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Bosch rexroth ML3 Operating Instructions Manual
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Bosch rexroth ML3 Operating Instructions Manual

Self-cooled linear motors
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ML3
Self-Cooled Linear Motors
Operating Instructions
R911389762
Edition 04

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  • Page 1 Self-Cooled Linear Motors Operating Instructions Edition 04 R911389762...
  • Page 2 Edition 04, 2021-10 tab. 1-1 "Record of revisions" on page Copyright © Bosch Rexroth AG 2021 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). R911389762_Edition 04 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 R911389762_Edition 04...
  • 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. R911389762_Edition 04 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 R911389762_Edition 04...
  • 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). R911389762_Edition 04 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 R911389762_Edition 04...
  • 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. R911389762_Edition 04 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 R911389762_Edition 04...
  • 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). R911389762_Edition 04 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 R911389762_Edition 04...

  • Page 13: Table Of Contents

    General notes............................15 Mechanical assembly........................... 15 6.2.1 Air-gap, parallelism and symmetry of the motor components............15 Assembly of primary parts........................18 Installation of the secondary part segments..................20 Cover plate installation (option)......................24 6.5.1 Notes..............................24 R911389762_Edition 04 Bosch Rexroth AG...
  • Page 14 Operation.............................. 42 Maintenance and repair....................43 Cleaning and servicing......................... 43 Service repair, maintenance and spare parts..................44 Disassembly......................... 47 Environmental protection and disposal ............... 49 Troubleshooting......................51 11.1 Procedure............................. 51 Declaration of conformity..................... 53 Index..........................55 Bosch Rexroth AG R911389762_Edition 04...

  • Page 15: About This Documentation

    The signal word is intended to draw your attention to the safety instructions and describes the seriousness of the danger. The warning triangle with excla‐ mation mark indicates the danger for persons. DANGER Non-compliance with this safety instructions will result in death or severe per‐ sonal injury. R911389762_Edition 04 Bosch Rexroth AG...
  • Page 16 Warning against overhead load. Warning against crushing hazard. 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 R911389762_Edition 04...

  • Page 17: Safety Instructions

    Trademark right third parties Observe the trademark rights of third parties during assembly and use of sin‐ gle components delivered from Bosch Rexroth. For any infringement of the right, the customer is liable for the accruing damage. R911389762_Edition 04 Bosch Rexroth AG...

  • Page 18: Qualification Of Personnel

    Improper use of the components and non-observance of the described safety notes can lead to damage, bodily injury, electric shock or in extreme case lead to death. In the case of damage due to non-observance of the safety notes, Bosch Rexroth assumes no liability. Product- and technology-dependent safety instructions 2.6.1...

  • Page 19: Protection Against Magnetic And Electromagnetic Fields

    100 mm. Loose or not fastened components made of magnetizable materials can abruptly and inadvertently attracted with the permanent magnets. Apart from crushing hazard, even the danger of chipping recalcitrant material, caus‐ ing eye injury, exists. R911389762_Edition 04 Bosch Rexroth AG...

  • Page 20: Protection During Handling And Assembly

    The origin package of Rexroth is constructed in such a way that the mo‐ tor components with the permanent magnets are positioned within the pack‐ age with suitable distance, providing that the package is correctly used. Observe the following instructions during unpacking and handling. Bosch Rexroth AG R911389762_Edition 04...

  • Page 21: Protection Against Burns

    Allow the motor components 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. R911389762_Edition 04 Bosch Rexroth AG...

  • Page 22: Electrostatic Sensitive Devices (Esd)

    Avoid, e.g. direct contact of open wires of the connection cable of tempera‐ ture sensors without being electrostatically discharged or grounded. Do suitable ESD protective measures before you handle imper‐ iled components (e.g. ESD protective clothes, wristlets, conduc‐ tive floor, grounded cabinets and working surfaces). Bosch Rexroth AG R911389762_Edition 04...

  • Page 23: 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. R911389762_Edition 04 Bosch Rexroth AG...
  • Page 24 10/57 ML3 Self-Cooled Linear Motors Bosch Rexroth AG R911389762_Edition 04...

  • Page 25: About This Product

    11/57 About this product About this product Technical features Product Three phase synchronous motor Manufacturer Bosch Rexroth Electric Drives and Controls GmbH Buergermeister-Dr.-Nebel-Straße 2 97816 Lohr am Main, Germany Type Primary part ML3P03, -06, -11 Secondary part ML3S03, -06, -11 Listed acc.

