Bosch Rexroth Rho 4.0 User manual

Rexroth IndraControl VCP 20
Industrial
Hydraulics
Electric Drives
and Controls
Linear Motion and
Assembly Technologies Pneumatics
Service
Automation
Mobile
Hydraulics
Rexroth Rho 4.0
Connectivity manual
1070072365
Edition 04
Project planning

II Electric Drives
and Controls
Bosch Rexroth AG RhoMotion 1070072365 / 04
Rexroth Rho 4.0
Connectivity manual
Project planning
DOK-RHO*4*-RHO4.0*ANBE-PR04-EN-P
The present manual informs about:
Dtechnical data, operation and
Dconfiguration of the rho4.0
Description Release
Date Notes
DOK-RHO*4*-RHO4.0*ANBE-PR03-
EN-P 10.2003 Valid from VO07
DOK-RHO*4*-RHO4.0*ANBE-PR04-
EN-P 01.2005 Valid from VO08
EBosch Rexroth AG, 1998 − 2005
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).
The specified data is for product description purposes only and
may not be deemed to be guaranteed unless expressly confirmed
in the contract. All rights are reserved with respect to the content
of this documentation and the availability of the product.
Bosch Rexroth AG
Postfach 11 62
D-64701 Erbach
Berliner Straße 25
D-64711 Erbach
Tel.: [phone]
Fax: [phone]
Abt.: BRC/ESH (KW)
Title
Type of Documentation
Document Typecode
Purpose of Documentation
Record of Revisions
Copyright
Validity
Published by

Electric Drives
and Controls IIIBosch Rexroth AGRhoMotion1070072365 / 04
Overview of all manuals
Overview of all manuals
Manual Contents
Connection conditions Rho 4.0 2System overview
Connection conditions Rho 4.0
3 Installation
4Electrical connection
5 Interfaces
6LED display
7Maintenance and replacement
8Order numbers
System description Rho 4.0 2System overview
System description Rho 4.0
3Structure of the rho4.0
4 PCLrho4.0
5CAN-Bus peripheral unit
6SERCOS interface
7 Software
8File management
Connection conditions Rho4.1,
Rho 4.1/IPC300
2System overview
Connection conditions Rho4.1,
Rho 4.1/IPC300 3Security functions
4 Installation
5Electrical connection
6 Interfaces
7LED display
8Maintenance and replacement
9 Software
10 Order numbers
Connection conditions
Rho 4.1/BT155, Rho
2System overview
Connection conditions
Rho 4.1/BT155, Rho
4.1/BT155T, Rho 4.1/BT205
3Security functions
4.1/BT155T, Rho 4.1/BT205
4 Installation
5Electrical Connections
6 Interfaces
7Display and Operating Controls
8Maintenance and Replacemant
9 Software
10 Order numbers
System description Rho 4.1 2Structure of the rho4.1
System description Rho 4.1
3 PCL
4CAN-Bus peripheral unit
5SERCOS interface

IV Electric Drives
and Controls
Bosch Rexroth AG RhoMotion 1070072365 / 04
Overview of all manuals
Manual Contents
6 Software
7File management
8Scope of the rho4.1 Software
Manual Contents
Control functions 2 Survey of special functions
Control functions
3Accurate position switching
4Setting the machine position
5Calling operating system functions
6Parameterization of the belt characte-
ristic
7Selecting a point-file
8 Mirroring
9Belt type
10 System date and time
11 System counter
12 WC main range
13 Setting the belt counter
14 Recording of reference path
15 Flying measurement (rho4.1 only)
16 MOVE_FILE
17 Setting the block preparation
18 Exception−Handling
19 Belt counter current value
20 Automatic velocity adjustment for PTP
movements
21 Belt-synchronous working area belt
kind 4
22 Current belt speed
23 Changing the belt simulation speed
24 General functions
25 Process-oriented functions
26 BAPS3 keywords
Machine parameters 2General information
Machine parameters
3Application of the machine parameters
4General system parameters
5 Speeds
6 Positions
7Kinematic parameters

