Bosch Rexroth 2GE series Installation Instructions Manual Download | Manualshive

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2/3/4/5GE…

Montageanleitung | Installation Instructions

3 609 929 255

AC/09.2011
DE/EN

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Summary of Contents for 2GE series

Page 1: ...2 3 4 5GE Montageanleitung Installation Instructions 3 609 929 255 AC 09 2011 DE EN DEUTSCH ENGLISH ...

Page 2: ...h 49 71 92 22 208 per Fax 49 71 92 22 181 per E Mail schraubtechnik boschrexroth de Internet Informationen zu Rexroth Schraubtechnik finden Sie unter http www boschrexroth com schraubtechnik Ergänzende Hinweise zu Service Repara tur und Training sowie die aktuellen Adres sen unserer Vertriebsbüros finden Sie unter http www boschrexroth com Außerhalb Deutschlands nehmen Sie bitte Kontakt mit unsere...

Page 3: ...structions 47 2 6 1 General product dependent notes 47 2 6 2 Protection against accidental contact with electrical parts 47 2 6 3 Protective extra low voltage for protection against electric shock 49 2 6 4 Protection against dangerous movements 49 2 6 5 Protection against magnetic and electromagnetic fields during operation and assembly 51 2 6 6 Protection against accidental contact with hot parts...

Page 4: ... 63 11 1 Required tools 64 11 2 Disassembling 64 12 Disposal 65 12 1 Environmental protection 65 13 Extension and conversion 66 13 1 Converting the product 66 14 Troubleshooting 67 15 Technical data 67 16 Appendix 69 16 1 Complaints and repairs 69 16 2 Warranty 69 16 3 Service and sales 69 ...

Page 5: ...obligation of own judgment and verification Our products are subject to a natural process of wear and aging This document as well as the data specifications and other information set forth in it are the exclusive property of Bosch Rexroth AG It may not be reproduced or given to third parties without its consent The title pages shows an exemplary configuration The supplied product may therefore var...

Page 6: ...40 70 Bosch Rexroth AG XGE 3 609 929 255 2011 09 Contents ...

Page 7: ...y gearboxes X Read this documentation completely and particularly the chapter Safety In structions before working with the pro duct 1 2 Required and amending documentation Planetary gearboxes are components of Rexroth tightening spindles X Only commission the product if the do cumentation marked with the book symbol is available to you and you have understood and observed it NOTE Outdated document...

Page 8: ...instructions In this documentation there are safety in structions before the sequence whenever there is a risk of personal injury or damage to equipment The measures described to avoid these hazards must be observed Tab 1 Required and supplementary documentation Title Document number Document type Safety Instructions for Rexroth Tigh tening Systems 3 608 870 2DE Safety regulation Rexroth Tightenin...

Page 9: ...hazard can be avoided SIGNAL WORD Type of risk What occurs when the safety instruc tions are not complied with X Hazard avoidance Tab 2 Types of risk according to ANSI Z535 6 2006 Safety sign signal word Meaning DANGER identifies a dangerous situation that will result in death or serious injuries if it is not avoided WARNING identifies a dangerous situation that may result in death or serious inju...

Page 10: ...e numbers specify that the steps are completed one after the other Note This information refers to possible limitations with regard to the pro duct Menus Entry in the graphical interface of the software Tab 4 Designations Designation Meaning BS Operating program of the tightening system e g BS300 BS350 CS351 S Compact system of the tightening system 350 for the connection of tighte ning spindles T...

Page 11: ...e use Observe the operating conditions and per formance limits specified in the technical data Intended use includes having read and un derstood this documentation and especially the chapter Safety instructions 2 3 Improper use Any other use than that described in the intended use and than that described in the respective do cumentation is regarded as unintended use and is there fore inadmissible ...

Page 12: ...must observe the rules relevant to the subject area must be trained instructed and authori zed to switch electrical circuits and de vices on and off in accordance with the accepted rules of safety and current tech nology ground them and mark them ac cording to the job requirements must be sufficiently familiar with all war nings and precautions according to this documentation and the documentation...

Page 13: ...safety regulations and standards of the application 2 6 Product and technology dependent safety instructions In this chapter general safety instructions are listed that depend on the technology used in the product 2 6 1 General product dependent notes The warranty only applies to the delivered configuration The warranty will not apply if the product is incorrectly assembled or handled or not used ...

