Rexroth PPC-R22.1N-T-Q2-G2-NN-FW

Core Technical Specifications

• Nominal Power Supply: 24VDC control power, allowable operating range 19.2–30VDC (-15% / +20% voltage tolerance), maximum current draw 1.2A
• Real-Time Motion Processing Core: High-speed floating-point motion processor, cycle time minimum 0.25ms for multi-axis interpolation
• Axis Control Capacity: Supports synchronized closed-loop control of up to 16 servo/stepper axes via SERCOS digital drive bus
• Positioning Performance: Position repeatability ±0.01mm, torque control accuracy ±0.5% rated motor torque
• Communication Interfaces: Onboard Ethernet (T variant), SERCOS III digital drive bus, RS232 diagnostic serial port, PROFIBUS DP expansion compatible
• Built-in Expansion Slots: 3 internal expansion slots (U2, U3, U4) for additional I/O, encoder, communication modules
• Environmental Operating Range: 0°C ~ +60°C cabinet ambient temperature; storage -40°C ~ +85°C
• Physical Dimensions: 83mm width × 182mm height × 150mm depth
• Mounting Standard: Vertical plug-in installation into Rexroth RMB02.2 rack base, compatible with TS35 DIN rail rack mounting
• Protection Rating: IP20 for indoor control cabinet installation
• Compliance Standards: IEC 61131-3 PLC programming standard, EN 60204-1 machinery safety standard

Function & Performance Features

1. Full library of advanced motion control functions: Electronic cam profiling, electronic gear synchronization, multi-axis linear/circular interpolation, flying shear cut-to-length, position tracking
2. Integrated PLC logic processing independent of motion control task for machine safety interlock, sensor signal processing and auxiliary actuator control
3. Hardware synchronized SERCOS digital bus communication eliminates axis motion lag between multiple servo drives
4. Real-time status LED indicator array displays power supply, run mode, communication link, motion fault and expansion module status
5. Configurable safety motion functions: Safe stop, soft limit position detection, hardware travel limit input interlock
6. Offline programming and simulation via Rexroth IndraWorks engineering software; firmware and motion programs loaded via SD memory card
7. High-speed digital input module (Q2 DAQ03) captures position trigger signals with microsecond-level timing precision for registration mark cutting applications
8. LAG encoder interface (G2) accepts master encoder feedback from conveyor, printing cylinder or material feed roll for follow-up synchronized motion

Working Principle

Material & Structural Composition

• Rack housing: Cold rolled steel perforated frame with black anti-corrosion coating for passive convection heat dissipation
• Main control PCB: Multi-layer high-speed FR4 circuit board with gold-plated rack edge connectors for expansion slot signal transmission
• Interface terminals: Spring-loaded pluggable terminal blocks for power supply, digital I/O and encoder wiring separation
• Internal electronic components: Industrial grade high-speed FPGA motion processing chips, wide-temperature solid-state capacitors, isolated Ethernet transformers

Installation Requirements

1. Vertically insert into Rexroth RMB02.2 rack base only; horizontal mounting disrupts natural convection cooling airflow
2. Reserve minimum 40mm vertical clearance above and below the controller rack for heat dissipation
3. Separate servo drive high-power cable routing from low-level encoder and communication signal wiring with minimum 50mm separation distance
4. All shielded encoder and Ethernet cables must terminate shield screen to cabinet protective earth ground bar
5. Secure rack mounting screws to torque 1.0 N·m to resist machine operational vibration
6. Complete multi-axis synchronous motion test run for 4 hours post-installation to verify interpolation stability

Typical Application Scenarios

• High-speed packaging machinery: Carton filling, vertical form fill seal, multi-axis labeling and cutting equipment
• Printing & converting machinery: Rotogravure printing, slitter rewinder, laminator synchronized axis control
• Metal processing equipment: CNC bending machine, stamping press flying shear cut-to-length control
• Robotics and handling automation: Gantry multi-axis pick-and-place systems, palletizing robot coordinate motion control
• Textile manufacturing machinery: Warping machine, textile loom electronic cam and gear synchronization control

Mandatory Operation & Maintenance Precautions

1. Power supply must be fully disconnected and internal capacitors discharged for minimum 15 minutes before removing the controller from the rack
2. Static discharge wristband mandatory when accessing internal expansion slots or handling memory firmware cards
3. Avoid installing adjacent to high-power variable frequency drives to minimize electromagnetic interference with SERCOS motion bus communication
4. Conduct semi-annual inspection of rack edge connectors for dust accumulation or oxidation to prevent motion communication dropout
5. Backup all motion programs, cam profiles and PLC logic to external storage before firmware upgrade
6. Do not hot-swap expansion modules during machine running state to avoid processor crash and uncontrolled axis movement
7. If synchronized axis positioning deviation occurs, first inspect master encoder wiring and SERCOS bus cable shielding integrity