2 homed .........................................7-40 Ethernet setup............................................. 7-53
Axis 1 home switch .................................7-33 Ethernet TCP/IP address ............................ 7-57
Axis 1 negative overtravel switch .........7-34 Ethernet TCP/IP address setup .................. 7-55
Axis 1 positive overtravel switch...........7-33 Ethernet, serial converter setup.................. 7-54
Axis 1 waypoint 0 ....................................7-37 Ethernet, System Configurator .................. 7-56
Axis 1 waypoint 1 ....................................7-37 Ethernet, TCP/IP ........................................ 7-56
Axis 2 home switch .................................7-40 Ethernet, UDS-10 serial setup ................... 7-55
Axis 2 negative overtravel switch .........7-40 Excessive Thrust .....................................7-19
Axis 2 positive overtravel switch...........7-40 F217 error – Blower not connected......6-12
Baudrate ......................................................7-56 F217 error - DURADRIVE......................6-12
Blower DURADRIVE ..............................6-12 Fan DURADRIVE ....................................6-12
Branching conditions 20 ............................ 7-16 Firmware DURADRIVE ........................... 6-12
Branching conditions 21 ............................ 7-17 Frame accessories....................................... 6-10
Branching conditions 22 ............................ 7-17 Fuse F1 in ControlBoxD............................ 6-18
TransKit1 Index 2
Fuse F2 in ControlBoxD.............................6-18 PSERROR ..................................................7-9

heat exchanger – optional installation ........6-19 PSEXCTH .................................................7-19
Interface DURADRIVE ...........................6-12 PSPOWEN .................................................7-4
jumper – Int/Ext 24V ..................................6-18 PSPOWER .................................................7-7
Lantronix UDS-10 ......................................7-53 PSREADY...................................................7-8
Laptop .........................................................7-52 PSSTOP....................................................7-41
Mains supply voltage DURADRIVE .........6-16 PSTHMIS ..................................................7-19
Mode ...........................................................7-56 Rating – 24VDC inputs.............................6-7
modifications to TransKit .............................2-2 Rating – 24VDC outputs.............................. 6-8
Motor brake current .................................. 6-7 Rating - ControlBox..................................... 6-7
Motor power connection to DURADRIVE...6- Rating - DURADRIVE ................................ 6-6
16 Rating – supply voltage ............................6-7
Mounting DURADRIVE ............................6-11 Ready for power on...................................7-4
Mounting frame ............................................6-8 Ready to start.............................................7-8
Mounting variations....................................6-10 relais K1 .. K6 ............................................ 6-18
NC-program active.................................... 7-8 retrofit – ambient conditions........................ 4-1
NC-program, setup........................................8-3 retrofit – control topology............................ 4-1
opreation........................................................9-1 retrofit – I/O-configuration .......................... 4-4
parameters .....................................................4-4 retrofit – NC-program .................................. 4-5
parameters, setup ..........................................8-2 retrofit – quotation ....................................... 4-6
PCACKN400 ............................................7-27 retrofit – Trans-01 control parameters......... 4-4
PCACKN401 ............................................7-27 Reverse (homing) program start...........7-15
PCACKN404 ............................................7-28 RS232C ...................................................... 7-56
PCACKN405 ............................................7-28 RX connector of ControlBox..................... 7-44
PCACKN408 ............................................7-29 Safety Instructions for Electric Drives and
PCACKN409 ............................................7-29 Controls .................................................... 3-1
PCACKN412 ..................................7-30, 7-31 SERCOS ...................................................6-12
PCACKN413 ..................................7-30, 7-31 setup, NC-program....................................... 8-3
PCADV............................................7-14, 7-15 setup, parameters.......................................... 8-2
PCCLEAR.................................................7-10 software WinTrans ..................................... 7-56
PCCOND0 ................................................7-16 spare ..................................... 7-36, 7-38, 7-43
PCCOND1 ................................................7-17 spare parts - ControlBox ............................ 6-22
PCCOND2 ................................................7-17 Spindle.......................................................7-42
PCCOND3 ................................................7-18 spindle in position....................................7-42
PCENABL.................................................7-13 spindle speed Nmin attained.................7-42
PCEVENT.................................................7-18 St.1
PCL logic example - auxiliary functions....7-21 A10.........................................................7-10
PCMODE1................................................7-11 A11.........................................................7-16
PCPOWEN......................................... 7-4, 7-7 A12.........................................................7-13
PCPOWON ................................................ 7-5 A14...........................................................7-4
PCREV......................................................7-15 A15.........................................................7-40
PCSTOP ..................................................... 7-9 A16...........................................................7-3
PCUDRDY.................................................. 7-6 A2 .............................................................7-9
Port ..............................................................7-56 A3 .............................................................7-8
position feedback connection X4 / X8 .6-14 A5 ...........................................................7-37
Power enable ............................................. 7-4 A6 ...........................................................7-24
Power is on................................................. 7-7 A7 ...........................................................7-22
Power ON ................................................... 7-5 A8 ...........................................................7-28
Probe 1......................................................7-34 A9 ................................................ 7-30, 7-31
Program Stop............................................. 7-9 B1 ...........................................................7-42
Program stopped.....................................7-41 B10...........................................................7-5
PSACTIV..................................................... 7-8 B11.........................................................7-17
PSAUX400 ...............................................7-22 B12.........................................................7-14
PSAUX401 ...............................................7-22 B14.........................................................7-33
PSAUX404..................................................7-23 B15.........................................................7-40
PSAUX405 ...............................................7-23 B16...........................................................7-3
PSAUX408 ...............................................7-24 B2 ...........................................................7-41
PSAUX409 ...............................................7-24 B3 .............................................................7-8
PSAUX412 .....................................7-25, 7-26 B5 ...........................................................7-42
PSAUX413 .....................................7-25, 7-26 B6 ...........................................................7-24
TransKit1 Index 3
B7...........................................................7-22 SystemConfigurator setup.......................... 7-56

