Bosch Rexroth MAD100, Operating Instructions Manual

Page 1: ...MAD MAF Asynchronous Housing Motors Operating Instructions R911336186 Edition 02 ...

Page 2: ...l as in the event of applications for industrial prop erty rights Legal validity The data in this document are intended solely for product description purpo ses and are not intended to be understood as assured characteristics in legal terms We reserve the right to modify the contents of the documentation and sup plies of the products Published by Bosch Rexroth AG Dept DC AE EPI5 fs mb Bgm Dr Nebel...

Page 3: ... d entraînement coupez toujours la tension d alimentation Tenez compte des délais de décharge de condensateurs Gefahrbringende Bewegungen Lebensgefahr Halten Sie sich nicht im Bewegungsbereich von Maschinen und Maschinenteilen auf Verhindern Sie den unbeabsichtigten Zutritt für Personen Bringen Sie vor dem Zugriff oder Zutritt in den Gefahrenbereich die Antriebe sicher zum Stillstand Dangerous mov...

Page 4: ...roth Apenas pessoal qualificado pode trabalhar nos componentes de acionamento Explicações mais detalhadas relativamente às instruções de segurança constam no capítulo 1 desta documentação Pericolo di morte in caso di inosservanza delle seguenti indicazioni di sicurezza Mettere in funzione i prodotti solo dopo aver letto compreso e osservato per intero la documentazione e le indicazioni di sicurezz...

Page 5: ...o e de queimaduras com ácido Não desmonte nem danifique as baterias Não deite as baterias no fogo Utilizzo inappropriato delle batterie Pericolo di lesioni Non tentare di riattivare o ricaricare batterie scariche pericolo di esplosione e corrosione Non scomporre o danneggiare le batterie Non gettare le batterie nel fuoco Svenska Dansk Nederlands Livsfara om följande säkerhetsanvisningar inte följs...

Page 6: ...en arts Varma ytor 60 C Risk för brännskador Undvik att vidröra metallytor t ex kylelement Var medveten om att det tar tid för drivkomponenterna att svalna minst 15 minuter Varme overflader 60 C Risiko for forbrændinger Undgå at berøre metaloverflader f eks køleelementer Overhold drive components nedkølingstid min 15 min Hete oppervlakken 60 C Verbrandingsgevaar Voorkom contact met metalen oppervl...

Page 7: ...a při zasažení elektrickým proudem Komponenty pohonu smí být v provozu pouze s pevně nainstalovaným ochranným vodičem Než začnete zasahovat do komponent pohonu odpojte je od elektrického napájení Dodržujte vybíjecí časy kondenzátorů Vaarallisia liikkeitä Hengenvaara Älä oleskele koneiden tai koneenosien liikealueella Pidä huolta siitä ettei muita henkilöitä pääse alueelle vahingossa Pysäytä käyttö...

Page 8: ...a kvalifikovaný personál Bližšie vysvetlenia k bezpečnostným pokynom zistite z kapitoly 1 tejto dokumentácie Pericol de moarte în cazul nerespectării următoarelor instrucţiuni de siguranţă Punerea în funcţiune a produselor trebuie efectuată după citirea înţelegerea şi respectarea documentelor şi instrucţiunilor de siguranţă care sunt livrate împreună cu produsele În cazul în care documentele nu su...

Page 9: ...orespunzătoare a bateriilor Pericol de vătămare Nu încercaţi să reactivaţi sau să încărcaţi bateriile goale pericol de explozie şi pericol de arsuri Nu dezasamblaţi şi nu deterioraţi bateriile Nu aruncaţi bateriile în foc Magyar Български Latviski Az alábbi biztonsági útmutatások figyelmen kívül hagyása életveszélyes helyzethez vezethet Üzembe helyezés előtt olvassa el értelmezze és vegye figyelem...

