Rexroth Robotics Planning Manual 2.: Scara SR4/6/8plus, Turbo AR6/8

Industrial Electric Drives Linear Motion and Service Mobile
Hydraulics and Controls Assembly Technologies Pneumatics Automation Hydraulics
Rexroth Robotics
Version
2.0
Planning Manual
turboscara SR4/6/8plus, turbo AR6/8

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1.1 Overview ......................................................................................................................... 5
1.2 System overview ............................................................................................................. 6
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4.1 Variants ......................................................................................................................... 12
4.1.1 SR4/6/8plus standard version ....................................................................................... 12
4.2 Working area and dimensions ...................................................................................... 14
4.2.1 SR4plus with stand ....................................................................................................... 14
4.2.2 SR4plus with console .................................................................................................... 15
4.2.3 SR6plus with stand ...................................................................................................... 16
4.2.4 SR6plus with console .................................................................................................... 17
4.2.5 SR8plus with stand ...................................................................................................... 18
4.2.6 SR8plus with console ................................................................................................... 19
4.2.7 SR6/8 dustproof (SR-DP) ............................................................................................. 20
4.2.8 SR6/8 cleanroom (SR-CL) ............................................................................................ 20
4.2.9 Base plate .................................................................................................................... 21
4.2.10 Console ........................................................................................................................ 22
4.2.11 Gripper flange .............................................................................................................. 23
4.2.12 User interface ............................................................................................................... 24
4.2.13 User installation ............................................................................................................ 28
4.2.14 Driveless teaching ......................................................................................................... 29
4.2.15 Tool Connector ............................................................................................................. 30
4.3 Mounting of auxiliary equipment .................................................................................. 34
4.4 Technical data of the swivel-arm robots .................................................................. 36
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5.1 Variants ......................................................................................................................... 39
5.1.1 AR6/8 standard type ..................................................................................................... 39
5.2 Working area and dimensions....................................................................................... 39
5.2.1 Working area AR6 ........................................................................................................ 40
5.2.2 Working area AR8 ........................................................................................................ 42
5.2.3 Base plate ..................................................................................................................... 44
5.2.4 Gripper flange .............................................................................................................. 45
5.2.5 Electrical and pneumatic interfaces .............................................................................. 46
5.3 Technical Data of the Articulated Robots ..................................................................... 52
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6.1 Controller rho4 ............................................................................................................. 58
6.1.1 rho4.0 ............................................................................................................................ 58
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6.1.2 rho4.1 ........................................................................................................................... 60

6.2 Power supply and safety module EVS201 ................................................................... 63
6.3 Drive amplifier .............................................................................................................. 65
6.3.1 Drive amplifier AV201 for SR4/6/8plus ......................................................................... 65
6.3.2 Drive amplifier AV206 for turbo AR6/8 .......................................................................... 65
6.4 Technical data of the controller .................................................................................... 66
6.4.1 Arrangement of the components ................................................................................. 68
6.5 Control cabinet ............................................................................................................. 69
6.6 Operating block ............................................................................................................ 70
6.7 Field bus connection .................................................................................................... 71
6.8 I/O extension ................................................................................................................ 72
6.8.1 CANopen ...................................................................................................................... 74
6.8.2 PROFIBUS-DP ............................................................................................................ 77
6.8.3 I/O-Gateway ................................................................................................................. 80
6.9 PHG2000 hand-held programming device ................................................................... 81
6.10 Programming environments ......................................................................................... 82
6.10.1 easyrobot Suite (standard delivery) .............................................................................. 82
6.10.2 BAPSplus (option) ........................................................................................................ 84
6.11 Software tools .............................................................................................................. 85
6.11.1 OPC-Server4 (standard delivery).................................................................................. 85
6.11.2 WinSPS (option) ........................................................................................................... 85
6.11.3 WinDP/ WinCAN (option) .............................................................................................. 85
6.11.4 GateWay ....................................................................................................................... 85
6.12 robotvision .................................................................................................................... 87
6.12.1 Functions of robotvision ................................................................................................ 87
6.12.2 Characteristics and performance of robotvision ........................................................... 88
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7.1 Cycle time of swivel-arm robots .................................................................................... 89
7.2 easyrobot Suite ............................................................................................................ 91
7.3 Simulation with COSIMIR ............................................................................................. 92
7.4 3D-CAD......................................................................................................................... 92
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8.1 Load capacity................................................................................................................ 93
8.2 Mass moment of inertia................................................................................................. 93
8.3 Reaction forces ............................................................................................................. 93
8.4 Permissible load at the gripper flange .......................................................................... 94
8.5 Working area ................................................................................................................ 95
8.5.1 Planning sheet SR4plus with stand ............................................................................. 96
8.5.2 Planning sheet SR4plus with console .......................................................................... 97
8.5.3 Planning sheet SR6plus with stand ............................................................................. 98
8.5.4 Planning sheet SR6plus with console .......................................................................... 99
8.5.5 Planning sheet SR8plus with stand ........................................................................... 100
8.5.6 Planning sheet SR8plus with console ........................................................................ 101
8.6 Ambient conditions ..................................................................................................... 102
8.7 Other limits ................................................................................................................. 103
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9.1 Load capacity .............................................................................................................. 105
9.2 Mass moment of inertia ............................................................................................... 105
9.3 Permitted load at the gripper flange .......................................................................... 106
9.4 Working area ............................................................................................................... 107
9.4.1 Room requirements..................................................................................................... 107
9.4.2 Planning sheet AR6, side view ................................................................................... 108
9.4.3 Planning sheet AR6, top view .................................................................................... 109
9.4.4 Planning sheet AR8, side view ................................................................................... 110
9.4.5 Planning sheet AR8, top view ................................................................................... 111
9.5 Ambient conditions ..................................................................................................... 112
9.6 Other limits ................................................................................................................. 113
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12.1 Sales partners ............................................................................................................. 125
12.2 Technical support ........................................................................................................ 125
12.3 Training ...................................................................................................................... 126
12.3.1 Brief explanation of the courses ................................................................................. 127
12.4 Customer hotline ......................................................................................................... 129
12.5 Further components of the Bosch Rexroth program ................................................... 129
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- SR4/6/8plus
- SR6/8 dustproof, cleanroom
- AR6/8
3+* 3HULSKHUDOV
Online programming -SR CAN module in robot
Operation 8 digital inputs
Diagnostics 8 digital outputs
Setting the machine 4 analog inputs
parameters (MPP) up to 13 ASi slaves
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7RXFKVFUHHQ -remote I/O
TCP/IP
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- sensors
Offline programming - actuators
Online programming - I/O modules
Operation PCL programming e. g. B~IO module with 16I/16O
Diagnostics Operation ASi gateway(s)
Diagnostics
Setting the machine parameters (MP tool)
External picture processing
OPC server
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The turboVFDUD SR4/6/8plus robot systems consist of a four-axis swivel arm

mechanics, the turbo AR6/8 robot systems consist of a six-axis articulated mecha-
nical system and the IQ200 control with the control core rho4, the drive amplifier
and the power supply and safety module.
For the use of a robot, in addition to the control block, the programming manual
device (PHG2000), a control panel (e.g. Touchscreen) or any PC can be used.
For the programming, an external PC or in the IPC variant, the rho4.1 are conve-
nient possibilities. Data or programs are exchanged via the serial interface or the
internet protocol TCP/IP.
The PHG is used mainly for the teaching of the robot and for fault diagnosis. Robot
programs can also be modified and edited via the PHG2000.
The field bus (CAN, Profibus, Interbus) enables to control decentralized input and
output modules or other peripherals and therefore actuators and sensors.
Make use of the following advantages for your application:
• The UREXVWURERWPHFKDQLFV with KLJKHUORDGDQGPRPHQWRILQHUWLD is
predetermined for mounting tasks and rapid Pick-&-Place movements.
• 0LQLPXPF\FOHWLPH at high precision ensure high productivity.
• A ODUJHZRUNVSDFHGLIIHUHQWVWURNHV and DEVROXWHHQFRGHUV ensure high
flexibility in the integration.
• 'HILQHGPHFKDQLFDODQGHOHFWULFDOLQWHUIDFHV reduce the work for the appli-
cation.
• ,QWHJUDWHGXVHULQVWDOODWLRQ, optional up to the gripper for the connection of a
Tool Connector, simplifies the gripper installation.
• 7KH3&EDVHGFRQWUROLQDFRPSDFWDQG,3&YDULDQW offers safe movement
control and large, easy communication possibilities.
• 6HULDOO\LQWHJUDWHGVDIHW\WHFKQLFV (safety class III according to EN954)
makes it possible to operate the robot safety and comfortably for teaching,
setup and test mode. Its benefits are: Fast and well arranged processes with
highest personal safety. Teaching a robot with opened guard doors is possible
with highest personal safety.
• Additional SRZHUVXSSO\ options are 400 V A.C., 480 V A.C. or
115 V A.C. instead of 230 V A.C., a XVHUSRZHUXQLW (24 V) is included as
standard.
• The SURJUDPPLQJODQJXDJH%$36 is similar to PASCAL and can be rapidly
learnt to enable the creation of clear programs via the HDV\URERW
SURJUDPPLQJ6XLWH. The JUDSKLFDOSURJUDPPLQJHQYLURQPHQW BAPSplus is
also available.
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• Extension through FRPSDFWDQGIOH[LEOHLQSXWRXWSXWPRGXOHV:

B~IO modules or decentralised CAN-I/O modules (depending on the
application).
Round the turboscara SR4/6/8plus and turbo AR6/8 robot systems, we have a
large range of services, at Bosch Rexroth as well as at our sales partners in your
vicinity:
• Comprehensive hotline service for all of your questions concerning the robots
• Feasibility studies
• Practical training of your employees in our training center
• Fast on-site service from Bosch Rexroth's customer service department or one
of our contract partners
Up-to-date information and downloads in internet under:
ZZZERVFKUH[URWKGHURERWHU or ZZZERVFKUH[URWKFRPURERWV.
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You can find further information about ’Safety regulations’ on the documentation
CD, order No. 3842 524 619, or in Internet under:
http://www.boschrexroth.de/roboter or http://www.boschrexroth.com/robots.
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The planning manual has been prepared with great care. However with the today’s
technical standard, it cannot be guaranteed that the contents of this version are
absolutely topical.
You can find further information on the documentation CD,
order No. 3842 524 619, or in Internet under:
7KHSODQQLQJPDQXDOLVVXEMHFWWRPRGLILFDWLRQVDQGFRUUHFWLRQV
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For the configuration of a robot system and the choice of accessories, you can use
the order sheets in chapter 11. They contain all standard components and the
corresponding options and accessories.
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The planning manual is copyrighted. All rights are reserved.

