Bosch Rexroth FMS User manual

R320103174/2018-08
EN
ENGLISH
Instructions
Function modules FMS/FMB

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 (Originaldokumentation)
EN English
FR Français
IT Italiano
ES Español
PT Português
ZH 中文
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The data specified above only serves to
describe the product. No statements
concerning a certain condition or
suitability for a certain application can
be derived from our information.
The information given does not release
the user from the obligation of own
judgment and verification. It must be
remembered that our products are
subject to a natural process of wear and
aging.
© Bosch Rexroth AG reserves all rights,
including the right to apply for patent
protection. This document may not be
reproduced or given to third parties
without our consent.
The title page contains an illustration of
a sample configuration. The product as
delivered can differ from the illustration.
The original instructions are in the
German language.
Any dissemination of the product must
include these instructions and the safety
instructions for Linear Motion Systems.

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Contents
1 About these instructions........................................................................4
1.1 Scope and purpose of the documentation......................................4
1.2 Required and supplementary documentation.................................4
1.3 Presentation of information ............................................................4
2 Safety instructions .................................................................................6
3 Scope of supply ......................................................................................6
3.1 Delivery condition ...........................................................................6
3.2 Accessories .....................................................................................6
3.3 Overview of function modules ........................................................6
4 Product description................................................................................8
4.1 Features ..........................................................................................8
4.2 Product description FMS function modules ...................................8
4.3 Product description FMB function modules ...................................9
4.4 Identification of the product.........................................................10
5 Transport and storage ..........................................................................10
5.1 Transporting the product ..............................................................10
5.2 Storing the product.......................................................................11
6 Installation ............................................................................................12
6.1 Unpacking the product..................................................................12
6.2 Required accessories .................................................................... 12
6.3 Installation conditions...................................................................12
6.4 Installation position ......................................................................13
6.5 Fastening the product to the adjoining structure..........................13
6.6 Switching system installation........................................................15
7 Mounting the FMS drive ......................................................................16
7.1 Mounting the motor with mount and coupling..............................16
7.2 Mounting the motor with timing belt side drive............................18
8 Mounting the FMB drive.......................................................................20
8.1 Installing the mount and gear unit ................................................20
8.2 Mounting the motor ......................................................................21
9 Electrically connecting the function module .......................................21
10 Start-up .................................................................................................21
10.1 Easy start-up using the integrated wizard..................................... 22
10.2 Checking the operating conditions ...............................................22
10.3 Trial run, running in.......................................................................23
10.4 Moving the sensor.........................................................................23
12 Maintenance and repair........................................................................24
11 Operation..............................................................................................24
13 Lubrication............................................................................................25
13.1 Notes.............................................................................................25
13.2 Lube fittings ..................................................................................26
13.3 LSS lubrication.............................................................................. 27
14 Removal and replacement....................................................................28
14.1 Removing the sensor.....................................................................28
14.2 Disassembling the drive................................................................ 28
15 Disposal ................................................................................................29
16 Technical data.......................................................................................29
17 Operating conditions............................................................................29
17.1 Tightening torques ........................................................................29
18 Notes.....................................................................................................29

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1 About these instructions
1.1 Scope and purpose of the documentation
This documentation applies to the following products:
• Function modules in the “Function modules” 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.
XBefore 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 and supplementary documentation
Documentation which is indicated by the book symbol must be obtained before handling the product and must
be adhered to:
Tabelle 1: Required documentation
Title Document number Document type
Safety instructions for Linear Motion Systems R320103152 Safety instructions
FMS/FMB function modules R999001417 Catalog
Rexroth catalogs for drive technology Catalog
Safety data sheet for Dynalub 510 R320103160
Product data sheet for Dynalub 510 R310 2052
The Rexroth documentation is available for download at www.boschrexroth.com/mediadirectory.
1.3 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. These are explained in
the following sections.
1.3.1 Safety instructions in this manual
This manual contains safety instructions preceding any actions that involve a risk of personal injury or damage to
property. The safety precautions described must be adhered to.

