Bosch REXROTH mMS 4.0 User manual

R901429162/04.16
Operating manual
Replaces: R901429162/09.15
English
Training system mMS 4.0

This information is intended to describe the product.
If this information is to be applied, it only serves
as possible applications and suggestions.
Catalog information is not guaranteed features
of the product. The information provided does not
release the user from the obligation to conduct his
own assessments and tests. Our products
are subject to a natural process of wear and aging.
This document, as well as the data, specifications
and other information set forth in it, are the
exclusive property of Bosch Rexroth AG. We retain
all rights of use, including the rights of reproduction
and distribution.
An example configuration is shown on the
title page. The delivered product may differ from
the illustration.
Original operating instructions

Training system mMS 4.0 | R901429162/04.16 Bosch Rexroth AG 3/68
Contents
Contents
1About this documentation ...................................................................... 5
1.1 Validity of the documentation................................................................ 5
1.2 The following signs and symbols are used in this manual:..................... 5
1.3 Required and supplementary documentation ....................................... 5
1.4 Layout of documentation ....................................................................... 5
1.4.1 Safety instructions ........................................................................ 5
1.4.2 Symbols ......................................................................................... 6
1.4.3 Abbreviations ................................................................................ 7
2Safety instructions .................................................................................. 8
2.1 About this chapter.................................................................................. 8
2.2 Intended use........................................................................................... 8
2.3 Improper use .......................................................................................... 8
2.4 Staff qualification ................................................................................... 9
2.4.1 Firms offering apprenticeships ..................................................... 9
2.4.2 Transport, set-up, installation and commissioning..................... 10
2.4.3 Troubleshooting, maintenance and repair ................................. 10
2.5 General safety instructions................................................................... 11
2.6 Product- and technology-dependent safety instructions..................... 12
2.7 Personal protective equipment............................................................ 13
2.8 Duties of the operator .......................................................................... 13
2.9 Safety installations ............................................................................... 14
2.10 Operator operating positions .......................................................... 15
3General instructions concerning property damage and product damage
16
4Scope of supply..................................................................................... 17
5About this product................................................................................ 18
5.1 General information ............................................................................. 18
5.2 Product Description.............................................................................. 18
Control box left side - exterior .................................................................. 19
Control box right side - exterior ................................................................ 19
5.2.1 Rack, work piece detection station ............................................. 20
Control box................................................................................................ 21
5.2.2 Processing with press station...................................................... 22
Control box................................................................................................ 23
Circuit diagram for hydraulic press ........................................................... 23
Hydraulic power unit description .............................................................. 24
5.2.3 High rack storage station ........................................................ 25
Control box................................................................................................ 26
Zero point reference position ................................................................... 27
5.2.4 Conveyor R901371451 ................................................................ 28
5.2.5 Separating rack R115801073 ...................................................... 28
Filling the racks.......................................................................................... 29
5.2.6 Picking unit R115801073............................................................. 30
5.2.7 Sensors........................................................................................ 30
5.2.8 Light conductor R115801073 ...................................................... 31
5.2.9 Machine control panel VAM 40 R115801080 ............................. 31
5.2.10 Maintenance unit R480318553.............................................. 32
5.2.11 Light barrier R901396882....................................................... 32
5.2.12 Pinning unit R115701062 ....................................................... 33
Replenishing pins ...................................................................................... 33