B8...........................................................7-28 T-block mounting....................................... 6-11
B9.................................................7-30, 7-31 Terminal block X50 – ControlBoxD ......... 6-18
C1............................................................. 7-4 Three phase DURADRIVE supply............ 6-16
C10 ........................................................7-11 Thrust missing..........................................7-19
C11 ........................................................7-17 training courses ............................................ 8-1
C12 ........................................................7-34 Transfer control architectures ...................... 1-2
C13 ........................................................7-18 TransKit1...................................................... 1-1
C14 ........................................................7-34 TransKit1...................................................... 1-3
C15 ........................................................7-40 TransKit1 - configurations........................... 6-4
C16 .......................................................... 7-3 TransKit1 - single axis example .................. 6-5
C2...........................................................7-19 TX connector of ControlBox ..................... 7-44
C3...........................................................7-33 Type code, ControlBox................................ 6-2
C6.................................................7-25, 7-26 Type code, TransKit1................................... 6-3
C7 ............................................................7-23 waypoint ....................................................7-37
C8...........................................................7-27 X1 connector of ControlBox... 7-45, 7-46, 7-47
C9...........................................................7-29 X13 - DURADRIVE.................................. 6-16
D1...........................................................7-40 X13 mains connector – HDC01.1-A040N)6-15
D10 ........................................................7-15 X13 mains connector – HDC01.1-A100/200N)
D11 ........................................................7-18 ................................................................ 6-15
D12 ......................................7-6, 7-38, 7-43 X13 motor power connector – HDC01.1-
D13 .......................................................... 7-9 A040N)................................................... 6-15
D14 ........................................................7-33 X13 motor power connector – HDC01.1-
D16 .......................................................... 7-3 A100/200N)............................................ 6-15
D2...........................................................7-19 X2 connector of ControlBox... 7-45, 7-48, 7-49
D3............................................................. 7-7 X50 Terminal block in ControlBoxD........ 6-18
D4...........................................................7-37 X54
D6.................................................7-25, 7-26 1 7-32
D7...........................................................7-23 10............................................................7-32
D8...........................................................7-27 X55
D9...........................................................7-29 1 7-39
ST.3 connector – 115VAC ...........................7-1 10............................................................7-39

TK1 Aw02 en P - 032006

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TransKit1

Single/Dual Axis Solution

Type of Documentation Application description

Document Type code DOK-CONTRL-WZM*TK1-AW02-EN-P

Internal file reference Document number, 03-2006-02/EN

Purpose of Documentation This documentation describes pre-engineered single/dual axis motion

Record of Revisions Description Release Notes

Copyright © Rexroth Indramat GmbH, 2003

Publisher Bosch Rexroth Corporation

2 Important Usage Directions 2-1

3 Safety Instructions for Electric Drives and Controls 3-1

4 Trans-01 retrofitting check list 4-1

5 Frequently Asked Questions 5-1

115VAC IO, is it available? ...................................................................................................................... 5-2

6 TransKit1 Configurations 6-1

6.3 Ratings of TransKit1 elements ....................................................................................... 6-6

7 Interface Descriptions 7-1

10 Cables and Accessories 10-1

Centralized PLC control

Central PLC for total

Remote Remote Remote

MAC Motor MAC Motor MAC Motor

DSC drive DSC drive DSC drive

Fig. 1-1: Centralized transfer control architecture

Fig. 1-2: Distributed transfer PLC control architecture

Fig. 1-3: TRANS-01 / DSC retrofit architecture

Note: It is the integrators responsibility to review relevant product

The following sections provide safety information for applying electrical

2 Important Usage Directions

2.1 Appropriate Use

Note: Bosch Rexroth, as manufacturer, is not liable for any damages

Areas of Use and Application

The motion control and every drive controller has to be parameterized/

2.2 Inappropriate Use

3 Safety Instructions for Electric

Improper use of this equipment, failure to follow

Death or severe bodily harm will occur.

Death or severe bodily harm may occur.

Bodily harm or material damage may occur.

3.3 Hazards by Improper Use

High voltage and high discharge current!

Dangerous movements! Danger to life, severe

High electrical voltage due to wrong

Health hazard for persons with heart

Surface of machine housing could be extremely

Risk of injury due to improper handling! Bodily

Risk of injury due to incorrect handling of

3.4 General Information

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

3.5 Protection Against Contact with

Note: This section refers to equipment and drive components with

To be observed with electrical drive and filter components:

High electrical voltage on the housing! High

3.6 Protection Against Electric Shock by

High electrical voltage due to wrong

3.7 Protection Against Dangerous

⇒ Pay attention to unintended machine motion or other malfunction

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

- adding an external braking/ arrester/ clamping mechanism

3.8 Protection Against Magnetic and

Health hazard for persons with heart

3.9 Protection Against Contact with Hot

Housing surfaces could be extremely hot!