Rexroth MTA 200 Rexroth BTV 20.4A - Nuova Elva

Industrial 

Hydraulics 

Electric Drives 

and Controls 

exroth IndraControl VCP 20 

Rexroth MTA 200 

Rexroth BTV 20.4A 

Project Planning Manual 

Linear Motion and 

Assembly Technologies Pneumatics 

Service 

Automation 

Mobile 

Hydraulics 

R911306076 

Edition 01

About this Documentation Rexroth BTV 20.4A 

Title 

Type of Documentation 

Document Typecode 

Internal File Reference 

Purpose of Documentation 

Record of Revisions 

Copyright 

Validity 

Published by 

Note 

Rexroth MTA 200 


Project Planning Manual 

DOK-MTA200-BTV20.4A***-PR01-EN-P 

Document Number 120-1720-B317-01/EN 

This documentation describes the hardware components of the Rexroth 

MTA 200 control system which are included in the operating PC 

BTV 20.4A. 

Description Release 

Date 

Notes 

120-1720-B317-01/EN 06.2004 First issue 

© 2004 Bosch Rexroth AG 

Copying this document, giving it to others and the use or communication 

of the contents thereof without express authority, are forbidden. Offenders 

are liable for the payment of damages. All rights are reserved in the event 

of the grant of a patent or the registration of a utility model or design 

(DIN 34-1). 

The specified data is for product description purposes only and may not 

be deemed to be guaranteed unless expressly confirmed in the contract. 

All rights are reserved with respect to the content of this documentation 

and the availability of the product. 

Bosch Rexroth AG 

Bgm.-Dr.-Nebel-Str. 2 • D-97816 Lohr a. Main 

Telephone +49 (0)93 52/40-0 • Tx 68 94 21 • Fax +49 (0)93 52/40-48 85 

http://www.boschrexroth.com/ 

Dept. BRC/ESM5 (OI) 

Dept. BRC/ESM6 (DiHa) 

This document has been printed on chlorine-free bleached paper. 

DOK-MTA200-BTV20.4A***-PR01-EN-P

Rexroth BTV 20.4A Contents I 

Contents 

1 Overview 1-1 

1.1 System Concept ........................................................................................................................... 1-1 

1.2 Regarding this Documentation ..................................................................................................... 1-1 

1.3 Additional Documentation............................................................................................................. 1-2 

1.4 Important Directions for Use......................................................................................................... 1-4 

Appropriate Use....................................................................................................................... 1-4 

Inappropriate Use .................................................................................................................... 1-5 

Notes for Electro Static Discharge........................................................................................... 1-5 

1.5 Safety Instructions for Electric Drives and Controls ..................................................................... 1-6 

Introduction .............................................................................................................................. 1-6 

Explanations ............................................................................................................................ 1-6 

Hazards by Improper Use........................................................................................................ 1-7 

General Information................................................................................................................. 1-8 

Protection Against Contact with Electrical Parts ..................................................................... 1-9 

Protection Against Electric Shock by Protective Low Voltage (PELV) .................................. 1-11 

Protection Against Dangerous Movements ........................................................................... 1-11 

Protection Against Magnetic and Electromagnetic Fields During Operation and 

Mounting ................................................................................................................................ 1-14 

Protection Against Contact with Hot Parts ............................................................................ 1-15 

Protection During Handling and Mounting............................................................................. 1-15 

Battery Safety ........................................................................................................................ 1-15 

Protection Against Pressurized Systems .............................................................................. 1-16 

2 Machine Operator Terminal BTV 20.4A 2-1 

2.1 Brief Description ........................................................................................................................... 2-1 

Standard Configuration of the BTV 20.4 ................................................................................. 2-2 

Additional BTV 20.4A Modules................................................................................................ 2-2 

Firmware and Software Configurations ................................................................................... 2-3 

2.2 Front Plate, Keyboard................................................................................................................... 2-4 

Floppy Disk Flap, Reset Button............................................................................................... 2-4 

Operating Display .................................................................................................................... 2-5 

Overview of Keys..................................................................................................................... 2-5 

Machine and PLC Function Keys ............................................................................................ 2-7 

Addressing via PLC ................................................................................................................. 2-8 

Replacing the Slide-in Strips ................................................................................................... 2-9 

2.3 Keyboard Layout......................................................................................................................... 2-11 

2.4 Technical Data............................................................................................................................ 2-15 

General Technical Data......................................................................................................... 2-15 

Ambient Conditions ............................................................................................................... 2-15 


II Contents Rexroth BTV 20.4A 

Wear Parts............................................................................................................................. 2-16 

2.5 Measurements ............................................................................................................................ 2-17 

Housing Dimensions.............................................................................................................. 2-17 

2.6 Installation Dimensions............................................................................................................... 2-21 

2.7 Connections................................................................................................................................ 2-22 

General Connections............................................................................................................. 2-22 

Interfaces of NC CPU Card - Computer Configuration 45..................................................... 2-24 

LPT1 Printer Interface and SIS.............................................................................................. 2-26 

Internal Wiring........................................................................................................................ 2-28 

Sample Applications .............................................................................................................. 2-29 

2.8 Ordering Information................................................................................................................... 2-34 

Type Key................................................................................................................................ 2-34 

Configuration Type Key ......................................................................................................... 2-35 

Accessories ........................................................................................................................... 2-36 

2.9 Supplied Accessories (Scope of Delivery).................................................................................. 2-39 

3 PC CPU Configuration 45 3-1 


3.2 Technical Data.............................................................................................................................. 3-1 

Electrical Specifications........................................................................................................... 3-1 

CPU and Memory Specifications............................................................................................. 3-1 

3.3 PhoenixBIOS Setup...................................................................................................................... 3-2 

Main PhoenixBIOS Setup Menu.............................................................................................. 3-3 

PhoenixBIOS Settings for the BTV 20.4.................................................................................. 3-4 

3.4 Installation of SO-DIMM Memory Modules................................................................................... 3-9 

3.5 Temporary Connection of Additional IDE Devices ..................................................................... 3-10 

Connection for Power Supply Cable...................................................................................... 3-10 

IDE Port ................................................................................................................................. 3-11 

4 PC CPU Configuration 44 4-1 



Electrical Specifications........................................................................................................... 4-2 

CPU and Memory Specifications............................................................................................. 4-2 

4.3 PhoenixBIOS Setup...................................................................................................................... 4-2 

PhoenixBIOS Settings of the NC CPU .................................................................................... 4-3 

5 NC Multifunction Card NCM02 5-1 


5.2 Features........................................................................................................................................ 5-1 

5.3 Available Versions ........................................................................................................................ 5-2 

5.4 Interfaces ...................................................................................................................................... 5-3 

5.5 Coding and Component Diagrams ............................................................................................... 5-4 

+NCM0201 .............................................................................................................................. 5-4 

+NCM0202 .............................................................................................................................. 5-5 

+NCM0204 .............................................................................................................................. 5-6 


Rexroth BTV 20.4A Contents III 

5.6 Slot Brackets................................................................................................................................. 5-7 

CNC Fault (X21) ...................................................................................................................... 5-7 

Fast I/Os (X23) ........................................................................................................................ 5-8 

Status Indicators...................................................................................................................... 5-8 

5.7 Additional SERCOS Rings............................................................................................................ 5-9 

+NCMZ003 .............................................................................................................................. 5-9 

+NCMZ004 .............................................................................................................................. 5-9 

X24.* Transmitter................................................................................................................... 5-10 

X25.* Receiver....................................................................................................................... 5-10 

Status Indicators.................................................................................................................... 5-10 

Connections........................................................................................................................... 5-10 

NCM in the BTV20.4A ........................................................................................................... 5-11 

5.8 Connection Cable ....................................................................................................................... 5-11 

Cable Specifications .............................................................................................................. 5-12 

5.9 NCIO Card .................................................................................................................................. 5-12 

General Information............................................................................................................... 5-12 

Slot Bracket ........................................................................................................................... 5-13 

X22 I/O Interface ................................................................................................................... 5-13 

Installation.............................................................................................................................. 5-15 

5.10 Phoenix Block I/O Module ILB IB 24 DI16 DO16 ....................................................................... 5-15 

Connection............................................................................................................................. 5-16 

Signal Assignment................................................................................................................. 5-16 

6 PLC Modules MTS-P01.2 and MTS-P02.2 6-1 



General Information................................................................................................................. 6-3 

Power Supply........................................................................................................................... 6-3 

EMC......................................................................................................................................... 6-3 

Interfaces ................................................................................................................................. 6-4 

6.3 Communication............................................................................................................................. 6-4 

PLC Inputs for the Machine Function Keys (X8) ..................................................................... 6-4 

Connection of BTV 20 PLC Function Keys (X12).................................................................... 6-4 

PLC Ready (X5)....................................................................................................................... 6-5 

COM Interface (X16) ............................................................................................................... 6-5 

BT Bus (X15) ........................................................................................................................... 6-5 

6.4 Commissioning ............................................................................................................................. 6-8 

Assembly ................................................................................................................................. 6-8 

Setting of Addresses ............................................................................................................... 6-8 

Battery ..................................................................................................................................... 6-9 

Status Information and Error Diagnosis .................................................................................. 6-9 

6.5 INTERBUS Master Connection .................................................................................................. 6-12 

Brief Description .................................................................................................................... 6-12 

Setting the I/O Address ......................................................................................................... 6-13 

Technical Data....................................................................................................................... 6-13 

Interface Assignment............................................................................................................. 6-14 


IV Contents Rexroth BTV 20.4A 

6.6 PROFIBUS DP Connection ........................................................................................................ 6-15 

Brief Description of Master and Slave Connection................................................................ 6-15 

Setting I/O Addresses............................................................................................................ 6-16 

Status and Diagnosis Information.......................................................................................... 6-17 

Technical Data....................................................................................................................... 6-17 

Interface Assignment............................................................................................................. 6-18 

6.7 Connecting the Manual Operator Panel BTC 06........................................................................ 6-19 

6.8 Configurations............................................................................................................................. 6-21 

MTS-P0*.2-D2-B1-NN-NN-NN-FW ....................................................................................... 6-21 

MTS-P0*.2-D2-P1-NN-NN-NN-FW ....................................................................................... 6-22 

7 Tips and Tricks 7-1 

7.1 BTV Replacement......................................................................................................................... 7-1 

Hard Disk Image...................................................................................................................... 7-1 

Control Parameters (NCM Replacement) ............................................................................... 7-1 

CMOS Variables...................................................................................................................... 7-2 

PLC Retain Data (PLC Replacement)..................................................................................... 7-2 

8 Index 8-1 

9 Service & Support 9-1 

9.1 Helpdesk....................................................................................................................................... 9-1 

9.2 Service-Hotline ............................................................................................................................. 9-1 

9.3 Internet.......................................................................................................................................... 9-1 

9.4 Vor der Kontaktaufnahme... - Before contacting us... .................................................................. 9-1 

9.5 Kundenbetreuungsstellen - Sales & Service Facilities ................................................................. 9-2 


Rexroth BTV 20.4A Overview 1-1 

1 Overview 

1.1 System Concept 

1.2 Regarding this Documentation 


The consistent implementation of PC technology and the use of 

international industry standards has made it possible to fully integrate the 

control hardware in the operator PC while still ensuring simple and clear 

connections to drives and I/O peripherals. 

This integral solution guarantees that only defined and tested device 

configurations will be provided and supplied. 

The defined combination of various hardware components forms the 

basis of the MTA 200 control system. The operator PC itself as well as 

the components that are already installed in the operator PC on delivery 

are described in detail in this documentation. 

Fig. 1-1: Control architecture 

MTA Steuerungsarchitektur.jpg

1-2 Overview Rexroth BTV 20.4A 

1.3 Additional Documentation 

This includes the following components: 

Type Description Chapter 

BTV 20.4A Operator PC with integrated control hardware 2 

ETXP3-700 PC-CPU 3 

ETXP3-400 NC-CPU 4 

NCM02 NC module with SERCOS interface 5 

NCIO I/O module for fast I/Os 5 

MTS-P Integrated PLC 6 

The openness of the control system allows the machine manufacturer to 

independently carry out application-specific hardware settings in the PC 

part, such as measured values recording, network connections, etc. In 

this case, the machine manufacturer must provide supplements to the 

hardware documentation. 

Fig. 1-2: System architecture 

Systemübersicht MTA.jpg 




The MTA 200 control system includes additional hardware components 

that are described in separate documents: 

Type Description Documentation 

BTA 20.4 Machine operator 

control panel 

DOK-SUPPL*-BTA20.4****-PR01-EN-P 

BTM 15 Machine user panel DOK-MTC200-BTM15******-PR02-EN-P 

BTM 16 Machine user panel DOK-MTC200-BTM16.1****-FKB1-EN-P 

PCK03 Drawer keyboard DOK-SUPPL*-PCK03.3****-PR01-DE-P 

BTC 06 Hand-held terminal DOK-SUPPL*-BTC06******-PR03-EN-P 

BTV 06 Mini control panel DOC-SUPPL*-BTV06.1****-PR02-EN-P 

RECO12 Switch cabinet I/Os for 

Interbus 

RMG12 Gateway module for I/O 

coupling 

DOK-CONTRL-RECO12.2***-PRJ2-EN-P 

DOK-CONTRL-RMG12.2****-PR02-EN-P 

RMC RECO analog module DOK-CONTRL-RMC12.2****-ANW1-EN-P 

SMx Protection type 

modules for Interbus 

RECO 

Inline 

RECO 

Fieldline 

Brief overview 

Interbus S system 

Profibus DP system 

Bus terminal, Interbus 

Bus terminal, Profibus 

Digital I/O modules 

Analog I/O modules 

Counter module 

Interbus devices 

Profibus devices 

DOK-CONTRL-SM*12.1****-PRJ2-EN-P 

DOK-CONTRL-R-IL*INLINE-KB02-EN-P 

DOK-CONTRL-R-IL*IBSSYS-AW02-EN-P 

DOK-CONTRL-R-IL*PBSSYS-AW02-EN-P 

DOK-CONTRL-R-IL*IBS-BK-FK04-DE-P 

DOK-CONTRL-R-IL*PB*-BK-FK02-EN-P 

DOK-CONTRL-R-IL*DIO***-FK05-EN-P 

DOK-CONTRL-R-IL*AIO***-FK02-EN-P 

DOK-CONTRL-R-IL*CNT***-AW02-EN-P 

DOK-CONTRL-RF-FLS-IB**-PR01-EN-P 

DOK-CONTRL-RF-FLS-PB**-PR01-EN-P 

The MTA 200 control system is supplemented by the intelligent digital 

drives of the Diax 04 and IndraDrive series.


1.4 Important Directions for Use 

Appropriate Use 

Introduction 

Bosch Rexroth products represent state-of-the-art developments and 

manufacturing. They are tested prior to delivery to ensure operating safety 

and reliability. 

The products may only be used in the manner that is defined as 

appropriate. If they are used in an inappropriate manner, then situations 

can develop that may lead to property damage or injury to personnel. 

Note: Bosch Rexroth, as manufacturer, is not liable for any damages 

resulting from inappropriate use. In such cases, the guarantee 

and the right to payment of damages resulting from 

inappropriate use are forfeited. The user alone carries all 

responsibility of the risks. 

Before using Bosch Rexroth products, make sure that all the prerequisites 

for appropriate use of the products are satisfied: 

• Personnel that in any way, shape or form uses our products must first 

read and understand the relevant safety instructions and be familiar 

with appropriate use. 

• If the product takes the form of hardware, then they must remain in 

their original state, in other words, no structural changes are permitted. 

It is not permitted to decompile software products or alter source 

codes. 

• Do not mount damaged or faulty products or use them in operation. 

• Make sure that the products have been installed in the manner 

described in the relevant documentation. 

Areas of use and application 

For BTV 20.4A Bosch Rexroth defines appropriate use for installation into 

control panel, into the wall or door of a switch cabinet or directly into 

enclosure of machine tool. 

It may only be operated under the mounting and installation conditions 

specified in this documentation, in the position of use described, and 

under the ambient conditions specified (temperature, protection category, 

humidity, EMC, and the like). 

Note: BTV 20.4A may only be used with the accessories and parts 

specified in this document. If a component has not been 

specifically named, then it may not be either mounted or 

connected. The same applies to cables and lines. 

Operation is only permitted in the specified configurations and 

combinations of components using the software and firmware 

as specified in the relevant function descriptions. 

Every MTA 200 control system has to be parameterized and programmed 

before start-up from qualified application staff. 



Inappropriate Use 

Notes for Electro Static Discharge 


Typical applications of MTA 200 control system are machine tools for 

following processing technologies: 

• Milling and grinding crankshafts 

• Grinding camshafts 

• Cogwheel processing 

Using the BTV 20.4A outside of the above-referenced areas of application 

or under operating conditions other than described in the document and 

the technical data specified is defined as “inappropriate use". 

BTV 20.4A may not be used if 

• they are subject to operating conditions that do not meet the above 

specified ambient conditions. This includes, for example, operation 

under water, in the case of extreme temperature fluctuations or 

extremely high maximum temperatures or if 

• Bosch Rexroth has not specifically released them for that intended 

purpose. Please note the specifications outlined in the general Safety 

Guidelines! 

In case of discharging via the controller or printed circuit boards, these 

components can be damaged by electrostatic charging of persons and/or 

tools. Therefore, please observe the following notes: 

CAUTION 

Risk of damage to the electronic components 

and deterioration of their operating safety by 

electrostatic charging! 

⇒ Bodies coming into contact with components and 

printed circuit boards must be discharged by 

grounding. Otherwise, errors in the controller can 

occur. 

Example for such bodies: 

• when soldering, the soldering gun 

• your own body (grounding by contact with a conductive, grounded 

object) 

• parts and tools (when deposited on a conductive surface) 

Components exposed to this risk may only be stored in conductive 

packaging.


1.5 Safety Instructions for Electric Drives and Controls 

Introduction 

Explanations 

Read these instructions before the initial startup of the equipment in order 

to eliminate the risk of bodily harm or material damage. Follow these 

safety instructions at all times. 

Do not attempt to install or start up this equipment without first reading all 

documentation provided with the product. Read and understand these 

safety instructions and all user documentation of the equipment prior to 

working with the equipment at any time. If you do not have the user 

documentation for your equipment, contact your local Bosch Rexroth 

representative to send this documentation immediately to the person or 

persons responsible for the safe operation of this equipment. 

If the equipment is resold, rented or transferred or passed on to others, 

then these safety instructions must be delivered with the equipment. 

WARNING 

Improper use of this equipment, failure to follow 

the safety instructions in this document or 

tampering with the product, including disabling 

of safety devices, may result in material 

damage, bodily harm, electric shock or even 

death! 

The safety instructions describe the following degrees of hazard 

seriousness in compliance with ANSI Z535. The degree of hazard 

seriousness informs about the consequences resulting from noncompliance 

with the safety instructions. 

Warning symbol with signal 

word 

DANGER 

WARNING 

CAUTION 

Degree of hazard seriousness according 

to ANSI 

Death or severe bodily harm will occur. 

Death or severe bodily harm may occur. 

Bodily harm or material damage may occur. 

Fig. 1-3: Hazard classification (according to ANSI Z535) 



Hazards by Improper Use 


DANGER 

DANGER 

WARNING 

WARNING 

CAUTION 

CAUTION 

CAUTION 

High voltage and high discharge current! 

Danger to life or severe bodily harm by electric 

shock! 

Dangerous movements! Danger to life, severe 

bodily harm or material damage by 

unintentional motor movements! 

High electrical voltage due to wrong 

connections! Danger to life or bodily harm by 

electric shock! 

Health hazard for persons with heart 

pacemakers, metal implants and hearing aids in 

proximity to electrical equipment! 

Surface of machine housing could be extremely 

hot! Danger of injury! Danger of burns! 

Risk of injury due to improper handling! Bodily 

harm caused by crushing, shearing, cutting and 

mechanical shock or incorrect handling of 

pressurized systems! 

Risk of injury due to incorrect handling of 

batteries!


General Information 

• Bosch Rexroth AG is not liable for damages resulting from failure to 

observe the warnings provided in this documentation. 

• Read the operating, maintenance and safety instructions in your 

language before starting up the machine. If you find that you cannot 

completely understand the documentation for your product, please ask 

your supplier to clarify. 

• Proper and correct transport, storage, assembly and installation as 

well as care in operation and maintenance are prerequisites for 

optimal and safe operation of this equipment. 

• Only persons who are trained and qualified for the use and operation 

of the equipment may work on this equipment or within its proximity. 

• The persons are qualified if they have sufficient knowledge of the 

assembly, installation and operation of the equipment as well as an 

understanding of all warnings and precautionary measures noted in 

these instructions. 

• Furthermore, they must be trained, instructed and qualified to switch 

electrical circuits and equipment on and off in accordance with 

technical safety regulations, to ground them and to mark them 

according to the requirements of safe work practices. They must have 

adequate safety equipment and be trained in first aid. 

• Only use spare parts and accessories approved by the manufacturer. 

• Follow all safety regulations and requirements for the specific 

application as practiced in the country of use. 

• The equipment is designed for installation in industrial machinery. 

• The ambient conditions given in the product documentation must be 

observed. 

• Use only safety features and applications that are clearly and explicitly 

approved in the Project Planning Manual. 

