Bosch R911274804 Project Planning Manual Download

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Rexroth IndraControl VCP 20

Industrial
Hydraulics

Electric Drives
and Controls

Linear Motion and
Assembly Technologies

Pneumatics

Service
Automation

Mobile
Hydraulics

Rexroth MKE synchronous motors
for potentially hazardous areas

R911274804
Edition 01

Project Planning Manual

Summary of Contents for R911274804

Page 1: ...l Hydraulics Electric Drives and Controls Linear Motion and Assembly Technologies Pneumatics Service Automation Mobile Hydraulics Rexroth MKE synchronous motors for potentially hazardous areas R911274804 Edition 01 Project Planning Manual ...

Page 2: ...TOR MKE PRJ1 EN E1 44 06 97 1 st E Dok INDRAMAT GmbH 1997 Copying this document and giving it to others and the use or communi cation 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 electronic documentation E Doc...

Page 3: ...ve shaft 2 5 Available versions 2 5 Shaft loads 2 5 2 5 Holding brake 2 8 2 6 Connection variants and cable output directions 2 9 2 7 Speed and Torque 2 10 3 Electrical connections 3 1 3 1 Overview of connections 3 1 3 2 Connections for motors with terminal boxes 3 2 Terminal diagram 3 2 Thermal cutout connection 3 3 Power cable 3 3 Feedback cable 3 5 Technical data of the power and feedback cable...

Page 4: ...ort and Handling 9 1 9 1 Notes on the packaging 9 1 9 2 Storage 9 1 9 3 Transport and Handling 9 2 10 Safety Guidelines for electrical drives 10 1 10 1 General information 10 1 10 2 Note on protection against contact with live parts 10 1 10 3 Notes on safely isolated low voltages 10 2 10 4 Notes on handling and mounting 10 3 10 5 Notes on protection against dangerous movements 10 3 11 Mounting and...

Page 5: ...MKE DOK MOTOR MKE PRJ1 EN E1 44 06 97 Introduction to MKE digital AC motors III 12 3 Contacting Customer Service 12 2 13 Index 13 1 ...

Page 6: ...MKE IV Contents DOK MOTOR MKE PRJ1 EN E1 44 06 97 ...

Page 7: ...l intelligent INDRAMAT drive controllers MKE digital AC motors create cost effective drive systems with a broad range of functionalities for use in potentially explosive areas Motors with the following continuous standstill torques and nominal speeds are available Fig 1 1 Continuous torque at standstill of the available MKE motors Applications Overview of performance ...

Page 8: ...side wall of the motor peak torque which can be used over a broad rotational speed range accomplished with electronic commutation continuous start stop operations with high repetitive frequencies is possible accomplished with electronic commutation easy mounting to the machine with a flange as per DIN 42948 any mounting orientation pinions and belt pulleys can be directly mounted the design of the...

Page 9: ...wer to the motor is shutdown See section 2 5 for details They are available with plain shaft standard or shaft with keyway optional For details see section 2 4 These are motor specific implementing either a terminal box For details see section 11 4 Connecting the motor Page 11 2 1 3 Motor feedback The drive controller requires the current position of the motor to regulate motor speed or when posit...

Page 10: ...emental encoder on the motor Features of the digital resolver feedback Given a power failure or after the initial POWER ON it is necessary to first run the axis to its reference point before work can begin When placing the reference point switches and during the referencing procedure itself it must be taken into account that during the course of a mechanical motor revolution several zero pulses ar...

Page 11: ... area MKE motors are prototype tested as per EN 50014 ff European stan dards and have been released for use in potentially explosive areas The relevant drive controllers and any plugin connectors for the lines power and feedback connections must be situated outside of the potentially dangerous area DANGER Danger of explosion Danger to life severe injury and property damage Do not install drive con...

Page 12: ...ntee Motors used outside of the specified conditions could be damaged Such use also results in forfeiture of gua rantee Please therefore note the following instructions Fig 2 2 Load factors as dependent on ambient temperature and installation ele vation If either ambient temperature or installation elevation exceed nominal ratings then Multiply the continuous standstill torque listed in the select...