  • Page 26: Type Plate Ml3

    Conformity with applicable EC Directives RoHS 2 conformity Tab. 4-1: Certification mark at type plate For further information about the certification mark please refer to the project planning manual (see table Other applicable docu‐ ments) of these motors. Bosch Rexroth AG R911389762_Edition 04...

  • Page 27: Transport And Storage

    0.6 kg up to 11.6 kg, depending from their frame size. Never touch connection points NOTICE electrostatic sensitive devices! Mounted components (e.g. KTY) contain parts susceptible to electrical discharge (ESD). Observe the ESD safety measures. R911389762_Edition 04 Bosch Rexroth AG...

  • Page 28: Product Storage

    Use coverings to protect the products from moisture. Store them only in rainproof and dry rooms. Upon delivery, protective sleeves and covers can be attached to Bosch Rexroth motors. They have to remain on the motor for transport and storage.

  • Page 29: Assembly

    Take the values of in‐ stallation dimensions from the following tableTab. 6-1 The exact dimensions and specifications for form and position tolerances can be taken from Fig. 6-2 R911389762_Edition 04 Bosch Rexroth AG...
  • Page 30 If cover plates are used, the air gap must be increased by the thickness of the cover plates Tab. 6-2. Installation height (see Tab. 6-1) Fig. 6-2: Values for levelness and parallelism Bosch Rexroth AG R911389762_Edition 04...
  • Page 31 If the installation height and thus the height of the air gap is ex‐ ceeded above the tolerances, this leads to an exponential deterio‐ ration of the linear motor specifications. A too small air gap can lead to damage or destruction of the motor. R911389762_Edition 04 Bosch Rexroth AG...

  • Page 32: Assembly Of Primary Parts

    6 mm Tab. 6-3: Fastening screws with tightening torques for ML3P primary parts Dowels Size primary part Dowels (rust-free) ML3P03 ... 11 (with internal thread M3 for disassembly) Tab. 6-4: Dowels for ML3P primary part Bosch Rexroth AG R911389762_Edition 04...
  • Page 33 The effect of liquid screw lock is damaged by loosening or re- tightening of screws (e.g. due to torque tests) and must be re‐ newed. Observe the instructions of the adhesive manufacturer about correct screw lock. R911389762_Edition 04 Bosch Rexroth AG...

  • Page 34: Installation Of The Secondary Part Segments

    The calculation of screw connection for fastening the secondary part are based on the assumption that the screwing surface of the secondary part and the screwing surface of the machine is clean and the secondary part is screwed in direct contact with the machine. Bosch Rexroth AG R911389762_Edition 04...
  • Page 35 Fasten the secondary part with screws. As necessary, install additional secondary parts in the same order. The secondary part that is installed last must have a minimum clearance of 10 cm to the primary part. R911389762_Edition 04 Bosch Rexroth AG...
  • Page 36 ① Mounting holes ② Dowel holes (blind hole at the bottom) ③ Reference marks Fig. 6-4: Mounting holes, dowel holes and reference marks at ML3S Remove the transport and assembly protection at installed secondary parts. Bosch Rexroth AG R911389762_Edition 04...
  • Page 37 Position the slide with the primary part over the assembled secondary part and lock it against unintended movement. Fig. 6-6: Assemble the remaining secondary parts according to working step 1 - Afterwards, remove the transport and assembly protection. R911389762_Edition 04 Bosch Rexroth AG...

  • Page 38: Cover Plate Installation (Option)

    2. Position the slide at one end of the axis to uncover the majority of the magnetic strip. 3. Unroll the strip over the free part of the magnetic strip. Fig. 6-7: Cover plate attachment at first side 4. Move the slide to the center of the axis Bosch Rexroth AG R911389762_Edition 04...
  • Page 39 The magnetic strip does not serve as conductive grounding con‐ nection of the cover strip. Ensure grounding in accordance with the machine safety standard and check this before commission‐ ing. R911389762_Edition 04 Bosch Rexroth AG...

  • Page 40: Hall Unit Installation (Option)

    Rotation to the motion Alignment to the side ML3P... Screws axis [degrees] of the primary part "Z" (+/- 10%) pins ± 1 mm 3.1 Nm Ø 5 F8 Tab. 6-7: Installation requirements of analog Hall unit Bosch Rexroth AG R911389762_Edition 04...

