Electromechanical Cylinders EMC
R320103102/2015-04
EN
Instructions
EN
The data specified only serves to describe the
product. Statements concerning condition or
suitability for a certain application cannot be
derived from this information. The information
does not constitute the user's own judgment
and verification. It is important to note that our
products are subject to a natural process of
wear and aging.
© All rights reserved by Bosch Rexroth AG,
even in cases of proprietary rights applications.
Copying and distribution to third parties is only
permitted with our explicit consent.
The illustration on the front page represents an
example configuration. The delivered product
may thus deviate from the illustration.
The original instructions were prepared in
German.
Distribution of the product is only permitted
together with this manual.
Die vorliegende Anleitung ist in folgenden Sprachen verfügbar.
These instructions are available in the following languages.
Les présentes instructions sont disponibles dans les langues suivantes.
Le presenti istruzioni sono disponibili nelle lingue seguenti.
Las presentes instrucciones están disponibles en los siguientes idiomas.
As presentes instruções estão disponíveis nas seguintes línguas.
本说明书具有下列语言版本。
DE
Deutsch (original version)
EN
English
FR
Français
IT
Italiano
ES
Español
PT
Português
ZH
中文
R320103102/2015-04 EMC
Bosch Rexroth AG
3
Contents
1 About these instructions.......................................................................... 4
2 Safety instructions................................................................................... 7
3 Scope of supply........................................................................................ 7
4 Product description................................................................................. 8
5 Transport and storage............................................................................ 10
6 Mounting................................................................................................13
7 Initial operation...................................................................................... 41
8 Operation............................................................................................... 45
9 Cleaning and care................................................................................... 46
10 Maintenance and repair......................................................................... 47
11 Disassembly and replacement............................................................... 51
12 Disposal.................................................................................................. 55
13 Technical data........................................................................................ 55
14 Operating conditions............................................................................. 56
EN
4
Bosch Rexroth AG
EMC R320103102/2015-04
1
About these instructions
1.1
Scope and purpose of the documentation
This documentation applies to the following products:
•• Electromechanical Cylinders (EMC) as described in the “Electromechanical
Cylinders EMC” catalog.
This documentation is intended for assembly/installation personnel, line
operators and machinery/plant users.
This documentation contains important information for proper and safe
installation, operation, maintenance and disassembly of the product and for
troubleshooting simple errors oneself.
XX Before commencing any work with the product, be sure to read these
instructions and the “Safety Instructions for Linear Motion Systems”
carefully and completely.
1.2
Required documentation
Documentation which is indicated by the book symbol
before handling the product and must be adhered to.
Table 1:
must be obtained
Required documentation
Title
Document
number
Description
Safety Instructions for Linear Motion Systems
R320103152
Safety instructions
Electromechanical Cylinders EMC
R310 3306
Catalog
IndraDrive C for Linear Motion Systems
R310 2730
Catalog
IndraDrive Cs for Linear Motion Systems
R310 2735
Catalog
Material safety data sheet for Dynalub 510
R320103160
Safety instructions
Product data sheet for Dynalub 510
R310 2052
Catalog
System documentation of the machinery/
system manufacturer
Manuals for the other machine/system
components
The Rexroth documentation is available for download at:
www.boschrexroth.com/mediadirectory.
R320103102/2015-04 EMC
1.3
Bosch Rexroth AG
5
Presentation of information
To enable users to work rapidly and safely with the product while following these
instructions, this documentation uses standardized safety instructions, symbols,
terms and definitions, and abbreviations. For clearer understanding, these are
explained in the following sub-sections.
1.3.1
Safety notices in these instructions
These instructions contain safety (warning) notices preceding any actions that
involve a risk of personal injury or damage to property. The safety precautions
described must be adhered to.
Warning notices are structured as follows:
SIGNAL WORD
Type of hazard!
Consequences if ignored.
ff Hazard avoidance precautions.
•• Warning sign: draws attention to the hazard
•• Signal word: indicates the severity of the hazard
•• Type of hazard: indicates the type or source of the hazard
•• Consequences: describes the consequences that may occur if the hazard
avoidance precautions are ignored
•• Hazard avoidance precautions: indicates how to avoid the hazard
The warning notices cover the following hazard levels. The hazard level describes
the risks involved if the warning notice is ignored.
Hazard levels as per ANSI Z535:
Warning sign,
signal word
Meaning
DANGER
Indicates an imminently hazardous situation which, if not
avoided, will result in death or serious injury.
WARNING
Indicates a potentially hazardous situation which, if not
avoided, could result in death or serious injury.
CAUTION
Indicates a potentially hazardous situation which, if not
avoided, may result in minor or moderate injury.
NOTE
Damage to property: Risk of damaging the product or the
surrounding environment.
EN
6
Bosch Rexroth AG
1.3.2
EMC R320103102/2015-04
Symbols
The following symbols designate notes or cross-references that are not safetyrelevant but increase the clarity of the documentation.
Table 2:
Meaning of the symbols
Symbol
Meaning
If this information is not observed, the product will not be used or
operated optimally.
XX
1.
Single, independent work step
Numbered work steps
2.
The sequence of the work steps is indicated by the numbers.
3.
! 7
! Fig. 7.1
See section 7
See figure 7.1
Screw with strength class...
Tightening torque
Friction factor for screws
u
m
1.3.3
Abbreviations
The following abbreviations are used in this document:
Table 3:
Abbreviations and definitions
Abbreviation
EMC
Ball screw
Meaning
ElectroMechanical Cylinder
Ball screw drive
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2
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7
Safety instructions
The general safety instructions for this product can be found in the documentation
“Safety Instructions for Linear Motion Systems”. You must have read and
understood these before handling the product.
