Bosch Rexroth VKK User manual

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Instructions
Feed Modules VKK R320103150/2012-10
Replaces: 2009.09
EN

Die vorliegende Anleitung ist in folgenden Sprachen verfügbar.
These operating instructions are available in the following languages.
Les présentes instructions de service sont disponibles dans les langues suivantes.
Le presenti istruzioni per l‘uso sono disponibili nelle lingue seguenti.
El presente manual de instrucciones está disponible en los siguientes idiomas.
As presentes instruções de serviço estão disponíveis nas seguintes línguas.
DE Deutsch (Originaldokumentation)
EN English
FR Français
IT Italiano
ES Español
PT Português
Die vorliegende Anleitung ist in folgenden Sprachen verfügbar.
These operating instructions are available in the following languages.
Les présentes instructions de service sont disponibles dans les langues suivantes.
Le presenti istruzioni per l‘uso sono disponibili nelle lingue seguenti.
El presente manual de instrucciones está disponible en los siguientes idiomas.
As presentes instruções de serviço estão disponíveis nas seguintes línguas.
DE Deutsch (Originaldokumentation)
EN English
FR Français
IT Italiano
ES Español
PT Português
This data has been provided solely for the
purpose of product description. No statement
regarding any particular quality or suitability
for any particular use can be derived from this
information. The information does not release
the user from making his/her own inspections
and evaluations. It should be noted that our
products are subject to a natural process of
aging and wear and tear.
© Bosch Rexroth AG reserves all rights,
including the right to apply for patent protection.
We reserve all rights of disposition, including all
reproduction and dissemination rights.
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.
2/40 Bosch Rexroth AG Feed Modules VKK | R320103150/2012-10

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R320103150/2012-10 | Feed Modules VKK Bosch Rexroth AG 3/40
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 supply.......................................................................................6
3.1 Delivery...........................................................................................6
3.2 Accessories.....................................................................................6
4 Product description ................................................................................7
4.1 Features ..........................................................................................7
4.2 Equipment description ..................................................................7
4.3 Identicationoftheproduct........................................................... 8
5 Transport and storage............................................................................. 8
5.1 Transporting the Feed Modules...................................................... 8
5.2 Storing the VKK............................................................................... 9
6 Mounting ...............................................................................................10
6.1 Installation conditions ..................................................................10
6.2 Mounting orientation ..................................................................11
6.3 Required accessories.................................................................... 11
6.4 Fastening the Feed Module to the adjoining structure................. 11
6.5 Mounting the drive........................................................................13
6.6 Mounting the switching system .................................................... 22
6.7 Mounting the accessories.............................................................26
6.8 Connecting the electrical power supply to the VKK ..................... 29
7 Putting into service ...............................................................................30
7.1 Easy start-up thanks to integrated assistant ................................ 30
7.2 Checking the operating conditions............................................... 31
7.3 Trial run, running in ......................................................................31
7.4 Shifting the switches ....................................................................31
8 Operation ..............................................................................................32
9 Cleaning and care..................................................................................33
10 Maintenance and repair ........................................................................33
10.1 Lubrication....................................................................................34
10.2 Repair ...........................................................................................36
11 Disassembly and replacement ..............................................................36
11.1 Removing the switches................................................................. 36
11.2 Removing the drive .......................................................................37
12 Disposal................................................................................................. 39
13 Technical data .......................................................................................39
13.1 Tightening torques........................................................................39
14 Operating conditions ............................................................................ 39

