CC 220n Rack Bosch Manual

DATASHEET
BOSCH REXROTH
CC 220N
OTHER SYMBOLS:
CC220N, CC 220N
RGB ELEKTRONIKA AGACIAK CIACIEK

SPÓŁKA JAWNA
Jana Dlugosza 2-6 Street

51-162 Wrocław www.rgbelektronika.pl
Poland
[email protected]
+48 71 325 15 05
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Antriebs- und Steuerungstechnik
rho 3
Interface Conditions
102
Version
Automationstechnik
rho 3
Interface Conditions
1070 073 025-102 (95.01) GB
Reg. Nr. 16149-03
E 1991 - 1995
by Robert Bosch GmbH,

All rights reserved, including applications for protective rights.
Reproduction or handing over to third parties are subject to our written permission.
Discretionary charge 40.– DM

CONTENT rho 3
Flexible Automation Interface Conditions
CONTENT
1 System design
1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Card rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.2.1 Rack Version 1 (4 slots) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.2.2 Rack version 2 ( 5 slots ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.2.3 Rack version 3 ( 19" 5/8 Slots ) . . . . . . . . . . . . . . . . . . . . . . . . 8
1.2.4 Rack version 4 (19" 5/7 Slots ) . . . . . . . . . . . . . . . . . . . . . . . . 10
1.2.5 Rackvariante 5 (6 Steckplätze) . . . . . . . . . . . . . . . . . . . . . . . . 12
1.2.6 Rack version 6 (8 Slots) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.2.7 Rack VERsion 7 rho 3.2 (6 Slots) . . . . . . . . . . . . . . . . . . . . . . 16
1.2.8 Rack version 8 rho 3.2 (8 Slots) . . . . . . . . . . . . . . . . . . . . . . . 18
1.2.9 rho 3 with external PLC Input/Output Cards . . . . . . . . . . . . . 20
2. Dimensions, installation and interface conditions

2.1. Dimensions - Card rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.2. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.2.1. Installation distances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.3. Card rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.3.1. RC card rack 1.0 - 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.3.2. RC/PLC card rack 1.0 - 5/8 . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.4. Electrical connection

2.4.1. Power supply (general) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
2.4.2. Voltages and tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2.4.3. 24 V power supply for load and logic supply . . . . . . . . . . . . 36
2.4.4. PE conductor, 0 V, neutral conductor, analog ground . . . . . 37
2.4.5. Voltage connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2.4.6. Interference suppression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
2.4. Operating conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
2.6. Maintenance
2.6.1. Control panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
2.6.2. Card rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
2.6.3. CP/MEM 4 module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
2.6.4. PLC modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
3 Plug-in units
3.1 Processor/memory module CP/MEM4 . . . . . . . . . . . . . . . . . . 50
3.2 Processor/memory module CP/MEM5 . . . . . . . . . . . . . . . . . . 55
3.2.1 Input Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
3.2.2 Data Interfaces on CP/MEM 5 . . . . . . . . . . . . . . . . . . . . . . . . . 57
3.2.3 Interface assignment x11,x12,x22 . . . . . . . . . . . . . . . . . . . . . . 60
3.3. Processor module CP 2.5 . . . . . . . . . . . . . . . . . . . . . . . . . 61
3.4. Memory module MEM 5 . . . . . . . . . . . . . . . . . . . . . . . . . . 68
I – 3
CONTENT rho 3
3.5 Servo loop interface SERVO 3-5

3.5.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
3.5.2 Measuring system inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
3.5.7 Analog setpoint outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
3.5.8 Probe inputs / 5V probe switching voltage . . . . . . . . . . . . . 79
3.5.8.1 Technical data, probe inputs . . . . . . . . . . . . . . . . . . . . . . . . . . 79
3.5.8.2 Pin assignment, probe inputs . . . . . . . . . . . . . . . . . . . . . . . . . 80
3.5.8.3 Connection options for probes . . . . . . . . . . . . . . . . . . . . . . . . 81
3.6. Servo loop interface SERVO 8

3.6.1. Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
3.6.2. Measuring system inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
3.6.4. Analog setpoint outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
3.7. Servo card modular SERVO . . . . . . . . . . . . . . . . . . . . . . . 95

3.7.1. Overview of modular Servo abs8 . . . . . . . . . . . . . . . . . . . . . . 96
3.7.2. Overview of modular Servo abs7/inc1 . . . . . . . . . . . . . . . . . . 97
3.7.3. Overview of modular Servo abs5 . . . . . . . . . . . . . . . . . . . . . . 98
3.7.4. Overview of modular Servo inc6/poti1 . . . . . . . . . . . . . . . . . . 99
3.7.5. Incremental measuring system inputs . . . . . . . . . . . . . . . . . . 100
3.7.5.1. Approved incremental digital measuring . . . . . . . . . . . . . . . . 101
3.7.5.2. Pin assignments of incremental measuring systems . . . . . 103
3.7.6. Absolute encoder module . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
3.7.6.1. Pin assignment for absolute encoder module . . . . . . . . . . . 107
3.7.7. Potentiometer measuring system module . . . . . . . . . . . . . . . 108
3.7.7.1. Pin assignment for potentiometer module . . . . . . . . . . . . . . 109
3.7.8.1. Pin assignment OUT ANALOG X22 . . . . . . . . . . . . . . . . . . . . 112
3.8 Control Loop Card Modular SERVO m.i. . . . . . . . . . . . . 113

3.8.1 Identification of connections . . . . . . . . . . . . . . . . . . . . . . . . . . 114
3.8.2 Overview of SERVO m.i. ABS3 . . . . . . . . . . . . . . . . . . . . . . . . 115
3.8.3 Overview of SERVO m.i. ABS4/INC1 . . . . . . . . . . . . . . . . . . . 116
3.8.6 Overview of SERVO m.i. ABS9 . . . . . . . . . . . . . . . . . . . . . . . . 119
3.8.7 Overview of SERVO m.i. ABS6/INC1/Potentiometer . . . . . . 120
3.8.8 Incremental measuring system inputs . . . . . . . . . . . . . . . . . . 121
3.8.8.1 Permissible incremental measuring systems . . . . . . . . . . . . 121
3.8.8.2 Rotary measuring systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
3.8.8.3 Linear measuring systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
3.8.8.4 Recommended pulse shaper electronics (EXE) . . . . . . . . . . 124
3.8.8.5 Connection assignment for incremental measuring systems 125
3.8.8.6 Cable Servo measuring system (ROD) . . . . . . . . . . . . . . . . . 128
3.8.9 Absolute encoder module . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
3.8.9.1 Interface characteristics of absolute measuring systems . . 129
3.8.9.2 Permissible absolute measuring systems . . . . . . . . . . . . . . 130
3.8.9.3 Pin assignment for absolute encoder module . . . . . . . . . . . 132
3.8.10 Potentiometer measuring system module . . . . . . . . . . . . . . . 133
3.8.10.1 Pin assignment for potentiometer module . . . . . . . . . . . . . . 134
3.8.11 Analog setpoint outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
I – 4
CONTENT rho 3
3.8.11.1 Pin assignment analog outputs . . . . . . . . . . . . . . . . . . . . . . . . 137

3.8.12 Fast inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
3.8.12.1 Technical data, fast inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
3.8.12.2 Pin assignment, fast inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
3.8.13 Probe inputs / 5V probe switching voltage . . . . . . . . . . . . . 140
3.8.13.1 Technical data, probe inputs . . . . . . . . . . . . . . . . . . . . . . . . . . 140
3.8.13.2 Pin assignment, probe inputs . . . . . . . . . . . . . . . . . . . . . . . . . 141
3.8.13.3 Connection options for probes . . . . . . . . . . . . . . . . . . . . . . . . 142
3.9. Servo interface SERVO i

3.9.1. Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
3.9.2. Measuring system inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
3.9.4. Fast inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
3.9.4.1. Technical data, fast inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
3.9.4.2. Pin assignment, fast inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
3.9.5. Probe inputs / 5V probe switching voltage . . . . . . . . . . . . . 157
3.9.5.1. Technical data, probe inputs . . . . . . . . . . . . . . . . . . . . . . . . . . 157
3.9.5.2. Pin assignment, probe inputs . . . . . . . . . . . . . . . . . . . . . . . . . 158
3.9.5.3. Connection options for probes . . . . . . . . . . . . . . . . . . . . . . . . 159
3.10 Modulo I/O 24/0.1 with PIC250 . . . . . . . . . . . . . . . . . . . . 160
3.11 Input/Output Module I/O32/16 0.5A . . . . . . . . . . . . . . 166

3.11.1 Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
3.11.3 Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
3.11.4 Generating and Applying the 24 Volts . . . . . . . . . . . . . . . . . . 169
3.11.5 Extensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
3.12 Module NCPLCI/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
3.13 Module NCPLCBit (Bit Coupler) . . . . . . . . . . . . . . . . . 175

3.13.1 Connection cable NCPLCBit to AG/Z or AG/P. . . . . . . . . . . 176
3.13.2 Connection cable NCPLCBit to AG/ZS or AG/PS. . . . . . . 177
3.14 Power supply PS 75 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
3.15 Module PS 200 (power supply) . . . . . . . . . . . . . . . . . . . . 180
4 Programmable manipulator PHG 3

4.1 Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
4.2 Environmental conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
4.3 Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
4.4 Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
4.5 Emergency stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
4.6 Confirmation key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
4.7 Cable and Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
4.8 Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
4.9 Adaptor cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
4.10 Extension cable for the PHG . . . . . . . . . . . . . . . . . . . . . . . . . . 187
I – 5
rho3
Flexible Automation Interface conditions
1 System design
1.1 General
GeneralThe rho 3 a modular design, i.e. different function areas such as processor,
memory, servo loops etc. are located on separate plug-in units.
The card rack accommodates all the plugged-in modules required. It combines
the individual modules to produce an electrical and mechanical unit (logic unit).
The control rho3 is available with two different processor concepts:
the rho 3.1, where the CPU and memory are located in one module
(see plug-in unit CP/MEM 4 CP/MEM 5),
the rho 3.2, where the CPU and memory are located on separate
modules (see plug-in units CP2.5 and MEM5)
In addition to the logic unit, the control system may also include the following ele
ments:
` Programming system
` Handheld programmer
` Handling system/robot
` external PLC
1
rho3
Online/Offline programming system Hand-held programmer

ÊÊÊ
ÀÀÀ
ÊÊÊ
ÀÀÀ
ÀÀÀ
ÀÀÀ
ËËËËËËËË
ËËËËËËËË
CP/MEM 4
DUMMY PANEL
DUMMY PANEL
E/A
rho 3.1 in the 19'' rack
I/O
I/O
I/O
I/O
I/O
I/O
I/O
I/O
NC-PLC I/O
SERVO i
I/O BUS
PS 75
X22
SPS CL300,CL500 Robot

PC400/PC600
2
rho3
Example: RC card rack Example: RC/PLC I/O card rack

equipped with CP/MEM4, Servo i, equipped with CP/MEM4, Servo i, NC-PLC
I/O 24/0.1 and PS 75 I/O, PS 75 and I/O cards
ËËËËË or
ËËËËËËËËËËËËËË
ËËËËË ËËËËËËËËËËËËËË
CP/MEM 4
CP/MEM4
SERVO i
DUMMY PANEL
DUMMY PANEL
DUMMY PANEL
PS 75
I/O
I/O
I/O
I/O
I/O
I/O
I/O
I/O
I/O
NC-PLC I/O
I/O BUS
SERVO i
PS 75
x11
x11
x12 x12
x21 x21
x22 x22
PC free PHG PC free PHG
System design rho 3.1 (schematic)
3
System Structure rho 3
Flexible Automation Card Rack Interface Conditions
1.2 Card rack

The rho 3.1 is available in the following versions 1 through 6, and the rho 3.2 in the
version 7 and 8.
1.2.1 RACK VERSION 1 (4 SLOTS)

CP/MEM5
reserved for 2nd I/O or servo i
I/O with integrated PIC 250
PS 75
rho 3.1 - C
. PS 75
. I/O- 32/24 0,2 A with PIC and CAN

` I/O- 32/16 0,5 A with PIC and CAN
` I/O- 64/40 0,2 A with PIC and CAN
` BIT coupler to Bosch PLC CAN
` PC/IO coupler to Bosch PLC I/O cards
with PIC250 and CAN
- I/O expansion, for example for direct I/O`s

- Servo 3 ,
- Servo 5 ,
- Servo 4i or 6i
- Servo m.i ABS 3
. CP/MEM5 up to 512 KByte user memory

Interfaces V24_1/20mA, V24_2, PHG
4
Version table for

rack version 1
Rack slot RACK 1.0 - 4
Card 201 202 203 204
CP/MEM5 up to 512 kB
I/O 32/24 with PIC + CAN
NC - PLC (B) with CAN
PC - IO with PIC + CAN
SERVO 3 narrow
SERVO 5 narrow
SERVO 4i
SERVO 6i
SERVO ABS 3i
I/O 32/24
I/O 64/40
I/O 32/16
I/O 32/16 with PIC
I/O 32/24 with PIC
I/O 64/40 with PIC
NC - PLC (B)
PC - IO with PIC 250

PS 75
Card can be inserted in this slot and occupies one slot.
5
1.2.2 RACK VERSION 2 ( 5 SLOTS )
Please note :
Max. measuring system current is limited to 1.5 A with PS75.

CP/MEM5
It may be necessary to have power supply

the encoder at the customer end.

I/O with integrated PIC 250
Up to 10 analog outputs can be operated.

When absolute valuators are used they must be
PS 75
externally supplied.
SERVO module
rho 3.1 rho 3.1

. PS 75
. I/O- 32/24 0,2 A with PIC250

` I/O- 32/16 0,5 A with PIC250
` I/O- 64/40 0,2 A with PIC250
` BIT coupler to Bosch PLC
with PIC250

- Servo 4i or 6i
- Servo m.i ABS 3 with PIC250 and CAN
. Servo 3 ,
` Servo 5 ,
` Servo 4i or 6i
` Servo m.i ABS 3
` Servo m.i modularly equipped

6
Rack slot RACK 1.0 - 5 Version table for

Card 201 202 203 204 205 rack version 2
CP/MEM 5 until 512kB
SERVO 3 narrow
SERVO 5 narrow
SERVO8 wide
SERVO 4iS
SERVO 6iS
SERVO ABS 3i
SERVO m.i.ABS4/INC1 Card can be inserted in
this slot and occupies
SERVO m.i.ABS6/INC1 one slot.
SERVO m.i.ABS8/INC1
SERVO m.i.ABS9
Card occupies two
slots
I/O 32/24 0,2A 24V DC

I/O 64/40 0,2A 24V DC
I/O 32/16 0,5A 24V DC

I/O 32/16 with PIC
I/O 32/24 with PIC
I/O 64/40 with PIC

NC - PLC (B)

PS 75
7
1.2.3 RACK VERSION 3 ( 19" 5/8 SLOTS )
Please note the following when using a

PS75 :
CP/MEM5
The max. measuring system current is

Dummy cover
limited to 1.5 A; if required use PS200

or supply the encoder externally.
Up to 10 analog outputs can be
I/O card
operated with dem PS 75.

PS 75
I/O card
I/O card
I/O card
PC/IO coupler
When absolute valuators are used

they must be externally supplied.
SERVO module
rho 3.1 im 19'' - Rack
8 slots for I/O cards

. PS 75
` PS 200
. PC/IO coupler to Bosch PLC I/O cards

with integrated PIC250
` BIT coupler to external Bosch PLC

- Servo 4i or 6i
- Servo m.i ABS 3
. Servo 3 ,
` Servo 5 ,
` Servo 4i or 6i
` Servo m.i ABS 3
` Servo m.i. modularly equipped

8
Rack slot RACK NC 5/8 19" with PC - IO

Card 201 202 203 204 205 206 1 2 3 4 5 6 7 8
CP/MEM 5 512kB
SERVO 3 narrow
SERVO 5 narrow
SERVO8 wide
SERVO 4iS
SERVO 6iS
SERVO ABS 3i
SERVO m.i.ABS4/INC1 Card can be inserted

in this slot and occu
SERVO m.i.ABS6/INC1 pies one slot
SERVO m.i.ABS8/INC1
SERVO m.i.ABS9
Card occupies
I/O 32/24 two slots
I/O 64/40
I/O 32/16
I/O 32/16 with PIC
I/O 32/24 with PIC
I/O 64/40 with PIC

NC - PLC (B)

PS 75
PS 200 *)
PLC I/O card
*) PS200 for configurations with more than 1.5 A measuring system current and/or
when operating more than 10 analog outputs.
9
1.2.4 RACK VERSION 4 (19" 5/7 SLOTS )

CP/MEM5
Dummy cover
NC PLC bit coupler
ZE300
PS 75
I/O card
I/O card
I/O card
NT1
SERVO module
5 I/O slots
. ZE300
. NT1
rho 3.1 im 19'' - Rack
. PS75
` PS200
. Bit coupler to integrated

CL 300
- I/O card, for example for direct I/O`s

- 2. Servo 4i or 6i
- 2. Servo m.i ABS 3
. Servo 3 ,
` Servo 5 narrow or Servo 8 wide
` Servo 4i or 6i
` Servo m.i ABS 3
` Servo m.i ABS9 modularly equipped
. CP/MEM up to 512 KByte user memory

interfaces V24_1/20mA, V24_2, PHG
10
Rack slot RACK NC/CL 5/7 19"with Bitkoppler

Card 202 203 204 205 206 207 208 209
CP/MEM5 512kB
SERVO 3 narrow
SERVO 5 narrow
SERVO8 wide
SERVO 4iS
SERVO 6iS Cards can be inserted
in this slot and occu
SERVO ABS 3i
pies one slot
SERVO m.i. ABS4/INC1

SERVO m.i. ABS8/INC1 Card occupies two
slots
SERVO m.i.ABS6/INC1/POT
SERVO m.i. ABS9
I/O 32/24
I/O 64/40
I/O 32/16
I/O 32/16 with PIC
I/O 32/24 with PIC
I/O 64/40 with PIC

NC - PLC (B)

PS 75
PS 200 *)
NT1
ZE300
PLC I/O card
*) PS200 for configurations with more than 1.5 A measuring system current and/or when ope
rating more than 10 analog outputs.
11
1.2.5 RACKVARIANTE 5 (6 STECKPLÄTZE)
bei Einsatz eines PS75 bitte beachten :

CP/MEM5
I/O 64/40 with integrated PIC 250

Max. measuring system current is limited to 1.5 A with PS75.

It may be necessary to have power supply
the encoder at the customer end.
PS 75
Up to 10 analog outputs can be operated.

When absolute valuators are used they must be
externally supplied.
SERVO module
rho 3.1
. PS 75
` PS 200
. I/O- 32/24 0.2 A with PIC [and CAN]

` I/O- 32/16 0.5 A with PIC [and CAN]
` BIT coupler to Bosch PLC [and CAN]
with PIC250 [and CAN]

- Servo 4i or 6i
- Servo m.i ABS 3
- Servo m.i modularly equipped
. Servo 3 ,
- Servo 5 ,
- Servo 4i odr 6i
- Servo m.i ABS 3
- Servo 8 (wide)
12

Card 201 202 203 204 205 206 207
Version table
CP/MEM 5 up to 512kB for rack 5
SERVO 3 narrow
SERVO 5 narrow
SERVO 8 wide
SERVO 4iS
SERVO 6iS
SERVO ABS 3i
SERVO m.i. ABS6/INC/POT Card can be in
serted in this slot
SERVO m.i. ABS9 and occupies one
slot
Card occupies
I/O 32/24 two slots
I/O 64/40
I/O 32/16
I/O 32/16 with PIC
I/O 32/24 with PIC
I/O 64/40 with PIC

NC - PLC (B)
*) PS200 for configurations
PC - IO with PIC + CAN with more than 1.5 A measu
ring system current and/or
PC - IO with PIC 250 when operating more than 10
PS 75 analog outputs.
PS 200 *)
13
1.2.6 RACK VERSION 6 (8 SLOTS)

CP/MEM5

Dummy cover
PS 200
Dummy cover
rho 3.2
. PS75
` PS 200
. I/O- 32/24 0.2 A with PIC [and CAN]

` BIT coupler to Bosch PLC [and CAN]
with PIC250 [and CAN]
- I/O expansion, for example for direct I/O's

- Servo 4i or 6i
- Servo m.i ABS 3
. Servo 3 ,
- Servo 5 ,
- Servo 4i or 6i
- Servo m.i ABS 3
- Servo 8 (wide)
. CP/MEM5 up to 512 kByte user memory

14

Card 201 202 203 204 205 206 207 208 209
Version table
CP/MEM 5 up to 512kB for rack version 6
SERVO 3 narrow
SERVO 5 narrow
SERVO8 wide
SERVO 4iS
SERVO 6iS
SERVO ABS 3i
SERVO m.i.ABS4/INC1
SERVO m.i.ABS6/INC1 Card can be in
SERVO m.i.ABS8/INC1 serted in this slot
and occupies
SERVO m.i.ABS6/INC1/POT one slot
SERVO m.i.ABS9
Card occupies
I/O 32/24 two slots
I/O 64/40
I/O 32/16
I/O 32/16 with PIC
I/O 32/24 with PIC
I/O 64/40 with PIC

NC - PLC (B)

PS 75
PS 200 *)
*) PS200 for configurations with more than 1.5 A measuring system current and/or when operating
more than 10 analog outputs.
15
1.2.7 RACK VERSION 7 RHO 3.2 (6 SLOTS)

CP2.5
PS 200
MEM5
rho 3.2
. PS 200
. I/O- 32/24 0,2 A with PIC

` I/O- 32/16 0,5 A with PIC
` I/O- 64/40 0,2 A with PIC
` PC/IO coupler to Bosch PLC I/O cards with PIC250

- Servo 4i or 6i
- Servo m.i ABS 3
. Servo 3 ,
- Servo 5 ,
- Servo 4i or 6i
- Servo m.i ABS 3
- Servo 8 (wide)
. MEM5 up to 2.5MB user memory
. CP2.5 with 4 interfaces

interfaces V24_1/20mA, V24_2, PHG,RS422
- CP2.5 processor card with 2 CPU/FPU - cards15 MHz

serial interface
Interface RS 232/20mA for connecting
the Offline programming system
Serial interface for connecting the PHG
2 free serial interfaces (RS232/20mA)
1 free serial interface (RS 422)
- MEM5 Memory with 128 KBYTE user memory
expandable to 2.5 MB
- SERVO 3 Control and evaluation for 3 axes
incremental, measuring probe input
- I/O 32/24 0,2A with intergrated PLC PIC250
4k program step EEPROM
- PS200 power supply
16

Card 201 202 203 204 205 206 207
Version table
CP2.5 for rack version 7
MEM5 bis 2,5 MB
SERVO 3 narrow
SERVO 5 narrow
SERVO8 wide
SERVO 4iS
SERVO 6iS
SERVO ABS 3i
SERVO m.i.ABS4/INC1
SERVO m.i.ABS6/INC1
SERVO m.i.ABS8/INC1
SERVO m.i.ABS9
I/O 32/24
I/O 64/40
I/O 32/16
I/O 32/16 with PIC
I/O 32/24 with PIC
I/O 64/40 with PIC

NC - PLC (B)
PS 200
17
1.2.8 RACK VERSION 8 RHO 3.2 (8 SLOTS)

CP2.5
PS 200
Dummy cover
MEM5
rho 3.2
. PS 200
. I/O- 32/24 0.2 A with PIC

` I/O- 32/16 0.5 A with PIC
` I/O- 64/40 0.2 A with PIC
` PC/IO coupler to Bosch PLC I/O cards with PIC250