For example, the following areas of use are not permitted: construction 

cranes, elevators used for people or freight, devices and vehicles to 

transport people, medical applications, refinery plants, transport of 

hazardous goods, nuclear applications, applications sensitive to high 

frequency, mining, food processing, control of protection equipment 

(also in a machine). 

• The information given in the documentation of the product with regard 

to the use of the delivered components contains only examples of 

applications and suggestions. 

The machine and installation manufacturer must 

• make sure that the delivered components are suited for his 

individual application and check the information given in this 

documentation with regard to the use of the components, 

• make sure that his application complies with the applicable safety 

regulations and standards and carry out the required measures, 

modifications and complements. 

• Startup of the delivered components is only permitted once it is sure 

that the machine or installation in which they are installed complies 

with the national regulations, safety specifications and standards of the 

application. 




• Operation is only permitted if the national EMC regulations for the 

application are met. 

The instructions for installation in accordance with EMC requirements 

can be found in the documentation "EMC in Drive and Control 

Systems". 

The machine or installation manufacturer is responsible for 

compliance with the limiting values as prescribed in the national 

regulations. 

• Technical data, connections and operational conditions are specified in 

the product documentation and must be followed at all times. 

Protection Against Contact with Electrical Parts 

Note: This section refers to equipment and drive components with 

voltages above 50 Volts. 

Touching live parts with voltages of 50 Volts and more with bare hands or 

conductive tools or touching ungrounded housings can be dangerous and 

cause electric shock. In order to operate electrical equipment, certain 

parts must unavoidably have dangerous voltages applied to them.


DANGER 

High electrical voltage! Danger to life, severe 

bodily harm by electric shock! 

⇒ Only those trained and qualified to work with or on 

electrical equipment are permitted to operate, maintain 

or repair this equipment. 

⇒ Follow general construction and safety regulations 

when working on high voltage installations. 

⇒ Before switching on power the ground wire must be 

permanently connected to all electrical units according 

to the connection diagram. 

⇒ Do not operate electrical equipment at any time, even 

for brief measurements or tests, if the ground wire is 

not permanently connected to the points of the 

components provided for this purpose. 

⇒ Before working with electrical parts with voltage higher 

than 50 V, the equipment must be disconnected from 

the mains voltage or power supply. Make sure the 

equipment cannot be switched on again unintended. 

⇒ The following should be observed with electrical drive 

and filter components: 

⇒ Wait five (5) minutes after switching off power to allow 

capacitors to discharge before beginning to work. 

Measure the voltage on the capacitors before 

beginning to work to make sure that the equipment is 

safe to touch. 

⇒ Never touch the electrical connection points of a 

component while power is turned on. 

⇒ Install the covers and guards provided with the 

equipment properly before switching the equipment on. 

Prevent contact with live parts at any time. 

⇒ A residual-current-operated protective device (RCD) 

must not be used on electric drives! Indirect contact 

must be prevented by other means, for example, by an 

overcurrent protective device. 

⇒ Electrical components with exposed live parts and 

uncovered high voltage terminals must be installed in a 

protective housing, for example, in a control cabinet. 




To be observed with electrical drive and filter components: 

DANGER 

High electrical voltage on the housing! 

High leakage current! Danger to life, danger of 

injury by electric shock! 

⇒ Connect the electrical equipment, the housings of all 

electrical units and motors permanently with the 

safety conductor at the ground points before power is 

switched on. Look at the connection diagram. This is 

even necessary for brief tests. 

⇒ Connect the safety conductor of the electrical 

equipment always permanently and firmly to the 

supply mains. Leakage current exceeds 3.5 mA in 

normal operation. 

⇒ Use a copper conductor with at least 10 mm² cross 

section over its entire course for this safety conductor 

connection! 

⇒ Prior to startups, even for brief tests, always connect 

the protective conductor or connect with ground wire. 

Otherwise, high voltages can occur on the housing 

that lead to electric shock. 

Protection Against Electric Shock by Protective Low Voltage (PELV) 

All connections and terminals with voltages between 0 and 50 Volts on 

Rexroth products are protective low voltages designed in accordance with 

international standards on electrical safety. 

WARNING 

Protection Against Dangerous Movements 

High electrical voltage due to wrong 

connections! Danger to life, bodily harm by 

electric shock! 

⇒ Only connect equipment, electrical components and 

cables of the protective low voltage type (PELV = 

Protective Extra Low Voltage) to all terminals and 

clamps with voltages of 0 to 50 Volts. 

⇒ Only electrical circuits may be connected which are 

safely isolated against high voltage circuits. Safe 

isolation is achieved, for example, with an isolating 

transformer, an opto-electronic coupler or when 

battery-operated. 

Dangerous movements can be caused by faulty control of the connected 

motors. Some common examples are: 

• improper or wrong wiring of cable connections 

• incorrect operation of the equipment components 

• wrong input of parameters before operation 

• malfunction of sensors, encoders and monitoring devices 

• defective components 

• software or firmware errors


Dangerous movements can occur immediately after equipment is 

switched on or even after an unspecified time of trouble-free operation. 

The monitoring in the drive components will normally be sufficient to avoid 

faulty operation in the connected drives. Regarding personal safety, 

especially the danger of bodily injury and material damage, this alone 

cannot be relied upon to ensure complete safety. Until the integrated 

monitoring functions become effective, it must be assumed in any case 

that faulty drive movements will occur. The extent of faulty drive 

movements depends upon the type of control and the state of operation. 




DANGER 

Dangerous movements! Danger to life, risk of 

injury, severe bodily harm or material damage! 

⇒ Ensure personal safety by means of qualified and 

tested higher-level monitoring devices or measures 

integrated in the installation. Unintended machine 

motion is possible if monitoring devices are disabled, 

bypassed or not activated. 

⇒ Pay attention to unintended machine motion or other 

malfunction in any mode of operation. 

⇒ Keep free and clear of the machine’s range of motion 

and moving parts. Possible measures to prevent 

people from accidentally entering the machine’s 

range of motion: 

- use safety fences 

- use safety guards 

- use protective coverings 

- install light curtains or light barriers 

⇒ Fences and coverings must be strong enough to 

resist maximum possible momentum, especially if 

there is a possibility of loose parts flying off. 

⇒ Mount the emergency stop switch in the immediate 

reach of the operator. Verify that the emergency stop 

works before startup. Don’t operate the machine if 

the emergency stop is not working. 

⇒ Isolate the drive power connection by means of an 

emergency stop circuit or use a starting lockout to 

prevent unintentional start. 

⇒ Make sure that the drives are brought to a safe 

standstill before accessing or entering the danger 

zone. Safe standstill can be achieved by switching off 

the power supply contactor or by safe mechanical 

locking of moving parts. 

⇒ Secure vertical axes against falling or dropping after 

switching off the motor power by, for example: 

- mechanically securing the vertical axes 

- adding an external braking/ arrester/ clamping 

mechanism 

- ensuring sufficient equilibration of the vertical axes 

The standard equipment motor brake or an external 

brake controlled directly by the drive controller are 

not sufficient to guarantee personal safety!


⇒ Disconnect electrical power to the equipment using a 

master switch and secure the switch against 

reconnection for: 

- maintenance and repair work 

- cleaning of equipment 

- long periods of discontinued equipment use 

⇒ Prevent the operation of high-frequency, remote 

control and radio equipment near electronics circuits 

and supply leads. If the use of such equipment 

cannot be avoided, verify the system and the 

installation for possible malfunctions in all possible 

positions of normal use before initial startup. If 

necessary, perform a special electromagnetic 

compatibility (EMC) test on the installation. 

Protection Against Magnetic and Electromagnetic Fields During 

Operation and Mounting 

Magnetic and electromagnetic fields generated near current-carrying 

conductors and permanent magnets in motors represent a serious health 

hazard to persons with heart pacemakers, metal implants and hearing 

aids. 

WARNING 

Health hazard for persons with heart 

pacemakers, metal implants and hearing aids in 

proximity to electrical equipment! 

⇒ Persons with heart pacemakers, hearing aids and 

metal implants are not permitted to enter the 

following areas: 

- Areas in which electrical equipment and parts are 

mounted, being operated or started up. 

- Areas in which parts of motors with permanent 

magnets are being stored, operated, repaired or 

mounted. 

⇒ If it is necessary for a person with a heart pacemaker 

to enter such an area, then a doctor must be 

consulted prior to doing so. Heart pacemakers that 

are already implanted or will be implanted in the 

future, have a considerable variation in their electrical 

noise immunity. Therefore there are no rules with 

general validity. 

⇒ Persons with hearing aids, metal implants or metal 

pieces must consult a doctor before they enter the 

areas described above. Otherwise, health hazards 

will occur. 



Protection Against Contact with Hot Parts 


CAUTION 

Protection During Handling and Mounting 

Battery Safety 

Housing surfaces could be extremely hot! 

Danger of injury! Danger of burns! 

⇒ Do not touch housing surfaces near sources of heat! 

Danger of burns! 

⇒ After switching the equipment off, wait at least ten 

(10) minutes to allow it to cool down before touching 

it. 

⇒ Do not touch hot parts of the equipment, such as 

housings with integrated heat sinks and resistors. 

Danger of burns! 

Under certain conditions, incorrect handling and mounting of parts and 

components may cause injuries. 

CAUTION 

Risk of injury by incorrect handling! Bodily 

harm caused by crushing, shearing, cutting and 

mechanical shock! 

⇒ Observe general installation and safety instructions 

with regard to handling and mounting. 

⇒ Use appropriate mounting and transport equipment. 

⇒ Take precautions to avoid pinching and crushing. 

⇒ Use only appropriate tools. If specified by the product 

documentation, special tools must be used. 

⇒ Use lifting devices and tools correctly and safely. 

⇒ For safe protection wear appropriate protective 

clothing, e.g. safety glasses, safety shoes and safety 

gloves. 

⇒ Never stand under suspended loads. 

⇒ Clean up liquids from the floor immediately to prevent 

slipping. 

Batteries contain reactive chemicals in a solid housing. Inappropriate 

handling may result in injuries or material damage. 

CAUTION 

Risk of injury by incorrect handling! 

⇒ Do not attempt to reactivate discharged batteries by 

heating or other methods (danger of explosion and 

cauterization). 

⇒ Never charge non-chargeable batteries (danger of 

leakage and explosion). 

⇒ Never throw batteries into a fire. 

⇒ Do not dismantle batteries. 

⇒ Do not damage electrical components installed in the 

equipment.


Protection Against Pressurized Systems 

Note: Be aware of environmental protection and disposal! The 

batteries contained in the product should be considered as 

hazardous material for land, air and sea transport in the sense 

of the legal requirements (danger of explosion). Dispose 

batteries separately from other waste. Observe the legal 

requirements in the country of installation. 

Certain motors and drive controllers, corresponding to the information in 

the respective Project Planning Manual, must be provided with 

pressurized media, such as compressed air, hydraulic oil, cooling fluid 

and cooling lubricant supplied by external systems. Incorrect handling of 

the supply and connections of pressurized systems can lead to injuries or 

accidents. In these cases, improper handling of external supply systems, 

supply lines or connections can cause injuries or material damage. 

CAUTION 

Danger of injury by incorrect handling of 

pressurized systems ! 

⇒ Do not attempt to disassemble, to open or to cut a 

pressurized system (danger of explosion). 

⇒ Observe the operation instructions of the respective 

manufacturer. 

⇒ Before disassembling pressurized systems, release 

pressure and drain off the fluid or gas. 

⇒ Use suitable protective clothing (for example safety 

glasses, safety shoes and safety gloves) 

⇒ Remove any fluid that has leaked out onto the floor 

immediately. 

Note: Environmental protection and disposal! The media used in the 

operation of the pressurized system equipment may not be 

environmentally compatible. Media that are damaging the 

environment must be disposed separately from normal waste. 

Observe the legal requirements in the country of installation. 


Rexroth BTV 20.4A Machine Operator Terminal BTV 20.4A 2-1 

2 Machine Operator Terminal BTV 20.4A 

2.1 Brief Description 

L 1-8 machine 

function keys 

Line in strips 

for Key lable 

HALT 

NACH 

TAKTENDE 

OPERATOR PROG 

MASCHINE 

STOP 

EINHEIT 

STOP 


L1 

L2 

L3 

L4 

L5 

L6 

L7 

L8 

EINHEIT 

STOP 

The BTV 20.4A is a PC-based machine operator terminal that also 

contains all the hardware of the MTA 200 control system. Depending on 

the configuration, slots are available for customer-specific extensions in 

the PC bus. 

Note: This chapter describes the BTV 20.4A in its version for the 

MTA 200 control system. The BTV 20 can also be procured as 

a pure industrial PC, as a PC with integrated PLC, or as a PC 

with integrated MTC200 control system. These versions are 

described in the general BTV 20 documentation 

DOK-MTC200-BTV20.3****-PR03-EN-P. 

The figure below shows the structure of the BTV 20.4 front plate: 

F2 F3 

OP2 

ZUM 

WERKZEUG- 

WECHSEL 

F4 F5 F6 F7 F8 F9 

OP3 OP4 OP5 OP6 OP7 OP8 OP9 

SONDER- 

FUKTIONEN 

FEHLER 

LÖSCHEN 

SYSTEM200 

Fig. 2-1: BTV 20.4 front plate 

R1 

R2 

R3 

R4 

R5 

R6 

R7 

R8 

TEMP HD POWER 

7 8 9 N + - 

< F1 F1 F10 F10< > - + 

4 5 

6 

. . 

. 

PROG 

SFT 

PROG 

- SHIFT 

, 

1 

2 

3 

, 

, 

NEXT INFO TAB INS DEL 

NEXT INFO TAB INS DEL 

0 

CTRL ALT 

SP SP 

CTRL ALT 

ESC 

OK 

Machine 

control keys 

R 1-8 machine 

function keys 

3.5-in floppy disk 

drive / Smart card 

Connector for 

ext. keyboard + mouse 

Status indicators 

POWER 

HD 

TEMP 

=Power supply: 

ON 

= Hard disk access 

= Overtemperature 

indicator 

Front.FH7 

The front plate consists of a 4 mm-thick aluminum plate with beveled 

edges. It is coated with a chemically resistant polyester film with an 

imprint that covers the entire front plate. The integrated 10.4" TFT color 

display provides for excellent visualization of the data. A 3.5" disk drive, a 

reset button and a connection for an external keyboard or mouse are 

located behind the flap for floppy disks. Three LEDs indicate the operating 

status of the BTV 20.4. A key-operated switch locks safety functions.

2-2 Machine Operator Terminal BTV 20.4A Rexroth BTV 20.4A 

Standard Configuration of the BTV 20.4 

Additional BTV 20.4A Modules 

Furthermore, the BTV 20.4 is equipped with an extensive applicationoriented 

function keyboard with the following keys: 

• Machine function keys 

• Function and operation keys 

• PLC function keys with intermediate stages 

• Keypad 

For further information regarding the functioning and assignment of the 

individual keys as well as the front plate elements discussed above, see 

the description of the front plate in chapter 4. 

• Pentium SLOT CPU, min. 700 MHz, with integrated graphics 

controller, 4 MB screen memory and Ethernet connection 

• Either 128 or 256 MB RAM 

• At least 3 GB hard disk 

• 3.5" floppy disk drive 

• 10.4" TFT color display 

• 115 - 230 V AC power pack 

In the model functioning as an MTA 200 control system, the BTV 20.4A is 

equipped with the following additional modules: 

• NC CPU Pentium Slot CPU with 400 MHz 

• NCM NC module with one SERCOS interface 

• NCZ module with one or two additional SERCOS interfaces 

• PLC module with INTERBUS-S or Profibus master connection 

• NIO module for parallel connection of fast I/Os 

All currently existing configurations can be found in the configuration type 

key (see page 2-35). 

All the listed modules are described in detail in the following chapters. 



Firmware and Software Configurations 


Operating System 

Due to licensing reasons, the BTV 20.4 is delivered only with a 

preinstalled operating system. 

The following firmware configurations are available for the BTV 20.4A: 

Firmware type Description 

FWA-BTV*44-WNT-04VRS-DE-OEM WindowsNT 4.0 German 

FWA-BTV*44-WNT-04VRS-EN-OEM WindowsNT 4.0 English 

FWA-BTV*44-WNT-05VRS-DE-OEM Windows2000 German 

FWA-BTV*44-WNT-05VRS-EN-OEM Windows2000 English 

Fig. 2-2: Firmware configurations for MTA 200 

The SWA, SWL, SWS and/or SWP ordered together with the BTV 20.4A 

are installed on the BTV prior to delivery. 

Bosch Rexroth does not pre-install any software requiring export 

authorization; the final customer has to install this type of software 

subsequently when commissioning the BTV 20.


2.2 Front Plate, Keyboard 

Floppy Disk Flap, Reset Button 

Under the floppy disk flap, there is a reset button, which can be reached 

using a thin object (pen, etc.), as well as the connection for an external 

keyboard. This connection can be used as a service interface if the 

PCK03 drawer keyboard is not available. 

Note: When the reset button is pressed, all open applications are 

terminated without saving and the computer is rebooted. 

CAUTION 

In the MTA 200, the reset button affects only the PC part 

of the control. The NC part is initially unaffected and 

continues to run. When booting the PC part, however, 

the communication task to the NC will get stuck - now the 

BTV must be restarted. 

⇒ For that reason, it is recommended that the reset 

button not be used with the MTA. 

STEM200 

Fig. 2-3: Position of the reset button 

R1 

R2 

R3 

R4 

R5 

R6 

R7 

R8 

TEMP HD POWER 

Reset button 

Floppyklappe.FH7 

Note: When you use the disk drive, keep the floppy disk flap open. 

When the flap is closed, the diskette may be ejected, leading 

to write and read errors. 



Operating Display 

Overview of Keys 

L1 

M9 

L2 

M10 

L3 

M11 

L4 

M12 

L5 

M13 

L6 

M14 

L7 

M15 

L8 

M16 

OPERATOR PROG 

F2 F3 

OP2 

Indramat 

F2 F3 

OP2 


Under the floppy disk flap, there are 3 LEDs with the following 

explanations: 

Temp Temperature monitoring 

Power Lights up when the BTV 20 is supplied with voltage and is 

switched on 

HDD Lights up during disk access 

R8 

7 

< 

Fig. 2-4: Operating displays 

F4 F5 F6 F7 F8 F9 


R1 

M1 

R2 

M2 

R3 

M3 

R4 

M4 

R5 

M5 

R6 

M6 

R7 

M7 

R8 

M8 

TEMP 

TEMP HD POWER 

8 

F1 

TEMP HD POWER 

9 

F10 

SYSTEM200 BTV20 

7 8 9 N + 

7 

< 

8 9 N + 

< 

F1 F10 - 

F1 F10 > - 

4 5 6 . 

4 5 6 . 

SFT 

PROG 

- 

, 

1 2 3 , 

DEL 

NEXT INFO TAB INS INS 

0 

SP SP 

HD POWER 

CTRL ALT 

ESC 

OK 

F4 F5 F6 F7 F8 F9 


Fig. 2-5: Position of OP and F keys 

N 

< 

< 

+ - 

ESC 

Key pad 

7 8 9 N + 

< F1 F10 - 

4 

PROG 

1 

NEXT 

5 

2 

INFO 

0 

SP 

6 

3 

TAB 

. 

, 

- 

INS 

< 

CTRL ALT 

OK 

Betriebsanz.FH7 

SFT 

DEL 

Function keys 

Operation keys 

OP_Tast1.FH7 

The second function of keys with dual assignments can be triggered by 

pressing the Shift key at the same time.


Note: The OP key row can also be individually labeled with a slide-in 

strip (see page 2-9). 

Explanation and Replication of Keys 

The BTV 20 keys can be replicated on a PC keyboard using the following 

key combinations: 

Key on BTV 20.3 Corresponding key on standard 

keyboard 

OP2 

through 

OP9 

PROG 

NEXT 

INFO 

Maximize in cursor center 

Menu 

Change windows 

Grasp window 

CTRL + SHIFT + ALT + F2 

CTRL + SHIFT + ALT + F9 

CTRL + SHIFT + ALT + Q 

CTRL + SHIFT + ALT + N 

ALT 

Fig. 2-6: Key combinations for BTV 20 keys 

CTRL + SHIFT + ALT + I 

CTRL + SHIFT + ALT + M 

CTRL + F6 

CTRL + F7 



Machine and PLC Function Keys 

Machine function keys 

on the left 

L1 

L2 

L3 

L4 

L5 

L6 

L7 

L8 

OPERATOR PROG 

%Q*.1.6 

%I*.1.6 

%Q*.1.7 

%I*.1.7 


L1 

M9 

L2 

M10 

L3 

M11 

L4 

M12 

L5 

M13 

L6 

M14 

L7 

M15 

L8 

M16 

OPERATOR PROG 

Indramat 

%I*.0.0 

%Q*.0.0 

%I*.0.7 

%Q*.0.7 

F2 F3 

OP2 

F4 F5 F6 F7 F8 F9 


%I*.0.1 

%Q*.0.1 

%I*.1.0 

%Q*.1.0 


R1 

M1 

R2 

M2 

R3 

M3 

R4 

M4 

R5 

M5 

R6 

M6 

R7 

M7 

R8 

M8 

TEMP 

TEMP HD POWER 

7 8 9 N + 

7 

< 

8 9 N + 

< 

F1 F10 - 

F1 F10 > - 

4 5 6 . 