Page 10: ...lületek 60 C Égésveszély Ne érjen hozzá fémfelületekhez pl hűtőtestekhez Vegye figyelembe a hajtás alkatrészeinek kihűlési idejét min 15 perc Горещи повърхности 60 C Опасност от изгаряне Не докосвайте метални повърхности например радиатори Съблюдавайте времето на охлаждане на задвижващите компоненти мин 15 минути Karstas virsmas 60 C Apdedzināšanās risks Neskarieties pie metāliskām virsmām piemēra...

Page 11: ...φοδοσία των στοιχείων μετάδοσης κίνησης Λάβετε υπόψη τους χρόνους αποφόρτισης των πυκνωτών Pavojingi judesiai Pavojus gyvybei Nebūkite mašinų ar jų dalių judėjimo zonoje Neleiskite netyčia patekti asmenims Prieš patekdami į pavojaus zoną saugiai išjunkite pavaras Ohtlikud liikumised Eluohtlik Ärge viibige masina ja masinaosade liikumispiirkonnas Tõkestage inimeste ettekavatsematu sisenemine masina...

Page 12: ...sitsemine Vigastusoht Ärge üritage kunagi tühje patareisid reaktiveerida või täis laadida plahvatus ja söövitusoht Ärge demonteerige ega kahjustage patareisid Ärge visake patareisid tulle Ακατάλληλος χειρισμός μπαταριών Κίνδυνος τραυματισμού Μην επιδιώκετε να ενεργοποιήσετε ξανά ή να φορτίσετε κενές μπαταρίες κίνδυνος έκρηξης και διάβρωσης Μην διαλύετε ή καταστρέφετε τις μπαταρίες Μην απορρίπτετε ...

Page 13: ...etic and electromagnetic fields 5 2 6 4 Protection against burns 5 3 Scope of delivery 7 4 About this product 9 4 1 Product description 9 4 1 1 Technical features 9 4 1 2 Frame size 9 4 1 3 Type of protection 10 4 1 4 Output shaft 10 4 1 5 Bearings 11 4 1 6 Cooling 11 4 2 Product identification 12 4 2 1 Type code 12 4 2 2 Type plate example MAF100 14 5 Transport and storage 15 5 1 Notes about tran...

Page 14: ...ervicing 37 8 2 Service repair maintenance and spare parts 38 9 Disassembly and exchange 39 9 1 Tools required 39 9 2 Preparing storage 39 10 Environmental protection and disposal 41 10 1 Environmental protection 41 10 2 Disposal 41 11 Extension and modification 43 11 1 Optional accessories 43 11 1 1 Ready made connection cables 43 11 1 2 Air pressure connection 43 11 1 3 Gearboxes 43 12 Troublesh...

Page 15: ...MAF Project Planning Manual DOK MOTOR MAD MAF PR P Rexroth Connection Cable Selection Data DOK CONNEC CABLE INDRV AU P Tab 1 2 Additional documentation 1 4 Information presentation Safety instructions The safety instructions in this documentation describe signal words danger warning caution note and a signal symbol acc to ANSI Z535 6 2006 dan ger warning caution note The signal word is intended to...

Page 16: ...dling step 1 2 3 Numbered instruction The numbers show that the action steps must be taken one after the other Warning against dangerous electric voltage Warning against hot surfaces Warning against rotating machine parts Warning against overhead load Electrostatic sensitive devices Access for persons with cardiac pacemaker forbidden Do not carry along metal parts or clocks Hammer scales are forbi...

Page 17: ...c installation must comply with the protection requirements of the EMC Directive 2004 108 EC The plant manufacturer is responsible for ap propriate installation for example physical separation of signal and power cables using shielded cables The EMC instructions of the converter manufacturer must be observed Start up is prohibited as long as the conformity with these directives is de clared 2 3 Un...

Page 18: ...d elec tricians Tools for electricians VDE tools are absolutely necessary Before working 1 Enable 2 Secure against reactivation 3 Ensure de energization 4 Ground and short circuit 5 Cover or shield any adjacent live parts After completing the job cancel the measures in reverse order Dangerous voltage occurs during operation Danger to life risk of injury by electric shock Before start up connect th...