- Servo 4i or 6i
- Servo m.i ABS 3
. Servo 3 ,
- Servo 5 ,
- Servo 4i or 6i
- Servo m.i ABS 3
- Servo 8 (wide)
. MEM5 up to 2.5MB user memory
. CP2.5 with 4 interfaces

interfaces V24_1/20mA, V24_2, PHG,RS422
18

Card 201 202 203 204 205 206 207 208 209
Version table
CP2.5 for rack version 8
MEM5 up to 2.5 MB
SERVO 3 narrow
SERVO 5 narrow
SERVO8 wide
SERVO 4iS
SERVO 6iS
SERVO ABS 3i
SERVO m.i.ABS4/INC1
SERVO m.i.ABS6/INC1
SERVO m.i.ABS8/INC1
SERVO m.i.ABS9
I/O 32/24
I/O 64/40
I/O 32/16
I/O 32/16 with PIC
I/O 32/24 with PIC
I/O 64/40 with PIC

NC - PLC (B)
PS 200
Card can be inserted in this slot and occupies two slots.
19
1.2.9 rho 3 with external PLC Input/Output Cards
Rack version 5 or 7 Rack version 6 or 8
CP2.5
CP2.5
PS 200
Valid for rack versions
PS 200
Dummy cover 1 and 2
PC/IO coupler
PC/IO coupler
MEM5
MEM5
rho 3.2 rho 3.2
Card rack
7 slots
048 982
Cable :
Order no. 064754 Length : 0.55 m
064753 Length : 1.8 m
AG/Z-S
Card rack 14 slots

047 269
AG/Z-S
I/O card
I/O card
I/O card
20
Dimensions rho 3
Flexible Automation Card-Rack Interface conditions
2. Dimensions, installation and interface conditions
2.1. Dimensions - Card rack
ÉÉÉÉÉÉÉÉ
Front view Side view
ÉÉÉÉÉÉÉÉ 205,4
100 mm
clearance
ËËËËË
187,5 307,5 1,5
ËËËËË
133,3
11,7
386,15 -0,3
488,1
146,1
133,3
37,7
~
377
100 mm
clearance
Cable entry
ÉÉÉÉÉÉÉÉ
Fan connection 24V =
Top view Assembly cut-out

(reduced)
160,4
187,5
M6 or
ø7
133,3
170
146,1
492
133,3
39,7
RC-Card-Rack 1.0 - 5
21
Dimensions rho 3
ÉÉÉÉÉÉÉÉ
ÉÉÉÉÉÉÉÉ 100 mm
clearance
266,5
248,5 307,5 1,5
ËËËËËË
133,3
11,7
386,15 -0,3
488,1
146,1
133,3
37,7
~
377
100 mm
clearance
ÉÉÉÉÉÉÉÉ
Cable entry
Fan connection 24V =

(reduced)
221,36
248,5
M6 or
ø7
133,3
231
146,1
492
133,3
39,7
RC-Card-Rack 2.5 - 6
22
Dimensions rho 3
ÉÉÉÉÉÉÉÉÉÉÉ 100 mm
clearance
327,4
307,5 1,5
ËËËËËËËË
309,5
ËËËËËËËË
133,3
11,4
-0,3
7
386,15
488,1
146,1
133,3
37,7
100 mm ~377
ÉÉÉÉÉÉÉÉÉÉÉ
clearance
Cable entry
Fan connection
ÉÉÉÉÉÉÉÉÉÉÉ ~
220 V

(reduced)
282,4
309,5
M6 or
ø7
133,3
292
146,1
492
133,3
39,7
RC-CARDRACK 2.5 - 8
23
Dimensions rho 3
ÉÉÉÉÉÉÉÉÉÉÉÉÉ 100 mm
clearance
480
307,5 1,5
ËËËËËËËËËËË
461,9
ËËËËËËËËËËË
133,3
11,7
-0,3
7
386,15
488,1
146,1
133,3
37,7
100 mm ~377
ÉÉÉÉÉÉÉÉÉÉÉÉÉ
clearance
Cable entry
Fan connection 24 V
ÉÉÉÉÉÉÉÉÉÉÉÉÉ
(reduced)
435 461,9
M6 or
ø7
133,3
450
146,1
492
133,3
39,7
RC/SPS -CARDRACK 1.0 -5/8 und RC/CL 1.0-5/7
24
rho 3
Intallation
2.2. Installation
The RC logic unit can be mounted on the front or rear side. The assembly kit or
der No. 050409 (bracket + screws) is required for rear mounting.
Installation Vertical. Make sure that there is a clearance on all sides

Position : of 100 mm and a clearance of 5 mm from the rear wall for
ventilation purposes.
Type of
installation: Control cabinet installation in accordance with IP 54.
Rear installation
Hole pattern for rear installation

133,3
M6 or
ø7
Card-Rack
146,1
133,3
39,7
187,5
(RC logic unit)
461,9
(Combined rack)
25
rho 3
Intallation
2.2.1. Installation distances

The individual RC and PLC card racks require certain clearances for ventilation
and cable routing.
` In the RC card rack, the minimum clearance is 100 mm. Cable ducts may
be located in this clearance.
` The maximum distance between the RC and PLC card racks is restricted
by their connecting cables (refer to the system description PC 60, P. No.
3594, for information on distance and design of the PLC modules them
selves).Cable lengths for bit coupling between RC and PLC:
Cable NC-PLC-bit to AG/Z or AG/P: 0.55m
(Order No. 041535)
Cable NC-PLC-bit to AG/P: 1.8m
(Order No. 048081)
Cable length for word coupling between RC and PLC:
Cable NC-PLC-Word to AG/NC3: 0.7m
(Order No. 060742)
Cable NC-PLC-Word to AG/NC3: 1.5 m
(Order No. 060743).
Recommended installation of RC and PLC card racks:
Install PLC rack flush right above RC rack. Vertical distance between
the two racks 100 mm.
` The distances from sources of interference (transformers, reactors, drive
amplifiers, power contactors etc.) must be as large as possible. If neces
sary, sources of interference must be partitioned off by screen plates.
26
System design rho 3
Flexible Automation Card rack Interface conditions
2.3. Card rack

Two different card rack versions are available for the rho 3.1:
` RC card rack 1.0-5 (RC logic unit with max. 5 plug-in units).
` RC/PLC card rack 1.0-5/8 (RC-PLC I/O logic unit with max. 5 plug-in units
and 8 PLC modules).
2.3.1. RC card rack 1.0 - 5
The housing is designed to accommodate a maximum of 5 plug-units. The

plug-in fan unit underneath the card is operated with 24 V DC.
Example:
RC card rack equipped with the modules CP/MEM4, SERVO 6i, I/O 24/0.1
I/O 24/0.1 and PS 75
27
System design rho 3
2.3.2. RC/PLC card rack 1.0 - 5/8
The rho 3.1 section is extended here by a rack section for PLC I/O modules. A total
of 8 slots are available for PLC modules.
The fan underneath the PLC cards (24 V DC) is already prewired with the plug-in
fan unit.
ËËËËËËËËËËËËËËË
ËËËËËËËËËËËËËËË DUMMY PANELS
DUMMY PANEL
CP/MEM 4
I/O
I/O
I/O
I/O
I/O
I/O
I/O
I/O
NC-PLC I/O
SERVO i
I/O BUS
PS 75
X21
X22
Example:
RC/PLC card rack equipped with the modules CP/MEM4, SERVO i, RC-PLC I/O, PS 75
and PLC I/O cards
1.2.3 Equipment variants
The card rack (rho 3.1 section) is prepared for the following rho cards. The respec
tive figures schematically show the equipment possibilities for the RC card rack
1.0-5 and the RC/PLC card rack 1.0-5/8.
`CP/MEM4, processor/memory module
- Max. 512 kByte RAM (user memory)
- Max. 64 kByte EEPROM
`Servo modules
Servo3
Servo5
Servo8
Servo3i, Servo4i, Servo6i - these cards may be installed twice
Modular servo for connection of up to 8 axes with different measuring sys
tems
`Power supply PS 75
- The power supply supplies the internal voltages for the logic circuits of all
plug-in units.
28
System design rho 3
rho 3.1 Logic unit

1. 5. Slot
Dummy-
I/O
Panel
24/0.1
SERVO
3i Second
I/O
NC-PLC
BIT
CP/
MEM4 SERVO PS 75
SERVO 3i
4i
SERVO
4i
SERVO NC-PLC
6i SCP2 I/O
*) only on CC 220 M
Slots 1 and 5
Slots 1 and 5 are reserved for the modules CP/MEM4 and PS75 in both card
racks.
In the RC/PLC card rack, slot 6 is always additionally equipped with a dummy
panel.
rho 3.1-PLC I/O logic

unit
1. 2 3 4 5 6 Slot
DUMMY DUMMY
NC-PLC
PANEL PANEL
I/O
SERVO
3i I/O I/O I/O I/O I/O I/O I/O I/O
Second
I/O
CP/
MEM4 SERVO PS 75
SERVO 3i
4i
SERVO
4i
SERVO PS 200
6i SCP2
29
System design rho 3
`Servo variants, servo loop modules (servo cards)

- Servo 3i with 3 incremental measuring system inputs and 3 analog setpoint
outputs.
outputs
outputs
- A maximum of 2 servo i cards can be installed.
rho 3.1-Logic unit
2. 3. Slot
DUMMY
I/O
PANEL
24/0.1
SERVO
3i Second
I/O
NC-PLC
BIT
CP/
MEM4 SERVO PS 75
SERVO 3i
4i NC-PLC
WORD*)
SERVO
4i
SERVO NC-PLC
6i SCP2 I/O
*) Only on CC 220 M
Slot 3
Slot 3 can be alternatively used for a second servo card (Servo 3i, Servo 4i), a sec
ond I/O card or one SPC2 card. The cards installed in slots 2 and 4 are decisive
here. A dummy panel is fitted instead of a second servo or I/O card or the SPC
card.
Slot 2
Slot 2 is intended for one Servo i card in both card rack versions (Servo 6i, Servo 4i,
Servo 3i).
rho 3.1-PLC I/O Logic

unit
1. 2 3 4 5 6 Slot
DUMMY DUMMY
NC-PLC
PANEL PANEL
I/O
SERVO
3i I/O I/O I/O I/O I/O I/O I/O I/O
Second
I/O
CP/
MEM4 SERVO PS 75
SERVO 3i
4i
SERVO
4i
SERVO PS 200
6i SCP2
30
System design rho 3
Slot 3
Slot 3 can be alternatively used for a second Servo i card (Servo 3i, Servo 4i) or a
dummy panel.
31
System design rho 3
`PLC-variants
- I/O 24/0.1 with PIC 250
I/O card with 64 inputs and 40 outputs and internal PLC (PIC 250).
Installation of a second I/O card (without PIC 250) is possible.
- Bit coupling
RC-PLC bit coupler, interface module to external PLC
(PC600, CL300).
- RC-PLC I/O coupling
Direct coupling with PLC I/O cards which are accommodated in the
combined rack or an external rack.
rho 3.1-Logic unit

3. 4. Slot
DUMMY
I/O
PANEL
24/0.1
SERVO
3i Second
I/O
NC-PLC
BIT
CP/
MEM4 SERVO PS 75
SERVO 3i
4i NC-PLC
WORD*)
SERVO
4i
SERVO NC-PLC
6i SCP2 I/O
*) Only on CC 220 M
Slot 3
A second I/O card or a second servo card (Servo 6i, 4i or Servo 3i) can be fitted in
slot 3.
Slot 4
The slot can be used alternatively for an I/O card, the RC-PLC I/O coupling card
or RC-PLC bit coupling card. The system connection to the external PLC is es
tablished with this card (connecting cable RC-PLC bit to AG/Z or AG/P)
32
System design rho 3
rho 3.1-PLC I/O Logic

unit
3. 4. 6. Slot
SERVO DUMMY
3i PANEL
PLC section
CP/ NC-PLC DUMMY

MEM4 PS 75 PANEL
SERVO SERVO I/O
4i 3i
SERVO SERVO
6i 4i
Slot 3
Slot for a second servo card (Servo 3i or Servo 4i). This slot is covered with a
dummy panel if no card is equipped here.
Slot 4
The slot is intended for the RC-PLC I/O coupling card. The connection between
the RC and PLC I/O modules is made internally via the backplane.
33
rho 3
Electrical connection
2.4. Electrical connection
The robot installation is normally supplied with power from the 3-phase AC mains supply. All internal system
voltages are derived from this. The relevant standards and regulations must be taken into account for the mains
power supply.
The electrical connections specific to the RC and PLC are described in the following sections
2.4.1. Power supply (general)
5 3 x 380 V / 50 Hz
3 220 V / 50 Hz
Load power supply Logic power supply
380 VAC 380 VAC
24 VDC 24 VDC
2
24 V logic circuit
2 24 V load circuit
PLC (PC600)
DG
PU
NT
EZ
ZE 601
ZE 602
ZE 603
O
Memory
I
I
220V
220V
Possible rho 3 variant

CP/MEM4
I/O 24/0.1
SERVO i
SERVO i
PS 75
X22
X31
X31
X10
X10
X10
24V=
34
rho 3
5 3 x 380 V / 50 Hz
3 220 V / 50 Hz
Load power supply Logic power supply
380 VAC 380 VAC
24 VDC 24 VDC
2
24 V logic circuit
2 24 V load circuit
PLC (PC600)
DG
PU
NT
EZ
ZE 601
ZE 602
ZE 603
O
Memory
I
I
220V
220V
RC
SERVO 6i
SERVO 6i
I/O 24/0.1
PS 200
MEM 5
CP 2.5
X31
X31
X10
X10
220V
35
rho 3
2.4.2. Voltages and tolerances
220 V supply 24 V logic supply 24 V load supply
~ 220 VNorm +10%/ -15% ~ 24 VDC ,+30%/ -15% ~ 24 VDC ,+ 30%/ -15%
~ 48 - 62 Hz ~ 5 A for powersupply PS 75 (*) ~ max.4 A I/O 24/0.1 (**)
~ max. interruption time ~ 6 A for power supply PS 200(*) for PLC dependent on
10 ms all 10 sec. ~ Residual ripple max. 1.2 Vpp configuration approx.
at Unorm 0.5 A for fan
~ Max. interruption time ~ Residual ripplet max. 1.2 Vpp
10 ms all 10 sec. at Unorm
(*) Values at UNom (clock power supply)

(**) Load dependend
2.4.3. 24 V power supply for load and logic supply
L1 L2 L3
380V +5%
380V
380V -5%
PE
0V
Safety transformer to VDE 0551.

Connection in accordance with
VDE 0551. + 24V
Power supplies to VDE 0550
Order number 913485 913486 913487 913488

Input voltage 380 V, 3-phase, 50 Hz
Input current at nominal load 0.3 A~ 0.45 A~ 0.83 A~ 1.7 A~
Input current in no-load condition 0.05 A~ 0.08 A~ 0.19 A~ 0.19 A~
Output voltage 24 VDC; +/-10 % unregulated, residual ripple approx. 4.8 %
Max. output current 6A 10 A 20 A 40 A
Fuse (output side) Mini. fuse Termal excess-current Fuse
with LED circuit-breaker (NEOZED)
Efficiency at nominal load approx. . 72% 77% 80% 86%
Connection terminals 1.5 mm2 1.5 mm2 2.5 mm2 4 mm2
Isolation group Group C for 380 V
Type of protection IP 00
Dimensions in mm (W x H x D) 300x165x100 300x165x100 340x185x140 420x240x140
Weight in kg 6.3 6.4 10.9 19.5
36
rho 3
2.4.4. PE conductor, 0 V, neutral conductor, analog ground

The potential bonding connections of all system parts (particularly between RC
and drives) must be kept as short as possible.
All screens must be connected at both ends, subject to the precondition that the
system parts are electrically networked.
Exception:
Refer to the individual drives for details of screen connection in the case of set
point lines.
all PE
for 220 VAC
all screens (exception: setpoint lines!)
load
all housings/bolts/machine parts
min. 62
Neutral conductor
min. 62
Zero volt bar - load
1,52
X10 Auxiliary function Interface
PE bar
PSU (*)
24 V load
min. 62
Zero volt bar - logic
162 1,52 62 42 42 42 42
Connection only for GND-
X10 bonded amplifier inputs!
PSU (*) Drives
24 V logic
Axes
(*) Power supply unit
Observe the relevant VDE regulations (e.g. VDE 0100) and the regulations of
our local power supply company!
37
rho 3
2.4.5. Voltage connection
min. 62 PE Drives (setpoint)

-Stud of card racks, control panels etc. (PE)
min. 62 Axes
all housing parts
min. 62
all screens 62 4242 42 42
bonded amplifier inputs!
min. 62
0 volt bar - logic
PE Logic PSU
L1 380 VAC 0 V Interface

0V
L2 0 V Auxiliary function
L3 24 VDC 0 V probe
24V
0 V-......
min. 62
0 volt bar - load
PE Load PSU 6 3
L1 380 VAC
0V 3
L2 1.52 (2) (3)
L3 24 VDC
24V 6
PLC (PC600)
DG
PU
NT
EZ
PE bar
ZE 601
ZE 602
ZE 603
E
E
A
Memory
220V
L1 24V
PE
N 0V
220V
PE
L1
PE Possible RC variant
N
X22 CP/MEM4
I/O 24/0.1
SERVO i
PS 75
X10
X31
X10
X10
24V
0V
2) .5 mmý, up to 20 m
3 2.5 mmý, up to 35 m
162 24V A separate on-the-spot power
3 supply is required for distances
over 35 m!
0V
3) Multi-terminal busbar if possible
38
rho 3
min. 62 PE Drives (setpoint)

-Stud of card racks, control panels etc. (PE)
min. 62 Spindles Axes
all housing parts
min. 62
all screens 62 42
42 42 42
bonded amplifier inputs!
min. 62
0 volt bar - logic
PE Logic PSU
L1 380 VAC 0 V interface

0V 1.52 (*) (**)
L2 0 V auxiliary function
L3 24 VDC 0 V probe
24V
0 V-......
min. 62
0 volt bar - load
PE Last-Netzteil 6 3
L1 380 VAC
0V 3
L2 1.52 (*) (**)
L3 24 VDC
Schutzleiter-Schiene
24V 6
PLC (PC600)
DG
PU
NT
EZ
ZE 601
ZE 602
ZE 603
O
Memory
I
I
220V
L1 24V
PE
N 0V
220V
PE
L1
PE RC variants
N
SERVO 6i
SERVO 6i
I/O 24/0.1
PS 200
MEM 5
CP 2.5
X31
X31
X10
X10
24V
0V
PE 220V
(*) 1.5 mm2, up to 20 m 2.5
3 mmý, up to 35 m
162 24V A separate on-the-spot power
L1 3 supply is required for distances
PE 0V
over 35 m!
N (**) Multi-terminal busbar if possible
39
rho 3
2.4.6. Interference suppression

Electrically operated and controlled machine installations can cause electromag
netic fields (radio and audio frequency) and disturbances in the mains power sup
ply network. For this reason, interference suppression is necessary in accordance
with the applicable regulations.
VDE regulations apply in addition to the corresponding legal regulations, e.g.:
VDE 0874
Principles for realization of measures for radio interference suppression
VDE 0875
Regulations for radio interference suppression of devices, machines and installa
tions for nominal frequencies from 0 to 10 kHz.
The corresponding interference suppression measures have already been im
plemented in Bosch controls. However, the operating reliability of a control may
be impaired by wire-carried interference.
The external circuitry (control cabinet) must therefore include
- spare-quenching circuits
- attenuation of inductive switching peaks
- limitation of the switching voltages of fast semiconductors
- screen
It is important that all these components are taken into account in interference
suppression measures, since they produce an optimum and economical solution
only as a whole.
Please note
- Perform interference suppression as close as possible to the source of in-
terference.
- Limit leakage currents in accordance with the applicable safety regulations
(shock-hazard protection!).
- Provide suppressors with good mechanical support in order to prevent
breakage by vibration.
- Use only components which are identified as interference suppressors.
The question of electrical symmetry or asymmetry is also important. This is be

cause asymmetrical interference voltages occur in addition to the symmetrical in
terference voltage components produced between the supplied cables. The for
mer are caused, for example, by capacitive coupling of the interference source
with the mains supply. The following diagram shows a common interference sup
pression circuit. Here, the asymmetrical interference voltages are discharged via
Cy to the housing. Cx attenuates the symmetrical interference.
40
rho 3
L Cy
L Cx Mains supply
Cy
41
rho 3
Interference suppression examples
Contact circuitry
(AC, DC, superposed DC)
a) b) c) d)
D
R R
VDR
Rp R U
C C
b) for sensitive contacts, residual current when contact is open!

c) for highly-inductive load
d) voltage-dependent resistance, residual current when contact is open
Circuitry for an inductive load

(Motors, solenoids, relay and contactor coils)
a) b) c) d) e) f)
-
D R R
VDR
R D
U
ZD C
+
c) drop-out delay for relays!

d) defined drop-out delay for relays
f) gas-discharge tube
Mains power circuitry
L1
L1
L2 M
Cx Cy 3
M ~
L3
Cx
~
N Cy
Cx Cx Cx
SL SL
42
rho 3
Operating cobditions
2.4. Operating conditions
Ambient/operating conditions
Ambient temperatures from +5 °C to +55 °C.
If the angle from the vertical does not exceed +/-305 and a clearance of 100 mm
(see dimension drawings) exists:
Storage temperature from -25 °C to +70 ° C.
The ambient temperature may drop to 0 °C when the control is switched on. The
ambient temperature range refers to the temperature in the housing:
Temperature change rates of up to 3 °C per minute are permitted.
Humidity
Humidity class F in accordance with DIN 40 040.
The bench mark values for relative humidity are 50 % at 40 5C and 90 % at
20 °C. Dew formation in the control is not permitted.
Mechanical loading
a) Vibration test *) IEC 68-2-6
Loading by 3 axes offset at 905 to each other
Test conditions:
Frequency range: 10 - 150 Hz
Deflection amplitude 10 - 57 Hz: 0.075 mm
Acceleration amplitude 57 - 150 Hz: 1 g
Test duration per axis: 10 frequency cycles
Frequency change rate:1 octave/min
b) Shock test *) IEC

68-2-27
Shock loading with three shocks in each principal positive and negative axis
direction
Pulse strength 15 g
Pulse duration 11 ms
Pulse shape semi-sinusoidal
c) Transport vibration test in accordance

with Bosch guideline N42 AP 450
*) Examples apply to PLC
Corrosive influences
The ambient air must be free of high concentrations of acids, lyes, corrosive
agents, salts, metal vapors or other electrically conducted contamination.
Electromagnetic interference
Strong electromagnetic fields must not occur in the direct proximity of the equip
ment.
43
rho 3
Interference immunity
a) Static discharge in accordance with IEC 801-2, severity better than 3.
b) Conducted interference of the power supply in accordance with IEC 801-4,

severity better than 3.
c) Non-conducted interference IEC 801-3

Test field strength in the frequency band 27-50 MHz > 10 V/m.
Dirt (EN 60 204, Part 1 Paras. 7.2.1 and 8.1.2)

Dust-free air is demanded for the environment of our built-in devices. Housings
and compartments in which the devices are accommodated must comply at least
with type of protection IP 54 in accordance with DIN 40 050.
Installation position, installation location

Installation position: vertical (card rack)
Installation location: control cabinet installation
in accordance with IP 54 (card rack)
Positioning of the control panel

The operating personnel must have a clear view from the control panel to the mo
ved machine parts irrespective of the chosen location of the control.
Direct sunlight reduces display readability and should be avoided.
Control panel installation
44
rho 3
Type of protection
IP 20 in accordance with DIN 40 050 for card rack
Air pressure
In operation up to 3000 m above sea level.
Boundary conditions
Standards, regulations and guidelines
The control is based on the following standards and guidelines:
` Bosch safety guidelines
` VDE 0113 (EN 60 204) *)
` VDE 0160 *)
` IEC 801 (interference definitions) *)
` IEC 68 (mechanical load)
` Humidity class F in accordance with DIN 40 040
` Types of protection in accordance with DIN 40 050 (also including IP 00, IP

20, IP 54).
` Transport vibration test in accordance with Bosch standard N42 AP 450
` Control connection and operation in accordance with IEC 550 and VDE 551
*) is not completely satisfied
45
rho 3
Maintenance
BOSCH BOSCH BOSCH BOSCH BOSCH

CNC CNC CNC CNC CNC
c Rechte bei ROBERT BOSCH GMBH, auch für den F all von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.
Output
X
EPROM 1
MODUL 1
Battery
CP/MEM4 E/A 24/0.1 PS75

Write O
Prot. I
X
Input
2
1
V24.1/20mA
X
1
1
X
Input
2
X 2
V24.2
1
2
V out
Ready
24V
X
X R 24V
1 24 V
2 G 0V
0
1 B 0V
Reset
Ready 2
P
X A X
2 N 2
2 E 0
L
F10A
24V
24V X
X 1
1 24V 0V
0V 0 0V
0
0V
SERVO 6i
Alle BVE 15239-5
46
rho 3
Maintenance
2.6. Maintenance
The control electronics, interface cabinet and mechanical components of a robot
installation must be serviced at regular intervals in order to guarantee problem-
free operation.
Caution!
Perform maintenance and inspection work only when the system is switched off
and de-energized - if not otherwise described.
2.6.1. Control panels

` Clean the monitor screen surface at least once weekly with an anti-static
cloth or window cleaning agent containing spirit.
Do not use any solvents (thinner or similar).
` Readjust screen brightness every 6 months.
` Check plug-in and terminal connections annually.
2.6.2. Card rack

` Check plug-in and terminal connections annually.
` Check ventilators of the plug-in fan units annually to make sure that they
are running properly and that ventilation is functioning.
Check air filter mats for soiling. Watch out filter mats in soap solution if nec
essary. Fit again only when they have dried.
Fit new filter mats if necessary.
Order No.: 066796 (RC section); 066797 (PLC section)
` Inspection of filter mats
Caution!
Revolving fan impeller. Perform maintenance work only in de-energized
condition!
The plug-in fan unit is located in the RC card rack (filter support plate with
ventilators) under the plug-in units and behind the cable duct.
The RC/PLC card possesses an additional plug-in fan unit underneath the
PLC I/O modules (see figure).
47
rho 3
Maintenance
Cable flanges (voltage connection for

Plug-in fans) and left and right of card rack
Plug-in fan unit
fan unit
Fixing screws for cover Plug-in fan unit
Fig.: RC/PLC card rack; location of plug-in fan units
RC card rack
- The horizontal plug-in fan unit can be pulled out to the front after removing the
cable duct (2 quick-release screws). Pay attention to the connecting cable!
The filter mat is located under the support plate behind a inch-down frame.
- After inspection, carefully push in the support plate again together with the in
serted filter mat. Screw on the cable duct again.
RC/SPS card rack
- Undo the four screws on the cover plate. Remove the plate.
- Undo the quick-release screw of the filter support frame (with screwdriver or
coin; 1/4 turn to left)
- Hinge up the filter support frame so that the filter mat can be removed.
- Insert the filter mat again after inspection. Press in the quick-release screw.
- Screw on the cover plate again.
2.6.3. CP/MEM 4 module

` Replace the buffer battery annually (the Bosch shipment date applies).
The battery must be replaced within 14 days after the error "CP/MEM BAT
TERY EMPTY" occurs for the first time at the latest.
Battery type: Alkaline battery, 4.5 V.
Perform battery replacement within 5 min. with the control switched off
(data will be lost if this time is exceeded).
48
rho 3
Maintenance
Procedure: 1. Control "Off".