4/40 Bosch Rexroth AG Feed Modules VKK | R320103150/2012-10
1 About these Instructions
1.1 Scope and purpose of the documentation
This documentation applies to the following products:
Feed Modules VKK as described in the “Feed Modules VKK” 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
deinstallation 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 documentation
Documentation which is indicated by the book symbol must be obtained before handling the product and must
be adhered to.
Table 1: Required documentation
Title Document no. Description
Safety Instructions for Linear Motion Systems R320103152 Safety instructions
Feed Modules VKK R310DE2403 Catalog
IndraDrive C for Linear Motion Systems R310 2730 Catalog
IndraDrive Cs for Linear Motion Systems R310 2735 Catalog
Material safety data sheet for Dynalub 510 R320103160 Safety instructions
Product data sheet for Dynalub 510 R310 2052 Product data sheet
System documentation of the machinery/system
manufacturer
Manuals for the other machine/system components
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 sub-sections.
1.3.1 Sicherheitshinweise in dieser Anleitung
These Instructions contain safety (warning) notices 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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Warning notices are structured as follows:
SIGNAL WORD
Type of hazard!
Consequences if ignored.
fHazard avoidance precautions.
•Safety alert symbol: 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 avoidance precautions: indicates how to avoid the hazard
The warning notices cover the following hazard levels. The hazard level describes the risks involved if the warning
notice is ignored.
Table 2: Hazard levels as per ANSI Z535
Safety alert symbol,
signal word
Meaning
DANGER Indicates an imminently hazardous situation which, if not avoided, will result in death
or serious injury.
WARNING Indicates a potentially hazardous situation which, if not avoided, could result in
death or serious injury.
CAUTION Indicates a potentially hazardous situation which, if not avoided, may result in
minor or moderate injury.
NOTICE Damage to property: Risk of damaging the product or the surrounding environment
1.3.2 Symbols
The following symbols designate notes or crossreferences that are not safety-relevant but increase the clarity of the
documentation.
Table 3: Meaning of the symbols
Symbol Meaning
If this information is not observed, the product will not be used optimally.
XSingle, independent work step
1.
2.
3.
Numbered work steps
The sequence of the work steps is indicated by the numbers.
!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 document:
Table 4: Abbreviations and definitions
Abbreviation Meaning
VKK Feed Modul VKK

6/40 Bosch Rexroth AG Feed Modules VKK | R320103150/2012-10
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:
•VKK (as ordered per catalog)
•1 copy of “Safety Instructions for Linear Motion Systems”
•1 copy of the Instruction manual for “Feed Modules VKK”
•Final inspection certificate
3.1 Delivery
Delivery as ordered, e.g. complete with pre-assembled drive.
3.2 Accessories
The following accessories are available:
•Mounting elements
•Switches
•Protective bellows
•Cable drag chain and fastening elements
•Connection elements from the EasyHandling range
Dimensions, part number, and further information !“VKK” catalog.

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4 Product description
4.1 Features
Feed Modules are ready-to-install linear axes. Further information !“VKK” catalog.
4.2 Equipment description
Fig. 1: Structural design of the VKK
A Feed Modul consists of the following parts:
1 Mounting interface for adapter flange
2 Thrust rod
3 End seal
4 Frame
5 Motor mount for motor attachment
6 Drive journal
7 Mounting surface with centering holes
1
2 3
5
7
4
6

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4.3 Identification of the product
The nameplate of the product carries the following information:
Table 5: Details given on nameplate
Nameplate details Meaning
MNR Part number
SYN Serial number
FD Date of manufacture
CS Customer order number
XFurther information about the nameplate !7.
XWhen ordering replacement parts, please always state all data given on the nameplate.
Fig. 2: Nameplate
5 Transport and storage
Take note of the environmental conditions !14 and “VKK” catalog.
For special environmental conditions, please consult us.
5.1 Transporting the Feed Modules
WARNING
Risk of product crashing down due to inadequate load hoisting equipment!
Severe personal injury or even death.
fUse only safety-inspected and suitable load hoisting equipment.
fAttach load hoisting equipment only to the frame (main body) or at the designated points.
fDo not stand under hoisted loads.
NOTICE
Risk of damage to motor attachment through vibrations!
Motor may break off.
fWhen transporting the product with attached motor, always provide support for the motor, or
fRemove the motor before transporting the product

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5.2 Storing the VKK
NOTICE
Risk of damage due to incorrect storage!
Potential corrosion of product parts.
fStore the product only in dry, roofed areas.
fProtect the product against humidity and corrosive agents.
1. Before hoisting the VKK, take note of the weight !“VKK” catalog.
2. Hoist the VKK
Fig. 3: Transporting the VKK
NOTICE
Damage to the product due to improper transport
Damage to the VKK.
fRetract the thrust rod.
fLift the VKK only by the frame.
fThe ball screw is not self-locking.
fPrevent the VKK from swinging during lifting operations.