3
Scope of supply
The scope of supply includes:
•• Electromechanical Cylinders EMC, and any ordered motors, controllers, control
systems and accessories
•• 1 Instruction manual “Electromechanical Cylinders EMC”
EN
3.1
Accessories
The following accessories are available:
•• Mounting elements
•• Switches
•• Motor mounting kit (flange, coupling, timing belt side drive)
•• Load sensor
•• Cover screws
•• Plug-in connectors
Dimensions and part numbers of the accessories as well as additional
mounting accessories ! “Electromechanical Cylinders EMC” catalog.
8
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4
Product description
4.1
Description of features
An Electromechanical Cylinder EMC consists of the following parts:
1 Piston rod (stainless steel)
2 Hex socket head cap screw on the cover with internal thread for mounting
accessories
3 Protective profile
4 Hex socket head cap screw on the base with internal thread for mounting
accessories, motor flange or timing belt side drive
5 Drive journal
6 Hexagon nut
3
2
6
1
Fig. 1: Structural design of the EMC
5
4
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4.2
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9
Identification of the product
The name plate of the product carries the following information:
Table 4:
Details given on the name plate
1 MNR
Part number
2
TYP
Short product name
3
080
Size
4
CS
Customer information
5
FD
Date of manufacture
6
7210
Manufacturing location
7
smax
Maximum travel range
8
u
Lead constant without motor mounting
9
vmax
Maximum speed
10
amax
Maximum acceleration
11
M1max
Maximum drive torque at motor journal
12
d
Direction of rotation of the motor for travel in positive (+) direction
13
i
Transmission ratio
EN
XX When ordering replacement parts, please always
state all data given on the name plate.
4
1
3
2
5
MNR: R12345678
TYP: EMC-080-NN-2
CS:
9876543210
20
6
Bosch Rexroth AG
D-97419 Schweinfurt
Made in Germany
FD:
07
483
smax (mm) u (mm/U) vmax (m/s) amax (m/s2) M1max (Nm)
7210
d
i
--
--
--
--
--
--
--
7
8
9
10
11
12
13
Fig. 2: Name plate
10
Bosch Rexroth AG
5
EMC R320103102/2015-04
Transport and storage
Observe the environmental conditions ! 14 on page 56 and
“Electromechanical Cylinders EMC” catalog.
For special environmental conditions, please consult us.
5.1
Transporting the EMC
Electromechanical Cylinders are pre-assembled as ready-to-install units.
WARNING
Risk of product crashing down due to inadequate load hoisting equipment!
Serious injury or even death.
ff Use only safety-inspected and suitable load hoisting equipment.
ff Attach load hoisting equipment only to the frame (main body) or at the
designated points.
ff Do not stand under hoisted loads.
NOTE
Risk of damage to motor attachment by vibrations!
Motor may break off.
ff When transporting the product with attached motor, always provide
support for the motor, or
ff Remove the motor before transporting the product.
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!
1
11
2
!
3
4
5
EN
Fig. 3: Transporting the EMC
12
Bosch Rexroth AG
EMC R320103102/2015-04
NOTE
Damage to the product due to improper transport ! Fig. 3 on page 11!
Damage to the EMC.
ff Retract the piston rod (1).
ff Lift the EMC only by its protective profile.(2).
ff Do not lift the EMC by the piston rod (3). The ball screw is not self-locking.
ff Use eyebolts only on the round-neck nuts on the cover of the EMC. Subject
these to tensile stress only (4).
ff Prevent the EMC from swinging during lifting operations (5).
1. Before hoisting the EMC, note the weight ! “Electromechanical Cylinders
EMC” catalog, “Technical Data” section.
2. Hoist the EMC.
5.2
Storing the EMC
NOTE
Risk of damage due to incorrect storage!
Potential corrosion of product parts.
ff Store the product only in dry, roofed areas.
ff Protect the product against humidity and corrosive agents.
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13
Mounting
Dimensions and part numbers of the individual components !
“Electromechanical Cylinders EMC” catalog.
WARNING
Risk of product crashing down due to inadequate load hoisting equipment!
Serious injury or even death.
ff Use only safety-inspected and suitable load hoisting equipment.
ff Attach load hoisting equipment only to the frame (main body) or at the
designated points.
ff Do not stand under hoisted loads.
Risk of product crashing down in vertical or hanging installations due to lack
of protection against falling loads.
Serious injury or even death.
ff Secure the product against dropping.
ff Do not stand under the product in the hazard zone.
XX Before hoisting the EMC, note the weight ! “Electromechanical Cylinders EMC”
catalog, “Technical Data” section.
6.1
Installation conditions
Heed the operating conditions ! 14 on page 56 and “Electromechanical
Cylinders EMC” catalog.
XX For special requirements, please contact us.
NOTE
Risk of damage due to non-permissible loads!
Damage to the product.
ff No overhanging loads (see catalog for maximum values)
ff Do not subject the piston rod to torsion (it is not designed to absorb torque).
ff The protective profile is not intended for attachment of other machine
elements for absorbing force.
EN
14
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F
F
M
Fig. 4: Non-permissible loads
6.2
Mounting orientation
The EMC can be mounted in any orientation.
WARNING
For vertical or inclined installation risk of the piston rod crashing due to lack
of self-locking!
Serious injury or even death.
ff In vertical or slanting installations, secure the piston rod so that it cannot
drop out.
ff Do not stand in line with the direction in which the piston rod could fall.
Fig. 5: Dropping of the piston rod
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15
Required accessories
Required mounting accessories ! “Electromechanical Cylinders EMC” catalog,
“Mounting Elements” section.