2. Short-circuit new battery for approx. 2 sec.
3. Remove the cover for EPROM modules and battery
socket.
4. Remove old battery and insert new one.
Pay attention to polarity
5. Screw on battery cover again.
The processor/memory module CP/MEM4 must not be pulled out for battery re
placement.
Note:
- Batteries must not be forcibly opened, charged or thrown into a fire.
- Dispose of exhausted batteries properly.
Refer to the section "CP/MEM4" for further information on the battery of the CP/
MEM4.
2.6.4. PLC modules

Remember that the batteries of the PLC modules RAM600 and ZE603 must also
be replaced annually. Please refer to the PLC manual for instructions on how to
change the batteries in these modules.
49
Plug-in units rho 3
Flexible Automation CP/MEM4 Interface conditions
3 Plug-in units
3.1 Processor/memory module CP/MEM4
BOSCH Toggle switch 1

CNC Write protection for EEPROM
S I
1 O Rotary switch S2
Switch for internal test purposes
S
2 (Position 1 = Normal operation)
EPROM
MODUL
Battery
Buffer battery for data in RAM
CP/MEM4
V24.1/20 mA
X
1
1 Serial data interface 1
V.24 or 20 mA
(Socket X11, Sub-D, 25-pole)
X
V24.2
1
V.24
X RGB signal output to color panel

RGB
21 (Socket X21, Sub-D, 15-pole)
X Connection to control panel (PHG)

22
Panel
Socket X22, Sub-D, 20-pole with inte

grated coaxial connector)
PSU 24 V logic dc
(Connection X10. Weid-
müller terminal strip with X 24V
max. cross-section of 10 24V
1.5 mm2) 0V
0V
Front view of CP/MEM4
Caution:
The module CP/MEM4 must be removed only when the control is switched off.
Internal RAM data (e.g. time) is then buffered for max. 5 minutes.
50
Plug-in units rho 3
` Input voltage
Input voltage 24 V dc logic (connector X10)

Weidmüller terminal strip for connection of 24 V = (logic dc). The voltage connec
tion must be routed directly from the logic power supply.
Toggle switch 1
Write protection for EEPROM ( = protected).
Rotary switch S2
Switch for internal test purposes.
Buffer battery for data in RAM memory
The battery must be replaced annually.
The battery voltage is automatically checked when the control is switched on. An
error message "CP/MEM BATTERY EMPTY" appears if the voltage is too low.
RAM buffering of at least 14 days is guaranteed after the first error display under
normal battery charge conditions.
The CP/MEM4 possesses a capacitor for interim buffering of the data in the RAM.
However, the voltage interruption must not exceed 5 min. when the battery is re
placed while the control is switched off.
In order to change the battery, remove the battery cover and push the battery up
out of the holder.
Battery 4.5 V, alkaline battery Order No. 107 - 913 572The operating system is
located on a soft board under the cover..
` Data interfaces
Serial data interface 1 (connector X11)

V24/20 mA interface for connection of a data terminal (socket X11, Sub-D,
25-pole).
Both interface variants (V24 and 20 mA) are wired at the socket. The V24 interface
behaves like the 20 mA interface with respect to the data. Parameterization of the
interface (baud rate, stop bits etc.) is performed via the PHG or by machine para
meters.
Following parameters are set as defaults: 8 data bits , NO parity,
1 stop bit, 9600 baud
Variable parameters: Baud rate 110-9600 baud, 1/1.5/2 stop bits.
20mA interface (current loop)

The following interface lines are used on the RC end:
TX+, TX- Transmit data, transmit line of the RC.

RX+, RX- Receive data, receive line of the RC.
DTR+, DTR- Data terminal ready, a HIGH signal indicates to the connected
device that the RC is ready to receive.
DSR+, DSR- Data set ready, a HIGH signal indicates to the RC that the
51
Plug-in units rho 3
connected device can receive data.

GND Signal ground.
In the case of a 20 mA connection, one device must always be connected as an
active device and the other as a passive device (active: the device acts as current
source). The 20 mA control interface can be switched active by jumpering pins 9
and 10.
The interface is parameterized as passive if this jumper is missing.
Technical data:
Leel HIGH: approx. 20 mA (min. 12 mA)

LOW: approx. 0 mA (max. 3 mA).
Transfer rate: max. 9600 baud with handshake.
Max. external voltage drop: 3.5 V
(connected as 20 mA active)
(connected as 20 mA passive)
driving device: max. 12 V
Notes on the 20 mA interface:

- A handshake is possible only by device control (software handshake) for
baud rates < 600 baud.
- The cable length should not be greater than 50 or 100 m for a 20 mA connec
tion in order to ensure reliable data transfer. A maximum cable length of 100
m is permitted if the RC is used as the driving device (20 mA active). A maxi
mum of 50 m is permitted if the peripheral interface functions as current
source (CNC: 20 mA passive). Suitable repeaters must be installed in the
line for greater distances.
Serial data interface 2 (connector X12)
V24 interface (socket X12, Sub-D, 25-pole)

TX Transmit data, transmit line of the RC.
RX Receive data, receive line of the RC.
DTR Data terminal ready, a HIGH signal indicates to the connected
DSR Data set ready, a HIGH signal indicates to the RC that the connected
device can receive data.
GND Signal ground.
The status line CTS is not evaluated by the RC. Pin 4 (RTS) is permanently con
nected to 10 V on the RC end.
Technical data:
Level HIGH: +3V to +9V

LOW: -3V to -9V.
52
Plug-in units rho 3
Notes on V24 interface:

baud rate < 600 baud.
- The cable length for a V24 connection should not be greater than 15 m in
order to ensure reliable data transfer. Either suitable repeaters must be con
nected in the line or the 20 mA interface used for greater distances.
- Pin 20 must be jumpered with pin 6 at the RC end if the connected device
does not support a hardware handshake.
53
Plug-in units rho 3
` Interface assignment x11, x12, x22
RC Interface distributor AF 5
Socket X 11 3m
Connector Socket x11
Sub-D, 25 pole Sub-D, 25 pole
Data
TX_1 2 2
Data
RX_1 3 3
V24/RS232
CTS_1 4 4
Control
DSR_1 6 6
DTR_1 20 20
SGND 7 7
DSR1 + 11 11
RX1 + 12 12
TX1 + 13 13
DSR1 - 14 14
20mA passive
DTR1 - 16 16
DTR1 + 19 19
RX1 - 22 22
TX1 - 23 23
Vgnd 9
Vout 10
RC Free serial interface RS232

Socket X 12 Socket x12
Data
TX_2 2 2
RX_2 3 Data 3
V24/RS232
CTS_2 4 4
Control
DSR_2 6 6
DTR_2 20 20
SGND 7 7
Screen housing
RC PHG connection
Socket X 22 Socket x22
Vin 17
PHG Anschluß
Vout 10 10
TX+ 18 13
RX+ 19 12
RS+ 20 16
PGND 16 21
Screen housing 5 EMERGENCY-STOP
7 EMERGENCY-STOP
11 STATUS KEY
15 STATUS KEY
RGB signal (connector X21)

This connection is not currently used on the rho3.
54
Plugin Modules rho 3
Flexible Automation CP/MEM5 Interface Conditions
3.2 Processor/memory module CP/MEM5

The processor and memory module CP/MEM5 is compatible with CP/MEM4 and
can be used as a replacement. Module CP/MEM5 is equipped with either a 15
Mhz CPU module or a 30 Mhz CPU module, depending on the customer's require
ments. When the module is supplied, the front panel is marked to show which pro
cessor module is fitted.
BOSCH Rocker switch S1

CNC Write protection for EEPROM
S I
1 O Rotary switch S2
S
2 (Position 1 = Normal operation)
EPROM
MODULE
Battery
Buffer battery for data
in RAM memory
CP/MEM5
V24.1/20 mA
X
1
V.24 or 20 mA
(Socket X11, SUBD, 25pole)
X
V24.2
1
V.24
X RGB signal output to color

RGB
21 panel
X Connection to operating panel

22
Panel
(PHG)
(Socket X22, SUBD, 20pole with
integrated coaxial connector)
Power supply
24V logic dc
(Connection X10. Weidmüller X 24V
terminal strip with max. 10 24V
diameter of 1.5 mm2) 0V
0V
Frontansicht CP/MEM5
55
Caution:
The CP/MEM5 module must only be disconnected when the controller is swit
ched off! Internal RAM data (e.g. time) are then buffered for a maximum of 5 mi
nutes.
3.2.1 Input Voltage
` Input voltage 24V dc logic (connection X10)

Weidmüller terminal strip for connection of 24V= (Logic dc). The power connec
tion must be routed directly from the logic mains unit.
Rocker switch S1
Write protection for EEPROM (1=protected).
Rotary switch S2
Buffer battery for data in RAM memory

The battery must be replaced once a year!
The battery voltage is automatically tested when the controller is switched on. If
low voltage is detected, an error message appears
"CP/MEM BATTERY EMPTY".
With a normal battery charge, RAM buffering of at least 14 days is assured after
the first error display.
The CP/MEM5 has a condenser for intermediate buffering of the data in the RAM
memory. When the battery is replaced quickly with the controller switched off, ho
wever, the power interruption must not last more than 5 minutes.
To change the battery, remove the battery cover and push the battery up out of the
bracket.
Battery: 4.5 alkali battery, order No. 107 913 572
The operating system is located on a pluggable circuit board (soft board) under
the cover.
56
3.2.2 Data Interfaces on CP/MEM 5
` Serial data interface 1 (terminal X11)

V24/20mA interface for connection of a data terminal unit
Both interface varieties (V24 and 20 mA) are wired on the socket.
As far as the data are concerned, the V24 interface acts just the same as the 20mA
interface. The parameterisation of the interface (baud rate, stop bits etc.) is imple
mented via the PHG or by machine parameters.
The following parameters are implemented: 8 data bits, NO parity,
1 stop bit, 9600 baud
Variable parameters: Baud rate 1109600 baud,
1/1.5/2 stop bits.
` 20mA interface (current loop)

On the RC side, the following interface lines are used:
TX+, TX Transmit data, transmission line of RC.

RX+, RX Receive data, reception line of RC.
DTR+, DTR Data terminal ready, HIGH signal tells the connected
device that the RC is ready for reception.
DSR+, DSR Data set ready, HIGH signal tells the RC that the
connected device can accept data.
GND Signal ground.
In the 20 mA connection, one device must always be switched as the active de
vice, the other as the passive one (active: the device works as the power source).
The 20mA interface of the controller is switched active by bridging pins 9 and 10.
If this bridge is not present, the interface is parameterised as passive.
Technical data:
Level: HIGH: appr. 20 mA (min. 12 mA)
LOW: appr. 0 mA (max. 3 mA)
Transmission rate: max. 9600 baud with handshake.
Max. external voltage fall: 3.5 V
(switched as 20mA active)
Voltage fall in the controller: max. 3.5 V
(switched as 20mA passive)
Power supply of the
leading device max. 12 V
` Notes on the 20mA interface:

For baud rates < 600 baud, handshake is only possible via the device con
trol (software handshake).
For reliable data transmission, the cable length for a 20mA connection
should be no more than 50 or 100 m. If the RC is used as the leading device
(20 mA active), the maximum permitted cable length is 100 m. If the periphe
ral interface works as the power source (CNC: 20 mA passive), the maxi
mum permitted length is 50 m. For longer distances, suitable intermediate
repeaters must be included.
57
CP/MEM 4 < 50 m Peripherals

Socket X11 Socket
subminiature, 25 pin Connector Connector
subminiature, 25 pin
RX+ 22 TX+
Data
RX- 12 TX-
TX+ 23 RX+
Data
TX- 13 RX-
DSR+ 11 DTR+
Status
DSR- 14 DTR-
DTR+ 19 DSR+
Status
DTR- 16 DSR-
Shield on housing Shield on housing
20mA passive (interface of connected device acts as power source)
CP/MEM 4 < 100 m Peripherals

Socket X11 Socket
subminiature, 25 pin Connector Connector
RX+ 12 TX+
Data
RX- 24 TX-
TX+ 13 RX+
Data
TX- 25 RX-
DSR+ 14 DTR+
Status
DSR- 18 DTR-
DTR+ 16 DSR+
Status
DTR- 21 DSR-
Active in 9
Active out 10
Shield on housing Shield on housing
20mA active (interface of CP/MEM5 as power source)
58
Serial data interface 2 (terminal X12)
V24 interface (socket X12, SUBD, 25pole)

On the RC side, the following interface lines are used:
TX Transmit data, transmission line of RC.
RX Receive data, reception line of RC.
DTR Data terminal ready, HIGH signal tells the connected
device that the RC is ready for reception.
DSR Data set ready, HIGH signal tells the RC that the
connected device can accept data.
GND Signal ground.
The status line CTS is note evaluated by the RC. Pin 4 (RTS) is permanently con
nected to 10V on the RC side.
Technical data:
Level: HIGH: +3V to +9V

LOW: 3V to 9V
Transmission rate: max. 9600 baud with handshake.
Notes on the V24 interface:

- For baud rates < 600 baud, handshake is only possible via the device con
trol (software handshake).
- For reliable data transmission, the cable length for a V24 connection should
not be greater than 15 m. For greater distances, either suitable interme
diate repeaters must be installed, or the 20mA interface must be used.
- If the connected device does not support a hardware handshake, pin 20

must be bridged with pin 6 on the RC side.
59
3.2.3 Interface assignment x11,x12,x22
RC Interface distributor AF 3
Socket X11 3m
Socket X11
subminiature, 25 pinStecker subminiature, 25 pin
Data
TX_1 2 2
Data
RX_1 3 3
V24/RS232
CTS_1 4 4
Control
DSR_1 6 6
DTR_1 20 20
SGND 7 7
RX+ 22
RX- 12
TX+ 23
20mA passive
TX- 13
DSR+ 11
DSR- 14
DTR+ 19
DTR- 16
Vgnd 9
Vout 10
Shield on housing
RC Free serial interface RS232

Socket X12
subminiature, 25 pin Socket X12
Data
TX_2 2 2
Data
RX_2 3 3
V24/RS232
CTS_2 4 4
Control
DSR_2 6 6
DTR_2 20 20
SGND 7 7
Shield on housing
RC PHG connection
Socket X22 Socket X22
Vin 17
PHG connection
Vout 10 10
TX+ 18 13
RX+ 19 12
RS+ 20 16
PGND 16 21
Shield on housing 5 EMERGENCY STOP
7 EMERGENCY STOP
11 CONFIRMATION KEY
15 CONFIRMATION KEY
RGB signal (terminal X21)

This connection is currently not used in the rho3.
60
Plug-in units rho 3
Flexible Automation CP 2.5 Interface conditions
3.3. Processor module CP 2.5
BOSCH
CNC F
r
S2
o Rotary switch
n
t
v
CP 2.5 i
e
w
NMI pushbutton
Baudrate
Side view CP 2.5
Rotary switch
(Component mount
only for test purposes ing side)
Terminal2-5
Terminal 2-5
Terminal 1
V24 / 20mA
Terminal 1 (V24/20 mA)

Screen connections
System
Intercon
System Intercom
Front view CP 2.5
Caution:
The processor module CP2.5 must be removed only when the control is switched
off. Internal RAM data (e.g. time) is then buffered for a maximum of 10 minutes.
61
Plug-in units rho 3
NMI pusbutton
The READY 2 contact drops out when this pushbutton is pressed.
Rotary switch for baud rate

Currently no function if CP 2.5 is used as the processor module of the rho 3.
Rotary switch S2
Currently no function if the CP 2.5 is used as the processor module of the rho 3.
Terminals 2-5 (connector X13)

4 interfaces are available at this connector.
f Interface for PHG connection

f Two RS232/V24 or 20 mA interfaces
f One interface in accordance with RS422
The interfaces are controlled by a separate intelligent module which his plugged
onto the CP 2.5 card.
The following diagram shows the assignment of the 50-pole D-sub socket.
An interface distributor AF5 with corresponding cables is available for connection
purposes.
The 20 mA interfaces can also be operated in active mode. In this case, 12 V must
be supplied externally.
62
Plug-in units rho 3
RC 3m Interface distributorAF 5
Socket X 13
Sub-D, 50 pole Plug connector
Data Socket x11
TX_1 28 2 Sub-D, 25-pole
Data
V24/RS232
RX_1 12 3
V24/RS232
RTS_1 17 4
Control 5
CTS_1 33
Control
DSR_1 13 6
SGND 14 7
DTR_1 27 20
12V_IN 11 9
DSR1 + 3 11
RX1+ 36 12
TX1+ 34 13
DSR1 - 35 14
20mA
20mA
DTR1 - 37 16
DTR1 + 38 19
RX1 - 19 22
TX1 - 21 23
Socket x12
Data
TX_2 15 2 Sub-D, 25-pole
Data
RX_2 30 3
V24/RS232
V24/RS232
RTS_2 32 4
Control 5
CTS_2 16
Control
DSR_2 31 6
SGND 14 7
DTR_2 29 20
12V_IN 2 9
DSR2 + 22 11
RX2 + 18 12
20mA
TX2 + 6 13
DSR2 - 1 14
20mA
DTR2 - 4 16
DTR2 + 23 19
RX2 - 5 22
TX2 - 7 23
TX3- 42 2 Socket x31

RX3 - Sub-D, 15-pole
45 4
V11/RS422
DTR3 -
V11/RS422
46 6
DSR3 - 50 8
TX-3 + 44 9
RX3 + 47 11
DTR3 + 48 13
DSR3 + 49 15
Socket x22
KENN 8 Sub-D, 25-pole
in 20
KENN 17
out 10
V in 24 9
PHG interface
V out 43 10
PHG interface
RX+ 9 12
TX+ 25 13
RS+ 8 16
PGND in 40 20
PGND out 41 21
5 EMERGENCY-STOP
Screen to housing 7 EMERGENCY-STOP
11 STATUS KEY
15 STATUS KEY
63
Plug-in units rho 3
Terminal 1 (connector X11)

A combined V24/RS232, 20 mA interface is available at connector X11. The pin
assignment is shown in the following diagrams.
CNC < 15 m Peripherals

Socket X 11 Plug connector Plug connector e.g. DCR
Sub-D, 25-pole Sub-D, 25-pole
TX 2 Data 3 RX
RX 3 Data 2 TX
DTR 20 Status 6 DSR
DSR 6 Status 20 DTR
GND 7 7 GND
Screen to housing Screen to housing
V24/RS232 assignment
V24 interface
TX Transmit data, transmit line of the RC.
RX Receive data, receive line of the RC.
DTR Data terminal ready, a HIGH signal indicates to the connected
DSR Data set ready, a HIGH signal indicates to the RC that the connected
device can receive data.
GND Signal ground.
The status line CTS is not evaluated by the RC. Pin 4 (RTS) is permanently con
nected to 10 V on the RC end.
Pin 20 must be jumpered with pin 6 at the RC end if the connected device cannot
generate any status signals.
Technical data:
Level HIGH: +3V to +9V

LOW: -3V to -9V.
Transferrate: max. 9600 baud with handshake.
64
Plug-in units rho 3
Information on V24 interface:

- The cable length for a V24 connection should not be greater than 15 m in
order to ensure reliable data transfer. Either suitable repeaters must be con
nected in the line or the 20 mA interface used for greater distances.
- It is possible to restrict the maximum transfer rate to values of < 9600 Baud if
special line drivers or receivers are used. In this case, refer to the technical
data of the devices in question.
- Pin 20 must be jumpered with pin 6 at the CNC end if the connected device
does not support a hardware handshake.
20 mA interface (current loop)
CNC < 50 m Peripherie

Socket X 11 Socket
Sub-D, 25-pole Plug connector Plug connector
Sub-D, 25-pole
RX+ 22 TX+
Data TX-
RX- 12
TX+ 23 RX+
Data RX-
TX- 13
DSR+ 11 DTR+
Status DTR-
DSR- 14
DTR+ 19 DSR+
Status DSR-
DTR- 16
20 mA passive (interface of the connected device functions as current source)
CNC < 100 m Peripherie

Socket X 11 Socket
Sub-D, 25-pole Plug connector Plug connector
Sub-D, 25-pole
RX+ 12 TX+
Data
RX- 24 TX-
TX+ 13 RX+
Data
TX- 25 RX-
DSR+ 14 DTR+
Status
DSR- 18 DTR-
DTR+ 16 DSR+
Status
DTR- 21 DSR-
Active in 9
Active out 10
20 mA active (interface of the CP 2.5 functions as current source)
65
Plug-in units rho 3
The following interface lines are used at the RC end:
TX+, TX- Transmit data, transmit line of the RC.

