Bosch WS502 User manual

Instruction manual
Robotics Trainings System
WS502
R901508696
Version: 01-01 EN

The data stated is used for the product description.
If particulars are also furnished they are only
examples and proposals. Catalogue specifications
are not warranted characteristics. The information
does not release the user from their obligation for
their own assessments and tests. Our products are
subject to natural wear and tear as well as the
ageing process.
 All rights reserved by Bosch Rexroth AG, also in
case of registration of industrial property rights. We
retain all powers of disposition such as the right to
copy and forward.
The title page shows an example of a configuration.
The delivered product may therefore differ from the
figure.

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Contents
Contents
1About this documentation ........................................................................... 6
1.1 Validity of the documentation ............................................................. 6
1.2 Required and supplementary documentation..................................... 6
1.3 Presentation of information ................................................................ 6
1.3.1Safety information .............................................................. 6
1.3.2 Symbols.............................................................................. 7
1.3.3 Abbreviations...................................................................... 8
2Safety information ...................................................................................... 8
2.1 About this chapter .............................................................................. 8
2.2 Appropriate use.................................................................................. 8
2.3 Non-intended use............................................................................... 8
2.4 Qualification of personnel................................................................... 9
2.4.1 Teaching............................................................................. 9
2.4.2 Transport, assembly, installation and commissioning....... 10
2.4.3 Troubleshooting, maintenance and repair ........................ 10
2.5 General safety information ............................................................... 10
2.6 Product and technology-specific safety information ......................... 11
2.7 Personal protection equipment......................................................... 11
2.8 Obligations of the operating organisation......................................... 12
2.9 Safeguards....................................................................................... 12
2.10 User workstations............................................................................. 14
3General information on preventing property damage and damage to product15
4Scope of supply ....................................................................................... 16
5About this Product.................................................................................... 17
5.1 General ............................................................................................ 17
5.2 General plan..................................................................................... 18
5.3 Agilus industrial robot....................................................................... 19
5.3.1 Gripper on the Agilus robot............................................... 20
5.3.2 Connections on the Agilus robot....................................... 21
5.4 Cube rack......................................................................................... 23
5.5 Cube chute....................................................................................... 24
5.6 Control cabinet ................................................................................. 25
5.6.1 Connection and controls on the control cabinet................ 26
5.7 Pneumatic maintenance unit............................................................ 28
6Technical data, Type plate........................................................................ 29
6.1 Technical data.................................................................................. 29
6.2 Identification of the WS502 training system ..................................... 30
7Operating and display elements................................................................ 31
7.1 EMERGENCY STOP button ............................................................ 31
7.2 Hand control VH2110....................................................................... 32
7.3 smartPAD hand control .................................................................... 33
7.4 Signal tower ..................................................................................... 33
8Transport and storage .............................................................................. 34
8.1 Delivery and unpacking.................................................................... 34
8.1.1 Make the gripper ready for operation................................ 34

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Contents
8.1.2 Assembling the VH2110 hand control...............................35
8.2 Transport ..........................................................................................36
8.2.1 Transport within a building ................................................36
8.2.2 Transportation between two buildings...............................36
8.3 Storage .............................................................................................37
9Assembly, installation and commissioning ................................................. 38
9.1 Assembling the WS502 training system ...........................................38
9.2 Check and connect the pneumatic supply ........................................39
9.3 Check and connect the electrical installation ....................................39
10 Operation of the training system ............................................................... 40
10.1 Switching on the training system ......................................................40
10.2 Setting the robot speed.....................................................................40
10.3 Predefined robot programs ...............................................................41
10.4 Adjustment of the zero position on the mounted mMS 4.0 ...............41
10.4.1 Correction of the horizontal and vertical zero position.......42
10.4.2 Save the new zero position...............................................42
10.5 Selecting the operating mode and program......................................43
10.6 Start the program..............................................................................43
10.7 Program stop (stop cycle).................................................................43
10.8 Stop movement.................................................................................43
10.9 Stop movement (immediate stop) .....................................................44
10.10 Perform home position run................................................................44
10.11 Move the robot in jog mode ..............................................................45
10.12 Saving the current robot position ......................................................46
10.13 Open / close gripper .........................................................................47
10.14 Restore operational readiness after gripper collision........................48
10.15 Reset the set position points to the as delivered condition ...............49
10.16 Switch off the training system ...........................................................49
11 Description of the user interface................................................................ 50
11.1 Main screen ......................................................................................50
11.2 Position data screen .........................................................................52
11.2.1 Structure of a position data record ....................................52
11.2.2 Changing a position data record .......................................53
11.3 Setup screen.....................................................................................54
11.4 Description of the coordinate system................................................55
11.5 mMS 4.0 attachment.........................................................................55
11.6 Connect the Bosch Rexroth mMS 4.0 with the WS502 training system
56
11.6.1 Modification of an existing mMS 4.0 for use with the WS502
training system..................................................................56
11.6.2 Connect the mMS 4.0 with the training system.................57
12 Help in case of faults................................................................................ 59
13 Service and inspection ............................................................................. 59
13.1 General information ..........................................................................59
13.2 Service and inspection plan..............................................................60
14 Maintenance work.................................................................................... 61
14.1 General information ..........................................................................61
14.2 Maintenance schedule......................................................................61