Page 13: ... jet of water ejected out of a nozzle sprayed at the housing from all directions jet of water WARNING Danger to personnel or damage to property Improperly mounted power and feedback connections can injure personnel or damage the motor Make sure that the power and feedback connections are mounted by properly trained personnel Use MKE motors only in an environment where the indicated protection cate...

Page 14: ...iable Unit Maximum va lue of longi tundinal axis Maximum va lue in Lateral axis Amplitude of the dis placemen at 2 to 9 Hz mm 0 3 3 0 Amplitude of acceleration at 9 to 200 Hz m s 1 10 Fig 2 4 Limit data for sinusoidal oscillations Influencing variable Unit Maximum va lue of longi tundinal axis Maximum va lue of lateral axis Total shock response spectrum per IEC721 1 ed 1990 table 1 section 6 type ...

Page 15: ...ke sure that liquids cannot collect at the drive shaft 2 4 Drive shaft Available versions For a backlash free and non positive transmission of torque Use clamping sets tension sleeves or other tension elements for coupling pinions pulleys or other similar drive elements Per DIN 6885 sheet 1 edition 08 1968 For a form fitting transmission of torque with low demands at the shaft hub joint CAUTION Da...

Page 16: ...termine the maximum per missible radial force Fradial_max for your application Make sure that the radial force thus determined is not exceeded during actual operations The permissible radial force Fradial depends on the bearing lifespan desi red It is dependent on the arithmetic average rotational speed of the motor nmittel and distance x of application point of force see Fig 2 6 Shaft load forces...

Page 17: ...thing is unacceptably increased The use of drive elements with bearings which are connected to the motor shaft via an axial compensating coupling is thus recommended If permissible radial and axial forces are not exceeded then the following applies to nominal bearnig lifespan L10h 30 000 operating hours calculated per ISO 281 edition 12 1990 Bearing lifespan otherwise drops to L F F 10h radial rad...

Page 18: ...sonnel Body parts could be pinched or se vered The holding brake itself does not guarantee personnel safety Personnel safety must be secured by other measures such as protective bars or an additional brake in the machine CAUTION Premature wear of the holding brake is possible The holding brake wears down after approximately 20 000 motor revolutions in a closed state Do not use the holding brake to...

Page 19: ...is generally used for the MKE motor power and feedback connections The desired cable output direction can be set at the time of mounting by turning the cable connection box Fig 2 9 Possible cable output directions Note The cable output direction set at the factory can be altered at the time of mounting Please see section 11 4 Connecting the motor page 11 2 ...

Page 20: ...uous ope rating curve MdN of the averaged speed arithmetic average Record information from the selection documentation Fig 2 10 Example diagram to illustrate speed torque characteristics Corresponds to the theoretically possible maximum torque of the motor The drive controller can limit it Note The maximum torque of a motor controller combination is always specified in the selection lists S6 inter...

Page 21: ...oltage or the power supply unit used 1 HDS or HDD attached to supply units HVR 2 HDS or HDD with power supply unit HVE with a mains connection of 3 x AC 480 V or DKC 7 with 3 x AC 480 V 3 HDS or HDD with power supply unit HVE with a mains connection of 3 x AC 440 V or DKC 7 with 3 x AC 440 V 4 HDS or HDD with power supply unit HVE with a mains connection of 3 x AC 400 V or DKC 7 with 3 x AC 400 V ...

Page 22: ...MKE 2 12 Mechanical integration into the machine DOK MOTOR MKE PRJ1 EN E1 44 06 97 ...

Page 23: ... AC motors there are a power connection includes connections for temperature sensors and holding brake and a feedback connection Depending on the motor both connections are conducted into the cable connection box with the use of EExd cable leadthroughs where they are mounted with a plug contact see section 11 4 Connecting the motor page11 2 Fig 3 1 Schematic terminal plan of MKE motors ...

Page 24: ...inal diagram Note Only direct connections between motor and drive controller are depicted The terminal diagrams however also apply to all other types e g with intermediate connector as the allocation of the connections of motor and drive controller never change Fig 3 2 Terminal diagram of MKE motor with terminal box ...