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Safety instructions are structured as follows:
SIGNAL WORD
Type of hazard!
Consequences if ignored.
fHazard prevention measure.
• 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 prevention measure: Indicates how to avoid the hazard
The safety instructions cover the following hazard levels. The hazard level describes the risks involved if the safety
instruction is not complied with.
Tabelle 2: Hazard levels as per ANSI Z535
Warning sign, signal word Meaning
DANGER Indicates an imminently hazardous situation which will result in death or serious injury if not
avoided.
WARNING Indicates a potentially hazardous situation which could result in death or serious injury if not
avoided.
CAUTION Indicates a potentially hazardous situation which may result in minor or moderate injury if not
avoided.
NOTICE Damage to property: Risk of damaging the product or the surrounding environment.
1.3.2 Symbols
The following symbols indicate notes that are not safety-critical but make the documentation easier to understand.
Tabelle 3: Meaning of the symbols
Symbol Meaning
If this information is not observed, the product will not be optimally used or operated.
XSingle, independent work step
1.
2.
3.
Numbered work steps
The numbers indicate the sequence of the work steps.
!7See section 7
!Fig. 7.1 See Figure 7.1
Screw with strength class...
uTightening torque
mFriction factor for screws

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2 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: Function module, drive (motor and gear unit, installed) if ordered together.
3.1 Delivery condition
Depending on the order, completely assembled with drive.
3.2 Accessories
Available accessories: !Catalog.
Dimensions and part numbers of the accessories as well as additional mounting accessories !catalog.
H
LA
FMx A
(mm)
H
(mm)
-080 80 107
-110 110 89
Fig. 1: Overview of function modules
3.3 Overview of function modules
2.1 Overview of types
The function modules are available in different sizes and shapes. Specific data and dimensions !catalog.
1.3.3 Abbreviations
The following abbreviations are used in this documentation:
Tabelle 4: Abbreviations and definitions
Abbreviation Meaning
FMS Function modules with Ball Rail System and Ball Screw Assembly
FMB Function module with Ball Rail System and belt drive
BASA Ball Screw Assembly
LSS Initial lubrication done at the factory
do(mm) Nominal diameter of Ball Screw Assembly
P (mm) Lead of Ball Screw Assembly
C (N) Dynamic load capacity of guideway or Ball Screw Assembly
Fm(N) Dynamic equivalent load
Fm/C (-) Load ratio

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FMS-xxx-SN-x
(single-rail)
FMS-xxx-DN-x
(dual-rail)
AA
HH1
H1
AA
H
AA
HH1
H1
AA
H
Without motor attachment
Motor attachment with timing belt side drive
Motor attachment with mount and coupling
FMB-xxx-SN-x
(single-rail)
FMB-xxx-DN-x
(dual-rail)
AA
HH1
H1
AA
H
AA
HH1
H1
AA
H
Without motor attachment
Motor attachment with gear reducer

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Attachments/accessories
9 Magnetic sensor
10 Optical sensor
11 Switching cam for optical sensor
4 Product description
4.1 Features
Please refer to the notes, technical data, dimensions and descriptions of the products in the catalog.
4.2 Product description FMS function modules
Fig. 2: Components of the FMS function module
FMS function module components:
1 Drive-side end block
2 Ball Screw Assembly (covered)
3 Carriage with T-slots and Runner Block
4 Cover plate
5 End plate
6 Frame
7 Runner Block
8 Guide Rail
10
11
1
4
5
2
3
6
7
8
9

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4.3 Product description FMB function modules
Attachments/accessories:
9 Magnetic sensor
10 Optical sensor
11 Switching cam for optical sensor
FMB function module components:
1 Idler end enclosure
2 Toothed belt (covered)
3 Carriage with T-slots and Runner Block
4 Cover plate
5 Drive end enclosure
6 Frame
7 Runner Block
8 Guide Rail
Fig. 3: Components of the FMB function module
9
1
4
5
2
3
6
7
8
10
11