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Contents
14.2.1 Operating materials, auxiliary materials, tools, measuring
instruments....................................................................... 61
14.2.2 Replacing parts ................................................................ 62
15 Disposal .................................................................................................. 62
16 EC – Declaration of Conformity ................................................................. 63

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About this documentation
1About this documentation
1.1 Validity of the documentation
This document describes the “Trainings System Robotics WS502 ”.
For the sake of simplification, in the further course of the operating instructions
the term "WS502 training system” is used.
This documentation is aimed at fitters, operators, service engineers and plant
operators.
This documentation contains important information on how to safely and properly
assemble and transport the product along with how to put it into operation, use it,
maintain it, dismantle it and how to correct simple faults.
Read this documentation in its entirety and in particular the "Safety
Information" chapter before you work with the product.
1.2 Required and supplementary documentation
In addition to these operating instructions for the (ready-to-use) WS502 training
system the following additional documentation is also available:
•“Teachware" teacher and student manuals and software
–contains exercises in accordance with the recommendations
–Educational and information books on the topic of "robotics".
1.3 Presentation of information
To help you use this documentation to be able to quickly and safely use your
product, uniform safety information, symbols, terminology and abbreviations are
used. To improve understanding they are explained in the following sections.
1.3.1 Safety information
This documentation includes safety information before taking a sequence of
actions that involve the risk of personal injury or property damage. The described
measures for averting danger must be adhered to.

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About this documentation
Safety information are structured as follows:
•Warning symbol: Points out the hazard
•Signal word: Indicates the severity of the hazard
•Type and source of the hazard: Identifies the type and source of the hazard
•Consequences: Describes the consequences of non-compliance
•Protection: States how you can avoid the hazard
Warning symbol, signal
word
Meaning
HAZARD
Indicates a hazardous situation which will result in death or
serious bodily injury if it is not avoided.
WARNING
Indicates a hazardous situation which could result in bodily
injuries if it is not avoided.
CAUTION
Indicates a hazardous situation which could result in minor
or moderate bodily injuries if it is not avoided.
NOTE
Indicates property damage: The product or the
environment can be damaged/harmed.
Tabelle 1: Hazard classes according to ANSI Z535.6-2006
1.3.2 Symbols
The following symbols indicate instructions that are not safety-relevant but which
enhance the clarity of the documentation.
Symbol
Meaning
If this information is not observed, the product cannot be
optimally used or operated.

Individual, independent process steps
1.
2.
3.
Numbered job instruction:
The digits indicate that the process steps follow one
another.
Tabelle 2: Meaning of the symbols
SIGNAL WORD
Type and source of the hazard
Consequences of non-compliance
Measures for averting danger

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Safety information
1.3.3 Abbreviations
This documentation uses the following abbreviations:
Abbreviation
Meaning
Agilus 6-axis Agilus industrial robot, type KR Sixx, Manufacturer: KUKA
Roboter GmbH
WS502 training
system
Robotics training system with WS502 robot
Tabelle 3: Abbreviations
2Safety information
2.1 About this chapter
The product was manufactured in accordance with the generally recognized rules
of technology. However there remains the danger of personal injury and property
damage if you do not adhere to the safety information in this documentation.
Read this documentation thoroughly and in its entirety before you work with
the product.
Keep the documentation so that it is user-accessible at all times for all users.
Always pass the product on to third parties together with the required
documentation.
2.2 Appropriate use
The WS502 training system is a mechanical and electrical system.
It may only be used to impart the technical training and development knowledge
and skills in the sector of robotics as well as to control and feedback control
systems technology.
For the development of complete systems and simulations use only devices and
sets approved for the WS502 training system.
Operation is only permitted under the operating conditions stated in chapter 5.
The product is intended for professional use only and not for private use.
Proper use also includes that this documentation and in particular the "Safety
Information" chapter have fully read and understood.
2.3 Non-intended use
Any use other than the use described in intended use is not proper and therefore
impermissible.
If unsuitable products are installed or used in safety-relevant applications,
unintentional operating states can occur in the application which can cause
injuries/damage to persons and/or property. For that reason use a product in
safety-relevant applications only if such use is expressly stated and allowed in the
documentation of the product. For example in explosion-protection areas or in
safety-related parts of a control system (functional safety).
Bosch Rexroth AG assumes no liability for damage in the event of improper use.
The risks associated with non-intended use are the sole responsibility of the user.