4 5 6 . 

SFT SFT 

PROG 

- 

, 

1 2 

3 , 

DEL 

NEXT INFO TAB INS INS 

0 

SP SP 

HD POWER 

CTRL ALT 

ESC 

OK 

PLC function keys 

(Addressing) 

%I*.0.2 

%Q*.0.2 

%I*.1.1 

%Q*.1.1 

%I*.0.3 

%Q*.0.3 

%I*.1.2 

%Q*.1.2 

%I*.0.4 

%Q*.0.4 

%I*.1.3 

%Q*.1.3 

< 


on the right 

%I*.0.5 

%Q*.0.5 

%I*.1.4 

%Q*.1.4 

Fig. 2-7: Position of machine and PLC function keys 

Machine Function Keys 

R1 

R2 

R3 

R4 

R5 

R6 

R7 

R8 

%I*.0.6 

%Q*.0.6 

%I*.1.5 

%Q*.1.5 

S1-7 

S8-14 

M_plc_tasten.FH7 

The machine function keys are implemented in the PLC as direct, hardwired 

inputs which are triggered with an absolute address. These keys 

are used to start projected PLC or CNC movements. 

PLC Function Keys 

Furthermore, the BTV 20 has LEDs that can be labeled using slide-in 

strips. Together with the key-operated switch, these keys are connected 

to the PLC; they replace the standard switching elements for fixed PLC 

functions such as ‘Basic setting’ or ‘Stop after end of cycle’, etc.


Addressing via PLC 

Alternatives with address 

constants 

Machine Function Keys 

In BTVs with an integrated PLC, the machine function keys are connected 

directly to the PLC; as a result, they can be addressed directly via the 

PLC program. 

Machine function keys Address 

L1 %I0.1480.0 

L2 %I0.1480.1 

L3 %I0.1480.2 

L4 %I0.1480.3 

L5 %I0.1480.4 

L6 %I0.1480.5 

L7 %I0.1480.6 

L8 %I0.1480.7 

R1 %I0.1481.0 

R2 %I0.1481.1 

R3 %I0.1481.2 

R4 %I0.1481.3 

R5 %I0.1481.4 

R6 %I0.1481.5 

R7 %I0.1481.6 

R8 %I0.1481.7 

Fig. 2-8: Addressing of machine function keys 

Address constants can be used instead of direct addressing for Bosch 

Rexroth firmware data types. 

Machine function keys, left/right 

PLC program identifier Address constants Data type 

MFT_L A#iMFK_L MFK_L 

MFT_R A#iMFK_R MFK_R 

Fig. 2-9: Addressing with address constants 

Data type MFK_L contains the elements L1, L2,..., L8 of type BOOL. 

Data type MFK_R contains the elements R1, R2,..., R8 of type BOOL. 

PLC program example: MFT_L.L1 



Replacing the Slide-in Strips 


PLC Function Keys 

PLC function key Address key Address LED 

S1 (see illustration) %I*.0.0 %Q*.0.0 

S2 %I*.0.1 %Q*.0.1 

S3 %I*.0.2 %Q*.0.2 

S4 %I*.0.3 %Q*.0.3 

S5 %I*.0.4 %Q*.0.4 

S6 %I*.0.5 %Q*.0.5 

S7 %I*.0.6 %Q*.0.6 

S8 %I*.0.7 %Q*.0.7 

S9 %I*.1.0 %Q*.1.0 

S10 %I*.1.1 %Q*.1.1 

S11 %I*.1.2 %Q*.1.2 

S12 %I*.1.3 %Q*.1.3 

S13 %I*.1.4 %Q*.1.4 

S14 %I*.1.5 %Q*.1.5 

Key-operated switch, 

left (Operator) 

Key-operated switch, 

right (Prog) 

Fig. 2-10: Addressing PLC function keys 

%I*.1.6 %Q*.1.6 

%I*.1.7 %Q*.1.7 

Two free logical addresses within the PLC configuration are to be 

assigned for inputs and outputs. 

The 14 PLC function keys on the front of the BTV 20 can be labeled using 

slide-in strips. The row of keys above the PLC function keys (OP2 - OP9) 

are also freely configurable using slide-in strips. 

The strips, which are already inserted when the machine is delivered, can 

be replaced as desired. Preprinted strips as well as a diskette with 

templates so that you can create your own key labels are also included in 

the scope of delivery. A description of how to replace the slide-in strips is 

provided below.


Aperture for 

changing the 

Slide-in labels 

Fig. 2-11: Position of slide-in strip openings 

Procedure for Replacing Slide-in Strips 

Einschub.FH7 

1. Cut the strips that are supplied or that you have created yourself 

along the lines. 

2. Chamfer the corners at the right end of each strip to simplify insertion. 

3. Now carefully insert the strip. 

a) To do this, hold the strip at an acute angle to the front plate and 

thread it into the housing opening (see Fig. 2-12, part A). 

Note: The slide-in strip must be inserted into the pocket of the gluedon 

front membrane (see Fig. 2-12). If the strip is not supposed 

to be in the membrane pocket, insertion is possible only up to 

the first stage of the front plate. 

b) Slowly push the strip further into the membrane pocket. Do not kink 

the paper strip (see Fig. 2-12, part B). 



A 

2.3 Keyboard Layout 

External keyboard 


B 

Fig. 2-12: Slide-in strip replacement 

Einschub01.FH7 

4. Insert the strip up to the stop. 

5. Check the front to see whether the label is above the key. 

If the alignment is not yet perfect, remove the strip, shorten it on the 

right side and insert it again. 

6. The projecting remainder may not be cut off to the degree that 

subsequent replacement of the slide-in strip is impossible. 

In order to ensure problem-free functioning of both the internal and the 

external keyboards on the BTV 20, a few things must be taken into 

account. 

When it is delivered, the keyboard driver and thus the keyboard layout of 

the desired language is already correctly configured under Windows (this 

is the language of the installed operating system). The connection of an 

external keyboard, such as the PCK03 drawer keyboard, is also correctly 

preset when the device is delivered. Changes are required only if a 

keyboard is connected whose keyboard layout does not agree with the 

preset keyboard language. At the same time, the software of the internal 

membrane keyboard on the front of the BTV 20 must be readapted. How 

this change is to be made is described below. 

Changing the Keyboard Language 

To adapt the external keyboard, the following steps must be carried out: 

1. Call menu item "Keyboard" in the Windows NT control panel. 

Path: Start - Settings - Control Panel - Keyboard


Fig. 2-13: Control panel icon "Keyboard" 

Systemstg01.bmp 

2. Switch to the "Input" tab. 

The preset keyboard layout is displayed here. 

3. Press the "Add…" button. 

4. Select the language to be used for the external keyboard from the list 

(input locale). 

Use the default characteristics for this input locale. 

Fig. 2-14: "Input" tab 

Eingabe.bmp 



Internal keyboard 


This method is used to add a keyboard layout, i.e. several keyboard 

languages are now displayed in the window and the desired language is 

to be selected. 

The "Characteristics" item in the Input tab of the control panel can 

be used to change the keyboard layout directly to the desired 

language. 

Note: However, only the changed keyboard appears in the window 

after the change. You cannot change the selection of the old 

and the new keyboard layouts as is the case for "Add". 

To adapt the internal membrane keyboard, the additional "BTV 20" icon is 

present in the Windows NT control panel. The following steps must be 

carried out: 

1. Call menu item "BTV 20" in the Windows NT control panel. 

Path: Start - Settings - Control Panel - BTV 20 

Fig. 2-15: Control panel icon "BTV 20" 

Systemstg02.bmp 

2. If the "BTV 20" icon is not included in the control panel, the 

associated program must first be installed. For this purpose, a utility 

diskette (SWD-BTV20*-UTI-01VRS) is supplied with the BTV 20. 

Installation: Insert the diskette in drive A: and enter the A:\SETUP 

command via Start - Run. After installation is complete, shut down the 

operating system and start again at point 1. 

3. In the following window, select the desired keyboard layout and 

confirm by pressing "OK".


Fig. 2-16: Selection menu for internal keyboard layout 

Tastatur.bmp 

Note: The language that is set here must agree with the settings for 

the external keyboard in the operating system. 



2.4 Technical Data 

General Technical Data 

PC processor 

RAM 

Hard disk 

Interfaces (PC conf.) 

Display unit 

Slots 

Keyboard 

Protection class 

Front panel surface 

Plug-in unit dimensions 

Dimensions with front panel 

Power supply 

Max. power consumption 

Typical heat loss 

Max. heat loss 

Weight 

Ambient Conditions 


Pentium slot CPU (min. 700 MHz) with integrated graphics controller 

128 MB (standard), 256 MB (optional) 

At least 3 GB 

1 serial (RS232), 1 parallel (Centronics), 1 Rexroth RS232, RS422 and 

RS485, 1 Ethernet 10Base-T/100Base-Tx, 2 USB (not supported by 

Windows NT 4.0) 

10.4" TFT color display 

2 unassigned PCI slots on the PC CPU side 

Machine user keyboard, 16 machine function keys 

Front panel IP 65, housing IP 20; DIN 40 050, IEC 529 

Color: RAL 7035 (light gray) 

372 x 335 x 209 mm (WxHxD) 

407 x 370 x 220 mm (WxHxD) 

115/230 VAC ± 15%; 47-63 Hz 

250 VA 

100 W 

200 W 

Approx. 10.5 kg (without control cards) 

In operation Storage/transport 

Max. ambient temperature +5 °C to +45 °C -20 °C to +60 °C 

Max. temperature gradient 10 K/h 15 K/h 

Relative humidity 75% (average), 

80% (occasionally) 

Atmospheric pressure 860 to 1060 hPa, 1500 m 12,000m 

75% (average), 

80% (occasionally) 

non-condensing 

Max. external magnetic field 6 x 10 -4 Tesla 6 x 10 -4 Tesla 

Max. vibration 10-57 Hz: 

Continuous: 0.0375 mm amplitude 

Occasionally: 0.075 mm amplitude 

57-150 Hz: 

Continuous: 0.5 g constant acceleration 

Occasionally: 1.0 g constant acceleration 

To be applied to each of the three vertically positioned axes 

(according to standard 60068-2-6) 

Max. shock Occasional peaks up to 15 g over 11 ms, half sine wave in each of 

the three vertically positioned axes. (according to standard 60068-2- 

27) 

Fig. 2-17: Ambient conditions for BTV 20.4


Wear Parts 

Wear parts that are not under 

guarantee 

• Fans 

• Backlight tubes 

• Floppy disk drive (FDD) 

• Hard disk drives (HDD) 

• Battery (slot CPU) 

The average expected lifetime of the wear parts is 20,000 operating 

hours. After this time has elapsed, it is recommended that these 

components be replaced within the framework of preventive maintenance. 



2.5 Measurements 

Housing Dimensions 

370 

360 

352,5 

185 

17,5 

10 

0 

L1 

L2 

L3 

L4 

L5 

L6 

L7 

L8 

OPERATOR PROG 

F2 F3 

OP2 


10,4" 

F4 F5 F6 F7 F8 F9 


6 


R1 

R2 

R3 

R4 

R5 

R6 

R7 

R8 

7 

< 

4 

PROG 

TEMP HD POWER 

8 

F1 

5 

ESC 

9 

F10 

6 

1 2 3 

NEXT INFO TAB 

0 

SP 

N 

ESC OK 

. 

, 

. 

CTRL ALT 

0 10 

139 268 397 

17,5 389,5 407 

Fig. 2-18: Dimensions - front plate 

< 

OK 

- 

INS 

+ - 

SFT 

DEL 

Mass1.FH7


min. clearance 

of 20 mm 

for air circulation 

min. clearance 

of 20 mm 

for air circulation 

407 

389,5 

287,5 

Fig. 2-19: Rear view 

17,5 

370 

352,5 

46 

37,5 

17,5 


0 

0 

Mass2.FH7


Space require for 

connector 

ca. 100 mm 

46 

37,5 

17,5 


0 

Fig. 2-20: Side view 

201,5 

55 

38 

Clearance 

0 

4 

Mass3.FH7


0 

1 

X22 

X23.2 

UE1 UE2 

NC IO card 

X16 

X2 

X20 

X9 

X90 

X100 

PC-CPU module 

U1 U2 U3 U4 U5 U6 U7 U8 U9 U10 

X7 

X23 

X25.1 

Rx 

X24.1 

Tx 

NC multifunction card 

Fig. 2-21: View from below 

PC bus NC bus 

X25.2 

Rx 

X24.2 

Tx 

SERCOS interface 

module 

X64 

X60 

INTERBUS 

module 

X15 

X5 

X16 

MTS-P 

PLC 

module 

NC-CPU module 

Ansicht_Unten_BTV204.FH7 



2.6 Installation Dimensions 

350 

343 

175 


7 

0 

0 

7 

10x Tallow-drop 

screws with gasket 

M5x16 

Device 

assembly 

from the front 

(336) 

129 

10x 6,0 or 

10x M5 

Mounting cutout 

(373) 

Fig. 2-22: Mounting detail 

258 

Mounting plate 

10x Comb. 

nuts M5 

Flat seal 

380 

387 

Mass5.FH7


2.7 Connections 

General Connections 

0 

1 

X22 

X23.2 

UE1 UE2 

NC IO card 

X16 

X2 

X20 

X9 

X90 

X100 

PC-CPU module 

PC bus NC bus 

U1 U2 U3 U4 U5 U6 U7 U8 U9 U10 

X7 

X23 

X25.1 

Rx 

X24.1 

Tx 

NC multifunction card 

X25.2 

Rx 

X24.2 

Tx 

SERCOS interface 

module 

X64 

X60 

INTERBUS 

module 

X15 

X5 

X16 

MTS-P 

PLC 

module 

Fig. 2-23: View from below in a typical MTA 200 configuration 

NC-CPU module 

Ansicht_unten_BTV204.FH7 



M7 

M8 

TEMP HD POWER 

7 8 9 N - 

F9 < F1 F10 > + 


0 

1 

KBDDATA 

MSEDATA 

GND 

+5V 

KBDCLK 

MSECLK 

KBDDATA 

MSEDATA 

GND 

+5V 

KBDCLK 

MSECLK 

N 

L 

1 

2 

3 

4 

5 

6 

1 

2 

3 

4 

5 

6 

X7 

Fig. 2-24: Standard connections 

Power Supply 

115/230 VAC ± 15%; Autorange 

P 250 VA 

50/60 Hz 

Ground Terminal 

min. 6 mm² to 

central ground terminal 

Caution: Remove or insert connector only after 

voltage has been switched off 

External keyboard or mouse 

connector 

PS/2 - Keyboard and 

mouse connector 

A_std.FH7


Interfaces of NC CPU Card - Computer Configuration 45 

COM2-SIS 

LPT 

LAN 

COM1 

VGA 

USB 

egen tec Mating er connector 

max. 32 mm 

max. 32 cm 

Fig. 2-25: Position of plug connections 

Serial Interface COM1 

Fig. 2-26: COM1 interface 

Pin Description Pin Description 

1 DCD 2 RxD 

3 TxD 4 DTR 

5 GND 6 DSR 

7 RTS (Note1) 8 CTS 

9 RI 

Fig. 2-27: Pin assignment of serial interface COM1 

Slot_PICMGCarrier_1.eps 

Note: The RS232 channel runs only with a 5 V power supply. 

Com1_Belegung.tif 




VGA Screen Connection 

Fig. 2-28: VGA Screen Connection 


1 Video Signal Red 2 Video Signal Green 

3 Video Signal Blue 4 N.C. 

5 DIG-GND 6 ANA-GND 

7 ANA-GND 8 ANA-GND 

9 VCC 10 DIG-GND 

11 N.C. 12 DDCDAT 

13 HSYNC 14 VSYNC 

15 DDCCLK 

Fig. 2-29: Pin assignment of the SVGA screen connection 

Graphics card ATI Rage Mobility-based AGP graphics card. 

Fig. 2-30: Graphics card in BTV 20.3 

Ethernet Interface (10 Base-T / 100 Base-Tx) 

Fig. 2-31: Ethernet interface 

1 8 


1 TxD+ 2 TxD- 

3 RxD+ 4 N.C. 

5 N.C. 6 RxD- 

7 N.C. 8 N.C. 

Fig. 2-32: Pin assignment of Ethernet interface 

XGA_SVGA_Belegung.tif 

Network card Intel(R) 82559ER PCI 10BASE-T / 100BASE-Tx 

Fig. 2-33: Network card in BTV 20.4 

10Base_T.fh7


USB Interface 

Universal serial bus with USB legacy keyboard and USB floppy boot 

support. Compatible with version 1.0 of the USB standard. 

Fig. 2-34: USB interface 

Pin Description 

1 USB power supply (max. 500 mA) 

2 Data - 

3 Data + 

4 USB-ground 

LPT1 Printer Interface and SIS 

Fig. 2-35: Pin assignment of USB interface 

USB_Belegung.tif 

Serial interface COM2 (X16) is switched according to the Rexroth 

standard (SIS). The LPT1 printer interface has the standard Centronics 

assignment. Both interfaces are described in more detail in the following. 

LPT1 interface 

Fig. 2-36: LPT1 interface 

Pin Signal designation Pin Signal designation 

1 /STB - Strobe 2 PD0 

3 PD1 4 PD2 

5 PD3 6 PD4 

7 PD5 8 PD6 

9 PD7 10 /ACK - Acknowledge 

11 Busy 12 PE - Paper End 

13 SLCT - Select 14 /AFD - Auto Feed 

15 /ERR - Error 16 /INIT 

17 /SLCTIN - Select In 18 GND 

19 GND 20 GND 

21 GND 22 GND 

23 GND 24 GND 

25 GND 

Fig. 2-37: Pin assignment of LPT1 interface 

LPT1_Belegung.tif 




COM2 SIS Interface 

Fig. 2-38: COM2 SIS interface 


1 Protected Ground 2 TxD (RS232) 

Com2_SIS_Belegung.tif 

3 RxD (RS232) 4 RS485+ / RxD+ (RS422) 

5 RS485- /RxD- (RS422) 6 Data Set Ready (RS232) 

7 Signal Ground 8 Data Carrier Detected (RS232) 

9 TxD+ (RS422) 10 GND 

11 TxD- (RS422) 12 +5V 

13 Request To Send (RS232) 14 Clear To Send (RS232) 

15 Data Terminal Ready 

Fig. 2-39: Pin assignment of COM2 SIS interface 

Configuration 

The COM2 SIS interface is configured using Windows tool "SISControl". 

A shortcut to this tool is located on the Windows desktop. 

Fig. 2-40: COM2 SIS interface configuration tool "SISControl" 

SISControl.tif 

The COM2 SIS interface is configured internally using the COM4 port. 

Therefore, always select COM4 from the COM ports - it is shown as the 

default here. Then select the desired SIS mode 0 to 7, corresponding to 

the RS485 or RS422 interface, from the table. 

Note: The RS232 mode of the COM2 SIS interface is always active, 

regardless of the settings selected for RS485 and RS422!


Internal Wiring 

Fig. 2-41 shows a view of the insides of the BTV 20.4A. The figure shows 

how the cards are arranged and how they are to be interconnected, as 

well as how they are to be connected to the hard disk and floppy disk 

drives. 

Fig. 2-41: View of the insides of the BTV 20.4A 

BTV20-Innen.jpg 



Sample Applications 

Indramat 

OPERATOR PROGRAMMER 

IKS 0056 

BTV20 

(MTS-P) 

INTERBUS-S 

OUT 

INTERBUS-S 

IN 

INTERBUS-S 

OUT 

DO 

DO 

GND 

DI 

DI 

+5V 

RBST 

DO1 

DO1 

GND 

DI1 

DI1 

RECO12 - Module 

RMK12.1-IBS-BKL 

+U L 

0V L 


MTS-P 

Complete 

INTERBUS-S cable 

DO2 

DO2 

GND 

DI2 

DI2 

+5V 

RBST 


F1 

F 2,5A 

X60 

1 

6 

3 

2 

7 

5 

9 

1 

6 

3 

2 

7 

X2 

1 

6 

3 

2 

7 

5 

9 

X60 

X3 

1 

2 

3 

X1 

Sample Application for BTV 20.4A with INTERBUS 

Connection 

TEMP HD POWER 

IKS 0056 

X3 

X2 

I 

N 

T 

E 

R 

B 

U 

S 

- 

S 

X4 

ALARM 

GND 

X3 

Remote Bus Interconnect 

for further 

INTERBUS-S devices 

X1 

IN 

X2 

X1 

OUT X2 

INTERBUS - S 

BA 

IKS 0056 

IKS 0056 

Remote Bus Interconnect 

for further 

INTERBUS-S devices 

3 x 0,75 mm 2 

INTERBUS - S 

BA 

X1 

X2 

MASCHINE 

EIN 

MASCHINE 

AUS 

X6 

X2 

BTA20 

BA 

INTERBUS - S 

BETRIEBSART 

AUTO 

START 

LOCAL 

MACHINE CONTROL 

INTERBUS - S 

BA 

X1 

Fig. 2-42: INTERBUS-S sample connection 

E-STOP 

X2 

BA 

X7 

INTERBUS - S 

INTERBUS - S 

X2 

X6 

X7 

X1 

% 

10 20 30 40 F 

8 50 

6 

60 

4 

70 

2 

80 

1 

100 

0 

120 

BA 

1 

2 

3 

4 

ZUSTIMM- 

TASTER 

1 

6 

3 

2 

7 

1 

6 

3 

2 

7 

5 

9 

ANSCHLUß 

HANDBEDIEN- 

GERÄT 

DO1 

DO1 

DI1 

DI1 

0VL 

GND 

DO2 

DO2 

GND 

DI2 

DI2 

+5V 

RBST 

+24 VDC 

RECO12 

INTERBUS-S 

IN 

BTA20 

INTERBUS-S 

OUT 

~ 

0V L 

IKS 0056 

+24 VDC 

App_ib.FH7



IKB 0015 (RS422) 

E-STOP 

MASCHINE 

EIN 

MASCHINE 

AUS 


MTS-P0x.2 

X16 

X8A 

BETRIEBSART 

AUTO 

START 

LOCAL 


X9 

TEMP HD POWER 

% 

10 20 30 40 F 

8 50 

6 

60 

4 

70 

2 

80 

1 

100 

0 

120 

ZUSTIMM- 

TASTER 

ANSCHLUß 

HANDBEDIEN- 

GERÄT 

Sample Connection with BTA 10/20 and BTC 06 Handheld 

Terminal 

IKB 0015 

X1 

CTRL-KEY 

FOR 

BTC06 

E-STOP 

PLUG 

FOR 

BTC06 

Fig. 2-43: Device arrangement 

X2 

BTA10 

IKS 0190 

max. 6 units 

IKB 0015 

BTC06 

X1 X2 

CTRL-KEY 

FOR 

BTC06 

IKB 0015 

E-STOP 

PLUG 

FOR 

BTC06 

Only one BTC can be operated at a time. 