Electric Drives
and Controls VBosch Rexroth AGRhoMotion1070072365 / 04
Overview of all manuals
Manual Contents
8Measuring system parameters
9Belt parameters
10 Drive parameters Servodyn-GC
11 Drive parameter Servodyn-D
12 Table of parameters
Manual Contents
BAPS3 Programming manual 2Program structure
BAPS3 Programming manual
3 Constants
4 Variables
5Program control
6Value assignments and combinations
7 Functions
8Movement statement
9Write/read functions
10 BAPS3 keywords
BAPS3 Short description 2Program structure
BAPS3 Short description
3Constants and variables
4Program structure
5Value assignments and combinations
6Standard functions
7Movements and speeds
8Belt synchronous
9Workspace limitation
10 Write/read functions
11 Special functions
12 Library functions
13 Fix files
14 BAPS3 keywords
Signal descriptions 2rho4 interface description
Signal descriptions
3Signal description of PCL inputs
4Signal description of PCL outputs
Status messages
and warnings
2rho4 status messages
Status messages
and warnings 3 Warnings
4 CANopen error codes
ROPS4/Online 2General information
ROPS4/Online
3Activation and functions of Online
4The function key box

VI Electric Drives
and Controls
Bosch Rexroth AG RhoMotion 1070072365 / 04
Overview of all manuals
Manual Contents
5Function key assignment
6The marker box
7File ROPS4WIN.ini
8Selection of a file
9TCP/IP settings for ROPS4
Manual Contents
DLL library 2Library functions
DLL library
3Calling library functions in BAPS
4Block structure of the rho4.1
5Library server
6Application development
7rho4 library functions
8Variable access per DLL
PHG2000 2Hand-held programming unit
PHG2000
3PHG2000 system variables
4Selection of PHG functions
5Info function of the PHG
6Controlling the PHG2000 output
7 Define/Teach
8SRCAN functions
9File and User Memory Functions
10 File list
11 Process info
12 Restoring the PGH display
13 Variable assignment of PHG keys
14 Select point file and point name
15 BDT editor
Connection conditions
Rho 4.1/IPC 40.2
2System Overview
Connection conditions
Rho 4.1/IPC 40.2 3Security Functions
4 Installation
5Eelectrical Connections
6 Interface Ports & Connectors
7Display- and Operating Components
8Maintenance and Replacement
9 Software
10 Ordering Informations

Electric Drives
and Controls VIIBosch Rexroth AGRhoMotion1070072365 / 04
Overview of all manuals
Manual Contents
DDE-Server 2 Introduction
DDE-Server
3Hardware and Software
4 Operation
5Items of Server 4
6Scope of function

VIII Electric Drives
and Controls
Bosch Rexroth AG RhoMotion 1070072365 / 04
Overview of all manuals
Notes:

Electric Drives
and Controls IXBosch Rexroth AGRhoMotion1070072365 / 04
Contents
Contents
Page
1 Safety Instructions 1−1. . . . . . . . . . . . . . . . . . . . . . .
1.1 Intended use 1−1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2 Qualified personnel 1−2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3 Safety markings on products 1−3. . . . . . . . . . . . . . . . . . . . . . . . . .
1.4 Safety instructions in this manual 1−4. . . . . . . . . . . . . . . . . . . . . .
1.5 Safety instructions for the described product 1−5. . . . . . . . . . . .
1.6 Documentation, software release and trademarks 1−7. . . . . . .
2 System Overview 2−1. . . . . . . . . . . . . . . . . . . . . . . .
2.1 Modular mimic display 2−4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2 Versions 2−5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3 Specifications 2−6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4 Operating conditions 2−7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.5 Standards compatibility 2−8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 Installation 3−1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1 Installed positions and clearances 3−1. . . . . . . . . . . . . . . . . . . . .
3.2 Dimension diagram 19” housing 3−2. . . . . . . . . . . . . . . . . . . . . . .
3.3 Dimension diagram 19” housing with extended
remanence (LR) 3−3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.4 Dimension diagram drive housing 3−4. . . . . . . . . . . . . . . . . . . . .
4 Electrical Connections 4−1. . . . . . . . . . . . . . . . . . .
4.1 Protective Earth (PE) conductor & screening information 4−2.
4.2 Interference suppression information 4−3. . . . . . . . . . . . . . . . . . .
4.3 24 VDC power connection 4−6. . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3.1 Power connections 4−9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4 Monitoring of the system voltage 4−9. . . . . . . . . . . . . . . . . . . . . .
4.5 Monitoring of the temperature and the CPU ventilator 4−10. . . .
5 Interface Ports & Connectors 5−1. . . . . . . . . . . . .
5.1 Overview 5−1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2 V24_1/X33 through V24_3/X33 serial PC ports 5−3. . . . . . . . . .
5.2.1 Pin assignment 5−3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3 Floppy interface 5−6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.4 X34 PHG2000 5−7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.4.1 X10s safety relevant signals and 24-V power supply
for digital outputs and PHG 5−9. . . . . . . . . . . . . . . . . . . . . . . . .
5.5 Ethernet-interface 5−10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.5.1 Ethernet (MAC)- and IP address 5−11. . . . . . . . . . . . . . . . . . . . .
5.6 SERCOS interface 5−12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.7 X51, X52, X53 CAN-drives, CAN-transmitter, SR-CAN-module,
CAN-user-I/O 5−13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.7.1 Connection examples for the CAN interfaces 5−14. . . . . . . . . .

