Bosch Rexroth 2GE series User manual
2/3/4/5GE…
Montageanleitung | Installation Instructions
3 609 929 255
AC/09.2011
DE/EN
DEUTSCH
ENGLISH
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Anhang
Vertrieb
Bosch Rexroth AG
Electric Drives and Controls
Schraub- und Einpress-Systeme
Postfach 1161, 71534 Murrhardt
Fornsbacher Str. 92, 71540 Murrhardt
Deutschland
Sie erreichen uns
• telefonisch +49 71 92 22 208
• per Fax +49 71 92 22 181
•perE-Mail
Internet
Informationen zu Rexroth-Schraubtechnik
finden Sie unter
http://www.boschrexroth.com/
schraubtechnik
Ergänzende Hinweise zu Service, Repara-
tur und Training sowie die aktuellen Adres-
sen unserer Vertriebsbüros finden Sie unter
http://www.boschrexroth.com
Außerhalb Deutschlands nehmen Sie bitte
Kontakt mit unserem für Sie nächstgelege-
nen Ansprechpartner auf.
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Contents
ENGLISH
Contents
1 About this documentation ................................................................... 41
1.1 Validity of the documentation .................................................................... 41
1.2 Required and amending documentation ................................................ 41
1.3 Representation of information ................................................................... 42
1.3.1 Safety instructions ....................................................................................... 42
1.3.2 Symbols ......................................................................................................... 44
1.3.3 Designations ................................................................................................. 44
1.3.4 Abbreviations ................................................................................................ 44
2 Safety Instructions ............................................................................... 45
2.1 About this chapter ....................................................................................... 45
2.2 Intended use ................................................................................................. 45
2.3 Improper use ................................................................................................. 45
2.4 Personnel qualifications ............................................................................. 46
2.5 General safety instructions ........................................................................ 46
2.6 Product- and
technology-dependent safety instructions ............................................. 47
2.6.1 General product-dependent notes .......................................................... 47
2.6.2 Protection against accidental contact with electrical parts ............... 47
2.6.3 Protective extra-low voltage for protection against electric shock ... 49
2.6.4 Protection against dangerous movements ............................................ 49
2.6.5 Protection against magnetic and electromagnetic fields during
operation and assembly ............................................................................. 51
2.6.6 Protection against accidental contact with hot parts .......................... 51
3 Scope of delivery .................................................................................. 52
4 About this product ............................................................................... 52
5 Transport and storage ......................................................................... 53
6 Assembly ............................................................................................... 54
6.1 Required tools .............................................................................................. 55
6.2 Assembling the product ............................................................................. 55
7 Commissioning ..................................................................................... 59
8 Operation .............................................................................................. 59
9 Maintenance and repair ...................................................................... 60
9.1 Cleaning and care ....................................................................................... 60
9.2 Maintenance schedule ................................................................................ 61
9.3 Maintenance .................................................................................................. 61
9.4 Spare parts .................................................................................................... 62
10 Decommissioning .................................................................................. 62
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Contents
11 Disassembly and replacement ............................................................. 63
11.1 Required tools .............................................................................................. 64
11.2 Disassembling .............................................................................................. 64
12 Disposal ................................................................................................. 65
12.1 Environmental protection ........................................................................... 65
13 Extension and conversion .................................................................... 66
13.1 Converting the product .............................................................................. 66
14 Troubleshooting ................................................................................... 67
15 Technical data ...................................................................................... 67
16 Appendix ............................................................................................... 69
16.1 Complaints and repairs .............................................................................. 69
16.2 Warranty ........................................................................................................ 69
16.3 Service and sales ........................................................................................ 69
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Contents
ENGLISH
The data specified above serves to describe the
product. If information is also provided regarding the
use, it only constitutes application examples and
suggestions. Catalog specifications are no warranted
properties. Theinformation givendoes not release the
user from the obligation of own judgment and
verification. Our products are subject to a natural
process of wear and aging.