The planning manual may not be copied, reproduced or translated neither
completely nor in parts or transferred on another medium without the authorization
of Bosch Rexroth AG.
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The Rexroth turboVFDUDSR4/6/8plus replace the Bosch turboVFDUDSR4/6/8
systems. Decisive improvements in mechanics and control make the integration in
systems easier and their use safer and easier. The possibilities of use are also
improved:
• 0DLQWHQDQFHIUHHDEVROXWHHQFRGHUV\VWHPVare standard equipment for all
three product sizes. A referencing is not necessary. This enables to realize
more compact cells and arrange process stations in the robot workspace more
freely.
• 7KHLQVWDOODWLRQWHFKQLFVLQ$UPis accessible for all systems more easily.
The ASi bus available as an option at the Tool Connector is suited above all for
applications with rapid gripper change.
• The EXWWRQIRUGULYHOHVVWHDFKLQJis standard for all robots. This enables to
shift the lift- turn spindle manually.
The AR6 and AR8 articulated robots from Bosch Rexroth expand the robot
technology by two degrees of freedom. This allows the robot tool to take any
orientation in the working area. The slim and modern mechanical system as well
as table and ceiling mounting characterize the robots. Further features are:
• User-friendly installation technology through the LQWHJUDWHG65&$1PRGXOH
LQWKHURERWEDVH with electric and pneumatic I/Os as well as an electronic
name plate.
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Following features apply to both robot systems:

• The robots are delivered with the FRPSDFWFRQWUROUKR as a standard. It
contains all robot specific functions, the SoftSPS and the optional field bus
extensions. The rho4.1 control - now with 128 MB for faster performance of
windows applications - is still available.
• Both robot systems have been extended by the inclusion of 23&VHUYHU as a
standard.
• (96, the new power supply and safety module is standard for all „plus“-
systems. The FOHDUVHSDUDWLRQRIWKHHPHUJHQF\VWRSFLUFXLW enables to
integrate the EVS201 very easily into higher safety systems, and makes also all
required safety functions and interfaces available for the use of the IQ200 as
cell control according to the safety class III. For the automatic and manual
operations, there are now 4 operating modes through an additional key switch
for maximum and reduced power.
• The comfortable SURJUDPPLQJHQYLURQPHQWHDV\URERW6XLWHensures easy
implementation.
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• The new %UDQGQDPH5H[URWKfollows the united manufacturing strategy for

products of the Bosch Rexroth AG (100% subsdiary of Robert Bosch GmbH).
Behind this name, the same team works in development, production, sales and
service of the robots. Our efforts are turned to the constant improvement of the
system in functionality and quality.
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Fixture Stand Stand Stand

length 500 mm length 500 mm length 500 mm
Stroke 200 mm 200 mm 200 mm
(sleeve) (Ø 20 mm) (Ø 20 mm) (Ø 20 mm)
Connection cable plugged 2 m connection cable 2 m connection cable
continous continous
User installation User installation in User installation in User installation in
installation area on installation area on installation area on
arm 2 arm 2 arm 2
Bellows without
Control cabinet 19“-rack
Control IQ200 standard version with rho4.0
optional with rho4.1
Protection type/ IP54
environment optional:
IP65: SR6/8 DP (with incremental encoders) for severe conditions
IP65: SR6/8 CL (with incremental encoders) for areas where cleanromm con-
ditions are required. Clean air class 1 according to US Federal Standard
209E.
Optional versions, see following chapters.
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User installation (AWI)
Bellows (FB)
Connection
Sleeve cable
Stroke Console
Stand
Connection cable
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You can find further information about dimensions in the product documentation
’SR4/6/8plus’, Order No. 3842 524 619, and on the CAD drawings, which you can
download in internet under:
http://www.boschrexroth.de/roboter or http://www.boschrexroth.com/robots
65SOXVZLWKVWDQG
537
R400
50 452
R230
R139
143°
R170 105°
AWI
horizontal
Stand length S Standard 500
optional
250 to 700
Stroke axis 3 H 200
650
Sleeve-Ø 20 I
P
Standard Sleeve length P 471
Flange height F 87,5
With bellows (FB) Sleeve length P 555
Flange height F 48,5 F
With horizontal User I 550 A3 H
user installation installation
(AWI) height
With horizontal User I 589 S
user installation installation forbidden area
(AWI) and bellows height stand (r=78,5)
(FB)
30
All data in [mm]

230 170
A1 A2 A4
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R400
4360
452
R230
R139
143°
R170 105°
AWI
horizontal
Stroke axis 3 H 200
Sleeve-Ø 20
Standard Sleeve length P 471
Flange height F 91,5
550
With bellows (FB) Sleeve length P 555

Flange height F 139,5 I
P
With horizontal User I 550
(AWI) height
With horizontal User I 589 F
(AWI) and bellows height
(FB) A3
H
All data in [mm]

246 230 170
A1 A2 A4
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830,0
652
87,1
179
R166
150°
R270
R330
R600
140°
Stand length S Standard 500 AWI vertical

optional 250 to 700
Stroke axis 3 H 200 200 400
Sleeve-Ø 20 25 25
Standard Sleeve P 471 471 671
580
length I
Flange F 50 50 50
heihgt P
With bellows Sleeve P 555 555 805
(FB) length
Flange F 11 11 -14
heihgt F
A3 H
With vertical User I 620 620 861
(AWI) height
With horizontal User I 591 581 775 S forbidden
user installation installation area
(AWI) height stand
(R=78,5)
30

(AWI) and height 330 270
bellows (FB) A1 A2 A4
With horizontal User I 630 620 840
(AWI) and height
bellows (FB)
All data in [mm]

on call: axis 3 also with stroke up to 600 mm
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5073,1
898
179
R166
150°
R270
R330
140° R600

Sleeve-Ø 20 25 25
length
580
Flange F 148 148 148

height I
(FB) length P
Flange F 187 187 212
height F
246
A3 H
(AWI) height
(AWI) height
(AWI) and height
bellows (FB)
330 270
user installation installation A1 A2 A4
(AWI) and height
bellows (FB)
All data in [mm]
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526,3
852
114,7
R183 187
155°
R370
R430
R800
140°
Stand length S Standard 500

optional 250 to 700
Sleeve-Ø 20 25 25
615
length I
Flange F 60 60 60 P
height
(FB) length
Flange F 21 21 -4
F
height A3 H
(AWI) height S forbidden area
With horizontal User I 604 594 788 stand
user installation installation (r=78,5)
(AWI) height
30
user installation installation 430 370

(AWI) and height
bellows (FB) A1 A2 A4
(AWI) and height
bellows (FB)
All data in [mm]

on call: axis 3 also with stroke up to 600 mm
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1813,7
1098
187
R183
155°
R370
R430
R800
140°

Sleeve-Ø 20 25 25
length
615
Flange F 148 148 148

height I
With bellows Sleeve P 555 555 805 P
(FB) length
Flange F 187 187 212
height F
A3 H
(AWI) height
(AWI) height
(AWI) and height
bellows (FB) 430 370
user installation installation A1 A2 A4
(AWI) and height
bellows (FB)
All data in [mm]
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65GXVWSURRI is for use in especially severe conditions. This robot is

completely sealed and uses the full scope of the robot family performance
characteristics in dusty or wet work areas. Protection type is IP 65.
This variant is only available with incremental encoders. For details concerning
these components, see the product documentation in internet.
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65FOHDQURRP65&/
For the use in the cleanroom, robotic65 FOHDQURRP is available. The

independent institute IPA has certified the robots up to clean air class 10 according
to US Federal Standard 209E. The clean air class 1 is reached with additional
suction. All rotating parts and drive elements of the SR6 and SR8 cleanroom are
completely encapsulated. The electrical and pneumatic cables are laid through the
sleeve to the gripper. The sleeve itself is encapsulated with special, tested bellows.
This variant is only available with incremental encoders. For details concerning
these components, see the product documentation in internet.
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The standard’s base plate is fastened by M12 bolts.
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The robots can be mounted on the wall or at a pillar. In this case a console replaces
the stand.
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The gripper flange is mounted on the sleeve and serves as a mount for a Tool
Connectors and/or other various gripper tools.
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As a standard the following is included on arm 2:

• two connections for pneumatics LW4 Sleeve 25 - 6 AD LW4
Sleeve 20 - 4 AD LW2
• connections for 8 digital inputs and outputs
• connections for 4 analog inputs
• ASi-Bus (optional, if SRCAN/ASi is ordered)
(OHFWULFDOLQWHUIDFHV
External/internal
ASi supply
Following interfaces are provided:

• 8 inputs
• 8 outputs
• 4 analog inputs
• 24 V D.C. (2 A)
• ASi bus, 4 slaves (16 I/O) without external power supply,
13 slaves (corresponds to 52 I/O) with external power supply
including LED’s for error diagnosis
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1 ASi-
2 ASi+
3 A0
4 A1
5 A2
6 A3
7 A4
8 A5
9 A6
10 A7
11 +24 V D.C.
12 0V
13 ASi bridge
remove bridge if Asi power supply is external
14
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14 E0
13 E1
12 E2
11 E3
10 E4
9 E5
8 E6
7 E7
6 Analog E3
5 Analog Ground PE
4 Analog E2
3 Analog E1
2 Analog Ground PE
1 Analog E0
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active internal ASi power supply active
JP1, JP2
not active external ASi power supplyl
/('GLVSOD\ 0HDQLQJ
LED1
green logic voltage supply is ok

red overload sensor supply
LED2
green on-load voltage is ok

red overload outputs
LED3
red module in EXVE))state

red flashing invalid Node-ID
red fast flashing module in HUURUSDVVLYHstate
green module in RSHUDWLRQDOstate
green flashing module in SUHRSHUDWLRQDOstate
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Through the ’User installation’, these connections will be installed clean and closed
directly up to the gripper flange (not for 600 mm stroke).
The connection of sensors and the supply of vacuum or compressed air is ensured
at the place where it is typically required.
horizontal vertical
/HQJWK,VHHWDEOHVLQFKDSWHUHWVHTT
The connections are provided with sockets of type molex 2.50 mm SPOX (2 x 8-
pin, order no. 22-01-1084 and 1 x 4-pin, order no. 22-01-1044).
At the 25-mm sleeve the two pneumatic lines LW2 are extended to two pneumatic
lines LW4.
In case of restricted height the variant with horizontally offgoing, corrugated cable
duct (so-called horizontal user installation) is available.
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With the SR6/8plus the new horizontal user installation is available. In the delivery
status it juts out on the left side beyond the arm (values, see table). A change over
to the right side is possible.
B B B
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200 B 150 175 -
400 B - 165 200
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With this option it is possible to bring the robot flange into the desired position and
release the brakes of the axes 3 and 4 directly on the robot with switches. This can
move the robot out of an area or teach points without the drive. The controller must
be on in order to activate the brakes.
button
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The Tool Connector (TC) has user I/Os and up to four 5/2 directional control
compressed air valves directly on the gripper flange. The cables/lines are
completely integrated into the robot. The TC enables ultra-short cycle times via the
short supply line between the valves and the gripper. It also enables a simple and
fast application and start-up via the clear installation procedure.
The TC has 5 inputs and 8 outputs. The user
installation guides the 8 inputs and 8 outputs through
the turboscara’s sleeve down to the TC. 5 inputs and 8
outputs are connected directly to the TC. The 3
additional inputs are available on a separate plug.
The mounting of the Rexroth gripper PPG11/21/31 is
achieved very quickly with intermediate flanges. Valve
sets with 4 valves each - electrical (impulse) - are not
included in the delivery scope of the Tool Connector
and must be ordered separately.
Order number:
• Tool Connector: 3 842 521 300
• 5/2 Valves (double solenoid): 3 842 521 297
7HFKQLFDOGDWD
Housing dimensions 94×127×80 mm

Interference cicle diameter 155 mm
Weight 0,85 kg
Power supply 24 V, 0 V, PE
Max. current 2A
Protection type IP54
Outputs 8
Inputs 5
Operating pressure 1,5 to 7 bar
Compressed air filtered 5 µm
Rated flow per valve at 6 bars 96 l/min
Valve switching response time < 15 ms
Switching frequency 5 Hz
3842 530 881 (03.08) en

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3842 530 881 (03.08) en

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digital outputs
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X 11 - 4
-
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-
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analog inputs
X 21 1 BAPS-Analog-Input 401
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-
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+ -
B
X 21 2 Analog Ground
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-
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3842 530 881 (03.08) en