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4.4 Identification of the product
The nameplate of the product carries the following information:
Tabelle 5: Details given on nameplate
Nameplate details Meaning
MNR Part number
SYN Serial number
FD Manufacturing date
CS Customer order number
Manufacturing location
XWhen ordering replacement parts, please always state all data given on the nameplate.
Fig. 4: Nameplate
5 Transport and storage
5.1 Transporting the product
WARNING
Risk of product crashing down due to inadequate load hoisting equipment!
Severe personal injury or even death.
fUse only safety-inspected, appropriate load hoisting equipment.
fCarefully attach load hoisting equipment only to the frame (main body) or at the designated points.
fDo not stand under suspended loads.
On the nameplate you will find additional technical data for start-up.
With these parameters and the EasyWizard software, starting up the drives of Linear Motion Systems becomes
easier, faster and more effective than ever before !10 Start-up.
Bosch Rexroth AG
D-97419 Schweinfurt
Made in Germany
7210
CNR: R12345678
TYP: FMx-xxx-xx-1
CS: 9876543210 0030 0001
FD: 5129
smax (mm) u (mm/U) vmax (m/s) amax (m/s2) M1max (Nm) d i
-- -- -- -- -- -- --
MNR: R87654321

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L
LLL
LL
1/91/9 2/9 3/9 2/9
1. Before hoisting the product, take note of the weight !catalog.
2. Hoist the product as shown in the illustration using suitable load hoisting equipment.
Fig. 5: Hoisting the product
5.2 Storing the product
NOTICE
Risk of damage due to incorrect storage!
Potential corrosion of product parts.
fStore the product only in dry, roofed areas.
fProtect the product from humidity and corrosive agents.
L
L
LL
2/7 2/73/7
L ≤2000mm
NOTICE
Risk of damage to motor attachment through vibrations!
Motor may break off.
fWhen transporting the product with ready-mounted motor, always provide support for the motor
or
fremove the motor prior to transport.
Selection of the wrong anchor points
fWhen lifting and transporting, do not put pressure on end enclosures and screw journals.
fNever suspend just in the center or just at the ends!
L >2000mm

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6 Installation
Dimensions and part numbers of the individual components !catalog.
WARNING
Risk of product crashing down due to inadequate load hoisting equipment!
Severe personal injury or even death.
fUse only safety-inspected, appropriate load hoisting equipment.
fCarefully attach load hoisting equipment only to the frame (main body) or at the designated points.
fDo not stand under suspended loads.
XBefore hoisting the product, take note of the weight !catalog.
Risk of product and carriage crashing down in vertical, slanting or suspended installations when not secured
sufficiently!
Severe personal injury or even death.
fSecure the product against dropping.
fDo not stand under the product in the hazard zone.
fWith a vertical or slanting product, secure the carriage so that it cannot drop down.
fDo not stand in the fall direction of the carriage.
6.1 Unpacking the product
1. Before hoisting the product, take note of the weight !catalog.
2. Take the product out of the packaging and remove the packaging material.
3. Dispose of the packaging material according to the local regulations in your country.
6.2 Required accessories
XRequired mounting accessories !catalog.
XUse suitable screws for fastening.
6.3 Installation conditions
XTake note of the operating conditions !17 and catalog.
XFor special operating conditions, please contact us.
NOTICE
Risk of damage due to non-permissible loads!
Damage to the product.
fDo not attach any overhanging loads.

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Fig. 7: Securing the carriage
6.4 Installation position
The product can generally be installed in any position.
6.5 Fastening the product to the adjoining structure
Fig. 6: Minimum distance to the end plates / maximum permissible deflection
XWhen mounting to the frame, keep a minimum distance of 5 mm from the end plates.
A
B
min. 5 mm
fmax
F
300 mm 300 mm 300 mm 300 mm
NOTICE
Risk of loosening or warping of the product due to incorrect mounting!
Damage to the product.
fFasten the product using the recommended fastening elements.
fDo not secure or support the product at the end plates.
fObserve the tightening torques.
fObserve the maximum permissible deflection fmax (please refer to the diagrams in the catalog)!
If high system dynamics are required, supports (B) must be provided every 300 mm ! Fig. 7.