4/68 Bosch Rexroth AG Training system mMS 4.0 | R901429162/04.16
Contents
5.2.13 Portal R115701064 .................................................................34
5.2.14 Press R115701072...................................................................35
5.2.15 High-stack storage R115701074 .............................................35
6Technical data and dimensions ............................................................. 36
6.1 Technical data .......................................................................................36
6.1.1 Training system mMS 4.0 ............................................................36
6.2 Identification of the mMS 4.0 training system......................................37
7Operating and display elements ........................................................... 38
7.1 EMERGENCY STOP button.....................................................................38
7.2 Operating elements on the training system .........................................39
7.2.1 Machine control panel VAM........................................................39
7.2.2 HMI small operating panel VCP ...................................................40
8Transport and storage .......................................................................... 41
8.1 Delivery and unpacking .........................................................................41
8.2 Transport...............................................................................................42
8.2.1 Transport inside the building.......................................................42
8.2.2 Transporting between two buildings...........................................43
8.3 Storage ..................................................................................................44
9Set-up, installation and commissioning ................................................ 45
9.1 Setting up the mMS 4.0 training system ...............................................45
9.2 Check the pneumatic supply .................................................................46
9.3 Check electric installation .....................................................................47
9.4 Installing installation and stations.........................................................48
9.5 Commissioning the training system ......................................................52
9.6 Check the EMERGENCY STOP circuit .....................................................52
10 Description of the operating functions ................................................. 53
10.1 Select the operating mode ...............................................................53
10.2 Manual mode operation ..................................................................54
10.3 Operating Single Step mode.............................................................54
10.4 Automatic mode operation ..............................................................55
10.5 Homing mode operation ..................................................................56
10.6 „Check Stock“ function.....................................................................56
10.7 „Clear Stock“ function ......................................................................56
10.8 Description of the buttons ...............................................................57
11 Fault assistance .................................................................................... 59
11.1 Faults ................................................................................................59
11.2 Troubleshooting ...............................................................................60
12 Maintenance and inspection ................................................................ 61
12.1 General information .........................................................................61
12.2 Maintenance and inspection schedule.............................................62
13 Maintenance work................................................................................ 63
13.1 General information .........................................................................63
13.2 Maintenance schedule .....................................................................64
13.2.1 Working materials, consumables, tools, measuring devices ..64
13.2.2 Replace parts ..........................................................................65
14 Disposal ................................................................................................ 65
15 Declaration of conformity..................................................................... 66

Training system mMS 4.0 | R901429162/04.16Bosch Rexroth AG 5/68
About this documentation
1About this documentation
1.1 Validity of the documentation
This documentation describes the “mMS 4.0”training system.
For reasons of simplicity, we refer to it as “mMS 4.0”in the following.
This documentation is intended for assemblers, operators, service technicians
and the system end-user.
This documentation contains important information on how to assemble,
transport, commission, operate, use, maintain and disassemble the product safely
and properly and to resolve simple faults independently.
Read the documentation in full, in particular, the “Safety information”chapter
before you start working with the product.
1.2 The following signs and symbols are used in this manual:
Activity symbol: The text next to this symbol describe activities which are
to be carried out from top to bottom in the indicated sequence.
1.3 Required and supplementary documentation
In addition to this manual on the (turnkey) mMS 4.0 training system, the following
additional documentation applies:
All user manuals for the components.
These can be viewed on the enclosed CD.
Documentation about mMS 4.0 from Bosch Rexroth.
1.4 Layout of documentation
To be able to use this documentation quickly and safely, standard safety
instructions, symbols, terms and abbreviations are used. These are explained
in the following sections to aid understanding.
1.4.1 Safety instructions
This documentation contains safety information prior to the directions whenever
there is a risk of personal injury or damage to equipment. The measures
described to avert danger must be observed.

6/68 Bosch Rexroth AG Training system mMS 4.0 | R901429162/04.16
About this documentation
The safety instructions are structured as follows:
Warning sign: Draws attention to the hazard
Signal word: Indicates the seriousness of the hazard
Type and source of danger: Designates the type and source of danger
Consequences: Describes the consequences of non-compliance
Precaution: Indicates how to avoid the danger
Table 1: Risk classes according to ANSI Z535.6-2006
Warning sign/signal word
Meaning
DANGER
Identifies a dangerous situation that will result in death
or serious injuries if not avoided/prevented.
WARNING
Identifies a dangerous situation that could result in death
or serious injuries if it not avoided/prevented.
CAUTION
Identifies a dangerous situation that could result in minor
to serious injuries if not avoided/prevented.
NOTE
Indicates property damage: The product or the damage
can sustain damage.
1.4.2 Symbols
The following symbols denote suggestions which are not safety-relevant but
improve the comprehensibility of the documentation.
Table 2: Meaning of symbols
Symbol
Meaning
If this information is not observed, the product will not
be able to be used or operated optimally.