The key switch activates the interface 

on the BTA module. 

10 

8 

6 

4 

2 

1 

0 

20 30 40 

50 

60 

70 

80 

100 

120 

% 

BTC06 

BTA10 

Further 

BTA10 

Appl_BTA_Geräte.FH7 

Connect the BTA 20 via the cable IKB0015 directly to the connector X16 

of the PLC assembly used (see Fig. 2-44). 

Note: Only RS422 communication is possible between the devices. 



BTV20 (MTS-P0x.2) 

X16 

BTA10 

TxD+ 

TxD- 

GND 

RxD+ 

RxD- 

TxD+ 

TxD- 

GND 

RxD+ 

RxD- 

X1 

BTA10 

module NA/VA 

0V L 

+24 VDC 

~ 

TxD+ 

TxD- 

GND 

RxD+ 

RxD- 

24V 

0V 

TxD+ 

TxD- 

GND 

RxD+ 

RxD- 

X2 

+24 VDC 

0VL 


13 

12 

14 

11 

10 

9 

11 

7 

4 

5 

9 

2 

1 

11 

7 

4 

5 

9 

11 

7 

4 

5 

INS645/K01 

termination on 

3 

4 

5 

1 

2 

INS645/K01 


X3A 

1 

2 

3 

4 

3 

4 

5 

1 

2 

INS645/K01 


3 

4 

5 

1 

2 

Connection to MTS-P0x.2 (BTV 20) 

central 

mass point 

IKB 0015 (RS422) 

IKB 0015 

IKB 0190 

IKB 0015 

INS645/K01 


+24 VDC 

1 

2 

5 

3 

4 

INS645/K01 


INS645/K01 


1 

2 

5 

3 

4 

X1 

4 

5 

7 

9 

11 

13 

12 

14 

11 

10 

2 

1 

4 

5 

7 

9 

11 

X8A 

Fig. 2-44: Connecting a BTA 10/20 to a BTV 20 

0V L 

1 

2 

5 

3 

4 

4 

5 

7 

9 

11 

RxD+ 

RxD- 

GND 

TxD+ 

TxD- 

1 

2 

3 

4 

X9 

RxD+ 

RxD- 

GND 

TxD+ 

TxD- 

RxD+ 

RxD- 

GND 

TxD+ 

TxD- 

24V 

0V 

RxD+ 

RxD- 

GND 

TxD+ 

TxD- 

BTA20 

0V L 

+24 VDC 

BTC06 

further BTA10 

X1 

Appl_BTA_RS422.FH7


Operator terminal 

BTV20.3A 

Drive amplifier 

DIAX04 

Sample Application of BTV 20.4A and SERCOS Interface 

Indramat 


Rx 

SEI011x 

Tx 

Tx 

Supply module 

HVE od. HVR 

SEI011x 

Rx 

TEMP HD POWER 

Fig. 2-45: SERCOS connection 

Fibre optic cable IKO0985/... 

Fibre optic cable IKO0982/... 

Max. 8 drive modules 

for each SERCOS fibre optic 

HDS or HDD 

Tx 

Rx 

BTV20_DIAX.FH7 

BTV 20.4A with a SERCOS interface module (i.e. for up to 8 axes). 




Ready-to-Use Interface Plugs 

Plugs that make termination possible within the housing are available for 

RS422 and RS485 communications. The cable can be attached using 

screw terminals. For the pin assignment of the two plugs, please refer to 

the drawing (see Fig. 2-46). 

The table in section "Accessories", page 2-36 indicates which plug 

housing is used for interface cables. 

INS0619/K01 

RS485+ 

RS485- 

SGND 

+ 5 V 

GND 

4 

5 

7 

12 

390W 

10 

150W 

0 1 

390W 

1 

2 

3 

1 

2 

3 

INS0645/K01 

RxD+ 

RxD- 

TxD+ 

TxD- 

SGND 

+5V 

GND 

Fig. 2-46: Plug assignment of ready-to-use plug housings 

Termination can be activated using a switch. 

4 

5 

9 

11 

7 

12 

10 

390W 

150W 

0 1 

390W 

1 

2 

3 

4 

5 

Stecker.FH7


2.8 Ordering Information 

Type Key 

Fig. 2-47: Type key for BTV 20.4 

Type.tif 



Configuration Type Key 


BTV 20.4A 

Fig. 2-48: Configuration type key for BTV 20.4A 

Cfg_BTV20_4A.tif


Accessories 

Ordering name of 

ready-to-use cables 

IKB0005 

MN: 278,141, 2 m 

MN: 278,144, 5 m 

MN: 278,142, 10 m 

MN: 278,143, 15 m 

(RS232, max. 15 m) 

IKB0012/000,0 

MN: 281 715 

(RS232, max. 15 m) 

IKS0106/000,0 

MN: 260 838 

(RS232, max. 15 m, 

Profibus configuration) 

IKS0190 

MN: 279,743, 3 m 

MN: 279,743, 5 m 

MN: 279,744, 10 m 

MN: 279 745, 15 m 

(RS422, max. 15 m) 

IKB0193 

MN: 282041 

(RS232, max. 15 m) 

IKB0015/000,0 

MN: 282 870 

(RS422, max. 400 m) 

Selection List of Plugs and Ready-to-Use Cables 

Counter-plug on 

the device 

INS439 

15-pin male 

connector 

INS439 

15-pin male 

connector 

INS526 

9-pin female 

connector 

Bosch Rexroth cable Execution of 

cable end 

INK572 

INK572 

INK572 

INS526 

9-pin female 

connector 

INS588 

9-pin female 

connector 

INS588 

9-pin female 

connector 

INS0624/C INS0631/C 

INS0525/L01 INS0526/L01 

9-pin male 

connector 

INK0234 

9-pin female 

connector 

INS645 INS645 

15-pin male 

connector 

INK234 

15-pin male 

connector 





IKB0016/000,0 

MN: 282 871 

(RS422, max. 400 m) 

IKB0017/000,0 

MN: 282 872 

(RS485, max. 400 m) 

IKB0018/000,0 

MN: 282 874 

(RS485, max. 400 m) 

IKB0019/000,0 

MN: 282 875 

(RS485, max. 400 m) 

IKB0030/000,0 

MN: 291 736 

(Interbus configuration, 

max. 15 m) 

IKB0031/000,0 

MN: 291 805 

(INTERBUS, max. 400 m) 

IKB0031/000,5 

MN: 291 806 

(INTERBUS, 0.5m) 

IKB0032/000,0 

MN: 291 807 

(INTERBUS, max. 400 m) 


9 

1 

9 

1 


the device 


cable end 

INS645 INS526 

15-pin male 

connector 

INK234 

INK572 

9-pin female 

connector 

INS619 INS619 

15-pin male 

connector 

INK572 

15-pin male 

connector 

INS619 INS526 

15-pin male 

connector 

INS619 

15-pin male 

connector 

1 

9 

INS0702/L01 

9-pin female 

connector 

INK572 

IKB0030 IKB0030 

INK0572 

9-pin female 

connector 

Connector 

sleeves 

INS0702/L01 

1 

9-pin female 

connector 

INS0703/L01 INS0702/L01 

9-pin male 

connector 

INS0703/L01 

9-pin male 

connector 

IKB0031 IKB0031 

INK0699 

IKB0032 IKB0032 

INK0699 

9 

9-pin female 

connector 

1 

9




IKB0033/000,0 

MN: 291 808 

(Profibus, max. 1,000 m) 

IKB0034/000,0 

MN: 291 809 

(Profibus, max. 1,000 m) 

INS0619/K01 

MN: 279 583 

INS0645/K01 

MN: 282 040 

INS0540/K01 

MN: 279 538 

INS0541/K01 

MN: 279 539 


the device 


cable end 

INS0541/K01 INS0541/K01 

IKB0033 IKB0033 

INK0698 

9-pin male 

connector 

INS0541/K01 

9-pin male 

connector 

INS0619/RS485 

(15-pin male connector) 

INS0645/RS422 

INS0540/Profibus (male) 

INS541/Profibus 

(male/female connector) 

Fig. 2-49: MTS-R accessories 

IKB0034 

INK0698 

IKB0034 

Y-plug for self-finishing with 

termination 

Plug for self-finishing with 

termination 

Profibus plug for self-finishing 

with termination 

Profibus plug for self-finishing 

with termination 

(attachable side by side) 

9-pin male 

connector 




Lockable Floppy Disk Flap 

It is also possible to order the following set of accessories for the 

BTV 20.4 to retrofit the device with a lockable floppy disk flap: 

SUP-M01-BTV20 

Fig. 2-50: Lockable floppy disk flap SUP-M01-BTV20 

2.9 Supplied Accessories (Scope of Delivery) 

Assembly kit 

• 10 fillister-head screws, M5 x 12 

• 10 seals, M5, Nyltite 

Floppy_Schließ.FH7 

• 1 inlet connector for non-heating appliances, 3-pin, socket (only for 

model with 230V power pack) 

• Front plate seal, 404 x 4 x 0.8 mm 

• Front plate seal, 365 x 4 x 0.8 mm 

Set of inscription plates 

• Preprinted sample slide-in strips 

• Diskette with templates for independent creation of labels 

SWD-BTV20*-UTI-01VRS-MS-C1,44 

• Diskette with software for setting the keyboard language 

Slip case with software package 

• Compilation of the ordered firmware and software



Rexroth BTV 20.4A PC CPU Configuration 45 3-1 

3 PC CPU Configuration 45 



Electrical Specifications 


Fig. 3-1: Slot CPU card 

Power supply +5, +12 V (+/- 3%) 

Power consumption Typically 10-20 W (depending on processor type) 

Battery +3.6 Volt lithium battery, size ½ AA 

CPU and Memory Specifications 

Fig. 3-2: Electrical specifications 

Processor INTEL, Mobile Pentium III, min. 700 MHz 

CPU clock rate Min. 700 MHz 

System clock rate 100 MHz frontside bus 

BGR_SlotCPU.tif 

Program memory 1 144-pin SO-DIMM 3.3 V PC100, max. 256 MB. Only use 256-MB 

“stacked” SO-DIMM modules. Do not use 256 MegaBit modules. 

System core INTEL 440BX AGP Set 

Fig. 3-3: CPU and memory specifications

3-2 PC CPU Configuration 45 Rexroth BTV 20.4A 

3.3 PhoenixBIOS Setup 

The BIOS of the BTV 20.4 is a "Phoenix BIOS 4.0 Release 6.1, 256 KByte 

FLASH-BIOS, NV-EEPROM". It contains a battery-buffered CMOS 

memory for storing the date, time and system configuration. 

Note: Incorrect settings can cause damage to the system or prevent 

it from booting. 

The main menu of the BIOS system is accessed by pressing the key 

when the following message appears during the boot procedure: 

"Press to Enter Setup" 

Help Screen (Online Help) 

Use to call the "General Help". Information regarding the operation 

of PhoenixBIOS Setup is shown here. 

"Item Specific Help", i.e. help for the currently selected menu item, is 

shown on the right side of the various menus. 

Navigation in PhoenixBIOS Setup 

The following keys are important in PhoenixBIOS Setup: 

Keys Function 

or Call "General Help" 

Exit the menu 

← or → arrow keys Select the various menus 

↑ or ↓ arrow keys Select the desired menu items 

or Jump to the next/previous menu item 

or Move the cursor to the start/end of the current menu 

or Move the cursor to the next/previous menu 

or Select the previous entry in the menu item list 

or Select the next entry in the menu item list 

Load the default values for this menu 

Save and exit 

Execute the command or select the submenu 

Update the display 

Fig. 3-4: PhoenixBIOS key functions 



Main PhoenixBIOS Setup Menu 


The PhoenixBIOS Setup screen is divided into four sections. 

Part of Setup 

screen 

Position on screen Function 

Menu bar Top Display and selection of all toplevel 

menus 

Navigation bar Bottom Display of the Setup navigation key 

functions 

Specific help Right Help for the currently selected 

menu item 

Menu contents Left Display of the current menu 

General help Front and center Display of the Help 

Fig. 3-5: Division of the PhoenixBIOS Setup menu 

Default Settings 

Pressing the key loads the default setup configuration. However, 

these are not the default values for the BTV 20.4! 

Note: The default values for the BTV 20.4 are listed in the following 

tables. 

Special MTA Settings 

It is not necessary to make any changes to the BIOS settings in the 

BTV 20.4A for the MTA 200 control system. 

But since the NC CPU is equal to the PC CPU only in its appearance, it 

must be ensured that the PC CPU is not used as the NC CPU and vice 

versa. 

Otherwise, the different BIOS settings of NC CPU and PC CPU would 

prevent the BTV 20.4A from booting. 

Note: The BTV 20.4A with computer configuration 45 mandatorily 

requires an MTA software version 23VRS or higher. It is not 

possible to operate the BTV 20.4A with older versions.


PhoenixBIOS Settings for the BTV 20.4 

Main 

System Time Current time 

System Date Current date 

Legacy Diskette A 1.44/1.25 MB 3½" 

Legacy Diskette B Disabled 

Primary Master Autodetected drive / submenu 

Primary Slave Autodetected drive / submenu 

Secondary Master Autodetected drive / submenu 

Secondary Slave Autodetected drive / submenu 

Memory Shadow Submenu 

Memory Cache Submenu 

System Memory Display of system memory 

Extended Memory Display of extended memory 

Fig. 3-6: Main menu 

Type 

Primary / Secondary Master / Slave 

Primary Master: Auto 

Primary Slave: None 

Secondary Master: Auto 

Secondary Slave: None 

CHS Format 

Cylinders Display depends on IDE device 

Heads Display depends on IDE device 

Sectors Display depends on IDE device 

Maximum Capacity Display depends on IDE device 

LBA Format 

Total Sectors Display depends on IDE device 

Maximum Capacity Display depends on IDE device 

Multi-Sector Transfer Display depends on IDE device 

LBA Mode Control Display depends on IDE device 

32-Bit I/O Enabled 

Transfer Mode Display depends on IDE device 

Ultra DMA Mode Display depends on IDE device 

Fig. 3-7: "IDE Device" submenu 

Memory Shadow 

CC00 - CFFF Disabled 

D000 - D3FF Disabled 


D800 - DBFF Disabled 

DC00 - DFFF Disabled 

Fig. 3-8: "Memory Shadow" submenu 




Memory Cache 

Memory Cache Enabled 

Cache System BIOS area Write Protect 

Cache Video BIOS area Write Protect 

Cache Extended memory area Write Back 






Fig. 3-9: "Memory Cache" submenu 

Advanced Menu 

Advanced Chipset Control Submenu 

PNP OS installed No 

Reset Configuration Data No 

Secured Setup Configuration Yes 

PCI Configuration Submenu 

PS/2 Mouse Autodetect 

Keyboard Features Submenu 

I/O Device Configuration Submenu 

Large Disk Access Mode DOS 

SMART Device Monitoring Enabled 

Halt On Errors Yes 

Fig. 3-10: "Advanced" menu 

Advanced Chipset Control 

Graphics Aperture 64 

Enabled memory gap Disabled 

ECC Config Disabled 

SERR signal condition None 

8 bit I/O Recovery 4.5 


Fig. 3-11: "Advanced Chipset Control" submenu


PCI Configuration 

PCI IRQ line 1 Auto Select 




PCI/PNP ISA UMB Region Exclusion Submenu 

PCI/PNP ISA IRQ Resource Exclusion Submenu 

Default Primary Video Adapter AGP 

ISA graphics device installed No 

Assign IRQ to PCI VGA No 

Fig. 3-12: "PCI Configuration" submenu 

PNP/UMB Region Exclusion 

CC00 - CFFF Available 

D000 - D3FF Reserved 

D400 - D7FF Available 

D800 - DBFF Available 

DC00 - DFFF Available 

Fig. 3-13: "PCI/PNP UMB Region Exclusion" submenu 

PCI/PNP ISA IRQ Resource Exclusion 

IRQ3 Available 








Fig. 3-14: "PCI/PNP ISA IRQ Resource Exclusion" submenu 

Keyboard Features 

NumLock Auto 

Key Click Disabled 

Keyboard auto-repeat rate 30/sec 

Keyboard auto-repeat delay ½ sec 

Fig. 3-15: "Keyboard Features" submenu 




I/O Device Configuration 

Local Bus IDE adapter Both 

Onboard FDC Enabled 

Base I/O address Primary 

External FDC Disabled 

Serial port A Enabled 

Base I/O address 3F8 

Interrupt IRQ4 

Serial port B Enabled 

Mode Normal 

Base I/O address 2F8 


Serial port C Enabled 

Base I/O address 3E8 


Serial port D Enabled 

Base I/O address 2E8 


Mode Normal 

External LPT Enabled 

Mode Bi-directional 

Base I/O address 278 


Legacy USB Support Enabled 

Watchdog Settings Submenu 

Fig. 3-16: "I/O Device Configuration" submenu 

Watchdog Settings 

Mode Disabled 

Fig. 3-17: "Watchdog Settings" submenu 

Security 

Supervisor Password Is Clear 

User Password Is Clear 

Set Supervisor Password 

Set User Password 

Password on boot Disabled 

Fixed disk boot sector Normal 

Diskette access Supervisor 

Virus check reminder Disabled 

System backup reminder Disabled 

Fig. 3-18: "Security" menu


Power 

Power Savings Disabled 

Idle Mode Off 

Standby Timeout Off 

Auto Suspend Timeout Off 

Hard Disk Timeout Disabled 

Video Timeout Disabled 

Resume On Time Off 

Resume Time 00:00:00 

Power Supply ATX 

Fig. 3-19: "Power" menu 

Boot 

Floppy Check Disabled 

Summary Screen Disabled 

QuickBoot Mode Enabled 

Dark Boot Disabled 

Boot Device Priority Submenu 

Onboard LAN RPL ROM Disabled 

Fig. 3-20: "Boot" menu 

Removable Devices 

Hard Drive 

CD-ROM Drive 

Network Boot 

Boot Device Priority 

Fig. 3-21: "Boot Device Priority" submenu 



3.4 Installation of SO-DIMM Memory Modules 


1. Insert the SO-DIMM memory module at a 30° angle into the socket, 

as shown below. 

2. Carefully press the module down until it locks in. 

Fig. 3-22: Installation of SO-DIMM modules, illustration A 

Fig. 3-23: Installation of SO-DIMM modules, illustration B 

SODIMM_Modul_A.tif 

SODIMM_Modul_B.tif


3.5 Temporary Connection of Additional IDE Devices 

Connection for Power Supply Cable 

It is possible to connect additional IDE devices to the BTV 20.4 without 

changing the cables of the internal HDD. The figure below shows the 

connection for the power supply cable and the IDE port: 

Fig. 3-24: Position of temporary connections 

IDE_Anschluss.jpg 

To provide power to the IDE device, an additional external power source 

must be connected to the slot CPU card. To do this, use a standard 

power supply cable for 5.25" PC disk drives. 

The connection is assigned as follows: 

Pin Color Meaning 

1 Yellow +12 V 

2 Black GND 

3 Black GND 

4 Red +5 V 

Fig. 3-25: Connection assignment 

Power5_25.jpg 



IDE Port 


The IDE port of the BTV 20.4 is a free port (primary IDE port) to which an 

additional hard disk or a CD-ROM drive can be connected. 

The device that is connected must be selected in the BIOS. When it is 

delivered, the Primary Master is set to "Automatic Detection" and the 

Primary Slave is deactivated. 

Note: The maximum permitted cable length for IDE cables is 50 cm! 

Fig. 3-26: Connection assignment 

IDE_Stecker.tif




4 PC CPU Configuration 44 



Fig. 4-1: Slot CPU card 

BGR_SlotCPU.tif 

In its appearance, the NC CPU is equal to the PC CPU that is described 

in Chapter 3. However, it contains a different processor and memory 

module and a different BIOS setting. The peripherals for HD/FD, serial 

interface and Ethernet contained on the card are not used and are 

deactivated via the BIOS.