Page 25: ...nected with the temperature cutout circuit TM TM of the drive controller The temperature class of INDRAMAT MKE motors is T4 as per EN 50014 3 77 European standard This makes a highly reliable sur face temperature of the equipment with 135 C possible The PTC thermistor made up of three thermistors built into the MKE motors gua rantees in conjunction with the evaluation circuits of the drive control...

Page 26: ...RJ1 EN E1 44 06 97 Fig 3 3 Different types of connecting cables Please find the type that suits your motor controller combination in the table below If type designations are specified for two cables or a cable and a flan ged socket then order both ...

Page 27: ... connect MKE motors with terminal boxes to drive controller family DIAX 04 or ECODRIVE Available cable lengths 5 10 15 20 30m All other lengths available upon request When ordering just enter the cable type and desired length Example IKG 0307 power cable for DKC length 5m Note Maximum total length of the cable connection from motor to drive controller with two intermediate plugin locations equals ...

Page 28: ...ing Technical data of the power and feedback cables Name Unit Data Power cables Feedback cables Ready made cable type designa tion IKG0307 IKG0308 IKS0203 Type designation of cable cable parts INK0653 INK0650 INK0448 Diameter of power or supply strands mm 4 x 1 0 4 x 1 5 2 x 0 5 Control strand diameter holding brake temperature monitor or control voltage mm 2 x 2 x 0 75 2 x 2 x 0 75 4 x 2 x 0 25 D...

Page 29: ...osive areas cables with a minimum temperature resistance of 80 C 176 F must be used The cables listed in the INDRAMAT cable selection lists meet these requirements Individual parts Note INDRAMAT cables can be put together by the customer The parts needed in this case are listed in the document Connecting accessories for INDRAMAT drives doc no 209 0050 4399 ...

Page 30: ...MKE 3 8 Electrical connections DOK MOTOR MKE PRJ1 EN E1 44 06 97 ...

Page 31: ...ºC 20 to 80 maximum installation elevation 6 m 1000 above sea level Protection category 7 IP 65 insulation class DIN VDE 0530 section 1 F ignition protection category per EN 50014 3 77 EExd II C T4 PTB no Ex 97 D 1010 housing coat black primary coat RAL 9005 1 Depends on torque requirements of the application For standard applications see nmax in the selection lists of the motor controller combina...

Page 32: ...e UN V DC 24 10 Nennstrom IN A 0 4 Moment of inertia JB kgm 0 08 x 10 4 Release delay tl ms 4 Clamping delay tK ms 3 Mass mB kg 0 25 Fig 4 2 Technical data holding brake MKE035 Optional 4 2 Speed torque characteristics For details see section 2 7 Speed and Torque page 2 10 Fig 4 3 Rotational speed torque characteristics MKE035B 144 ...

Page 33: ...Fig 4 4 MKE035 permissible maximum radial force Fradial_max and permissible radial force Fradial F F axial radial 0 58 Faxial permissible axial force in N Fradial permissible radial force in N Fig 4 1 MKE035 permissible axial force Permissible maximum radial force Fradial_max and permissible radial force Fradial Permissible axial force Faxial ...

Page 34: ...MKE 4 4 MKE 035 DOK MOTOR MKE PRJ1 EN E1 44 06 97 4 4 Dimensions Fig 4 5 Dimensional data MKE035 ...

Page 35: ...MKE DOK MOTOR MKE PRJ1 EN E1 44 06 97 MKE 035 4 5 4 5 Available versions and type codes Fig 4 6 Type codes MKE035 ...

Page 36: ...MKE 4 6 MKE 035 DOK MOTOR MKE PRJ1 EN E1 44 06 97 ...

Page 37: ...mperature TL ºC 20 to 80 maximum installation elevation 6 m 1000 above sea level Protection category 7 IP 65 insulation class DIN VDE 0530 section 1 F ignition protection category per EN 50014 3 77 EExd II B H2 T4 PTB no Ex 97 D 1010 housing coat black primary coat RAL 9005 1 Depends on torque requirements of the application For standard applications see nmax in the selection lists of the motor co...