Page 14: ...nnected to the components at the intended points X Disconnect the device from the mains or voltage source before accessing electrical parts with voltages greater than 50 V Protect it against accidential switch on X After switching off the power supply wait 10 seconds for the system to discharge be fore opening the housing or starting repair maintenance work X For electrical drive and filter compon...

Page 15: ...en switched on or after an indefinite operating time The monitoring devices in the drive compo nents almost completely eliminate malfunc tions in the connected drives However in view of personal safety especially that invol ving risk of injury and or damage to equip ment this alone is not sufficient Until the in stalled monitoring devices reach full effectivity faulty drive movements whose magnitu...

Page 16: ...ediate vicinity Check the function of the emergency OFF system before commissioning If the emergency OFF switch malfunctions do not operate the device X Protection against unintended start up by means of an emergency OFF circuit X Safely bring the drives to a standstill before accessing or entering the danger zone X Additionally secure vertical axes from falling or dropping after the motor is swit...

Page 17: ...rent or fu ture pacemaker versions varies greatly For this reason no generally applicable rules exist X Persons with metal implants metal shrapnel in the body or hearing aids must consult a physician before ente ring these types of areas as adverse health effects must be expected in these areas CAUTION Hot surfaces possible on motor housings and gearboxes Risk of injury Risk of burns X Do not touc...

Page 18: ...planetary gearbox 4 About this product The space saving planetary gearbox con verts the low motor torque into a high drive torque This allows for very good efficiency The planetary gearbox is simply bolted to the EC motor Several gearboxes are avai lable per series for use in various applicati ons see fig 1 Abb 1 Sizes of the planetary gearboxes Size 2 Size 3 4 Size 5 ...

Page 19: ...y to be installed in partly com pleted machinery or in a machine or system If Rexroth tightening spindles are not in stalled in partly completed machinery or in a machine or system X Note Storage notes on page 53 How to handle packing material The original packing of Rexroth tightening spindles consists of recyclable material and can be recycled CAUTION Not secured Rexroth tightening spindle durin...

Page 20: ...n unsuitable manner could cause injuries Injury due to crushing shearing cutting impact X Observe the general construction and safety regulations for handling and assembly disassembly X Use suitable assembly disassembly and transport equipment X Prevent trapping and crushing inju ries by taking suitable precautions X Only use suitable tools Use special tools if stipulated X Use lifting equipment a...

Page 21: ...n the operating conditi ons temperatures during or after operation may exceed 60 C 140 F X After switching off the motors allow them to cool down sufficiently before accessing them X Wear protective gloves or do not work near hot surfaces NOTE Insufficient heat dissipation The heat resulting in the tightening pro cess caused by the waste heat of the EC motor may restrict the functionality of the t...

Page 22: ...tion of the two components in the as sembly Malfunctions of the spindles in later operation X During assembly at the width flat of the EC motor you must maintain cor responding counterpressure Other wise there is the risk that the motor flange loosens The width flat is located at the inter face to the planetary gearbox and at the motor flange Tab 6 Tightening torques Installation EC motor at plane...

Page 23: ... connection between the planetary gearbox and motor Proceed as follows when assembling pla netary gearboxes of size 3 and 4 1 Clamp the EC motor carefully into a bench vise 2 Screw the planetary gearbox manually to the connection of the EC motor 3 Tighten the planetary gearbox to the torque according to tab 6 on page 56 using a suitable fork wrench Lubricate the mechanical inter faces of the exter...

Page 24: ...nd the internal square using a suitable lub ricant before continuing with the assembly This prevents the forma tion of fretting 4 Plug the measurement transducer or the adapter into the housing of the pla netary gearbox mating teeth establi shing a flush connection Ensure that the mating teeth engage correctly and planetary gearbox and measurement transdu cer adapter are firmly teethed 5 Tighten t...

Page 25: ...ted CAUTION Hot surfaces possible on motor housings and gearboxes Risk of injury Risk of burns X Do not touch device housing sur faces at heat sources Risk of burns X Do not touch housing surfaces of motors and gearboxes Risk of burns X Depending on the operating conditi ons temperatures during or after operation may exceed 60 C 140 F X After switching off the motors allow them to cool down suffic...

Page 26: ...ings with higher torques are car ried out with a hand held Rexroth tighte ning spindle injuries particularly at the joints may result due to the acting forces X Assemble and use a torque support CAUTION Direct contact with the detergent Direct skin or eye contact with the deter gent as well as swallowing or inhaling the detergent may cause injuries X Avoid direct physical contact with the detergen...