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Safety information
Non-intended use of the product includes, in particular, that
•the WS502 training system is used playfully and not properly during the
practical exercises or is used outside of the training session,
•the components are used in a different training system,
•devices or sets are used that are not approved for the WS502 training system,
•pneumatic pressure circuits are merged,
•the WS502 training system is operated with (even partially) deactivated or non-
functional safeguards
•The WS502 training system is operated despite identified defects.
2.4 Qualification of personnel
2.4.1 Teaching
Apprentices and trainees may work on the WS502 training system only
•under the direct supervision and
•with the appropriate instruction
of an instructor or by trained personnel.
The instructors for the WS502 training system must be trained specialists who are
qualified in the field of mechatronics and robotics.
The instructor must
•give clear instructions if apprentices or participants work on the WS502 training
system,
•check the installation and functional impacts of the control circuit for safe
operation,
•answer questions clearly and understandably.
Trained staff can also be used for the supervision of the WS502 training system
during the exercises.
These are qualified persons who have been taught and instructed on:
•instructed tasks,
•possible hazards in the event of improper use,
•safeguards and protective measures.
Instructors
Trained staff

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Safety information
2.4.2 Transport, assembly, installation and commissioning
Work on the WS502 training system such as assembly, connection, maintenance
and repair shall only be performed by authorised specialised personnel or
persons with sufficient skills and authorization.
Persons charged with working on the WS502 training system must be capable of
understanding the information in this documentation as well as independently
performing any details necessary due a possible lack of information based on
their own professional qualifications.
2.4.3 Troubleshooting, maintenance and repair
Maintenance, repair, troubleshooting and breakdown maintenance require special
knowledge and may only be carried out by a qualified specialist!
•Only a qualified electrician is allowed to work on the electrical equipment.
A qualified electrician is a person who, based on his technical training and
experience as well as his knowledge of the relevant provisions is able to
assess, recognize possible dangers, and take suitable safety measures for the
work assigned.
•Only qualified personnel with special knowledge and experience are permitted
to work with the pneumatics. Special knowledge in pneumatics means that the
personnel must
–be capable of reading and completely understanding pneumatic control circuit
diagrams,
–completely comprehend in particular the correlations of the built in safeguards
and
–have knowledge of the function and construction of pneumatic components.
2.5 General safety information
•Observe the valid regulations for the prevention of accidents and on the
protection of the environment.
•Observe the safety rules and regulations of the country in which the product is
used/is applied.
•Use Rexroth products only in technically perfect condition.
•Comply with the instructions on the product.
•Persons who install, operate, disassemble or maintain Rexroth products must
not be under the influence of alcohol, other drugs or medication which could
influence responsiveness.
•Use only manufacturer-approved accessories and spare parts to exclude
personal injury hazards due to unsuitable replacement parts.
•Adhere to the technical data and environmental conditions stated in the product
documentation.
•If unsuitable products are installed or used in safety-relevant applications,
unintended operating states can occur in the application which can cause
injuries/damage to persons and/or property. For that reason use a product in
safety-relevant applications only if such use is expressly stated and allowed in
the documentation of the product.
•You may start using the product only after it has been established that the end
product (for example, a machine or plant) in which the Rexroth products are
installed meets the country-specific regulations, safety regulations and
standards of the application.

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Safety information
2.6 Product and technology-specific safety information
2.7 Personal protection equipment
The personal protective equipment for users of the WS502 training system
consists of:
•Safety footwear during the entire teaching activity
All constituent parts of the personal protective equipment must be intact.
WARNING
High electrical voltage!
Risk of death or injury due to electric shock or serious injury!
Always deenergize the WS502 training system before you do any electrical
work.
Secure the plant/system from reconnection.
Operate the WS502 training system only in a network with a functional RCD
protective conductor or a protective ground.
Manipulated and/or non-functional safeguards and protection equipment!
Risk of serious injury!
Immediately stop the system!
The fault or manipulation must be immediately repaired by specialists.
Danger caused by incorrect assembly and installation!
Risk of serious injury in subsequent operation!

