Bosch Rexroth MAD100 Operating Instructions Manual
Asynchronous housing motors
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- Operating instruction (72 pages) ,
- Project planning manual (276 pages)
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Summary of Contents for Bosch Rexroth MAD100
- Page 1 MAD / MAF Asynchronous Housing Motors Operating Instructions Edition 02 R911336186...
- Page 2 Ausgabe 02, 2022-03 tab. 1-1 "Record of revisions" on page Copyright © Bosch Rexroth AG 2022 All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial prop‐ erty rights.
- Page 3 Comply with the time required for the (p. ex. dissipateurs thermiques). Respectez le Kühlkörpern). Abkühlzeit der drive components to cool down (at least 15 délai de refroidissement des composants Antriebskomponenten einhalten minutes). d’entraînement (au moins 15 minutes). (mind. 15 Minuten). R911336186_Edition 02 Bosch Rexroth AG...
- Page 4 Antes de entrar ou aceder à área perigosa, Prima di accedere alla zona di pericolo, la zona de peligro, los accionamientos se imobilize os acionamentos de forma segura. arrestare e bloccare gli azionamenti. tienen que haber parado con seguridad. Bosch Rexroth AG R911336186_Edition 02...
- Page 5 Sørg for at koble spændingsforsyningen fra, aardleiding. arbete på drivkomponenter. inden du rører ved drive components. Schakel voor toegang tot Var medveten om kondensatorernas Overhold kondensatorernes afladningstider. aandrijvingscomponenten de urladdningstid. spanningsvoorziening uit. Neem de ontlaadtijden van condensatoren in acht. R911336186_Edition 02 Bosch Rexroth AG...
- Page 6 Batterierna får inte tas isär eller skadas. Undlad at skille batterier ad eller at Batterijen niet demonteren of beschadigen. Släng inte batterierna i elden. beskadige dem. Smid ikke batterier ind i Nooit batterijen in het vuur werpen. åben ild. Bosch Rexroth AG R911336186_Edition 02...
- Page 7 Unikać kontaktu z powierzchniami Nedotýkejte se kovových povrchů (např. jäähdytyslevyt). Noudata käyttölaitteen metalowymi (np. radiatorami). Przestrzegać chladicích těles). Dodržujte dobu ochlazení komponenttien jäähtymisaikoja (väh. 15 czasów schładzania podzespołów napędów komponent pohonu (min. 15 minut). minuuttia). (min. 15 minut). R911336186_Edition 02 Bosch Rexroth AG...
- Page 8 Pred prijemom ali dostopom v nevarno območje varno zaustavite vse gnane dele. Pred zásahom alebo prístupom do Înainte de intervenţia sau accesul în zona nebezpečnej oblasti uveďte pohony periculoasă, opriţi în siguranţă componentele bezpečne do zastavenia. de acţionare. Bosch Rexroth AG R911336186_Edition 02...
- Page 9 áramellátást. Pirms darba pie piedziņas komponentiem Преди работа по задвижващите atslēdziet elektroapgādi. Ügyeljen a kondenzátorok kisülési idejére! компоненти, изключете захранващото Ņemiet vērā kondensatoru izlādes laikus. напрежение. Обърнете внимание на времето за разреждане на кондензаторите. R911336186_Edition 02 Bosch Rexroth AG...
- Page 10 агресивен агент). Az akkumulátorokat ne szedje szét, és ne Neizjauciet un nesabojājiet baterijas. Не разглобявайте и не повреждайте rongálja meg! Az akkumulátort ne dobja Nemetiet baterijas ugunī. батерии. Не хвърляйте батерии в огън. tűzbe! Bosch Rexroth AG R911336186_Edition 02...
- Page 11 Venkite liesti metalinius paviršius (pvz., radiaatorid) puudutamist. Pidage kinni επιφάνειες (π.χ. μονάδες ψύξης). Λάβετε radiatorių). Išlaikykite pavaros komponentų ajamikomponentide mahajahtumisajast υπόψη το χρόνο ψύξης των στοιχείων atvėsimo trukmę (bent 15 minučių). (vähemalt 15 minutit). μετάδοσης κίνησης (τουλάχιστον 15 λεπτά). R911336186_Edition 02 Bosch Rexroth AG...