RX+, RX- Receive data, receive line of the RC.
DTR+, DTR- Data terminal ready, a HIGH signal indicates to the connected
DSR+, DSR- Data set ready, a HIGH signal indicates to the RC that the
connected device can receive data.
GND Signal ground.
Other status lines (RTS, CTS) are not set or evaluated by the RC.
In the case of a 20 mA connection, one device must always be connected as an

active device and the other as a passive device (active: the device acts as current
source). The 20 mA control interface can be switched active by jumpering pins 9
and 10. The interface is parameterized as passive if this jumper is missing.
66
Plug-in units rho 3
Technical data:
Level HIGH: ca. 20 mA (min. 12 mA)

LOW: ca. 0 mA (max. 3 mA).
Max. external voltage drop: 3.5 V
(connected as 20 mA active)
Voltage drop in control: max. 3.5 V
(connected as 20 mA passive)
Power supply of the
driving device: max. 12 V
Information on 20 mA interface:
- The cable length for a 20 mA connection should not be greater than 50 or

100 m in order to ensure reliable data transfer. A maximum cable length of
100 m is permitted if the RC is used as the driving device (20 mA active). A
maximum length of 50 m is permitted if the peripheral interface acts as the
current source (RC: 20 mA passive). Suitable repeaters must be connected
in the line for greater distances.
- It is possible to restrict the maximum transfer rate to values of < 9600 baud if
special line drivers or repeaters are used. Please refer to the technical data
of these devices if they are used.
System Intercon (connector X12)

Being prepared.
Party line connection to connect the logic unit with the control panel of the rho 3.2.
(Socket, Sub-D, 15-pole).
67
Plug-in unit rho 3
Flexible Automation MEM5 Interface conditions
3.4. Memory module MEM 5
Cover retaining screw

BOSCH
CNC
Cover for EPROM modules and
EPROM- battery socket
Modul
1
EPROM module 1
MEM 5
2
EPROM module 2
3
EPROM module 3
Battery
G1
Battery socket
G2
Parity-
LED parity error
Error
Front view MEM 5
Caution:
The memory module MEM 5 must be removed only when the control is switched
off.
If the memory module MEM 5 is removed, never remove both batteries at the sa
me time, otherwise all data in the RAM will be lost.
Please remember that internal RAM data and the current time of the CP 2.5 are
also buffered by the batteries of the MEM 5. The data of the CP 2.5 is buffered for
a maximum of 10 minutes if the control is switched off and the MEM 5 removed.
68
Plug-in unit rho 3
Flexible Automation MEM5 Interface conditions
Basic configuration of the MEM 5:

` 512 kByte RAM
` 32 kByte EEPROM
Options:
` RAM: 1 MByte, 2.5 MByte
` EEPROM: 64 kByte
RAM
Memory area for part programs. The whole RAM area is buffered in order to pre
vent data information loss when the control is switched off (or when the module is
removed) (also see the section "Battery").
EEPROM
This memory area is used to save the machine parameters.
The MEM 5 can be equipped with up to 3 EPROM modules on which the operating
system software of the rho 3 is stored; 2 of these modules are currently used.
Battery
2 lithium batteries are used (size C, 3.6 V, Order No. 046800), each with a capacity
of 5.2 Ah for buffering the MEM5 RAM area. The typical value of the buffer time is
around 1 year per battery (replace with cycle: annual). The batteries are connec
ted in the hardware in such a way that the battery which is fitted first is discharged
first. The unused battery is in "standby mode".
The batteries are protected against reverse polarity, short-circuits and leakage.
The corresponding battery must be replaced within 30 days after the error "MEM
BATTERY 1 EMPTY" or "MEM BATTERY 2 EMPTY" appears for the first time. Refer
to the section "Maintenance" for battery replacement instructions.
LED parity error

The LED indicates a parity error in the RAM area of MEM 5. The READY contact
(see PS200) is opened in the event of a parity error. The control is then no longer
ready for operation!
It may be possible to remedy the error by restarting the control (Reset); otherwise,
the MEM card must be replaced.
69
SERVO rho 3
Flexible Automation Interface SERVO 3 - 5 Interface connections
3.5 Servo loop interface SERVO 3-5

The servo card is used for output of the analog speed setpoints and closes the
position control loop by evaluation of the signals of the connected incremental po
sition measuring systems. The servo sampling rate depends on machine parame
ter P5. The overall system may contain a maximum of one SERVO 3-5. A mixed
configuration (SERVO 3-5/ SERVO 6i) is permitted.
3.5.1 Overview
BOSCH
1st measuring system input CNC
X
1
1
2nd measuring system input
X
1
2
3rd measuring system input S
(Socket X13, Sub-D, 15-pole) E
R
X V
1 O
3
optionaly
4th measuring system input
X
1
optionaly 4
X
1
5
1
Analog setpoint outputs 1-5
(Connector X21) X
2
1
Probe inputs
Probe switching voltage 5 V
(Connector X31)
X
3
1
Frontview SERVO 3 - 5 small
Caution:
The servo card SERVO 3-5 must be removed only when the control is switched
off!
70
SERVO rho 3
Basic configuration of the SERVO 3:

` 3 axis
Optios:
` Upgrading for up to 5 axes
3.5.2 Measuring system inputs
(Sockets X11 to X15)

Measuring systems from Messrs. Heidenhain are used. These are suitable either
for direct connection or connection via a pulse shaper (EXE). The connection in
structions of the manufacture with respect to cable lengths and routing must be
observed.
The power supply for a directly connected encoder or an EXE with external 5 V
supply is provided via the measuring system input socket.
The following data generally applies to SERVO 3 - 5 measuring system inputs:
` Max. permissible
cable length/input: 35 m or manufacturer's
specification
` Max. permissible cable

length difference at allinputs : 15 m
` Cable type: Special cable NFS 7264

0 x 0.14 mm2 + 4 x 0.5 mm2
(not for trailing operation!)
` Signal inputs: Differential line reciever

Ri = 120 W
` Input signals: A, B, R, A, B, R (TTL level);

min. voltagedifferences between
>
A and A, B and B, R and R = 600 mV
` Pulse multiplication: Quadruplication of the input frequen-

cey (foue-edge evaluation)
` Max permitted input frequencey: 500 kHz
` Encoder/EXE power supply: +5 V (adjustable at PSU PS200)
` Max. permissible current

consumption per encoder/EXE 350 mA
The signal lines of the measuring systems must be connected exactly in accor
dance with these conditions. It is not permitted to change around the signal
lines for the purpose of direction reversal owing to the resultant decoding of
the zero pulse! Direction reversal is possible in the software by means of the ma
chine parameters.
71
SERVO rho 3
Measuring direction: Positive Negative Positive
a a a a a b a a b a
A/Ua1
A/Ua1
B/Ua2
B/Ua2
R/Ua0
R/Ua0
c c a > 250 ns
=
b > 0 ns
=
Both operating conditions are permissible c > 100 ns
=
3.5.3 Approved digital measuring systems

The system combinations from the ROD/LS and EXE product range of Messrs.
Heidenhain must be adapted individually to the requirements of the machine and
control in question.
In principle, it is possible to install direct-connection rotary encoders from
Messrs. Heidenhain subject to the following preconditions:
- 5 V encoder power supply

- Square-wave signal output
- Line driver in accordance with RS 485
- Encoder current consumption < 350 mA
>
- Min. edge spacing between two active counting pulses = 250 ns
>
- Min. edge spacing for direction reversal =0 ns
>
- Safety distance for reference signal = 100 ns
In addition, it is possible to install EXEs from Messrs. Heidenhain if the following

preconditions are satisfied:
- 5 V or external 220 V power supply
- Line drive in accordance with RS 485
- Max. encoder and EXE current consumption with 5 V supply: < 350 mA
>
- Min. edge spacing between active counting pulses = 250 ns
>
>
72
SERVO rho 3
3.5.4 Rotary measuring systems

` Rotary encoder f. direct conn.: ROD 220 (Messrs. Heidenhain)
ROD 420 "
ROD 426 "
ROD 428 "
Recommended rotary encoders for direct connection:

ROD 428 "
` Rotary encoders for connection

via EXE 604 C, EXE 605 C: ROD 250 (Messrs. Heidenhain)
ROD 450 "
ROD 456 "
ROD 700 "
ROD 800 "
` Rotary encoder for connection

via EXE 702, EXE 816: ROD 800 (Messrs. Heidenhain)
3.5.5 Linear measuring systems

` Linear scales for connection to
EXE 604 C, EXE 605 C, EXE 610,
EXE 801, EXE 802, EXE 803
EXE 804, EXE 805, EXE 813: LS 703 (Messrs. Heidenhain)
LS 707 "
LS 903 "

EXE 808, EXE 816: LS 300 (Messrs. Heidenhain)
LIDA 325 "
Recommended electronic pulse shaper (EXE)

Of the EXEs with external 5 V supply, we recommend the following:
` EXE 604 C (Messrs. Heidenhain)
However, EXEs with own 220 V power supply should be preferred.
Recommendation for electronic pulse shaper (EXE) and encoder

We recommend using the EXE 604 C and encoder ROD 428. These types do not
have any capacitive connection between 0 V of the supply voltage and the hous
ing. This leads to higher interference immunity. In addition, these types possess
an extended measuring system monitoring function which informs the Bosch
control of errors by tri-state switching of the output signals. The EXE 604 C was
developed specially for Bosch controls. It corresponds to the EXE 601 and addi
73
SERVO rho 3
tionally possesses a ground stud as well as a 12-pole Souriau connector at the

RC end.
Notes:
- The list of suitable measuring systems can only be considered as a general
recommendation owing to frequent technical modifications and increasing
product priority.
- Please enquire if it is wished to use other measuring systems.
- The encoder supply voltage is +5 V +/- 5 % for all connected encoders

and the permitted cable lengths (measured directly at the encoder input).
The encoder supply voltage is set at the potentiometer VMS of the power
supply when PS200 is used.
- The encoder cable from the RC control to the ROD encoder can be supplied
by Bosch. This is equipped with a 15-pole Sub-D connector at the RC end
and a 12-pole circular socket of the type "Souriau" at the encoder end.
Preassembled encoder cables are available with length of 5 m, 8 m, 16 m, 25
m, 35 m .
- If the ROD encoder is supplied by Bosch, its cable (0.5 m) is equipped with a
circular connector of the type "Souriau".
. The error signal Uas is not evaluated by the SERVO 8. The EXEs 604 C and
605 C signal a measuring system error by tri-state switching of the output
signals. If the EXEs 604 C and 605 C are not used, this means that any errors
which occur in the area of the measuring system - EXE input cannot be de
tected! In this case, the user must take other suitable protective measures.
74
SERVO rho 3
3.5.6 Pin assignments

The cable shield must possess a continuous connection from the front panel of
the SERVO 3 - 5 to the measuring system.
. The connector pin assignment applies only to cables and encoders

supplied by BOSCH
Socket Cable Encoder Measuring

X11 - X15 (10 x 0.14 mm2 + 4 x 0.5 mm2) Signal output system
max. 1 m
1 1 wh/ye 0.14 1 1 br
A/Ua1
2 2 gn 0.14 2 2 gn
A/Ua1
3 3 gr 0.14 3 3 gr
B/Ua2
4 4 pk 0.14 4 4 pk
B/Ua2
5 5 br 0.5 5 5 bl Sensor
+5 V
6 6 wh 0.14 6 6 rd
R/Ua0
7 7 wh/gr 0.14 7 7 bk
R/Ua0
8 8 vio 0.14 8 8 vio
+ 5V
9 9 rd 0.5 9 9 br
+5V
10 10 sw 0.5 10 10 wh Sensor
11 11 0V
12 12 bk 0.5 12 12 wh
0V
lamp 0V
Connection via metallic housing of the D-sub

connector and pin 11 of the Souriau socket.
max. 50 m
The connecting cables from EXE to the measuring systems are cables from
Messrs. Heidenhain.
Socket Cable EXE Signal- Measuring

X11 - X15 (10 x 0.14 mm2 + 4 output system
x 0.5 mm2)
1 1 wh/ye 0.14 1
A/Ua1 Ua1 Ie1+
2 2 gn 0.14 2
A/Ua1 Ua1 Ie1-
3 3 gr 0.14 3
B/Ua2 Ua2 Ie2+
4 4 pk 0.14 4
B/Ua2 Ua2 Ie2-
5 5 br 0.5 5
+ 5V
6 6 wh 0.14 6
R/Ua0 Ua0 Ie0+
7 7 wh/gr 0.14 7
R/Ua0 Ua0 Ie0-
8 8 vio 0.14 8
Uas Uas + 5V
9 9 rd 0.5 9
+5V + 5V + 5V
10 10 bk 0.5 10
0V
11
Screen
12 12 bl 0.5 12
0V 0V 0V
lamp 0V
Connection via
metallic housing
of the D-sub connector
and pin 11 of the Souriau socket.
75
SERVO rho 3
Cable: Servo - measuring system (ROD)
Connector
Socket
1 2
3 4 5
6 7
8 9 10
11 12
Strain relief
Wiring side
Screen attachment on metallic housing
Cable: LY 10 x 0.14 + 4 x 0.5 (max. cable length 50 m)

Not suitable for trailing operation!
Pin assignment
Color Connector X11 Color Socket X2
white-yellow 1 white-yellow 1
green 2 green 2
grey 3 grey 3
pink 4 pink 4
brown 0.5 V 5 brown 0.5 V 5
white 6 white 6
white-grey 7 white-grey 7
violet 8 violet 8
red 0.5 V 9 red 0.5 V 9
black 0.5 V 10 black 0.5 V 10
blue 0.5 V 12 blue 0.5 V 12
Screen Connector Screen 11
housing
76
SERVO rho 3
3.5.7 Analog setpoint outputs

(Connectors X21 )
Speed-proportional voltages for controlling the individual axes are available at
these outputs. The spindle must be considered as an asynchronous axis.
. An undefined output voltage may be output at the setpoint outputs of

the SERVO 3-5 when the control is switched off. For this reason, the load
voltage must be switched off first and then the logic voltage when the
control is switched off.
In addition, the following points must be observed with respect to the analog set
point outputs of the SERVO 3-5 :
` Recommended cable type: Belden 2 x 0.5 mm2

(8762-20)
` The screen connection depends on the drives used (e.g. for Servodyn T:
connection at both ends).
` Max. output range: +/- 10,0 V
` Output voltage (rapid traverse): + (-) 7,5 V
` The output voltages are non-isolated.

` Permitted load resistance at output: min. 10 kW
` The output stages are resistant to sustained short circuits. However, if sever
al outputs are short-circuited, the output operational amplifier may be de
stroyed as a result of the increased power loss.
` The inputs at the drive amplifiers must be connected as a difference amplifi
er. Ground-bonded circuits must be avoided.
77
SERVO rho 3
3.5.7.1 Pin assignments analog setpoint output
Connector
X21
1
+/-10 V
2 1st setpoint output
0V
3
+/-10 V
4 2nd setpoint output
0V
5
+/-10 V
6 3rd setpoint output
0V
7
+/-10 V
8 4th setpoint output
0V
9
+/-10 V
0V
Screen terminals at
the front panel
78
SERVO rho 3
3.5.8 Probe inputs / 5V probe switching voltage

(Connector X31)
Connector X31 has two inputs (24 V DC, 5 V DC) for switching probes (label on front
panel: "Pr"). Internally, the two inputs are linked via an OR function.
An additional switching voltage for a 5V probe is also available (load capacity: max. 10
mA). This voltage can be switched by the switching contact of a probe and returned to
the controller at the 5 V DC probe input.
The inputs of connector X31 are used in the rho 3 controller in the configuration level
"fast measuring".
Further information on this function can be found in document "rho 3 software Re
leases", article No. 073077, and in document "rho3 description of machine parameters",
article No. 073027.
3.5.8.1 Technical data, probe inputs

The following general points must be taken into account for the probe inputs of the
SERVO :
` The input signals must be free from radio interference and bounce. .
` Shielded cables must be used.
` An open input is detected as "logically 0".
` All inputs are galvanically isolated from the logic voltage by optical couplers.
24 V probe input
` Max. permissible input voltage: +32 V

` HIGH level: +17 to +32 V
` LOW level: 3 bis +5 V (or open input)
` Rated input current (at 24 V): 8 mA
` Typical switching threshold: +12 V
5 V probe input
` LOWPegel: 3 to +0.8 V (or open input)
79
SERVO rho 3
3.5.8.2 Pin assignment, probe inputs
Connector
X31
1
24 V probe input
2
5 V probe input
3
0 V load
4
5 V probe switching voltage (max. 10 mA)
5
0V
6
7
8
Shield connection on
Servo front panel
80
SERVO rho 3
3.5.8.3 Connection options for probes
24 V probe 5 V probe
Potential free contact,
Potential-free contact, switched to 5 V,
switched to 24 V internal 5 V voltage used
Terminal block (*) Probe
1 1
Probe
2 2
3 3
(*): Connect terminal block

4 near the cable entry 4
24 V load points on the switching
5 5
cabinet!
0 V load
Driver output, Driver output,

switched to 24 V switched to 5 V
1 1
Probe
2 2
Probe
3 3
4 4
24 V load
5 5 5 V external
0 V load
0 V extern
"Open collector" output

switched to 0 V (5 V internal)
1
Shield connections on
2 Servo front panel
3
(taper pin)
4 Probe
5
Potential-free contact,
switched to 24 V and 5 V
Probe
1 24 V load
2 5 V external (*)
3 0 V load
4
5
(*): Potential connection to 0 V load
81
SERVO rho 3
Flexible Automation SERVO 5 - 8 Interface connections
3.6. Servo loop interface SERVO 8

The servo card is used for output of the analog speed setpoints and closes the
position control loop by evaluation of the signals of the connected incremental po
sition measuring systems. The servo sampling rate depends on machine parame
ter P5. The overall system may contain a maximum of one SERVO 8. A mixed con
figuration (SERVO 8 / SERVO 6i) is permitted.
3.6.1. Overview
BOSCH
CNC (Socket X16, Sub-D, 15-pole)
1st measuring system input
2nd measuring system input 7th measuring system input

(Socket X12, Sub-D, 15-pole) (Socket X17, Sub-D, 15-pole)

3rd measuring system input (Socket X18, Sub-D, 15-pole)

Screen terminals

6 Analog setpoint outputs 6-8

(Connector X22)
1
(Connector X21) Screen terminals
Probe inputs High speed I/O

Probe switching voltage 5 V Connector X31, Sub-D, 25-pole)
(Connector X51)
SERVO 8
Front view SERVO 8
Caution:
The servo card SERVO 8 must be removed only when the control is switched off!
82
SERVO rho 3
Basic configuration of the SERVO 8:

` 5 axis
Optios:
` Upgrading for up to 8 axes
` High Speed I/O
3.6.2. Measuring system inputs
(Sockets X11 to X18) (X16 to X18 optional)

Measuring systems from Messrs. Heidenhain are used. These are suitable either
for direct connection or connection via a pulse shaper (EXE). The connection in
structions of the manufacture with respect to cable lengths and routing must be
observed.
The power supply for a directly connected encoder or an EXE with external 5 V
supply is provided via the measuring system input socket.
The following data generally applies to SERVO 8 measuring system inputs:
` Max. permissible
cable length/input: 50 m or manufacturer's
specification

length difference at allinputs : 15 m

0 x 0.14 mm2 + 4 x 0.5 mm2

Ri = 120 W

min. voltagedifferences between
>
` Pulse multiplication: Quadruplication of the input frequen-

cey (foue-edge evaluation)
` Max permitted input frequencey: 500 kHz

consumption per encoder/EXE 350 mA
lines for the purpose of direction reversal owing to the resultant decoding of
the zero pulse! Direction reversal is possible in the software by means of the ma
chine parameters.
83
SERVO rho 3
a a a a a b a a b a
A/Ua1
A/Ua1
B/Ua2
B/Ua2
R/Ua0
R/Ua0
c c a > 250 ns
=
b > 0 ns
=
Both operating conditions are permissible c > 100 ns
=
Approved digital measuring systems

The system combinations from the ROD/LS and EXE product range of Messrs.
Heidenhain must be adapted individually to the requirements of the machine and
control in question.
In principle, it is possible to install direct-connection rotary encoders from
Messrs. Heidenhain subject to the following preconditions:
>
>
>

>
>
>
Rotary measuring systems

` Rotary encoder f. direct conn.: ROD 220 (Messrs. Heidenhain)
ROD 420 "
ROD 426 "
ROD 428 "
84
SERVO rho 3

ROD 428 "
` Rotary encoders for connection

via EXE 604 C, EXE 605 C: ROD 250 (Messrs. Heidenhain)
ROD 450 "
ROD 456 "
ROD 700 "
ROD 800 "
` Rotary encoder for connection

via EXE 702, EXE 816: ROD 800 (Messrs. Heidenhain)
85
SERVO rho 3
Linear measuring systems

EXE 604 C, EXE 605 C, EXE 610,
EXE 801, EXE 802, EXE 803
LS 707 "
LS 903 "

LIDA 325 "


control of errors by tri-state switching of the output signals. The EXE 604 C was
developed specially for Bosch controls. It corresponds to the EXE 601 and addi
tionally possesses a ground stud as well as a 12-pole Souriau connector at the
RC end.
Notes:
- The list of suitable measuring systems can only be considered as a general
recommendation owing to frequent technical modifications and increasing
product priority.
- The encoder supply voltage must be adjusted so that the encoder supply
voltage is +5 V +/- 5 % for all connected encoders and the permitted cable
lengths (measured directly at the encoder input). The encoder supply volt
age is set at the potentiometer VMS of the power supply PS200.
- The encoder cable from the RC control to the ROD encoder can be supplied
m, 35 m or 50 m.
- If the ROD encoder is supplied by Bosch, its cable (0.5 m) is equipped with a
86
SERVO rho 3
87
SERVO rho 3
3.6.3. Pin assignments

The cable screen must possess a continuous connection from the front panel of
the SERVO 8 (screen terminals) to the measuring system.

supplied by BOSCH

max. 1 m
1 1 wh/ye 0.14 1 1 br
A/Ua1
2 2 gn 0.14 2 2 gn
A/Ua1
3 3 gr 0.14 3 3 gr
B/Ua2
4 4 pk 0.14 4 4 pk
B/Ua2
+5 V
6 6 wh 0.14 6 6 rd
R/Ua0
7 7 wh/gr 0.14 7 7 bk
R/Ua0
8 8 vio 0.14 8 8 vio
+ 5V
9 9 rd 0.5 9 9 br
+5V
10 10 sw 0.5 10 10 wh Sensor
11 11 0V
12 12 bk 0.5 12 12 wh
0V
lamp 0V

max. 50 m
The connecting cables from EXE to the measuring systems are cables from
Messrs. Heidenhain.
Socket Cable EXE Signal- Measuring

x 0.5 mm2)
1 1 wh/ye 0.14 1
A/Ua1 Ua1 Ie1+
2 2 gn 0.14 2
A/Ua1 Ua1 Ie1-
3 3 gr 0.14 3
B/Ua2 Ua2 Ie2+
4 4 pk 0.14 4
B/Ua2 Ua2 Ie2-
5 5 br 0.5 5
+ 5V
6 6 wh 0.14 6
R/Ua0 Ua0 Ie0+
7 7 wh/gr 0.14 7
R/Ua0 Ua0 Ie0-
8 8 vio 0.14 8
Uas Uas + 5V
9 9 rd 0.5 9
+5V + 5V + 5V
10 10 bk 0.5 10
0V
11
Screen
12 12 bl 0.5 12
0V 0V 0V
lamp 0V
Connection via
metallic housing
of the D-sub connector
and pin 11 of the Souriau socket.
88
SERVO rho 3
Connector
Socket
1 2
3 4 5
6 7
8 9 10
11 12
Strain relief
Wiring side

Pin assignment
green 2 green 2
grey 3 grey 3
pink 4 pink 4
white 6 white 6
violet 8 violet 8
red 0.5 V 9 red 0.5 V 9
blue 0.5 V 12 blue 0.5 V 12
housing
89
SERVO rho 3
3.6.4. Analog setpoint outputs

(Connectors X21 and X22) (X22 optional)
these outputs. The spindle must be considered as an asynchronous axis.