XElectric Drives
and Controls
Bosch Rexroth AG RhoMotion 1070072365 / 04
Contents
5.8 X21 and X22 Digital In (24 V) 5−15. . . . . . . . . . . . . . . . . . . . . . . . .
5.9 X11 Digital Out (24 V) 5−16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.10 PCI-Slot A1 5−17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.11 Expansion Card Interfaces 5−18. . . . . . . . . . . . . . . . . . . . . . . . . . .
5.11.1 PCI_BM-xxx Card 5−18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.11.2 PCI_CAN Card 5−21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 LED Display 6−1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 Maintenance and Replacement 7−1. . . . . . . . . . . .
7.1 CF card 7−1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.2 Battery 7−2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 Order numbers 8−1. . . . . . . . . . . . . . . . . . . . . . . . . .
8.1 Accessories 8−1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.2 Spare parts 8−2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A Appendix A−1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A.1 Abbreviations A−1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A.2 Index A−2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electric Drives
and Controls 1−1Bosch Rexroth AGRhoMotion1070072365 / 04
Safety Instructions
1 Safety Instructions
Please read this manual before you startup the rho4.
Store this manual in a place to which all users have access at any time.
1.1 Intended use
This instruction manual presents a comprehensive set of instructions
and information required for the standard operation of the described
products. The described products are used for the purpose of operating
with a robot control rho4.
The products described
Dhave been developed, manufactured, tested and documented in
compliance with the safety standards. These products normally pose
no danger to persons or property if they are used in accordance with
the handling stipulations and safety notes prescribed for their con-
figuration, mounting, and proper operation.
Dcomply with the requirements of
Dthe EMC Directives (89/336/EEC, 93/68/EEC and 93/44/EEC)
Dthe Low-Voltage Directive (73/23/EEC)
Dthe harmonized standards EN 50081-2 and EN 50082-2
Dare designed for operation in industrial environments, i.e.
Dno direct connection to public low-voltage power supply,
Dconnection to the medium- or high-voltage system via a trans-
former.
The following applies for application within a personal residence, in
business areas, on retail premises or in a small-industry setting:
DInstallation in a control cabinet or housing with high shield attenu-
ation.
DCables that exit the screened area must be provided with filtering
or screening measures.
DThe user will be required to obtain a single operating license is-
sued by the appropriate national authority or approval body. In
Germany, this is the Federal Institute for Posts and Telecommuni-
cations, and/or its local branch offices.
.This is a Class A device. In a residential area, this device may cause
radio interference. In such case, the user may be required to intro-
duce suitable countermeasures, and to bear the cost of the same.
The faultless, safe functioning of the product requires proper transport,
storage, erection and installation as well as careful operation.

1−2 Electric Drives
and Controls
Bosch Rexroth AG RhoMotion 1070072365 / 04
Safety Instructions
1.2 Qualified personnel
The requirements as to qualified personnel depend on the qualification
profiles described by ZVEI (central association of the electrical industry)
and VDMA (association of German machine and plant builders) in:
Weiterbildung in der Automatisierungstechnik
edited by: ZVEI and VDMA
MaschinenbauVerlag
Postfach 71 08 64
D-60498 Frankfurt.
The present manual is designed for RC technicans. They need special
knowledge on handling and programming robots.
Interventions in the hardware and software of our products, unless de-
scribed otherwise in this manual, are reserved to specialized Rexroth
personnel.
Tampering with the hardware or software, ignoring warning signs at-
tached to the components, or non-compliance with the warning notes
given in this manual may result in serious bodily injury or damage to pro-
perty.
Only electrotechnicians as recognized under IEV 826-09-01 (modified)
who are familiar with the contents of this manual may install and service
the products described.
Such personnel are
Dthose who, being well trained and experienced in their field and famil-
iar with the relevant norms, are able to analyze the jobs being carried
out and recognize any hazards which may have arisen.
Dthose who have acquired the same amount of expert knowledge
through years of experience that would normally be acquired through
formal technical training.
With regard to the foregoing, please note our comprehensive range of
training courses. Please visit our website at
http://www.boschrexroth.com
for the latest information concerning training courses, teachware and
training systems. Personal information is available from our Didactic
Center Erbach,
Telephone: (+49) (0) 60 62 78-600.