© This document, as well as the data, specifications,
and other information set forth in it, are the exclusive
property of Bosch Rexroth AG. It may not be
reproduced or given to third parties without its
consent.
The title pages shows an exemplary configuration.
The supplied product may therefore vary from the
illustration.
Translation of the original operating instructions. The
original operating instructions have been prepared in
German.
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Contents
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About this documentation
ENGLISH
1 About this documen-
tation
This chapter contains general information
on the present instructions.
1.1 Validity of the documen-
tation
This documentation applies to planetary ge-
arboxes.
This documentation aims at persons com-
missioned with the assembly, commissio-
ning, maintenance, troubleshooting and di-
sassembly of planetary gearboxes.
This documentation contains important in-
formation on the safe and appropriate as-
sembly, transportation, commissioning,
maintenance, disassembly and simple trou-
bleshooting of planetary gearboxes.
XRead this documentation completely
and particularly the chapter "Safety In-
structions", before working with the pro-
duct.
1.2 Required and amending
documentation
Planetary gearboxes are components of
Rexroth tightening spindles.
XOnly commission the product if the do-
cumentation marked with the
book
symbol is available to you and you have
understood and observed it.
NOTE
Outdated documentation!
If you use an outdated version of the pre-
sent as well as the required and supple-
mentary documentation, this may lead to
an incorrect assembly and operation of
the product.
XMake sure that you always have and
use the current version of any docu-
mentation. The current version of the
documentation of Bosch Rexroth can
be found in the media directory:
http://www.boschrexroth.com/medi-
enverzeichnis
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About this documentation
Additional information on the pro-
ject planning can be found in the
project planning manual of the
Rexroth Tightening System. Notes
on the commissioning can be found
in the online help for the operating
system.
1.3 Representation of infor-
mation
In order to enable you to work with your pro-
duct in a fast and safe way, uniform safety
instructions, symbols, terms and abbreviati-
ons are used. For a better understanding,
they are explained in the following sections.
1.3.1 Safety instructions
In this documentation, there are safety in-
structions before the sequence whenever
there is a risk of personal injury or damage
to equipment. The measures described to
avoid these hazards must be observed.
Tab.1: Required and supplementary documentation
Title Document number Document type
Safety Instructions for Rexroth Tigh-
tening Systems
3 608 870 2DE Safety regulation
Rexroth Tightening Spindle 3 608 870 0… Installation instructions
Documentation of the machine or
system manufacturer
Instructions for the other system
components
Generally applicable, legal and
other binding regulations of Euro-
pean and national legislation
Provisions for accident prevention
and environmental protection appli-
cable in your country
DIN 13 sheet 13
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About this documentation
ENGLISH
Safety instructions are set out as follows: • Safety sign: draws attention to the risk
•Signal word: identifies the degree of ha-
zard, see tab. 2 on page 43
•Type of risk: identifies the type or
source of the hazard
•Consequences: describes what occurs
when the safety instructions are not com-
plied with
•Precautions: states how the hazard can
be avoided
SIGNAL WORD
Type of risk
What occurs when the safety instruc-
tions are not complied with
XHazard avoidance
Tab.2: Types of risk according to ANSI Z535.6-2006
Safety sign, signal word Meaning
DANGER
identifies a dangerous situation that will result in
death or serious injuries if it is not avoided.
WARNING
identifies a dangerous situation that may result in
death or serious injuries if it is not avoided.
CAUTION
identifies a dangerous situation that may result in mi-
nor to moderate injuries if it is not avoided.
NOTE
Damage to property: The product or the environment
may be damaged.
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About this documentation
1.3.2 Symbols
The following symbols mark notes that are
not safety-relevant but increase the under-
standing of the documentation.
1.3.3 Designations
This documentation uses the following desi-
gnations:
1.3.4 Abbreviations
This documentation uses the following ab-
breviations:
Tab.3: Meaning of the symbols
Symbol Meaning
If this information is disregarded,
the product cannot be used and/
or operated to the optimum ex-
tent.
X
single, independent step
1.