Electrical Specifications 

Power supply +5, +12 V (+/- 3%) 

Power consumption Typically 10-20 W (depending on processor type) 

Battery entfällt 

CPU and Memory Specifications 

Fig. 4-2: Electrical specifications 

Processor INTEL, Mobile Pentium III, min. 400 MHz 

CPU clock rate Min. 400 MHz 

System clock rate 100 MHz frontside bus 

Program memory 1 144 Pin SO-DIMM 3,3 V PC100, 128 MB 

System core INTEL 440BX AGP Set 

4.3 PhoenixBIOS Setup 

Fig. 4-3: CPU and memory specifications 

The BIOS of the NC CPU is a “Phoenix BIOS 4.0 Release 6.8, 256 Kbyte 

FLASH-BIOS, NV-EEPROM”. It contains a battery-buffered CMOS 

memory for storing the date, time and system configuration. 

Note: Incorrect settings can cause damage to the system or prevent 

it from booting. 

The BIOS settings of the NC CPU cannot be checked directly at the BTV 

20.4A. A check of these settings, if necessary, requires that a monitor and 

a keypad be directly connected to the NC CPU. 

Chapter 3 describes how to start and operate the BIOS editor. 



PhoenixBIOS Settings of the NC CPU 


Main 

System Time Current time 

System Date Current date 

Legacy Diskette A 1.44/1.25 MB 3½" 

Legacy Diskette B Disabled 

Primary Master None 

Primary Slave None 

Secondary Master None 

Secondary Slave None 

Memory Shadow Submenu 

Memory Cache Submenu 

System Memory Display of system memory 

Extended Memory Display of extended memory 

Fig. 4-4: Main menu 

Memory Shadow 






Fig. 4-5: "Memory Shadow" submenu 

Memory Cache 

Memory Cache Enabled 

Cache System BIOS area Write Protect 

Cache Video BIOS area Write Protect 

Cache Extended memory area Write Back 






Fig. 4-6: "Memory Cache" submenu


Advanced Menu 

Advanced Chipset Control Submenu 

PNP OS installed No 

Reset Configuration Data No 

Secured Setup Configuration No 

PCI Configuration Submenu 

PS/2 Mouse Disabled 

Keyboard Features Submenu 

I/O Device Configuration Submenu 

Large Disk Access Mode DOS 

SMART Device Monitoring Enabled 

Halt On Errors No 

Fig. 4-7: "Advanced" menu 

Advanced Chipset Control 

Graphics Aperture 64 Mb 

Enabled memory gap Disabled 

ECC Config Disabled 

SERR signal condition Multiple bit 



Fig. 4-8: "Advanced Chipset Control" submenu 

PCI Configuration 

PCI IRQ line 1 [9] 




PCI/PNP ISA UMB Region Exclusion Submenu 

PCI/PNP ISA IRQ Resource Exclusion Submenu 

Default Primary Video Adapter PCI 

ISA graphics device installed No 

Assign IRQ to PCI VGA Yes 

Fig. 4-9: "PCI Configuration" submenu 

PNP/UMB Region Exclusion 

CC00 - CFFF Available 



D800 - DBFF Available 

DC00 - DFFF Available 

Fig. 4-10: "PCI/PNP UMB Region Exclusion" submenu 




PCI/PNP ISA IRQ Resource Exclusion 









Fig. 4-11: "PCI/PNP ISA IRQ Resource Exclusion" submenu 

Keyboard Features 

NumLock Auto 

Key Click Disabled 

Keyboard auto-repeat rate 30/sec 

Keyboard auto-repeat delay ½ sec 

Fig. 4-12: "Keyboard Features" submenu 

I/O Device Configuration 

Local Bus IDE adapter Disabled 

Onboard FDC Enabled; Primary 

External FDC Disabled 

Serial port A Disabled 

Serial port B Disabled 

Serial port C Disabled 

Serial port D Disabled 

External LPT Disabled 

Legacy USB Support Disabled 

Watchdog Settings Submenu 

Fig. 4-13: "I/O Device Configuration" submenu 

Watchdog Settings 

Mode Disabled 

Fig. 4-14: "Watchdog Settings" submenu


Security 

Supervisor Password Is Clear 

User Password Is Clear 

Set Supervisor Password 

Set User Password 

Password on boot Disabled 

Fixed disk boot sector Normal 

Diskette access Supervisor 

Virus check reminder Disabled 

System backup reminder Disabled 

Fig. 4-15: "Security" menu 

Power 

Power Savings Disabled 

Idle Mode Off 

Standby Timeout Off 

Auto Suspend Timeout Off 

Hard Disk Timeout Disabled 

Video Timeout Disabled 

Resume On Time Off 

Resume Time 00:00:00 

Power Supply AT 

Fig. 4-16: "Power" menu 

Boot 

Floppy Check Disabled 

Summary Screen Disabled 

QuickBoot Mode Enabled 

Dark Boot Disabled 

Boot Device Priority Submenu 

Onboard LAN RPL ROM Disabled 

Fig. 4-17: "Boot" menu 

Removable Devices 

Hard Drive 

CD-ROM Drive 

Network Boot 

Boot Device Priority 

Fig. 4-18: "Boot Device Priority" submenu 


Rexroth BTV 20.4A NC Multifunction Card NCM02 5-1 

5 NC Multifunction Card NCM02 


5.2 Features 


The NC multifunction card is the heart of the NC CPU. Being provided 

with up to 4 SERCOS interfaces, it is responsible for drive 

communication. A flash memory is available to store machine-specific 

data, the axis resolution, the ramp curves, etc. The direct I/Os to the CNC 

are available via an Interbus master. 

Fig. 5-1: NC multifunction card 

NCM-Karte.jpg 

• PCI interface 

• Flash memory of up to 1024 kbytes 

• 4 SERCOS interfaces, each with 2/4/8/16 Mbauds Bus-master 

capability for cyclic data transmission between the SERCON 

components and the main memory. 

• 32-bit RISC communication processor, supplied with 40 MHz cycles, 

128-kB flahs EPROM, 10-kB RAM, and 2-kB dual-port RAM to the PCI 

bus. 

• 3 processor-internal serial interfaces.

5-2 NC Multifunction Card NCM02 Rexroth BTV 20.4A 

5.3 Available Versions 

The NC multifunction card is available in various component versions. 

Series 

01 Series 1 

02 Series 2 

Version 

0 Version 

SERCOS rings 

1 1 SERCOS ring 

2 2 SERCOS rings 

4 4 SERCOS rings 

Fig. 5-2: Numerical code NCM card 

+ N C M 0 2 0 2 

NCM-Nummern.AI 



5.4 Interfaces 


N C M < - > N C I O ( o p t i o n a l ) 

1 . S E R C O S R I N G F a s t I / O s 

2 . S E R C O S 

r i n g 

r e l a y c o n t a c t N C f a u l t 

3 . S E R C O S 

r i n g 

4 . S E R C O S 

r i n g 

N C P C I B U S 

Fig. 5-3: Interfaces of the NC multifunction card 

F l a s h 

M e m o r y 

S E R C O N 8 1 6 

I / O 

S E R C O N 8 1 6 

H a n d w h e e l a d a p t e r 

H a n d w h e e l 

i n t e r f a c e 

a d a p t e r 



a d a p t e r 



a d a p t e r 



a d a p t e r 

S E RR C O NN 8 1 6 

S E RR C O NN 8 1 6 

NCIO 

I/O 

NCM Schnittstellen.AI 

Note: The MTA 200 does not provide the handwheel interfaces nor 

the 4 th SERCOS ring.


5.5 Coding and Component Diagrams 

+NCM0201 

X24.1 

J2 

X25.1 

X16 

Flash 

Memory 

X23 

X29 

X2 

X9 

X17 

X27 

X6 

X28 

J10 

X26 

J3 

X21 

Fig. 5-4: NC multifunction card, with 1 SERCOS ring 

J1 

X1 

X4 

SERCON816 

J13 

1. Ring 

X30 

X11 

X13 

NCM Bestückung 1 SERCOS Ring.AI 



+NCM0202 


X24.1 

J2 

X25.1 

X16 

Flash 

Memory 

X23 

X29 

X2 

X9 

X17 

X27 

X6 

X28 

J10 

X26 

J12 

J3 

X21 

X1 

X4 

SERCON816 

SERCON816 

Fig. 5-5: NC multifunction card, with 2 SERCOS rings 

J1 

J11 

2. Ring 

J13 

1. Ring 

X30 

X3 

X11 

X13 

NCM Bestückung 2 SERCOS Ringe.AI


+NCM0204 

X24.1 

J2 

X25.1 

X16 

Flash 

Memory 

X23 

X29 

X2 

X9 

X17 

X27 

X6 

X28 

J10 

X26 

J9 

J5 

J12 

J3 

X21 

X1 

SERCON816 

SERCON816 

SERCON816 

SERCON816 

Fig. 5-6: NC multifunction card, with 4 SERCOS rings 

J1 

X4 

X7 

X10 

X12 

J8 

J4 

4. Ring 

3. Ring 

J11 

2. Ring 

J13 

1. Ring 

X30 

X3 

X8 

X11 

X13 

NCM Bestückung 4 SERCOS Ringe.AI 



5.6 Slot Brackets 

CNC Fault (X21) 


CNC fault 

X21 

Fast I/O s 

X23 

SERCOS receiver (RX) 

X25.1 

SERCOS transmitter (TX) 

X24.1 

1 2 3 

Fig. 5-7: Slot bracket of the NC multifunction card 

State display H6 



NCM-Slotwinkel.AI 

The CNC Fault contact is a relay contact which is closed via a hardware 

watchdog. It is permanently triggered by the NC operating system. In case 

of an error (hardware error, firmware error, system error, etc.), the contact 

is forced open. The CNC Fault contact can, for instance, be wired in the 

emergency stop chain of the machine. 

Contact load: 

• U = 24V 

max 

• I = 150 mA 

max


Fast I/Os (X23) 

Status Indicators 

Fast I/O signals can be connected directly to connector X23, bypassing 

the PLC. A total of 16 inputs and 16 outputs are available. The interface is 

designed as a standard Interbus-S interface. The signals must be 

connected via an Interbus-S I/O module. This can be achieved in two 

ways: 

• Internal implementation via NCIO card: 

This option provides a solution with a 37-pin Sub-D connector, that is 

compatible with the earlier BTVs (see page 5-12). 

• External implementation via Phoenix Block I/O module: 

The I/O module can also be mounted in the switch cabinet, away from 

the BTV (see page 5-15). 

SERCOS Ring H4 

LED Description 

Green Data is being received 

Yellow Data is being sent 

Red Distortion or wire break 

Fig. 5-8: Status indicators for SERCOS ring H4 

Fast I/Os H5 


Yellow 1 Peripheral error 

Yellow 2 Not used 

Yellow 3 Host error 

Fig. 5-9: Status indicators for fast I/Os H5 

Fast I/Os H6 


Green Ready for operation 

Yellow ??? 

Red Error 

Fig. 5-10: Status indicator for fast I/Os H6 



5.7 Additional SERCOS Rings 

+NCMZ003 

+NCMZ004 


The NC multifunction card provides an optical fiber connection pair for the 

first SERCOS ring. For the connection of additional SERCOS rings, the 

interface adaptors +NCMZ003 (for one additional SERCOS ring) and 

+NCMZ004 (for two additional SERCOS rings) are available. 


X25.x 


X24.x 

Fig. 5-11: Slot bracket for one additional SERCOS ring 


X25.x 


X24.x 


X25.x 


X24.x 

Fig. 5-12: Slot bracket for two additional SERCOS rings 


NCMZ1 Slotwinkel.AI 



NCMZ2 Slotwinkel.AI


X24.* Transmitter 

X25.* Receiver 

Status Indicators 

Connections 

X24.2 transmitter (TX) 2 nd SERCOS ring 

X24.3 transmitter (TX) 3 rd SERCOS ring 

X25.2 receiver (RX) 2 nd SERCOS ring 

X25.3 receiver (RX) 3 rd SERCOS ring 

SERCOS Ring H4 


Green Data is being received 

Yellow Data is being sent 

Red Distortion or wire break 

Fig. 5-13: Status indicator for SERCOS ring H4 

4. SE RCOS RING 




+NCMZ003 

+NCMZ004 

X3 X8 

Flash 

Memory 

X7 

J8 

SERCON816 

J4 J11 

Fig. 5-14: Connection of additional SERCOS rings to the NCM 

4. Ring 

SERCON816 

3. Ring 

SERCON816 

2. Ring 


J13 

SERCON816 

SERCON816 

1. Ring 

NCM SERCOS Schnittstellen.AI


NCM in the BTV20.4A 

5.8 Connection Cable 


The NC multifunction card is always inserted in slot U5 of the BTV20.4A. 

If more SERCOS rings than one are required, the slot bracket with the 

additional optical fiber components is fitted in slot U6. 

The following assignment applies: 

SERCOS rings Slot U5 Slot U6 

1 +NCM0201 Blind panel 

2 +NCM0202 +NCMZ003 

3 +NCM0204 +NCMZ004 

Fig. 5-15: Combination matrix 

Note: A maximum of 3 SERCOS rings can be used in the MTA 200. 

The SERCOS fiber optics cables connect the SERCOS interface card of 

the MTA 200 to the drives. The connection is designed as a ring, i.e. at 

least two SERCOS fiber optics cables are required, depending on the 

number of drives. 

Depending on the location of use, two different cables are use: 

• For cabling within the switch cabinet, a fiber optics cable with a 

diameter of 2.2 mm is used. 

• Outside of the switch cabinet, a sheathed fiber optics cable with a 

diameter of 6.0 mm is used to resist higher mechanical loads. 

LWL L eitung 2,2 mm 

F ib r e o p t ic c a b le 2 . 2 m m 

LWL L eitung 6,0 mm 

F ib r e o p t ic c a b le 6 . 0 m m 

Fig. 5-16: Internal and external SERCOS fiber optics cable 

Sercoskabel.AI


Cable Specifications 

5.9 NCIO Card 


Cable length: Max. 20 m 

Bending radius: Min. 50 mm 

Internal cable: Ø 2.2 mm 

External cable: Ø 6.0 mm 

ATTENTION 

⇒ The SERCOS fiber optics cable must not be kinked; 

the bending radius must not be less than 50 mm! 

You can find further information regarding the handling of fiber optics 

cables in documentation DOK-CONNEC-CABLE*LWL**-AW02-EN-P. 

The NCIO card serves for converting the bus signals of the 9-pin Sub-D 

connector on the NC multifunction card to a 37-pin Sub-D jack connector 

strip. Here, the 16 digital inputs and 16 digital outputs are applied. The 

assignment and designation of the signals are exactly the same as those 

on the MIO card of the prior controls. 

The CIO card is connected to the NCM via the connection cable IKS0031, 

which is included in the scope of delivery of the BTV20.4A if it is delivered 

with the NCIO option (…-2V-… in the type code). 

Fig. 5-17: NCIO Card 

NCIO-Karte.jpg 



Slot Bracket 

X22 I/O Interface 


I/O 

X22 

to NCM 

X23.2 

Fig. 5-18: NCIO slot bracket 

NCIO-Slotwinkel.AI 

The I/O interface of the NCIO card is provided with 16 DC-decoupled 

inputs and outputs. Design: 37-pin SUB D socket 

Pin Signal designation Type Signal 

1 GND only for port 23, bit 0 Uextern 2 Port 23, bit 0, encoder+ (24V) Input * 1 

3 Port 23, bit 1 Input * 







10 +24V input (for output signals) Uextern 11 GND (for output signals) Uextern 12 Not assigned Output 

13 Not assigned Output 






19 Not assigned Output


Pin Signal designation Type Signal 

20 Read enable Input 1 

21 Processing enable Input 1 

22 Not assigned Input 




26 Feed enable all axes Input 1 

27 EMERGENCY OFF Input 0 

28 GND (for input signals) U extern 

29 GND (for input signals) U extern 









* Input (addressable via analog-C commands; see LINPOS) 

1: Active signal level = high (1) 

0 : Active signal level = low (0) 

CAUTION 

⇒ The EMERGENCY STOP contacts must always be 

laid out as NC contacts so that they immediately 

stop all movements if a break occurs in the 

connecting cables. 

Note: Signal level: 24 V DC, +/- 10% 

Max. load per output: 80 mA 

Input current: approx. 5 mA 



Installation 


The NCIO card is always inserted in the slot UE1. The Interbus 

connection from connector X23 of the NCM module to the connector 

X23.2 of the NCIO card must be fitted externally; the cable IKB0031 is 

included in the scope of delivery of the BTV20.4A, if it is delivered with the 

NCIO option. 

0 

1 

X23.2 

UE1 UE2 

Fig. 5-19: NCIO card connection 

X22 

X16 

X2 

X20 

X9 

X90 

X100 

PC bus NC bus 

U1 U2 U3 U4 U5 U6 U7 U8 U9 U10 

5.10 Phoenix Block I/O Module ILB IB 24 DI16 DO16 

Fig. 5-20: ILB IB 24 DI16 DO16 

X7 

X23 

X25.1 

Rx 

X24.1 

Tx 

X25.2 

Rx 

X24.2 

Tx 

X64 

X60 

X15 

X5 

X16 

MTS-P 

Ansicht_Unten_BTV204_mit_Kabel.FH7 

Phoenix ILB.eps


Connection 

Signal Assignment 

The Phoenix block module can be connected via the Rexroth cable 

IKB0032. The 9-pin D-Sub connector must be connected to the NCM 

card, connector X23. The other end of the cable has free core ends which 

must be connected in connector 1 of the module as follows: 

Terminal point Allocation Comment Aderfarbe 

1.1 DO1 Receiving Green 

2.1 DO1 Receiving Yellow 

1.2 DI1 Sending Pink 

2.2 DI1 Sending Gray 

1.3 GND Reference 

potential 

Brown 

Not assigned White 

1.4, 2.4 Shield Shielding Shielding braid 

Fig. 5-21: IKB0032 pin assignment 

If this I/O assembly is used, the following signal assignment is applicable: 

Inputs: 

Terminal Signal designation IBS data bit Note 

1.1 Read enable 8 1 

1.2 Processing enable 9 1 

1.3 Set-up mode 10 

1.4 Not assigned 11 



1.7 Feed enable for all 

axes 

14 1 

1.8 Emergency stop 15 0 

1.9 Port 23, bit 0, 

encoder+ 

0 1,* 

1.10 Port 23, bit 1 1 * 

1.11 Port 23, bit 2 2 * 

1.12 Port 23, bit 3 3 * 

1.13 Port 23, bit 4 4 * 

1.14 Port 23, bit 5 5 * 

1.15 Port 23, bit 6 6 * 

1.16 Port 23, bit 7 7 * 

Fig. 5-22: Input signal assignment 




Outputs: 

Terminal Signal designation IBS data bit Note 









2.9 Spindle speed = 0 0 1 

2.10 Spindle ramps 1 1 







Fig. 5-23: Output signal assignment 

Remarks: 

*: Input can be addressed via analog-C commands (see LINPOS) 

1: Active signal level = high (1) 

0: Active signal level = low (0)



Rexroth BTV 20.4A PLC Modules MTS-P01.2 and MTS-P02.2 6-1 

6 PLC Modules MTS-P01.2 and MTS-P02.2 



The MTS-P01.2 and MTS-P02.2 PLC modules are efficient PLC controls 

in ISA bus plug-in card format, intended for being fitted in a BTV 20/30 or 

in a commercially available industrial PC. The MTS-P02.2 is equipped 

with a hardware which, contrary to the MTS-P01.2, shows a performance 

increased by a factor of 2 to 2.5 (depending on the program structure). 

The MTS-P consists of a basic unit with an ISA bus (the actual PLC) and 

an active PC/104 interface, as well as various PC/104 plug-in modules. 

These plug-in modules are, for example, field bus connections, serial 

interfaces and I/O modules. A serial COM user interface (RS232) that is 

operated via the PLC user program is available for connecting a printer, a 

read/write memory or an operation and visualization device such as the 

BTV 04/05 from Bosch Rexroth. Multimode operation of the interface 

(RS232/RS422/RS485) is configured using a PLC function module. 

In addition, the MTS-P01.2 and MTS-P02.2 are provided with a BT 

(BedienTerminal = operator terminal) bus which can be used to operate 

up to 4 operator terminals (BTM 15/16, BTA 20, etc.). This can be 

achieved using cable lengths of up to 50 m (between the interbus 

connection and the last user). 

The MTS-P0*.2 is provided with 16 TTL inputs and 16 TTL outputs. 

These can be used to, for instance, directly connect the machine function 

keys and key switches of the BTV20. 

The MTS-P module can be operated as a stand-alone PLC or, in 

connection with an MTC-P, as a slave PLC. The firmware of the PLC, 

which is stored in a flash EPROM, serves to distinguish between master 

and slave operation. 

Communication with decentralized I/O units or operating units is 

established by means of field bus connections (which can be plugged on 

as an option) and/or serial interfaces. These optional connections and 

interfaces are designed as PC/104 modules. The following are currently 

available: 

• INTERBUS master connection 

• PROFIBUS master connection 

• PROFIBUS slave connection 

Up to 4 PC/104 modules can be operated on an MTS-P01.2 or MTS- 

P02.2.