Page 27: ...y gearboxes of size 5 are maintenance free up to 500 000 tighte ning cycles see Maintenance schedule on page 61 With planetary gearboxes of size 5 proceed as follows for performing the re lubrication 1 Remove the first planetary stage from the gearbox 2 Distribute the grease quantity specified in the Maintenance schedule evenly to the internal gearing of the gear ring which becomes visible Tab 8 N...

Page 28: ...xroth com and in the address directory in the Service and distri bution section 10 Decommissioning Proceed as follows to decommission the tightening spindle X Switch the controller off The light emitting diodes LEDs at the controller will go out The disassembly and replacement of your product is described in the Disassembly and replacement chapter as are the rele vant safety instructions ...

Page 29: ...arts and components in an unsuitable manner could cause injuries Injury due to crushing shearing cutting impact X Observe the general construction and safety regulations for handling and assembly disassembly X Use suitable assembly disassembly and transport equipment X Prevent trapping and crushing inju ries by taking suitable precautions X Only use suitable tools Use special tools if stipulated X...

Page 30: ... housing of the pla netary gearbox CAUTION Hot surfaces possible particularly on motor housings and gearboxes Risk of injury Risk of burns X Do not touch device housing sur faces at heat sources Risk of burns X Do not touch housing surfaces of motors and gearboxes Risk of burns X Depending on the operating conditi ons temperatures during or after operation may exceed 60 C 140 F X After switching o...

Page 31: ...spose of the device in accor dance with the currently applicable regulati ons in your country Devices manufactured by us can moreover be returned free of charge for disposal However one prerequi site is that there are no objectionable films such as oil grease or other contamination on the device Further no improper foreign substances or foreign components may be included with the return Please sen...

Page 32: ...to fear negative consequences for the environment Material components Tab 9 on page 66 shows the components that are basically contained in our products 13 Extension and conversion 13 1 Converting the product You must not convert the components of the Rexroth tightening spindles i e you must neither open or disassemble the com ponents nor change the mechanical proper ties dimensions bores etc In c...

Page 33: ...ther find at http www boschrexroth com or in section Service and sales 15 Technical data Rexroth is constantly adapting its technology to the latest standards This is why changes in the technical data of the components cannot be excluded Tab 10 Technical data of the planetary gearbox Size Order no 0 608 Use at the motor Reduc tion ratio i Efficiency n Moutput drive max Nm Drive Weight kg 2 720 043...

Page 34: ...box 0 4 42 8 54 3 0 8 55 0 5 79 0 93 9 4 720 056 4 E 510 EC304 19 3 0 9 55 pinion cut on motor shaft z 14 0 7 4 DR 77 EC304 58 6 0 85 150 1 1 720 057 100 0 4 D 65 4 D 77 24 9 0 9 80 pinion scre wed into motor shaft depending on gearbox 1 0 37 6 50 5 0 85 150 1 3 82 8 106 9 5 720 058 5 E 713 1 EC305 19 3 0 9 150 pinion cut on motor shaft z 14 2 9 720 041 67 9 0 85 500 3 7 Tab 10 Technical data of t...

Page 35: ...cluded from the warranty 16 3 Service and sales Service We are always the right partner when it co mes to system know how For any problem Service from Rexroth You can reach us around the clock at 49 9352 40 50 60 Or contact us by e mail service svc boschrexroth de Worldwide service Our global service network can be reached at any time in over 40 countries You can find detailed information on our s...

Page 36: ...9 71 92 22 208 By fax 49 71 92 22 181 Per e mail schraubtechnik boschrexroth de Internet Information on Rexroth s tightening techno logy can be found on the Internet at http www boschrexroth com schraubtechnik Additional information on service repairs and training as well as the current addres ses of our sales offices can be found at http www boschrexroth com If you are located outside of Germany ...

Page 37: ...XGE 3 609 929 255 2011 09 Bosch Rexroth AG 71 72 Appendix ENGLISH ...

Page 38: ...s Postfach 1161 71534 Murrhardt Fornsbacher Str 92 71540 Murrhardt Deutschland Tel 49 71 92 22 208 Fax 49 71 92 22 181 schraubtechnik boschrexroth de www boschrexroth com schraubtechnik Subject to modifications Printed in Germany 3 609 929 255 70 ...

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