  • Page 41: Digital Hall Unit

    ML3P... Screws axis [degrees] of the primary part (+/- 10%) pins "Z" 8.4 mm 8.4 mm ± 1 mm 1.3 Nm Ø 5 F8 9.4 mm Tab. 6-8: Installation requirements of digital Hall unit R911389762_Edition 04 Bosch Rexroth AG...

  • Page 42: Electrical Connection

    Please note that self-assembled cables or cable systems of other manufactures may not comply with these re‐ quirements. Bosch Rexroth shall not be held responsible for resulting mal‐ functions or damages. Ensure that the complete machine fulfills all necessary regula‐...

  • Page 43: Electrical Connection Primary Part

    Fig. 6-9. Cables that are not suitable for drag chains must be routed in fixed installa‐ tion (see Fig. 6-15) to a junction, e.g. device connector or terminal box. From R911389762_Edition 04 Bosch Rexroth AG...
  • Page 44 Connection example connector Connection via terminal box If the primary part is to be connected to the controller by means of a terminal box, this terminal box has to be provided by the cus‐ tomer. Bosch Rexroth AG R911389762_Edition 04...

  • Page 45: Routing Of Connection Cables

    If a fixed installation is not possible, provide the connection cable with a strain relief (see Fig. 6-15) to protect the cable and the primary part from any dam‐ age (e.g. cable break). R911389762_Edition 04 Bosch Rexroth AG...
  • Page 46 Installation of a collective cable with higher cross section (Fig. 6-19) The first possibility offers the benefit of smaller bending radii. The whole cross section of parallel installed cables must be according to the increased cross section for parallel motor connections. Bosch Rexroth AG R911389762_Edition 04...
  • Page 47 ① Drive controller ② Energy chain ③ Power cables ④ Junction (e.g. connector, terminal boxes) ⑤ Connection cable (power) ⑥ Connection cable (temperature) ⑦ ML3P primary part Fig. 6-18: Parallel arrangement, separate power cables R911389762_Edition 04 Bosch Rexroth AG...

  • Page 48: Connection Designations At Rexroth Controllers

    6.7.4 Connection designations at Rexroth controllers Single arrangement ① ML3P primary part ② Rexroth - controller ③ Shield connection on the controller Fig. 6-20: Connection on drive controller - single arrangement primary part Parallel arrangement Bosch Rexroth AG R911389762_Edition 04...

  • Page 49: Rexroth Connection Cable For Ml3 Motors

    6.7.5 Rexroth connection cable for ML3 motors For connection of motors, Bosch Rexroth offers a wide range of connectors and ready-made cables as accessories. Please con‐ tact your Rexroth distributor. 6.7.6...
  • Page 50 Before the Hall unit can be connected, the connection cable of the Hall unit must be equipped with a D-SUB connector with pins. The assignment of the connector depends on the type of the Hall unit (digitally or analoge) Bosch Rexroth AG R911389762_Edition 04...
  • Page 51 S1 (OR) A- (YE) 0V (WH) S2 (GN) B+ (BU) 0V (BK) B- (RD) 5V (BN) S3 (YE) Connector housing Cable shield Cable shield Tab. 6-14: Connection assignment of D-SUB connector for Hall unit connection R911389762_Edition 04 Bosch Rexroth AG...
  • Page 52 Adapter box ↔ encoder evaluation on drive controller RKG0050 Digital Hall unit ↔ adapter box (max. cable length 30 m) RKG0051 Length measuring system ↔ Adapter box Fig. 6-23: Connection overview of ML3P with digital Hall unit Bosch Rexroth AG R911389762_Edition 04...
  • Page 53 Power and temperature connection points RG2-022ABB... Analog Hall unit ↔ Encoder evaluation at drive controller RKG0051 Length measuring system ↔ Encoder evaluation at drive controller Fig. 6-24: Connection overview of ML3P with analog Hall unit R911389762_Edition 04 Bosch Rexroth AG...
  • Page 54 40/57 ML3 Self-Cooled Linear Motors Bosch Rexroth AG R911389762_Edition 04...

  • Page 55: Commissioning And Operation

    Ensure that the motor and all participating components of the drive are undamaged (e.g. length measuring system). ● Make sure that the axis can freely move over the whole traverse path. ● Please observe the general safety instructions on the protection against hazardous movements. R911389762_Edition 04 Bosch Rexroth AG...