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3842 530 881 (03.08) en

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On turboscara SR4/6/8plus it is possible to mount attachments on the left and right

sides of arm 2. For this purpose there are 4 threaded holes M5 (2 right, and 2 left)
on arm 2.
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Rated load 2 2 2 kg
Maximum load 5 5 5 kg
(sleeve Ø 20 mm)
Maximum load (option) - 8 8 kg
(sleeve Ø 25 mm)
Rated maximum mass 500 500 500 kgcm2
moment of inertia
(axis 4)
Max. mass moment of 1000 1000 1000 kgcm2
inertia (axis 4)
Horizontal force, conti- 90/225 60/150 60/150 N
nous/max. (axis 1, 2)
Vertical force, 200/300 200/300 200/300 N
continous/max.
Torque (axis 4), 5/10 5/10 5/10 Nm
rated/max.
5HSHDWDELOLW\ 65SOXV 65SOXV 65SOXV 8QLW
x, y ±0,025 ±0,025 ±0,025 mm

Axis 3 ±0,05 ±0,05 ±0,05 mm
Axis 4 ±0,05 ±0,05 ±0,05 °
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±0,5 ±0,5 ±0,5 mm
3842 530 881 (03.08) en

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Reach 400 600 800 mm

Inside radius 139 167 183 mm
Swivel angle axis 1 ±105 ±140 ±140 °
Lift sleeve Ø20 mm 200 200 200 mm
Lift sleeve Ø25 mm - 200 200 mm
(optional)
(optional)
(on call)
with user installation
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Cycle 25-300-25 - <450 <490 ms

Cycle 25-150-25 <300 - - ms
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Digital inputs 8 8 8
Digitale outputs 8 8 8
Analog inputs 4 4 4
ASi bus (max. 200 mA) 4 Slaves 4 Slaves 4 Slaves
without external power
supply
ASi bus with external 13 Slaves 13 Slaves 13 Slaves
power supply
pneumatic lines 2 x LW4
3842 530 881 (03.08) en

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with stand 41 48 51 kg
with console 32 40 43 kg
:HLJKW 65 65
Variant dustproof 52 55 kg
Variant cleanroom 52 55 kg
3URWHFWLRQW\SH 65SOXV 65 65

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IP54 IP65 IP65
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Fixture Base Base

length 203 mm length 203 mm
Contact termination Connection plugs in the base Connection plugs in the base
User installation In the robot base, up to the In the robot base, up to the wrist
wrist (in delivery condition) (in delivery condition)
Control cabinet 19“-rack
Control IQ200 standard with rho4.0
option with rho4.1
Protection type/environ- IP40
ment Option:
AR6/8 DP, for severe conditions and areas where cleanroom conditi-
ons are required.
Up to joint 3: IP54
After joint 4: IP65
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You can find further information about dimensions in the product documentation
’turbo AR6/8plus’ on the documentation CD, Order No. 3842 524 619, and on the
CAD drawings, which you can download in internet under:
3842 530 881 (03.08) en

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Working area,
defined by Point P
Point P
Point TCP
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Working area,
defined by Point P
Point P
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3842 530 881 (03.08) en

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The base plate is fastened by M10 x 30 mm bolts (strength class: 12.9).
200
160
2x
46
H7
6660.0
2
41
4x
18460.0
200
160
0
20
0
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140
500
500mm space for
Raumbedarf für cable
Kabel
3842 530 881 (03.08) en

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The gripper flange (in accordance with DIN EN ISO 9409-1-A31,5) fastens the
gripper.
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deep
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ep
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As a standard, there are available:

• User interface on the wrist, see chapter 5, Interface valves
with 3x5/2 impulse valves (pre-assigned with BAPS output
1 to 6) and 10 0 freely available lines (pre-assigned with 24 V, 0 V,
BAPS input 1 to 6, ASi+ and ASi-)
User interface on the wrist
Interface on the robot base
• Interface on the robot base, see following pages

JC1 - Central connection plug to the control unit
JC3 - I/O interface to peripherals, ASi bus termination is available
JC4 - Interface for brake box
3842 530 881 (03.08) en

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JC1 creates the electrical connection between IQ200 and AR6/8. For detailed
information, see wiring diagram.
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3842 530 881 (03.08) en

Assignment at delivery:
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1 CN21 - pin 1 +24 V

2 CN21 - pin 2 0V
3 CN21 - pin 3 ASi+ (for SR-CAN-ASi option, otherwise open)
4 CN21 - pin 4 ASi- (for SR-CAN-ASi option, otherwise open)
5 CN21 - pin 5 BAPS input 1
11 Valve output Y1A BAPS output 1
12 Valve output Y1B BAPS output 2
17 BAPS input 7
18 BAPS input 8
19 BAPS output 7
20 BAPS output 8
21 Analog input 401
22 Analog input 402
23 Analog input 403
24 Analog input 404
25 Analog GND
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3842 530 881 (03.08) en

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red Overload sensor supply

(only for Asi option)
ASi
green Logic voltage supply OK

(only for Asi option)
red Module in %XV2IIcondition
flashes red invalid node ID

CAN
rapidly flashes red Module in (UURU3DVVLYHmode

green Module in 2SHUDWLRQDOcondition
flashes green Module in 3UH2SHUDWLRQDOcondition

red Outouts overload
Power
green 24 V D.C. supply OK
3842 530 881 (03.08) en

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On the wrist in the installation chamber, the following interfaces are available:
• 3x5/2 impule valves, M5 connection thread, pre-assigned with BAPS output
1 to 6
• 10 freely available lines (pre-assigned with 24 V, 0 V, BAPS input
1 to 6, ASi+ and ASi-)
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1 +24 V
2 0V
3 ASi+
4 ASi-
5 BAPS input 1
6 BAPS input 2
7 BAPS input 3
8 BAPS input 4
9 BAPS input 5
10 BAPS input 6
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3842 530 881 (03.08) en

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3A 3B
BAPS Valves AIR2
A1 Y1A
A2 Y1B
A3 Y2A
A4 Y2B Y3A Y 3B
A5 Y3A BAPS R P S BAPS
A6 Y3B Output 5 Output 6
2A 2B
Y2A Y 2B
BAPS R P S BAPS
Output 3 Output 4
Air connection on the wrist
1A 1B
Y1A Y 1B
BAPS R P S BAPS
Output 1 Output 2
black transparent
LW4 R LW4
AIR1 AIR2
At the robot base
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Operating pressure 1,0 bar to 3,9 bar

Maximum pressure 4,9 bar
Valves 3x5/2 impulse valves
Maximum flow rate 30 N/min
Reaction time at 4,9 bar ≥15 ms
Maximum switching frequency 10 Hz
Operating temperature -5° to 50 °C, no condensation formation per-
mitted
3842 530 881 (03.08) en

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653 854 mm
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733 934 mm
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270 (lower arm) 365 (lower arm) mm

+ 295 (upper + 405 (upper
arm and wrist) arm and wrist)
= 565 = 770
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axis 1 ±170 ±170 °
axis 2 +100 / -135 +100 / -135 °
axis 3 +209 / -76 +209 / -79 °
axis 4 ±190 ±190 °
axis 5 ±120 ±120 °
axis 6 ±360 ±360 °
3842 530 881 (03.08) en

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axis 1 300 200 °/s

axis 2 270 225 °/s
axis 3 330 225 °/s
axis 4 330 330 °/s
axis 5 330 330 °/s
axis 6 540 540 °/s
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axis 1 1585 1056 °/s2
axis 2 1268 1056 °/s2
axis 3 1585 1056 °/s2
axis 4 2308 2000 °/s2
axis 5 2308 2000 °/s2
axis 6 3692 3200 °/s2
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at the TCP 8200 7600 mm/s
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in x, y and z directions ±0,02 ±0,03 mm
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±0,5 ±0,5 mm
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Maximum load capacity 5 5 kg
Maximum permitted 0,295 0,295 kgm2
moments of inertia for
rotation of axis 4 and 5
Maximum permitted 0,045 0,045 kgm2
moments of inertia for
rotation of axis 6
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Mechanical system 28 29 kg
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Digital inputs 8 6
Digital outputs 8 -
(max. 24 V, 0,5 A per
output, 50 % simulta-
neity)
Analog inputs 4 -
Pneumatic lines 2xLW4 3x5/2 solenoid valves
1x arbitrary clearance
ASi bus (option) CAN ASi transducer, max. 13 slaves
200 mA internal ASi power pack,
2 A max. with external power pack
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IP40 IP40
3842 530 881 (03.08) en

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Encoder system Encoder with battery buffer
Motors A.C. servo motors (Uzw = 325 V D.C.)
Brakes in axis 2 to 6 (supply of 24 V D.C. via control unit)
3842 530 881 (03.08) en

3842 530 881 (03.08) en

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The IQ200 robot controller was designed to control the Rexroth robots
SR4/6/8plus and AR6/8. With its expanded capabilities in parallel processing,
even additional tasks can be solved, as for example peripheral control, diagnosis,
operator guidance and much more.
The IQ200 is a powerful controller on the basis of standard components of PC
technology and integrated safety technics with safety class III and intelligent servo
amplifiers.
The IQ200 gives the optimal answer to the corresponding application require-
ments through the scalable control core with rho4.0 or rho4.1.
The controller is programmed with the pascal similar programming language
BAPS3 (Bewegungs- und Ablauf-Programmiersprache, Motion and flowchart
programming language, Version 3). The real-time operating system enables the
parallel control of independent kinematics, the cell periphery and other processes.
Even data exchange with external computers, vision systems or other sensor
systems via interfaces is possible from the application program. Several data
transfer protocols are available for this, among others the TCP/IP protocol.
Easy and comfortable programming and commissioning is possible via the
programming environment easyURERW Suite. Programs can be developed, tested
and visualized offline.
With the interfaces OPC (OLE for Process Control), DDE (Dynamic Data
Exchange) and DLL (Dynamic Link Library), the data exchange between user
process and Windows applications is standardized. In addition to the creation of
your own process surfaces, it is also possible to execute remote-controlled
functions and status inquiries via the Windows applications.
The programmable logic controller PCL (Soft SPS) integrated as a standard
makes a high functionality available for extensive peripheral control.
The IQ200 makes all internally required supply voltage available. Additionally, an
uncontrolled supply voltage of 24 V D.C./15 A (EVS201) for the system periphery
is available. The electrical connections are realized in plug-in or clamp techniques.
3842 530 881 (03.08) en

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The rho4.0 has a high-performance PC microprocessor as well as a 1,8 MB

memory for BAPS applications.
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Following robot control interfaces are provided on the rho4.0:

• three serial interfaces V24_1 bis V24_3
• one network interface Ethernet
• two CAN (Controller Area Network) interfaces CAN1 and CAN2
• a further interface for SERCOS drives
• 16 digital inputs and 8 digital outputs
V24_3 can also be used as a serial 20 mA interface.
In addition, there are four virtual TCP/IP interfaces WIN1 to WIN4 available. These
interfaces can be reserved and parametrized depending on the application.
3842 530 881 (03.08) en

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Maximum transfer rate 1 MBaud

Maximum cable length 25 m with 1 MBaud
200 m with 128 kBaud
Data driver short circuit protected,
ungalvanized
Bus terminator 120 Ω internal, activated through
connectors
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Maximum transfer rate 215 kBaud

Maximum cable length 15 m
ungalvanized
Handshake signals channels 1, 2 DSR, DTR
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Maximum transfer rate 19200 Baud

ungalvanized
Receiver low is recognised up to 4,5 mA
high is recognised up to 7,5 mA
Handshake signals channel3 DSR, DTR, optional
channel 3 has a 20 mA control signal
(DTR) for the connection of a mem-
ber, which needs Hardware control
3842 530 881 (03.08) en

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The rho4.1 has a high-performance PC microprocessor as well as a 4 MB memory

for BAPS applications and a 128 MB working memory for Windows applications.
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PC interfaces and robot control interfaces are provided on the rho4.1.
PC Interfaces:
• four serial PC interfaces COM1 to COM4
(COM4 is planned for the uninterruptable power supply (UPS))
• a parallel interface LPT1
• a network interface Ethernet
Robot control interfaces:

• four serial interfaces V24_1 to V24_4
• two CAN (Controller Area Network) interfaces CAN1 and CAN2
V24_1 and V24_2 can also be used as a 20 mA interface.
In addition, there are still four virtual TCP/IP interfaces WIN1 to WIN4 available.
These interfaces can be reserved and parameterized depending on the application
3842 530 881 (03.08) en

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Maximum permitted input frequency 800 kHz

Minimum flank distance between ≥250 ns
active counting pulse
Input resistance 120 Ω
Minimum voltage difference ≥600 mV
Maximum cable length 20 m with an internal power supply
and maximum 350 mA
sensor power supply
Sensor power supply 5 V ±5 % in case of a short circuit, the
PC shuts down completely
Maximum permitted sensor current 350 mA
consumption
Longer cables can be used via the external power supply of the sensor. The possi-
bility of a limit depend in this case on the specification of the sensor.
0HDVXUHPHQWLQSXW
Fast 24 V input, galvanically separated by OPTO photo coupler and an incre-
mental sensor interface.
Voltage range 0 -3 V to 5 V, maximum 0,5 A

Voltage range 1 11 V to 30 V, 4 mA to 30 mA
Switching response time (delay) maximum 1,5 µs
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Maximum transfer rate 1 MBaud

Maximum cable length 25 m with 1 MBaud
200 m with 128 kBaud
ungalvanized
Bus terminator 120 Ω internal, not disconnectable
3842 530 881 (03.08) en

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ungalvanized
Handshake signals channels 1, 2 DSR, DTR
Handshake signals channels 3, 4 none
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ungalvanized
idle speed voltage: 12 V
internal resistance: 464 Ω
short circuit current maximum:
26 mA
Receiver low is recognised up to 4,5 mA
high is recognised up to 7,5 mA
Handshake signals channel3 none
channel 1 has a 20 mA control signal
(RTS) for the connection of a PHG
3842 530 881 (03.08) en

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The EVS201 provides the necessary power supply of the IQ200 and the periphery.
The system signals of the IQ200 for operating block, releases, user signals etc. are
distributed via pre-assembled connection lines. The earthing point is in the lower
right corner. Another component of the EVS201 is the complete emergency-stop
wiring and the safety door monitoring in two-channel design. The integration of
further emergency stop switching elements of higher systems is possible.
The requirements of safety class III according to EN 954 are met. This serially
integrated safety technics makes it possible to operate the robot safety and
comfortably for teaching, setup and test mode. Its benefits are: Fast and well
arranged processes with highest personal safety.
The component EVS201 is located between rho4 and drive amplifier. A voltage of
24 V D.C. is available at the connection XE14 for user periphery.
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• Worldwide use through transformator modules
• 24-V power supply, capacity of up to 15 A maximum
• Diagnosis function via LEDs, potential-free user interface
• Separation of safety stages Emergency stop, safety guard and power off.
• Variable input voltages through transformator module
• Potential free 2-channel outputs for Emergency-stop and safety door with a
capacity of up to 4 A, safety class III through 3-protective circuit
• Potential free 2-channel outputs for power-Off with a capacity of up to 4 A
• 4 operating modes that can be freely selectable (AUTOMATIC/MANUAL -
MAXIMUM/REDUCED)
• 2 function keys on the operating block that can be freely programmed
3842 530 881 (03.08) en

• 3 free PLC outputs

• 1 free potential free relay contact, with a capacity of 2 A
• Introduction of standard 5*20 mm glass tube fuses
3842 530 881 (03.08) en

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The IQ200 drive unit consists of a card rack, which contains the servo power
supply and amplifier cards Servodyn-D (four at AV201, six at AV206) and the end
stage component. The data are exchanged between the different amplifier cards
and the robot control rho4 via the digital drive interface CAN.
The drive unit is supplied from the EVS.
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3842 530 881 (03.08) en

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External dimension (rack) w = 19" (482,6 mm) w = 19" (482,6 mm)

d = 222 mm d = 300 mm
h (rho4.0) = 1 HE h (rho4.1) = 3 HE
h (EVS) = 3 HE h (EVS) = 3 HE
h (AV201) = 4 HE h (AV201) = 4 HE
h (AV206) = 5 HE h (AV201) = 5 HE
-> overall with AV201 = 8 HE -> overall with AV201 = 10 HE

(355,6 mm) (444,5 mm)
-> overall with AV206 = 9 HE -> overall with AV206 = 11 HE
(400,05 mm) (488,95 mm)
100 mm of installation space 100 mm of installation space

should be planned in front of should be planned in front of
the rack for wiring! the rack for wiring!
Power supply EVS201 115 V A.C., 50/60 Hz, max. fuse rating 32 A slow-blowing
230 V A.C., 50/60 Hz, max. fuse rating 16 A slow-blowing
Power consumption 2kVA
interfaces:
on SR4/6/8plus on arm 2
- digital inputs 8 (SRCAN, arm 2)
- digital outputs 8 (SRCAN, arm 2)
- analog inputs 4 (SRCAN, arm 2)
-ASi bus with ASi bus additionally
13 ASi slaves (52 I/O), 4 slaves without external power supply
Interfaces:
on AR6/8, base and
wrist
- digital inputs 8 (24 V input)
- digital outputs 8 (max. 0,5 A per output, 50 % simultaneity)
- analog inputs 4 (±10 V)
- ASi bus with ASi bus additionally
max. 13 ASi slaves (52 I/O), 4 slaves without external power sup-
ply
TCP/IP 4 channels (WIN_1 to WIN_4)
Serial robot
control interfaces 3, one for the PHG2000
3842 530 881 (03.08) en

UKR UKR
CAN/CANopen 2 for drives and fieldbus I/O 2 for drives and fieldbus I/O
SERCOS interface standard optional
PC interface: 4 (COM1 to COM4), one for the
- serial integrated UPS (uninterrupta-
ble power supply) and one for
the Touchscreen
- parallel 1 (LPT1)
- Ethernet serial network interface
Processor Pentium MMX

RAM 1,8 MB BAPS memory 128 MB
4 MB BAPS memory
Operating system VxWorks VxWorks/WindowsNT
Robot programming BAPS3 language
Power supply for 24 V D.C., 15 A, uncontrolled according to DIN 19 240
process periphery
Protection type IP20, IP54 in control cabinet
EMV interference immunity DIN/EN 50081 part 2
EMV interference emission DIN/EN 50082 part 2
Operating temperature for the 5 to 40 °C
control cabinet
Maximum power loss $500 W
Number of amplifiers 4 amplifiers in the AV201 drive unit for SR4/6/8plus
6 amplifiers in the AV206 drive unit for AR6/8
3842 530 881 (03.08) en

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rho4.1
rho4.0
EVS201
1 2 31 2 3 4
AV201 AV206
3842 530 881 (03.08) en

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A 19" control cabinet is available for the installation of the IQ200 components. It
has a cut-out for the operating block and an installed main switch assembly.
Additionally, a PE kit for the necessary ground connections is added next to the
ventilation assembly.
([WHUQDOGLPHQVLRQV
• Width: 600 mm
• Height: 620 mm
• Depth: 600 mm
Protection type: IP54
All combinations can be fitted in this cabinet.
3842 530 881 (03.08) en

2SHUDWLQJEORFN
The operating block with its switches and LED enables the operation of the basic
functions of the IQ200:
• Operating mode selection (automatic/manual)
• Selection of the power type (maximum/reduced)
• Start, stop and continuation of user programs
• On and off switching of the drive performance
• Reset
• Display of operating conditions
• Emergency switch
• Two keys that can be assigned freely
,QVWDOODWLRQGLPHQVLRQV'RRUVHFWLRQ
201
∅4 103,5 4
52
48
207
3842 530 881 (03.08) en

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Additional bus connections can be achieved with optional plug-in cards. The bus
cards are inserted directly in the rho4 and delivered configured. The signals are
evaluated in the PLC program.
When making configurations with an additional bus card, an additional 16 byte I/O
is available.
This number can be expanded by upgrading the PCL version from PCL-S to
PCL-L or PCL-X:
• PCL-S: 128 I + 128 O 16K instructions in AWL
• PCL-L: 256 byte I/O 64K instructions in AWL
• PCL-X: 8192 byte I/O 128K instructions in AWL
The configuration of the modules occurs with WinDP or WinCAN.
3URILEXV'3PDVWHUFDUG
With the Profibus-DP master card it is possible to connect I/O modules as
Profibus-DP slaves to the controller.
&$1RSHQ
With this card it is possible to connect CANopen I/O modules to the controller.
,QWHU%XV6
With this card it is possible to connect InterBus-S I/O modules to the controller.
$6L%XV
With the SRCAN ASi Gateway on the SRplus series it is also possible to connect
max. 13 ASi Slaves (corresponding 52 I/O) or 4 Slaves without external power
supply.
3842 530 881 (03.08) en

,2H[WHQVLRQ
The number of available inputs and outputs can be extended with the IQ200 via a
decentralised I/O module.
%a,2PRGXOHVEXVa,2PRGXOHV
Rexroth has suitable modules in various versions available, see ordering sheets in
chapter 11. The inexpensive compact B~IO versions offer all common combina-
tions of inputs and outputs and integrate the fieldbus switch. There are also
modular B~IO versions with analog I/O combined digital outputs or with relay
combined digital outputs.
It is possible to order a compact B~IO K-16DI/16DO with 16 digital inputs and
outputs and already integrated into the IQ200.
*HQHUDOGDWD%a,2.','2
,QSXWV
Input voltage at 0 3 V..5 V

Input voltage at 1 11 V..30 V
Input current at 0 $2,5 mA
Input current at 1 2,8 mA$i$6mA
3842 530 881 (03.08) en

2XWSXWV
Output voltage 24 V
8 outputs 0,5 A
4 outputs 1A
4 outputs 2A
electrically separated CAN interface

Further work to be carried out by the customer enables the I/O configuration to be
extended:
• The maximum total number of CAN-E/A in the PLC program is 48 Bytes of
inputs and 48 Bytes of outputs, where a digital input or output engages 1 bit and
an analog input or output engages 2 bytes.
• From these I/O, up to 199 inputs and 199 outputs or 8 analog inputs and 16
analog outputs can be addressed in the BAPS program.
As a default, in the PLC program for the BAPS programs, the following is
provided:
-199 CAN-I/O for BAPS
-4 analog inputs of the SRCAN module in Arm 2, filtered on 8 bits.
• When a higher number of I/O is to be used, the configuration of the B~IO-
modules must be taken into account (maximum number of nodes on the CAN2).
Please contact your system integrator.
&RPSOHWHVFRSHRIGHOLYHU\VHHRUGHULQJVKHHWVLQFKDSWHU
3842 530 881 (03.08) en

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.&$1','2
Bus plug BL-SET-SA-K32
&RPSDFWPRGXOHZLWKRXWSXWVDQGLQSXWV
• 16 intputs 24 V D.C. according to type 1
To both output bytes Q0 and Q1 apply:
• 0,5 A outputs, bit 0 to 3
• 1 A outputs, bit 4 and 5
3842 530 881 (03.08) en

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Bus control I/O modules

Modular plug connector
Bus cable CANopen, BL-SET-SA bus contr. B~IO M BL-SET-SA-8DI/DO/RV

piece goods CANopen,
bus plug
B~IO M-CAN is the modular representative of the B~IO family for the CANopen.
Starting from the basic model of bus switching, it is possible to compose, at any
time modify and extend a decentralized slave with the different I/O modules
according to the individual requirements. Even the change-over of the complete
slave onto another bus system is easily possible through the change of the module
’Bus switching’.
3842 530 881 (03.08) en

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As the basis for the assembly of a modular bus participant at the CANopen,
Rexroth makes the bus wiring B~IO M-CAN available.
'LJLWDORXWSXWPRGXOH'LJLWDOLQSXWPRGXOH
8DO 8DI
3842 530 881 (03.08) en