Page 38: ...ge UN V DC 24 10 Nominal current IN A 0 35 Moment of inertia JB kgm 0 16 x 10 4 Release delay tl ms 28 Clamping delay tK ms 14 mass mB kg 0 25 Fig 5 2 Technical data holding brake MKE045 Optional 5 2 Speed torque characteristics For details see section 2 7 Speed and Torque page 2 10 Fig 5 3 Speed torque characteristics MKE045B 144 ...

Page 39: ...MKE045 Permissible maximum radial force Fradial_max and permissible radial force Fradial F F axial radial 0 44 Faxial permissible axial force in N Fradial permissible radial force in N Fig 5 5 MKE045 permissible axial force Faxial Permissible maximum radial force Fradial_max and permissible radial force Fradial Permissible axial force Faxial ...

Page 40: ...MKE 5 4 MKE 045 DOK MOTOR MKE PRJ1 EN E1 44 06 97 5 4 Dimensions Fig 5 6 Dimensional data MKE045 ...

Page 41: ...MKE DOK MOTOR MKE PRJ1 EN E1 44 06 97 MKE 045 5 5 5 5 Available versions and type codes Fig 5 7 Type codes MKE045 ...

Page 42: ...MKE 5 6 MKE 045 DOK MOTOR MKE PRJ1 EN E1 44 06 97 ...

Page 43: ...t temperature TL ºC 20 to 80 maximum installation elevation 6 m 1000 above sea level Protection category 7 IP 65 insulation class DIN VDE 0530 section 1 F ignition protection category per EN 50014 3 77 EEx d IIB T4 PTB no Ex 97 D 1036 housing coat black primary coat RAL 9005 1 Depends on torque requirements of the application For standard applications see nmax in the selection lists of the motor c...

Page 44: ...N V DC 24 10 Nominal current IN A 0 5 Moment of inertia JB kgm 1 1 x 10 4 Release delay tl ms 29 Clamping delay tK ms 20 mass mB kg 0 65 Fig 6 2 Technical data holding brake MKE096 Optional 6 2 Speed torque characteristics For details see section 2 7 Speed and Torque page 2 10 Fig 6 3 Rotational speed torque characteristics MKE096B 047 ...

Page 45: ...MKE096 Permissible maximum radial force Fradial_max and permissible radial force Fradial F F axial radial 0 33 Faxial permissible axial force in N Fradial permissible radial force in N Fig 6 5 MKE096 Permissible axial force Faxial Permissible maximum radial force Fradial_max and permissible radial force Fradial Permissible axial force Faxial ...

Page 46: ...MKE 6 4 MKE 096 DOK MOTOR MKE PRJ1 EN E1 44 06 97 6 4 Dimensions Fig 6 6 Dimensional data MKE096 ...

Page 47: ...MKE DOK MOTOR MKE PRJ1 EN E1 44 06 97 MKE 096 6 5 6 5 Available versions and type codes Fig 6 7 Type codes MKE096 ...

Page 48: ...MKE 6 6 MKE 096 DOK MOTOR MKE PRJ1 EN E1 44 06 97 ...

Page 49: ...ing the bands CAUTION Uncontrolled movements of the metal bands upon removal Mechanical injuries are possible Metal bands must be carefully removed Sufficient distance must be maintained 7 3 Shipping papers The entire delivery is accompanied by one copy of the shipping papers in an envelope This lists merchandise by name and order designation In the event that the listed contents are distributed o...

Page 50: ...MKE 7 2 Condition at delivery DOK MOTOR MKE PRJ1 EN E1 44 06 97 ...

Page 51: ... that the contents are distributed over several cartons transport containers such will be noted in the delivery slip or the freight papers 8 2 Barcode sticker There is a barcode sticker on each motor package will lists the following information type designation of the motor customer delivery slip number consignment freight company The barcode sticker serves to identify the contents at the time of ...

Page 52: ...type plate on the motor is somehow covered or not visible due to the contours of the machine Fig 8 2 Type plate Example The type plate serves the identification of the motor to obtain replacement parts in the event of a breakdown service information in general Type designations are printed on the cable sheath Type designations are on the plastic bag Label at cable end with type designations Note T...