6.4
Mounting options
1 By the cover
2 By the timing belt side drive
3 By the base
4 By the piston rod end
EN
1
3
2
4
Fig. 6: Mounting options
16
6.5
40
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Mounting elements
Elektromechanischer Zylinder EMC | Konfiguration und Bestellung
6.5.1
Overview of mounting elements
Befestigungselemente
Table 5:
Overview of mounting elements
Befestigungselement
Mounting element
1
2
3
5
Ausführung
Version
6
Gruppe
Group
1
00
ohne
Without
ohne
Flansch
Flange-less
OF01
OF01
ohne
Without
3
00
ohne
Without
01
01
01
02
07
03
Gabelbefestigung
mit
Clevis mount with force
measurement
bolts
Kraftmessbolzen
With
flange und
and coupling
mit
Flansch
Kupplung
MF01
MF01
2
00
Edelstahl
Stainless
steel
02
04
03
06
EMC-32 - EMC-50
04
05
With
belt side drive
mit timing
Riemenvorgelege
RV01bis
to RV03
RV01
RV03
06
Edelstahl
Stainless
steel
Bosch Rexroth AG, R310DE 3306 (2014-11)
EMC-63 - EMC100XC
4
00
ohne
Without
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Bosch Rexroth AG
Konfiguration und Bestellung | Elektromechanischer Zylinder EMC
1
2
3
17
41
5
Ausführung
Version
Gruppe
Group
5
00
ohne
Without
6
00
ohne
Without
011)
With
flange und
and coupling
mit
Flansch
Kupplung
MF01
MF01
031)
051)
EMC-32 - EMC-50
EMC-63 - EMC-100XC
06
EMC-32 - EMC-50
EMC-63 - EMC-100XC
07
01
EMC-32 - EMC-50
02
With
timing belt side drive
mit Riemenvorgelege
RV01bis
to RV03
RV01
RV03
EMC-63 - EMC-100XC
08
03
04
EMC-32 - EMC-50
EMC-63 - EMC-100XC
10
05
Gabelbefestigung
mit
Clevis mount with force
measurement
bolts
Kraftmessbolzen
Hinweis: Befestigungselemente liegen bei
1)
Befestigungselemente bei Ausführung mit Flansch und Kupplung bereits angebaut
Bosch Rexroth AG, R310DE 3306 (2014-11)
EN
18
Bosch Rexroth AG
6.5.2
EMC R320103102/2015-04
Permitted forces when installing the unit using mounting
elements
CAUTION
The attainable forces may vary according to the version, mounting
orientation and maximum travel!
Injuries.
ff Ensure that the actual load does not exceed the maximum axial force values
! Section “Maximum Axial Loading of Mechanical Cylinder System Fmax EMC”
in the “Electromechanical Cylinders EMC” catalog.
Fmax EMC can be attained with suitably designed customer-built mounting elements.
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19
Fastening the mounting elements
NOTE
Risk of twisting the piston rod due to incorrect assembly!
Damage to the EMC due to application of torque.
ff Take care not to subject the piston rod to torsion when tightening and
loosening the hex nuts.
ff Use the wrench contact surface as a holding point only.
EN
Fig. 7: Fastening the swivel head
•• The EMC is supplied with the ordered mounting elements.
•• Except for the foot mount, these mounting elements are not pre-assembled to
the EMC on delivery.
•• The foot mount is pre-assembled on delivery.
•• The mounting elements can also be ordered separately as accessories.
20
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XX Remove the set screws (if present) from the bearing plate on the timing belt
side drive before mounting it.
XX Fasten the mounting elements as shown in the illustration ! Fig. 8. Tighten
the fastening bolts evenly, taking care not to exceed the maximum screw-in
depth BG and the tightening torque MA max.
Table 6:
Tightening torques MA max
EMC
8.8, µ = 0.125
BG (mm)
u MA max (Nm)
32, 40
M6
50, 63
M8
80, 100
M10
100XC
M12
16
9.6
16
23.0
20
46.0
26
79.0
BG
Fig. 8: Fastening the mounting elements
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21
Installing the EMC
NOTE
Risk of warping due to incorrect mounting!
Product malfunction
ff Avoid subjecting the cover/base and the protective profile to tension !
Fig. 9.
F
F
EN
F
Fig. 9: Warping of cover/base and protective profile
1. Bring the EMC into position (extend/retract piston rod).
2. Tighten the fastening bolts evenly.
Take care not to exceed the maximum permitted tightening torques MA max !
Table 18 on page 55.
22
Bosch Rexroth AG
6.6.1
EMC R320103102/2015-04
Air equalization slit (optional)
NOTE
Malfunctioning caused by blocking of the air equalization slit!
Product malfunction.
ff Keep the area surrounding the air equalization slit free from obstruction.
1. Mount the EMC in such a way that the air equalization slit (1) remains
unobstructed.
1
Fig. 10: Air equalization slit
6.7
Mounting the drive
NOTE
Risk of excessive torque and rotary speed if limits are exceeded!
Damage to the product.
ff Keep within specified maximum values.
Technical data and maximum values ! “Electromechanical Cylinders EMC”
catalog.
The Electromechanical Cylinder EMC has the following drive options ! Fig. 11:
•• Motor (1) with flange and coupling (2)
•• Motor (1) with timing belt side drive (3)
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23
1
1
2
3
EN
Fig. 11: Drive options
6.7.1
Motor mounting kits for motors according to customer
specification
In order to determine the appropriate attachment kit, the connection geometry
of the motor is crucial. For more information, see the catalog “Electromechanical
Cylinder EMC”.
The following table lists the recoding from the motor geometry code to the
motor designation (required for motor mounting in the following section).
Table 7:
Third-party motor code
Motor geometry code
Motor designation
09-20-040-2.5-063-M05-010-055
M1002
14-30-060-3.0-075-M06-008-072
M1004
19-40-080-3.0-100-M06-010-096
M1005
24-50-110-3.5-130-M08-010-126
M1006
32-58-130-3.5-165-M10-013-155
M1007
38-80-180-4.0-215-M12-013-192
M1008
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6.7.2
Mounting the motor via flange and coupling
1. Push the coupling (1) onto the drive journal of the EMC. While doing so keep
the necessary (B) distance ! Fig. 12. Clamp the coupling with clamping
screw (3) terminals onto the motor pin with MA max1.