- Page 12 Μην απορρίπτετε τις μπαταρίες στη φωτιά. 中文 如果不按照下述指定的安全说明使用，将会导致人身伤害！ 在没有阅读，理解随本产品附带的文件并熟知正当使用前，不要安装或使用本产品。 如果没有您所在国家官方语言文件说明，请与 Rexroth 销售伙伴联系。 只允许有资格人员对驱动器部件进行操作。 安全说明的详细解释在本文档的第一章。 高电压！电击导致生命危险！ 只有在安装了永久良好的设备接地导线后才可以对驱动器的部件进行操作。 在接触驱动器部件前先将驱动器部件断电。 确保电容放电时间。 危险运动！生命危险！ 保证设备的运动区域内和移动部件周围无障碍物。 防止人员意外进入设备运动区域内。 在接近或进入危险区域之前，确保传动设备安全停止。 电磁场/磁场！对佩戴心脏起搏器、金属植入物和助听器的人员会造成严重的人身伤害 ! 上述人员禁止进入安装及运行的驱动器区域，或者必须事先咨询医生。 热表面（大于 60 度）！灼伤风险！ 不要触摸金属表面（例如散热器）。驱动器部件断电后需要时间进行冷却（至少 15 分钟）。 安装和运输不当导致受伤危险！当心受伤！ 使用适当的运输和安装设备。 使用适合的工具及用适当的防护设备。 电池操作不当！受伤风险！ 请勿对低电量电池重新激活或重新充电（爆炸和腐蚀的危险）。 请勿拆解或损坏电池。请勿将电池投入明火中。 Bosch Rexroth AG R911336186_Edition 02...
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Page 13: Table Of Contents
Transport and storage....................15 Notes about transport (shipping)......................15 Notes about internal transport to the machine..................16 Storage instructions..........................17 Assembly........................19 Motor assembly............................ 19 6.1.1 Flange assembly..........................19 6.1.2 Foot mounting............................ 19 6.1.3 Mount transmission elements......................21 R911336186_Edition 02 Bosch Rexroth AG... - Page 14 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 Troubleshooting......................45 12.1 Procedure............................. 45 Technical data......................47 Appendix........................49 14.1 Declaration of conformity........................49 Index..........................53 Bosch Rexroth AG R911336186_Edition 02...
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Page 15: About This Documentation
DANGER Non-compliance with this safety instructions will result in death or severe per‐ sonal injury. WARNING Non-compliance with this safety instructions can result in death or severe personal injury. R911336186_Edition 02 Bosch Rexroth AG... - Page 16 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 forbidden. Tab. 1-3: Meaning of symbols Bosch Rexroth AG R911336186_Edition 02...
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Page 17: Safety Instructions
For the purpose of this manual, qualified personnel means persons who are familiar with transporting, installing, mounting, commissioning and operating the components of the electrical drive and control system and the associated hazards and have an appropriate qualification for their job. R911336186_Edition 02 Bosch Rexroth AG... -
Page 18: General Safety Instructions
In the case of damage due to non-observance of the safety notes, Bosch Rexroth assumes no liability. Applications for functional safety are only allowed if the motors have the SI sign on the rating plate. -
Page 19: Protection Against Magnetic And Electromagnetic Fields
● Allow the motors to cool down long enough before touching them. ● Temperature-sensitive components may not come into contact with the motor surface. Ensure appropriate mounting distance of connection ca‐ bles and other components. R911336186_Edition 02 Bosch Rexroth AG... - Page 20 6/57 MAD / MAF Asynchronous Housing Motors Bosch Rexroth AG R911336186_Edition 02...
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Page 21: Scope Of Delivery
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. R911336186_Edition 02 Bosch Rexroth AG... - Page 22 8/57 MAD / MAF Asynchronous Housing Motors Bosch Rexroth AG R911336186_Edition 02...