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%)
6 6

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Bus plug BL-SET-SA-K32
&RPSDFWPRGXOHZLWKRXWSXWVDQGLQSXWV
• 16 intputs 24 V D.C. according to type 1
To both output bytes Q0 and Q1 apply:
• 0,5 A outputs, bit 0 to 3
3UHUHTXLVLWH7KHUHKDVWREHD352),%86'3FDUGLQWKHUKRRU*DWHZD\
'3
3842 530 881 (03.08) en

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Bus control I/O module

Bus cable Profibus-DP, piece goods

Profibus-DP, bus plug
BL-SET-SA bus contr. B~IO M BL-SET-SA-8DI/DO/RV
B~IO M-DP is the modular representative of the B~IO family for the Profibus-DP.
Starting from the basic model of bus switching, it is possible to compose, at any
time modify and extend a decentralized slave with the different I/O modules
according to the individual requirements. Even the change-over of the complete
slave onto another bus system is easily possible through the change of the module
’Bus switching’.
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As the basis for the assembly of a modular bus participant at the PROFIBUS,
Rexroth makes the bus switching B~IO M-DP available.
'LJLWDORXWSXWPRGXOH'LJLWDOLQSXWPRGXOH
8DO 8DI
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Bus plug Bus plug
BL-SET-SA bus contr. B~IO M BL-SET-SA bus contr. B~IO M
The I/O-Gateway enables to transfer data between two different field bus systems
(Profibus-DP, CANopen, CANrho, DeviceNet and INTER-BUS-S). It is even
possible to use the I/O gateway between bus systems of the same type. 20 bytes
of input information and 20 bytes of output information are exchanged between the
coupled systems (Reduction to 8 bytes I/ 8 bytes O possible).
3842 530 881 (03.08) en

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With the PHG, it is possible

• to test programs
• to patch programs
• to modify parameters
Additional functions:
• Diagnosis of robot systems
• Teaching points via manual robot movement
• Release brakes manually
The PHG2000 is equipped with a separate microprocessor, enabling to create
your own user masks and menu levels. As a further property, it is possible to
access to system variables of the rho4 with the PHG2000.
The PHG2000 is equipped with a two-channel emergency-stop switch and a two-
channel confirmation key. This enables to move the robot even with safety doors
opened in the power mode ’Reduced’.
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PHQWDWLRQ&'2UGHU1RRULQ,QWHUQHWXQGHUKWWSZZZERVFK
UH[URWKGHURERWHURUKWWSZZZERVFKUH[URWKFRPURERWV
3842 530 881 (03.08) en

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Two different programming methods are available. With the first one, the
comfortable programming environment easyURERW Suite fulfills all functional wishes
with the language BAPS3. With the second one, the graphical programming
environment BAPS+ enables to create sequences of movement rapidly and easily.
HDV\URERW6XLWHVWDQGDUGGHOLYHU\
easyURERW Suite is the comfortable programming environment for the Bosch

Rexroth AG robot technology. Advantages:
• Creation of sequence programs offline in BAPS3. ( BAPS3 means in German
Process Programming Language, Version 3. It is a task-oriented, pascal similar
programming language similar to PASCAL for the programming of the rho4
control family.)
• Test and startup with debug-function, offline
• Visualisation of the robot movement
3842 530 881 (03.08) en

The programming environment compromises the following functions:

• Windows application orientated user interface which enables the user to work
intuitively and effectively.
• Project management which allows the creation and the editing of several
HoldProjects.
• Text editor to write, check and debug user programs in the programming
language BAPS.
• Compiler and debugger
• Visualisation of digital bit and byte inputs/outputs in dockable windows.
• Point editor to enter, clear and change points.
• File transfer via Windows Explorer. The control is addressable as an additional
drive. Files can be transferred to the control unit and can be deleted or renamed
there.
• Control diagnosis with control information in table form.
• Virtual robot operator control elements: Virtual panel and virtual PHG.
• 3D visualisation to illustrate the movement of the robot.
3842 530 881 (03.08) en

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BAPSplus is a graphic, structure oriented programming system, with which

sequence programs can be rapidly and easily created, documented and tested in
the Top-Down draft. Advantages are the automatic code generation and the
possibility of the process observation. The program process is composed in form
of a program process plan from picture symbols.
• Integrated BAPS translator translates the created motion programs with help
of the ASCII editor.
• Program archiving (load, save, list, delete, name etc.)
• Remote control functions: program start, display of axis position, I/O status etc.
• Coupling functions: transfer of files from/to rho4, connection to the rho4 via
serial interface or TCP/IP.
• Offline/online points editor
• Process functions: process selection, process start, process stop etc.
Through the conversion of the BAPS source code into the graphic programming
system, the advantages of BAPSplus - easy, graphic programming, clear
documentation, debugger for rapid startup - can be used.
3842 530 881 (03.08) en

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With the OPC Server 4, the robot controller IQ200 has a system-overlapping
interface.
OPC (OLE for Process Control) is an established standard in the automation
technique and defines interfaces. They enable interoperability between the robot
controller IQ200 and communication and visualisation systems of different
manufacturers, such as Indusoft, InTouch, LabView, Visual Basic, Visual C++ etc.
The Microsoft component model DCOM based on the OPC allows the realization
of distributed applications. Not only does OPC enable to exchange data on a robot
controller, but all data of all OPC servers of the network are available to a OPC
client.
VBA or Delphi as OPC clients enable the data access for office programs such as
Excel, Access etc. Multi-client access is possible, i.e. requests from different OPC
clients can be answered at the same time.
:LQ636RSWLRQ
The integrated software SPS (PCL) can be programmed with WinSPS. As a future
programming tool WinSPS offers the famous Windows Look & Feel for instruction
lists (AWL), operation language (AS), function plan (FUP) and contact plan (KOP).
Optionally, a WinSPS license can be directly ordered when ordering the robot
system. This license contains:
• Basic WinSPS license
• License for the PCL
• License for the central programming (enables the SPS programming on
another computer that is connected with the rho4).
:LQ'3:LQ&$1RSWLRQ
WinDP resp. WinCAN are used for the configuration of inputs and outputs that are
connected to the optional Profibus-DP-Master card or CANopen card.
*DWH:D\
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GateWay is a Windows application for Windows95 or WindowsNT. It serves the

TCP/IP communication between the rho4 and all external clients and Servers.
3842 530 881 (03.08) en

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A TCP/IP address consist of 2 components: the IP address of the computer (host)
and a port number. The IP address is the world wide definitive address of the PC.
The address is comparable to a normal house address with country, city, street
and house number. The port number is the number of a server or client on the
computer. This is comparable to the name of the person at the address. The port
numbers 6000 to 6200 and 5000 to 5200 are reserved for Bosch Rexroth.
(VWDEOLVKLQJDFRQQHFWLRQ
GateWay can be started after the controller is up and running. During the initiali-
sation GateWay builds a TCP/IP link to the corresponding server for all adjusted
connections in the file GateWay.ini. At the same time a GateWay server branch is
started for each of these connections. It is available for the linking of a client. Since
GateWay runs under the Windows part of the PC, the IP address is the IP address
of the physical Ethernet card.
3842 530 881 (03.08) en

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robotYLVLRQ, the image processing system for Rexroth robotics, solves object
recognition tasks according to the position of the object. So the robot is able to grip
defined unsorted objects, among other things from the running conveyor belt
(tracking). In a very short time, new objects are taught-in. robotYLVLRQ is entirely
integrated into the programming and testing field of the robot control. In the
Windows environment you configure and calibrate your system, the control of the
processes takes over the robot program.
$GYDQWDJHV
• Stationary camera (SR4/6/8plus and AR6/8)
• Moving camera (SR4/6/8plus only)
• Easy camera calibration
• Comfortable ’Teaching’ of the object characteristics
3842 530 881 (03.08) en

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robotYLVLRQ is an image processing system specially adapted to applications with

the Rexroth robot family. It distinguishes itself by the following advantages:
8VHUIULHQGOLQHVV
Camera calibration, teaching of object characteristics, system configuration and
operation are done in the Windows environment. The sequential control is entirely
integrated in the robot programming BAPS.
5HFRJQLWLRQRIREMHFWVLQVSOLWVHFRQGV
During the processing of the image acquired by the camera it is possible to
integrate three powerful tools:
• Comparison of characteristics in the pattern recognition
• Segmentation in the binary image analysis
• Location of grey value skips in the edge detection
,QWHJUDWHGVXSSRUWRIPXOWLSOHFDPHUDV
Up to four stationary cameras or moving at the robot arm (Sr4/6/8plus only) are
supported.
,QWHJUDWLRQLQWRWKHUKRFRQWURO
The hardware of the robotYLVLRQ is designed as plug-in card. The software is
entirely installed on the rho4.1. The access to robotvision through several control
systems at the same time is possible via TCP/IP links.
The scope of delivery of robotYLVLRQ includes the robotYLVLRQ card with an upgrade
of the rho4.1 to 128MB RAM and Windows NT, a calibration help and the installed
robotYLVLRQ software. The software variant patmax differs from the variant patquick
in a higher recognition accuracy and additional evaluation possibilities of the image
processing. Moreover, it is possible to commute to the more rapid variant patquick.
If more than 2 camera connections are required, a further adapter is necessary.
Accessories such as cameras and lighting equipment are not included in the
delivery.
Optionally you can get the rho4.1 with a Pentium III 400 MHz processor.
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URERWHURUKWWSZZZERVFKUH[URWKFRPURERWV
3842 530 881 (03.08) en

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Three different tools are available to aid your application planning. A simple PC
software tool is available for an early and rapid calculation of movements of
SRplus swivel-arm robots. The cycle times have accuracy of ±15 %. We
recommend easyURERW Suite for accurate statements. COSIMIR enables the
simulation of all processes in your robot cell including peripherals; thereby
assisting in collision avoidance, and estimation of cycle time.
&\FOHWLPHRIVZLYHODUPURERWV
The cycle time program gives a very good estimation of the turboscara
SR4/6/8plus cycle time without using a robot control, which can be downloaded
from our internet homepage:
www.boschrexroth.de/roboter or www. boschrexroth.com/robots
Take also necessary processing times (e.g. grip times) into account for the deter-
mination of the cycle time and remember that not every process allows maximum
acceleration and velocity.
Remember that very high angular accelerations can occur when swivel arm robots
move with maximum velocity. As a result, the piece may disengage from the
gripper.
3842 530 881 (03.08) en

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Procedure for the use of the cycle time program:

• Select the configuration of the robot mechanics and define its load.
• Define starting, intermediate and final points in the robot coordinate system for
the part motion. Take also into account from which side the arm should
negotiate the point.
The movement theoretically calculated in the cycle time program goes to all
these points directly. Practically, movement time can be saved through spatial
curving at the intermediate points.
• With the modification of the robot position, it is possible to optimize the cycle
time of your application, since the best cycle times are reached when both axes
run the same paths.
Intermediate point Intermediate point
Start point End point
Robot position
Robot coordinate system
Original coordinate system
3842 530 881 (03.08) en

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Programs can be executed via the SURJUDPPLQJHQYLURQPHQWHDV\URERW6XLWH.

Robot movements can be visualized at the same time and it can be checked
logically if then can be performed. Statements on cycle times are possible with
great accuracy. A robot is not required. The connection to a control is necessary
for executing the programs.
3842 530 881 (03.08) en

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The VLPXODWLRQV\VWHP&26,0,5 enables the complete modeling of a robot cell.