10/40 Bosch Rexroth AG Feed Modules VKK | R320103150/2012-10
6 Mounting
WARNING
Risk of product crashing down due to inadequate load hoisting equipment!
Severe personal injury or even death.
fUse only safety-inspected and suitable load hoisting equipment.
fAttach load hoisting equipment only to the frame (main body) or at the designated points.
fDo not stand under hoisted loads.
Risk of product crashing down in vertical or hanging installations due to lack of protection against falling
loads!
Severe personal injury or even death.
fSecure the product against dropping.
fDo not stand under the product in the hazard zone.
XBefore hoisting the VKK, take note of the weight !“VKK” catalog.
6.1 Installation conditions
Take note of the operating conditions !13 and “VKK” catalog.
fFor special operating conditions, please ask.
NOTICE
Risk of damage due to non-permissible loads!
Damage to the product.
fDo not attach any overhanging loads.
fDo not subject the thrust rod to torsion (it is not designed to absorb torque).
fThe frame is not intended for attachment of other machine elements for absorbing force.
Fig. 4: Non-permissible loads
FF
M

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NOTICE
Incorrect fastening may cause product to work loose or become distorted!
Damage to the product.
fFasten the product with the recommended fastening elements.
fAlways fasten or support the product by the frame (main body).
fTake note of the tightening torques.
6.2 Mounting orientation
The VKK can be mounted in any orientation.
WARNING
Risk of thrust rod crashing down in vertical or slanting installations due to lack of arrestor devices!
Severe personal injury or even death.
fIn vertical or slanting installations, secure the thrust rod so that it cannot drop out.
fDo not stand in line with the direction in which the thrust rod could fall.
6.3 Required accessories
Required mounting accessories !“VKK” catalog.
6.4 Fastening the Feed Module to the adjoining structure
6.4.1 Mounting the Feed Module by the frame
Fig. 5: Dropping of the thrust rod

12/40 Bosch Rexroth AG Feed Modules VKK | R320103150/2012-10
XLocating holes (1) are provided for precise alignment when fastening the Feed Module by the frame.
XMatching centering rings (2) and pliers (3) for easy removal are available as mounting accessories.
XData and dimensions can be found in the “VKK” catalog.
Fig. 6: Locating holes on the frame
XThe Feed Module can be mounted by means of clamping fixtures.
XRecommended number of clamping fixtures:
Type 1: 4 pieces per side/per 300 mm
Type 2: 2 pieces per side/per 300 mm
Type 3: 1 pieces per side/per 300 mm
XTake note of the tightening torques. !12.1.
XDetails of clamping fixtures !“VKK” catalog.
1
2
3
Fig. 7: Mounting the VKK by the frame with clamping fixtures
A±0,1
B
Type 1 Type 2 Type 3

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6.4.2 Mounting the Feed Module to other linear systems
NOTICE
Risk of product damage due to incorrect mounting!
Damage to the product.
fFasten the product with the recommended fastening elements.
fAlways fasten or support the product by the frame (main body).
fTake note of the tightening torques.
XFasten the VKK to already installed linear systems by using clamping fixtures and centering rings.
No intermediate plate is needed.
Fig. 8: Mounting the Feed Module to a Compact Module or a Bridge Module
6.5 Mounting the drive
NOTICE
Risk of excessive torque and rotary speed if limits are exceeded!
Damage to the product.
fKeep within specified maximum values.
Technical data and maximum values !“VKK” catalog.
Drive options:
•Motor (1) with motor mount and coupling (2)
•Motor (1) with timing belt side drive (3)
Fig. 9: Drive options
2
1
1
3

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6.5.1 Mounting the motor via motor mount and coupling
Fig. 10: Mounting the motor mount and coupling
1. Push the coupling (2) onto the drive journal. Make sure the mounting orientation is correct: The diameters of
the bores in the coupling and the drive journal must match up.
2. Adjust dimension A and tighten the two fastening screws (4) (tightening torque MA1).
3. Loosely pre-mount the motor mount (1) to the end block.
4. Check dimension B.
5. Screw down the motor mount to the end block using four screws (3) (tightening torque MA2).
Table 6: Tightening torque MA max
8.8, µ = 0,125 M3 M4 M5 M6 M8
uMA1 max (Nm) 1,7 3,5 8 14 30
uMA2 max (Nm) 1,3 2,7 - 9,5 23
Dimensions A and B for motor mount and coupling
Motor (mm)
A B Lf
VKK 15-50 MSM019B 5,0 10,0 45,0
MSM031B 1,5 5,5 50,0
MSK030C 1,5 5,5 50,0
VKK 15-70 MSM031C 2,0 11,0 72,0
MSM041B 6,5 18,5 83,0
MSK030C 5,0 5,0 75,0
MSK040C 2,0 10,5 77,5
VKK 25-110 MSM041B 25,0 6,0 90,0
MSK050C 23,0 11,0 115,0
6. Push the motor into the locating feature of the motor mount and coupling and screw down to the motor mount
using four screws (5) (tightening torque MA2).
2
3
1B A
Lf
4