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Page 23: About This Product
About this product About this product Product description 4.1.1 Technical features The motors of MAD/MAF series are asynchronous housing motors for ope‐ rating converters or inverters of Bosch Rexroth. Product AC motor Bosch Rexroth AG Manufacturer Buergermeister-Dr.-Nebel-Straße 2 97816 Lohr am Main, Germany... -
Page 24: Type Of Protection
MAD / MAF Centering hole , acc. to DIN 332-2 DS M16 ■ ■ DS M20 ■ ■ ■ Tab. 4-4: Centering hole Key (option) MAD / MAF , acc. to DIN 6885-AS 10×8×45 ■ 12×8×80 ■ Bosch Rexroth AG R911336186_Edition 02... -
Page 25: Bearings
Delivery of air which contains a high dust load, e.g., extraction of saw dust ● Delivery of combustible gases/particles ● Use of the ventilator as a technical safety component or as a component assuming safety-relevant functions R911336186_Edition 02 Bosch Rexroth AG... -
Page 26: Product Identification
The coolant flow direction can be arbitrarily selected. Expand the cooling circuit with anticorrosive. Observe the information in the motor project planning manual Asynchronous Housing Motors MAD/MAF. Product identification 4.2.1 Type code Fig. 4-3: Type code (1/2) Bosch Rexroth AG R911336186_Edition 02... - Page 27 MAD / MAF Asynchronous Housing Motors 13/57 About this product Fig. 4-4: Type code (2/2) R911336186_Edition 02 Bosch Rexroth AG...
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Page 28: Type Plate (Example Maf100)
This way, you can read the motor data at any time without having to work in areas that are difficult to access and where the motor may be attached. Bosch Rexroth AG R911336186_Edition 02... -
Page 29: Transport And Storage
Unless otherwise speci‐ fied, the specified values are the values of the particular class. However, Bosch Rexroth reserves the right to adjust these values at any time based on future experiences or changed environmental factors. -
Page 30: Notes About Internal Transport To The Machine
Please comply with DIN 580 on the transport of motors using lifting eyebolts. Non-observance of the information in this standard can cause overstress to the lifting eye bolts and result in personal injury and/or product damage. Bosch Rexroth AG R911336186_Edition 02... -
Page 31: Storage Instructions
● protected against light or direct sunlight Upon delivery, protective sleeves and covers can be attached to Bosch Rexroth motors. They have to remain on the motor for transport and storage. Do not remove these parts until shortly before assembly. - Page 32 Transport and storage fied, the specified values are the values of the particular class. However, Bosch Rexroth reserves the right to adjust these values at any time based on future experiences or changed environmental factors. Allowed classes of ambient conditions during storage acc. to DIN EN...
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Page 33: Assembly
2. Align the motor so that the center line of the motor shaft is aligned with the center line of the machine connecting shaft. To align the motor, use sheet steel strips as a base. 3. Connect the motor firmly to the machine. R911336186_Edition 02 Bosch Rexroth AG... - Page 34 Forces taking effect via the gear shaft must be supported against the gear. ● Incorrect installation situations give rise to forces which may cause short-term damage to the motors. ● If necessary, consider "flange assembly" as an alternative. Bosch Rexroth AG R911336186_Edition 02...
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Page 35: Mount Transmission Elements
Tools for electricians (VDE tools) are absolutely necessary. Prior to commencing work: 1. Isolate (even auxiliary circuits). 2. Secure against reactivation. 3. Ensure de-energization. 4. Ground and short-circuit. 5. Cover or shield any adjacent live parts. R911336186_Edition 02 Bosch Rexroth AG... -
Page 36: Power Connection With Device Connector
Completely tighten the screw-type device connector. The vibrating O- ring must no longer be visible. ● Connect or disconnect plug connections only in de-energized, dry and clean state. ● Protect the device connectors from external force effect. Bosch Rexroth AG R911336186_Edition 02... - Page 37 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 ready-made connection cables of Rexroth. See docu‐ mentation Rexroth Connection Cables. R911336186_Edition 02 Bosch Rexroth AG...