Individual, independent action
1.
2.
3.
Numbered instruction:
The numbers indicate that the actions follow each other.
SIGNAL WORD
Type and source of danger
Consequences for non-compliance
Measures on hazard avoidance

Training system mMS 4.0 | R901429162/04.16Bosch Rexroth AG 7/68
About this documentation
1.4.3 Abbreviations
The following abbreviations are used in this documentation:
Table 3: Abbreviations
Abbreviation
Meaning
OCE
Open Core Engineering
mMS 4.0
Modular Mechatronics System for Industry 4.0
Smart Device
Android or iOS smart phone or tablet
HMI
Human Machine Interface
Station
One of three mMS 4.0 stations
Installation
All three mMS 4.0 stations together
MDI
Machine Data Interface, CNC manual data entry

8/68 Bosch Rexroth AG Training system mMS 4.0 | R901429162/04.16
Safety instructions
2Safety instructions
2.1 About this chapter
The mMS 4.0 training system has been manufactured in accordance with
the general rules of technology. Nevertheless, there is the danger of personal
injury or property damage if this chapter and the safety instructions in this
documentation are not observed.
Read this documentation fully and thoroughly before you work with
the mMS 4.0 training system.
Keep the documentation in a place where there are available to all users
at any time.
Whenever passing on the Training system to third parties, include the required
documentation.
2.2 Intended use
The mMS 4.0 training system is a mechanical and electrical system with
pneumatics and/or hydraulics systems.
It may only be used to impart knowledge and expertise of advanced technical
education in the high-level programming language area and control engineering.
With respect to the set-up of whole assemblies and simulations, only the devices
and device sets are only used for the mMS 4.0 training system.
Operation is only permitted under the indicated operating conditions.
The mMS 4.0 training system is only intended for professional and not
for private use.
The mMS 4.0 training system made by Bosch Rexroth has been designed and
is intended for industrial power supply networks. Supplying the demo system
from different supply network requires additional disturbance suppression
measures (line filter, throttles, etc.).
Intended use also includes having thoroughly read and understood the safety
regulations, product information and operating instructions below, in particular,
the “Safety instructions”.
2.3 Improper use
Any other use than that described under intended use, is not intended use and
is therefore not authorized.
If unsuitable products are installed in safety-relevant applications, unintended
operating states may arise in the application which could cause personal injury
and/or property damage. Therefore, only use the product in safety-relevant
applications if such a use is specified and allowed in the product documentation.
For example in explosion-protected areas or in safety-relevant parts of a control
(functional safety).
Bosch Rexroth AG cannot assume liability for damage in the event of improper use
of the product. The user is solely responsible for the risks due to improper use.

Training system mMS 4.0 | R901429162/04.16Bosch Rexroth AG 9/68
Safety instructions
Improper use of the product is defined as in particular
Failing to the mMS 4.0 training system seriously in an appropriate manner
during the exercises and outside of lesson time,
Using the parts in a different training system,
Connecting or using other devices or device sets than that authorized
for the mMS 4.0 training system,
Combining or modifying pneumatic pressure circuits.
Supplying the system without supplementary disturbance suppression
measures (filters, throttles, etc) from non-industrial supply networks.

2.4 Staff qualification
2.4.1 Firms offering apprenticeships
Students and apprentices may only work on the mmS 4.0 training system:
Under direct supervision,
after being given appropriate instructions
by a instructor or trained member of staff.
The instructor working with the mMS 4.0 training system must be a trained
specialist familiar with the electrical pneumatic and mechanical device and
the mechatronics field.
The instructor must
give clear instructions when students or participants in the training program
are required to install control circuits in the mMS 4.0 training system,
inspect the installation and functional effects of the control circuit ensuring
safe use before switch on,
answers questions in a clear, understandable way.
Trained members of staff may also be used to supervise the mMS 4.0 training
system during the exercises.
These are qualified persons to be trained and instructed about:
the information given,
possible dangers in the event of improper use,
safeguards and safety measures.
Instructor
Trained personnel

