Bosch rexroth PSK Gen 2 User manual

Operating instructions
PSK Precision
Modules
Gen 2
Bosch Rexroth Corporation, R320103170/2021-01Bosch Rexroth Corporation, R320103170/2021-01

2/44 PSK Precision Modules
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The data specied 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 verication. It must be remembered that our products are subject to a natural
process of wear and aging.
© Bosch Rexroth Corporation
All rights reserved, including the right to apply for patent protection.
It may not be reproduced or given to third parties without our consent.
The title page contains an illustration of a sample conguration.
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 documentation ..................................................................4
1.3 Presentation of information ..............................................................4
2 Safety instructions ................................................................................... 6
3 Scope of delivery ..................................................................................... 6
3.1 Delivery condition ............................................................................6
3.2 Accessories ......................................................................................6
4 Product description ................................................................................. 7
4.1 Features ...........................................................................................7
4.2 Product description ........................................................................7
4.3 Precision Modules overview .............................................................8
4.4 Identication (start-up) ....................................................................8
5 Transport and storage.............................................................................. 8
5.1 Transporting the product .................................................................8
5.2 Storing the product ..........................................................................9
6 Assembly................................................................................................ 10
6.1 Unpacking the product ...................................................................10
6.2 Required accessories .....................................................................10
6.3 Installation conditions ....................................................................11
6.4 Installation position .......................................................................11
6.5 Attaching Precision Module to adjoining structures .......................12
6.6 Installing the drive .........................................................................13
6.7 Installing the motor with timing belt side drive ..............................16
6.8 Switch mounting ............................................................................23
6.9 Installing carriage plates on Precision Modules with cover panel .. 27
6.10 Installing the cover panel ...............................................................28
7 Connecting the Precision Module to power ........................................... 29
8 Start-up.................................................................................................. 30
8.1 Easy start-up using the integrated wizard ....................................... 30
8.2 Checking operating conditions ....................................................... 31
8.3 Test run, running in ........................................................................ 32
9 Operation............................................................................................... 33
10 Maintenance and repair ......................................................................... 33
11 Lubrication ............................................................................................ 34
11.1 Notes .............................................................................................34
11.2 Overview of lubrication types......................................................... 35
11.3 Lube ttings ...................................................................................35
11.4 Lubricants ...................................................................................... 36
11.5 LSS/LCF/LSC-type lubrication ....................................................... 38
11.6 LPG-type lubrication ...................................................................... 38
11.7 Relubrication amounts/intervals (for LSS, LPG, LCF, LSC) ............ 39
11.8 Repairs ...........................................................................................39
12 Removal and replacement...................................................................... 39
12.1 Removing the drive ......................................................................... 39
13 Disposal ................................................................................................. 40
14 Technical data........................................................................................ 40
15 Operating conditions ............................................................................. 40
15.1 Tightening torques ......................................................................... 40
16 Service and support............................................................................... 41
17 Notes ..................................................................................................... 42

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1 About these instructions
1.1 Scope and purpose of the documentation
This documentation applies to the following products:
• PSK Precision Modules as described in the “PSK Precision 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 working with the product, be sure to read these instructions
carefully and completely, especially the section titled “Safety
instructions”.
1.2 Required documentation
Documentation which is indicated by the book symbol must be
obtained before handling the product and must be observed:
Required documentation
Title Document
number
Document type
Safety instructions for Linear Motion
Systems R320103152 Safety instructions
PSK Precision Modules catalog R999000480 Catalog
IndraDrive C for Linear Motion Systems R310 2730 Catalog
IndraDrive Cs for Linear Motion Systems R310 2735 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 denitions, 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.
Safety instructions are structured as follows:

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SIGNAL WORD
Type of hazard.
Consequences if ignored.
fPrecautions to avoid hazard.
• Warning sign: draws attention to the hazard
• Signal word: indicates the degree of hazard
• Type of hazard: indicates the type or source of the hazard
• Consequences: describes the consequences that may occur if
precautions to avoid the hazard are not taken
• Precautions: indicates how the hazard can be avoided
The safety instructions cover the following hazard levels. The hazard level
describes the risks involved if the safety instruction is not complied with.
Hazard levels per ANSI Z535.6 - 2011
Warning sign, signal word Meaning
DANGER Indicates an hazardous situation which will result
in death or serious injury if not avoided.
WARNING Indicates a hazardous situation which may result in
death or serious injury if not avoided.
CAUTION Indicates a hazardous situation which may result in
minor or moderate injury if not avoided.
NOTICE Property damage The product or surroundings may
be damaged
1.3.2 Symbols
The following symbols indicate information that is not related to safety
but makes the documentation easier to understand.
Meaning of the symbols
Symbol Meaning
If this information is not observed, the product will not be
optimally used/operated.
▶Single, 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
1.3.3 Abbreviations
The following abbreviations are used in this documentation:
Abbreviations and denitions
Abbreviation Meaning
PSK Precision Modules
BASA BAll Screw Assembly