6-2 PLC Modules MTS-P01.2 and MTS-P02.2 Rexroth BTV 20.4A 

Addressing the 

MTS-P01.2 

PLC inputs for 

machine 

function keys 

BTV 20/30 

Storage battery PC/104 bus PC ISA bus 

Addressing the 

MTS-P02.2 

Fig. 6-1: MTS-P01.2 

PLC inputs for 

machine 

function keys 


Storage battery PC/104 bus PC ISA bus 

Fig. 6-2: MTS-P02.2 

PLC function connection keys 

of the BT V20 

(local I/Os) Bosch Rexroth local bus 

(not for stand alone PLCs) 

MTS-P11.FH7 

PLC function connection keys 

of the BTV 20 

(local I/Os) Bosch Rexroth local bus 

(not for stand alone PLCs) 

MTS-P12.FH7 






Status display 

X15 BT bus to connect 

up to 4 operator fields 

X16 COM interface 

DEVICE: 0 SERNR: 0 

In the PLC for 

programming the 

addresses used. 

8. 

1 6 

X15 

X5 

1 9 

X16 

MTS-P 

Fig. 6-3: Front view of MTS-P01.2 and MTS-P02.2 

X5 Watchdog: PLC ready 

PLC 

READY 

1 

2 

Contacts: 

Umax = 24V 

Imax = 150 mA 

Humidity: 75 %, non-condensing (operation) 

95 %, non-condensing (transport) 

DIN 40 040 Class F 

Atmospheric pressure: Ranging from 860 to 1080 hPa, 1500 m (operation) 

Ranging from 660 to 1080 hPa, 3500 m (transport) 

Ambient temperature during operation: Ranging from 0 to 50 °C, DIN 40 040 Class KV 

Storage temperature: from -20 °C to +70 °C 

Dimensions (W x H x D) 22 mm x 145 mm x 295 mm 

Weight: approx. 0.3 kg 

Power Supply 

X5 

MTS-P01_Anschl.FH7 

Nominal value: +5V +12V -12V 

Permissible ripple content: 50mV 120mV 120mV 

Permissible voltage range: +4.875 +11.4V to +12.6V -12.6V to -11.4V 

Max. power consumption (+5V): (MTS-P01.2) 0.6 A (+ supply voltage for PC/104 modules of up to max. 2.5 A) 

(MTS-P02.2) 1.8 A (+ supply voltage for PC/104 modules of up to max. 2.5 A) 

EMC 

Noise emittance acc. to EN 55022 Class A (industrial 

environment) 

Immunity according to IEC 1000-4-2 (ESD) Evaluation criterion B 

Immunity according to IEC 1000-4-4 (burst) Evaluation criterion B 

Data only in 

connection with 

BTV 20/30


Interfaces 

General serial interface (COM) RS232/RS422/RS485 (D-SUB, 15 pins, socket) 

BT bus Bosch Rexroth BT bus (D-SUB, 9 pins, socket) 

Optional interfaces INTERBUS (D-SUB, 9 pins, socket) 

PROFIBUS-DP (D-SUB, 9 pins, socket) 

2x RS232 and 2x RS422/485 (D-SUB, 9 pins, male connectors) 

6.3 Communication 

Communication with the Computer 

With the PC CPU as well as the operating and programming interface, 

data is exchanged via the NC CPU and the PCI/PCI bridge of the 

backplane. 

Communication with the NC Control 

The MTS-P0*.2 exchanges data with the NC CPU of the MTA200 control 

system via the NC bus in the BTV20.2A. 

PLC Inputs for the Machine Function Keys (X8) 

If the MTS-P0*.2 is used in Bosch Rexroth industrial PCs of type 

BTV 20/30, the machine function keys are directly wired onto the PLC 

assembly (X8). 

To use the machine function keys, select the ”M keys” activation through 

the WinPCL I/O configurator (see DOK-CONTRL-WINPCL*6VRS-AW01- 

EN-P). Here, the left key row is assigned to the less significant input byte, 

and the right key row to the more significant input byte. 

Connection of BTV 20 PLC Function Keys (X12) 

The MTS-P0*.2 is provided with 16 inputs and 16 outputs with TTL level. 

This allows direct connection of the machine operating keys of the BTV20 

(including the key switch). 

Addressing 

The PLC function keys, the lamps, the key switch, and the displays of the 

BTV 20 are addressed by assigning a logical user number to the inputs 

and outputs in the PLC I/O configurator. 

This results, for instance, in the following addresses: 

• 10 = logical user number of the inputs 

• 11 = logical user number of the outputs 

LK PEA4_MFK-Tast.FH7 

Fig. 6-4: Input and output addresses of PLC function keys in BTV 20 



PLC Ready (X5) 

COM Interface (X16) 

BT Bus (X15) 


The PLC Ready contact is a relay contact which is closed via a hardware 

watchdog. It is permanently triggered by the running PLC program. In 

case of an error (hardware error, firmware error, system error, etc.), the 

contact is forced open. The PLC Ready contact can, for instance, be 

wired in the emergency stop chain of the machine. 

By default, the multimode COM user interface is supplied as an RS232 

interface. The parameters for RS422/RS485 operation are set by 

programming the OPEN_COM standard PLC function block and 

assigning the COM function block input correspondingly. For more 

detailed information, please refer to the PLC programming instructions 

(DOK-CONTRL-WINPCL*6VRS-AW01-EN-P). 

The BT bus can be used to connect up to four operator panels of type 

BTM 15/16 or BTA 20. The maximum length of the BT bus may be up to 

50 m (from the connection point to the last user). This applies to the 

connection of only one device and the permissible maximum number of 4 

devices. It is not possible to directly access the I/O data of the operator 

panels from the PLC (e.g. %IBP*.*). Data is exchanged exclusively via the 

core image memory. 

The address assignments required for programming can be found in the 

corresponding documents of the devices to be connected.


Indramat 



MTS-P 

X15 

IKS 0056 BT-Bus 

IKS 0056 

BT-Bus 

Up to 2 further 

operator terminals 

in the BT-Bus 

TEMP HD POWER 

E-STOP 

Indramat 

Fig. 6-5: BT bus overview 

MASCHINE 

EIN 

MASCHINE 

AUS 

BTA 20 

BETRIEBSART 

AUTO 

START 

LOCAL 


BTM 16 

10 20 30 40 

8 50 

6 

60 

4 

70 

2 

80 

1 

100 

0 

120 

% 

75 80 85 90 

70 95 

65 

100 

60 

105 

55 

110 

50 

115 

45 

120 

% 

% 

10 20 30 40 F 

8 50 

6 

60 

4 

70 

2 

80 

1 

100 

0 

120 

ZUSTIMM- 

TASTER 

80 

- 

90 

ANSCHLUß 

HANDBEDIEN- 

GERÄT 

0 

10 

20 

70 

30 

60 

40 

50 


+ 

BT-Bus_Uebers.FH7


From 

control 


% 

10 

20 30 

40 F 

8 50 

6 

60 

4 

70 

2 

80 

1 

100 

0 

120 

% 

10 20 30 40 S 

8 50 

6 

60 

4 

70 

2 

80 

1 

100 

0 

120 

Addressing 

The BT bus is addressed by assigning a logical user number in the I/O 

editor of the PLC programming interface. Each input core image memory, 

as well as each output core image memory, is assigned its own address. 

Each of the two core image memories has a size of 128 bytes, which are 

available for the connected operating devices. The number of bytes 

assigned in the core image memory depends on the operator panel (see 

Fig. 6-6). 

Device type Memory assignment in the input/output core image 

BTM 15 Depending on the configuration 2 bytes for digital I/Os 

(always assigned) 2 additional bytes for each module 

(except handwheel) 4 additional bytes for handwheel 

module 

BTM 16 14 bytes 

BTA 20 6 bytes 

Fig. 6-6: Memory requirements of the operator panels 

Depending on the physical order of the operating devices connected to 

the BT bus, the device addresses are assigned in the input and output 

core image memory without any gaps according to the storage 

requirements of the operating devices. The example (Fig. 6-7) illustrates 

the principle of the memory assignment of the BT bus. 

BTA 20 BTM 16 

IN OUT 

Input core 

image 

memomr 

I 

Output core 

image 

memory 

Q %QB*.1 

0 

20 3040 

80 85 90 

10 

810 50 

7075 95 

90 

6 60 

65 100 

4 

70 60 

105 80 

20 

2 

80 55 

110 

1 

100 50 

115 

0 

120 45 

120 70 

30 

60 

40 

% 

% 

50 

IN OUT 

2x8 Input und 

2x8 Output 

BTM 15 

%IB*.0 

%IB*.1 

%IB*.2 

%IB*.3 

%IB*.4 

%IB*.5 

%IB*.6 

%IB*.7 

%IB*.8 

%IB*.9 

%IB*.10 

%IB*.11 

%IB*.12 

%IB*.13 

%IB*.14 

%IB*.15 

%IB*.16 

%IB*.17 

%IB*.18 

%IB*.19 

%IB*.20 

%IB*.21 

%IB*.22 

%IB*.23 

%IB*.24 

%IB*.25 

%IB*.26 

%IB*.27 

%IB*.28 

%IB*.29 

%IB*.30 

%QB*.0 

%QB*.2 

%QB*.3 

%QB*.4 

%QB*.5 

%QB*.6 

%QB*.7 

%QB*.8 

%QB*.9 

%QB*.10 

%QB*.11 

%QB*.12 

%QB*.13 

%QB*.14 

%QB*.15 

%QB*.16 

%QB*.17 

%QB*.18 

%QB*.19 

%QB*.20 

%QB*.21 

%QB*.22 

%QB*.23 

%QB*.24 

%QB*.25 

%QB*.26 

%QB*.27 

%QB*.28 

%QB*.29 

%QB*.30 

Fig. 6-7: Memory assignment in BT bus 

- 

0 

+ 

IN 

Indramat 

0 

10 20 30 40 

75 80 85 90 

90 10 

8 50 

70 95 

6 

60 

65 

100 

4 

70 

60 

105 

80 

20 

2 

80 

55 

110 

1 

100 

50 

115 

0 

120 

45 

120 70 

30 

% 

% 

60 

40 

50 

Example: 

BTM 15 assignes the addressed 6...17. 

Thereby the addressing the physical order 

of connected operating units is effected. 

%IB*.31 

%QB*.31 

%IB*.32 

. 

. 

. 

. 

. 

. 

%QB*.32 

. 

. 

. 

. 

. 

. 

- 

BT-Bus_Adress.FH7 

+


6.4 Commissioning 

Assembly 

Setting of Addresses 

O P E N 

1 2 3 4 5 6 7 8 

Plug the MTS-P module into an unoccupied ISA bus slot of your industrial 

PC. If possible, fasten the module using the supplied holder to prevent the 

card from loosening due to shocks or vibrations. In Bosch Rexroth 

BTV 20/30 devices, this is realized by means of a transverse rail to which 

the modules, including the holder provided for this purpose, are screwed 

and held down. The holder is an integral part of the configured MTS-P0*.2 

modules. 

Before the MTS-P module can be plugged in the PC, some presets must 

be made for startup; these will be explained in the following sections. 

Note: Depending on the configuration, i.e. on additional PC/104 

modules, an MTS-P assembly can require up to 5 slots in an 

industrial PC (e.g. BTV 20/30). 


Before the MTS-P module can be plugged into a Bosch Rexroth 

BTV 20/30 or an industrial PC, the addresses must be set. This is 

achieved by means of the DIP switch represented in Fig. 6-8, depending 

on the type of control (master/slave). 

OFF ON e.g., 1st MTS-P (state at delivery) 

Fig. 6-8: Position of addressing switch 

PLC module 

MTS-P01_Adress.FH7 

MTS-P0*.2 1 2 3 4 5 6 7 8 I/O address (hex) 

MTA 200 OFF OFF OFF OFF OFF OFF OFF OFF $31C 

Fig. 6-9: DIP switch configuration of MTS-P0*.2 modules 



Battery 

Data involved 

Charging the battery 

Status Information and Error Diagnosis 


If an MTS assembly is not operated or is stored for more than 6 months, 

user-specific PLC data may be lost. 

The following data are involved: 

• PLC user program 

• Residual data 

The battery is charged during commissioning of an MTS-P module. If the 

battery is completely discharged, the following charging times apply: 

Charging time: 1h -> approx. 100 h buffer time 

Charging time: 50h -> approx. 5000 h buffer time (battery fully 

charged) 

Under normal operating conditions, the battery life is 7 to 10 years. 

Continuous charging of the battery does not affect its lifetime (continuous 

control operation). 

Operating Status Display 

A diagnosis of the MTS-P0*.2 module can be made using 7-segment 

display H1. The various states are displayed via the one-digit error codes 

shown below. 

Code Meaning 

- Power-fail signal triggered (control must be reset) 

b Ready for operation (PLC is running) 

0. 0. Startup state (reset test) 

F. F. Firmware in the flash EPROM is invalid 

J. J. J. Boot lockout for firmware activated 

S System stack overflow 

P Local bus not connected 

Fig. 6-10: Operating states of MTS-P0*.2 

Note: If any other one-digit code (followed by a period) is displayed, 

customer service must be notified immediately.


Error Display 

Error states are indicated by three-digit error codes on the successively 

flashing 7-segment display. The error codes represented correspond to 

the system error messages of the user interface BOF/GBO. 

Code Meaning 

007 007 Software version error 

008 008 Self-test of control was not successful 

052 052 PLC - program invalid 

055 055 Max. cycle time of PLC exceeded 

071 071 Operating voltage of PLC too low 

081 081 2-ms implementation time exceeded 

082 082 INTERBUS failure 

083 083 INTERBUS storage overflow 

084 084 INTERBUS configuration error 

085 085 085 INTERBUS bus error 

086 086 086 INTERBUS hardware / firmware error 

087 087 INTERBUS module error of peripheral bus 

088 088 INTERBUS not ready 

089 089 INTERBUS general error of generation 4 

090 090 Profibus initialization error 

093 093 BT bus error 

Fig. 6-11: Error codes of MTS-P0*.2 

Interface Assignment 

The assignments of the interfaces of the MTS-P modules are shown in 

the tables below. 


1 NC 2 Transmit Data (RS232) 

3 Receive Data (RS232) 4 RS485+ or RxD+ (RS422) 

5 RS485- or RxD- (RS422) 6 NC 

7 GND 8 NC 

9 TxD+ (RS422) 10 GND 

11 TxD- (RS422) 12 +5V 

13 Request To Send (Modem) 14 Clear To Send (Modem) 

15 NC 

Fig. 6-12: Pin assignment for COM interface X16 


1 Data Out + 2 Data In + 

2 GND 4 NC 

5 +5V 6 Data Out - 

7 Data In - 8 NC 

9 Assignment detection 

Fig. 6-13: Pin assignment of BT BUS X15 




Pin Function 

X1.1 - X1.4 Supply voltage VCC 

X1.5 - X1.20 Input (0 - 15) 

X1.21 - X1.36 Output (0 - 15) 

X1.37 - X1.40 GND 

Fig. 6-14: Pin assignment of 40-pin I/O connector X12 


1 +5VDC 2 +5VDC 

3 S0 4 S1 

5 S2 6 S3 

7 S4 8 S5 

9 S6 10 S7 

11 S8 12 S9 

13 S10 14 S11 

15 S12 16 S13 

17 S14 18 S15 

19 GND 20 GND 

Fig. 6-15: Pin assignment for machine function keys X8


6.5 INTERBUS Master Connection 

Brief Description 

I/O address 

setting 

O 

F 

F 

1 

2 

3 

4 

5 

6 

7 

8 

OFF ON 

X8 

X9 

LK IBM 2 

INTERBUS 

module (B1) 

1 6 

X64 

1 6 

X60 

IBS- 

MASTER 

Fig. 6-16: PCB IBM2 

X64 INTERBUS diagnostics 

interface RS232 C 

X60 INTERBUS interface 

(remote bus) 

X1 

LK IBM2_Anschl.FH7 

Printed circuit board IBM 2 is an INTERBUS master connection of the 4 th 

generation in PC104 format. It can be used for the connection of simple 

sensors and actuators as well as of intelligent field devices via 

INTERBUS. The INTERBUS permits bridging of distances of up to 12.8 

km (from the connection point to the last connected remote bus user), 

divided in segments of up to 400 m. 



Setting the I/O Address 

Technical Data 


PCB IBM 2 has the following features: 

• INTERBUS protocol (DIN E 19 258), 

• up to 256 bus segments, 

• up to 16 user levels, 

• up to 512 users per configuration, 

• up to 4096 inputs and 4096 outputs per configuration (512 bytes), 

• up to 32 INTERBUS loop users per bus segment, 

• CMD G4 support. 

Configuration and commissioning of the INTERBUS is performed through 

the Interbus configurator IBS CMD G4 (see DOK-CONTRL-IBS*CMD****- 

AW...) and the I/O editor of the WinPCL programming interface (see 

DOK-CONTRL-WINPCL*6VRS-AW....). 

DIP switch S1 must be set as follows (default setting) so that PCB IBM2 

can be addressed via the PC/104 bus: 

1 2 3 4 5 6 7 8 Address 

OFF OFF ON OFF OFF ON OFF OFF 120h 

Fig. 6-17: DIP switch S1 settings 

Power supply 

Operating voltage: +5VDC, 5% / 400 mA 

Interface data 

Communication interface 2-wire remote bus, RS-422, 

without electric isolation 

Diagnosis interface RS-232-C 

Operating conditions 

Ambient temperature: 0°C - +55°C 

Humidity: -25°C - +70°C 

Atmospheric pressure: max. 75%, non-condensing




1 NC 2 TxD - Transmit Data 

3 RxD - Receive Data 4 NC 

5 SGND - Ground 6 NC 

7 RTS - Ready To Send 8 CTS - Clear To Send 

9 NC 

Fig. 6-18: Pin assignment of INTERBUS diagnostic interface X64 (RS232 C) 


1 DO 2 DI 

3 COM 4 GND 

5 +5V 6 DO 

7 DI 8 Vcc 

9 RBST 

Fig. 6-19: Pin assignment of INTERBUS interface X60 (remote bus) 



6.6 PROFIBUS DP Connection 

Brief Description of Master and Slave Connection 

Default setting of the 

I/O address $CA000 

A 19 

A 18 

A 17 

A 16 

A 15 

A 14 

A 13 

11001010 

C A 

PROFIBUS interface 

(Slave) 

IRQ 9 

A 13 

A 14 

A 15 

A 16 

A 17 

A 18 

A 19 

PROFIBUS diagnostics 


(Project interface) 


ST ER RU RD 

LK DPM01 or 

LK DPS01 

IRQ 11 

IRQ 10 

IRQ 3 

IRQ 4 

IRQ 5 

IRQ 6 

IRQ 7 

IRQ 15 

IRQ 14 

IRQ 12 

PROFIBUS-DP 

Slave module (P2) 

SCL 

1 6 

1 6 

DIAG 

RDYRUN 

ERRSTA 

PROFIBUS-DP 

Master module (P1) 

SCL 

1 6 

1 6 

DIAG 

RDY RUN 

ERRSTA 

Fig. 6-20: Profibus connections 

PROFIBUS interface 

(Master) 

PROFIBUS diagnostics 


(Project interface) 

LK DP_1_Anschl.FH7 

PCBs DPM01 (master) and DPS01 (slave) are intelligent PROFIBUS DP 

connections in PC104 format. They are used to process the protocols of 

the data transfer between the PLC and the decentralized Profibus input 

and output units. The built-in microprocessor allows automatic execution 

of the entire data transfer, thus relieving the PLC of real-time tasks. 

Data exchange between the PLC and PCBs DPM01 and DPS01 is 

implemented via an 8-kbyte dual-port memory (DPM). The DPM is a 

memory which can be simultaneously accessed by the PLC and the 

microprocessor of PCBs DPM01 and DPS01.


Setting I/O Addresses 

Configuration and commissioning of PLC DPM/DPS01 is performed by 

the system configurator SyCon (see DOK-CONTRL-SYCON****DP- 

AW......). The interface cable IKS0106 is required for configuration. 

The PROFIBUS-DP master connection PCB DPM01 permits connection 

of up to 32 PROFIBUS-DP users within one bus segment. If several bus 

segments are connected to each other via a repeater, a maximum of 125 

slaves can be operated in the maximum configuration. However, each 

repeater in use reduces the maximum number of slaves within one 

segment, with the repeater, as a passive user, not being assigned any 

user address. 

Depending on the transmission rate set in each case, line lengths of up to 

1200 m can be realized between the Profibus DP users. With a 

transmission rate of 1.5 MBaud, the line length is a maximum of 200 m, 

and with 12MBaud, a maximum of 100 m. 

Slaves with inputs of a maximum of 244 bytes and outputs of a maximum 

of 244 bytes can be connected to the master LK DPM01. The total of the 

inputs and outputs of all slaves must not exceed 512 bytes each. 

The slave PCB DPS01 must be configured such that the total of the 

inputs and/or outputs of the individual modules is a maximum of 244 

bytes each. Please make sure that the total of the inputs and outputs of 

all modules does not exceed 368 bytes. 

Note: In order to ensure proper functioning of the PROFIBUS 

interface, only cables IKB0033 / IKB0034 or cables meeting 

PROFIBUS specification RS485 (cable type A) may be used. 