10/68 Bosch Rexroth AG Training system mMS 4.0 | R901429162/04.16
Safety instructions
2.4.2 Transport, set-up, installation and commissioning
Work on the mMS 4.0 training system such as set-up, connection,
commissioning, and repair must only be performed by experts or persons with
sufficient qualifications and authorization who have been instructed to do so.
Persons instructed to work on the mMS 4.0 training system must be able to follow
the information in this documentation, and also, in the event of missing
information, and supplement missing information independently on account
of their professional qualifications.
2.4.3 Troubleshooting, maintenance and repair
Maintenance, repair, troubleshooting and fault removal require particular
knowledge. This work may only be performed by trained skilled workers!
Work on the electrical equipment must only be performed by a qualified
felectrician.
A qualified electrician is someone who can recognize possible hazards and
implement the appropriate safety measures due to their professional training,
knowledge, and experience, as well as their understanding of the relevant
conditions pertaining to the work to be done.
Only skilled personnel with special expertise and experience in pneumatic
components are allowed to work on the pneumatic system. Special knowledge
of pneumatics means that personnel must
–be able to read and understand pneumatic plans completely,
–in particular, fully understands the interdependencies of the installed safety
installations and
–are familiar with the function and arrangement of pneumatic components.
Only skilled personnel with special expertise in and experience of hydraulic
components are allowed to work in the hydraulics system. Specialist knowledge
of hydraulics means that the employee must
–be able to read and understand hydraulic plans completely,
–in particular, fully understands the interdependencies of the installed safety
installations and
–be familiar with the function and arrangement of hydraulic components.

Training system mMS 4.0 | R901429162/04.16Bosch Rexroth AG 11/68
Safety instructions
2.5 General safety instructions
Follow the valid regulations on accident prevention and environmental
protection.
Observe the safety regulations and provisions of the country in which
the product is used.
Only use Rexroth products when they are in a technically faultless condition.
Observe all information about the product.
Persons permitted to assemble, operate, disassemble or maintain Rexroth
products must not be under the influence of alcohol, other drugs or medication
which can impair responsiveness when doing so.
Only use accessories or spare parts approved by the manufacturer to prevent
hazards to persons owing to unsuitable spare parts.
Adhere to the technical data and environmental conditions given in the product
documentation.
If unsuitable products are installed or used in safety-relevant applications,
unintended operating states may arise in the application which could cause
personal injury and/or property damage. Therefore, only use the product in
safety-relevant applications if such a use is specified and allowed in the product
documentation.
You may only put the product into operation after it has been established that
the end product (e.g. a machine or installation) in which the Rexroth products
are fitted, meet the country-specific regulations, safety regulations and
standards for the application.
The product must not be put into operation unless this operating manual has
been read and understood.

12/68 Bosch Rexroth AG Training system mMS 4.0 | R901429162/04.16
Safety instructions
2.6 Product- and technology-dependent safety instructions
WARNING
High electrical voltage
Danger to life, danger of injury due to electrical shock or severe injury!
Always de-energize the installation.
Secure the installation against being switched on accidentally.
Do not operate a device terminal box or sockets which are not connected
to the power supply (fuse boxes) of the mMS 4.0 training system. All of the
components not powered by the device's own electrical control boxes, but
using components (in use) installed in the mMS 4.0 training system are
unaffected by an EMERGENCY STOP circuit (and OFF switch). The mains
voltage continues to apply in the electrical control box.
Do not open the electrical control box. If opening is necessary, only have
the electrical control box open by a qualified electrician.
When connecting additional consumers to the mMS 4.0 training system, only
use ones approved by the manufacturer.
Only operate the mMS 4.0 training system from a supply with a functioning FI
circuit-breaker or protective earthing.
The energy cables which carry 230 V AC must not be disconnected from
the drive while the system is in operation.
Manipulated and/or non-functioning safety devices and safeguards!
Major risk of injury
Shut off the installation immediately.
Skilled personnel must remedy the fault or manipulation immediately.
Hazard caused by incorrect assembly and installation
Major risk of injury during live operation!
Assembly works and commissioning work may only be carried out
by employees at Bosch Rexroth or specialists instructed to do so.
This also applies when the product is returned to service after repair work.
Maintenance work must only be carried out by skilled workers.
WARNING
Danger of crushing by the system!
Risk of injury!
Do not remove any safeguards (e.g. door switches, isolating elements)
Under no circumstances remove safety instructions or signage - make sure
they are installed.