6
4
7
5
9
3
1
2
8
Fig. 12: Mounting the motor via flange and coupling
2. Mount the coupling housing (4) with four screws (5) at the base of the
cylinder. MA max 2 ! Table 9 please note. Pay attention to the alignment of the
closing hole.
3. Mount the motor plate (8) with four / six screws (9) to the coupling housing (4).
MA max 2 ! Table 9.
B
Fig. 13: Set dimensions B
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4. Slide the motor (6) with coupling (1) into the motor plate (8) and the clutch
housing (4). Mount engine with four screws (7) on the motor plate with
MA max 2. Clamp the clutch on the drive stud of the cylinder with MA max 1 !
Table 8 (2).
5. Close the clutch housing with the plug screw.
Table 8:
MA max 1 (steel – steel)
8.8, µ = 0.125
u MA max (Nm)
Table 9:
M4
M5
M6
M8
M10
M12
2.8
5.5
9.6
23
46
79
MA max 2 (steel – alu / alu – alu)
8.8, µ = 0.125
u MA max (Nm)
M4
M5
M6
M8
M10
M12
2.4
4.8
8.5
20
41
70
EN
Table 10:
EMC
32
40
50
63
80
100
100XC
Dimensions B for flange and coupling
Motor type
MSM019B, MSM031B
MSK030C, M1002
MSM031C
MSK030C, MSK040C
M1004
MSM031C, MSM041B
MSK040C
MSK050C, M1005
MSM041B
MSK040C
MSK050C, MSK060C, M1005
MSK050C, MSK060C
MSK076C
M1006
MSK060C
MSK071D, MSK076C
M1007
MSK071E
MSK101D
M1008
Dimensions B (mm)
2.5
3.0
3.5
4.0
3.5
3.5
4.0
3.5
15.5
17.5
15.5
8.5
7.5
8.0
9.5
8.5
9.0
19.5
21.5
19.5
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6.7.3
Mounting the motor via timing belt side drive
Timing belt side drive without support bearing
During assembly, apply Loctite 242 to the threads of all screws/bolts that
were not coated with threadlocking adhesive on delivery.
The timing belt side drive can be attached in the following orientations:
RV01
RV02
RV03
2
2
1
2
1
Fig. 14: Mounting orientations for the timing belt side drive
1 Lube fitting on EMC
2 Motor connector
1
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27
16
1
14
15
3
2
13
4
EN
12
11
5
6
9
7
10
8
Fig. 15: Mounting the motor and timing belt side drive without support bearing
1 Base plate
6 Tensioning unit type 2
2 Motor plate
3 Housing
7 Hex socket head cap
screw
4 Hex socket head cap
screw
8 Tensioning unit
9 Belt
5 Hex socket head cap
screw
10 System-side belt pulley
11 Motor-side belt pulley
12 Hex socket head cap
screw
13 Centering plate
(necessary for some
motors)
14 Hex socket head cap
screw
15 Motor
16 Hex socket head cap
screw
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EMC R320103102/2015-04
Assembling the base plate and system-side belt pulley
1. Screw-fasten the housing (1) of the timing belt side drive to the base of the
EMC. When doing this, observe the specified tightening torques ! Table 18
on page 55.
2. Push the belt pulley (10) with fitted toothed belt (9) onto the drive journal of
the EMC.
NOTE
Insufficient lubrication by use of false lubricant!
Damage to the product.
ff Do not use oil with MoS2 additives!
3. Lightly oil the tensioning elements.
4. Type 2: Push on the tensioning unit. The tensioning elements must be
completely inserted into the bore of the belt pulley.
Fig. 16: Tensioning unit type 2
5. Lightly tighten the screws (5).
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29
1
9
10
7
EN
8
Fig. 17: Mounting the system-side belt pulley
6. Adjust distance A to the base plate
Table 11:
EMC
Clearance dimensions for belt pulley
Motor
Clearances (mm)
to the
to the Motor
i = 1 i = 1,5 i = 2
base
plate
32
A
Fig. 18: Adjust the systemside belt pulley
distance
MSM019B
MSM031B, MSK030C
M1002
40
MSM031C
MSK030C
MSK040C
M1004
50
MSM031C
MSM041B
MSK040C
MSK050C
M1005
63
MSM041B
MSK040C
MSK050C
MSK060C
M1005
80
MSK050C
MSK060C
MSK076C
M1006
100
MSK060C, MSK076C
M1006
M1007
100XC MSK071E, MSK101D
M1008
1
A
1
B
–
C
–
1
2
–
–
1
2
2
14
12
–
–
2
3
14
–
14
14
14
–
–
–
3
4
3
3
7
3
5
5
4
3
3
4
2
3
2
3
–
2
2
28
2
4
3
–
–
–
D
–
18,0
7,5
19,0
–
19,0
19,0
21,0
–
21,0
21,0
–
–
30
EMC R320103102/2015-04
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7. Evenly tighten the screws (7) cross-wise in several stages to the specified
tightening torques ! Table 12 on page 30.
Table 12:
Tightening torques for the tensioning units
m = 0.125
u MA max (Nm)
Type
1
2
M2,5
1.2
M3
2.1
M4
2.9
4.9
M5
6.0
9.7
M6
10.0
-
Mounting the second belt pulley and motor for i = 1
1. To make sure the second belt pulley can be easily inserted, pre-mount the
motor as close to the EMC as possible.
2. Push the belt pulley and tensioning unit onto the motor journal.
Fig. 19: Mounting the motor and motor-side belt pulley, i = 1
3. Adjust distance B ! Table 11 on page 29.
i=1
B
Fig. 20: Adjusting the clearance for the motor-side belt pulley, i = 1
4. Tighten the screws to the specified tightening torque ! Table 12 on
page 30.
R320103102/2015-04 EMC
Bosch Rexroth AG
31
Mounting the second belt pulley and motor for
i = 1.5 and i = 2
1. Connect belt pulley (10) and clamping set type 1 (12)
for i = 2 and type 2 (13) for i = 1.5 to the pins of
the motor. Lightly tighten the screws (8).
