Bachmann SEM201 SERCOS Master Module
1. Product Description
A high-performance industrial SERCOS (Serial Real-Time Communication System) Master module designed for precise, real-time motion control in automation systems. The Bachmann SEM201 acts as a central communication hub, enabling seamless data exchange between Bachmann controllers (e.g., MPC240) and SERCOS-compatible slave devices (e.g., servo drives, frequency inverters). It supports high-speed real-time synchronization, multi-axis motion control, and robust fault handling, with seamless integration with Bachmann backplanes (e.g., BS208/BS209) and HMI panels (e.g., OT115/R). Its rugged design and anti-interference performance make it ideal for harsh industrial environments requiring ultra-reliable motion control (e.g., CNC machining, robotic assembly lines).
2. Detailed Specifications
2.1 SERCOS Communication Performance
- SERCOS Version Support: SERCOS III (IEC 61491 standard); backward compatible with SERCOS II (via firmware setting)
- Maximum Communication Rate: 100 Mbps (full-duplex, fiber optic or twisted-pair)
- Real-Time Synchronization Accuracy: ±1 µs (between master and slave devices)
- Maximum Slave Nodes: Up to 31 SERCOS slave devices per module
- Cycle Time: Configurable from 125 µs to 10 ms (adapts to motion control precision needs)
2.2 Interface Configuration
- SERCOS Interfaces: 2×SERCOS ports (1×fiber optic, 1×twisted-pair; for ring or line topology)
- Backplane Interface: 1×backplane connector (compatible with Bachmann BS208/BS209 backplanes)
- Diagnostic Interface: 1×USB 2.0 port (for local configuration, firmware updates, and fault logging)
- Auxiliary Signal Interface: 2×digital input (for emergency stop, enable signals); 2×digital output (for status indication)
2.3 Motion Control Capabilities
- Supported Motion Modes: Position control, speed control, torque control; interpolated motion (linear, circular, helical)
- Axis Synchronization: Multi-axis electronic gearing, electronic cam, and camming synchronization
- Fault Handling: Real-time error detection (communication loss, slave fault); automatic fault recovery (configurable retry logic)
- Data Exchange: Supports 32-bit process data (input/output) per slave; up to 1024 bytes of parameter data per slave
2.4 Power Supply
- Input Voltage: 24 V DC ±20% (powered via backplane or external 24 V DC)
- Power Consumption: Typical 5 W, Maximum 7 W (excluding slave device power)
- Power Protection: Overvoltage, undervoltage, reverse polarity, and surge protection (EN 61000-4-5 compliant)
2.5 Operating Environment
- Operating Temperature: -40°C ~ +70°C
- Storage Temperature: -40°C ~ +85°C
- Relative Humidity: 5% ~ 95% (non-condensing)
- Vibration Resistance: 10-500 Hz, 2 g acceleration (IEC 60068-2-6)
- Shock Resistance: 30 g acceleration, 11 ms duration (IEC 60068-2-27)
- EMC Compliance: EN 61000-6-2 (industrial immunity), EN 61000-6-4 (industrial emissions)
2.6 Physical & Software
- Dimensions: 120×75×28 mm (Length×Width×Height)
- Mounting: DIN rail (via backplane integration; EN 50022 standard)
- Programming Software: Bachmann Studio (v4.0+; SERCOS topology setup, motion parameter configuration, fault diagnostics)
- LED Indicators: 2×SERCOS status LEDs (green: normal; red: fault); 1×power LED (green); 1×communication LED (yellow: active); 2×auxiliary I/O LEDs (green: input active)
3. Advantages & Features
- High-Speed Real-Time Control: 100 Mbps communication rate + ±1 µs synchronization accuracy meet ultra-precise motion needs (e.g., CNC machining).
- Dual SERCOS Interfaces: Fiber optic + twisted-pair ports support flexible topologies (ring/line) and adapt to different installation environments.
- Multi-Axis Synchronization: Enables electronic gearing/camming for complex motion sequences (e.g., robotic assembly lines).
- Seamless Integration: Works with Bachmann controllers, backplanes, and HMIs—no extra adapters for system build.
- Robust Fault Handling: Real-time error detection and automatic recovery reduce unplanned downtime in critical motion processes.
4. Application Fields
- CNC Machining: High-precision milling machines, lathes, and grinding machines (multi-axis synchronization control).
- Robotic Automation: Industrial robots (6-axis robotic arms, SCARA robots) for assembly, welding, and material handling.
- Packaging Machinery: High-speed packaging lines (film wrapping machines, labeling machines) for precise speed/torque control.
- Printing & Converting: Web printing machines, paper converting equipment (tension control, web alignment via servo drives).
- Automotive Manufacturing: Car body welding lines, engine assembly stations (robotic arm synchronization, conveyor speed control).
5. Precautions
- Installation: Integrate only with compatible Bachmann backplanes; use shielded twisted-pair cables (CAT5e/CAT6) or industrial-grade fiber optic cables for SERCOS connections; ensure ring topology is properly terminated (120 Ω terminator for twisted-pair).
- Topology Setup: Test SERCOS communication latency before system startup; configure cycle time based on motion precision needs (shorter cycle time for higher precision).
- Slave Compatibility: Verify slave devices (servo drives) support SERCOS III (or II for backward compatibility); update slave firmware to match module firmware version.
- Emergency Stop: Connect emergency stop signals to auxiliary digital inputs (not via SERCOS communication) to ensure safety compliance (EN ISO 13849).
- Maintenance: Inspect SERCOS cables/connectors quarterly (check for damage or loose connections); back up motion parameters via Bachmann Studio; do not disassemble the module (voids warranty).
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