Page 19: ...direct envi ronment of motor components Persons with heart pacemakers and metallic implants are not allowed to approach or handle these motor components Crushing hazard of fingers and hands due to strong attractive forces of the magnets Handle only with protective gloves Risk of destruction of sensitive parts Keep watches credit cards check cards and identity cards and all ferro magnetic metal par...

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Page 21: ...r output shaft plug connections and coolant connec tions of water cooled motors On delivery immediately verify whether the delivered goods are those speci fied on the delivery note The forwarder must be promptly informed of any damage on the packaging and goods which is detected on delivery Start up of damaged goods is prohibited MAD MAF Asynchronous Housing Motors 7 57 Scope of delivery R91133618...

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Page 23: ... optional centering hole DIN 332 part 2 Installation altitude 0 1000 m Sound pressure level 75 dB A Insulation class 155 DIN EN 60034 1 Balancing Complete or half key balancing Electrical connection Power connection Terminal boxes or device connectors Encoder connection Device connector Encoder system S2 optically Singleturn EnDat 2 1 2 048 signal periods M2 optically Multiturn EnDat 2 1 2 048 sig...

Page 24: ...Output shaft with shaft seal ing ring IP65 Option Output shaft with labyrinth seal IP65 Option Power connection Fan connection IP65 Terminal box or plug Motor encoder connection IP65 Motor fan IP65 Fan grille IP65 Fan grille IP24 Tab 4 3 Defining the motor components subject to protection 4 1 4 Output shaft Centering hole Centering hole acc to DIN 332 2 MAD MAF 100 130 160 180 225 DS M16 DS M20 Ta...

Page 25: ...hat the axial fan can move the required air volume a minimum distance for letting the air in and out must be kept between the fan grille and the machine This distance is based on the motor construction 3 2 80 mm 1 Machine Air outlet space Air inlet space Fig 4 2 MAD ventilation The use of the fan under the following conditions is expressly not suitable Delivery of air which contains abrasive parti...

Page 26: ...n be arbitrarily selected Expand the cooling circuit with anticorrosive Observe the information in the motor project planning manual Asynchronous Housing Motors MAD MAF 4 2 Product identification 4 2 1 Type code Fig 4 3 Type code 1 2 12 57 About this product MAD MAF Asynchronous Housing Motors Bosch Rexroth AG R911336186_Edition 02 ...

Page 27: ...Fig 4 4 Type code 2 2 MAD MAF Asynchronous Housing Motors 13 57 About this product R911336186_Edition 02 Bosch Rexroth AG ...

Page 28: ...d current 19 Company address 20 Rated speed 21 China RoHs 2 label 22 Designation of origin 23 Rated torque in operation mode S1 24 Rated current in mode S1 25 Rated power in mode S1 26 Operation mode S1 27 Motor power in operation mode S6 28 Operation mode S6 44 29 Material number Fig 4 5 MAF type plate example MAD MAF motors are delivered with 2 type plates each Attach the second type plate to an...

Page 29: ...cify classifications and lim it values which are allowed for our products while they are transported by land sea or air Refer to the detailed description of the classifications to take all of the factors which are specified in the particular class into account Allowed classes of environmental conditions during transport acc to DIN EN 60721 3 2 Classification type Allowed class Classification of cl...

Page 30: ... the ESD safety measures Risk of injury and material damage due to improper handling during transport WARNING Only use hoisting gear suited for the weight of the motors Use the eyebolts provided on the housing to lift the motor All lifting eye bolts must be used and tightened before use Never walk under hanging loads Do not lift the motor at the shaft or when using MAD motors on the fan housing Us...

Page 31: ...emain on the motor for transport and storage Do not remove these parts until shortly before assembly Based on DIN EN 60721 3 1 the tables below specify classifications and lim it values which are allowed for our products while they are stored Refer to the detailed description of the classifications to take all of the factors which are specified in the particular classification into account Allowed...