Page 53: ... 9 2 Storage WARNING Motor damage and forfeiture of guarantee Motors not properly stored could be damaged The gua rantee is also forfeited in this case Please therefore note the following instructions Maintain the following conditions during storage permissible temperature range 20 C to 80 C motors must be stored dry dust free and shock free motors must be stored horizontally Protective cover of p...

Page 54: ...used if excessive shocks are expected du ring transport Note the limit data as outlined in section 2 2 Maximum vibration and shock requirements page 2 3 Transport in horizontal position only When picking up the motor use a crane or lifting belts Motor flange and drive shaft must not be damaged Avoid impacts to drive shaft Protective cover made of plastic is on the drive shaft and must not be remov...

Page 55: ...s and precuationary mea sures as outlined in this document Personnel is also trained if it has been instructed or if it may switch electric circuits on and off ground and label them Trained personnel must also have appropriate safety equipment and be instructed in first aid Use only those replacement parts designated as acceptable Safety guidelines and regulations must be complied with The motors ...

Page 56: ...onnections of the components are not to be touched when on Before switching the machine on cover live parts ot prevent contact Make sure that there is also sufficient against indirect contact as per DIN EN 50178 edition11 94 5 3 2 3 WARNING High leakage current DANGER to life or severe injury Prior to switching on connect the electrical devices of each drive controller supply unit and the motor wi...

Page 57: ...oking Comply with the general setup and safety guidelines on handlnig and mounting Use suitable mounting and transport devices and special took if necessary Squeezing and pinching can be prevented with the proper measures If necessary wear suitable protective clothing for ex ample protective eyewear shoes and gloves Do not stand under hanging loads Spilled liquids must be wiped up immediately to a...

Page 58: ...sible measures against accidental accessing of personnel are protective fences protective railings protective covers and photosensors Make sure that fencing and covers are strong enough to absorb maximum motional energy E stop switches must be easily accessible and in clo se proximity to the user Check the E stop prior to commissioning to make sure it is operating properly Secure against unintenti...

Page 59: ...ounting the motor Obtain lifting devices auxiliary aids measuring and testing equipment Check the transferrable holding torque of the holding brake If the holding torque listed in the dimensional data sheets is not achie ved then go to section 11 5 page 11 7 first before taking the following steps Check all the components for cleanliness Check whether the components have visible damage Do not moun...

Page 60: ...inst being unintentionally and accidentally switched back on Prior to starting work check using suitable equip ment whether components are still under any residual voltage e g from capacitors or similar Wait until completely discharged WARNING Injury to personnel or damage to property possible Interrupting or connecting live leads can cause unantici pated dangerous situations or property damage Th...

Page 61: ...terminal box or cables High tightening torques can damage screwed joints or pinch cables If screwed joints are damaged then the protection category IP 65 at the terminal box can no longer be guaranteed Do not therefore use automatic screwdrivers such as an electrical pneumatic or hydraulic screwdriver MKE motors are equipped with a terminal box Use ready made INDRAMAT cables to mount them Mount th...

Page 62: ...tig plugs X1 X2 and X3 must be mounted as per MKE motor plans see Fig 3 2 Terminal diagram of MKE motor with termi nal box Note Crimping pliers are available from INDRAMAT to mounting connector X3 part no 262 293 The ground ring terminals 10 and 11 must be screwed to the termi nal box lid 9 with 1 3 Nm X1 X2 and feedback connector X3 must be placed into position on the motor mounting panel The 4 c...

Page 63: ...rewdrivers such as electrical pneumatic or hydraulic screwdrivers MKE motors are equipped with terminal boxes Cables which correspond to ready made INDRAMAT cables must be used for connections Mount the cables in the following order Fig 11 3 EExd screwed joints with terminal box lid for MKE 096 Release lid screws 8 and remove terminal box lid 9 The EExd cable screwed jonts are mounted at the facto...

Page 64: ...erminal diagram of MKE motor with terminal box Note Crimping pliers are available from INDRAMAT to mounting connector X3 part no 262 293 The ground ring terminals 10 and 11 must be screwed to the termi nal box lid 9 with 1 3 Nm X1 X2 and feedback connector X3 must be placed into position on the motor mounting panel The 4 connecting screws plugin bushing of power cable connector part no 259698 of X...