Electric Drives
and Controls 1−3Bosch Rexroth AGRhoMotion1070072365 / 04
Safety Instructions
1.3 Safety markings on products
Warning of dangerous electrical voltage!
Warning of danger caused by batteries!
Electrostatically sensitive components!
Warning of hazardous light emissions
(optical fiber cable emissions)!
Disconnect mains power before opening!
Lug for connecting PE conductor only!
Functional earthing or low-noise earth only!
Connection of shield conductor only

1−4 Electric Drives
and Controls
Bosch Rexroth AG RhoMotion 1070072365 / 04
Safety Instructions
1.4 Safety instructions in this manual
DANGEROUS ELECTRICAL VOLTAGE
This symbol is used to warn of a dangerous electrical voltage. The
failure to observe the instructions in this manual in whole or in part may
result in personal injury.
DANGER
This symbol is used wherever insufficient or lacking compliance with in-
structions may result in personal injury.
CAUTION
This symbol is used wherever insufficient or lacking compliance with in-
structions may result in damage to equipment or data files.
.This symbol is used to draw the user’s attention to special circum-
stances.
LThis symbol is used if user activities are required.

Electric Drives
and Controls 1−5Bosch Rexroth AGRhoMotion1070072365 / 04
Safety Instructions
1.5 Safety instructions for the described product
DANGER
Danger of life through inadequate EMERGENCY-STOP devices!
EMERGENCY-STOP devices must be active and within reach in all
system modes. Releasing an EMERGENCY-STOP device must not
result in an uncontrolled restart of the system!
First check the EMERGENCY-STOP circuit, then switch the sys-
tem on!
DANGER
Danger for persons and equipment!
Test every new program before starting up a system!
DANGER
Retrofits or modifications may adversely affect the safety of the
products described!
The consequences may include severe injury, damage to equip-
ment, or environmental hazards. Possible retrofits or modifica-
tions to the system using third-party equipment therefore have to
be approved by Rexroth.
DANGER
Do not look directly into the LEDs in the optical fiber connection.
Due to their high output, this may result in eye injuries.
When the inverter is switched on, do not look into the LED or the
open end of a short connected lead.
DANGEROUS ELECTRICAL VOLTAGE
Unless described otherwise, maintenance works must be per-
formed on inactive systems! The system must be protected
against unauthorized or accidental reclosing.
Measuring or test activities on the live system are reserved to
qualified electrical personnel!

1−6 Electric Drives
and Controls
Bosch Rexroth AG RhoMotion 1070072365 / 04
Safety Instructions
CAUTION
Danger to the module!
Do not insert or remove the module while the controller is
switched ON! This may destroy the module. Prior to inserting or
removing the module, switch OFF or remove the power supply mo-
dule of the controller, external power supply and signal voltage!
CAUTION
use only spare parts approved by Rexroth!
CAUTION
Danger to the module!
All ESD protection measures must be observed when using the
module! Prevent electrostatic discharges!
The following protective measures must be observed for modules and
components sensitive to electrostatic discharge (ESD)!
DPersonnel responsible for storage, transport, and handling must have
training in ESD protection.
DESD-sensitive components must be stored and transported in the
prescribed protective packaging.
DESD-sensitive components may only be handled at special ESD-
workplaces.
DPersonnel, working surfaces, as well as all equipment and tools
which may come into contact with ESD-sensitive components must
have the same potential (e.g. by grounding).
DWear an approved grounding bracelet. The grounding bracelet must
be connected with the working surface through a cable with an inte-
grated 1 MWresistor.
DESD-sensitive components may by no means come into contact with
chargeable objects, including most plastic materials.
DWhen ESD-sensitive components are installed in or removed from
equipment, the equipment must be de-energized.