The bus address is set using the jumpers of plugboard J2. The address 

line is specified next to each jumper. 

Depending on the expansion slot, the addresses must be set as follows 

(X = jumper fitted): 

Connection Address A19 A18 A17 A16 A15 A14 A13 

Master $CA000 X X X 

Slave $CC000 X X X 

Fig. 6-21: Setting the module type 



Status and Diagnosis Information 

Technical Data 


After having been switched on, the P.C.B.s DPM01 and DPS01 perform a 

self-test. After the initialization phase of this test (2 to 3 seconds), the two 

LEDs ERR and STA turn dark, and the yellow RDY LED emits light if the 

test is completed successfully. If not, the RDY LED starts flashing, and 

processing of the program is stopped. The further meanings of the 

indicators during the initialization phase are listed below. 

RDY Yellow LED Ready 

On DPM01 or DPS01 ready for operation 

Flashes cyclically Bootstrap loader active 

Flashes irregularly Hardware or system error 

Off Hardware defect 

RUN Green LED RUN (communication) 

On Communication running 

Flashes cyclically Ready for communication 

Flashes irregularly Improper configuration 

Off No Communication 

ERR Red LED Error 

On Communication interface error 

Off Communication interface OK 

STA Yellow LED Status 

On Data exchange with slaves active (master) 

Data exchange with master active (slave) 

Off No data exchange 

Power supply 

Operating voltage: +5 VDC, ±5% / 650 mA 

Interface data 

Communication interface PROFIBUS DP, max. 12 Mbaud, 

potential-free 

Diagnosis interface RS 232C, 9600 baud 

Operating conditions 

Operating temperature: 0°C - +55°C 

Storage temperature: -25°C - +70°C 

Humidity: max. 75%, non-condensing 

Fig. 6-22: Technical data for PROFIBUS DP connection



The interfaces of the Profibus connections are assigned as follows: 


1 NC 2 RxD - Receive Data 

3 TxD - Transmit Data 4 DTR - Data Terminal Ready 

5 GND - Operating ground 6 NC 

7 RTS - Ready To Send 8 CTS - Clear To Send 

9 NC 

Fig. 6-23: Pin assignment of diagnosis interface RS232C (X74, X79) 


1 RGND - Reference ground 2 NC 

3 RxD/TxD-P - Send/receive 4 NC 

5 DGND - Reference potential 6 VP - Supply voltage plus 

7 NC 8 RxD/TxD-N - Send/receive 

9 NC 

Fig. 6-24: Pin assignment of PROFIBUS interface (X70, X75) 



6.7 Connecting the Manual Operator Panel BTC 06 

X40 

X41 

RS 422 

X35 

X36 

RS 232C 

X64 

X60 

IBS- 

MASTER 


8. 

X15 

X5 

X16 

MTS-P 

The manual operator panel BTC 06 may only and exclusively be 

connected via the machine operator panels BTA 10 and BTA 20. RS232 

operation is converted to RS422 operation by the interface converter 

integrated in the BTA 10/20 (see Fig. 6-25). Furthermore, RS422 

operation with the BTC 06 is possible only using the BTA 10/20. No 

interface conversion takes place in this case, however. The interface 

connector is merely adapted to the BTC 06 connector (see Fig. 6-26). 

E-STOP 

X8 

BTA 20.3 


X9 

% 

10 20 30 40 F 

8 50 

6 

60 

4 

70 

2 

80 

1 

100 

0 

120 

RS422 

IKB0015 

MTS-P X35/36 

X8 

TxD 

RxD 

SGND 

DTR 

RTS 

BTC 06 

X35 

X36 

RxD+ 

RxD- 

SGND 

TxD+ 

TxD- 

24V 

0V 

3 

2 

5 

4 

7 

13 

12 

14 

11 

10 

2 

1 

RS232 

IKB0193 

RS232 operation either 

at X35 and/or at X36 

~ 

+24 VDC 

0VL 

RS232 

IKB193 

RS422 

IKS 190 

min. 6mm² 

central 

machine ground 

min. 6mm² 

RS422 

IKS 190 

Fig. 6-25: MTS-P with BTC 06 via RS232 interface 

X1 

4 

3 

2 

1 

2 

3 

5 

4 

7 

13 

12 

14 

11 

10 

2 

1 

RxD 

TxD 

SGND 

DTR 

RTS 

additional 

BTA 10/20 units 

10 20 40 30 

8 

50 

4 6 

60 70 

80 

2 

1 

100 

0 

120 

% 

BTA 20 

SYSTEM200 BTC06 

BTC 06 

BTA 20 

Module NA/VA 

TxD+ 

TxD- 

SGND 

RxD+ 

RxD- 

24V 

0V 

0VL +24 VDC 

MTS-P_BTC232.FH7


X40 

X41 

RS 422 

MTS-P 

X35 

X36 

RS 232C 

X64 

X60 

IBS- 

MASTER 

8. 

X15 

X5 

X16 

MTS-P 

X40 

X41 

X16 

RS422 

IKB0015 

RS422 operation either 

at X16 and/or at X40/41 

MTS-P 

OR 

BTC 06 

TxD+ 

TxD- 

SGND 

RxD+ 

RxD- 

TxD+ 

TxD- 

SGND 

RxD+ 

RxD- 

RxD+ 

RxD- 

SGND 

TxD+ 

TxD- 

24V 

0V 

RS422 

IKB0016 

9 

11 

9 

3 

5 

6 

4 

13 

12 

14 

11 

10 

2 

1 

X16 

7 

4 

5 

3 

4 

5 

1 

2 

X40/41 

INS0645 

Termination on 

~ 

+24 VDC 

0VL 

E-STOP 

RS422 

IKB0015 

RS422 

IKB0016 

X8A 

RS422 

IKS 190 

BTA 20.3 


min. 6mm² 

X9 

% 

10 20 30 40 F 

8 50 

6 

60 

4 

70 

2 

80 

1 

100 

0 

120 

INS0645 

Termination on 

central 

machine ground 

RS422 

IKB0015 

RS422 

IKS 190 

X8A 

Fig. 6-26: MTS-P with BTC 06 via RS422 interface 

1 

2 

5 

3 

4 

X1 

5 

7 

4 

3 

2 

1 

4 

9 

11 

13 

12 

14 

11 

10 

2 

1 

additional 

BTA 10/20 units 

8 10 20 30 40 50 

6 

60 

4 

70 

12 

80 100 

0 

120 

% 

SYSTEM200 BTC06 

BTC 06 

RxD+ 

RxD- 

SGND 

TxD+ 

TxD- 

BTA 20 

BTA 20 

Module NA/VA 

TxD+ 

TxD- 

SGND 

RxD+ 

RxD- 

24V 

0V 

+24 VDC 

0VL MTS-P_BTC422.FH7 



6.8 Configurations 

MTS-P0*.2-D2-B1-NN-NN-NN-FW 

17,5 

1,5 

13 

S1 

X8 

X9 


LK IBM 2 

PC/104 - expansion slot 

X64 

X60 

IBS- 

MASTER 

280 

8. 

X15 

X5 

X16 

MTS-P 

X8 

X12 


INTERBUS 

module 

140 

X7 

LK MTS11/12 

PLC 

module 

Bosch Rexroth local bus 

(only with slave PLC) 

X15 

X16 

X5 

1 2 

124 

122 

110 

0 

PLC module 

INTERBUS 

module 

MTS-P02_B1.FH7 

Fig. 6-27: Structure of MTS-P0*.2-D2-B1-NN-NN-NN-FW configurations


MTS-P0*.2-D2-P1-NN-NN-NN-FW 

17,5 

1,5 

13 

S1 

X8 

LK DPM01 

X9 

PC/104 - expansion slot 

SCL 

DIAG 

RDY RUN 

ERR STA 

280 

X15 

X5 

X8 

X12 


PROFIBUS 

module 

8. 

X16 

MTS-P 

140 

X7 

LK MTS11/12 

PLC 

module 

Bosch Rexroth local bus 

(only with slave PLC) 

X15 

X16 

X5 

1 2 

124 

122 

110 

0 

PLC module 

PROFIBUS 

module 

MTS-P02_P1.FH7 

Fig. 6-28: Structure of MTS-P0*.2-D2-P1-NN-NN-NN-FW configurations 


Rexroth BTV 20.4A Tips and Tricks 7-1 

7 Tips and Tricks 

7.1 BTV Replacement 

Hard Disk Image 


If the entire BTV, or parts thereof, must be replaced during servicing, data 

must be backed up and transferred to the new hardware. 

If the entire BTV/hard disk is to be replaced, the hard disk data must be 

backed up first. This is best done by creating a hard disk image 

(DriveImage or Ghost programs) that can then be transferred to the new 

hard disk. 

The documentation DOK-MTA200-MTGUI***V23-AW01-EN-P, chapter 9 

describes the various data backup methods, including the full backup 

using a hard disk image. 

Backup of All Hard Disk Data 

Using a network connection (one-to-one) from the BTV to a laptop, an 

image of the BTV hard disk can be created: 

• Boot the BTV under DOS with the network 

• Enable the drive and connect it to the laptop 

• Create the image 

Restoring the Hard Disk Data 

Restore the image on the new hard disk. 

Control Parameters (NCM Replacement) 

Parameters are handled by means of the Project Navigator of the MTA 

user interface. This ensures that a copy of the current parameters for the 

NCM card is always stored on the hard disk. 

After the BTV or NCM has been replaced, all you have to do is reload the 

last valid parameter set to the NCM using the "Download" function. 

Note: Before being used in the BTV 20.4A, the NCM card must be 

initialized. This initialization is carried out by the Bosch Rexroth 

Testing Division. 

For that reason, replacement cards may only be requested 

from and delivered by the Testing Division.

7-2 Tips and Tricks Rexroth BTV 20.4A 

CMOS Variables 

PLC Retain Data (PLC Replacement) 

In the BTV 20.4A, CMOS data is saved on the hard disk and is 

automatically loaded to the main memory on booting of the system. 

After the hard disk data is restored completely, the CMOS data is also 

restored in its current version. 

It is also possible to transfer CMOS data from one control to another. To 

achieve this, the NVRAM.DAT and NVRAM.DAT.BAK files in the 

D:\Programs\Indramat\Mtgui\ExternalApp\Andron\System 

must be transferred. 

If the NVRAM.DAT and NVRAM.DAT.BAK files cannot be found in the 

directory specified on booting, an error message is emitted. On 

acknowledgement of the error message, all CMOS data is re-initialized. 

Residual variables are stored on the PLC card if they are used in the PLC 

project. These variables are lost when the PLC card is replaced, firmware 

is downloaded or a new project is loaded. The retain data can be stored 

directly in the PLC programming. 

Under WinPCL, the retain data are saved with 

Start --> Variable Values 


Rexroth BTV 20.4A Index 8-1 

8 Index 


A 

Address constants 2-8 

Ambient conditions 2-15 

Analog module 1-3 

Appropriate use 

Introduction 1-4 

Uses 1-4 

Atmospheric pressure 2-15 

B 

Backlight tubes 2-16 

Battery 6-9 

BIOS settings 

Especially for MTA 200 3-3 

BT bus 6-1, 6-5 

Addressing 6-7 

BTA 10/20 2-31 

BTA 20 6-1 

BTC 06 hand-held terminal 2-30 

BTM 15/16 6-1 

BTV 20.4 inside 2-28 

BTV 20.4A 2-35 

C 

Charging times 6-9 

COM user interface 6-5 

COM1 2-24 

COM2 2-26 

Component versions 5-2 

Configuration 6-8 

Connections 2-22 

Core image storage unit 6-7 

CPU 3-1, 4-2 

D 

Dimensions 2-15 

DIP switch 6-8, 6-13 

Display unit 2-15 

DPM01 6-15 

DPS01 6-15 

Drawer keyboard 1-3 

E 

Emergency stop chain 6-5 

Error display 6-10 

Ethernet interface 2-25 

External keyboard 2-11 

F 

Fans 2-16 

Field bus connections 6-1 

Flash EPROM 6-1 

Floppy disk flap 2-4 

Lockable 2-39 

Front panel 2-15

8-2 Index Rexroth BTV 20.4A 

G 

Gateway module 1-3 

H 

Hand-held terminal 1-3 

Hardware components 

Additional 1-3 

Hardware watchdog 6-5 

Heat loss 2-15 

Housing dimensions 2-17 

Housing opening 2-10 

I 

Inappropriate use 1-5 

Consequences, Discharge of liability 1-4 

Input locale 2-12 

Insertion strip openings 2-10 

Insertion strips 2-7, 2-9 

INTERBUS loop 6-13 

INTERBUS master connection 6-1, 6-12 

INTERBUS-S 2-29 

INTERBUS-S connection 2-29 

Interface assignment 6-10, 6-18 

Internal membrane keyboard 2-13 

J 

Jumpers 6-16 

K 

Key combinations 2-6 

Key labels 2-9 

Key switch 6-1, 6-4 

Keyboard 2-15 

Keyboard driver 2-11 

Keyboard language 2-11 

Keyboard layout 2-11 

L 

LPT1 2-26 

M 

Machine function keys 2-8, 6-1, 6-4 

Machine operating keys 6-4 

Max. external magnetic field 2-15 

Max. shock 2-15 

Max. vibration 2-15 

Maximum ambient temperature 2-15 

Maximum temperature gradient 2-15 

Membrane pocket 2-10 

Memory 3-1, 4-2 

Memory module 3-9 

Mini control panel 1-3 

MTS-P01.2 6-1 

MTS-P02.2 6-1 

N 

Network connections 1-2 


Rexroth BTV 20.4A Index 8-3 


O 

OPEN_COM 6-5 

Operating displays 2-5 

Operating status display 6-9 

Operating system 2-3 

Operator terminal 6-1 

Ordering key 2-34 

P 

PC/104 interface 6-1 

PLC function keys 2-7 

Addressing 6-4 

PLC ready contact 6-5 

Plug housing 2-33 

Power consumption 2-15 

Power supply 2-15 

Printer interface 2-26 

Processor 2-15 

PROFIBUS DP connection 6-15 

PROFIBUS master connection 6-1 

PROFIBUS slave connection 6-1 

Protection class 2-15 

R 

Rear view 2-18 

RECO-Inline 1-3 

Recording measured values 1-2 

Relative humidity 2-15 

Remote bus user 6-12 

Repeater 6-16 

Reset button 2-4 

S 

Safety Instructions for Electric Drives and Controls 1-6 

Sample applications 2-29 

Scope of delivery 2-39 

SERCOS 2-32 

SERCOS interface 2-32 

SERCOS interface module 2-32 

Service interface 2-4 

Side view 2-19 

Signal level 5-14 

Slide-in strip replacement 2-10 

Slots 2-15 

SO-DIMM modules 3-9 

Stand-alone PLC 2-2 

Standard connections 2-23 

T 

Technical data 

NC CPU 4-2 

Slot CPU card 3-1 

Technical Data 2-15 

Type key 2-34 

U 

Use See appropriate use and inappropriate use 

V 

View from below 2-20

8-4 Index Rexroth BTV 20.4A 

W 

Wear parts 2-16 

Weight 2-15 

X 

X22 I/O interface 5-13 


Rexroth BTV 20.4A Service & Support 9-1 

9 Service & Support 

9.1 Helpdesk 

Unser Kundendienst-Helpdesk im Hauptwerk Lohr 

am Main steht Ihnen mit Rat und Tat zur Seite. 

Sie erreichen uns 

9.2 Service-Hotline 


Our service helpdesk at our headquarters in Lohr am 

Main, Germany can assist you in all kinds of inquiries. 

Contact us 

- telefonisch - by phone: 49 (0) 9352 40 50 60 

über Service Call Entry Center Mo-Fr 07:00-18:00 

- via Service Call Entry Center Mo-Fr 7:00 am - 6:00 pm 

- per Fax - by fax: +49 (0) 9352 40 49 41 

- per e-Mail - by e-mail: service.svc@boschrexroth.de 

Außerhalb der Helpdesk-Zeiten ist der Service 

direkt ansprechbar unter 

9.3 Internet 

After helpdesk hours, contact our service 

department directly at 

+49 (0) 171 333 88 26 

oder - or +49 (0) 172 660 04 06 

Unter www.boschrexroth.com finden Sie 

ergänzende Hinweise zu Service, Reparatur und 

Training sowie die aktuellen Adressen *) unserer 

auf den folgenden Seiten aufgeführten Vertriebsund 

Servicebüros. 

Verkaufsniederlassungen 

Niederlassungen mit Kundendienst 

Außerhalb Deutschlands nehmen Sie bitte zuerst Kontakt mit 

unserem für Sie nächstgelegenen Ansprechpartner auf. 

*) Die Angaben in der vorliegenden Dokumentation können 

seit Drucklegung überholt sein. 

At www.boschrexroth.com you may find 

additional notes about service, repairs and training 

in the Internet, as well as the actual addresses *) of 

our sales- and service facilities figuring on the 

following pages. 

sales agencies 

offices providing service 

Please contact our sales / service office in your area first. 

*) Data in the present documentation may have become 

obsolete since printing. 

9.4 Vor der Kontaktaufnahme... - Before contacting us... 

Wir können Ihnen schnell und effizient helfen wenn 

Sie folgende Informationen bereithalten: 

detaillierte Beschreibung der Störung und der 

Umstände. 

Angaben auf dem Typenschild der betreffenden 

Produkte, insbesondere Typenschlüssel und 

Seriennummern. 

Tel.-/Faxnummern und e-Mail-Adresse, unter 

denen Sie für Rückfragen zu erreichen sind. 

For quick and efficient help, please have the 

following information ready: 

1. Detailed description of the failure and 

circumstances. 

2. Information on the type plate of the affected 

products, especially type codes and serial 

numbers. 

3. Your phone/fax numbers and e-mail address, 

so we can contact you in case of questions.

9-2 Service & Support Rexroth BTV 20.4A 

9.5 Kundenbetreuungsstellen - Sales & Service Facilities 

Deutschland - Germany vom Ausland: (0) nach Landeskennziffer weglassen! 

from abroad: don’t dial (0) after country code! 

Vertriebsgebiet Mitte 

Germany Centre 

Rexroth Indramat GmbH 

Bgm.-Dr.-Nebel-Str. 2 / Postf. 1357 

97816 Lohr am Main / 97803 Lohr 

Kompetenz-Zentrum Europa 

Tel.: +49 (0)9352 40-0 

Fax: +49 (0)9352 40-4885 

Vertriebsgebiet Süd 

Germany South 


Landshuter Allee 8-10 

80637 München 

Tel.: +49 (0)89 127 14-0 

Fax: +49 (0)89 127 14-490 

Vertriebsgebiet Nord 

Germany North 


Walsroder Str. 93 

30853 Langenhagen 

Tel.: +49 (0) 511 72 66 57-0 

Service: +49 (0) 511 72 66 57-256 

Fax: +49 (0) 511 72 66 57-93 

Service: +49 (0) 511 72 66 57-783 

SERVICE 

CALL ENTRY CENTER 

MO – FR 

von 07:00 - 18:00 Uhr 

from 7 am – 6 pm 

Tel. +49 (0) 9352 40 50 60 

service.svc@boschrexroth.de 

Vertriebsgebiet West 

Germany West 


Regionalzentrum West 

Borsigstrasse 15 

40880 Ratingen 

Tel.: +49 (0)2102 409-0 

Fax: +49 (0)2102 409-406 

+49 (0)2102 409-430 

Vertriebsgebiet Mitte 

Germany Centre 


Regionalzentrum Mitte 

Waldecker Straße 13 

64546 Mörfelden-Walldorf 

Tel.: +49 (0) 61 05 702-3 

Fax: +49 (0) 61 05 702-444 

SERVICE 

HOTLINE 

MO – FR 

von 17:00 - 07:00 Uhr 

from 5 pm - 7 am 

+ SA / SO 

Tel.: +49 (0)172 660 04 06 

oder / or 

Tel.: +49 (0)171 333 88 26 

Gebiet Südwest 

Germany South-West 


Service-Regionalzentrum Süd-West 

Siemensstr.1 

70736 Fellbach 

Tel.: +49 (0)711 51046–0 

Fax: +49 (0)711 51046–248 

Vertriebsgebiet Ost 

Germany East 


Beckerstraße 31 

09120 Chemnitz 

Tel.: +49 (0)371 35 55-0 

Fax: +49 (0)371 35 55-333 

SERVICE 

ERSATZTEILE / SPARES 

verlängerte Ansprechzeit 

- extended office time - 

♦ nur an Werktagen 

- only on working days - 

♦ von 07:00 - 18:00 Uhr 

- from 7 am - 6 pm - 

Tel. +49 (0) 9352 40 42 22 

Vertriebsgebiet Ost 

Germany East 


Regionalzentrum Ost 

Walter-Köhn-Str. 4d 

04356 Leipzig 

Tel.: +49 (0)341 25 61-0 

Fax: +49 (0)341 25 61-111 



Europa (West) - Europe (West) 

Austria - Österreich 

Bosch Rexroth GmbH 

Electric Drives & Controls 

Stachegasse 13 

1120 Wien 

Tel.: +43 (0)1 985 25 40 

Fax: +43 (0)1 985 25 40-93 

Great Britain – Großbritannien 

Bosch Rexroth Ltd. 