Programs created in BAPS can be executed and it can be reliably checked if a
sequence of movements can be performed. Robot movements are visualized,
cycle times can be calculated. A controller is required for the simulation. The
complex simulation system COSIMIR enables to simulate complete cells and
systems. COSIMIR is recommended especially for complex applications as well as
for the use of the turbo AR6/8. The simulation helps the visualisation of collision
and cycle time problems.
'&$'
'GDWDRIWKHURERWVLQWKH&$'V\VWHP make it possible to check

geometrically if movements can be performed and 3D-data can be used directly in
the mechanical construction environment. Statements on the cycle time and the
execution of programs are not possible.
.
3842 530 881 (03.08) en

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Load is defined as all attached mass (e.g. gripper, workpiece, tool) on the flange
surface as well as attached periphery on arm 2.
7KHVXPRIDOOLQGLYLGXDOPDVVHVPXVWQRWH[FHHGWKHSHUPLWWHGRYHUDOOORDG
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The effective mass moment of inertia around the fourth axis is a combination of the
moments of inertia of the individual masses attached to the flange surface.
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The diagram contains the permissible transverse forces acting on the lift/rotation
axis. A distinction is made between the continuous value and the maximum value:
The continuous value arises out of the permissible thermal stress on the motor. If
the continuous value is exceeded for a significant length of time, the drives shut
down. This, however, does not lead to any damages of the device.
The maximum value takes into account the maximum torque of the motor and the
permissible loading capacity of the bearings. If this value is exceeded, it leads to
large positional deviations in the X Y planes and the drives shut down after approx.
2 seconds. Repeatedly exceeding the maximum values will cause damage to the
device.
200
Maximum value
Lateral force Fxy in N
150
100
Continuous value
50
0
0 50 100 150 200 250 300 350 400 450 500
Distance to upper final position in mm
3842 530 881 (03.08) en

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The working area shown in the dimensioned diagrams is valid for the Tool Center
Point: the center of the flange surface. During the layout, take into consideration
that attachments and bulky tools do not cause collisions with the robot stand. If this
should be the case, you can limit the working area via the software limit switch.
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WDWLRQ&'2UGHU1RXQGHU&$'GDWDRIWKHURERWVRULQ,QWHUQHW
XQGHUKWWSZZZERVFKUH[URWKGHURERWHURUKWWSZZZERVFKUH[URWKFRP
URERWV
3842 530 881 (03.08) en

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Not to scale
Swivel angle: Lift:
axis 1: ±105° axis 3: 200 mm
axis 2: ±143°
axis 4: ±180°
3842 530 881 (03.08) en

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Not to scale
Swivel angle: Lift:
axis 1: ±105° axis 3: 200 mm
axis 2: ±143°
axis 4: ±180°
3842 530 881 (03.08) en

Not to scale
Swivel angle: Lift:
axis 1: ±140° axis 3: 200 mm
axis 2: ±150°
axis 4: ±180°
3842 530 881 (03.08) en

Not to scale
Swivel angle: Lift:
axis 1: ±140° axis 3: 200 mm
axis 2: ±150°
axis 4: ±180°
3842 530 881 (03.08) en

Not to scale
Swivel angle: Lift:
axis 1: ±140° axis 3: 200 mm
axis 2: ±155°
axis 4: ±180°
3842 530 881 (03.08) en

Not to scale
Swivel angle: Lift:
axis 1: ±140° axis 3: 200 mm
axis 2: ±155°
axis 4: ±180°
3842 530 881 (03.08) en

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Ambient conditions must be considered in order to receive the full functionality with
the given technical data. Observe the given temperature ranges. Provide for a
shock-reduced set-up. Protect the system from contact with aggressive
substances and from condensation.
If the robot will be used in severe conditions, e.g. in areas with machine tools, it is
recommended to use the option with bellows for the sleeve in order to protect the
sleeve from wear and tear or the dustproof variant with protection type IP65.
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The position of the stand/the console in a station is to be chosen in such a way that
feeding and discharging units and the real workspace are positioned in the
workspace of the robot. As a result, a smaller swivel angle must be covered and
the cycle time is minimized.
When the variant and stand length of 250mm are to be used, it must be taken into
account that the cable can be lead through the ground plate. A cable leading
through the opening on the back is only possible with stand lengths >250 mm.
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Different lengths are available as standard as Z-stroke. Unnecessary lengths

should be avoided since it causes restrictions in stability, accuracy and therefore
also in velocity. For 600 mm stroke or stroke lengths deviating from standard
program, there are no user installation or expansion bellows available.
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The connection cable between the robot and control must be long enough.
Besides a variant with fixed cable connection, there exists a variant with plugged
cable. Moreover, the cable can be led either to the back from the stand or through
the ground plate. A cable leading through the opening on the backside is only
possible with stand lengths >250 mm.
There are cables available with following lengths: 3 m, 6 m, 10 m and 20 m.
8VHULQVWDOODWLRQIRUVWURNHPPRQO\
Interfaces for user installations in the installation room on arm 2 are offered as a
standard. If they are required at the front at the gripper flange, this is realized
through an optional user installation in closed cable hose and through the sleeve
up to the flange.
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Digital inputs 8 8 8
Digital outputs 8 8 8
24 V D.C./0 V D.C. 3 3 3
Ground wire PE 1 1 1
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Pneumatic lines 2xLW2 2xLW4
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Load is defined as all attached mass (e.g. gripper, workpiece, tool) on the flange
surface as well as attached periphery on arm 2.
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The effective mass moment of inertia around the fourth, fifth and sixth axis is a
combination of the moments of inertia of the individual masses attached to the
flange surface.
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400 mm
500 mm
600 mm
700 mm
62,3 kg
49,0 kg
41,7 kg
34,5 kg
3842 530 881 (03.08) en

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Z = 100 mm
Z = 400 mm
36 kg Z = 550 mm
Z = 700 mm
28 kg
20 kg
15 kg
Y
x
600 mm
Y = 500 mm
Y = 600 mm
Y = 700 mm
23,8 kg 25 kg 28 kg 40 kg
Y = 800 mm
Z
550 mm
Y
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The working area shown in the diagrams is valid for the Tool Center Point: the
center of the flange surface. During the layout, take into consideration that
attachments and bulky tools do not cause collisions with the robot stand. If this
should be the case, you can limit the working area via the software limit switch.
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3842 530 881 (03.08) en

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Not to scale
Swivel angle:
axis 1: ±170° axis 4: ±190°
axis 2: +100° / -135° axis 5: ±120°
axis 3: +209° / -76° axis 6: ±360°
3842 530 881 (03.08) en

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Not to scale
Swivel angle:
axis 1: ±170° axis 4: ±190°
axis 2: +100° / -135° axis 5: ±120°
axis 3: +209° / -76° axis 6: ±360°
3842 530 881 (03.08) en

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Not to scale
Swivel angle:
axis 1: ±170° axis 4: ±190°
axis 2: +100° / -135° axis 5: ±120°
axis 3: +209° / -79° axis 6: ±360°
3842 530 881 (03.08) en

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Not to scale
Swivel angle:
axis 1: ±170° axis 4: ±190°
axis 2: +100° / -135° axis 5: ±120°
axis 3: +209° / -79° axis 6: ±360°
3842 530 881 (03.08) en

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Ambient conditions must be considered in order to receive the full functionality with
the given technical data. Observe the given temperature ranges. Provide for a
shock-reduced set-up. Protect the system from contact with aggressive
substances and from condensation.
If the robot will be used in severe conditions, e.g. in areas with machine tools, it is
recommended to use the dustproof variant with protection type IP54 up to axis 3
and protection type IP65 from axis 4.
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The position of the stand/console in a station is to be chosen in such a way that

feeding and discharging units and the real workspace are positioned in the
workspace of the robot. As a result, a smaller swivel angle must be covered and
the cycle time is minimized.
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The connection cable between the robot and control must be long enough.
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Interfaces for user installations on the base and on the wrist are offered as a
standard (delivery condition).

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Digital inputs 8 5
Digital outputs 8 -
Analog inputs 4 -
Analog Ground 1 -
24 V D.C. / 0 V D.C. 1 1
Pneumatic lines 2xLW4 3x5/2 solenoid valves

1x arbitrary clearance
ASi bus (option) with ASi bus additionally

max. 13 slaves (52 I/O),
4 slaves without external power supply
3842 530 881 (03.08) en

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You can find further information about the documents on the documentation CD
that can be made available by your sales partner or in Internet under:
The documentation for the robot system is delivered with the CD-ROM, the safety
instructions and the wiring diagrams.
On the documentation CD, order No. 3842 524 619 you can find manuals and CAD
drawings and example programs on the following subjects.
3ODQQLQJ
> Basic information: Planning manual 2.0

order number 3842 530 880 (German)
order number 3842 530 881 (English)
> Detailed information: Mechanic manual

turboVFDUD SR4/6/8plus, chapter 2,3
Mechanic manual
turbo AR6/8, chapter 2,3, 4
Manual robotYLVLRQ for Rexroth robots
Service manual turbo AR6/8
,QVWDOODWLRQDQGVWDUWXS
> Mechanics: Mechanic manual

turboVFDUD SR4/6/8plus, chapter 2,3
Mechanic manual
turbo AR6/8, chapter 2,3, 4
> Control system: Manual IQ200 Robot Control System
SR4/6/8plus, chapter 3, 5
Manual IQ200 Robot Control System

AR6/8plus, chapter 3, 5
3842 530 881 (03.08) en

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> Introduction: Manual IQ200 Robot Control System

SR4/6/8plus, chapter 8

AR6/8plus, chapter 8
> Programming environment: easyURERWSuite
ROPS4 Online
> Programming language: BAPS3 Programming
BAPS3 Short description (only syntax)
BAPSplus
BAPS - BAPSplus Converter

(ReCompiler)
> IQ200-PCL Manual IQ200 Robot Control System

project description: SR4/6/8plus, chapter 7

AR6/8plus, chapter 7
> PCL: Introduction in the software PLC,
System description (PCL)
Programming and operating,

Software manual (PCL and CL550)
> robotvision: Manual robotYLVLRQ for Rexroth robots, chap-

ter 5, 6
3842 530 881 (03.08) en

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turboVFDUD SR4/6/8plus, chapter 4
Mechanic manual
turbo AR6/8, chapter 5
> Control system: Manual IQ200 Robot Control System

SR4/6/8plus, chapter 8, 9

AR6/8plus, chapter 8, 9
rho4.0 Connectivity manual
rho4.1/IPC300 Connectivity manua
> Spare parts: Spare parts catalog MTparts
Spare parts overview IQ200
> Maintenance: Service manual turbo AR6/8
)XUWKHUFXUUHQWPDQXDOV
> Safety: Safety Instructions

turboVFDUD SR6/8 dustproof
Mechanic manual
turboVFDUD SR6/8 cleanroom
> Systems: System Description rho4.0
System Description rho4.1
> Control system: Machine Parameters
Signal Descriptions
Control Functions
Status Messages and Warnings
3842 530 881 (03.08) en

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> Programming: DLL Library
DDE Server 4
> Accessories: K-CAN16DO, K-CAN32DI, K-CAN16DI/

16DO, Module Description (B~IO)
K-DP16DO, K-DP32DI, K-DP16DI/16DO,

Module Description (B~IO)
Bus Connectors for I/O-Modules B~IO-M,

Module Description/Project Engineering
M-DP, 8DO, 8DI, 16DI,

Module Description
Input / Output modules for CL150, B~IO,

Module Description
PHG2000, Software Manual
Installation Engineering
BF2xxT / BF3xxT,
Control Panel Connectivity Manual
See also further offers in internet such as application reports or FAQ’s.
3842 530 881 (03.08) en

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For the configuration of a robot system and the choice of the accessories, you can
use the order forms on the following pages. They contain all standard components
and the corresponding options and accessories.
Only accessories can be ordered and delivered regardless of the robot system.
3842 530 881 (03.08) en