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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 delivery
The following is included in delivery:
• Precision Module
• Drive (with motor and mount, or motor and timing belt side drive
installed) if ordered
• Switch if ordered
• Final inspection certicate
XUpon receipt of the delivery, immediately check for completeness
against the receipt and notify the carrier or Bosch Rexroth Corporation
if any parts are missing.
3.1 Delivery condition
• Depending on the order, fully assembled with drive.
• Precision Modules come lubricated or preserved, depending on the
order.
3.2 Accessories
The following accessories are available:
• Mounting accessories
• Switch
• Motor attachment
Dimensions and part numbers of the accessories as well as
additional mounting accessories !see catalog.

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4 Product description
4.1 Features
Precision Modules are precise, ready-to-install Linear Motion Systems
that feature high performance in a compact size and can be delivered
quickly at an affordable price.
4.2 Product description
1
2
3
5
8
9
10
23
24
26
27
Fig. 1: Parts of the Precision Module (with drive)
A Precision Module has the following parts:
1 Frame
2 Motor
3 Mount (integrated or attached)
5 Timing belt side drive
8 Carriage (driven)
9 Carriage (undriven)
10 Switch
23 Mounting channel
24 Switching cam
26 Cover panel
27 Carriage plate
Second carriage
• The two carriages are not connected.
• Only the carriage on the drive side is driven.
• The attachment determines the distance LW.
• Observe LW min ! see catalog.

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4.3 Precision Modules overview
Precision Modules are available in three sizes ! see catalog.
The name plate of the product contains the following information:
Table 1: Information on name plate
Name plate information Meaning
MNR Part number
SYN Serial number
FD Date of manufacture
CS Customer order number
4.4 Identication (start-up)
Bosch Rexroth AG
D-97419 Schweinfurt
Made in Germany
7210
CNR: R12345678
TYP: PSK-090-NN-2
CS:9876543210 0030 0001 FD:5129
smax (mm) u (mm/U) vmax (m/s) amax (m/s2) M1max (Nm) d i
-- -- -- -- -- -- --
MNR: R123456789
Fig. 2: Name plate
The name plate contains 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 ! see Section 7 “Start-up”.
5 Transport and storage
5.1 Transporting the product
Precision Modules come ready to install.
WARNING
Risk of product falling due to inadequate load handling equipment.
Death or serious injury.
fUse only inspected and suitable load handling equipment.
fAttach load handling equipment only to the frame or at the
designated points.
fDo not stand under suspended loads.

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NOTICE
Risk of damage to motor connection through vibration.
Motor breaks off.
fWhen transporting the product with motor attached, always provide
support for the motor, or
fRemove the motor prior to transport
1. Before hoisting the product, note the weight ! see catalog.
2. Hoist the product as shown in the gure.
Fig. 3: Hoisting the product
5.2 Storing the product
NOTICE
Risk of damage due to improper storage.
Potential corrosion of product parts.
fStore the product only in dry, covered areas.
fProtect the product from humidity and corrosive agents.

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6 Assembly
For dimensions and part numbers of the individual components !see
catalog.
WARNING
Risk of product falling due to inadequate load handling equipment.
Death or serious injury.
fUse only inspected and suitable load handling equipment.
fAttach load handling equipment only to the frame or at the
designated points.
fDo not stand under suspended loads.
Risk of product falling if installed vertically or suspended due to lack
of fall protection.
Death or serious injury.
fSecure the product against falling.
fDo not stand under the product in the hazard zone.
XBefore hoisting the product, note the weight ! see catalog.
6.1 Unpacking the product
1. Before hoisting the product, note the weight ! see 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
XUse suitable screws for fastening.

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6.3 Installation conditions
XNote operating conditions ! see Section 15 and catalog.
XFor special operating conditions, please contact us.
NOTICE
Risk of damage due to improper loads.
Damage to the product.
fDo not attach any projecting loads.
6.4 Installation position
The Precision Module can generally be installed in any position.
WARNING
Risk of carriage falling if installed vertically or at an angle due to lack
of fall protection.
Death or serious injury.
fIf the Precision Module is installed vertically or at an angle, secure
carriage against falling.
Fig. 4: Securing carriage for vertical installation