Broadway Lane, South Cerney 

Cirencester, Glos GL7 5UH 

Tel.: +44 (0)1285 863000 

Fax: +44 (0)1285 863030 

sales@boschrexroth.co.uk 

service@boschrexroth.co.uk 

France – Frankreich 

Bosch Rexroth SAS 


91, Bd. Irène Joliot-Curie 

69634 Vénissieux – Cedex 

Tel.: +33 (0)4 78 78 53 65 

Fax: +33 (0)4 78 78 53 62 

Italy - Italien 

Bosch Rexroth S.p.A. 

Via del Progresso, 16 (Zona Ind.) 

35020 Padova 

Tel.: +39 049 8 70 13 70 

Fax: +39 049 8 70 13 77 

Norway - Norwegen 

Bosch Rexroth AS 


Berghagan 1 or: Box 3007 

1405 Ski-Langhus 1402 Ski 

Tel.: +47 (0) 64 86 41 00 

Fax: +47 (0) 64 86 90 62 

Hotline: +47 (0)64 86 94 82 

jul.ruud@rexroth.no 

Sweden - Schweden 

Bosch Rexroth AB 


Ekvändan 7 

254 67 Helsingborg 

Tel.: +46 (0) 42 38 88 -50 

Fax: +46 (0) 42 38 88 -74 


vom Ausland: (0) nach Landeskennziffer weglassen, Italien: 0 nach Landeskennziffer mitwählen 

from abroad: don’t dial (0) after country code, Italy: dial 0 after country code 

Austria – Österreich 

Bosch Rexroth GmbH 


Industriepark 18 

4061 Pasching 

Tel.: +43 (0)7221 605-0 

Fax: +43 (0)7221 605-21 

Finland - Finnland 

Bosch Rexroth Oy 


Ansatie 6 

017 40 Vantaa 

Tel.: +358 (0)9 84 91-11 

Fax: +358 (0)9 84 91-13 60 



Via G. Di Vittorio, 1 

20063 Cernusco S/N.MI 

Hotline: +39 02 92 365 563 

Tel.: +39 02 92 365 1 

Service: +39 02 92 365 326 

Fax: +39 02 92 365 500 

Service: +39 02 92 365 503 



Via Isonzo, 61 

40033 Casalecchio di Reno (Bo) 

Tel.: +39 051 29 86 430 

Fax: +39 051 29 86 490 

Spain - Spanien 

Bosch Rexroth S.A. 


Centro Industrial Santiga 

Obradors s/n 

08130 Santa Perpetua de Mogoda 

Barcelona 

Tel.: +34 9 37 47 94 00 

Fax: +34 9 37 47 94 01 

Switzerland East - Schweiz Ost 

Bosch Rexroth Schweiz AG 


Hemrietstrasse 2 

8863 Buttikon 

Tel. +41 (0) 55 46 46 111 

Fax +41 (0) 55 46 46 222 

Belgium - Belgien 

Bosch Rexroth NV/SA 

Henri Genessestraat 1 

1070 Bruxelles 

Tel: +32 (0) 2 582 31 80 

Fax: +32 (0) 2 582 43 10 

info@boschrexroth.be 

service@boschrexroth.be 

France - Frankreich 



Avenue de la Trentaine 

(BP. 74) 

77503 Chelles Cedex 

Tel.: +33 (0)164 72-70 00 

Fax: +33 (0)164 72-63 00 

Hotline: +33 (0)608 33 43 28 



Via Paolo Veronesi, 250 

10148 Torino 

Tel.: +39 011 224 88 11 

Fax: +39 011 224 88 30 

Netherlands - Niederlande/Holland 

Bosch Rexroth Services B.V. 

Technical Services 

Kruisbroeksestraat 1 

(P.O. Box 32) 

5281 RV Boxtel 

Tel.: +31 (0) 411 65 16 40 

+31 (0) 411 65 17 27 

Fax: +31 (0) 411 67 78 14 

+31 (0) 411 68 28 60 

services@boschrexroth.nl 

Spain – Spanien 

Goimendi S.A. 


Parque Empresarial Zuatzu 

C/ Francisco Grandmontagne no.2 

20018 San Sebastian 

Tel.: +34 9 43 31 84 21 

- service: +34 9 43 31 84 56 

Fax: +34 9 43 31 84 27 

- service: +34 9 43 31 84 60 

sat.indramat@goimendi.es 

Switzerland West - Schweiz West 

Bosch Rexroth Suisse SA 

Av. Général Guisan 26 

1800 Vevey 1 

Tel.: +41 (0)21 632 84 20 

Fax: +41 (0)21 632 84 21 

Denmark - Dänemark 

BEC A/S 

Zinkvej 6 

8900 Randers 

Tel.: +45 (0)87 11 90 60 

Fax: +45 (0)87 11 90 61 

France - Frankreich 



ZI de Thibaud, 20 bd. Thibaud 

(BP. 1751) 

31084 Toulouse 

Tel.: +33 (0)5 61 43 61 87 

Fax: +33 (0)5 61 43 94 12 



Via Mascia, 1 

80053 Castellamare di Stabia NA 

Tel.: +39 081 8 71 57 00 

Fax: +39 081 8 71 68 85 

Netherlands – Niederlande/Holland 

Bosch Rexroth B.V. 

Kruisbroeksestraat 1 

(P.O. Box 32) 

5281 RV Boxtel 

Tel.: +31 (0) 411 65 19 51 

Fax: +31 (0) 411 65 14 83 

www.boschrexroth.nl 

Sweden - Schweden 

Bosch Rexroth AB 


- Varuvägen 7 

(Service: Konsumentvägen 4, Älfsjö) 

125 81 Stockholm 

Tel.: +46 (0)8 727 92 00 

Fax: +46 (0)8 647 32 77


Europa (Ost) - Europe (East) 

Czech Republic - Tschechien 

Bosch -Rexroth, spol.s.r.o. 

Hviezdoslavova 5 

627 00 Brno 

Tel.: +420 (0)5 48 126 358 

Fax: +420 (0)5 48 126 112 

Poland – Polen 

Bosch Rexroth Sp.zo.o. 

Biuro Poznan 

ul. Dabrowskiego 81/85 

60-529 Poznan 

Tel.: +48 061 847 64 62 /-63 

Fax: +48 061 847 64 02 

Russia - Russland 

ELMIS 

10, Internationalnaya 

246640 Gomel, Belarus 

Tel.: +375/ 232 53 42 70 

+375/ 232 53 21 69 

Fax: +375/ 232 53 37 69 

elmis_ltd@yahoo.com 

Czech Republic - Tschechien 

DEL a.s. 

Strojírenská 38 

591 01 Zdar nad Sázavou 

Tel.: +420 566 64 3144 

Fax: +420 566 62 1657 

Romania - Rumänien 

East Electric S.R.L. 

Bdul Basarabia no.250, sector 3 

73429 Bucuresti 

Tel./Fax:: +40 (0)21 255 35 07 

+40 (0)21 255 77 13 

Fax: +40 (0)21 725 61 21 

eastel@rdsnet.ro 

Turkey - Türkei 

Bosch Rexroth Otomasyon 

San & Tic. A..S. 

Fevzi Cakmak Cad No. 3 

34630 Sefaköy Istanbul 

Tel.: +90 212 413 34 00 

Fax: +90 212 413 34 17 

www.boschrexroth.com.tr 

vom Ausland: (0) nach Landeskennziffer weglassen 

from abroad: don’t dial (0) after country code 

Hungary - Ungarn 

Bosch Rexroth Kft. 

Angol utca 34 

1149 Budapest 

Tel.: +36 (1) 422 3200 

Fax: +36 (1) 422 3201 

Romania - Rumänien 


Str. Drobety nr. 4-10, app. 14 

70258 Bucuresti, Sector 2 

Tel.: +40 (0)1 210 48 25 

+40 (0)1 210 29 50 

Fax: +40 (0)1 210 29 52 

Turkey - Türkei 

Servo Kontrol Ltd. Sti. 

Perpa Ticaret Merkezi B Blok 

Kat: 11 No: 1609 

80270 Okmeydani-Istanbul 

Tel: +90 212 320 30 80 

Fax: +90 212 320 30 81 

remzi.sali@servokontrol.com 

www.servokontrol.com 

Poland – Polen 


ul. Staszica 1 

05-800 Pruszków 

Tel.: +48 22 738 18 00 

– service: +48 22 738 18 46 

Fax: +48 22 758 87 35 

– service: +48 22 738 18 42 

Russia - Russland 

Bosch Rexroth OOO 

Wjatskaja ul. 27/15 

127015 Moskau 

Tel.: +7-095-785 74 78 

+7-095 785 74 79 

Fax: +7 095 785 74 77 

laura.kanina@boschrexroth.ru 

Slowenia - Slowenien 

DOMEL 

Otoki 21 

64 228 Zelezniki 

Tel.: +386 5 5117 152 

Fax: +386 5 5117 225 

brane.ozebek@domel.si 



Africa, Asia, Australia – incl. Pacific Rim 

Australia - Australien 

AIMS - Australian Industrial 

Machinery Services Pty. Ltd. 

28 Westside Drive 

Laverton North Vic 3026 

Melbourne 

Tel.: +61 3 93 14 3321 

Fax: +61 3 93 14 3329 

Hotlines: +61 3 93 14 3321 

+61 4 19 369 195 

enquires@aimservices.com.au 

China 

Bosch Rexroth China Ltd. 

15/F China World Trade Center 

1, Jianguomenwai Avenue 

Beijing 100004, P.R.China 

Tel.: +86 10 65 05 03 80 

Fax: +86 10 65 05 03 79 

Hongkong 

Bosch Rexroth (China) Ltd. 

6 th Floor, 

Yeung Yiu Chung No.6 Ind Bldg. 

19 Cheung Shun Street 

Cheung Sha Wan, 

Kowloon, Hongkong 

Tel.: +852 22 62 51 00 

Fax: +852 27 41 33 44 

alexis.siu@boschrexroth.com.hk 

Indonesia - Indonesien 

PT. Bosch Rexroth 

Building # 202, Cilandak 

Commercial Estate 

Jl. Cilandak KKO, Jakarta 12560 

Tel.: +62 21 7891169 (5 lines) 

Fax: +62 21 7891170 - 71 

rudy.karimun@boschrexroth.co.id 

Korea 

Bosch Rexroth-Korea Ltd. 

1515-14 Dadae-Dong, Saha-gu 


Pusan Metropolitan City, 604-050 

Tel.: +82 51 26 00 741 

Fax: +82 51 26 00 747 

eunkyong.kim@boschrexroth.co.kr 

Taiwan 

Bosch Rexroth Co., Ltd. 

Taichung Branch 

1F., No. 29, Fu-Ann 5th Street, 

Xi-Tun Area, Taichung City 

Taiwan, R.O.C. 

Tel : +886 - 4 -23580400 

Fax: +886 - 4 -23580402 

jim.lin@boschrexroth.com.tw 

david.lai@boschrexroth.com.tw 


Australia - Australien 

Bosch Rexroth Pty. Ltd. 

No. 7, Endeavour Way 

Braeside Victoria, 31 95 

Melbourne 

Tel.: +61 3 95 80 39 33 

Fax: +61 3 95 80 17 33 

mel@rexroth.com.au 

China 

Bosch Rexroth China Ltd. 

Guangzhou Repres. Office 

Room 1014-1016, Metro Plaza, 

Tian He District, 183 Tian He Bei Rd 

Guangzhou 510075, P.R.China 

Tel.: +86 20 8755-0030 

+86 20 8755-0011 

Fax: +86 20 8755-2387 

India - Indien 

Bosch Rexroth (India) Ltd. 


Plot. No.96, Phase III 

Peenya Industrial Area 

Bangalore – 560058 

Tel.: +91 80 51 17 0-211...-218 

Fax: +91 80 83 94 345 

+91 80 83 97 374 

mohanvelu.t@boschrexroth.co.in 

Japan 

Bosch Rexroth Automation Corp. 

Service Center Japan 

Yutakagaoka 1810, Meito-ku, 

NAGOYA 465-0035, Japan 

Tel.: +81 52 777 88 41 

+81 52 777 88 53 

+81 52 777 88 79 

Fax: +81 52 777 89 01 

Malaysia 

Bosch Rexroth Sdn.Bhd. 

11, Jalan U8/82, Seksyen U8 

40150 Shah Alam 

Selangor, Malaysia 

Tel.: +60 3 78 44 80 00 

Fax: +60 3 78 45 48 00 

hockhwa@hotmail.com 

rexroth1@tm.net.my 

Taiwan 

Bosch Rexroth Co., Ltd. 

Tainan Branch 

No. 17, Alley 24, Lane 737 

Chung Cheng N.Rd. Yungkang 

Tainan Hsien, Taiwan, R.O.C. 

Tel : +886 - 6 –253 6565 

Fax: +886 - 6 –253 4754 

charlie.chen@boschrexroth.com.tw 

China 

Shanghai Bosch Rexroth 

Hydraulics & Automation Ltd. 

Waigaoqiao, Free Trade Zone 

No.122, Fu Te Dong Yi Road 

Shanghai 200131 - P.R.China 

Tel.: +86 21 58 66 30 30 

Fax: +86 21 58 66 55 23 

richard.yang_sh@boschrexroth.com.cn 

gf.zhu_sh@boschrexroth.com.cn 

China 

Bosch Rexroth (China) Ltd. 

A-5F., 123 Lian Shan Street 

Sha He Kou District 

Dalian 116 023, P.R.China 

Tel.: +86 411 46 78 930 

Fax: +86 411 46 78 932 




Advance House, II Floor 

Ark Industrial Compound 

Narol Naka, Makwana Road 

Andheri (East), Mumbai - 400 059 

Tel.: +91 22 28 56 32 90 

+91 22 28 56 33 18 

Fax: +91 22 28 56 32 93 

singh.op@boschrexroth.co.in 

Japan 

Bosch Rexroth Automation Corp. 


2F, I.R. Building 

Nakamachidai 4-26-44, Tsuzuki-ku 

YOKOHAMA 224-0041, Japan 

Tel.: +81 45 942 72 10 

Fax: +81 45 942 03 41 

Singapore - Singapur 

Bosch Rexroth Pte Ltd 

15D Tuas Road 

Singapore 638520 

Tel.: +65 68 61 87 33 

Fax: +65 68 61 18 25 

sanjay.nemade 

@boschrexroth.com.sg 

Thailand 

NC Advance Technology Co. Ltd. 

59/76 Moo 9 

Ramintra road 34 

Tharang, Bangkhen, 

Bangkok 10230 

Tel.: +66 2 943 70 62 

+66 2 943 71 21 

Fax: +66 2 509 23 62 

Hotline +66 1 984 61 52 

sonkawin@hotmail.com 

China 

Shanghai Bosch Rexroth 

Hydraulics & Automation Ltd. 

4/f, Marine Tower 

No.1, Pudong Avenue 

Shanghai 200120 - P.R.China 

Tel: +86 21 68 86 15 88 

Fax: +86 21 58 40 65 77 

China 

Melchers GmbH 

BRC-SE, Tightening & Press-fit 

13 Floor Est Ocean Centre 

No.588 Yanan Rd. East 

65 Yanan Rd. West 

Shanghai 200001 

Tel.: +86 21 6352 8848 

Fax: +86 21 6351 3138 



S-10, Green Park Extension 

New Delhi – 110016 

Tel.: +91 11 26 56 65 25 

+91 11 26 56 65 27 

Fax: +91 11 26 56 68 87 

koul.rp@boschrexroth.co.in 

Korea 

Bosch Rexroth-Korea Ltd. 

Electric Drives and Controls 

Bongwoo Bldg. 7FL, 31-7, 1Ga 

Jangchoong-dong, Jung-gu 

Seoul, 100-391 

Tel.: +82 234 061 813 

Fax: +82 222 641 295 

South Africa - Südafrika 

TECTRA Automation (Pty) Ltd. 

71 Watt Street, Meadowdale 

Edenvale 1609 

Tel.: +27 11 971 94 00 

Fax: +27 11 971 94 40 

Hotline: +27 82 903 29 23 

georgv@tectra.co.za


Nordamerika – North America 

USA 

Headquarters - Hauptniederlassung 

Bosch Rexroth Corporation 


5150 Prairie Stone Parkway 

Hoffman Estates, IL 60192-3707 

Tel.: +1 847 6 45 36 00 

Fax: +1 847 6 45 62 01 

servicebrc@boschrexroth-us.com 

repairbrc@boschrexroth-us.com 

USA East Region – Ost 



Charlotte Regional Sales Office 

14001 South Lakes Drive 

Charlotte, North Carolina 28273 

Tel.: +1 704 5 83 97 62 

+1 704 5 83 14 86 

Canada East - Kanada Ost 

Bosch Rexroth Canada Corporation 

Burlington Division 

3426 Mainway Drive 

Burlington, Ontario 

Canada L7M 1A8 

Tel.: +1 905 335 5511 

Fax: +1 905 335 4184 

Hotline: +1 905 335 5511 

michael.moro@boschrexroth.ca 

USA Central Region - Mitte 



Central Region Technical Center 

1701 Harmon Road 

Auburn Hills, MI 48326 

Tel.: +1 248 3 93 33 30 

Fax: +1 248 3 93 29 06 

USA Northeast Region – Nordost 



Northeastern Technical Center 

99 Rainbow Road 

East Granby, Connecticut 06026 

Tel.: +1 860 8 44 83 77 

Fax: +1 860 8 44 85 95 

Canada West - Kanada West 

Bosch Rexroth Canada Corporation 

5345 Goring St. 

Burnaby, British Columbia 

Canada V7J 1R1 

Tel. +1 604 205 5777 

Fax +1 604 205 6944 

Hotline: +1 604 205 5777 

david.gunby@boschrexroth.ca 

Südamerika – South America 

Argentina - Argentinien 

Bosch Rexroth S.A.I.C. 

"The Drive & Control Company" 

Rosario 2302 

B1606DLD Carapachay 

Provincia de Buenos Aires 

Tel.: +54 11 4756 01 40 

+54 11 4756 02 40 

+54 11 4756 03 40 

+54 11 4756 04 40 

Fax: +54 11 4756 01 36 

+54 11 4721 91 53 

victor.jabif@boschrexroth.com.ar 

Columbia - Kolumbien 

Reflutec de Colombia Ltda. 

Calle 37 No. 22-31 

Santafé de Bogotá, D.C. 

Colombia 

Tel.: +57 1 368 82 67 

+57 1 368 02 59 

Fax: +57 1 268 97 37 

reflutec@neutel.com.co 

reflutec@007mundo.com 

Argentina - Argentinien 

NAKASE 

Servicio Tecnico CNC 

Calle 49, No. 5764/66 

B1653AOX Villa Balester 

Provincia de Buenos Aires 

Tel.: +54 11 4768 36 43 

Fax: +54 11 4768 24 13 

Hotline: +54 11 155 307 6781 

nakase@usa.net 

nakase@nakase.com 

gerencia@nakase.com (Service) 

USA Southeast Region - Südwest 



Southeastern Technical Center 

3625 Swiftwater Park Drive 

Suwanee, Georgia 30124 

Tel.: +1 770 9 32 32 00 

Fax: +1 770 9 32 19 03 

USA West Region – West 


7901 Stoneridge Drive, Suite 220 

Pleasant Hill, California 94588 

Tel.: +1 925 227 10 84 

Fax: +1 925 227 10 81 

Mexico 

Bosch Rexroth Mexico S.A. de C.V. 

Calle Neptuno 72 

Unidad Ind. Vallejo 

07700 Mexico, D.F. 

Tel.: +52 55 57 54 17 11 

Fax: +52 55 57 54 50 73 

mariofelipe.hernandez@boschrexroth.com.m 

x 

Brazil - Brasilien 

Bosch Rexroth Ltda. 

Av. Tégula, 888 

Ponte Alta, Atibaia SP 

CEP 12942-440 

Tel.: +55 11 4414 56 92 

+55 11 4414 56 84 

Fax sales: +55 11 4414 57 07 

Fax serv.: +55 11 4414 56 86 

alexandre.wittwer@rexroth.com.br 

USA SERVICE-HOTLINE 

Mexico 

- 7 days x 24hrs - 

+1-800-REX-ROTH 

+1 800 739 7684 

Bosch Rexroth S.A. de C.V. 

Calle Argentina No 3913 

Fracc. las Torres 

64930 Monterrey, N.L. 

Tel.: +52 81 83 65 22 53 

+52 81 83 65 89 11 

+52 81 83 49 80 91 

Fax: +52 81 83 65 52 80 

mario.quiroga@boschrexroth.com.mx 

Brazil - Brasilien 

Bosch Rexroth Ltda. 

R. Dr.Humberto Pinheiro Vieira, 100 

Distrito Industrial [Caixa Postal 1273] 

89220-390 Joinville - SC 

Tel./Fax: +55 47 473 58 33 

Mobil: +55 47 9974 6645 

prochnow@zaz.com.br 



Notes 


R911307076 


Electric Drives and Controls 

P.O. Box 13 57 

97803 Lohr, Germany 

Bgm.-Dr.-Nebel-Str. 2 

97816 Lohr, Germany 

Phone +49 (0)93 52-40-50 60 

Fax +49 (0)93 52-40-49 41 

service.svc@boschrexroth.de 

www.boschrexroth.com 

Printed in Germany

Rexroth MTA 200 Rexroth BTV 20.4A - Nuova Elva

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