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Customer: already reserved: no / yes, week /
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• Stand 500 mm with plug connection • rho4.0 incl. 16 E / 8 A • Robot operating system • CD-ROM
• Sleeve Ø 20 mm (internal 14 mm) • EVS201 • PCL Software: PCL-S • Safety notes
• Stroke (axis 3) 200 mm • AV 201 • rho4-SW functions (printed)
• User installation on arm 2 • Cable set Enclosed on CD: • Circuit diag.
with digital 8I/ 8O and 4 analog I • 19" rack version • easyURERW Suite (printed)
• Rated load 2 kg (max. 5 kg) • ROPS4/Online (w/o license)
• Driveless teaching • DDE-Server4 (w/o license)
• WINSPS (w/o license)
• WinDP/WinCAN (w/o license)
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2SWLRQVIRUURERWZRFRQWURO
Stand 250 300 400 600 700
Console instead of stand
ASi Gateway on arm 2
plug/connction cable cable 3 m cable 6 m cable 10 m cable 20 m
User installation User installation (electric, pneumatic) to flange
Cover, bellows for sleeve
ESD version
2SWLRQV,4
rho4.1 (rho4.1 instead of rho4.0) Pentium PIII-Processor 400 MHz (instead PI-Processor)
EVS201 - connection voltage EVS201 EU400 EVS201 US115 EVS201 US480
Control cabinet with main switch (operating block must also be ordered)
Operating block
B~IO CAN compact module 16I /16O, installed, wired, configured, with plug connections
Field buses Profibus DP Master CANopen Interbus-S
Language, operating systems in English
Trigger input, with rho4.1 available only
Additional documentation
Touchscreen BF312T incl. set of cables, 10 m (loosely enclosed), with rho4.1 available only
Licenses, additional software ROPS4 incl. BAPSplus ROPS4 incl. BAPSplus
DDE-Server4 as well as BAPSplus recompiler
WinSPS (basis package + PCL + central programming)
PCL-L PCL-X
WinDP WinCAN
Hardlock (dongle)
robotvision robotvision quick robotvision max
with rho4.1 available only Connection adapter for 3rd/4th camera
65SOXVDFFHVVRULHV
Tool Connector (TC) (3 842 521 300)
Valve for TC Pulse (3 842 521 297) Pneumatic spring (3 842 521 298)
PHG 2000 hand-held programming device (1 070 918 443)
Holder for PHG 2000 (1 070 918 445)
Keyboard template in English for PHG 2000 (1 070 918 446)
(Date) (Company stamp and signature)
3842 530 881 (03.08) en

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• Stand 500 mm with plug connection • rho4.0 incl. 16 E / 8 A • Robot operating system • CD-ROM
• Sleeve Ø 20 mm (internal 14 mm) • EVS201 • PCL Software: PCL-S • Safety notes
• Stroke (axis 3) 200 mm • AV 201 • rho4-SW functions (printed)
• Perm. conn. cable, length 2 m • Cable set Enclosed on CD: • Circuit diag.
• User installation on arm 2 • 19" rack version • easyURERW Suite (printed)
with digital 8I/ 8O and 4 analog I • ROPS4/Online (w/o license)
• Rated load 2 kg (max. 5 kg) • DDE-Server4 (w/o license)
• Driveless teaching • WINSPS (w/o license)
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Stand 250 300 400 600 700
ASi Gateway on arm 2
Stroke/sleeve Ø 25 mm, carrying capacity 8 kg 200 mm stroke 400 mm stroke 600 mm stroke
Plug/connection cable 3 m cable 6 m cable 10 m cable 20 m cable
User installation Vertical user installation (electric, pneumatic) to flange
Horizontal user installation (electric, pneumatic) to flange (for 200 mm stroke only)
Cover, bellows for sleeve (already included in DP and CL)
ESD version
2SWLRQV,4
rho4.1 (rho4.1 instead of rho4.0) Pentium PIII-Processor 400 MHz (instead of PI-Processor)
Operating block
Field buses Profibus-DP Master CANopen Interbus-S
Language, operating systems in Englisch
Touchscreen BF312T incl. set of cables 10 m (loosely enclosed) with rho4.1 available only
Lizenz, zusätzliche Software ROPS4 incl. BAPSplus ROPS4 incl. BAPSplus
DDE-Server4 as well as BAPSplus Recompiler
WinSPS (basis package + PCL + central programming)
PCL-L PCL-X
WinDP WinCAN
Hardlock (dongle)
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Valve group for TC Pulse (3 842 521 297) Pneumatic spring (3 842 521 298)
Holder for PHG 2000 (1 070 918 445)
3842 530 881 (03.08) en

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• Stand length 500 mm • rho4.0 • WindowsNT • CD-ROM
• Sleeve Ø 20 mm (internal 14 mm) 128 MB • Software PCL PCL-S • Safety notes
• Stroke (axis 3) 200 mm • EVS • Winrho (printed)
• Perm. conn. cable length 2 m • AV 200 • rho4 SW functions • Circuit diag.
• User installation on arm 2 • Cable set • easyURERW Suite (printed)
with digital 8I / 8O and 4 analog I • 19" rack • ROPS4/Online (w/o license)
• Rated load 2 kg (max. 5 kg) • DDE-Server4 (w/o license)
• WINSPS (w/o license)
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Stand 250 300 400 600 700
Stroke/Sleeve Ø 25 mm, load max. 8 kg 200 mm stroke 400 mm stroke 600 mm stroke
Driveless teaching, button to release brakes, axis 3 and axis 4
Plug/Connection cable 6 m cable 10 m cable 20 m cable
User installation Vertical user installation (electric, pneumatic) to flange
Horizontal user installation (electric, pneumatic) to flange (only for 200 mm stroke)
2SWLRQV,4
Operating block
B~IO CAN compact module 16I /16O, installed, wired, configured, with plug connectors
Trigger input
Additional Documentation
Touchscreen BF312T incl. set of cables, 10 m (loosely included)
License, additional software ROPS4 incl. BAPSplus ROPS4 incl. BAPSplus
DDE Server4 as well as BAPSplus Recompiler
WinSPS (basic package + PCL + central programming)
PCL-L PCL-X
WinDP WinCAN
Hardlock (dongle)
Connection adapter for 3rd/4th camera
65'3&/$FFHVVRULHV
Valve Group for TC Pulse (3 842 521 297) Pneumatic spring (3 842 521 298)
Holder for PHG 2000 (1 070 918 445)
Keyboard template in English PHG 2000 (1 070 918 446)
3842 530 881 (03.08) en

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• Absolute encoders • rho4.0 incl. 16 E / 8 A • Robot operating system • CD-ROM
• Plug connection in stand • EVS201 • PCL software: PCL-S • Safety notes
• Rated load 2 kg (max. 5 kg) • AV 206 • rho4 SW functions (printed)
• Driveless teaching • Cable set Enclosed on CD: • Circuit diag.
• User installation on arm 2 • 19" rack • easyURERW Suite (printed)
with digital 8I / 8O and 4 analog I • ROPS4/Online (w/o license)
• 3 pulse valves in arm • DDE-Server4 (w/o license)
• Plug connection on arm 2 • WINSPS (w/o license)
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AR6 AR8 with IQ200
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ASi Gateway in stand
Plug/connection cable 3 m cable 6 m cable 10 m cable 20 m cable
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rho4.1 (rho4.1 instead of rho4.0) Pentium PIII-Processor 400 MHz (instead of PI-Processor)
Operating block
Touchscreen BF312T incl. set of cables 10 m (loosely enclosed) with rho4.1 available only
Licence, additional software ROPS4 incl. BAPSplus ROPS4 incl. BAPSplus
DDE-Server4 as well as BAPSplus Recompiler
WinSPS (basic package + PCL + central programming)
PCL-L PCL-X
WinDP WinCAN
Hardlock (dongle)
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Holder for PHG 2000 (1 070 918 445)
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..... Units B~IO K-CAN 16DI/16DO compact (1070 079 749)
.....Units BL-SET-SA-K32, screw terminal (1070 080 343)
.....Units 9-pin CAN bus plug (1070 919 029)
.....Units CAN bus cable, 20 m per unit (1070 085 783)
......Units B~IO K-DP 16DI/16DO compact (1070 079 745)

.....Units BL-SET-SA-K32, screw terminal (1070 080 343)
.....Units 9-pin PROFIBUS-DP bus plug (1070 918 539)
.....Units PROFIBUS-DP bus cable, 20 m per unit (1070 085 782)
......Units B~IO M-CAN Bus control (1070 079 755)

.....Units BL-SET-SA bus contr. B~IO M, screw terminal (1070 080 344)
.....Units 9-pin CAN bus plug (1070 919 029)
.....Units CAN bus cable, 20 m per unit (1070 085 783)
......Units B~IO M-DP Bus control (1070 079 751)

.....Units BL-SET-SA-Busan. B~IO M, screw terminal (1070 080 344)
.....Units 9-pin PROFIBUS-DP bus plug (1070 918 539)
.....Units PROFIBUS-DP bus cable, 20 m per unit (1070 085 782)
......Units B~IO modular, Gateway (1070 083 150)

.....Units Modular plug connector (1070 079 782)
......Units B~IO 8DI modular (1070 079 757)

.....Units BL-SET-SA-8DI/8DO/RV, screw terminal (1070 080 340)
......Units B~IO 8DO modular (1070 079 759)

.....Units BL-SET-SA-8DI/8DO/RV, screw terminal (1070 080 340)
......Units Hardlock, instead of Crypkey (1070 919 875)
......Units Touchscreen BF312T (1070 079 484)

.....Units rho4.1/BF312T connection cable, 10 m (1070 080 744)
.....Units rho4.1/BF312T connection cable, 10 m (1070 921 384)
3842 530 881 (03.08) en

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The sales department of the Bosch Rexroth AG as well as your regional partner
are at your disposal for questions about the Rexroth robots. You can find their
addresses in internet under the following addresses:
Or contact:
Bosch Rexroth AG
Vetrieb Roboter BRL/VRO
Löwentorstraße 68
P.O. B. 30 02 07
'6WXWWJDUW
Tel.: +49-(0)711-811-31518
Fax: +49-(0)711-811-7875
E-Mail: turboscara@boschrexroth.de
7HFKQLFDOVXSSRUW
You can obtain support for the system design and startup from our Technical
application support:
'HSDUWPHQW%5/952
7HO

For further services round the robot, such as programming, contact your regional
partner (Hotline, see chapter 12.4).
3842 530 881 (03.08) en

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In addition to the services of your regional partner, the whole course range of our
training center in Erbach is also available. All courses are very pratical and include
excercise blocks, in which the learnt knowledge will be trained on original systems.
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IQ200-GL Robotic basics X X X X
IQ200-B Basic operating and X

programming
IQ200-I Maintenance of SR, X X

SRplus with IQ200
IQ200-P Programming for X

advanced users
IQ200-PCL PCL programming in X

robot systems
SR-E SR setup X X X
with operating device
AR-E AR setup X X X
with operating device
robotYLVLRQ robotYLVLRQ for IQ200 X
easyURERW-P Handling with easyURERWSuite X X X
BAPSplus-P The graphic programming tool X X X
rho4.0-I Change from rho4.1 to rho4.0 X X X
AR-I AR robot maintenance X
)XUWKHU%56FRXUVHV
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WinSPS PCL programming with WinSPS X
WinDP-I WinDP software, X

bus configuration
FB-GL Field bus basics X
PCL-P Projecting X X
and programming
3842 530 881 (03.08) en