Electric Drives
and Controls 1−7Bosch Rexroth AGRhoMotion1070072365 / 04
Safety Instructions
1.6 Documentation, software release and trademarks
Documentation The present manual provides the user with comprehensive information
about technical data, operation and configuration of the rho4.0.
Overview of available documentation Part no.
German English
Rho 4.0 Connectivity Manual 1070 072 364 1070 072 365
Rho 4.0 System description 1070 072 366 1070 072 367
Rho 4.1/IPC 40.2 Connectivity Manual R911308219 R911308220
Rho 4.1/BT155, Rho 4.1/BT155T, Rho
4.1/BT205 Connectivity manual 1070 072 362 1070 072 363
Rho 4.1, Rho 4.1/IPC300 Connectivity man-
ual 1070 072 360 1070 072 361
Control panels BF2xxT/BF3xxT, connection 1070 073 814 1070 073 824
Rho 4.1 System description 1070 072 434 1070 072 185
ROPS4/Online 1070 072 423 1070 072 180
BAPS plus 1070 072 422 1070 072 187
BAPS3 Short description 1070 072 412 1070 072 177
BAPS3 Programming manual 1070 072 413 1070 072 178
Control functions 1070 072 420 1070 072 179
Signal descriptions 1070 072 415 1070 072 182
Status messages and warnings 1070 072 417 1070 072 181
Machine parameters 1070 072 414 1070 072 175
PHG2000 1070 072 421 1070 072 183
DDE-Server 4 1070 072 433 1070 072 184
DLL-Library 1070 072 418 1070 072 176
Rho 4 available documentation on CD ROM 1070 086 145 1070 086 145
.In this manual the floppy disk drive always uses drive letter A:, and
the hard disk drive always uses drive letter C:.
Special keys or key combinations are shown enclosed in pointed
brackets:
DNamed keys: e.g., <Enter>, <PgUp>, <Del>
DKey combinations (pressed simultaneously): e.g., <Ctrl> + <PgUp>

1−8 Electric Drives
and Controls
Bosch Rexroth AG RhoMotion 1070072365 / 04
Safety Instructions
Release
.This manual refers to the following versions:
Hardware version: rho4
Software release: ROPS4
Trademarks All trademarks of software installed on Rexroth products upon delivery
are the property of the respective manufacturer.
Upon delivery, all installed software is copyright-protected. The software
may only be reproduced with the approval of Rexroth or in accordance
with the license agreement of the respective manufacturer.
MS-DOSrand Windowstare registered trademarks of Microsoft
Corporation.
PROFIBUSris a registered trademark of the PROFIBUS Nutzerorga-
nisation e.V. (user organization).
MOBYris a registered trademark of Siemens AG.
AS-Iris a registered trademark of AS-International Association.
SERCOS interfacetis a registered trademark of Interessengemein-
schaft SERCOS interface e.V. (Joint VDW/ZVEI Working Committee).
INTERBUS-Sris a registered trade mark of Phoenix Contact.
DeviceNetris a registered trade mark (TM) of ODVA (Open DeviceNet
Vendor Association, Inc.).

Electric Drives
and Controls 2−1Bosch Rexroth AGRhoMotion1070072365 / 04
System Overview
2 System Overview
The rho4.0 is a robot, handling and movement control in which the whole
processor is available for the real time part since it can run without Win-
dows. VxWorks is used as Task Scheduler.
The hardware core of the rho4.0 is PC-based and extended by the hard-
ware required for a real-time control.
8 axes and 8 kinematics can be controlled in the basis function scope.
The rho4.0 is composed of a power supply unit, a carrier board, a PC
board and a PCI plug point in which one of the 3 BOSCH field bus cards
(CAN, INTERBUS-S and PROFIBUS-DP) can be operated.
CAUTION
Damage to the PC or the application software can be caused
by using extension cards that are not released.
Install only released extension cards and have them only by
authorized qualified personnel installed.
Installation of extension cards, see section 7.1.
The PC Board is available optional with a 266- or a 400-MHz processor
and 64-MB-SO-DIMM. A Compact-Flash card is used as hard disk.
The rho4.0 is provided with an internal 3,6 V-Lithium battery of size AA
with a capacity of 1,75 Ah. It buffers the SRAM components and the RTC
on the ETX Board and should be changed every 3 years for security re-
asons. See section 7.2.

2−2 Electric Drives
and Controls
Bosch Rexroth AG RhoMotion 1070072365 / 04
System Overview
There are 2 types of housing: one in the form of a drive module and one
as 19” rack.
The drive housing is located vertically near a drive module. The 19” hou-
sing is 44mm high and is located horizontally in a 19” control cabinet.
Dimensions:
rho4.0
19” housing (horizontal) H: 43,6 mm B: 482,6 mm T: 222 mm
rho4.0LR*,rho4.0LRX*
19” housing (horizontal) H: 43,6 mm B: 482,6 mm T: 303,99 mm
rho4.0
Drive housing (vertical) H: 445 mm B: 43,6 mm T: 250 mm
Weight: approx. 3,5
kg
The protection type of both housing types is IP20.
* LR = large remanence
X = 400 MHz variant