the SERVO 8 when the control is switched off. For this reason, the load
voltage must be switched off first and then the logic voltage when the
control is switched off.
point outputs of the SERVO 8:
` Recommended cable type: Belden 2 x 0.5 mm2

(8762-20)
` Max. output range: +/- 13.3 V
` Output voltage (rapid traverse): + (-) 10 V

` Permitted load resistance at output: min. 10 kW
al outputs are short-circuited, the output operational amplifier may be de
90
SERVO rho 3
Pin assignments
Connector
X21
1
+/-10 V
0V
3
+/-10 V
0V
5
+/-10 V
0V
7
+/-10 V
0V
9
+/-10 V
0V
Screen terminals at
the front panel
Connector
X22
1
+/-10 V
0V
3
+/-10 V
0V
5
+/-10 V
0V
Screen terminals at
the front panel
91
SERVO rho 3
92
SERVO rho 3
93
Plug-in units rho 3
Flexible Automation Modular SERVO Interface conditions
3.7. Servo card modular SERVO
The servo card (modular Servo) is used for output of analog speed setpoints and
closes the position servo loop by evaluation of the signals of the connected posi
tion measuring systems. The servo sampling rate depends on machine parame
ters P5. The overall system may contain a maximum of one modular SERVO. A
mixed configuration (modular SERVO/SERVO 6i) is permitted.
Die modulare Servokarte ist für unterschiedliche Meßsyteme modular bestück
bar .
The modular servo card is suitable for modular installation on conjunction with dif
ferent measuring systems.
Evaluation modules are available for the following measuring systems:
Incremental module, one module per measuring system
Absolute module, one module per measuring system
Potentiometer module, for up to 12 potentiometer measuring systems;
this module occupies 2 module slots.
Up to 8 analog outputs are available on the card. These are used for output of the
nominal speed. Outputs which are not assigned to any controlled axis can be
used for other functions (refer to rho 3 description of machine parameters and rho
3 description of additional features).
95
Plug-in units rho 3
3.7.1. Overview of modular Servo abs8
BOSCH
CNC
MODULE NO. 1
MODULE NO. 6
(Socket, Sub-D, 15-pole)
Measuring system identification Measuring system identification
ABS X71 ABS X76
MODULE NO. 2 MODULE NO. 7

(Socket, Sub-D, 15-pole) (Socket, Sub-D, 15-pole)
ABS X72 ABS X77


ABS X73 ABS X78
MODULE NO. 4
Measuring system identification

ABS X74
MODULE NO. 5

ABS X75
High speed I/O Analog setpoint outputs 1-8

(Connector X31, Sub-D, 25-pole) (Connector X22)
not currently used in rho 3
Front view of modular SERVO 8 with 8 absolute measuring systems
96
Plug-in units rho 3
3.7.2. Overview of modular Servo abs7/inc1
BOSCH
CNC
MODULE NO. 1
MODULE NO. 6
ABS X71 ABS X76

ABS X72 ABS X77


ABS X73 ABS X78
MODULE NO. 4

ABS X74
MODULE NO. 5

ABS X75

High speed I/O (Connector X22
(Connector X31, Sub-D, 25-pole) Socket Sub-D 37-pole)
Front view of modular SERVO abs7/inc1
97
Plug-in units rho 3
3.7.3. Overview of modular Servo abs5
BOSCH
CNC
MODULE NO. 1

ABS X71
MODULE NO. 2

ABS X72
MODULE NO. 3
Socket, Sub-D, 15-pole)

ABS X73
MODULE NO. 4

ABS X74
MODULE NO. 5

ABS X75

(Connector X22
Socket Sub-D 37-pole
Front view of modular SERVO 8 with 5 absolute measuring systems
98
Plug-in units rho 3
3.7.4. Overview of modular Servo inc6/poti1
BOSCH
CNC


INC X41 INC X46

INC X42 pot X91


INC X43
pot X92
MODULE NO. 4

INC X44
MODULE NO. 5

INC X45

(Connector X22
High speed I/O Socket Sub-D 37-pole)
(Connector X31, Sub-D, 25-pole)
Front view of modular SERVO inc6/poti1
Caution:
The servo card "modular SERVO" must be removed only when the control is
switched off.
99
Plug-in units rho 3
3.7.5. Incremental measuring system inputs

The following data applies generally to the incremental measuring system inputs:
length/input: 50 m or manufacturer's
specification
length difference at all inputs: 15 m
10 x 0.14 mm2 + 4 x 0.5 mm2
` Signal inputs: Differential line receiver
Ri = 120 W W
min. voltage between
>
` Pulse multiplication: Quadruplication of the input
frequency (four-edge evaluation)
` Max. permitted input
frequency: 500 kHz
consumption per encoder/EXE: 350 mA
lines for the purpose of direction reversal because this will lead to decoding
of the zero pulse. Direction reversal can be realized in the software by means of
machine parameter P308.
Measuring direction Positive Negative Positive
a a a a a b a a b a
A/Ua1
A/Ua1
B/Ua2
B/Ua2
R/Ua0
R/Ua0
c c a > 250 ns
=
b > 0 ns
=
Both operating states are permitted c > 100 ns
=
100
Plug-in units rho 3
3.7.5.1. Approved incremental digital measuring
Measuring systems for direct connection or connection via a pulse shaper (EXE)
are used. The interface condition of the manufacturer with respect to cable length
and routing must be observed.
Power is supplied to a directly connected encoder or an EXE with external 5 V sup
ply via the measuring system input socket.
Combinations from the ROD/LS and EXE product range from Messrs. Heidenhain
must be adapted to the requirements of the machine and control in each case.
Rotary encoders for direct connection from Messrs. Heidenhain can be installed
subject to the following preconditions:

>
>
- - Min. edge spacing for direction reversal =0 ns
>

>
>
>
` Rotary encoder for

direct connection: ROD 220 (Messrs. Heidenhain)
ROD 420 "
ROD 426 "
ROD 428 "

ROD 428 "
` Rotary encoders for connection via

EXE 604 C, EXE 605 C: ROD 250 (Messrs. Heidenhain)
ROD 450 "
ROD 456 "
ROD 700 "
ROD 800 "

EXE 702, EXE 816: ROD 800 (Messrs. Heidenhain)
101
Plug-in units rho 3

EXE 604 C, EXE 605 C, EXE 610,
EXE 801, EXE 802, EXE 803
LS 707 "
LS 903 "

LIDA 325 "


control of errors by tri-state switching of the output signals.
The EXE 604 C was developed specially for Bosch controls. It corresponds to the
EXE 601 and additionally possesses a ground stud as well as a 12-pole Souriau
connector at the RC end.
Notes:
` The list of measuring systems should be considered only as a general
recommendation owing to frequent technical modifications and in
creasing product priority.
` Please enquire if it is wished to use other measuring systems.
` The encoder supply voltage must be adjusted so that the encoder supply
voltage is +5 V +/- 5 % for all connected encoders and the permitted cable
lengths (measured directly at the encoder input). The encoder supply volt
age is set at the potentiometer VMS of the power supply PS200.
` The maximum permissible load of the measuring system supply volt
age depends on the power supply module used and is a maximum of 3
A for the PS200 and a maximum of 1.5 A for the PS75.
` The encoder cable from the RC control to the ROD encoder can be supplied
m, 35 m or 50 m.
` If the ROD encoder is supplied by Bosch, its cable (0.5 m) is equipped with a
102
Plug-in units rho 3
3.7.5.2. Pin assignments of incremental measuring systems

The cable screen must possess a continuous connection from the front panel of
the servo card (screen terminal) to the measuring system.

supplied by BOSCH

max. 1 m
1 1 wh/e 0.14 1 1 br
A/Ua1
2 2 gn 0.14 2 2 gn
A/Ua1
3 3 gr 0.14 3 3 gr
B/Ua2
4 4 pk 0.14 4 4 pk
B/Ua2
+5 V
6 6 wh 0.14 6 6 rd
R/Ua0
7 7 wh/gr 0.14 7 7 bk
R/Ua0
8 8 vio 0.14 8 8 vio
+ 5V
9 9 rd 0.5 9 9 br
+5V
10 10 bk 0.5 10 10 wh Sensor
11 11 0V
12 12 bl 0.5 12 12 wh
0V
lamp 0V

max. 50 m
The connecting cables from EXE to the measuring system are cables from
Messrs. Heidenhain.
103
Plug-in units rho 3
Socket Cable EXE Signal Measuring

x 0.5 mm2)
1 1 wh/e 0.14 1
A/Ua1 Ua1 Ie1+
2 2 gn 0.14 2
A/Ua1 Ua1 Ie1-
3 3 gr 0.14 3
B/Ua2 Ua2 Ie2+
4 4 pk 0.14 4
B/Ua2 Ua2 Ie2-
5 5 br 0.5 5
+ 5V
6 6 wh 0.14 6
R/Ua0 Ua0 Ie0+
7 7 wh/gr 0.14 7
R/Ua0 Ua0 Ie0-
8 8 vio 0.14 8
Uas Uas + 5V
9 9 rd 0.5 9
+5V + 5V + 5V
10 10 bk 0.5 10
0V
11
Screen
12 12 bl 0.5 12
0V 0V 0V
lamp 0V
Connection via
metallic housing of the
D-sub connector and
pin 11 of the Souriau socket.
104
Plug-in units rho 3
Connector
Socket
1 2
3 4 5
6 7
8 9 10
11 12
Strain relief
Wiring side

Pin assignment
green 2 green 2
grey 3 grey 3
pink 4 pink 4
white 6 white 6
violet 8 violet 8
red 0.5 V 9 red 0.5 V 9
blue 0.5 V 12 blue 0.5 V 12
housing
105
Plug-in units rho 3
3.7.6. Absolute encoder module

The absolute encoder module permits connection of absolute encoders with syn
chronous serial interface (SSI). The module converts the serial data stream into
parallel information and monitors data transfer and the connection to the connec
ted measuring system.
The following monitoring functions are performed:
` Cable break monitoring - Check of correct level before and after

data transfer; measuring system alarm is
signalled in the event of an error.
` Watchdog monitoring - Conversion takes place cyclically and sets
measuring system error in the event of an
error
` Plausibility check - If double transmission mode is
active, the plausibility check function sets
a measuring system error if double transmis
sions
containing errors occur successively
` Supply voltage monitoring - The absolute encoder monitors its supply
voltage and sets a power failure flag in the
serial data stream in the event of a voltage
dip. The absolute encoder module gener-
ates a measuring system alarm from this.
Interface characteristics:
Max. permissible cable length 50 m for 24V encoders

35 m for 5V encoders
Max. permissible cable length difference with several encoders 10 m (for 5 V en
coders)
Cable type: Special cable 2*2*0.5 mm2 double screen 1*2*1.0 mm2
Resolution : 16-bits per revolution

16-bits number of revolutions
Approved encoder types: Stegmann AG 66 SSI

AG 110 SSI
The interface conditions and specifications of the encoder manufacturer must be
observed and taken into account.
When ordering the encoder, the following information is required:
Resolution per revolution
Max. number of revolutions
Coding of position information (grey, binary)
Power supply (24 V or 5 V)
It must be ensured that the encoder sets the POWER FAILURE BIT in the
event of a voltage dip.
106
Plug-in units rho 3
3.7.6.1.Pin assignment for absolute encoder module
Connector Absloute encoder

X7i
1
DATA-IN + + DATA-OUT
2
DATA -IN - - DATA-OUT
3
CLOCK-OUT + + CLOCK-IN
CLOCK-OUT -
4 - CLOCK-IN
5
Internal screen 6
Internal screen 7
8 Us
9
GND
10
11
12
13
14
15
Screen via
connector housing 24V GND
Pin assignment for encoders with external 24 V power supply
107
Plug-in units rho 3
3.7.7. Potentiometer measuring system module
The potentiometer measuring system module permits connection of up to 12 po

tentiometers as measuring sensors, whereby a maximum of 8 of these measuring
system inputs can be used as a position measuring system for controlled axes
since a maximum of 8 setpoint outputs are available on the modular Servo.
The Potentiometer measuring system module can also be used for connection of
sensors which supply a DC voltage signal of + 10 V.
The module occupies two module slots located under each other on the modular
Servo
` technical data:
Permissible potentiometer resistance 10kOhm
Potentiometer supply voltage ±10V + 1%
Max. cable length 50m
Min. cable cross-section 0,5 mm potentiometer
supply 0.14 mm for slider
connection
Max. temperature increase
of thecable 30_C
Max. permissible rate of change
of input voltage ± 20V/s
Caution !
Incorrect function
values may result
if this value is
exceeded.
Max. internal resistance of the
input voltage source 2,5kOhm
Min. permissible external loadresistance 10 MOhm
Load resistance of the module 10 MOhm
Conversion resolution 14 bits
Increment voltage 1,22mV
Number of input channels 12

Linearity 0,01%
Long-term stability, typical ± 0,5mV/1000h
Positive or negative full scale values (±10 V) are converted in the event of a short
circuit or discontinuity in the measuring system circuit. The software monitors the
function values of the individual input channels for 100 increments of the respec
tive full scale value. A measuring system error is signalled in the event of an error.
The monitoring area is lost to the working area.
The slider wire is monitored for a short-circuit with respect to the two supply
leads. There is no monitoring of the slider wire for discontinuity.
108
Plug-in units rho 3
Monitoring area
100 inc 100 inc
Working area
-10V 0V +10V
3.7.7.1.Pin assignment for potentiometer module
Connector
X91
+10V 24
IN1 25
13
-10V
12
GND
+10V 22
IN2 23
-10V 11
10
GND
+10V 20
IN3 21
9
-10V
8
GND
+10V 18
IN4 19
7
-10V
6
GND
+10V 16
IN5 17
5
-10V
4
GND
+10V 14
IN6 15
3
-10V
2
GND
Screen via
connector housing
Distribution cable
109
Plug-in units rho 3
Connector
X92
+10V 24
IN1 25
13
-10V 12
GND
+10V 22
IN2 23
11
-10V
10
GND
+10V 20
IN3 21
9
-10V
8
GND
+10V 18
IN4 19
7
-10V
6
GND
+10V 16
IN5 17
5
-10V
4
GND
+10V 14
IN6 15
3
-10V
2
GND
Screen via
connector housing
Distibution cable
110
Plug-in units rho 3

these outputs.

the modular SERVO when the control is switched off. For this reason,
the load voltage must be switched off first and then the logic voltage
when the control is switched off.
point outputs of the modular SERVO:
` Recommended cable type:
` - Max. output range: +/-13.3 V
` Output voltage (rapid traverse): +(-)10 V
` Permitted load resistance

at output: min. 10 kW
al outputs are short circuited, the output operational amplifier may be de

111
Plug-in units rho 3
3.7.8.1. Pin assignment OUT ANALOG X22
Connector
X22
+ 2
Setpoint 1 - 1
screen 20
+ 4
Setpoint 2 - 3
screen 22
+ 6
Setpoint 3 - 5
screen 24
+ 8
Setpoint 4 - 7
screen 26
+ 10 Cable 2*0.5 mm2,

Setpoint 5 - 9 double screen,
screen 28 length max. 50 m
per setpoint line
-
+ 12
Setpoint 6
- 11
screen 30
+ 14
Setpoint 7
- 13
screen 32
+ 16
Setpoint 8 - 15
screen 34
Screen via
connector housing
Distibution cable
36*0,14mm 2
Length max. 2m
112
Insertion Modules rho 3
Flexible Automation modular SERVO m.i. Connection conditions
3.8 Control Loop Card Modular SERVO m.i.
The control loop card Servo m.i. serves to output the analog speed nominal values and
closes the position control circuit by evaluating the signals of the connected position
measuring systems. The servo scanning rate is dependent on the machine parameter
P5.
This card is equipped with its own processor module to reduce the interpolation and po
sition control clock frequency.
The card has the hardware interface for "fast inputs.
If incremental measuring systems are used, the hardware interface for "fast measure
ment" (probe) is also present on the card.
The modular servo card SERVO m.i. is available in a narrow version as:
SERVO m.i. ABS3
for 3 absolute measuring systems with 3 analog outputs for setpoint setting. This card
only occupies one slot.
In the wide version, this card occupies two slots and can be fitted with the following mo
dules on a modular principle:
Incremental module one module per measuring system
Absoluts module one module per measuring system
Potentiometer module for up to 12 potentiometer measuring system.
This module occupies 2 module slots.
The wide version is available in the configuration as:
for four absolute and one incremental measuring system,
for six absolute and one incremental measuring system,
for eight absolute and one incremental measuring system,,
SERVO m.i. ABS6/INC1/POTI
for six absolute, one incremental
and one potentiometer module for connection of up to 12 potentiometer measuring
systems,
and as
SERVO m.i.ABS9 for nine absolute measuring systems.
Depending on the configuration, up to 10 analog outputs for setpoint output are present
on the card.
Analog outputs that are not assigned to an axis can be used for other functions (see rho3
description of machine parameters and rho3 description of configuration options).
On the following pages, all necessary conditions for the selection of suitable measuring
systems and their connection are described.
113
3.8.1 Identification of connections

All connections of the Servo m.i. are uniquely identified by a connector (socket) designa
tion.
Identification scheme of the interfaces:
X Y Z
Serial number of
interface type
Interface type:
1,4 Identification of incremental

measuring system inputs
7 Identification of measuring system

inputs
for absolute measuring systems
9 Identification for potentiometer

measuring system inputs
2 Identification for analog

outputs
3 Identification for
"fast inputs"
5 Identification for measuring key

inputs identification with the let
General interface
ter X
Example:
X72 identifies the 2nd measuring system in

put
for absolute measuring systems
114
3.8.2 Overview of SERVO m.i. ABS3
1st Measuring system input

(Socket X71, DSub, 15pin)
2nd Measuring system input

(Socket X72 , DSub, 15pin)
3rd Measuring system input

Connection "fast inputs"

Measuring key inputs

(Connection X51
Function only in connection with
incremental measuring systems)
Analog setpoint outputs 1 3

(Connector X23)
Identification of
CPU/FPU clock
frequency
SERVO m.i. ABS 3
115
3.8.3 Overview of SERVO m.i. ABS4/INC1
1st Measuring system input 4th Measuring system input

(Socket X71 , DSub, 15pin) (Socket X74 , DSub, 15pin)
2nd Measuring system input 5th Measuring system input


Identification of the superimposed

measuring system connections


(Connection X51
incremental
measuring systems)
Analog setpoint outputs 4 to 7
(Connector X21)
Analog setpoint outputs 1 to 3
( Connector X31 )
SERVO m.i. ABS 4 and INC 1
116
7th Measuring system input


2nd Measuring system input (Socket X74 , DSub, 15pin)

3rd Measuring system input (Socket X75 , DSub, 15pin)

Connection
"fast inputs"
(Socket X31, DSub,
25pin)


(Connection X51 )
incremental
measuring systems Analog setpoint outputs
4 to 7
(Connection X21)
Analog setpoint outputs

13
(Connection X23)
117

1st Measuring system input 7th Measuring system input



(Socket X72 , DSub, 15pin) 8th Measuring system input





(Connection X51
Function only in connection with Analog setpoint outputs
incremental measuring systems) 4 10
(Connection X21,X22)

1 3 (connection X23)
118
3.8.6 Overview of SERVO m.i. ABS9






Identification of the superimpo

sed


(Connection X51
incremental measuring systems) Analog setpoint outputs 4 10
(connection X21,X22)

SERVO m.i. ABS 9
119
3.8.7 Overview of SERVO m.i. ABS6/INC1/Potentiometer




(Socket X72 , DSub, 15pin) Potentiometer input 1 6


(Socket X73 , DSub, 15pin) Potentiometer input 7 12
Identification of the superimpo

sed


(Connection X51
incremental measuring systems) Analog setpoint outputs 4 10
(connection X21,X22)

SERVO m.i. ABS 6 INC 1 Potentiometer
120
3.8.8 Incremental measuring system inputs

The following details apply in general for incremental measuring system inputs:
` Max. permitted cable length/input: 50 m when using voltage supply module

PS200, or 30 m when using voltage supply module PS75.
If the encoder manufacturer prescribes a lower value, this value is binding.

` Max. permitted cable length difference at all inputs: 15 m
` Cable type Special cable NFS 7264
10 x 0.14 mm2 + 4 x 0.5 mm2
(not for trailing cable operation !)
` Signal inputs: Differential line receiver
Ri = 120 W
` Input signals: A, B, R, A , B, R (TTL level);
min. voltage difference between
A and A, B and B, R and R>
=600 mV
` Impulse multiplication Quadrupling of input frequency

(quad slope evaluation)
` Max. permissible input frequency: 800 kHz
` Encoder/EXE voltage
supply: +5 V (adjustable at power supply module
PS200)
` Max. permissible current consumption per encoder/EXE: 250
mA
` Max. permissible current consumption of all encoders and EXEs connected to
one modular SERVO m.i. 1.5 A
The signal lines of the measuring systems must be connected exactly in accordance
with these connection conditions.
Switching of the signal wires to change the direction is not permissible due to the
coding of the reset pulse!
A change of direction can be implemented with the software by means of machine para
meter P308.
3.8.8.1 Permissible incremental measuring systems

Measuring systems for direct connection or for connection via a pulse shaper (EXE) can
be used. The connection conditions stipulated by the manufacturer for cable length and
cable laying must be observed.
The power supply of a directly connected encoder or an EXE with an external 5V supply
is implemented via the measuring system input socket.
The specific details of the ROD/LS and EXE proposal from the Heidenhain company
must be adapted to the requirements of the machine and controller.
In general, rotary encoders for direct connection supplied by the companies Heidenhain
and Stegmann can be fitted subject to the following conditions:
121
5V encoder power supply

Rightangled signal output
Line driver conforming to RS485 or RS422
Encoder power consumption < 250 mA
Min. edge interval between active counting pulses>
=250 ns
Min. edge interval in rotation direction reversal>
=0 ns
Reliability interval for reference signal>
=100 ns
EXEs from the Heidenhain company can also be fitted subject to the following condi
tions:
5V or external 230V power supply
Rightangled signal output
Line driver conforming to RS485 or RS422
Max. encoder and EXE power consumption for 5V supply: < 350 mA
Min. edge interval between active counting pulses>
=250 ns
Min. edge interval in rotation direction reversal>
=0 ns
Reliability interval for reference signal>
=100 ns
Signal to time diagram

a a a a a b a a b a
A/Ua1
A/Ua1
B/Ua2
B/Ua2
R/Ua0
R/Ua0
c c a > 250 ns
=
b > 0 ns
=
Both switching states are permissible c > 100 ns
=
122
3.8.8.2 Rotary measuring systems

If the ROD encoder is supplied by Bosch, its cable (0.5 m) is fitted with a round plug of the
"Souriau" type. The encoder cable from RCY controllers to the ROD encoder can be sup
plied by Bosch fully assembled in the lengths 5m, 8m, 16m, 25m, 35m or 50m. At the
RCY end it contains a 15pole DSUB connector, and at the encoder end it contains a
12pole "Souriau" round socket.
` Rotary encoder for direct connection ROD 220 (Heidenhain com

pany).
ROD 420 "
ROD426 "
ROD 428 "
DG 60 (Stegmann company).
DG 90 D "
DG 100 D "
Recommended rotary encoder for direct connection:
ROD 428
DG 60 D
` Rotary encoder for connection via
EXE 604 C, EXE 605 C: ROD 250 (Heidenhain company).
ROD 450 "
ROD 456 "
ROD 700 "
ROD 800 "
EXE 702, EXE 816: ROD 800 (Heidenhain company).
3.8.8.3 Linear measuring systems
` Linear measuring systems for direct connection:

LS 323 (Heidenhain company).
LS 623 "
` Linear scales for connection via
EXE 604 C, EXE 605 C, EXE 610,
EXE 801, EXE 802, EXE 803,
EXE 804, EXE 805, EXE 813: LS 403 (Heidenhain company).
LS 703 "
LS 707 "
LS 903 "
` Linear scales for connection via
EXE 808, EXE 816: LS 300 (Heidenhain company).
LIDA 325 "
Intervalcoded measuring systems
` Rotary encoder: TE 60 (Stegmann company).