Page 32: ...es not entail any additional warranty claims Storage time Measures for commissioning 1 year Resurface the holding brake 1 5 years 1 Check the electric contacts to verify that they are free from corrosion 2 Let the motor run in without load for one hour at 800 1000 rpm 3 Resurface the holding brake 5 years 1 Replace bearings 2 Replace encoders 3 Resurface the holding brake 4 Check the electric cont...

Page 33: ... EN ISO 100 14 M12 84 28 738 130 225 18 M16 206 7 090 Tab 6 1 Fastening screws flange mounting tightening torque 6 1 2 Foot mounting Before attaching the motors according to the foot assembly method observe the clearance from the center of the motor shaft to the bottom edge of the foot specified in the particular motor dimension drawing Compare this dimen sion with the connection dimension on the ...

Page 34: ...surface 15 if foot assembly is selec ted The transmission of forces in other effective directions is not allowed 15 F 1 F F F F 15 F F F 15 Mounting feet Fig 6 1 Example MAF foot assembly Please note the following in case of foot assembly Forces which are transmitted by a gear and have an effect on the motor feet are not allowed Forces taking effect via the gear shaft must be supported against the...

Page 35: ...nt Use the centering hole for fitting transmission elements For details about centering holes refer to the project planning manual Asynchronous Hous ing Motors MAD MAF Heat the transmission element if necessary 6 2 Connecting the electric supply 6 2 1 Safety Danger Electric voltage Operations in the vi cinity of live parts are extremely dangerous WARNING Work required on the electric system may on...

Page 36: ...Rexroth See documentation Rexroth Connection Cables Observe the specified circuit diagrams within the project planning man ual Asynchronous Housing Motors MAD MAF The connections must be established such that a permanent safe elec trical connection is ensured Establish a safe protective conductor connection Do only use plug connectors free from dirt foreign bodies and humidity Completely tighten t...

Page 37: ...e in the socket housing Holding brake option Overall shield connection by clamping the cables of the strain relief in the connector Connection designations on the Rexroth drive controller Fig 6 3 Power connection via connector socket connection diagram Observe the necessary power wire cross section within the project planning manual Asynchronous Housing Motors MAD MAF to connect the motors Use rea...

Page 38: ...ng Motors MAD MAF to connect the motors Use ready made connection cables of Rexroth See docu mentation Rexroth Connection Cables Cables are screwed to the terminal box via adapter plates and if necessary thread reducing fittings These compo nents are included in the motor delivery If necessary how ever they can also be reordered separately Terminal box connection diagram 8 7 6 5 X5 X6 A1 24VBr A2 ...

Page 39: ...r rectly installed in the terminal box without tension to avoid abrasion or pressure marks on the cables The connections of the internal motor windings in the termi nal box must not be loosened Terminal box details Cover Seal Terminal block U V W PE connection O ring Adapter plate mounting screws Schutzabdeckung des Cable gland connection thread Adapter plate for cable gland Terminal strip brake t...

Page 40: ... of cable gland connection thread Adapter plate for cable gland Terminal strip brake temperature sensor Purge gas connection Option Clamping screws for setting the outgoing cable direction 4 pcs Fig 6 6 Terminal boxes Option D E H G 2 Check cable output direction and if necessary turn the terminal box Lossen terminal boxes Loosen the fastening screws and turn the terminal box by 90 up to 180 degre...

Page 41: ...or proper condition and correct position 7 Connect the cores according to the connection diagram for standard or double cabling Comply with the following tightening torques Screw tightening torques in Nm 10 for power connection Terminal boxes on U V W PE M6 M12 M8 M12 MAx100 160 2 5 3 5 MAx180 225 14 20 Tab 6 4 Screw tightening torques in Nm in terminal box 8 Close and fasten the terminal box cove...

Page 42: ... of the machine Motor housing Terminal box Holding brake option Potential equalization connection at the motor only available on MAF225C 0150 Potential equalization connection at the machine required for MAF225C 0150 Rexroth drive controller Fig 6 8 Double cabling connection diagram 28 57 Assembly MAD MAF Asynchronous Housing Motors Bosch Rexroth AG R911336186_Edition 02 ...