2.
3.
numbered step:
The numbers specify that the
steps are completed one after the
other.
Note This information refers to possible
limitations with regard to the pro-
duct.
Menus Entry in the graphical interface of
the software
Tab.4: Designations
Designation Meaning
BS Operating program of the
tightening system (e.g.
BS300/BS350)
CS351 S… Compact system of the
tightening system 350 for
the connection of tighte-
ning spindles
Tab.5: Abbreviations
Abbreviation Meaning
DIN Deutsches Institut für
Normung (German Stan-
dards Institution)
EMC Electromagnetic
Compatibility
EN Europäische Norm (Euro-
pean standard)
ISO International Organization
for Standardization
NEC National Electric Code
NEMA National Electrical Manu-
facturers Association
PELV Protective Extra Low Vol-
tage
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Safety Instructions
ENGLISH
2SafetyInstructions
This chapter describes the general safety
requirements and important information on
the safe assembly of the product.
2.1 About this chapter
The product has been manufactured accor-
ding to the accepted rules of current tech-
nology. There is, however, still a danger of
personal injury or damage to equipment if
this chapter and the safety instructions in
this documentation are not complied with.
XRead this documentation completely
and thoroughly before working with the
product.
XKeep this documentation in a location
where it is accessible to all users at all
times.
XAlways include the required documen-
tation when you pass the product on to
third parties.
2.2 Intended use
The product described in this documenta-
tion is exclusively intended for installation in
Rexroth tightening spindles in connection
with control and power electronics for Rex-
roth tightening systems and the related con-
necting cables.
The product is intended for industrial use
and not for private use.
Observe the operating conditions and per-
formance limits specified in the technical
data.
Intended use includes having read and un-
derstood this documentation and especially
the chapter "Safety instructions".
2.3 Improper use
Any other use
• than that described in the intended use
and
• than that described in the respective do-
cumentation
is regarded as unintended use and is there-
fore inadmissible.
Bosch Rexroth AG will not accept any liabi-
lity for damage caused by the unintended
use. The risks in case of unintended use are
exclusively borne by the user.
The unintended use of the product and its
components (if available) includes:
• that it is subjected to operating conditi-
ons that do not fulfill the specified ambi-
ent conditions. Operation is forbidden
e.g. under water, with extreme air humi-
dity, under extreme temperature fluctuati-
ons, or under extreme maximum tempera-
tures.
• that it is used in applications that have not
been explicitly approved by
Bosch Rexroth AG. Always observe the
safety instructions in the respective docu-
mentation.
• the structural change destroying the ori-
ginal state.
• the improper programming or configura-
tion of the tightening system.
The user is solely responsible for risks
caused by programming and configura-
tion of the tightening system.
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Safety Instructions
2.4 Personnel qualifications
Assembly, commissioning, maintenance,
troubleshooting and disassembly of this
Rexroth product and the handling of the
product require basic electrical and mecha-
nical knowledge, as well as knowledge of
the appropriate technical terms. Handling of
the product includes e.g. completion of a
Rexroth tightening spindle from the compo-
nents and the installation of a Rexroth tigh-
tening spindle into a system.
In order to ensure the safe use, the speci-
fied activities may therefore only be carried
out by qualified technical personnel or an in-
structed person under the direction and su-
pervision of qualified personnel.
In other words, only appropriately trained
and qualified personnel are permitted to
work with or near the product during the as-
sembly, commissioning, maintenance, trou-
bleshooting and disassembly.
Qualified personnel
• are those who can recognize possible ha-
zards and institute the appropriate safety
measures due to their professional trai-
ning, knowledge, and experience as well
as their understanding of the relevant
conditions pertaining to the work to be
done.
• must observe the rules relevant to the
subject area.
• must be trained, instructed, and authori-
zed to switch electrical circuits and de-
vices on and off in accordance with the
accepted rules of safety and current tech-
nology, ground them, and mark them ac-
cording to the job requirements.