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1 2 3
FMS/FMB A
(mm)
B
(mm)
-080 96 110 M5
-110 126 140 M5
FMS/FMB C
(mm)
-080 40 M4
-110 66 M4
Fig. 9: Fastening the product with sliding blocks
6.5.1 Fastening the product with clamping fixtures
fMount the product with clamping fixtures (1/2/3/4) on the mounting base as shown in the figure below.
fRecommended number of clamping fixtures per meter and side: 1: 6 pieces / 2: 4 pieces / 3: 3 pieces
fObserve the tightening torques !17.1.
fSuitable clamping fixtures !catalog.
Fig. 8: Fastening the product with clamping fixtures
K-K
K-K
A
B
C
±0,1
K-K
K-K
A
B
C
±0,1
4
6.5.2 Fastening the product with sliding blocks
fMount the product with sliding blocks on the mounting base as shown in the figure below.
fRecommended number per meter and side: 6 pieces
fObserve the tightening torques !17.1.
fSuitable sliding blocks !catalog.

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6.6 Switching system installation
NOTICE
Potential collision due to incorrect mounting of the switching system!
Damage to product, adjoining structure and workpieces.
fPrerequisite for the installation of the switching system is the fastening of the product.
fThe entire switching system must be mounted on one side of the product.
fMove the carriage by hand to check for potential collision with the carriage or a mounted workpiece.
6.6.1 Installing the magnetic sensor with sensor plates
1. Insert the sensor (1) into the sensor plates (2) and retain with a knurled screw (3).
2. Insert the sensor plates (2) (one each for start and finish point) into the corresponding slot on the frame and
use set screws (4) for retention.
3. Adjust the switching points and switching distances by moving the sensor plates.
Fig. 11: Installing the magnetic sensors
4
3
1
2
6.6.2 Optical Sensor
4. Install the switching cam (1) in the carriage center using two screws in the side carriage slot.
5. Insert the sensor plates (2) (one each for start and finish point) into the corresponding slot on the frame and
use set screws for retention.
6. Fix the sensors (3) to the sensor plates (2) using the enclosed socket head screws.
7. Adjust the switching points and switching distances by moving the sensor plates.
Fig. 10: Installing the switching cam/sensors
13
2

A
C
B
A
Fig. 12: FMS drive types
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7 Mounting the FMS drive
NOTICE
Risk of excessive torque and rotary speed if limit values are not adhered to!
Avoid tension due to the weight of the motor when mounting the motor!
Damage to the product.
fObserve the specified limit values. Technical data and limit values !catalog.
7.1 Mounting the motor with mount and coupling
The screw journal of the function module and the motor journal must be completely free of grease and oil
before mounting.
Observe the tightening torques !17.1
1. Push the coupling (4) onto the screw journal (5) of the function module (1) and tighten the screw (6) (system-
side) to tightening torque MA.
2. Push the mount (3) into the centering (2) on the function module (1) and tighten to the end plate (8) using four
screws (7) and tightening torque MA.
3. Push the motor (9) into the centering of the mount and coupling and using four screws (10) tighten to
tightening torque MA.
4. If necessary, release the motor brake and move the carriage (12) so that the screw journal can turn, and tighten
the motor-side clamping screw (11) of the coupling to tightening torque MA
(through the bore in the mount).
Drive types:
• Mount and coupling (B) with motor (A)
• Timing belt side drive (C) with motor (A)

FMS Motor A1(mm) Lf(mm)
-080
-110
MSM 031C
ECMAC20604
ECMAC10604
67.3 72.0
9
11 1
6
A₁±0,1
Lf
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Fig. 13: Mounting the motor with mount and coupling
4
5
28
11
7
10
3
1
12
9
6