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Page 38: Power Connection Via Terminal Box
Spare temperature sensor (connect spare sensor lines only if necessary) ③ Shield connection by clamping the cables of the strain relief in the cable gland ④ Connection designations on the Rexroth drive controller Fig. 6-4: Terminal box connection diagram Bosch Rexroth AG R911336186_Edition 02... - Page 39 Schutzabdeckung des Cable gland connection thread ⑧ Adapter plate for cable gland ⑨ Terminal strip (brake, temperature sensor) ⑩ Purge gas connection (Option) ⑪ Clamping screws for setting the outgoing cable direction (4 pcs.) Fig. 6-5: Terminal box details R911336186_Edition 02 Bosch Rexroth AG...
- Page 40 Tightening torque of the screws ⑪: 6.5 Nm (±10%) ⇒ A sealing is between terminal box and motor housing. After turning or before retightening the terminal box, check the proper condition and po‐ sition of the sealing. Bosch Rexroth AG R911336186_Edition 02...
- Page 41 ② on the ter‐ minal box cover. Double cabling Motor connection requires two power cables if an appropriate single cable cannot be used because of the large bending radius or because of its dimen‐ sions. R911336186_Edition 02 Bosch Rexroth AG...
- Page 42 ③ Holding brake (option) ④ Potential equalization connection at the motor (only available on MAF225C-0150) ⑤ Potential equalization connection at the machine (required for MAF225C-0150) ⑥ Rexroth drive controller Fig. 6-8: Double cabling connection diagram Bosch Rexroth AG R911336186_Edition 02...
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Page 43: Connect Motor Fan (Only For Mad Motors)
Observe the safety instructions. ● The tightness of the connector housing may not be reduced. ● Motor protective switch and electric fusing are selected by the machine manufacturer. Please observe the regulations in the country of installation. R911336186_Edition 02 Bosch Rexroth AG... -
Page 44: Connect Coolant Supply (Only For Maf Motors)
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 cone-shaped screw... - Page 45 1/8" ... 1/4" 23 ... 25 1/2" 28 ... 30 Tab. 6-7: Allowed tightening torque of the quick coupling ● that the allowed screw-in depths and tightening torques at the motor are kept. R911336186_Edition 02 Bosch Rexroth AG...
- Page 46 (these are not included in the scope of delivery). ● Ensure that the cooling water complies with the require‐ ments see project planning description Asynchronous Housing Motors MAD/MAF. Bosch Rexroth AG R911336186_Edition 02...
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Page 47: Encoder Connection
RGS1003 INS0629 Tab. 6-9: Encoder connector socket designations Pin assignment EncCLK- VCC_Encoder EncCLK+ 5V Sense GND_Encoder EncData- EncData+ 0V Sense ① Encoder type M2 / S2 ② Encoder type C0 Fig. 6-12: Pin assignment encoder R911336186_Edition 02 Bosch Rexroth AG... - Page 48 34/57 MAD / MAF Asynchronous Housing Motors Bosch Rexroth AG R911336186_Edition 02...
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Page 49: Commissioning And Operation
Ensure that the motor and all participating components of the drive are undamaged. ● Ensure that keys are protected against ejection. Commissioning For start up procedure refer to the project planning manual and the respec‐ tive documentation about drive controller or firmware description. R911336186_Edition 02 Bosch Rexroth AG... -
Page 50: Operation
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 "Troubleshooting" on page Bosch Rexroth AG R911336186_Edition 02... -
Page 51: Maintenance And Repair
Check in regular distances the connection cables on damage and re‐ place them if necessary. ● Check optionally existing drag chains (Drag chains) on defects. ● Check the protective conductor connection for proper condition and firm seating at regular intervals. Replace it, if necessary. R911336186_Edition 02 Bosch Rexroth AG... -
Page 52: Service Repair, Maintenance And Spare Parts
Wearing parts are reliably and professionally repaired and re‐ placed by the Bosch Rexroth Service in shopfloor-oriented quali‐ The Bosch Rexroth service helpdesk at our headquarters in Lohr, Germany and our worldwide service provide You can contact us 24/7. Service-Hotline... -
Page 53: Disassembly And Exchange
When motors are liquid-cooled, completely discharge the coolant from the cooling tubes (e.g., via purging the coolant holes with pressure air). This will prevent frost damage at storage temperatures ≤ 0° C. R911336186_Edition 02 Bosch Rexroth AG... - Page 54 40/57 MAD / MAF Asynchronous Housing Motors Bosch Rexroth AG R911336186_Edition 02...