• must be sufficiently familiar with all war-
nings and precautions according to this
documentation and the documentation of
the respective component and under-
stand their content.
• must have appropriate safety equipment
and be trained in first aid.
Persons who assemble, operate, disas-
semble, or maintain products from Bosch
Rexroth AG must not consume any alcohol,
drugs, or pharmaceuticals that may affect
their ability to respond.
2.5 General safety
instructions
• Observe the accident prevention and en-
viromental protection regulations applica-
ble to your country.
• Observe the safety regulations of the
country in which the product is used/ope-
rated.
• Use Rexroth products only when they are
in good technical order and condition.
• Observe all notes on the product.
• Persons who assemble, operate, disas-
semble or maintain Rexroth products
must not consume any alcohol, drugs or
pharmaceuticals that may affect their abi-
lity to respond.
• Only use accessories and spare parts
that are approved by the manufacturer.
• Observe the technical data and ambient
conditions specified in the product docu-
mentation.
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Safety Instructions
ENGLISH
• Don't work with the product in explosive
atmospheres where there are combus-
tible liquids, gases or dusts.
• If unsuitable products are installed or
used in safety applications, uncontrolled
operating statuses may occur in the appli-
cation that may cause physical injuries
and/or damage to property. Therefore
only use a product in safety applications
if this use is explicitly specified and per-
mitted in the product documentation.
• You may only commission the product if it
has been determined that the end pro-
duct (e.g. machinery or a system) into
which the Rexroth products are installed
complies with the country-specific provi-
sions, safety regulations and standards of
the application.
2.6 Product- and
technology-dependent
safety instructions
In this chapter, general safety instructions
are listed that depend on the technology
used in the product.
2.6.1 General product-dependent
notes
• The warranty only applies to the delivered
configuration.
• The warranty will not apply if the product
is incorrectly assembled or handled or
not used as intended.
• Do not expose the product to any mecha-
nical loads under any circumstances. Ne-
ver use the product as a handle or step.
Do not place any objects on it.
2.6.2 Protection against accidental
contact with electrical parts
This section only applies to devices
and components with voltages
above 50 V.
Contacting parts with voltages greater than
50 V can be dangerous to persons and lead
to electric shock. When electrical devices
are operated, specific parts of these de-
vices are under a dangerous voltage.
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Safety Instructions
DANGER
High voltage!
Danger to life, risk of injury due to electric shock, or risk of serious injury!
XBefore using the system or starting service/maintenance work, make sure you read
and understand these operating instructions.
XThis device may only be operated, maintained and/or repaired by personnel trained
and qualified to work on or with electrical devices.
XObserve the general construction and safety regulations for working with high-voltage
systems.
XFirmly connect the protective conductor to all electrical devices according to the con-
nection diagram before switching the system on.
XOperation, even briefly for measuring or testing purposes, is only permitted if the pro-
tective conductor is firmly connected to the components at the intended points.
XDisconnect the device from the mains or voltage source before accessing electrical
parts with voltages greater than 50 V. Protect it against accidential switch-on.
XAfter switching off the power supply, wait 10 seconds for the system to discharge be-
fore opening the housing or starting repair/maintenance work.
XFor electrical drive and filter components:
After switching off, take the specified discharging time for the respective components
into account before accessing the devices. To eliminate the risk of contact, measure
the voltage of the condensers before starting work.
XDo not touch the electrical connection points of the components when the device is
switched on.
European countries: Corresponding to EN 50178/1998, paragraph 5.3.2.3.
USA: See National Electrical Code (NEC), National Electrical Manufacturers Association
(NEMA), as well as regional building codes.
The operator must comply with all of the above listed at all times.
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Safety Instructions
ENGLISH
2.6.3 Protective extra-low voltage
for protection against electric
shock
All connections and terminals with voltages
of 5 to 50 V on Rexroth products are pro-
tective extra-low voltages which are desig-
ned to be safe to touch in accordance with
the product standards.
2.6.4 Protection against dangerous
movements
Dangerous movements can be caused by
improper actuation of connected motors.