` Linear scales: LIP 101 A
LS xxx C (Heidenhain company).
123
3.8.8.4 Recommended pulse shaper electronics (EXE)

Of the available EXEs with an external 5V supply, we recommend:
` EXE 604 C (Heidenhain company).
It is preferable, however, to use EXEs with their own 230V power supply.
Recommendation for pulse shaper electronics (EXE) and encoder

We recommend the use of EXE 604 C and the encoder ROD 428. These types have no
capacitative connection between 0V of the power supply and the housing. This provides
a reduced susceptibility to interference. Furthermore, these types have an extended
measuring system monitoring capacity which reports to the Bosch controller any errors
caused by tristate switching of the output signals.
EXE 604 C was specially developed for Bosch controllers. It corresponds to EXE 601,
and in addition it has an earthing pin and, at the RCY end, a 12pole Souriautype con
nector.
Notes:
` Due to the frequency of alterations and the increasing number of types, the
list of measuring systems can only be a general recommendation.
` Other measuring systems are available on request.
` The encoder supply voltage must be set so that for all encoders connected, and
the permissible cable lengths, the encoder supply voltage is +5V +/5% (directly
at the encoder input).
When using the PS200, the encoder supply voltage is adjusted in the potentiome
ter VMS of the power supply module.
` The maximum permissible load placed on the measuring system supply vol
tage by all encoders and EXEs connected to the controller is dependent on
the voltage supply module used; for the PS200 it is a maximum of 3A, for the
PS75 a maximum of 1.5A.
` The encoder cable from RCY controllers to the ROD encoder can be supplied by
Bosch. At the RCY end it contains a 15pole DSUB connector, and at the encoder
end it contains a 12pole "Souriau" round socket. Completely assembled encoder
cables can be supplied in the lengths 5 m, 8 m, 16 m, 25 m, 35 m or 50 m.
` If the ROD encoder is supplied by Bosch, its cable (0.5 m) is fitted with a round
plug of the "Souriau" type.
. The incremental measuring system module does not evaluate the error signal
Uas. EXEs 604 C and 605 C report a measuring system error by tristate switching of
the output signal. If EXEs 640 C and 605 C are not used, errors that occur in the area
of the measuring system EXE input can not be detected! In this case, the user must
implement other suitable protective measures!
124
3.8.8.5 Connection assignment for incremental measuring systems

The cable shield must have a continuous connection from the front panel of the servo
card (screen connections) to the measuring system.
Rotary encoder from Heidenhain company.
. The pin assignment only applies to cables and encoders supplied by

Bosch
Socket Cable Encoder signal Measuring

X4i (10 x 0.14 mm2 + 4 x 0.5 mm2) output system
Use metal covers max. 1 m
1 1 wh/ye 0.14 1 1 br
A/Ua1 Ua1
2 2 gn 0.14 2 2 gn
A/Ua1 Ua1
3 3 gr 0.14 3 3 gr
B/Ua2 Ua2
4 4 pi 0.14 4 4 pi
B/Ua2 Ua2
5 5 br 0.5 5 5 bl
Sensor +5V
6 6 wh 0.14 6 6 rd
R/Ua0 Ua0
7 7 wh/gr 0.14 7 7 blk
R/Ua0 Ua0
8 8 vio 0.14 8 8 vio
Uas
9 9 rd 0.5 9 9 br +5V
+5V
10 10 blk 0.5 10 10 wh
Sensor 0V
11 11
12 12 bl 0.5 12 12 wh
0V 0V
Connection via metal housing of D-SUB connector

and pin 11 of Souriau socket
max. 50 m
125
Rotary encoder from Stegmann company.
. The pin assignment only applies to cables and encoders supplied by Bosch
Socket Cable Encoder signal Measuring

X41 (10 x 0.14 mm2 + 4 x 0.5 mm2) output system
Use metal covers max. 1 m
1 1 wh/ye 0.14 1 1 wh
A/Ua1 K1
2 2 gn 0.14 2 2 br
A/Ua1 K1
3 3 gr 0.14 3 3 pi
B/Ua2 K2
4 4 pi 0.14 4 4 blk
B/Ua2 K2
5 5 br 0.5 5 5
6 6 wh 0.14 6 6 pu
R/Ua0 K0
7 7 wh/gr 0.14 7 7 ye
R/Ua0 K0
8 vio 0.14 8 8 gn
ALARM
9 9 rd 0.5 9 9 rd Us
+5V
10 10 blk 0.5 10 10
11 11
12 12 bl 0.5 12 12 bl
0V 0V
Connection via metal housing of D-SUB connector

and pin 11 of Souriau socket
max. 50 m
NOTE:
When using the BOSCH cable, only the housing form "1" with a cable tail of 0.5 m is per
missible for the encoder. A 12pin "Souriau" type round connector must then be fitted to
the encoder by the user.
126
Rotary encoder from the Heidenhain company with pulse shaper electronics (EXE)
The connection cables from EXE to the measuring system are cables supplied by the
Heidenhain company.
. The pin assignment only applies to cables and EXEs supplied by Bosch
Socket Cable EXE (5V) Signal Measuring

Use metal covers
1 1 wh/ye 0.14 1
A/Ua1 Ua1 Ie1+
2 2 gn 0.14 2
A/Ua1 Ua1 Ie1-
3 3 gr 0.14 3
B/Ua2 Ua2 Ie2+
4 4 pi 0.14 4
B/Ua2 Ua2 Ie2-
5 5 br 0.5 5
Sensor +5V
6 6 wh 0.14 6
R/Ua0 Ua0 Ie0+
7 7 wh/gr 0.14 7
R/Ua0 Ua0 Ie0-
8 vio 0.14 8
Uas + 5V
9 9 rd 0.5 9
+5V + 5V + 5V
10 10 blk 0.5 10
Sensor 0V
11
Shield
12 12 bl 0.5 12
0V 0V 0V
0V
Connection via metal

housing of D-SUB
connector and pin 11
of Souriau socket
Socket Cable EXE (230V) Signal Measuring

Use metal covers
1 1 wh/ye 0.14 1
A/Ua1 Ua1 Ie1+
2 2 gn 0.14 2
A/Ua1 Ua1 Ie1-
3 3 gr 0.14 3
B/Ua2 Ua2 Ie2+
4 4 pi 0.14 4
B/Ua2 Ua2 Ie2-
5 5 br 0.5 5
6 6 wh 0.14 6
R/Ua0 Ua0 Ie0+
7 7 wh/gr 0.14 7
R/Ua0 Ua0 Ie0-
8 vio 0.14 8
Uas + 5V
9 9 rd 0.5 9
+5V + 5V
10 10 blk 0.5 10
11
Shield
12 12 bl 0.5 12
0V 0V 0V
0V
Connection via metal

housing of D-SUB
connector and pin 11
of Souriau socket
127
3.8.8.6 Cable Servo measuring system (ROD)
Connector, DSUB, 15pin Socket, Souriau type, 12pin
Strainrelief clamp
Shield clamp on metal housing

Not suitable for trailing cable operation!
Pin assignment
Color DSUB connector Souriau socket
X4i
whiteyellow 1 1
green 2 2
grey 3 3
pink 4 4
brown 0.52 5 5
white 6 6
whitegrey 7 7
violet 8 8
red 0.52 9 9
black 0.52 10 10
blue 0.52 12 12
Shield Connector 11
housing
Ordering information
Type No.
Readyassembled cable length 5 m 048 662

Single parts:
Cable 10 x 0.14 + 4 x 0.52 903 499
Dconnector, 15pin. Pin904 440
Metal cover for 15pin D connector. 913 724
Socket 12 pin, Souriau909 131
Accessory kit for Souriau socket 909 688
128
3.8.9 Absolute encoder module

(Terminals X71 to X79)
The absolute encoder module permits the connection of absolute encoders with a syn
chronous serial interface (SSI). The module converts the serial data flow into parallel in
formation and monitors the transmission and link to the connected measuring system.
The following checks are carried out:
` Cable breakage check Checks befor and after a transmission

for correct level; In the event of an error
a measuring system alarm is reported
` Watchdog check _ Conversion proceeds cyclically, and in the event of
an error it reports a measuring system error
` Plausibility check If dual transmission is activated, a measuring
system error is set by the plausibility test if
defective dual transmissions occur one after
the other
` Supply voltage check the absolute encoder monitors its supply voltage,
when there is a voltage fall, the encoder sets a
power failure identifier in the serial data stream.
The absolute encoder module then creates a
measuring system alarm
3.8.9.1 Interface characteristics of absolute measuring systems

Max. permitted cable length: 180 m
Cable type : Special cable 2*2*0.5 mm2 ,double shielded

1*2*1.0 mm2
Interface : Synchronous serial (SSI)
Data input : TTL-compatible signals DATA and DATA

from differencial line drivers to EIA 422A
Pulse output : TTL-compatible signals PULSE and PULSE

from differencial line drivers
Pulse frequency : 125kHz
Numberf of pulses : In dual transmission

28 for single turn encoders
52 for multi-turn encoders
In single transmission
14 for single turn encoders
26 for multi-turn encodersr
Time between two transmissions: >35 m s
129
3.8.9.2 Permissible absolute measuring systems

Encoders can be used which fulfil the characteristics stipulated,
e.g. Stegmann AG 66 SSI
AG 110 SSI
Only encoders should be used which permit a dual transmission for the plausibility
check of the measured value.
The supply voltage for the encoders is not provided by the modular Servo m. i.s.
We recommend the use of encoders with a 24 V supply voltage. The 24 V logic voltage
can be used to supply the encoders. If a different voltage source is used, its 0 V must be
linked to the 0 V of the logic voltage.
If the supply voltage fails, the encoders must set a power failure bit in accordance
with the transmission format in order to detect incorrect measured values.
Encoder characteristics:
Resolution per revolution : max. 4096 steps/360
Number of revolutions : 1 for single turn

max. 4096 for multi-turn
Code: : Gray or binary
Transmission format:
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
Pulse
G - 10
G - 11
G - 12
G - 10
G - 11
G - 12
G-1
G-2
G-3
G-4
G-5
G-6
G-7
G-8
G-9
G-1
G-2
G-3
G-4
G-5
G-6
G-7
G-8
G-9
Data
PFB
PFB
1 0 0 1
1st transmission 2nd transmission
Fig. 1 Data telegram, single turn encoder
In Fig. 1 the illustration NO FLAG, the data word for a single turn encoder is represented
with a resolution of 4096 increments /360 . For lower resolutions, the unused lower
value bits (. . . ,G11,G12 ) must be transmitted as '0'. In single transmission, the data
word ends with the 14th pulse.
130
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 47 48 49 50 51
G -as8 pulses for 1st transmission

Pulse
G - 11
G - 10
G - 10
G - 11
G - 12
G - 10
G - 11
G - 12
G-1
G-2
G-3
G-4
G-5
G-6
G-7
G-8
G-9
G-9
G-7
G-6
Data
PFB
PFB
G11
G10
G9
G8
G7
G6
G5
G4
G3
G2
G1
1 G0 0 0
Number of revolutions Resolution/revolution
1st transmission 2nd transmission
Fig. 2 Data telegram multi-turn encoder
Fig. 2 shows the structure of the data word for a multi-turn encoder with a resolution of
4096 revolutions and 4096 increments/360°.
For lower resolutions, the unused higher value bits (G11,G10...) and the unused lower va
lue bits ( ...,G11,G12 ) must be transmitted as '0'. In single transmission, the transmis
sion of a data word ends with pulse 26.
Pulse
t2
G .. G .. G .. G12 PFB
Data
t1
Fig. 3 Time diagram for both encoders (single and multi-turn encoder)
T = 8 ms is pre-set by the controller

t1 < 0.5 ms (directly at the encoder)
12 ms < t2 < 35 ms
G11 : highest value data bit (MSB)
G12 : lowest value data bit (LSB)
PFB : power failure bit (in case of an error = '1')
131
The connection conditions of the encoder manufacturer must be observed and adhered
to.
The following data must be taken into account when selecting an encoder:
` Resolution per revolution

` Max. number of revolutions
` Coding of the path information (Gray or binary)
` Power failure bit as the last data bit
(when a voltage failure occurs)
` Power supply 24V
3.8.9.3 Pin assignment for absolute encoder module
Connector Absolute encoder

X7i
1 + DATA OUT
DATA IN +
2 - DATA OUT
DATA IN -
+ 3 +
PULSE OUT PULSE IN
- 4 PULSE IN
PULSE OUT -
5
Inner shield 6
Inner shield 7
8 Us
9
GND
10
11
12
13
14
15
Shielding over
connector housing 24V 0V
Logic voltage
Fig. 4 Pin assignment for absolute encoder module
132
3.8.10 Potentiometer measuring system module
( Terminals X91 and X92 )
The potentiometer measuring system module permits the connection of up to 12 poten

tiometers as measured result recorders. A maximum of 10 of these measuring system
inputs can be used as position measuring systems for controlled axes, as a maximum of
10 setpoint outputs are present on the modular servo card.
The potentiometer measuring system module can also be used for the connection of
sensors that provide a direct current signal of ±10V.
The module occupies two module slots situated one below the other.
Technical data:
` Permissible potentiometer resistance 10kOhm
` Potentiometer supply voltage ±10V + 1%

` Max. cable length 50m
` Min. cable cross section 0.5 mm 2 for potentiometer supply

0.14mm 2 for slider connection
` Max. temperature rise of cable 30_C
` Max. permissible alteration speed of

input voltage ± 20mV/ms
Caution !
Exceeding this value can cause
incorrect functional values.
` Max. internal resistance of

input voltage source 2.5kOhm
` Min. permissible external load resistance 10 MOhm

` Load resistance of the module 10 MOhm
` Conversion resolution 14 Bit
` Incremental voltage 1.22mV
` Number of input channels 12

` Linearity 0.01%
` Long-term stability, typical value ± 0.5mV/1000h

If there is a short circuit or an interruption in the measuring system circuit, the positive or
negative final value (± 10V) is converted. The software monitors the functional values of
the individual input channels up to 100 increments from the relevant final value. If an error
occurs, a measuring system error is reported.
The supervision area is not available for the working area.
The slider circuit is monitored for short circuits to the two supply circuits. The slider
circuit is not monitored for interruptions.
133
Monitoring area
100 inc 100 inc
Working area
-10V 0V +10V
Fig. 5
3.8.10.1 Pin assignment for potentiometer module
Connector
X91
+10V 24
IN1 25
13
-10V
12
GND
+10V 22
IN2 23
-10V 11
10
GND
+10V 20
IN3 21
9
-10V
8
GND
+10V 18
IN4 19
7
-10V
6
GND
+10V 16
IN5 17
5
-10V
4
GND
+10V 14
IN6 15
3
-10V
2
GND
Shield over
connector housing
Distribution cables
Fig. 6
134
Connector
X92
+10V 24
IN7 25
13
-10V 12
GND
+10V 22
IN8 23
11
-10V
10
GND
+10V 20
IN9 21
9
-10V
8
GND
+10V 18
IN10 19
7
-10V
6
GND
+10V 16
IN11 17
5
-10V
4
GND
+10V 14
IN12 15
3
-10V
2
GND
Shield over
connector housing
Distribution cables
Fig. 7
135
3.8.11 Analog setpoint outputs
(Terminals X21,X22 and X23)

At these outputs, speed-proportional voltages are available for accessing the individual
axes.
Folgendes ist für die AnalogSollwertausgänge der Servo m.i. zu beachten:
` Recommended cable type: Belden 2 x 0.5 mm2 (876220)

` Max. cable length: 50m
` The shield connection is dependent on the drives used
(e.g. for Servodyn T: connection on both sides).
` Max. output voltage range: + /13.3 V
` Incremental voltage (setpoint): 0.400 mV
` Output voltage (fast mode): +()10 V
` The output voltages are linked to potential.
` Permissible load resistance at the output min. 10 kW
` The output levels are permanently short-circuit-protected. However, if several
outputs are short circuited, the higher loss performance may cause the destruc
tion of the output operational amplifiers.
` The inputs of fhe drive amplifiers must be connected as differential amplifiers.
Ground-linked circuits must be avoided.
` If the READY signal goes to LOW, the setpoint outputs are immediately set to 0 V
(analog GND). This level is kept constant for a minimum of 1 sec. Therefore, the
drives must be switched off within 1 sec.
136
3.8.11.1 Pin assignment analog outputs
Connector
X22
0V
10. setpoint output
+/-10 V
0V
9. setpoint output
+/-10 V
Shield connections in
Servo front panel
Connector
X21
0V
8. setpoint output
+/-10 V
0V
7. setpoint output
+/-10 V
0V
6. setpoint output
+/-10 V
0V
5. setpoint output
+/-10 V
0V
1
+/-10 V
4. setpoint output
Shield connections in
Servo front panel
Connector
X23
+/-10 V
1. setpoint output
0V
+/-10 V
2. setpoint output
0V
+/-10 V
3. setpoint output
0V
Shiield connections in
Servo front panel
137
3.8.12 Fast inputs

Connection (connector X31)
General remarks
The inputs of connector X31 are used in the rho 3 controller in the configuration levels
"fast measuring" and "fast constant starting". Further information on these functions can
be found in the document "rho 3 configuration level description", P.No. 4268, article.
No. 073077, and the document "rho3 Description of machine parameters", P.No. 4262,
article No. 073027.
3.8.12.1 Technical data, fast inputs

The following data must be taken into account for the "fast inputs" of the SERVO
m.i.:
` The input signals must be free from radio interference and bounce.
` Input voltage range: 3 V to +32 V
` Voltage threshold for transition from
LOW to HIGH level: +8.5 V, +/1 V
` Hysteresis for transition from
HIGH to LOW level: 1 V, +/0.5 V
` An open input is recognized as "logically 0".
` Input current/ input: max. 8 mA, +/1 mA
Outputs
The outputs of X31 are currently not used with the rho 3 controller. The output le
vels are not defined. They can be 0V or 24V.
138
3.8.12.2 Pin assignment, fast inputs
NC front panel * Distributor cables Interface cables

(36 x 0.14 or (Single wires 0.25, each
single wires 0.25) one shielded)
Connector X31
(D-Sub, 25-pin) max. 2 m max. 50 m
HS In 1 2
HS In 2 3
HS In 3 4
HS In 4 5
HS In 5 6
HS In 6 7
HS In 7 8
HS In 8 9
HS In 9 15
1
+ 24 V
14 load
13
25 0 V load
Shield connections to the SERVO front Metal housing of the
panel or via the metalic housing of the plug in connection in the
D-SUB plug-in connector adapting cabinet
* = Distributor cable can be omitted if the interface cableis directly connected to the RCY
Voltage supply
The voltage supply is implemented via connector X31 in accordance with the pin assign
ment. The voltage source is the 24 V load voltage with the characteristics given in the
chapter on voltages and tolerances.
139
3.8.13 Probe inputs / 5V probe switching voltage

(Connector X51)
Connector X51 has two inputs (24 V DC, 5 V DC) for switching probes (label on front
panel: "Pr"). Internally, the two inputs are linked via an OR function.
An additional switching voltage for a 5V probe is also available (load capacity: max. 10
mA). This voltage can be switched by the switching contact of a probe and returned to
the controller at the 5 V DC probe input.
The inputs of connector X51 are used in the rho 3 controller in the configuration level
"fast measuring".
Further information on this function can be found in document "rho 3 configuration level
description", P.No. 4268, article No. 073077, and in document "rho3 description of ma
chine parameters", P.No. 4262, articla No. 073027.
The probe inputs are only used in connection with incremental measuring systems.
3.8.13.1 Technical data, probe inputs

The following general points must be taken into account for the probe inputs of the
SERVO i:
24 V probe input

5 V probe input
140
3.8.13.2 Pin assignment, probe inputs
Connector
X51
1
24 V probe input
2
5 V probe input
3
0 V load
4
5
0V
6
7
8
Servo front panel
141
3.8.13.3 Connection options for probes
1 1
Probe
2 2
3 3

5 5
cabinet!
0 V load

1 1
Probe
2 2
Probe
3 3
4 4
24 V load
5 5 5 V external
0 V load
0 V extern

1
2 Servo front panel
3
(taper pin)
4 Probe
5
Probe
1 24 V load
2 5 V external (*)
3 0 V load
4
5
142
Plug-in units rho 3
Flexible Automation Servo interface SERVO i Interface conditions
3.9. Servo interface SERVO i
3.9.1. Overview
The servo card is used for output of the analog speed setpoints and closes the position servo loop by
evaluation of the signals of the connected incremental position measuring systems.
The Servo i card is offered in various hardware versions which differ with respect to the number of mea
suring system inputs and setpoint outputs.
Servo 6i Servo 4i Servo 3i

6 measuring system inputs 4 measuring system inputs 3 measuring system inputs
7 analog setpoint outputs 4 analog setpoint outputs 3 analog setpoint outputs
The following descriptions refer to the Servo 6i. The details also apply to the Servo 4i and Servo 3i sub
ject to the corresponding hardware restrictions.
143
Plug-in units rho 3
BOSCH
CNC
1st measuring system input 4th measuring system input

2nd measuring system input 5th measuring system input

3rd measuring system input 6th measuring system input

8-fold analog input

(Connector X25, Sub-D, 15-pole)
(In preparation) High speed I/O
(Connector X31, Sub-D 25-pole),
Probe input for rho 3

Ground-neutral points
(Connector X51)

(Connector X22)
Screen terminals of the setpoint

lines
Analog setpoint outputs -5
(Connector X21)
SERVO 6i
Front view of SERVO 6i with analog setpoint outputs
144
Plug-in units rho 3
3.9.2. Measuring system inputs

(Sockets X11 to X16) (X14 to X16 optional)
Both encoders for direct connection and encoders for electronic pulse
shaper (EXE) can be connected to the measuring system inputs. The con
nection instructions of the manufacturers with respect to cable length and
cable routing must be observed here. The power supply of a directly con
nected encoder or an EXE with external 5 V supply is also provided via the
measuring system input socket.
The following data applies generally to the SERVO i measuring system in
puts:
` Max. permissible
cable length/input: 50 m or manufacturer
specification
` Max. permissible cable length

difference at all input 15 m
` Cable type: Special cabel NFS 7264

10 x 0.14 mm2 + 4 x 0.5 mm2
(not for trailingoperation!)