Fig. 21: Tensioning unit
type 1
2. To make sure the second belt pulley can be easily
inserted, pre-mount the motor as close to the
EMC as possible.
i = 1.5
i=2
EN
8
13
8
10
10
12
Fig. 22: Mounting the motor and motor-side belt pulley, i = 1,5 and i = 2
3. Adjust distance for C and D ! Table 11 on page 29.
i=2
i = 1.5
C
D
Fig. 23: Adjusting the clearance for the motor-side belt pulley, i = 1.5 and i = 2
4. Tighten the screws to the specified tightening torque ! Table 12 on
page 30.
5. Insert the pulley into the belt.
32
Bosch Rexroth AG
EMC R320103102/2015-04
6. Center the toothed belt on the belt pulley.
7. Screw the adjusting screw (14) through the base plate (1) into the motor
plate (2) .
8. Adjust belt frequency with frequency meter and adjusting screw as per
Table 13.
9. Tighten the screws (16) in the motor plate with tightening torque ! Table 18
on page 55.
14
1
2
16
Fig. 24: Preloading the timing belt side drive
10. Check belt frequency and adjust again if necessary.
11. Screw the housing tightly onto the (3) base plate.
3
Fig. 25: Mounting the housing
12. Perform a function check.
R320103102/2015-04 EMC
Table 13:
Bosch Rexroth AG
Belt frequency
±2
(Hz)
10
312
219
EMC
Motor
i
32
MSM019
MSM031B
MSK030
M1002
MSM031C
1
1
Frequency
P=
5
252
190
1
190
219
1
1,5
1
1,5
1
1,5
1
410
397
410
397
181
183
241
439
424
439
424
208
210
283
1,5
246
289
300
1
116
138
145
180
186
180
186
162
168
162
189
195
95
96
95
110
111
88
89
88
88
207
214
207
214
195
202
195
221
216
123
125
123
155
157
124
126
124
126
125
214
221
138
139
138
179
181
174
176
174
174
143
125
144
40
MSK030
50
63
80
100
100XC
33
MSK040
M1004
MSM031C
MSM041B
MSK040
MSK050
M1005
MSM041B
1
2
MSK040
1
2
MSK050
1
M1005
2
MSK060
1
MSK050
1
2
MSK060
1
M1006
2
MSK076
1
MSK060
1
M1006
2
MSK076
1
2
M1007
1
MSK070/71 1
MSK071E
1
MSK101D
1,5
M1008
P = ball screw lead
16
20
25
32
40
438
424
438
424
203
205
294
EN
207
214
207
214
209
216
209
214
221
142
143
142
179
181
179
181
179
179
34
Bosch Rexroth AG
6.8
EMC R320103102/2015-04
Mounting the switching system
NOTE
Potential collision due to false mounting of the switching system!
Damage to product, adjoining structure and workpieces.
ff The entire switching system must be mounted on one side of the product.
The T-slot strip for switches(1), retaining bracket (2) and switch (3)
(magnetic field sensors) need to be mounted by the customer.
The necessary magnet (4) is factory-fitted.
3
4
2
1
Fig. 26: Mounting the switching system
R320103102/2015-04 EMC
6.8.1
Bosch Rexroth AG
35
Mounting the T-slot strip for switches
NOTE
Potential collision due to false mounting of the switching system!
Damage to product, adjoining structure and workpieces.
ff The entire switching system must be mounted on one side of the product.
1. Align the T-slot strip for switches (1) with the leading edge (7) in the
longitudinal groove (6) in the protection profile. Align the T-slot strip for
switches between the base (8) and the cover (9) .
2. Line up the supplied mounting bracket (2) evenly along the T-slot strip for
switches.
3. Clamp mounting bracket with clamping screws (3/5) (tightening torque
1.9 Nm) in the protection profile.
EN
4. Fix the T-slot strip for switches into place with clamping screws (4) against
the protection profile.
5. Ensure that the T-slot strip for switches is firmly mounted.
9
6
9
4
5
2
4
7
1
Fig. 27: Mounting the T-slot strip for switches
3
36
Bosch Rexroth AG
6.8.2
EMC R320103102/2015-04
Mounting the switches
Switches can be inserted into either or both of the two T-slots.
NOTE
Potential collision due to false mounting of the switching system!
Damage to product, adjoining structure and workpieces.
ff The entire switching system must be mounted on one side of the product.
1. Place the switches (magnetic field sensors) in the T-slot of the T-slot strip
that the clamping screw (1) is facing outward ! Fig. 28.
2. Adjust the switches to the desired switch activation point.
Take care to ensure that the active zone of the switch is between L0 1Mag and
Lsmax 1Mag.! Fig. 29 on page 37 and Table 14 on page 37.
1
Fig. 28: Mounting the switches
R320103102/2015-04 EMC
Bosch Rexroth AG
Lsmax 1Mag
L0 1Mag
37
Lsmax 2Mag
L0 2Mag
Fig. 29: Setting the switching point
Table 14:
Setting the switching points
Size of ball screw Dimensions (mm)
At travel range 0 mm
At travel range smax mm
d0 x P (mm)
L0 1Mag
L0 2Mag
Lsmax 1Mag
Lsmax 2Mag
32
12x5
12.00
55.00
112.00
155.00
12x10
12.00
55.00
112.00
155.00
40
16x5
12.00
61.50
112.00
161.50
16x10
12.00
61.50
112.00
161.50
16x16
12.00
61.50
112.00
161.50
50
20x5
12.00
76.50
112.00
176.50
20x10
12.00
76.50
112.00
176.50
20x20
12.00
76.50
112.00
176.50
63
25x5
12.00
76.50
112.00
176.50
25x10
12.00
76.50
112.00
176.50
25x25
12.00
76.50
112.00
176.50
80
32x5
11.00
94.50
111.00
194.50
32x10
11.00
94.50
111.00
194.50
32x20
11.00
94.50
111.00
194.50
32x32
11.00
94.50
111.00
194.50
100
40x5
10.50
99.00
110.50
199.00
40x10
10.50
99.00
110.50
199.00
40x20
10.50
99.00
110.50
199.00
40x40
10.50
99.00
110.50
199.00
100XC
50x10
11.50
144.00
111.50
244.00
50x20
11.50
144.00
111.50
244.00
EMC
The dimensions given in the table show the position of the magnet
depending on the maximum path smax.