Causes can be any of the following:
• Careless or improper wiring
• Errors while operating the components
• Incorrect input of parameters prior to
commissioning
• Error in the measurement transducer or
signal transducer
• Defective components
• Software errors
These errors can occur immediately after
the system has been switched on or after an
indefinite operating time.
The monitoring devices in the drive compo-
nents almost completely eliminate malfunc-
tions in the connected drives. However, in
view of personal safety, especially that invol-
ving risk of injury and/or damage to equip-
ment, this alone is not sufficient. Until the in-
stalled monitoring devices reach full
effectivity, faulty drive movements, whose
magnitude depends on the controller type
and the operating condition, must be antici-
pated.
WARNING
High voltage due to improper con-
nection!
Danger to life, risk of injury due to elec-
tric shock!
XOnly devices, electrical components,
and cables with protective extra-low
voltage (PELV) may be connected to
connections and terminals with volta-
ges of 0 to 50 V.
XOnly connect voltages and electric
circuits that are safely isolated from
dangerous voltages. Safe isolation is
obtained by means of isolating trans-
formers, safe opto-couplers, or bat-
tery operation disconnected from the
mains.
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Safety Instructions
DANGER
Dangerous movements!
Danger to life, risk of serious injury or damage to equipment!
XEnsure personal safety, either by means of monitoring devices or by superior measures
directly on the system.
XThe measures depend on the specific system conditions and are determined based on
a risk and error analysis. The safety regulations applicable to the system must be taken
into consideration. Unintended machine movements or other malfunctions may occur
when the safety equipment is switched off, bypassed, or not activated.
XDo not enter the machine's and machine parts' range of movement. Possible measures
to prevent unauthorized entry of persons include e.g. protective barriers, protective en-
closures, protective cover or photocells.
XBarriers and covers must be rigid enough to withstand the maximum possible momen-
tum.
XThe emergency OFF switch must be easily accessible within immediate vicinity. Check
the function of the emergency OFF system before commissioning. If the emergency
OFF switch malfunctions, do not operate the device.
XProtection against unintended start-up by means of an emergency OFF circuit.
XSafely bring the drives to a standstill before accessing or entering the danger zone.
XAdditionally secure vertical axes from falling or dropping after the motor is switched off
by mechanical locking of the vertical axis, external braking/catching/clamping devices
and sufficient weight compensation of the axis.
XSwitch electrical equipment to a de-energized state at the mains and protect it against
unintentional switch-on during: Maintenance and repair works, cleaning and long dis-
ruptions in operation.
XAvoid operating high-frequency, remote-controlled, or radio devices in the vicinity of
the device electronics and cables. If this cannot be avoided, check the device and the
system for malfunctions in all working positions. In some cases, a special EMC inspec-
tion of the entire system may be necessary.
XUse a torque support if tightenings with higher torques are to be performed with a
hand-held tightening spindle.
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Safety Instructions
ENGLISH
2.6.5 Protection against magnetic
and electromagnetic fields
during operation and
assembly
2.6.6 Protection against accidental
contact with hot parts
DANGER
Health risk for persons with pace-
makers, metal implants, and hearing
aids in the immediate vicinity of
electrical equipment!
Magnetic and electromagnetic fields may
interfere with and impair the function of
pacemakers or hearing aids as well as
that of metal implants. This may lead to a
health risk for the persons concerned.
XPersons with pacemakers and metal
implants are prohibited from entering
areas in which electrical devices and
parts are assembled, operated, or
commissioned or in which motor
parts with permanent magnets are
stored, repaired, or assembled.
XIf persons with pacemakers need to
enter these types of areas, a physi-
cian must first be consulted. The in-
terference resistance of current or fu-
ture pacemaker versions varies
greatly. For this reason, no generally
applicable rules exist.
XPersons with metal implants, metal
shrapnel in the body, or hearing aids
must consult a physician before ente-
ring these types of areas, as adverse
health effects must be expected in
these areas.