Ri = 120 W
` Input signals: A, B, R, Uas, A, B, R

(min. voltage difference
between A and A, B and
>
B, R und R = 600 mV)
` Pulse multiplication: Quadruplication of thei

nput frequency (4-edge
evaluation)
` Max. permissible input frequency: 500 kHz
` Encoder/EXE power supply: +5 V
` Max. total current consumption

of all connected encoders/EXEn: 1.5 A
The signal lines of the measuring systems must be connected exactly in

accordance with these conditions. It is not permitted to change round
the signal lines for the purpose of direct reversal because this one
lead to decoding of the zero pulse! Direction reversal can be realized in
the software by means of the machine parameters.
145
Plug-in units rho 3
Measuring direction Positive Negative Positive
a a a a a b a a b a
A/Ua1
A/Ua1
B/Ua2
B/Ua2
R/Ua0
R/Ua0
c c a > 250 ns
=
b > 0 ns
=
Both operating states are permitted c > 100 ns
=
3.9.2.1. Approved digital measuring systems

Rotary encoders for direct connection for Messrs. Heidenhain and Steg
mann can be installed if they satisfy the following preconditions:
>
In addition, EXEs from Messrs. Heidenhain which satisfy the following pre
conditions can be installed:
>

` Rotary encoder for
direct connection: ROD 220 (Messrs. Heidenhain)
ROD 420 "
ROD 426 "
ROD 428 "
DG 60 D (Messrs. Stegmann)
DG 90 D "
DG 100 D "
ROD 428
DG 60
EXE 604 C, EXE 605 C: ROD 250 (Messrs. Heidenhain)
ROD 450 "
146
Plug-in units rho 3
ROD 456 "

ROD 700 "
ROD 800 "

EXE 702, EXE 816: ROD 800 (Messrs. Heidenhain)

EXE 604 C, EXE 605 C, EXE 610,
EXE 801, EXE 802, EXE 803,
LS 707 "
LS 903 "

LIDA 325 "
147
Plug-in units rho 3

Notes:
- The list of measuring systems should be considered only as a gener
al recommendation owing to frequent technical modifications and in
creasing product priority.
- In the case of rotary encoders with direct connection or EXEs, it is

recommended to use such types which do no have any capacitive
connection between 0 V or the supply voltage and the housing (e.g.
ROD 428, EXE 604 C). This improves immunity to interference.
- The SERVO i detects a measuring system error both through the in
put signal Uas and when the connected encoders/EXEs switch their
output stages to tri-state condition (high-resistance).
- Non-driven Uas lines are connected to inactive potential by pull-up
resistors on the SERVO i.
148
Plug-in units rho 3
3.9.2.2. Pin assignments

The cable screen must possess a continuous connection from the front
panel of the SERVO i (screen terminals) to the measuring system.
Heidenhain rotary encoders

supplied by BOSCH
Socket Cabel Encoder Measuring

max. 1 m
1 1 wh/ye 0.14 1 1 br
A/Ua1 Ua1
2 2 gn 0.14 2 2 gn
A/Ua1 Ua1
3 3 gr 0.14 3 3 gr
B/Ua2 Ua2
4 4 pk 0.14 4 4 pk
B/Ua2 Ua2
5 5 br 0.5 5 5 bl
6 6 wh 0.14 6 6 rd
R/Ua0 Ua0
7 7 wh/gr 0.14 7 7 bk
R/Ua0 Ua0
8 8 vio 0.14 8 8 vio
Uas Uas
9 9 rd 0.5 9 9 br +5V
+5V
10 10 bk 0.5 10 10 wh
11 11
12 12 bl 0.5 12 12 wh
0V 0V
lamp
Connection via metallic housing of the D-Sub

connector and pin 11 of the Souriau socket
max. 50 m
149
Plug-in units rho 3
Stegmann rotary encoders

supplied by BOSCH
Socket Cabel Encoder Measuring system

X11 - X16 (10 x 0.14 mm2 + 4 x 0.5 mm2) Signal output DG 60 D
DG 90 D
max. 1 m DG 100 D
TE 60
1 1 wh/ey 0.14 1 1 wh
A/Ua1 K1
2 2 gn 0.14 2 2 br
A/Ua1 K1
3 3 gr 0.14 3 3 rpk
B/Ua2 K2
4 4 pk 0.14 4 4 bk
B/Ua2 K2
5 5 br 0.5 5 5
6 6 wh 0.14 6 6 pu
R/Ua0 K0
7 7 wh/gr 0.14 7 7 ye
R/Ua0 K0
8 8 vio 0.14 8 8 gn
Uas ALARM
9 9 rd 0.5 9 9 rd Us
+5V
10 10 bk 0.5 10 10
11 11
12 12 bl 0.5 12 12 bl
0V 0V
lamp
Connection via metallic housing of the D-Sub

max. 50 m
150
Plug-in units rho 3
Heidenhain rotary encoders with electronic pulse shaper (EXE)

The connecting cables from the EXE to the measuring system are Heiden
hain cables.
. The connector pin assignment applies only to cables and EXEs

supplied by BOSCH
Socket Cabel EXE Signal Measuring

X11 - X16 (10 x 0.14 mm2 + 4 x output system
0.5 mm2)
1 1 wh/ey 0.14 1
A/Ua1 Ua1 Ie1+
2 2 gn 0.14 2
A/Ua1 Ua1 Ie1-
3 3 gr 0.14 3
B/Ua2 Ua2 Ie2+
4 4 pk 0.14 4
B/Ua2 Ua2 Ie2-
5 5 br 0.5 5
+ 5V
6 6 wh 0.14 6
R/Ua0 Ua0 Ie0+
7 7 wh/gr 0.14 7
R/Ua0 Ua0 Ie0-
8 8 vio 0.14 8
Uas Uas + 5V
9 9 rd 0.5 9
+5V + 5V + 5V
10 10 bk 0.5 10
0V
11
Screen
12 12 bl 0.5 12
0V 0V 0V
lamp 0V
Connection via
metallic housing of the D-Sub
151
Plug-in units rho 3
Plug connector
Socket
1 2
3 4 5
6 7
8 9 10
11 12
Strain relief
Wiring side
Screen attachment on metal housing
Cabel: LY 10 x 0,14 + 4 x 0,5 (max. cable length 50 m)

Not suitable for tailing operation!
Pin assignment
Farbe Stecker X11 Farbe Buchse X2
green 2 green 2
grey 3 grey 3
pink 4 pink 4
white 6 white 6
violet 8 violet 8
red 0.5 V 9 red 0.5 V 9
blue 0.5 V 12 blue 0.5 V 12
housing
Ordering data
Type No.
Cable ... 10 x 0,14 + 4 x 0,5 V 903 499

D-connector, 15-pole male 904 440
Metal cover for 15-pole D-connector 913 724
Socket 12-pole Souriau 909 131
Accessory set for Souriau socket 909 688
Preassembled cable, cable length 5 m 048 663
152
Plug-in units rho 3

(Connectors 21 and X22)
Speed-proportional voltages are available at these outputs for controlling
the individual axes.
The following points must be taken into account with respect to the analog
setpoint outputs of the Servo i:
` Recommended cable type: Belden 2 x 0.5 mm2 (8762-20)
` The screen connection depends on the drives used (e.g. for Servo
dyn T: connection at both ends) .
` Max. output voltage range: +/- 13.3 V
` Increment voltage (nom.): 406 mV
` Output voltage (rapid traverse): +(-)10 V
` Permissible load resistance

at output: min. 10 kW
` The output stages are resistant to sustained short circuits. However,

if several outputs are short-circuited, the output operational amplifi
er may be destroyed as a result of the increased power loss.
` The setpoint outputs are immediately set to 0 V (analog GND) if the

READY signal goes LOW. This level is kept constant for a maximum of
1 s. The drives must be switched off during this time
` The inputs at the drive amplifiers must be connected as difference

amplifiers. Ground-bonded circuits must be avoided.
153
Plug-in units rho 3
3.9.3.1. Pin assignment
Connector
X21
1
+/-10 V
0V
3
+/-10 V
0V
5
+/-10 V
0V
7
+/-10 V
0V
9
+/-10 V
0V
Screen terminals on
Servo front panel
Connector
X22
1
+/-10 V
0V
3
+/-10 V
0V
Screen terminals on
Servo front panel
154
Plug-in units rho 3
3.9.4. Fast inputs

Connection (connector X31)
General remarks
The inputs of connector X31 are used in the rho 3 controller in the configuration
levels "fast measuring" and "fast constant starting". Further information on these
functions can be found in the document "rho 3 configuration level description",
P.No. 4268, article. No. 073077, and the document "rho3 Description of machine
parameters", P.No. 4262, article No. 073027.
3.9.4.1. Technical data, fast inputs

The following data must be taken into account for the "fast inputs" of the
SERVO m.i.:
` The input signals must be free from radio interference and bounce.
` Input voltage range: 3 V to +32 V
` All inputs are galvanically isolated from the logic voltage by optical coup
lers.
` Voltage threshold for transition from
LOW to HIGH level: +8.5 V, +/1 V
` Hysteresis for transition from
HIGH to LOW level: 1 V, +/0.5 V
` An open input is recognized as "logically 0".
` Input current/ input: max. 8 mA, +/1 mA
Outputs
The outputs of X31 are currently not used with the rho 3 controller. The out
put levels are not defined. They can be 0V or 24V.
155
Plug-in units rho 3
3.9.4.2. Pin assignment, fast inputs
Plug RC Front * Distributor Interface cable

X31 panel cable (single cores 0.25,
(36 x 0.14 or screened)
single cores 0.25)
max. 2 m max. 50 m
HS In 1 2
HS In 2 3
HS In 3 4
HS In 4 5
HS In 5 6
HS In 6 7
HS In 7 8
HS In 8 9
HS In 9 15
HS Out 1 10
HS Out 2 11
HS Out 3 12
HS Out 4 24
HS Out 5 23
HS Out 6 22
HS Out 7 21
HS Out 8 20
HS Out 9 19
+ 24 V 1
14
13
0V 25
Screen connection at Plug connection in PLC

Servo Front Panel Panel
* = Distributor cable unnecessary when interface cables are directly connected to the CNC
Voltage supply
The voltage supply is implemented via connector X31 in accordance with the pin
assignment. The voltage source is the 24 V load voltage with the characteristics
given in the chapter on voltages and tolerances.
156
Plug-in units rho 3
3.9.5. Probe inputs / 5V probe switching voltage

(Connector X31)
Connector X31 has two inputs (24 V DC, 5 V DC) for switching probes (label on
front panel: "Pr"). Internally, the two inputs are linked via an OR function.
An additional switching voltage for a 5V probe is also available (load capacity:

max. 10 mA). This voltage can be switched by the switching contact of a probe
and returned to the controller at the 5 V DC probe input.
The inputs of connector X31 are used in the rho 3 controller in the configuration
level "fast measuring".
Further information on this function can be found in document "rho 3 software
Releases", article No. 073077, and in document "rho3 description of machine pa
rameters", article No. 073027.
3.9.5.1. Technical data, probe inputs

The following general points must be taken into account for the probe inputs of
the SERVO :
` All inputs are galvanically isolated from the logic voltage by optical coup
lers.
24 V probe input

5 V probe input
157
Plug-in units rho 3
3.9.5.2. Pin assignment, probe inputs
Connector
X31
1
24 V probe input
2
5 V probe input
3
0 V load
4
5
0V
6
7
8
Servo front panel
158
Plug-in units rho 3
3.9.5.3. Connection options for probes
1 1
Probe
2 2
3 3

5 5
cabinet!
0 V load

1 1
Probe
2 2
Probe
3 3
4 4
24 V load
5 5 5 V external
0 V load
0 V extern

1
2 Servo front panel
3
(taper pin)
4 Probe
5
Probe
1 24 V load
2 5 V external (*)
3 0 V load
4
5
159
Plug-in units rho 3
Flexible Automation E/A 24/0.1 (with PIC250) Interface coditions
3.10 Modulo I/O 24/0.1 with PIC250
Digital I/O with integrated PLC PIC250

60 inputs and 40 outputs are available for machine and interface purposes.
A second I/O 24/0.1 module (without integrated PIC) can be installed in order to
increase the number of inputs/outputs. 128 inputs and 80 outputs are then avail
able as machine signals.
The PIC250 is a PLC which functions parallel to the RC and which can be plugged
onto the I/O 24/0.1 module as a separate auxiliary card.
BOSCH
CNC
Digital outputs
E/A24/0.1
Write Prot.
0 Write protection for C 250
Digital inputs 1
(Connector X21,
Sub-D, 15-pole)
Digital inputs
(Connector X22,
Sub-D,50-polig)
Supply voltage input for X11

24V (Connector X10)
24V
0V
0V
Front view I/O 24/0.1
Caution:
The module must be removed only when the RC is switched off.
160
Plug-in units rho 3
Data of the PIC 250:

1024 digital inputs 8 times 1024 markers
1024 digital outputs 8 counters
Max. 8 k memory (EEPROM)
The processing speed is 10 ms for an 8 kB PIC program
The RC interface can be addressed via the PIC addresses
A0.0 to A88.7 (RC inputs) and
E0.0 to E88.7 (RC outputs).
Further information is contained in the manual rho 3 signal description and rho 3
description of machine parameters.
Write protection PIC 250

Position 0:
Access to the PIC program is possible (editing, deletion).
However, it is only possible to edit a PIC program which is not active.
Position 1:
PIC 250 memory is protected against write access.
Caution:
The write protection must be activated (position 1) after the PIC program is put into
operation. If this is not done, the PIC memory may be overwritten and the PIC pro
gram lost.
Supply voltage (connection X10)
The 24 V supply must be provided via a transformer in accordance with VDE 0551.
The 24 V supply is separate from the 24 V voltage supply for the NC power supply.
Incoming supply 24 V =; (plug-in terminal, 4-pole). Polarized supply voltage in

put for the digital outputs at X11. Maximum input current: 4 A.
F 10 A X10
24 V-
F1 24 V-
Power supply from 24 V
0V load power supply
0V
Reverse polarity protection
161
Plug-in units rho 3
Digital outputs (connection X11) (Socket, Sub-D, 50-pole)

These outputs are freely assignable. The signal assignment depends on the PLC
program. 40 outputs are available (Iout: max. 0.1 A per output). The assignment
between PLC addresses and output pins is shown in the following table:
ADR PIN ADR PIN ADR PIN ADR PIN ADR PIN ADR PIN ADR PIN ADR PIN
88.0 27 88.1 50 88.2 09 88.3 33 88.4 26 88.5 17 88.6 08 88.7 49
89.0 25 89.1 16 89.2 07 89.3 32 89.4 23 89.5 15 89.6 06 89.7 48
90.0 22 90.1 14 90.2 05 90.3 31 90.4 21 90.5 13 90.6 04 90.7 30 X11
91.0 20 91.1 12 91.2 03 91.3 29 91.4 36 91.5 11 91.6 02 91.7 28
92.0 19 92.1 10 92.2 01 92.3 47 92.4 18 92.5 34 92.6 35 92.7 37
Digital outputs (Connection X11) with second I/O card

93.0 27 93.1 50 93.2 09 93.3 33 93.4 26 93.5 17 93.6 08 93.7 49
94.0 25 94.1 16 94.2 07 94.3 32 94.4 23 94.5 15 94.6 06 94.7 48
95.0 22 95.1 14 95.2 05 95.3 31 95.4 21 95.5 13 95.6 04 95.7 30 X11
96.0 20 96.1 12 96.2 03 963 29 96.4 36 96.5 11 96.6 02 96.7 28
97.0 19 97.1 10 97.2 01 97.3 47 97.4 18 97.5 34 97.6 35 97.7 37
Digital inputs (connections X21 and X22) (X21: connector, Sub-D, 15-pole;
X22: Connector, Sub-D, 50-pole)
The inputs are interrogated by the internal PLC (PIC 250). They are freely assign
able. The signal assignments depends on the PLC program. 64 inputs are avail
able.
The assignment between PLC addresses and input pins is shown in the following
table:
88.0 48 88.1 47 88.2 50 88.3 49 88.4 33 88.5 32 88.6 17 88.7 16
89.0 46 89.1 15 89.2 31 89.3 45 89.4 30 89.5 14 89.6 29 89.7 44
90.0 13 90.1 12 90.2 28 90.3 43 90.4 11 90.5 27 90.6 42 90.7 10 X22
91.0 26 91.1 41 91.2 09 91.3 25 91.4 24 91.5 08 91.6 40 91.7 07
92.0 23 92.1 39 92.2 06 92.3 22 92.4 38 92.5 05 92.6 21 92.7 04
93.0 37 93.1 20 93.2 03 93.3 36 93.4 19 93.5 02 93.6 01 93.7 18
94.0 34 94.1 35 94.2 15 94.3 07 94.4 14 94.5 06 94.6 13 94.7 05

X21
95.0 12 95.1 04 95.2 11 95.3 03 95.4 10 95.5 02 95.6 09 95.7 01
Digital inputs (Connectors X21 and X22)(X21: Connector, Sub-D, 15-pole;

X22: Connector, Sub-D, 50-pole)
96.0 48 96.1 47 96.2 50 96.3 49 96.4 33 96.5 32 96.6 17 96.7 16
97.0 46 97.1 15 97.2 31 97.3 45 97.4 30 97.5 14 97.6 29 97.7 44
98.0 13 98.1 12 98.2 28 98.3 43 98.4 11 98.5 27 98.6 42 98.7 10 X22
99.0 26 99.1 41 99.2 09 99.3 25 99.4 24 99.5 08 99.6 40 99.7 07
100.0 23 100.1 39 100.2 06 100.3 22 100.4 38 100.5 05 100.6 21 100.7 04
101.0 37 101.1 20 101.2 03 101.3 36 101.4 19 101.5 02 101.6 01 101.7 18
102.0 34 102.1 35 102.2 15 102.3 07 102.4 14 102.5 06 102.6 13 102.7 05

X21
103.0 12 103.1 04 103.2 11 103.3 03 103.4 10 103.5 02 103.6 09 103.7 01
162
Plug-in units rho 3
Interface cable
X11 (PIC 250 output signals)
2500
Conector
400
Wiring side Pin-end connector
Pin assignment
Color Connector Color Connector Color Conn.
white 1 grey-brown 18 green-black 35

brown 2 white-pink 19 yellow-black 36
green 3 pink-brown 20 green-blue 37
yellow 4 white-blue 21 pink-blue 38
grey 5 brown-blue 22 grey-red 39
pink 6 white-red 23 pink-red 40
blue 7 brown-red 24 grey-black 41
red 8 white-black 25 pink-black 42
black 9 brown-black 26 blue-black 43
violet 10 grey-green 27 red-black 44
grey-pink 11 Yellow-grey 28 white-brown-black 45
red-blue 12 pink-green 29 yellow-green-black 46
white-green 13 yellow-pink 30 grey.pink-black 47
brown-green 14 green-blue 31 red-blue-black 48
white-yellow 15 yellow-blue 32 white-green-black 49
yellow-brown 16 green-red 33 brown-green-black 50
white-grey 17 yellow-red 34
163
Plug-in units rho 3
X21 (PIC 250 input signals)
2500
Socket
400
Wiring side Strip length 4 mm
Socket assignment
Color Connector
white 1
brown 2
green 3
yellow 4
grey 5
pink 6
blue 7
red 8
black 9
violet 10
grey-pink 11
red-blue 12
white-green 13
brown-green 14
white-yellow 15
164
Plug-in units rho 3
X22 (PIC 250 input signals)
2500
Socket
400
Wiring side Pin-end connector
Pin assignment
Color Connector Color Connector Color Conn.
white 1 grey-brown 18 green-black 35

brown 2 white-pink 19 yellow-black 36
green 3 pink-brown 20 green-blue 37
yellow 4 white-blue 21 pink-blue 38
grey 5 brown-blue 22 grey-red 39
pink 6 white-red 23 pink-red 40
blue 7 brown-red 24 grey-black 41
red 8 white-black 25 pink-black 42
black 9 brown-black 26 blue-black 43
violet 10 grey-green 27 red-black 44
grey-pink 11 Yellow-grey 28 white-brown-black 45
red-blue 12 pink-green 29 yellow-green-black 46
white-green 13 yellow-pink 30 grey.pink-black 47
brown-green 14 green-blue 31 red-blue-black 48
white-yellow 15 yellow-blue 32 white-green-black 49
yellow-brown 16 green-red 33 brown-green-black 50
white-grey 17 yellow-red 34
165
Input/Output Modul rho3
Flexible Automation I/O 32/16 0.5 A Interface condition
3.11 Input/Output Module I/O32/16 0.5A
Plugin terminals
BOSCH BOSCH
CNC CNC
x x
1 1
1 Output 1
Output
x x
1 PICEEPR 1
2 OM write 2
protect
switch
E A24/0.5 E A24/0.5
x x
2 2
1 1
x x
2 2
2 2
Input
Input
Monitoring LED
x x
2 2
3 3
x x
2 2
4 4
1 24V 1 24V
x x
2 24V 2 24V
1 3 24V 1 3 24V
0 0V 0 0V
0V 0V
Plugin terminals x
5
1
15pole CAN
socket D
SUB CAN
BUS
View: Installation side I/O

32/16 500mA
166
3.11.1 Power Supply
CONNECTOR X10
The power supply is 24 Volt +30%/ 15%.
The overall maximum nominal current consumption for a nominal voltage (24 V)
and a nominal load is 8.7 amperes.
Under nominal conditions, the current consumption is distributed between the in
dividual terminals (X10/1 to X10/3) as follows:
24V (X10/1) 0.8 amperes
24V (X10/2) 3.7 amperes
24V (X10/3) 4.2 amperes
These three terminals are separate power supply lines, so that if one power sup
ply line fails, the corresponding part of the outputs no longer functions.
Each of the three power supply lines is fused with 6.3 A.
3.11.2 Inputs
CONNECTORS X21,X22,X23,X24
The maximum permissible input voltage range is between 3 volts and 31.2 volts.
An input is detected as HIGH from 15 volts upwards.
Up to 10 volts input voltage, the input is regarded as LOW.
The input current per input in the permissible range for HIGH is a minimum of 1 mA
and a maximum of 15 mA (effective value, as the inputs are scanned). A light emit
ting diode is assigned to each input. It shows the logical status of the input. The
internal supply voltage for the inputs is derived from the 24V (1).
NOTE:
Even if the 24V is missing (X10/1), the light emitting diodes may light up when
signals are received at the inputs. The display does not guarantee that the RC
recognizes the input correctly (e.g. missing 24V (X10/1)).
The inputs are protected with suppressor diodes. They serve the function of limi
ting transient voltage peaks (switching peaks). The nominal limitation voltage is
approximately 60V. The current flow at that point is in the mA range. Larger cur
rents (in the ampere range) can be conducted, but this means that a higher vol
tage briefly occurs in the diode. If a voltage greater than 60V is applied statically,
and if the current flowing through the suppressor diode is greater than 10 mA, the
diode may be destroyed. First, the diode forms a short circuit. However, if the cur
rent flow persists, depending on the magnitude of the current flowing in the case
of a short circuit, the short circuit created by the suppressor diode may melt away
again (diode evaporates).
167
The inputs are distributed to the addresses as follows:
Input 1- 8 (Connector X21) to E88.0 E88.7

Input 9 - 16 (Connector X22) to E89.0 E89.7
Input 17 - 24 (Connector X23) to E90.0 E90.7
Input 25 -32 (Connector X24) to E91.0 E91.7
For diagnostic purposes, the outputs (X11 and X12) are internally directly rou
ted back to inputs. This enables the actual and nominal output status to be com
pared.
The output status that has just been set can only be read in in the next PLC
cycle.
(Output 18) Input E92.0 E92.7

(Output 916) Input E93.0 E93.7
The voltage monitoring units check the three 24 V power supplies. The actuation
thresholds lie between less than 13 volts for LOW (voltage not present) and grea
ter than 19 volts for HIGH (voltage present).
Operation is correct if the inputs are recognized as follows:
E 95.0 = LOW [24V(1)],

E 95.1 = HIGH [24V(2)] and
E 95.2 = HIGH [24V(3)]
3.11.3 Outputs
CONNECTORS X11 AND X12

The maximum permissible output current per output is 500 mA. The outputs can
only give off current. They are not allowed to accept current. The current output is
not limited to 0.5A.
The maximum internal voltage fall is 1.4 volts for nominal current. In LOW status
(OFF status) of the output, the output leakage current is less than 0.8 mA (must be
taken into account with highohmic inputs).
The distribution of the outputs:
Output 1 to 24V (X10/1)

Output 2 8to 24V (X10/2)
Output 9 16 to 24V (X10/3)
The outputs can be accessed at the following addresses:
ADDR PIN ADDR PIN ADDR PIN ADDR PIN ADDR PIN ADDR PIN ADDR PIN ADDR PIN
X11 88.0 1 88.1 2 88.2 3 88.3 4 88.4 5 88.5 6 88.6 7 88.7 8
X12 89.0 1 89.1 2 89.2 3 89.3 4 89.4 5 89.5 6 89.6 7 89.7 8
The outputs are permitted to work on ohmic or inductive loads. Each output has a
free running diode. It is connected to 0V on the anode side, and on the cathode
side it is connected with the output.
168
Capacitative loads must not be connected to the outputs.