3. Fasten in place using the clamping screw (1) ! Fig. 28 on page 36.
Hand tighten and check tightness of the switch.
EN
38
EMC R320103102/2015-04
Bosch Rexroth AG
6.8.3
Connecting the switches
1. Connect the switches as illustrated Fig. 30.
2
3
4
5,6
1
5
2
3
24
M8x1
4
1
3
37
R913037444
R913037443
R913037446
R913037445
NO
1
NC
+
1
4
PNP - NO
4
3
-
1
+
PNP - NC
4
NPN - NO
3
+
3
-
1
+
4
-
Fig. 30: Connecting the switches
1 Connection
2 Fastening screw
3 LED display
4 Position of sensor element : 2.0 mm
NPN - NC
3
-
R320103102/2015-04 EMC
Bosch Rexroth AG
39
NOTE
Collision between the ball nuts and base plate!
Damage to product, adjoining structure and workpieces.
ff Do not over-travel Table 14 on page 37 the indicated .positions.
2. After connecting, check the switching points at low speeds and adjust if
necessary.
Further technical data to the switches ! “Electromechanical Cylinders EMC”
catalog.
6.8.4
Connecting the EMC electronically
WARNING
Electrical shock from touching live parts!
Serious injury or even death.
ff Disconnect the power before working on the electrical installation and
secure against reconnection.
ff Observe the safety instructions in the documentation of the controller used.
1. While still disconnected from the power supply, switch on the relevant system
component.
2. Connect the EMC to the power supply as illustrated.
Fig. 31: Connecting the EMC electronically
EN
40
Bosch Rexroth AG
EMC R320103102/2015-04
XX Observe the information on electromagnetic compatibility.
XX Also note the information in the current publications. They can be ordered
from your sales partner under or downloaded at
www.boschrexroth.com/mediadirectory.
XX Refer to the documentation for the controller used. It is available for
download at
www.boschrexroth.com/mediadirectory.
R320103102/2015-04 EMC
7
Bosch Rexroth AG
41
Initial operation
XX Only initiate operation of the product when it has been verified that the
final product (such as a machine or system), into which the Rexroth product
is installed, complies with the national regulations, safety regulations and
standards for the application.
WARNING
Risk of injury from moving parts (e.g. piston rod)!
Contusions.
ff During operation, do not reach into moving parts.
ff Do not linger in dangerous zone in front of the piston rod.
ff Before start-up, check that there are no persons in front of the piston rod.
NOTE
Short circuiting of the motor caused by missing fasteners!
Engine damage due to ingression of liquids and debris.
ff Prior to initial operation, ensure that all connectors are plugged in correctly.
ff Prior to initial operation, ensure that all gaskets and seals of the
connections are tight.
NOTE
Collision caused by incorrectly adjusted limit switches!
Damage to the product.
ff Do not run the product to the physical stop limit.
ff If required by the application, the piston rod may be driven without force to
a stop point in the final position for referencing purposes. Do not exceed
the maximum approach speed of 0.01 m/sec.
ff Observe the EMC's maximum travel range.
ff Comply with all mounting positions for a two-sided safety distance
(overflow).
EN
42
7.1
Bosch Rexroth AG
EMC R320103102/2015-04
Checking the operating conditions
XX Check the ambient temperature, load, rotational speed, travel speed
and maximum travel range of the EMC ! Table 19 on page 56 and
“Electromechanical Cylinders EMC” catalog.
XX For special requirements, please contact us.
7.2
Trial run, start-up
XX Place the product into operation only after successful production-related
tests.
XX Proceed at a slow speed over the entire travel range. Most importantly, make
sure that the limit switches are correctly set and properly functioning.
XX If necessary, optimize interaction of mechanics and electronics.
7.3
Initial start-up
WARNING
Risk of injury from moving parts (e.g. piston rod)!
Contusions.
ff During operation, do not reach into moving parts.
ff Do not linger in dangerous zone in front of the piston rod.
ff Before start-up, check that there are no persons in front of the piston rod.
To extend the working life of the seals, apply some lubricant to the piston
rod in the vicinity of the seals prior to start-up.
R320103102/2015-04 EMC
Bosch Rexroth AG
43
1. Make sure that the travel range is free from obstructions. On delivery, the
piston rod is maximally retracted.
NOTE
Collision caused by incorrectly adjusted limit switches!
Damage to the product.
ff Do not run the product to the physical stop limit.
ff Comply with all mounting positions for a two-sided safety distance
(overflow).
ff Observe the EMC's maximum travel range.
ff First check to ensure that the spindle extends and retracts in the direction
of rotation.
ff Move the piston rod very slowly.
ff Make sure that the travel range is free from obstructions.
2. To extend, rotate the drive journal of EMC to the left. It is recommended to
turn the drive journal by hand. If the extension is to take place using a motor,
then only at a low speed.
Fig. 32: Extending the piston rod
EN
44
7.4
Bosch Rexroth AG
EMC R320103102/2015-04
Restarting after dismantling
1. When restarting the system, proceed as described in section “Start-up” !
7.3 on page 42.
R320103102/2015-04 EMC
8
Bosch Rexroth AG
45
Operation
WARNING
Electrical shock from touching live parts!
Serious injury or even death.
ff Disconnect the power before working on the electrical installation and
secure against reconnection.
ff Observe the safety instructions in the documentation of the controller used.
Risk of injury from moving parts (e.g. piston rod)!
Contusions.
ff During operation, do not reach into moving parts.
ff Do not linger in dangerous zone in front of the piston rod.
