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.

Robotics Trainings System WS502 Bosch Rexroth AG 3/64
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

4/64 Bosch Rexroth AG Robotics Trainings System WS502
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

Robotics Trainings System WS502 Bosch Rexroth AG 5/64
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

6/64 Bosch Rexroth AG Robotics Trainings System WS502
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.

Robotics Trainings System WS502 Bosch Rexroth AG 7/64
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

8/64 Bosch Rexroth AG Robotics Trainings System WS502
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.

Robotics Trainings System WS502 Bosch Rexroth AG 9/64
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

10/64 Bosch Rexroth AG Robotics Trainings System WS502
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.