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What is robotics,
technical terms and components of robotics
3 days
Prerequisite: Technological knowledge
,4UKR% %DVLFRSHUDWLQJDQGSURJUDPPLQJ
Operating the robot system with PHG and easyURERW Suite,
interaction of mechanics, electronics, and control
5 days
Prerequisite: rho4 basics, good knowledge of Windows including Explorer
,4UKR, 0DLQWHQDQFHRI6565SOXVZLWK,4
Servicing of the robot’s mechanical system,
control design and hardware
5 days
Prerequisite: Seminar IQ200/rho4-B,
good knowledge of Windows including Explorer
,4UKR3 3URJUDPPLQJIRUDGYDQFHGXVHUV
Programming with easyURERW Suite, using important functions of the control,
dealing with graphic simulation
5 days
Prerequisite: Seminar IQ200/rho4-B,
,4UKR3&/ 3&/SURJUDPPLQJLQURERWV\VWHPV
Basic knowledge of the design of PC based control technique
3 days
Prerequisite: Seminar IQ200/rho4-I
65( 65VHWXSZLWKRSHUDWLQJGHYLFH
Operating the swivel-arm robot via PHG,
becoming familiar with SR
2 days
Prerequisite: rho4 basics
3842 530 881 (03.08) en

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Operating the articulated robot via PHG,
becoming familiar with SR
2 days
Prerequisite: rho4 basics
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Becoming familiar with robotYLVLRQ, setup cameras
communication between robotYLVLRQ and BAPS
3 days
Prerequisite: Seminar IQ200/rho4-B / Seminar IQ200/rho4-P
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Becoming familiar with the programming environment easyURERWSuite
2 days
Prerequisite: IQ200/rho4-B,
%$36SOXV3 7KHJUDSKLFSURJUDPPLQJWRRO
Becoming familiar with the programming environment BAPSplus
2 days
Prerequisite: IQ200/rho4-B, good knowledge of Windows including Explorer
UKR, &KDQJHIURPUKRWRUKR
Becoming familiar with rho4 hardware components and rho4 software compon-
ents, carrying out maintenance work at the rho4.0
2 days
Prerequisite: IQ200/rho4-B / IQ200/rho4-I
$5, $5URERWPDLQWHQDQFH
Carrying out maintenance work,
control design and hardware
2 days
Prerequisite: IQ200/rho4-B / IQ200/rho4-I,
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More detailed information about the current training program can be requested
directly at the training center:
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Didactic
P.O.B. 11 62
D-64701 Erbach
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Please use our customer hotline, too:
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With products in the fields:

• Linear and assembly technics
• Pneumatics
• Drive and control technology
• Industrial hydraulics,
the Bosch Rexroth AG is a complete supplier in the factory automation. Please
send your questions to:
info@boschrexroth.de
In internet under http://www.boschrexroth.com you can find your regional contact

persons.
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AR6/8................................................. 39
Active 20 mA interfaces..................... 59, 62 Control ............................................... 12, 39
Ambient conditions ................................ 102 Control cabinet ............................ 12, 39, 69
Amplifier, amount .................................... 67 Control panel
Arbeitsraum Installation dimensions ...................... 70
SR4/6/8plus ....................................... 95 Controller rho4
ASi Bus.................................................... 71 rho4.0................................................. 58
ASi bus .................................................... 66 rho4.1................................................. 60
AV201 for SR4/6/8plus ............................ 65 Copyright ................................................... 9
AV206 for turbo AR6/8 ............................ 65 Customer hotline ................................... 129
Cycle time ................................................ 37
%
'
B~IO M-CAN and modules...................... 75
B~IO M-DP and modules ........................ 78 Digital input module ................................. 77
B~IO modules.......................................... 72 Digital output module......................... 76, 80
BAPS3 ............................................... 67, 82 Dimensions .............................................. 14
BAPSplus ................................................ 84 dimensions .............................................. 39
Base plate Display functions
AR6/8................................................. 44 AR6/8................................................. 49
SR4/6/8plus ....................................... 21 Documentation
Bellows .................................................... 12 Further current manuals .................. 117
Bus connections ...................................... 71 Installation and startup..................... 115
Bus control Maintenance .................................... 117
ASi bus .............................................. 71 Programming ................................... 116
CANopen ........................................... 71 Projecting......................................... 115
InterBus-S.......................................... 71 Driveless teaching ................................... 29
Profibus-DP ....................................... 71
Bus Control B~IO M-D............................. 79
(
& Electrical and pneumatical interfaces

AR6/8................................................. 46
CAN interface .................................... 59, 61 Electrical interfaces
CAN/CANopen ........................................ 67 Assignments SR4/6/8plus.................. 25
CANopen ................................................. 71 EVS201 ................................................... 63
K-CAN16DI/16DO ............................. 74
Circuit diagram
SR4/6/8plus ....................................... 32 )
Components ............................................ 68
Connection cable..................................... 12 Fixture...................................................... 12
SR4/6/8plus ..................................... 104 AR6/8................................................. 39
Console Further components .............................. 129
SR4/6/8plus ....................................... 22
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* SR4plus ........................................... 120

SR6/8DP/CL .................................... 122
GateWay ................................................. 85 SR6/8plus ........................................ 121
Gripper flange ......................................... 94 Outputs
AR6/8 ........................................ 45, 106 digital ................................................. 66
, 3
I/O gateway Path precision.......................................... 36

Design, possible field of application .. 80 PC interface
I/O interface to peripherals Ethernet ............................................. 67
JC3 .................................................... 47 parallel ............................................... 67
Inputs serial.................................................. 67
analog................................................ 66 PC interfaces
digital ................................................. 66 serial.................................................. 67
Installation ..................................... 103, 113 Planning sheet
Installation dimensions............................ 70 AR6, side view................................. 108
InterBus-S ............................................... 71 AR6, top view .................................. 109
Interface for brake box AR8, side view................................. 110
JC4 .................................................... 48 AR8, top view .................................. 111
Interface valves ....................................... 50 SR4 with console............................... 97
Interfaces ................................................ 66 SR4plus with stand............................ 96
SR6plus with console ........................ 99
SR6plus with stand............................ 98
/ SR8plus with console ...................... 101
Pneumatic line......................................... 28
Power loss, max. ..................................... 67
Lift sleeve ................................................ 37
Power type .............................................. 70
Limits............................................. 103, 113
Processor ................................................ 67
Load capacity .......................................... 93
Profibus-DP ............................................. 71
AR6/8 .............................................. 105
K-DP16DI/16DO ................................ 77
Protection type .................................. 38, 67
Protection type/environment.................... 12
0 AR6/8 ................................................ 39
Mass moment of inertia........................... 93

AR6/8 .............................................. 105
5
Measurement input ................................. 61
RAM ........................................................ 67
Reaction forces ....................................... 93
2 Repeatability............................................ 36
rho4.0
OPC-Server 4.......................................... 85 Interfaces........................................... 58
Operating block ....................................... 70 Processor .......................................... 58
Operating mode ...................................... 70 rho4.1
Operating system .................................... 67 Interfaces........................................... 60
Operating temperature ............................ 67 Processor .......................................... 60
Order form Robot programming................................. 67
AR6/8 .............................................. 123 robotvision ............................................... 87
IQ200 - accessories ........................ 124
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Scope of delivery ....................................... 9

SERCOS interface .................................. 67
Sleeve ..................................................... 12
SRCAN module ....................................... 73
Stroke .............................................. 12, 103
TCP/IP ..................................................... 66
Technical data
AR6/8................................................. 52
controller............................................ 66
rho4.1 ................................................ 66
SR4/6/8plus ....................................... 36
Technical support .................................. 125
Tool Connector .................................. 23, 30
Training ................................................. 126
User installation ......................... 12, 28, 104

AR6/8................................................. 39
horizontal ........................................... 28
SR4/6/8plus ..................................... 104
vertical ............................................... 28
User interface .................................... 24, 37
V_24 interfaces ....................................... 59

VxWorks .................................................. 67
Weight ..................................................... 38
WinDP/ WinCAN...................................... 85
WinSPS ................................................... 85
Working area ........................................... 37
AR6/8................................................. 39
SR4/6/8plus ....................................... 14
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Notes
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Notes
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Notes
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Bosch Rexroth AG
Linear Motion and
Assembly Technologies
Postfach 30 02 07
70442 Stuttgart, Germany
Tel. +49 (0)7 11 8 11-3 15 18
Fax +49 (0)7 11 8 11-78 75
www.boschrexroth.com/robots
Österreich France Danmark

Bosch Rexroth GmbH Bosch Rexroth SAS Bosch Rexroth A/S
Stachegasse 13 BP 13 - ZI de la Trentaine Gungevej 1
A-1120 Wien F-77501 Chelles Cedex DK-2650 Hvidovre
Tel. +43 (0)1 9 85 25 40-0 Tel. +33 (0)1 64 72 81 34 Tel. +45 36 77 44 66
Fax +43 (0)1 9 85 25 40-29 Fax +33 (0)1 64 72 81 31 Fax +45 36 77 08 66
Schweiz Belgique Suomi

Bosch Rexroth Schweiz AG Bosch Rexroth N.V. Bosch Rexroth Oy
Hemrietstraße 2 Industrielaan 8 Ansatie 6b
CH-8863 Buttikon B-1470 Ternat FIN-01740 Vantaa
Tel. +41 (0)62 3 91 50 56 Tel. +32 (0)2 5 82 31 80 Tel. +358 (0)9 8 49 11-1
Fax +41 (0)62 3 86 80 79 Fax +32 (0)2 5 82 43 10 Fax +358 (0)9 8 49 11-360
Great Britain Italia Norge

Bosch Rexroth Limited Bosch Rexroth S.p.A. Bosch Rexroth AS
Meridian South Via G. di Vittorio, 1 Berghagan 1
Meridian Business Park I-20063 Cernusco s/N (MI) NO-1405 Langhus
Braunstone, Leicester LE3 2WY Tel. +39 02 9 23 65-1 Tel. +47 64 86 41 00
Tel. +44 (0)11 62 81 44 45 Fax +39 02 9 23 65-5 00 Fax +47 64 86 90 62
Fax +44 (0)11 62 89 28 78
USA
Bosch Rexroth Corporation
816 East Third Street
Buchanan, MI 49107
Tel. +1 800 322 6724
Fax +1 616 697 5288
Ihr Vertragshändler Technische Änderungen vorbehalten

Your concessionary Subject to technical modifications
Printed in Germany
3 842 530 881
(03.08) en • BRL/VRO

Rexroth Robotics Planning Manual 2.: Scara SR4/6/8plus, Turbo AR6/8

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Rexroth Robotics Planning Manual 2.: Scara SR4/6/8plus, Turbo AR6/8

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Industrial Electric Drives Linear Motion and Service Mobile

Hydraulics and Controls Assembly Technologies Pneumatics Automation Hydraulics

turboscara SR4/6/8plus, turbo AR6/8

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6.1.2 rho4.1 ........................................................................................................................... 60

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The turboVFDUD SR4/6/8plus robot systems consist of a four-axis swivel arm

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• Extension through FRPSDFWDQGIOH[LEOHLQSXWRXWSXWPRGXOHV:

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The planning manual is copyrighted. All rights are reserved.

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Following features apply to both robot systems:

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• The new %UDQGQDPH5H[URWKfollows the united manufacturing strategy for

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Fixture Stand Stand Stand

Optional versions, see following chapters.

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User installation (AWI)

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All data in [mm]

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With bellows (FB) Sleeve length P 555

All data in [mm]

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Stand length S Standard 500 AWI vertical

user installation installation

All data in [mm]

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Stroke axis 3 H 200 200 400

Flange F 148 148 148

All data in [mm]

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Stand length S Standard 500

user installation installation 430 370

All data in [mm]

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Stroke axis 3 H 200 200 400

Flange F 148 148 148

All data in [mm]

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65GXVWSURRI is for use in especially severe conditions. This robot is

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The standard’s base plate is fastened by M12 bolts.

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As a standard the following is included on arm 2:

Following interfaces are provided:

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3842 530 881 (03.08) en

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green logic voltage supply is ok

green on-load voltage is ok

red module in EXVE))state

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