NOTE
Leaking lubricant due to vertical installation.
Pollution
ff Take appropriate measures to collect leaked grease and dispose of it
properly.
Engine overheating due to overload!
Fire.
ff Please note values, such as torque, maximum speed, motor data, etc. while
in operating mode ! “EMC Electromechanical Cylinders”
XX Please note values, such as load ratings, torque, maximum speed, motor data,
etc. while in operating mode ! “Electromechanical Cylinders EMC” catalog.
EN
46
Bosch Rexroth AG
9
EMC R320103102/2015-04
Cleaning and care
NOTE
Damage caused by the use of solvents and aggressive cleaning agents!
Destruction of seals and malfunction of the product.
ff Clean only with water and, if necessary, use a mild detergent.
1. Seal all openings with appropriate protective caps/devices.
2. Make sure all gaskets and seals of the connectors are firmly seated so that
during cleaning no moisture can get into the EMC.
3. To extend the life of the seal, apply some lubricant on the piston rod in the
vicinity of the seal after cleaning.
R320103102/2015-04 EMC
10
Bosch Rexroth AG
47
Maintenance and repair
The only maintenance required is greasing the ball screw drive with a
commercially available hand press. The basic lubrication is done at the
manufacturer.
Nozzle pipes with suitable mouthpiece can be ordered under the order number
R3455 030 44.
10.1
Lubrication
XX Read the relevant safety data sheets and take notice before using lubricants.
NOTE
Damage due to insufficient lubrication!
Drop in performance and corrosion.
ff Lubricate product every two years or if the specified travel range is
completed – whichever limit is reached first ! Table 15 on page 48.
Insufficient lubrication by use of false lubricant!
Damage to the product.
ff Do not use any oil which contains MoS2additives!
ff Use only recommended lubricants ! Table 16 on page 49.
Power change due to special operating conditions
Damage to the product.
ff Before starting-up the product under special operating conditions consult
Bosch Rexroth AG, particularly in cases involving glass fiber dust, wood dust,
solvents, short stroke and extreme temperatures.
EN
48
EMC R320103102/2015-04
Bosch Rexroth AG
10.1.1
Lubrication intervals
When the specified travel range is completed or after two years, whichever limit
is reached first.
To ensure the lubrication is distributed equally, the specified quantity of grease
per lubrication interval is to be applied.
Limit conditions:
•• Load
= ≤ 0.2 C
= 100 min–1
•• nmin
•• Installation position:
arbitrary
•• Mode of operation:
no short stroke (> smin)
•• Sealant:Standard
If the option “ball screw only preserved”, the double amount of lubrication is to
be applied prior to start up.
Table 15:
EMC
Lubrication intervals, lubricant quantities
P1)
smin
(mm)
32
40
50
63
80
100
100XC
1)
Rotations U (million)
Travel range (km)
Dynalub
510
Dynalub
510
Dynalub
520
Grease relubrication amount
(cm3)
Dynalub
520
5
40
–
37.5
250
187.5
0.41
10
40
–
37.5
500
375.0
0.41
5
70
50
37.5
250
187.5
0.83
10
70
50
37.5
500
375.0
1.09
16
70
50
37.5
800
600.0
1.50
5
90
50
37.5
250
187.5
1.24
10
90
50
37.5
500
375.0
1.91
20
90
50
37.5
1000
750.0
3.00
5
100
50
37.5
250
187.5
1.91
10
100
50
37.5
500
375.0
2.33
25
100
50
37.5
1250
937.5
4.24
5
100
50
37.5
250
187.5
2.74
10
100
50
37.5
500
375.0
3.83
20
100
50
37.5
1000
750.0
4.35
32
130
50
37.5
1600
1200.0
6.68
3.68
5
100
50
37.5
250
187.5
10
100
50
37.5
500
375.0
8.18
20
100
50
37.5
1000
750.0
10.61
40
150
50
37.5
2000
1500.0
17.55
10
130
10
7.5
100
75.0
13.20
20
130
10
7.5
200
150.0
12.38
Ball screw lead
XX Under normal operating conditions, relubricate according to Table 15.
XX For special requirements, please contact us.
R320103102/2015-04 EMC
10.1.2
Bosch Rexroth AG
49
Lubricant quantities
The EMC is designed for grease lubrication only.
Greases containing solid particles (e.g. graphite or MoS2) S2) must not be used!
Recommended lithium soap greases ! Table 16.
Table 16:
Recommended lubricant
Grease
Part number
Dynalub 510
R341603700
Dynalub 520
R341604300
10.1.3
Lubricating the EMC
1. In order to achieve the lubricating LLub position, move the piston rod to stroke
position S2. For this purpose, move S1 from the end position according to
tTable 17 on page 50. ! Fig. 33.
LLub
S1
S2
3.
1.
2.
Fig. 33: Lubricating the EMC
2. Apply grease to the ball screw drive using the lube nipple. Use the entire
amount of grease at once ! Table 17 on page 50.
3. Extend and retract the piston rod the entire travel range with three double
strokes.