Light bulbs are only permissible up to a total power of 5 watts per output. If light
bulbs up to 12 watts are connected, measures must be adopted to limit the ma
king current.
If the output is overloaded, the overloaded output driver heats up and switches off.
The switched off status can be detected by means of the feedback of the outputs.
The time that elapses before switching off varies, and is dependent on the am
bient temperature, the supply voltage, the intensity of fan operation, the load on
the other outputs and the extent of the overload of the output. After an output has
switched off because of overloading, the overheated output driver cools down in
accordance with the conditions given above. After the output driver has cooled,
the output assumes its nominal status. If an output is operating on a short circuit,
the current is below 1.7 amperes. The short circuit current is not constant. The
output is checked for a short circuit by periodically switching it on for a short time.
If the short circuit does not remain, or if the output is reset, the output driver inter
rupts the cyclical testing of the output. The output returns to its nominal status. All
time values and other details are approximate values and only reflect typical
conditions and approximations (orders of magnitude).
3.11.4 Generating and Applying the 24 Volts

The 24 volt supply must be implemented with a transformer conforming to VDE
0551. Furthermore, the 0V of the 24V load side (secondary side) must be connec
ted to the primary side (mains side) earth potential (PE).
The 24 volt supply is implemented separately from the 24 voltg uspply for the NC
power supply module. The 24 volt supply for the NC power supply module must
only be resorted to if it is assured that the power supply module load permits load
changing at the outputs without any effect on the NC supply.
The connection of the power supply is implemented with 1.5 cubic mm of Cu wire
per terminal. When the three 24 V circuits are combined, it is possible to call on a
total of 2 x 1.5 cubic mm of Cu wire for the 24 V circuits.
However, all three terminals must be assigned 24 volts.
The wires must be laid out twisted. The wires that conduct the 0 volt potential to
the I/O card must not bear any load from other consumers. The 0 volt wires must
be connected directly to the 0 volt bar for the load supply. The shortest possible
connection must be selected for all voltage supply connections. The wires for the
24 volt circuits and the 0 volt potential must each not be longer than 10 m. It is
important to adhere to the minimum voltage to the card. If the supply voltages
(24V(X10/2) or 24V(X10/3)) are switched off, the supply voltage of the respective
output driver is also switched off. If the voltage of a 24 V circuit that has failed or
been switched off is then switched on again, the outputs assume the nominal sta
tus that is valid at that point in time. The person who creates an emergency stop
circuit or disabling circuit is responsible for testing to what extent the suggestion
can be applied to the design of one of the above circuits.
169
3.11.5 Extensions
The I/O module can optionally be extended, as required, with a PIC250 (integra
ted PLC) and a CAN interface card (digital drive interface). The connection to the
CAN bus is implemented with connector X51 (15pole SUBD).
CAN 1 - H X51 (PIN 1,6,8)
CAN 1 - L
X51 (PIN 4,9,15)
X51 (PIN 5)
CAN 2 - H X51 (PIN 2,7,13)
CAN 2 - L
X51 (PIN 10,14)
X51 (PIN 12)
Pin assignment (CAN bus interface)
8 H
15
CAN BUS 1
L
H
CAN BUS 2
L
9
1
2 CAN bus systems

with
bus termination on the
rho 3 CAN connector
170
8 8
15 H 15 H
CAN BUS 1 CAN BUS 12
L L
H
CAN BUS 2
L
9 9
1 1
2 CAN bus systems 1 CAN bus system

without with
bus termination bus termination on the
the bus termination is rho 3 CAN bus
implemented on the connector
other bus station
8
15 H
CAN BUS 1
L
CAN BUS 2
2 CAN bus systems

without
bus termination
171
Flexible Automation NCPLCI/O Interface Conditions
3.12 Module NCPLCI/O

This module allows direct interfacing with PLC I/O modules in a combination rack
or with external PLC I/O modules. If used in a combination rack, connection to
PLC I/O modules is via the backplane. External PLC I/O modules are connected to
the AG/Z-S is by means of the NCPLCBit extension cable.
Note:
The I/O modules must be set consecutively starting at address 88.0; see also
rho3 Signal descriptions.
BOSCH
CNC
NC SPS
0 Write protection PIC 250

1
Write Prot.
System connection to the PLC

( AG/Z - S )
(Connector X11, submin., 50 pin)
LED Logic
Logic
LED 12 V
12V
X
24V Supply voltage
24V input
1 0V
0 0V (connection X10)
Front view NCPLCI/O interface module
172
Note:
Modules must be switched off before they are removed from the controller or
PLC.
Write protection PIC 250

Position 0:
Accessing the PIC program is possible (Edit, Delete).
However, it is only possible to edit one inactive PIC program.
Position 1:
PIC 250 memory is blocked for write protection.
Caution:
Write protection must be activated when the PIC program starts (position 1). It this
is not done, the PIC program may be lost!
Supply voltage input (connection X10)

Supply voltage 24V=; (plugin terminal, 4 pin). polarized supply voltage input for
the digital outputs at X11. Supplied from a 24V load power supply module. Maxi
mum input current: 4A.
F 10 A X10
24 V-
F1 24 V-
Voltage supply from the
0V 24V load power supply
0V
Polarizing
LED 12V
The internal 12V supply for the CMOS bus is present.
LED logic
The internal logic voltage for the PLCI/O module is present.
System connection to the external PLC (connection X11)

(Connector, subminiature, 50 pin).
Bus connection between the CNC and the PLC module AG/Z or AF/P to the bit
coupling between the CNC and PLC.
. The bus connection cable must be in a deenergized state before it is
connected to or removed from the CNC and the PLC.
DNC interface (option) (connection X31)

(Connector, subminiature, 25 pin)
For connection assignments, see section 1.4.5 "DNC interfaces".
173
3.12.1 NCPLCBit connection cable to the AG/Z
550
(1800)
Connector X11 Connector X11

NCPLCBit AG/Z or AG/P
D-connector, 50 pin Dconnector, 50 pin
Wiring end Wiring end
Pin assignment X11

Color Qty. Qty. Color Qty. Qty. Color Qty. Qty.
black 3 3 orange-white 20 20 orange-black 37 37

blue 4 4 brown-white 21 21 brown-black 38 38
brown 5 5 blue-red 22 22 red-green 39 39
beige 6 6 yellow-red 23 23 gray-green 40 40
yellow 7 7 green-red 24 24 violet-green 41 41
green 8 8 white-red 25 25 white-green 42 42
violet 9 9 orange-red 26 26 orange-green 43 43
pink 10 10 brown-red 27 27 brown-green 44 44
orange 11 11 red-black 28 28 red-yellow 45 45
transparent 12 12 blue-black 29 29 blue-yellow 46 46
red-white 13 13 green-yellow 30 30 violet-yellow 47 47
blue-white 14 14 yellow-black 31 31 white-yellow 48 48
yellow-white 15 15 green-black 32 32 brown-yellow 49 49
green-white 16 16 voilet-black 33 33 red-blue 50 50
violet-white 17 17 white-black 36 36
Type No.
Cable NCPLCBit 0.55m (for AG/Z ) 041 535

Cable NCPLCBit 1.8m 048 081
When using the PCI/OS interface card, use the following cables and interface modules:
Cable NCPLCBit 0.55m (for AG/Z-S ) 064754
Cable NCPLCBit 1.8m 048 755
174
Flexible Automation NCPLCBit Interface Conditions
3.13 Module NCPLCBit (Bit Coupler)

Using the module NCPLCBit, an external PLC (PC600, CL300, CL500) can be
coupled to the RC on the basis of a bit coupling. To do this, you need the PLC
module AG/Z or AG/P on the PLC side.
The PLC can then access the individual RC input/outputs. The corresponding ad
dresses for bit coupling to the RC can be found in rho3 Signal descriptions.
To prevent a conflict of addresses with PLC I/O signals, the start address of the rho
3 digital interface can be defined via machine parameter P20, cf.
rho3 Description of the machine parameters.
BOSCH
CNC
NC-SPS
Bit
System connection to the PLC

(AG/Z or AG/P)
Front view NCPLCBit
175
Caution:
The module must only be disconnected from the controller and PLC when it is
switched off!
System connection to the external PLC (terminal X11)

(Socket, SUBD, 50pole)
Bus connection between the RC and the PLC module AG/Z or AG/P for bit cou
pling between RC and PLC.
. The bus connection cable must only be connected or disconnected

when the RC
and PLC are switched off!
3.13.1 Connection cable NCPLCBit to AG/Z or AG/P.
550
(1800)
Connector X11 Connector X11

NCPLCBit AG/Z or AG/P
Dconnector, 50pole Dconnector, 50pole
Wiring end Wiring end
Type No.
Cable NCPLCBit 0.55m (for AG/Z or AG/P)041 535

Cable NCPLCBit 1.8m (for AG/P) 048 081
176
3.13.2 Connection cable NCPLCBit to AG/ZS or AG/PS.
Connector
X61
Cable AG/ZSAG/Z NCPLCBit to Cl500 Order No. 075008
Pin assignment X11

Color Qty. Qty. Color Qty. Qty. Color Qty. Qty.
black 3 3 orangewhite 20 20 orangeblack 37 37

blue 4 4 brownwhite 21 21 brownblack 38 38
brown 5 5 bluered 22 22 redgreen 39 39
beige 6 6 yellowred 23 23 greygreen 40 40
yellow 7 7 greenred 24 24 violetgreen 41 41
green 8 8 whitered 25 25 whitegreen 42 42
violet 9 9 orangered 26 26 orangegreen 43 43
pink 10 10 brownred 27 27 browngreen 44 44
orange 11 11 redblack 28 28 redyellow 45 45
transparent 12 12 blueblack 29 29 blueyellow 46 46
redwhite 13 13 greenyellow 30 30 violetyellow 47 47
bluewhite 14 14 yellowblack 31 31 whiteyellow 48 48
yellowwhite 15 15 greenblack 32 32 brownyellow 49 49
greenwhite 16 16 violetblack 33 33 redblue 50 50
violetwhite 17 17 whiteblack 36 36
Type No.
Cable NCPLCBit 1.80 m (for AG/ZS or AG/P_S) 0750008
177
Plug-in units rho 3
Flexible Automation PS 75 Interface conditions
3.14 Power supply PS 75

The power supply supplies the internal voltages for the logic circuits of all plug-in
units (CP/MEM4 etc.).
BOSCH
CNC
PS75
V out
Output voltage LED
Ready 2 LED Ready
24V input voltage

24 V
Reset Reset key
Ready 2 Relay contact (NO contact)

X
2
0
Fuse for 24V input

F10A
24V
X
Input voltage 1
24V DC +30% /-15% max. 0 0V
0V
Front view PS 75
Caution:
The module PS 75 must be removed only when the control is switched off.
178
Plug-in units rho 3
Output voltage LED

Output voltage indicator. The LED lights up when the logic supply voltage is out
put at the PS 75.
Ready 2 - LED
The control is ready for operation when the contact is closed and the green LED
READY lights up.
The control is not ready for operation if the contact is open.
This is equivalent to an EMERGENCY-STOP operation and must be correspond
ingly configured in the interface control.
The Ready 2 circuit monitors the following errors:

Voltage fault Overtemperature > equal to 58 °C supply air
Servo error Measuring system error
Watchdog-Error
24 V input voltage LED

The green LED lights up when the 24 V input voltage is present.
Reset key
Key to reset all error messages and restart the CNC (HW reset).
Ready 2 (X20)
Relay contact (NO contact) opens in the event of errors as described for the Ready
2 LED (switching capacity 50 W/24 V DC, Imax = 2 A).
Input voltage 24 V (connection X10)

Screw terminal, 4-pole.
Incoming supply of 24 V = +30 %/-15 %, max. 1.2 Vpp ripple voltage. The input is
polarized. Power consumption 125 W.
F 10 A X10
24 V 24 V-
F1 24 V-
0V logic power supply
0V 0V
(internal)
179
Plug-in units rho 3
3.15 Module PS 200 (power supply)

The power supply provides the voltages for the logic circuits of all plug-in units
(CP 2.5, MEM 5 etc.) and the measuring system supply voltages.
BOSCH
CNC
PS 200
VMS potentiometer
VMS Encoder supply voltage indicator
Output voltage indicator
Vout
Ready indicator
Ready
24 V error indicator
24V Interruption
Input voltage indicator
Vin > 20V
Reset key
Reset
+ Reset In
- Reset In, Reset Out, Ready 2
Reset Out (Connection X20)
Ready
Fuse F1 (M 15 A)
M 15A
Incoming supply 24 V
24V
24V (Connection X10)
0V
0V
Front view PS 200
Caution:
The module PS 200 must be removed only when the control is switched off.
180
Plug-in units rho 3
VMS potentiometer
This potentiometer is used to adjust the measuring system supply voltage. Ad
justment range: 5 V=; +20 %, -6 %
The encoder supply voltage must be adjusted so that the encoder supply voltage
is +5 V for all connected encoders and the permitted cable length (+/- 5 % mea
sured directly at the individual encoders).
Encoder supply voltage indicator

The LED lights up when the encoder supply voltage is output at the PS 200.
Output voltage indicator

The LED lights up when the supply voltage for the plug-in units in the card rack is
output at the PS 200.
Ready indicator
The LED lights up if none of the following errors are present:
- Internal voltage error
- Overtemperature (> 58 °C internal)
- Measuring system error- Servo loop error
- Processor error
24 V interruption indicator
The LED lights up if the external supply voltage at X10 has been interrupted briefly
(10 ms < t < 10 s).
The 24 V error is cleared by pressing the Reset key (CNC restart) or by a voltage
interruption of at least 30 seconds).
Input voltage indicator

The LED lights up when the external supply voltage (24 V =) is present at X10.
Reset key
Reset of all errors and CNC restart.
Incoming supply 24 V (connection X10)

Incoming supply 24 V =; (screw terminal, 4-pole).
Polarized supply voltage connection. Is supplied from a 24 V logic power supply
(see Section 1.9.2).
15A M X10
24 V 24 V-
F1 24 V-
0V logic power supply
0V 0V
181
Plug-in units rho 3
Reset in, Reset Out, Ready 2 (connection X20)

(Plug-in terminal, 6-pole)
Reset In: Relay input (same function as Reset key)
Reset Out: Relay contact (NO contact) opens in the event of an internal voltage
fault and overtemperature (> 58°Cinternal) and if the input voltage
is missing at X10.
Ready 2: Relay contact (NO contact) opens in the event of the same errors
as described under "Ready indicator".
The control is not ready for operation when the contact is open.
Consequently, Ready 2 must be correspondingly configured in
the interface control (with EMERGENCY-STOP).
For safety reasons, the load voltage must be switched off first
and then the logic voltage when the system is switched off
Reset key
X20
Reset
+
Reset In (24V=; +30%-15%)
-
Reset Out (24V=; max. 10W)
READY 2 (24V; max. 2A)
182
Programmable Manipulator rho 3
Flexible Automation PHG 3 Interface Conditions
4 Programmable manipulator PHG 3

The PHG 3 (from the German "Programmier-Handbediengerät", or program
mable manipulator) is used for programming and operating the rho 3 controller.
4.1 Construction
The PHG 3 programmable manipulator is designed for mobile use and consists of
a housing which contains the electrical components.
The housing is made of black highimpact plastic.
The key pad and display are located on the front, and the confirmation key and
EMERGENCY STOP button are on the side of the PHG.
The PHG is connected to the controller by means of an adaptor cable.
Protection rating : IP54
80
145 60
70
270
Confirmation key
Confirmation key
7 8 9
4 5 6
1 2 3
.
Shift
105
Fig. 1
183
4.2 Environmental conditions
Operating temperature range: + 5 to + 45° C
Storage temperature range: -20 to + 65° C
4.3 Keypad
The PHG 3 has a total of 36 keys.
The CONFIRMATION KEY is located on the side of the PHG 3.
Key assignment is by means of a replaceable key labelling mask which is

currently available in German and English.
4.4 Display
The PHG 3's display is a 4 line, 20 character LCD.
Character height: approx. 5 mm.
4.5 Emergency stop
The EMERGENCY STOP button is an emergency palm button with locked operat
ing element and safety contact.
Color: red operating element with yellow contrast surface.
Load: 24V/2A - The voltage in the EMERGENCY STOP circuit must

not deviate beyond 24V +20% -15%.
The EMERGENY STOP contact on the connector is for wiring into the
EMERGENCY STOP circuit.
4.6 Confirmation key
The CONFIRMATION KEY is located on the side of the PHG 3 and is a twochannel
design:
one channel is evaluated directly in the RC;

the second channel is available for wiring on the connector
as a potentialfree contact and must be linked to the interface
controller.
The confirmation key is arranged so that it can be used by righthanders as well as

lefthanders.
It must be pressed if a machine movement can be initiated in the MANUAL operat

ing mode (see also the rho 3 PHG operating instructions).
The confirmation key must be linked to the safety circuit of the interface controller
by means of an auxiliary relay.
184
4.7 Cable and Connector
Type: A special cable is used:

LIYCY-CY 4 x 0.3 mm2 + 3 x 2 x 0.19 mm2
Cable length: 8 m, standard
Cable assignment: See Fig. 1.1
Connector: 25pin subminiature connector
4.8 Interface
A special currentloop interface is used for reliably transmitting data of data. The
connection between the PHG 3 and the controller is permanently monitored. The
confirmation key is a twochannel design and is used for transmitting information
to the controller. In addition, it serves as a contact for interconnecting with the in
terface controller.
X22 on AF3 or AF5

or extention cable PHG 3
Cable
12 12 0.19 wh
TX+
13 13 0.19 br
RX+
16 16 0.19 gn
RS
21 21 0.19 bl
PGND
10 10 0.19 rd
+12V
9 9
11 11 0.30 vi
15 15 0.30 ye Confirmation key
5 5 0.30 gr
7 7 0.30 pi
8 8 EMERGENCY STOP
17 17
Fig. 1.1
185
4.9 Adaptor cable

The PHG cannot be directly connected to the interface of the rho 3 controller.
Instead, it is connected to the controller by means of an adaptor cable (see
Fig. 1.2. Für die zwei unterschiedlichen Hardwarekonzepte rho 3.1 und rho 3.2
stehen entsprechende Kabel zur Verfügung.
X22 on CP/MEM4 Subminiature connector

AF3 or AF5 X22
25 pin. Subminiature connector
25 pin
Cable
RX+ 19 19 0.19 wh 12
TX
TX+ 18 18 0.19 br 13
RX
RS+ 20 20 0.19 gn 16
PGND 16 16 0.19 bl 21 PGND

+12V In 10 10 0.19 rd 10 +12V
17 17
+12V out
Screening via
connector
0.30 mm 2 11
housing
o.30 mm 2 15 Confirmation key
0.30 mm 2 5
EMERGENCY STOP
0.30 mm 2 2 7
EMERGENCY STOP
Open leads for
wiring to the
EMERG. STOP
Screening via and confirmation
connector housing key
3.00 m
Connector assignment, adaptor cable CP/MEM4 AF 3 Art. no. 054955
Fig. 1.2
186
4.10 Extension cable for the PHG

The connection between the interface field (AF3 or AF5) and the PHG can be ex
tended with the proper extension cable by a max. of 45 m . See Fig. 1.4.
Extension cable
Subminiature connector max. 45 m Subminiature connector
25 pin 25 pin
Cable
12 12 0.19 wh 12
TX+
13 13 0.19 br 13
RX+
16 16 0.19 gn 16
RS
21 21 0.19 bl 21
PGND
10 10 0.19 rd 10
+12V
9 9
11 11 0.30 vi 11
15 15 Confirmation
15 0.30 ye key
5 5 0.30 gr 5
7 7 7 EMERGENCY
0.30 pi STOP
8
17
Screening via
connector housing
Fig. 1.4
187
Bosch-Automationstechnik
Robert Bosch GmbH Robert Bosch GmbH

Geschäftsbereich Geschäftsbereich
Automationstechnik Automationstechnik
Industriehydraulik Montagetechnik
Postfach 30 02 40 Postfach 30 02 07
D-70442 Stuttgart D-70442 Stuttgart
Telefax (07 11) 8 11-18 57 Telefax (07 11) 8 11-77 12

Fahrzeughydraulik Antriebs- und Steuerungstechnik
Postfach 30 02 40 Postfach 11 62
D-70442 Stuttgart D-64701 Erbach
Telefax (07 11) 8 11-17 98 Telefax (0 60 62) 78-4 28

Pneumatik Schraub- und Einpreßsysteme
Postfach 30 02 40 Postfach 11 61
D-70442 Stuttgart D-71534 Murrhardt
Telefax (07 11) 8 11-89 17 Telefax (0 71 92) 22-1 81
Robert Bosch GmbH

Geschäftsbereich
Automationstechnik
Entgrattechnik
Postfach 30 02 07
D-70442 Stuttgart
Telefax (07 11) 8 11-34 75
Technische Änderungen vorbehalten
Ihr Ansprechpartner
Robert Bosch GmbH

Geschäftsbereich
Automationstechnik
Antriebs- und Steuerungstechnik
Postfach 11 62
D-64701 Erbach
Telefax (0 60 62) 78-4 28
1070 073 025-102 (95.01) GB · HB RC · AT/VSP · Printed in Germany

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DATASHEET

RGB ELEKTRONIKA AGACIAK CIACIEK

Jana Dlugosza 2-6 Street

Buy this product at RGB AUTOMATYKA BUY ∠

1070 073 025-102 (95.01) GB

Reg. Nr. 16149-03

by Robert Bosch GmbH,

Discretionary charge 40.– DM

2. Dimensions, installation and interface conditions

2.4. Electrical connection

2.4. Operating conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

3.3. Processor module CP 2.5 . . . . . . . . . . . . . . . . . . . . . . . . . 61

3.4. Memory module MEM 5 . . . . . . . . . . . . . . . . . . . . . . . . . . 68

3.5 Servo loop interface SERVO 3-5

3.6. Servo loop interface SERVO 8

3.7. Servo card modular SERVO . . . . . . . . . . . . . . . . . . . . . . . 95

3.8 Control Loop Card Modular SERVO m.i. . . . . . . . . . . . . 113

3.8.11.1 Pin assignment analog outputs . . . . . . . . . . . . . . . . . . . . . . . . 137

3.9. Servo interface SERVO i

3.10 Modulo I/O 24/0.1 with PIC250 . . . . . . . . . . . . . . . . . . . . 160

3.11 Input/Output Module I/O32/16 0.5A . . . . . . . . . . . . . . 166

3.12 Module NCPLCI/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

3.13 Module NCPLCBit (Bit Coupler) . . . . . . . . . . . . . . . . . 175

3.14 Power supply PS 75 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178

3.15 Module PS 200 (power supply) . . . . . . . . . . . . . . . . . . . . 180

4 Programmable manipulator PHG 3

Online/Offline programming system Hand-held programmer

SPS CL300,CL500 Robot

Example: RC card rack Example: RC/PLC I/O card rack

PC free PHG PC free PHG

System design rho 3.1 (schematic)

1.2 Card rack

1.2.1 RACK VERSION 1 (4 SLOTS)

. I/O- 32/24 0,2 A with PIC and CAN

- I/O expansion, for example for direct I/O`s

. CP/MEM5 up to 512 KByte user memory

Version table for

PC - IO with PIC 250

Card can be inserted in this slot and occupies one slot.

1.2.2 RACK VERSION 2 ( 5 SLOTS )

Max. measuring system current is limited to 1.5 A with PS75.

It may be necessary to have power supply

the encoder at the customer end.

Up to 10 analog outputs can be operated.

rho 3.1 rho 3.1

. I/O- 32/24 0,2 A with PIC250

- I/O expansion, for example for direct I/O`s

. CP/MEM5 up to 512 KByte user memory

Rack slot RACK 1.0 - 5 Version table for

CP/MEM 5 until 512kB

I/O 32/24 0,2A 24V DC

I/O 32/16 0,5A 24V DC

I/O 32/24 with PIC + CAN

PC - IO with PIC + CAN

PC - IO with PIC 250

1.2.3 RACK VERSION 3 ( 19" 5/8 SLOTS )

Please note the following when using a

The max. measuring system current is

3.11 Input/Output Module I/O32/16 0.5A . . . . . . . . . . . . . . 166

3.12 Module NCPLCI/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

3.13 Module NCPLCBit (Bit Coupler) . . . . . . . . . . . . . . . . . 175