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7.2 Mounting the motor with timing belt side drive
Mounting the housing
XScrew the housing (1) of the timing belt side drive (5) onto the product (6) using screws (7). The timing belt
side drive can be attached in four different directions.
Tightening torques !17.1
Mounting the first belt pulley
1. Push the belt pulley (2) fitted with toothed belt (4) onto the screw journal.
2. Adjust distance Ato the housing.
3. Tighten the set screw (3) to tightening torque MA1 in accordance with Table 6 (! Fig. 14).
Fig. 14: Mounting the timing belt side drive / mounting the first belt pulley
FMS A
(mm)
± 0.1
-080
-110
MSM 031C
ECMAC20604
ECMAC10604
31
5
3
2
4
1
6
7
A
m = 0.125
M1.6 M2 M2.5 M3 M4 M5 M6 M8 M10 M12
A/F 0.7 0.9 1.3 1.5 2.0 2.5 3.0 4.0 5.0 6.0
MA1 max. (Nm) 8.8 – 0.17 0.4 0.8 1.9 3.5 5.5 9.5 23.0 46.0
S000 S090 S180 S270
Tabelle 6: Tightening torque MA1 for set screw (3)

B
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Mounting the second belt pulley
and the motor
Pre-assemble the motor:
XPre-assemble the motor (7)
with the two motor bars (8) as
close as possible to the function
module to permit problem-free
insertion of the second belt
pulley (9).
Mount the belt pulley:
XAttach the belt pulley (9) to the
motor journal and guide into the
belt.
XAdjust distance Bto the
housing.
Tighten the set screw (12) to
tightening torque MA1 in accordance
with Table 6 (! Fig. 14).
Tension the belt:
XUnfasten the motor.
XScrew suitable screws (10)
into the pre-tensioning thread
provided in both motor bars (8).
XPull the motor away from the
function module using the motor
bars. Set the belt frequency
using a frequency measuring
instrument (R913057897)
according to the notice inside
the housing and tighten the
mounting screws (11).
The preload force F
depends on the size of the
unit, the motor, belt pulleys, and
on the torque. It is indicated on the
inside of the housing. If the timing
belt side drive is not positioned
horizontally on assembly, make
allowance for the dead weight of
the motor.
Tightening torques !17.1
Fig. 15: Mounting the motor and second belt pulley
Fig. 16: Attaching the cover of the timing belt side drive
Attaching the cover of the timing
belt side drive
XAttach all covers to the housing
of the timing belt side drive.
Refer to the “Start-up”
section for the functional
check! !10
Fpr
10
8
11
9
8
12
FMS B
(mm)
± 0.1
-080
-110
MSM 031C
ECMAC20604
ECMAC10604
38.5
7

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8 Mounting the FMB drive
8.1 Installing the mount and gear unit
1. Insert the first coupling half (1) into the Tubular Shaft (2) of the end enclosure (8) and tighten the screw (3) to
tightening torque MA2 in accordance with Table 7 (! Fig. 17). (The journal and Tubular Shaft must be free of grease.)
2. Attach the second coupling half (4) to the first coupling half.
3. Install the mount (5) onto the gear unit (7) with four screws (6) using tightening torque MA (!17.1).
4. Vertically attach the gear unit and the mount to the end enclosure (8). Center these via the coupling (4).
5. Fasten the mount and gear unit on the end enclosure (8) using four screws (9) to tightening torque MA.
6. Tighten the clamping screw (10) of the 2nd coupling half (4) using the mount bore (11) to tightening torque MA2 in
accordance with Table 7 (! Fig. 17) for clamping on the gear shaft (12).
NOTICE
Risk of excessive torque and rotary speed if limit values are not adhered to!
Avoid tension due to the weight of the motor when mounting the motor!
Damage to the product.
fObserve the specified limit values. Technical data and limit values !catalog.
fInstall the motor in a vertical position.
Tightening torques !17.1
Fig. 17: Mounting the FMB drive
FMB (3 / 10)
MA2
(Nm)
-080 M6x18-12.9 ISO4762 16.5
-110
1
2
3
8
4
5
6
7
8
4
9
10
11
4
12
1. 2. 3.
4. 5.+6.
Tabelle 7: Tightening torque MA2 for
screws 3 and 10