Training system mMS 4.0 | R901429162/04.16Bosch Rexroth AG 13/68
Safety instructions
2.7 Personal protective equipment
The personal protective equipment for users of the product comprises:
Safety shoes for use during set-up/transportation of the training system
Safety gloves and eye protection for use during installation of pneumatic and
hydraulic components
All components of the personal protective equipment must be intact.
2.8 Duties of the operator
The operator must do the necessary prerequisites for the Installation and set-up
of the mMS 4.0 training system and
shall ensure that the mMS 4.0 training system is installed safely by its
personnel and/or persons instructed by him to carry out the work; he shall in
particular make sure that the underground / the surface of the table
–has sufficient load-bearing capacity
–is level and horizontal;
shall ensure compliance with accident prevention regulations (UVV), safety
regulations of the trade associations and other in-house, local requirements.
He shall instruct his employees and/or third party firm employees on possible
hazards at the place of installation.
The operator must provide adequate illumination around the area of installation
of the training system.
He must train his personnel on the following topics at regular intervals:
Observing and using the operating manual and complying with the legal
requirements;
Using the mMS 4.0 training system as intended;
Following the instructions of factory security offices and the operating
instructions from the operator;
Behavior in the event of an emergency.

14/68 Bosch Rexroth AG Training system mMS 4.0 | R901429162/04.16
Safety instructions
2.9 Safety installations
To protect personnel, the mMS 4.0 training system must be equipped with
the following safety installations:
EMERGENCY STOP buttons one for each station to complete
the EMERGENCY STOP circuit
Pneumatic and/or hydraulic pressure limitation
Mechanical safeguards
The above devices are described in greater detail as follows.
The front of the mMS 4.0 training system has an EMERGENCY STOP button
placed within easy reach.
The EMERGENCY STOP button must be pressed to prevent danger to personnel
or the mMS 4.0 training system.
A component with the EMERGENCY STOP button must be connected
to the mMS 4.0.
If a component with the EMERGENCY STOP button is not connected to the mMS
4.0, the EMERGENCY OFF button is not closed and thus will not be able
to operate.
Pressing the EMERGENCY STOP button puts the system out of operation,
i.e. the control and the drive is switched off; the mMS 4.0 training system is
stopped. The power supply unit, the PLC and the drive continue to be powered
by electricity.
The training system may only be operated at a maximum pneumatic operating
pressure of 5-6 bars. The pressure setting is made at the factory. The
compressed air is switched off when an EMERGENCY STOP is actuated.
The maximum hydraulic operating pressure for the training system is
50 bar. The pressure setting is made at the factory. The hydraulic
power unit is switched off when an EMERGENCY STOP is actuated.
To monitor circuitry in training mode, appropriate pressure gauges/pressure
limiting valves may need to be integrated in the exercise circuitry. The instructor
is responsible for doing so.
The following mechanical safeguards are available:
Contact protection for the racks, pinning unit
Contact protection on the conveyor belt
Contact protection on the press
Electrical control box for 115-230 V AC components
Casing of station 3
Additional control technology safeguards are affixed:
Light barriers on the conveyor belts
EMERGENCY STOP buttons
Pneumatic pressure limitation
Hydraulic pressure limitation
Mechanical safeguards
Control technology safeguards
WARNING
Risk of injury!
Do not remove any light barriers (e.g. from the conveyor belts)
Under no circumstances remove safety instructions or signage - make sure
they are installed.

Training system mMS 4.0 | R901429162/04.16Bosch Rexroth AG 15/68
Safety instructions
2.10 Operator operating positions
The training system must be placed on a level base as upright as possible,
and the guide rollers must be locked into place. In order to teach and learn
the procedures on the mMS 4.0 training system, the following space is provided
for the mMS 4.0 training system:
Fig. 1: Space requirement (in cm), mMS 4.0 training system
Fig. 2: Space requirement (in cm), mMS 4.0 training system
The following teaching stations are provided depending on how the mMS 4.0
training system is used:
Table 4: Teaching stations for an mMS 4.0 training system
Work step
Number of persons
working on the system
Number of persons
working on the system
per station
Alignment
1-4
1-3
Control points
(per station)
2
1-2
Teaching stations
80
0-80
400
234
80
80
234
240
80
80
80
0-80

16/68 Bosch Rexroth AG Training system mMS 4.0 | R901429162/04.16
General instructions concerning property damage and product damage
3General instructions concerning property damage
and product damage
NOTE
Installation pressurized and electrical voltage is present!
Damage to property!
Make sure that the system is completely depressurized.
Do not undo any lines, connections and components while the system
is under pressure.
Do not undo any plug connections while the installation remains energized.
De-energize the mMS 4.0 training system.
Incorrect adjustment of the pressure relief valves and pressure switches in
pneumatic and hydraulic components!
Damage to property!
The pneumatic and hydraulic components must only be operated at
the stipulated pressure values.
Risk to electrical equipment caused by high currents!
Damage to property!
Make sure overcurrent protection is available.
Secure the mains plug by disconnecting the mains plug.