Installation work and commissioning may only be performed by employees of
Bosch Rexroth or instructed trained specialists. This also applies to
restarting after repair work.
Have maintenance work performed by qualified personnel only.

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Safety information
2.8 Obligations of the operating organisation
The operating organisation must ensure the necessary conditions for the
assembly and the installation of the WS502 training system
•Ensures safe assembly of the WS502 training system by its staff and/or
persons it has authorised; in this respect it makes sure above all that the
undersurface
–has a sufficient load capacity and
–is flat and horizontal;
•Ensures that the accident prevention regulations (German: UVV), the safety
regulations of the professional associations as well as other in-company, local
conditions are adhered to.
It teaches its employees and/or those commissioned by third parties about the
potential hazards at the installation site.
The operating organisation must provide sufficient lighting in the installation area
of the training system.
It must regularly instruct its staff on the following topics:
•Compliance with and use of the operating instructions;
•Compliance with the legal provisions;
•Intended use of the WS502 training system;
•Observance of the instructions by works security and the operating instructions
of the operating organisation;
•Behaviour in case of emergency.
2.9 Safeguards
For the protection of persons the WS502 training system is equipped with the
following safeguards:
•3 EMERGENCY-STOP buttons on the cell
•1 EMERGENCY-STOP button on the VH2110 hand control
•1 EMERGENCY STOP button on the KUKA smartPAD (if the smartPAD is
connected to the training system)
•2 EMERGENCY-STOP switches on the safety doors of the cell
•EMERGENCY-STOP circuit to connected Bosch Rexroth expansion modules
•Guard on the cell
The stated equipment is described in detail below.
On the front and on the left and right side of the WS502 training system there is
an EMERGENCY-STOP button that must be easy to reach.
The EMERGENCY-STOP button must be pressed in order to prevent hazards to
persons or the WS502 training system.
The actuation of the EMERGENCY-STOP button puts the robot in Safe Torque
off, i.e it goes into safely reduced torque and brakes the motors/drives; the
WS502 training system is stopped. The control cabinet is still supplied with power.
The actuation of the EMERGENCY STOP button also activates the
EMERGENCY STOP on all Bosch Rexroth expansion modules (e.g. mMS 4.0)
that are connected to the WS502 training system.
EMERGENCY STOP button

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Safety information
There are two protective doors on the front of the WS502 training system. These
are provided with EMERGENCY-STOP door switches, which safely shut down
the system as soon as a door is opened.
There is a sliding door on the rear of the WS502 training system. It is provided
with EMERGENCY-STOP door switches which safely shut down the system as
soon as the sliding door is opened.
When operating the WS502 training system without a Bosch Rexroth expansion
module the sliding door must be closed.
If the WS502 training system is operated together with a Bosch Rexroth
expansion module, open the left sliding door (viewed from the rear) and mount
the expansion module to the rear of the WS502 training system. The existing
EMERGENCY-STOP door switch is then actuated by the mounted expansion
module.
The training system must only be operated with a maximum pneumatic operating
pressure of 5-6 bar. The pressure of the system is adjustable.
The WS502 training system is equipped with a guard (Makrolon panes) which
prevents contact of persons in the hazardous area of the system.
EMERGENCY-STOP switches on the
doors
Pneumatic pressure control
Guard
WARNING
Danger due to missing or incomplete guards!
Risk of injury when operating the WS502 training system with missing or
incorrectly installed pane elements!
In case of missing or incorrectly installed pane elements, immediately take
the WS502 training system out of service!
Install the protective panes supplied with the WS502 training system
correctly.

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Safety information
2.10 User workstations
Provide the following space for the WS502 training system to teach and learn the
procedures on the WS502 training system:
Abb. 1: WS502 training system space requirements
The following teaching stations are provided depending on the usage of the
WS502 training system:
Process step
Number of persons
Setup 3
Operation 2
Tabelle 4: Teaching stations in an WS502 training system
During setup, a maximum of three people are allowed to work simultaneously on
one WS502 training system. When operating, a maximum of two people plus the
instructor are allowed to perform work.
Teaching stations

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General information on preventing property damage and damage to product
3General information on preventing property
damage and damage to product
NOTE
The system stands under pressure and tension!
Property damage!
Do not loosen/remove any connected lines, connections and components
while there is pressure in the system.
Do not loosen/remove any plug connectors as long as the system is
energized.
Switch the system off on the main switch.
The robot controller is equipped with an uninterruptible power supply. Voltage
can still be present here approximately 5 minutes after switching off.
Incorrect setting of pressure relief valves and pressure switches of pneumatic
components!
Property damage!
Operate the pneumatic components only with the recommended pressure
values.
Hazards for the electrical equipment due to high electrical currents!
Property damage!
Ensure the provision of an overcurrent protector.
Secure the power socket by pulling the mains plug.