  • Page 56: Operation

    Check the motor for cleanliness. Check the monitoring devices and diagnostic / error messages of the con‐ trollers. Immediately decommission the drive when deviations from nor‐ mal operation exist. For further procedure refer to Chapter Trou‐ bleshooting. Bosch Rexroth AG R911389762_Edition 04...

  • Page 57: Maintenance And Repair

    Never do any provisional repairs on the connection cables. ● Check in regular distances the connection cables on damage and re‐ place them if necessary. ● Check optionally existing drag chains on defects. R911389762_Edition 04 Bosch Rexroth AG...

  • Page 58: Service Repair, Maintenance And Spare Parts

    For quick and efficient help, please have the following information ready: ● Detailed description of the fault and the circumstances ● Information on the rating plate of the products in question, particularly type codes and serial numbers Bosch Rexroth AG R911389762_Edition 04...
  • Page 59 ML3 Self-Cooled Linear Motors 45/57 Maintenance and repair ● Your contact data (phone number, fax number, e-mail address) R911389762_Edition 04 Bosch Rexroth AG...
  • Page 60 46/57 ML3 Self-Cooled Linear Motors Bosch Rexroth AG R911389762_Edition 04...

  • Page 61: Disassembly

    5. Secure the machine against accidental movements and against unau‐ thorized operation. 6. Wait until the discharge time of the electrical systems has elapsed and then disconnect all electrical connections. Lock electric cables and con‐ tacts against contact with other electrical parts. R911389762_Edition 04 Bosch Rexroth AG...
  • Page 62 Please also observe the infor‐ mation provided in chapter 5 "Transport and storage" on page 10. If necessary, record all measures in the commissioning log or machine maintenance plan. Bosch Rexroth AG R911389762_Edition 04...

  • Page 63: Environmental Protection And Disposal

    Our packaging materials do not contain any problematic materials and can therefor be easily disposed. Packaging materials are: Wood, carton and styr‐ ofoam Batteries and accumulators Batteries and accumulators can be labeled with this symbol. R911389762_Edition 04 Bosch Rexroth AG...
  • Page 64 In the case of a transport by air freight, please observe the dangerous goods regulations (IATA) for the secondary part. Deliver the products "free domicile" to the following address: Bosch Rexroth AG Electric Drives and Controls Buergermeister-Dr.-Nebel-Straße 2 97816 Lohr am Main, Germany Bosch Rexroth AG R911389762_Edition 04...

  • Page 65: Troubleshooting

    Stop the motor --> repair by manufacturer Tab. 11-1: Malfunctions on ML3 motors In the case of malfunctions or troubleshooting, please observe the notes in the project planning manual, too. Contact the manufac‐ turer, if necessary. R911389762_Edition 04 Bosch Rexroth AG...
  • Page 66 52/57 ML3 Self-Cooled Linear Motors Bosch Rexroth AG R911389762_Edition 04...

  • Page 67: Declaration Of Conformity

    ML3 Self-Cooled Linear Motors 53/57 Declaration of conformity Declaration of conformity R911389762_Edition 04 Bosch Rexroth AG Fig. 12-1: CE declaration of conformity...
  • Page 68 54/57 ML3 Self-Cooled Linear Motors Declaration of conformity Fig. 12-2: Translated CE declaration of conformity Bosch Rexroth AG R911389762_Edition 04...

  • Page 69: Index

    ML3 Self-Cooled Linear Motors 55/57 Index Index Accumulators............49 Failure cause Additional documentation........1 Measures............51 Air gap............. 16, 17, 24 Fastening screws Ambient temperature (operation)......11 Primary part........... 18 Assembly Secondary part..........20 Primary parts ..........18 Fault states............51 Secondary parts..........
  • Page 70 56/57 ML3 Self-Cooled Linear Motors Index Safety notes............4 Scope of delivery..........9 ML3P..............9 ML3S..............9 Screw lock............15 Service Helpdesk & Hotline........ 44 SHL03.1.............. 38 SHL03.1 adapter box.......... 38 Significant motor components......49 Skilled personnel..........15 Sound pressure level.......... 11 Spare parts............
  • Page 71 ML3 Self-Cooled Linear Motors 57/57 Notes...
  • Page 72 Bosch Rexroth AG P.O. Box 13 57 97803 Lohr a.Main, Germany Bgm.-Dr.-Nebel-Str. 2 97816 Lohr a.Main, Germany Phone +49 9352 18 0 Fax +49 9352 18 8400 www.boschrexroth.com/electrics *R911389762* R911389762 DOK-MOTOR*-ML3********-IT04-EN-P...

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