Page 43: ...onnect motor fan only for MAD motors The motor fan is connected to the supply network via a cable and a motor protective switch and is operated independently of the controller 1 2 3 M 3 4 RLS0782 RLS0782 0 75 1 5 mm 0 75 1 5 mm 0 75 1 5 mm L1 L2 L3 PE Power connection cable diameter Ø 7 10 mm Protective switch Plug connector Fan Fig 6 9 Fan connection To connect the motor fan the fan connector mus...

Page 44: ... torque may not be exceeded If the tightening torque or screw in depth is exceeded the motor may be damaged irreversibly The coolant connections on the motor side are provided for coolant connec tion threads with axial sealing Bosch Rexroth recommends to use threaded connections which contain an O ring for axial sealing of the screw connections For example seals consisting of hemp teflon tape or c...

Page 45: ...or the lock nipple Then screw the double nipple into the connection thread on the motor This procedure prevents the connection thread in the motor from being stressed repeatedly When mounting the quick coupling ensure that the seals are correctly positioned that the following tightening torques between the individual coupling components are kept Quick coupling thread size Allowed tightening range ...

Page 46: ... Do not bend or damage the motor sided screw connection 3 Screw the tube end with the mounting clamp tightly above the connec tion piece In service cases the quick coupling can be disconnected from the lock nipple by means of the coupling It is not necessary to discon nect the tube connection If a different connection method is used on the tube side other mounting steps may be required Mounting in...

Page 47: ... the motors is 6 bar 6 4 Encoder connection The motor sided connector socket and the cable sided coupling must be fit ted onto each other and screwed to each other manually Observe the me chanical coding Motor Frame size Device connector X3 for encoder connection M2 S2 M6 S6 C0 MAD 100 RGS1003 INS0629 130 225 RGS1004 INS0719 MAF 100 225 RGS1003 INS0629 Tab 6 9 Encoder connector socket designations...

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Page 49: ...onents touch hot surfaces 7 2 Commissioning MAD MAF Motors can only be commissioned with other components drive controller control unit Before Commissioning Prior to commissioning ensure that the following requirements are met Storage time of the motor Depending on the storage time take meas ures like run in bearings resurface the holding brake to ensure safe op eration see Tab 5 5 Ensure that mot...

Page 50: ...s MAD MAF Checks during operation Pay attention to exceptional noise Pay attention to increased vibrations Check the motors and fan units for cleanliness Check the tightness of the coolant connections Check the monitoring devices and diagnostic error messages of the con trollers Decommission the drive when deviations from normal operation exist For further procedure refer to chapter 12 Troubleshoo...

Page 51: ...ool down Wear safety gloves Do not work on hot surfaces Motors Excessive dirt chips or dust can negatively influence the motor functions In extreme cases lead to motor loss Clean the cooling fins of the motors at reg ular intervals after one year at the latest to reach a sufficiently high heat emission surface If the cooling fins are partially covered with dirt sufficient heat dissipation via the ...

Page 52: ...osch Rexroth service helpdesk at our headquarters in Lohr Germany and our worldwide service provide You can contact us 24 7 Helpdesk Service Hotline World Phone 49 0 9352 40 50 60 Outside Germany please contact your local service office first For hotline numbers refer to the sales office addresses on the Internet Fax 49 0 9352 40 49 41 Email service svc boschrexroth de Internet https www boschrexr...

Page 53: ...ect the shaft end when using pulling off tools Heat the output element if necessary 9 2 Preparing storage Before motors are stored the protection covers on device connector shaft and input openings for cooling water in case of liquid cooled motors which were attached on delivery must be re attached When motors are liquid cooled completely discharge the coolant from the cooling tubes e g via purgin...

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Page 55: ...ontain any undue foreign material or foreign components Deliver the products free domicile to the following address Bosch Rexroth AG Electric Drives and Controls Buergermeister Dr Nebel Straße 2 97816 Lohr am Main Germany Packaging Packaging materials consist of cardboard wood and polystyrene They can be recycled anywhere without any problem For ecological reasons please refrain from returning the...