Page 65: ... permitted with specific cable diameters The table below specifies these diameters for screwed joints of the power and feedback cables EExd screwed joint Screwed joint type Permitted cable diameters in mm Min Max Power cable VERSCHR M 20 0 GER EX 11 0 14 3 MS C4N 6 11 0 14 3 Feedback cable VERSCHR M 20 0 GER EX 07 5 11 9 MS C4N 6 7 5 11 9 Fig 11 5 Permissible cable diameter of EExd screwed joints ...

Page 66: ...fore note the following instructions Prerequisite The motor is equipped with a holding brake and has been stored for an extended period Check the transferrable holding torque of the holding brake If the holding torque listed in the dimensional data sheets is not achie ved then refinish the holding brake The following preconditions must be set before the holding brake can be refinished Prerequisite...

Page 67: ...GER Dangerous movements Danger to life and limb and serious property damage Switch power supply to drive controllers off and secu re against being switched back on Replace batteries only with control voltage on If con trol voltage is switched off with the battery removed then the reference dimension will be lost and faulty movement could occur once the machine is switched back on Allen screws 1 mu...

Page 68: ...nations of drive controllers and motors not functioning the state of the problem disturbance or diagnostic displays if machine is thus equipped Our Service Hotline can be reached as follows Monday Friday 7 23 CET Saturday 8 20 CET Sundays and holidays 9 19 CET at the following telephone numbers 0171 333 882 6 or 0172 660 040 6 If the decision has been made to return the motors then please make a c...

Page 69: ...MKE DOK MOTOR MKE PRJ1 EN E1 44 06 97 Service Notes 12 3 Fig 12 2 MKE on DKC ...

Page 70: ...MKE 12 4 Service Notes DOK MOTOR MKE PRJ1 EN E1 44 06 97 Fig 12 3 MKE on HDS HDD ...

Page 71: ...ral features 1 1 H Handling 9 1 Holding brake 2 8 Holding brakes 1 3 Housing finish 2 4 I Identification 7 1 Individual parts 3 7 Installation elevation 2 2 L Lifting belts 9 2 Load factor 2 2 Load factors 2 2 M Maintenance work 12 2 Metal bands 7 1 Minimum temperature resistance 3 7 MKE 035 Available versions and type codes 4 5 Determining maximum shaft load 4 3 Dimensions 4 4 Speed torque charac...

Page 72: ...speed 2 10 4 2 S Safety Guidelines Connecting the motor 11 2 General information 10 1 Protecting safely isolated low voltages 10 2 Protection against contact with live parts 10 1 Protection against dangerous movements 10 3 Protection when handling and mounting 10 3 Selection data 2 2 Shipping papers 7 1 Shock damping 9 2 Storage 9 1 Structure and components 1 2 T Torque 2 10 Transport 9 1 Type of ...

Page 73: ...e Lane Telefon 01285 658671 Telefax 01285 654991 Finnland Rexroth Mecman OY SF 01720 Vantaa Riihimiehentie 3 Telefon 0 848511 Telefax 0 846387 France Rexroth Sigma S A Division INDRAMAT F 92632 Gennevilliers Cedex Parc des Barbanniers 4 Place du Village Telefon 1 41475430 Telefax 1 47946941 France Rexroth Sigma S A Division INDRAMAT F 69634 Venissieux Cx 91 Bd 1 Joliot Curie Telefon 78785256 Telef...

Page 74: ...ntre 1 Jianguomenwai Avenue Withjing 100004 P R China Telefon 010 50 50 380 Telefax 010 50 50 379 China Rexroth China Ldt A 5F 123 Lian Shan Street Sha He Kou District Dalian 116 023 P R China Telefon 0411 46 78 930 Telefax 0411 46 78 932 Honkong Rexroth China Ldt 19 Cheung Shun Street 1st Floor Cheung Sha Wan Kowloon Honkong Telefon 741 13 51 54 and 741 14 30 Telex 3346 17 GL REX HX Telefax 786 4...

Page 75: ......

Page 76: ...nd 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 DOK MOTOR MKE PRJ1 EN P R911274804 ...

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