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Scope of supply
4Scope of supply
The WS502 training system is supplied packed as a turnkey system.
It stands on a sub-pallet and is held taut with non-metallic straps. It is packed in a
foil and stands in a wooden crate which is closed on the front by a cover. The
cover is fastened with nails or screws.
Designation
Unit
Value
Dimensions Length mm 1580
Width mm 940
Height mm 2200
Tabelle 5: Dimension of the wooden crate
1
5
4
2
3
Abb. 2: Crate with marking
The following details are provided: on the crate:
1Transport instructions or warnings
as needed
2Shipping number/barcode
3Delivery note in plastic bag
4Label: gross/if applicable net
weight
5Label: packaging in accordance
with the IPPC Standard
Dimensions of the wooden crate

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About this Product
The scope of delivery of the WS502 training system includes:
•1 WS502 training system with Agilus industrial robot, mounted
function modules and control cabinet, stationary
•1 Hand control Rexroth VH2110 with connecting cable
•1 KUKA smartPAD with connecting cable
•1 connecting cable for the connection of expansion modules (e.g. Bosch
Rexroth mMS 4.0)
•2 EMERGENCY STOP jumper plugs to operate the system without
attachments
(mounted)
•1 Operating instructions (DE, EN, ES)
•1 Circuit diagram (DE, EN, ES)
•3 Mechanical expansion modules for attachments:
–1 Actuator assembly for the door switch (for mounting on the Bosch Rexroth
mMS 4.0)
–2 Mounting bracket for fastening the attachment
•3 Cube demo objects
5About this Product
5.1 General
The following sections of these operating instructions show examples of
a variant of the WS502 training system and its components.
There are a multitude of attachment units and sets available for the WS502
training system. These components make the WS502 training system a complete,
customized and practice-oriented training and developmental education system.
Scope of supply

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About this Product
5.2 General plan
The WS502 training system consists of an aluminium profile frame with Makrolon
panes, adjustable mounts for fixed assembly, a KUKA Agilus robot, hand control,
control cabinet.
Abb. 3: Agilus training system
1EMERGENCY STOP, door switch,
no-contact
2Signal tower
3Aluminium profile frame with
protective doors and Makrolon
panes
4Agilus robot
5EMERGENCY STOP button
6Control cabinet
7KUKA robot controller
8Adjustable machine mounts for
fixed assembly
9Controls and connectors on the
control cabinet
10 Cube chute (concealed)
11 EMERGENCY STOP button
12 Cube racks with light barriers
13 Hand control VH2110 with bracket
3
4
5
6
7
9
11
12
8
13
2
1
8
10

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About this Product
5.3 Agilus industrial robot
The Agilus Sixx is an industrial robot with six axes.
The robot is equipped with a pneumatic gripper with an occupied control which is
protected against damage by a collision coupling system.
Abb. 4: KR6R700 Agilus Sixx
NOTE
Agilus robot system manufacturer documentation
You can find information about the Agilus robot system in the manufacturer
documentation.

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About this Product
5.3.1 Gripper on the Agilus robot
The Agilus robot is equipped with a pneumatic gripper with sensory occupied
control. The pneumatic triggering of the gripper is made through the internal
Agilus pneumatic functions.
If a cube is picked up with the gripper, the occupied control sensor detects the
object. The gripper assignment is displayed on the hand control.
A mechanical coupling system with sensory position monitoring prevents the
gripper from being damaged in case of accidental collisions.
In the event of a collision, the collision clutch yields and releases out of the
coupling mount. The collision is detected by a position sensor and the system is
stopped. The signal tower flashes red and a message is displayed on the hand
control.
Abb. 5: Gripper Agilus robot
1Sensor for "Collision clutch
engaged” signal
2Collision clutch
3Coupling mount with 4 spring-
loaded ball tensioners
4Pneumatic gripper with open/close
connections
5Gripper jaws
6Light sensor for "Gripper occupied”
signal
Pneumatics
Occupied control
Collision avoidance
5
5
4
1
6
1
3
2