REXROTH Indramat PPC-R Modular Controller Application Guide

REXROTH Indramat PPC-R Modular Controller Application Guide

Introduction

The Indramat PPC-R series modular controller is a high-performance control platform launched by Bosch Rexroth for the industrial automation field. This controller features a compact structural design, flexible modular configuration, and powerful motion control and PLC functions, making it suitable for various industrial scenarios such as printing, packaging, and machine tool processing. This article is based on the official technical manual "PPC-R02.2N-N-N1-V2-NN-FW Modular Controller", which comprehensively analyzes its hardware architecture, installation specifications, electrical characteristics, safety requirements, and system configuration, providing technical references for engineering and maintenance personnel.

Product Overview and Hardware Architecture

The PPC-R controller is divided into two structural versions: PPC-R01.2 (single width) and PPC-R02.2 (double width), with a protection level of IP20, suitable for installation inside control cabinets. This controller can be used as a PLC or NC controller, depending on the software loaded. Its core hardware configuration includes:

PowerPC processors provide powerful real-time computing capabilities;

8 MB SDRAM and 256 byte serial E ² PROM;

Four digit digital display, used for status indication;

3-channel digital input and 2-channel digital output, supporting external signal interaction;

2-channel serial interface, compliant with Indramat SIS (Serial Indramat Interface) standard, supporting RS232/RS422/RS485;

BT bus interface, used to connect operation terminals (such as BTM15/16, BTA20, etc.), with a maximum cable length of 50m;

SERCOS interface (SERCON 410 baud rate), used for high-performance motion control;

PC/104 expansion interface, capable of connecting various fieldbus modules (such as Interbus, Profibus, etc.);

RECOM/SPS interface, supports expansion of RECOM02 series I/O modules.

In addition, the controller can be equipped with a PSM firmware module, which includes complete firmware and user software, including 4 MB FLASH storage and 64 KB non-volatile RAM. Users can also expand the PMM storage module (4 MB SRAM with battery backup) and the real-time clock (RTC) battery module to support long-term data retention and time recording.

Installation and mechanical structure

1. Install the carrier system

The PPC-R controller needs to be installed on the RMB02.2 series module carrier:

RMB02.2-04 is a standard carrier that supports the installation of PPC-R and up to 15 RECOM02 I/O modules;

RMB02.2-02 is a dual carrier used only for fixing PPC-R and does not support RECOM bus expansion.

The carrier is installed using TS 35 × 27 × 15 DIN rails and secured with locking screws. Up to 4 RMB02.2-04 carriers can be installed in parallel to form an expansion system.

2. Mechanical dimensions

PPC-R01.2:41.5 × 192 × 150 mm, weighing approximately 1.1 kg;

PPC-R02.2: 83.7 × 192 × 150 mm, weighing approximately 1.3 kg.

3. Grounding and shielding

To ensure the electromagnetic compatibility (EMC) and operational safety of the system, a grounding wire of ≥ 6 mm ² must be used to connect the controller grounding pole to the central grounding point of the equipment, and a star shaped grounding structure must be adopted. All electrical unit casings must be reliably connected to protective grounding wires to avoid the risk of electrical leakage.

Electrical characteristics and technical specifications

1. Power supply requirements

Rated voltage: 24 VDC, allowable range 19.2-30 VDC;

Maximum current consumption: PPC-R01.2 is 0.7 A, PPC-R02.2 is 1.2 A;

I/O bus power supply: maximum 2.3 A (24 V) and 3.0 A (5 V), total power not exceeding 52 W;

Temperature derating: The power needs to be reduced to 85% (44 W) at 35-45 ℃.

2. Digital input/output

3-channel digital input: low level 0-5 V, high level 15-30 V, minimum input current 10 mA;

2-channel digital output: maximum 0.5 A, output delay ≤ 400 μ s, with short-circuit protection;

1-channel BB relay (watchdog): NO contact, 24 VDC/150 mA, lifespan ≥ 500000 times.

3. Interface definition

X1 (11 pin Phoenix interface): including digital I/O, external 24V power supply, and relay contacts;

PROG/COM interface (X10, X16): 15 pin D-SUB, supports full modulation and demodulation functions, and the PROG interface has electrical isolation;

BT bus interface (X15): 9-pin D-SUB, used to connect to the operation panel.

4. Environmental adaptability

Working temperature: 0 to+45 ℃;

Storage/transportation temperature: -25 to+70 ℃;

Humidity: 10-95% (no condensation);

Air pressure: 86-106 kPa (working), 70-106 kPa (storage).

System configuration and expansion

1. Slot addressing

Each RMB02.2-04 carrier is equipped with a DIP dip switch for setting the carrier address (00-03). The system supports up to 4 carriers in parallel, and PPC-R must be installed in slot 0 to control the RECOM bus.

2. Combination options

Single carrier+PPC-R01.2/02.2: expandable up to 15 I/O modules;

Multi carrier system: Only the PPC-R in slot 0 can access I/O, while the other controllers only function as independent computing units.

3. PC/104 expansion

Users can expand various fieldbus modules through the PC/104 interface to achieve integration with systems such as Profibus and Interbus.

Safety regulations and usage requirements

1. Applicable and Not Applicable Scenarios

PPC-R is designed for industrial machinery control, including printing, packaging, machine tool machining centers, and other scenarios. Prohibited for use in the following fields:

Construction cranes and manned elevators;

Medical equipment, dangerous goods transportation system;

Special environments such as nuclear facilities, mines, and food processing.

2. Electrical safety

All circuits above 50 V must be operated by professionals after power failure;

PELV (Protective Extra Low Voltage) circuit must be used to connect low voltage terminals;

The system grounding must be firm, and the leakage current may exceed 3.5 mA.

3. Sports safety

External monitoring devices (such as gratings and safety fences) must be configured;

The vertical axis needs to be equipped with mechanical braking or balancing devices to prevent falling after power failure;

The emergency stop button must be placed in a position accessible to the operator and its function should be tested regularly.

4. Electromagnetic and thermal safety

Access to pacemakers and metal implants is prohibited in areas with strong magnetic fields;

The controller casing may experience high temperatures during operation and needs to be cooled for 10 minutes after power failure before it can be touched.

5. Battery and pressure system

Lithium batteries need to be replaced annually, and dismantling or putting them into fire is strictly prohibited;

Hydraulic/pneumatic systems must be depressurized before disassembly, and protective equipment must be worn during operation.