EN
50
EMC R320103102/2015-04
Bosch Rexroth AG
Table 17:
EMC
Lubrication positions
Dimensions (mm)
LLub
36.0 + smax/22)
S1
S2
5
21.5 + smax/22)
33.0 + smax/22)
10
38.0 + smax/22)
18.5 + smax/22)
30.0 + smax/22)
5
35.5 + smax/22)
16.1 + smax/22)
28.1 + smax/22)
10
40.0 +
smax/22)
smax/22)
29.5 + smax/22)
16
48.0 + smax/22)
15.0 + smax/22)
27.0 + smax/22)
5
33.0 + smax/22)
10.0 + smax/22)
24.0 + smax/22)
10
42.5 + smax/22)
10.0 + smax/22)
24.0 + smax/22)
20
smax/22)
smax/22)
24.0 + smax/22)
P1)
32
40
50
63
80
100
100XC
52.0 +
17.5 +
10.0 +
5
35.0 + smax/22)
10.0 + smax/22)
24.0 + smax/22)
10
44.5 + smax/22)
10.0 + smax/22)
24.0 + smax/22)
25
smax/22)
smax/22)
24.0 + smax/22)
60.5 +
10.0 +
5
37.0 + smax/22)
10.0 + smax/22)
26.0 + smax/22)
10
49.0 + smax/22)
7.5 + smax/22)
26.0 + smax/22)
20
53.0 + smax/22)
7.5 + smax/22)
24.5 + smax/22)
32
smax/22)
smax/22)
24.5 + smax/22)
70.5 +
7.5 +
5
36.0 + smax/22)
7.9 + smax/22)
23.9 + smax/22)
10
43.0 + smax/22)
10.5 + smax/22)
23.9 + smax/22)
20
52.0 + smax/22)
4.5 + smax/22)
21.5 + smax/22)
40
79.5 +
smax/22)
smax/22)
21.5 + smax/22)
10
66.5 + smax/22)
15.3 + smax/22)
43.4 + smax/22)
20
77.5 + smax/22)
18.4 + smax/22)
46.5 + smax/22)
4.5 +
1)
Ball screw lead
2)
smax: maximum travel range of the EMC (see name plate)
NOTE
Damage caused by incorrect parameters when approaching the rear end
position!
Damage to the product.
ff Approaching the rear end position with the following parameters.
Maximum speed: 10 mm/s
Maximum force: 5% of Fmax EMC
R320103102/2015-04 EMC
11
Bosch Rexroth AG
51
Disassembly and replacement
Basically, the dismantling and replacing of modules must only be performed by
Rexroth to ensure the accuracy of the EMC after replacement of modules.
Excluded are the activities described in this chapter.
11.1
Dismantling the drive
WARNING
Electrical shock from touching live parts!
Serious injury or even death.
ff Disconnect the power before working on the electrical installation and
secure against reconnection.
For vertical or inclined installation risk of the piston rod crashing due to lack
of self-locking!
Serious injury or even death.
ff When mounted vertically or on an inclined surface securely fasten product
before removing the mounting screws securing the piston rod to prevent
crashing.
ff Do not stand in the direction of travel of the piston rod.
EN
52
EMC R320103102/2015-04
Bosch Rexroth AG
11.1.1
Removing the motor flange and coupling
1. Open the plug screw in the clutch housing (4). Open the clamping screw (2)
of the clutch.
2. Open the motor screws (7) and remove the motor (6) together with clutch
from the clutch housing (4).
3. Loosen the screws (9) and remove the motor plate (8).
4. Loosen the screws (5) and remove the clutch housing (4).
5
2
6
7
4
8
9
Fig. 34: Removing the motor flange and coupling
1
3
R320103102/2015-04 EMC
11.1.2
Bosch Rexroth AG
53
Removing the motor and belt transmission
1. Disassemble the cover (3) from the base plate (1) ! Fig. 35 on page 54.
CAUTION
Uncontrolled movements of the pre-tensioned belt when loosening the
screws!
Injuries.
ff Loosen the fastening screws on the motor carefully.
2. Loosen the fastening screws (17) holding the motor (16).
3. Loosen the tensioning unit (7) on the motor side belt pulley (12), take off the
tensioning unit and belt pulley.
4. Remove the belt (10).
5. Detach the tensioning unit (9) on the EMC belt pulley (11). To f facilitate
disassembly, forcing threads are present in the tensioning units.
6. Loosen the motor mount (17), and remove the motor (16).
EN
54
EMC R320103102/2015-04
Bosch Rexroth AG
16
1
14
15
3
2
13
4
12
11
5
6
9
8
7
Fig. 35: Removing the motor with belt transmission
10
R320103102/2015-04 EMC
12
Bosch Rexroth AG
55
Disposal
The EMC contains different substances: Aluminum, steel, plastics, grease and
possibly electronic components.
NOTE
Environmentally hazardous substances can be released into the environment
through improper disposal!
Pollution.
ff Collect and properly dispose of discharging lubricants.
ff Dispose of the product and its components appropriately and in accordance
with applicable national and international regulations and laws.
EN
13
Technical data
Technical data ! “Electromechanical Cylinders EMC” catalog.
13.1
Tightening torque
By default, screws of property class 8.8 are used. Deviations are marked
accordingly.
Table 18:
Tightening torque
8.8
u MA max (Nm) m = 0.125
M2
M2,5
M3
M4
M5
M6
M8
M10
M12
0.4
0.7
1.3
2.8
5.5
9.6
23
46
79
56
Bosch Rexroth AG
14
EMC R320103102/2015-04
Operating conditions
Table 19:
Operating conditions
Cylinder mechanism: –10 °C ... 50 °C
Ambient
temperature
ϑ
Cylinder with Rexroth Servomotor: 0 °C ... 40 °C,
performance degradation over 40 °C
Travel speed
max 1.6 m/s
Maximum
travel range
100 to 1500 mm
14.1
v
Service and Support
XX When ordering spare parts, mention all data on the name plate ! Fig. 2 on
page 9.
XX Please contact your regional center of Bosch Rexroth AG for ordering
replacement parts. These can be found at
www.boschrexroth.com/contact
In urgent cases, please contact the Bosch Rexroth service help-desk and hot line:
Phone:
+49 (0) 9352 40 50 60
Email:
servicelt@boschrexroth.de
Return address:
Bosch Rexroth AG
SERVICE
Röntgenstraße 5
97424 Schweinfurt, Germany
R320103102/2015-04 EMC
Bosch Rexroth AG
57
EN
Bosch Rexroth AG
Ernst-Sachs-Straße 100
97424 Schweinfurt, Germany
Phone +49 9721 937-0
Fax
+49 9721 937-275
www.boschrexroth.com
Subject to modifications
Printed in Germany
R320103102/2015-04