CAUTION
Hot surfaces possible on motor
housings and gearboxes!
Risk of injury! Risk of burns!
XDo not touch device housing sur-
faces at heat sources! Risk of burns!
XDo not touch housing surfaces of
motors and gearboxes! Risk of burns!
XDepending on the operating conditi-
ons, temperatures during or after
operation may exceed 60 °C
(140 °F).
XAfter switching off the motors, allow
them to cool down sufficiently before
accessing them.
XWear protective gloves or do not
work near hot surfaces.
XFor specific applications, the manuf-
acturer must undertake measures on
the end product, the machine, or the
system to prevent burn injuries du-
ring the end use. These measures
must be in accordance with the
safety regulations. Examples of pos-
sible measures are: safety warnings,
a separating safety device (shielding
or locking), and technical documen-
tation.
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Scope of delivery
3 Scope of delivery
The delivery contents include:
• Planetary gearbox
• Installation instructions for the planetary
gearbox
4 About this product
The space-saving planetary gearbox con-
verts the low motor torque into a high drive
torque. This allows for very good efficiency.
The planetary gearbox is simply bolted to
the EC motor. Several gearboxes are avai-
lable per series, for use in various applicati-
ons, see fig. 1.
Abb. 1: Sizes of the planetary gearboxes
Size 2
Size 3/4
Size 5
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Transport and storage
ENGLISH
5 Transport and storage
For storing and transporting the product, al-
ways observe the ambient conditions speci-
fied in the technical data of this product. In-
formation on the technical data is contained
in the corresponding section of these in-
structions.
Notes for transportation and shipping
Rexroth-tightening spindles are intended for
shipment by road, rail, plane or ship.
Rexroth-tightening spindles may be ship-
ped in individual packages or in multipacks.
Storage notes
Unpacking notes
After unpacking, Rexroth tightening spind-
les are ready to be installed in partly com-
pleted machinery or in a machine or system.
If Rexroth-tightening spindles are not in-
stalled in partly completed machinery or in a
machine or system:
XNote "Storage notes“ on page 53.
How to handle packing material
The original packing of Rexroth tightening
spindles consists of recyclable material and
can be recycled.
CAUTION
Not secured Rexroth tightening
spindle during transport!
Risk of injury due to unsecured Rexroth
tightening spindles falling down!
XSecure Rexroth tightening spindles
during transport.
NOTE
Damages!
Damages of the Rexroth tightening
spindle due to rust formation after unpa-
cking!
XMake sure that Rexroth tightening
spindles are packed in corrosion-pro-
tected packages. Rexroth tightening
spindles are protected against corro-
sion if packed in their original pa-
cking.
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Assembly
6Assembly
CAUTION
Incorrect product assembly/disas-
sembly possible!
Risk of injury and damage to the device
in later operation!
XAssemble/disassemble the product
according to the following informa-
tion in the correct order.
XOnly qualified personnel are authori-
zed to assemble/disassemble the
product.
XAlways switch off the power supply
to the relevant system component
before assembling/disassembling
the product.
CAUTION
Improper handling!
Under unfavorable conditions, handling
or assembling/disassembling specific
parts and components in an unsuitable
manner could cause injuries. Injury due
to crushing, shearing, cutting, impact!
XObserve the general construction
and safety regulations for handling
and assembly/disassembly.
XUse suitable assembly/disassembly
and transport equipment.
XPrevent trapping and crushing inju-
ries by taking suitable precautions.
XOnly use suitable tools. Use special
tools if stipulated.
XUse lifting equipment and tools pro-
perly.
XIf necessary, use suitable protective
equipment (for example, protective
goggles, safety shoes, protective
gloves).
XDo not stand under suspended
loads.
XAny fluids that have leaked onto the
floor must be wiped up immediately
to prevent slip hazards.
XLay cables and lines in accordance
with the permissible bending radiu-
ses so that they cannot be damaged
and no one can trip over them.
This manual suits for next models
3
Table of contents