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6.5 Attaching Precision Module to adjoining structures
NOTICE
Risk of product loosening or warping due to improper mounting.
Damage to the product.
fBe sure to use enough supports for the system dynamics at work.
Risk of frame bending.
Damage to the product.
fSupport the frame along its entire length (A)
fDo not support the Precision Module at the end blocks (B)
fRemove the cover panel or cover strip, if present. ! 6.10
fUse reference edges (29).
fFasten the product to the specied tightening torque.
fIf necessary, install cover panel ! see Section 6.10.
fWhen mounting to the frame, keep a minimum distance of 5 mm from
the end blocks.
A B
29
Fig. 5: Mounting

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6.6 Installing the drive
NOTICE
Risk of excessive torque and rotary speed if limits are not observed.
Damage to the product.
fObserve the specied limits.
For technical data and limits ! see catalog.
Drive types:
• Mount (3) and coupling (4) with motor (2)
• Integrated mount (3.1) and coupling (4) with motor (2)
• Timing belt side drive (5) with motor (2)
1
2
5
1
1
3.1
3
4
2
2
4
Fig. 6: Drive types

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6.6.1 Installing the motor with coupling
WARNING
Risk of electric shock due to contact with live parts.
Death or serious injury.
fBefore working on the electrical equipment, switch off the power
supply and secure it against reactivation.
NOTICE
Risk of excessive torque and rotary speed if limits are not observed.
Damage to the product.
fObserve the specied limits.
Risk of screws loosening due to improper installation.
Damage to the product.
fSecure uncoated screws with threadlocking adhesive.
Observe specied tightening torque.
Run initial cycles at reduced speed to test the function of the
limit switches and to optimize the interaction between the mechanical
equipment and the electronics.
1. Attached mount (9): Insert the mount (9) into the centering (10) on
the product (1) and fasten to the end
plate (5) with four screws to the specied tightening torque.
2. Insert coupling (4) onto the drive journal of the motor (2).
3. Set clearance A per the table.
4. Tighten the fastening screw (7) in the coupling on the side facing the
motor to the tightening torque specied under “Coupling tightening
torques”.
5. Insert motor (2) with coupling into the attached/integrated mount (3)
on the screw journal ofa the product (1) and fasten with four screws
to the specied tightening torque (6).
6. Tighten fastening screw (7) in the coupling on the side facing the product
(1)
to the tightening torque specied under “Coupling tightening
torques
” .
7. If necessary, release the motor brake and move the carriage (8) so the
screw journal turns.

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9
5
10
1
Coupling tightening torques
8.8 M2.5 M3 M4
MA (Nm) 1.0 1.7 4.0
Dimension table
PSK Motor A ±0.1 (mm)
-050 MSM 019B 11.0
MSM 031B 5.0
MS2N 03-B 5.0
-060 MSM 019B 10.0
MSM 031B 5.5
MS2N 03-B 5.0
-090 MSM 031C 6.0
MSM 041B 13.0
MS2N 03 5.0
MS2N 04 10.5
4
2
7
A
7
8
1
2
3
1
13
456
Fig. 7: Installing the motor with mount

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6.7 Installing the motor with timing belt side drive
The timing belt side drive can be attached on any side in four directions.
Fig. 8: Options for installing the timing belt side drive
CAUTION
Risk of excessive torque and rotary speed if limits are not observed.
Damage to the product.
fObserve the specied limits.
Risk of screws loosening due to improper installation.
Damage to the product.
fSecure uncoated screws with threadlocking adhesive.
Risk of insufcient lubrication due to use of improper lubricants.
Damage to the product.
fDo not use lubricant with MoS2 additives!
Observe specied tightening torque.
1. Fasten the housing of the timing belt side drive (5) onto the product
(1) and tighten to the specied tightening torque.
6.7.1 Installing the rst belt pulley
1. Lightly lubricate the tensioning unit, then insert it into the belt pulley
as far as it will go.
2. Push the belt pulley (11) and tensioning unit (12) with the toothed
belt (13) onto the screw journal of the product (1).
3. Set clearance A from the housing.
4. Thread the screws (14) into the tensioning unit and tighten slightly.
5. Tighten the screws evenly in a criss-cross pattern in several stages to
the tightening torque under “Tensioning unit tightening torques”.
S180 S270S090S000

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Belt pulley clearance (A)
PSK Motor A ±0.1 (mm)
-050 MSM019B 5.0
-060 MSM019B 5.0
MSM031B 7.0
MS2N03-B 7.0
-090 MSM031C 7.0
MSM041B 8.0
MS2N03 7.0
MS2N04 8.0
Tensioning unit tightening torques
8.8 M2.5 M3 M4 M5
MA (Nm) 1.2 2.1 4.9 9.7
A
13
1
5
11
12
14
15
5
Fig. 9: Installing the timing belt side drive