Training system mMS 4.0 | R901429162/04.16Bosch Rexroth AG 17/68
Scope of supply
4Scope of supply
The mMS 4.0 training system comes pre-packaged as a turnkey system.
It comprises three modules delivered on three wooden crates. The wood is heat
treated.
These stations stand on a base pallet which can be removed from four sides
by means of a pallet truck.
The upper parts of the wooden crate, comprising 4 side panels and a lid
are screwed and nailed together to bottom pallet.
Table 5: Dimensions of the wooden boxes
Designation
Unit
Value
Dimension
Length
mm
2,100
Width
mm
800
Height
mm
1,800
Table 6: Weight of the wooden boxes
Designation
Unit
Value
Weight
kg
100
Fig. 3: Crate with marking
The following information appears on the crate:
1Transport instructions or warning
notices as required
2Shipping code/barcode
3Delivery note in a plastic pouch
4Printed label: Gross/(where
applicable) net weight
5Printed label: Packaging to IPPC
standard
The scope of supply of the mMS 4.0 training system includes:
3 Stations with function modules
Optional accessories (as per delivery note; 2nd sample inside)
Product documentation
1
5
4
2
3
Dimensions of the wooden boxes
Weight of the wooden boxes
Scope of supply

18/68 Bosch Rexroth AG Training system mMS 4.0 | R901429162/04.16
About this product
5About this product
5.1 General information
The following sections of this operating manual illustrate
a variant of the mMS 4.0 training system and its components for example
purposes.
The three stations are described individually.
All operating manuals of the individual industrial components can be found
in the enclosed CD.
5.2 Product Description
The cube assembly installation comprises three stations:
Rack, workpiece detection station
Processing with pneumatic press station
High rack storage station
The three stations - rack, workpiece detection, processing with pneumatic press
and warehouse are arranged next to each other. They are connected to each other
mechanically, pneumatically and electrically. The cube assembly installation allows
the operator to set up, operate and monitor what is a fully automated process.
Fig. 4: Training system mMS 4.0
1Rack station
2Processing with
pneumatic/hydraulic press station
3High rack storage station
2
3
1

Training system mMS 4.0 | R901429162/04.16Bosch Rexroth AG 19/68
About this product
2
1
3
4
2
3
1
4
5
Control box left side - exterior
Identical for all stations.
Fig. 5: Control box left side - exterior
1Main switch of station
2Transition plug signals
and emergency stop circuit
3Connection cable 230 V AC
4Ethernet feed-through
5Maintenance unit
Control box right side - exterior
Identical for all stations.
Fig. 6: Control box right side - exterior
1Ethernet feed-through
2Connection socket 230 V AC
3Transition plug signals
and emergency stop circuit
4Compressed air feed-through

20/68 Bosch Rexroth AG Training system mMS 4.0 | R901429162/04.16
About this product
5.2.1 Rack, work piece detection station
The rack station consists of a table with lockable guide rollers and the following
function modules assembled on top of it:
2 separating racks
Conveyor belt
Sensors for materials testing
Picking unit
Machine control panel
Maintenance unit
Electrical supply with signal processing
–Main switch on left-hand side of the system
–Connector to right-hand/left-hand station
–Mains supply, fuses
–3 emergency stop relays
–Profibus coupler
Programmable logic controller XLC L25 with supplied PLC software
Two separation racks offer space for 10 work pieces each. The placement status
is monitored by microswitches. A pneumatic cylinder pushes the bottom most
workpiece in the stack onto a conveyor that runs it past four test stations.
One optical, capacitative and inductive sensor each acquires the material
properties with a pneumatic cylinder acquiring the contour. The test result
is saved in the controller. A work piece can be removed from the conveyor belt
by means of a pneumatic cylinder. At the end of the conveyor, a sensor is used
to determine that a work piece has arrived and to stop the conveyor.
Fig. 7: Rack station
1Separating racks
2Conveyor belt
3Sensors
4Profibus coupler
(behind conveyor belt)
5Picking unit
6Maintenance unit
1
2
6
3
4
5