REXROTH PIC-6115 Industrial Control Module

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    • Product Code: PIC-6115
    • Availability: In Stock


    REXROTH PIC-6115 Industrial Control Module

    Technical Documentation

    1. Overview

    The REXROTH PIC-6115 is a high-performance industrial control module designed for precise control and monitoring in automation systems. It provides reliable performance in various industrial applications, including manufacturing, process control, and robotics.

    This control module integrates seamlessly with other REXROTH components, providing a comprehensive solution for automation needs. Equipped with multiple communication interfaces including serial and Ethernet, the PIC-6115 allows for efficient data exchange and integration with existing systems.

    The module's compact size makes it easy to install in tight spaces, while its robust design ensures high reliability and durability, making it suitable for demanding industrial environments.

    REXROTH PIC-6115 Control Module

    2. Specifications

    Parameter Value
    Model Number PIC-6115
    Product Type Industrial Control Module
    CPU 32-bit PowerPC 604e
    Clock Speed 600 MHz
    Memory 128 MB SDRAM
    Storage 2 MB Flash Memory
    Power Supply 24 VDC
    Power Rating 12 VDC
    Power Consumption ≤ 300 mA
    Parameter Value
    Input Channels 8
    Output Channels 4 or 8
    Input Range 0-10 V or 4-20 mA
    Output Range 0-10 V or 4-20 mA
    Communication Interfaces Ethernet, RS-232, RS-485
    Communication Protocol Modbus, Profibus
    Operating Temperature Range -25°C to +70°C
    Storage Temperature Range -40°C to +85°C
    Protection Rating IP20 or IP65
    Dimensions 100mm x 100mm x 50mm or 150mm x 100mm x 50mm
    Weight 0.5 kg or 1.5 kg

    3. System Architecture

    The REXROTH PIC-6115 control module utilizes a modular architecture designed for flexibility and performance. The system consists of several key components working together to provide precise control and monitoring capabilities.

    The main processor, a 32-bit PowerPC 604e running at 600 MHz, serves as the core of the system, executing control algorithms and managing data flow. The module includes 128 MB of SDRAM for program execution and data processing, along with 2 MB of Flash memory for program storage and configuration data.

    The input/output subsystem provides interface capabilities for connecting to sensors and actuators, with 8 input channels and 4 or 8 output channels supporting both voltage (0-10 V) and current (4-20 mA) signals. The communication subsystem includes Ethernet, RS-232, and RS-485 interfaces, supporting Modbus and Profibus protocols for integration with other automation components.

    REXROTH PIC-6115 Internal Structure

    4. Installation Guide

    4.1 Safety Precautions

    • Ensure the power is disconnected before beginning installation.
    • Follow all lockout/tagout procedures to prevent accidental startup.
    • Wear appropriate personal protective equipment (PPE) including safety glasses and gloves.
    • Verify that the installation surface can support the weight of the module.
    • Ensure proper ventilation and cooling in the installation area.

    4.2 Installation Procedure

    1. Select an appropriate location in the control cabinet that meets the environmental requirements.
    2. Ensure proper spacing around the module for ventilation (minimum 30mm on all sides).
    3. Mount the module on a DIN rail or directly to the cabinet using the provided hardware.
    4. Connect the power supply to the PWR+ and PWR- terminals.
    5. Connect sensors to the input channels (SEN1-SEN8).
    6. Connect actuators to the output channels (ACT1-ACT4/8).
    7. Connect communication cables to the appropriate interface (Ethernet, RS-232, or RS-485).
    8. Double-check all connections for correctness and tightness.
    9. Apply power to the module and verify proper operation using the status indicators.
    REXROTH PIC-6115 Installation Diagram

    Installation Tips

    • Orientation: The module can be installed in any orientation.
    • Cable Length: Maximum recommended cable length is 100 meters for analog signals.
    • Environmental Protection: Ensure proper sealing if installed in harsh environments.
    • Electromagnetic Compatibility: Keep signal cables separate from power cables to minimize interference.

    5. Wiring Diagram

    REXROTH PIC-6115 Wiring Diagram

    5.1 Terminal Connections

    Terminal Description Wire Color
    PWR+ Power Supply Positive (24 VDC) Red
    PWR- Power Supply Negative (0 VDC) Black
    SEN1-SEN8 Sensor Input Channels Green
    ACT1-ACT4/8 Actuator Output Channels Yellow
    GND Signal Ground Blue

    5.2 Wiring Notes

    • Use shielded twisted pair cable for analog signals to minimize noise interference.
    • Ground the cable shield at one end only (preferably at the module).
    • Ensure proper wire gauge for the distance to maintain signal integrity.
    • Separate signal wires from power cables to avoid electromagnetic interference.
    • Use appropriate cable glands to maintain the environmental rating.

    6. Configuration Instructions

    6.1 Initial Setup

    1. Connect a PC to the module using the Ethernet or RS-232 interface.
    2. Install the REXROTH configuration software on the PC.
    3. Launch the configuration software and establish communication with the module.
    4. Load the default configuration or create a new configuration.
    5. Configure the input/output channels according to the application requirements.
    6. Set up communication parameters (baud rate, parity, protocol).
    7. Configure control algorithms and parameters.
    8. Save the configuration to the module's Flash memory.
    9. Test the configuration to ensure proper operation.