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6.7.2 Installing the support bearing
1. Push the rst retaining ring (16) onto the journal of the tensioning unit
to act as a stop.
2. Push the bearing (15) manually onto the journal of the tensioning unit
and secure it with the second retaining ring (17).
3. Carefully push the bearing ange (18) onto the bearing and screw to
the housing to the specied tightening torque.
Observe specied tightening torque.
Tightening torques
8.8 M3 M4 M5
MA (Nm) 1.3 2.7 5.5
17
15
16
18
17
15
16
18
3
Fig. 10: Installing the support bearing
6.7.3 Installing second belt pulley and motor for i = 1
Pre-installing the motor
1. Pre-install the motor (2) with the two motor mounting strips (20) as
close as possible to the product (1) with the screw (19) so the belt
pulley on the motor (11) can be inserted easily.
Installing the belt pulley:
2. Lightly lubricate the tensioning unit (12).
3. Insert belt pulley (11) and tensioning unit (12) onto the journal of the
motor (2), then thread the belt on.
4. Set clearance B from the housing.
5. Install the tensioning unit. See Section “6.7.1 Installing the rst belt
pulley”on page16.

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Tensioning the toothed belt:
We recommend a low pretension for the toothed belt.
NOTICE
Excessive belt pulley pretensioning can cause the toothed belt to
break at the product or the motor.
Damage to the product.
fObserve maximum limits.
6. Loosen the motor mounting screws.
7. Screw suitable screws (32) into the pretensioning thread in motor
mounting strips (20).
8. Set belt frequency with a force F to the frequency listed in Table 2 on
page20 using a frequency meter (R913057897). See also inside of
housing for belt frequency. Tighten the mounting screws (19) to the
specied tightening torque.
Observe specied tightening torque.
Belt pulley clearance (B)
PSK Motor B ±0.1 (mm)
-050 MSM019B 5.0
-060 MSM019B 5.0
MSM031B 7.0
MS2N03-B 7.0
-090 MSM031C 9.0
MSM041B 8.0
MS2N03 7.0
MS2N04 7.0
18
Tightening torques
8.8 M4 M5 M6 M8
MA (Nm) 2.7 5.5 9.5 23
B
1
2
20
11
12 19
4
32
20
F
F
Fig. 11: Installing second belt pulley and motor i = 1

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6.7.4 Installing second belt pulley and motor for i = 1.5
Installing the belt pulley:
1. Lightly lubricate the tensioning unit (12).
2. Insert belt pulley (11) and tensioning unit (12) or just the belt pulley
onto the journal of the motor (2), then thread the belt on.
Pre-installing the motor:
3. Pre-install the motor (2) with the two motor mounting strips (20) as
close as possible to the product (1) with the screw (19) so the belt
pulley on the motor (11) can be inserted easily.
4. Set clearance C from the housing.
5. Install tensioning unit (see Section “6.7.1 Installing the rst belt
pulley”on page16) or install belt pulley with set screw (21).
Tensioning the toothed belt:
We recommend a low pretension for the toothed belt.
NOTICE
Excessive belt pulley pretensioning can cause the toothed belt to
break at the product or the motor.
Damage to the product.
fObserve maximum limits.
6. Loosen the motor mounting screws.
7. Screw suitable screws (32) into the pretensioning thread in motor
mounting strips (20).
8. Set belt frequency with a force F to the frequency listed in Table 2
using a frequency meter (R913057897). See also inside of housing
for belt frequency. Tighten the mounting screws (19) to the specied
tightening torque.
Table 2: Belt frequency
PSK Motor i Frequency (Hz)
BASA do x p (mm)
8x1 8x2 8x2.5/8x5 12x2 12x5 12x10 16x5 16x10 16x16
-050 MSM019B 1135 208 224 – – – – – –
1.5 135 208 224 – – – – – –
-060
MSM019B 1 – – – 253 327 327 – – –
1.5 – – – 253 327 327 – – –
MSM031B 1 – – – 178 318 332 – – –
1.5 – – – 185 330 345 – – –
MS2N03-B 1 – – – 178 318 332 – – –
1.5 – – – 185 330 345 – – –
-090
MSM031C 1 – – – – – – 270 270 270
1.5 – – – – – – 243 243 243
MSM041B 1 – – – – – – 144 168 176
1.5 – – – – – – 144 168 176
MS2N03-D 1 – – – – – – 270 270 270
MS2N03-B 1.5 – – – – – – 243 243 243
MS2N04 1 – – – – – – 144 168 176
1.5 – – – – – – 144 168 176
Table 3: Belt frequency tolerances
Frequency (Hz) Tolerance (Hz) Frequency (Hz) Tolerance (Hz)
≤ 100 ± 3 > 300 ± 10
> 100 ≤ 200 ± 5
> 200 ≤ 300 ± 7