Page 56: ...tric and electronic assemblies can also be recycled by means of special separation processes Plastic parts of the products may contain flame retardants These plastic parts are labeled according to EN ISO 1043 They have to be recycled sepa rately or disposed of according to the applicable legal provisions 42 57 Environmental protection and disposal MAD MAF Asynchronous Housing Motors Bosch Rexroth ...

Page 57: ...gnation 100 INS0480 SUP M01 MHD MNR R911283006 130 160 INS0380 SUP M02 MHD MNR R911283007 Tab 11 2 Accessories air pressure connector kit The proper sealing function of the rotary shaft seal is important for the safe function of the sealing air application Observe the infor mation about maintenance intervals inFig 8 2 The assembly instruction is enclosed to the selected accessory 11 1 3 Gearboxes ...

Page 58: ... project planning manual MAD MAF Asynchro nous Housing Motors about permitted shaft load and mounting of drive ele ments 44 57 Extension and modification MAD MAF Asynchronous Housing Motors Bosch Rexroth AG R911336186_Edition 02 ...

Page 59: ...s Mounting screws loose Tighten and secure the screw connections as specified Running noise Foreign bodies within the motor Stop the motor repair by manufacturer Bearing is damaged Stop the motor repair by manufacturer High motor tempera tures Motor temperature monitoring is activated Operation outside of rated data Reduce load and check the dimensioning Heat dissipation is impaired Clean the moto...

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Page 61: ...ta and operating characteristic curves are described for all motor types in project planning manual Asynchronous Housing Motors MAD MAF MAD MAF Asynchronous Housing Motors 47 57 Technical data R911336186_Edition 02 Bosch Rexroth AG ...

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Page 63: ...he time of printing of these operating instructions Daily updated dec larations of confirmity can be found in the media directory of Bosch Rexroth https www boschrexroth com MediaDirectory search word DCTC 30319 001 MAD MAF Asynchronous Housing Motors 49 57 Appendix R911336186_Edition 02 Bosch Rexroth AG ...

Page 64: ...Fig 14 1 CE declaration of conformity MAD MAF 50 57 Appendix MAD MAF Asynchronous Housing Motors Bosch Rexroth AG R911336186_Edition 02 ...

Page 65: ...Fig 14 2 CE declaration of conformity MAD MAF MAD MAF Asynchronous Housing Motors 51 57 Appendix R911336186_Edition 02 Bosch Rexroth AG ...

Page 66: ...52 57 MAD MAF Asynchronous Housing Motors Bosch Rexroth AG R911336186_Edition 02 ...

Page 67: ...9 Environmental protection 41 F Fan connection 29 Flange 9 H Hazardous substances 41 Heat dissipation 37 I Improper use Improper use 4 Indented use Directives 3 Standards 3 Installation altitude 9 Installation types 9 10 Insulation class 9 Intended use 3 K Key 10 L Liquid cooling 30 Coolant connection thread 30 Inlet pressure 33 Inside hose diameter 32 Quick coupling 30 M Motor components subject ...

Page 68: ...ction scheme 24 Details 25 Power cable connection 26 Transmission element Fitting 21 Pulling off 39 Transport 17 Transport conditions 16 Troubleshooting 45 Failure cause 45 Measures 45 Type code 12 Type plate 14 U Unintended use 3 V Vibration severity grade 9 W Water cooling see liquid cooling 12 54 57 Index MAD MAF Asynchronous Housing Motors ...

Page 69: ...Notes MAD MAF Asynchronous Housing Motors 55 57 ...

Page 70: ...Notes 56 57 MAD MAF Asynchronous Housing Motors ...

Page 71: ...Notes MAD MAF Asynchronous Housing Motors 57 57 ...

Page 72: ...Bosch Rexroth AG Bgm Dr Nebel Str 2 97816 Lohr a Main Germany Phone 49 9352 18 0 Fax 49 9352 18 8400 www boschrexroth com electrics R911336186 R911336186 DOK MOTOR MAD MAF IT02 EN P ...