    6.2 Parameter Configuration

    Parameter Configuration Method Default Value
    Input Type Configuration software 4-20 mA
    Output Type Configuration software 4-20 mA
    Communication Protocol Configuration software Modbus RTU
    Baud Rate Configuration software 9600 bps
    Control Algorithm Configuration software PID

    6.3 Programming Languages

    The REXROTH PIC-6115 control module supports multiple programming languages for application development:

    Supported Languages

    • Structured Text (ST): A high-level language similar to Pascal, ideal for complex algorithms and mathematical operations.
    • Ladder Logic (LD): A graphical language resembling electrical ladder diagrams, suitable for discrete control applications.
    • Function Block Diagram (FBD): A graphical language using function blocks to represent control functions, ideal for process control applications.

    6.4 Communication Configuration

    The REXROTH PIC-6115 supports various communication protocols for integration with other automation components:

    1. Modbus RTU: Configure the baud rate, parity, stop bits, and slave address.
    2. Modbus TCP/IP: Configure the IP address, subnet mask, and gateway.
    3. Profibus DP: Configure the station address and communication parameters using the Profibus configuration tool.
    4. EtherNet/IP: Configure the IP address and connection parameters for Allen-Bradley compatibility.

    7. Troubleshooting

    7.1 Common Issues and Solutions

    Symptom Possible Cause Solution
    No power/indicator lights Power supply failure Check power connections and supply voltage
    No communication Incorrect communication settings Verify communication parameters and connections
    Erratic input readings Electromagnetic interference Check cable shielding and routing
    No output signal Output channel configuration error Check output configuration and programming
    Module overheating Insufficient ventilation Check mounting location and cooling

    7.2 Diagnostic Tests

    Power Supply Test

    1. Disconnect the module from the power supply.
    2. Measure the resistance between PWR+ and PWR- terminals.
    3. A reading of 50-100 ohms indicates a healthy power supply circuit.
    4. A reading of 0 ohms indicates a short circuit.
    5. A reading of infinity indicates an open circuit.

    Input/Output Test

    1. Connect a signal generator to an input channel.
    2. Monitor the input value using the configuration software.
    3. Verify that the displayed value matches the input signal.
    4. Configure an output channel to a known value.
    5. Measure the output signal using a multimeter.
    6. Verify that the measured value matches the configured value.

    7.3 Fault Codes

    Fault Code Description Action
    E01 Power supply error Check power connections and supply voltage
    E02 Memory error Reboot module or restore factory defaults
    E03 Communication error Check communication settings and connections
    E04 I/O channel error Check channel configuration and wiring

    8. Interactive System Diagram

    REXROTH PIC-6115 Interactive Diagram

    Component Information

    Click on any component in the diagram to view detailed information about it.

    9. Maintenance

    9.1 Regular Maintenance Schedule

    Maintenance Task Frequency Procedure
    Visual Inspection Monthly Check for physical damage, corrosion, or loose connections
    Cleaning Quarterly Remove dust and debris from the module and ventilation areas
    Connection Check Semi-annually Verify all connections are tight and secure
    Software Update Annually Update firmware to latest version if necessary
    Functional Test Annually Perform comprehensive functional test of all I/O channels

    9.2 Cleaning Procedures

    Proper cleaning of the REXROTH PIC-6115 control module is essential for maintaining reliable operation and extending the service life of the device.

    External Cleaning

    1. Disconnect power to the module before cleaning.
    2. Use a soft, dry cloth to remove dust and debris from the module surface.
    3. For more stubborn dirt, use a cloth dampened with mild detergent and water.
    4. Avoid using harsh chemicals, solvents, or abrasive materials.
    5. Ensure the module is completely dry before restoring power.

    9.3 Replacement Guidelines

    Consider replacing the module in the following situations:

    • When the module has been in service for more than 5 years.
    • When physical damage is visible or suspected.
    • When the module fails diagnostic tests or fault codes persist.
    • When the module has been exposed to extreme conditions beyond its specifications.
    • When the module is no longer supported by the manufacturer.

    10. Applications

    The REXROTH PIC-6115 control module is designed for a wide range of industrial applications where precise control and monitoring are critical. Its robust construction and reliable performance make it suitable for harsh environments.

    10.1 Key Applications

    • Manufacturing: Control of production lines, robotic systems, and automated machinery.
    • Process Control: Regulation of temperature, pressure, flow, and level in industrial processes.
    • Energy Management: Monitoring and control of power generation and distribution systems.
    • Building Automation: Control of HVAC, lighting, and security systems in commercial buildings.
    • Transportation: Control systems for railways, airports, and traffic management.

    10.2 Industry Applications

    Automotive

    Assembly lines, robotic welding, paint systems

    Chemical

    Batch processing, reactor control, mixing systems

    Food & Beverage

    Processing lines, packaging, quality control

    Pharmaceutical

    Precision dosing, sterile processing, labeling

    10.3 Application Notes

    • The PIC-6115 is suitable for both discrete and process control applications.
    • For critical applications, consider redundant module installation for increased reliability.
    • Ensure proper grounding and shielding to minimize electromagnetic interference.
    • Use appropriate signal conditioning for sensors with special requirements.
    • Regularly backup configuration data to facilitate quick recovery in case of module failure.

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