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Page 55: Environmental Protection And Disposal
Batteries and accumulators can contain hazardous substances which can harm the environment or people's health when improperly stored or disposed After use, the batteries or accumulators contained in Rexroth products must be properly disposed of according to the country-specific collection systems. R911336186_Edition 02 Bosch Rexroth AG... - Page 56 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. Bosch Rexroth AG R911336186_Edition 02...
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Page 57: Extension And Modification
MAD/MAF motors are suited for mounting of gearboxes and planetary gear‐ boxes. Bosch Rexroth recommends gearboxes of GTM series, which are compatible for these motors. When selecting the gearboxes, refer to the information about the type code of GTM gearboxes. - Page 58 44/57 MAD / MAF Asynchronous Housing Motors Extension and modification Observe the details of the project planning manual MAD/MAF Asynchro‐ nous Housing Motors about permitted shaft load and mounting of drive ele‐ ments. Bosch Rexroth AG R911336186_Edition 02...
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Page 59: Troubleshooting
For liquid cooling, check cooling circuit. Temperature sensor not connected Connect temperature sensor Wrong defective Connect backup temperature sensor temperature display Temperature sensor defective Stop the motor --> repair by manufacturer Tab. 12-1: Procedure troubleshooting R911336186_Edition 02 Bosch Rexroth AG... - Page 60 46/57 MAD / MAF Asynchronous Housing Motors Bosch Rexroth AG R911336186_Edition 02...
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Page 61: Technical Data
MAD / MAF Asynchronous Housing Motors 47/57 Technical data Technical data Technical data and operating characteristic curves are described for all motor types in project planning manual Asynchronous Housing Motors MAD/ MAF. R911336186_Edition 02 Bosch Rexroth AG... - Page 62 48/57 MAD / MAF Asynchronous Housing Motors Bosch Rexroth AG R911336186_Edition 02...
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Page 63: Appendix
The following declaration of conformity shows the status at the 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". R911336186_Edition 02 Bosch Rexroth AG... - Page 64 50/57 MAD / MAF Asynchronous Housing Motors Appendix Fig. 14-1: CE declaration of conformity MAD/MAF Bosch Rexroth AG R911336186_Edition 02...
- Page 65 MAD / MAF Asynchronous Housing Motors 51/57 Appendix Fig. 14-2: CE declaration of conformity MAD/MAF R911336186_Edition 02 Bosch Rexroth AG...
- Page 66 52/57 MAD / MAF Asynchronous Housing Motors Bosch Rexroth AG R911336186_Edition 02...
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Page 67: Index
MAD / MAF Asynchronous Housing Motors 53/57 Index Index Accumulators............41 Improper use Additional documentation........1 Improper use............ 4 Alignment.............. 9 Indented use Ambient temperature..........9 Directives............3 Assembly............19 Standards............3 Flange assembly..........19 Installation altitude ..........9 Installation types..........9, 10 Insulation class............. - Page 68 54/57 MAD / MAF Asynchronous Housing Motors Index Scope of delivery..........7 Shaft end............... 9 Significant components........41 Sound pressure level..........9 Storage conditions..........18 Technical data............. 47 Terminal boxes Connection scheme........24 Details............25 Power cable connection......... 26 Transmission element Fitting.............
- Page 69 MAD / MAF Asynchronous Housing Motors 55/57 Notes...
- Page 70 56/57 MAD / MAF Asynchronous Housing Motors Notes...
- Page 71 MAD / MAF Asynchronous Housing Motors 57/57 Notes...
- 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...