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7. Tighten the fastening screws (6) on the motor side of the coupling (tightening torque (MA1).
If necessary, release the motor brake and move the thrust rod so that the drive journal turns (7).
Fig. 11: Mounting the motor to the motor mount
6.5.2 Mounting the motor via timing belt side drive
1. Screw down the protective profile (1) of the timing belt side rive to the end block (tightening torque MA2).
Fig. 12: Mounting the protective profile
1
5
6
7

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Mounting the screw-side belt pulley
XLightly oil the tensioning unit (2).
Tensioning unit type 1:
1. Insert the tensioning unit (2) into the belt pulley (3) and drive screws into the tapped holes in the belt pulley.
2. Push the belt pulley with fitted toothed belt and tensioning unit onto the drive journal.
3. Adjust clearance A to the protective profile.
4. Tighten the screws on the tensioning unit.
Tensioning unit type 2:
1. Insert the tensioning unit into the belt pulley. The tensioning elements must be completely inserted into the
bore of the belt pulley.
2. Push the belt pulley (2) with fitted toothed belt and tensioning unit onto the drive journal.
3. Lightly tighten the screws.
4. Adjust clearance A to the protective profile.
5. Tighten the screws on the tensioning unit cross-wise in several equal steps until the tightening torque given in
the table is reached.
Fig. 13: Mounting the belt pulley and tensioning unit
Table 7: Dimension A for timing belt side drive
Motor A(mm)
i=1 i=1,5 / i=2
VKK 15-50 MSM019B 5,0 5,0
MSM031B 6,5 6,5
MSK030C 6,5 6,5
VKK 15-70 MSM031C 6,0 6,0
MSM041B 7,5 7,5
MSK030C 6,0 6,0
MSK040C 7,5 7,5
VKK 25-110 MSM041B 10,0 10,0
MSK050C 11,0 11,0
A
3
2
Type 1 Type 2
NOTICE
Risk of insufficient lubrication due to use of wrong lubricants
Damage to the product.
fDo not use oil with MoS2additives!

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Mounting the counterbearing (VKK 15-50 and VKK 15-70)
1. Push the first lock washer (5) onto the screw end as a stop.
2. Push the bearing (4) manually onto the screw end and secure it with the second lock washer (5).
3. Carefully push the bearing flange (6) onto the bearing and screw it down on the housing.
Fig. 14: Mounting the counterbearing
546
5

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Mounting the motor-side belt pulley and motor for i = 1
1. Pre-mounting the motor:
2. Pre-mount the motor with the two motor strips (3) as close as possible to the Feed Module. This will allow
easy insertion of the belt pulley (2). Do not tighten the motor mounting screws yet.
3. Mounting the belt pulley:
4. Lightly oil the tensioning unit (1).
5. Push the belt pulley and tensioning unit onto the motor journal.
6. Adjust clearance B to the protective profile.
7. Mount the tensioning unit.
8. Tensioning the belt !6.5.3.
Table 8: Dimensions B and C for timing belt side drive
Motor B(mm) C (mm)
VKK 15-50 MSM019B 5,0 7,5
MSM031B 6,5 12,0
MSK030C 6,5 11,5
VKK 15-70 MSM031C 9,0 14,5
MSM041B 8,0 15,0
MSK030C 7,0 12,5
MSK040C 7,0 14,0
VKK 25-110 MSM041B 9,5 16,0
MSK050C 9,0 19,0
Fig. 15: Mounting the belt pulley for i=1
B
12
3

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Mounting the motor-side belt pulley and motor for i = 1.5 or i = 2
1. Mounting the belt pulley:
2. Lightly oil the tensioning unit (1).
3. Push the belt pulley (2) and tensioning unit onto the motor journal.
4. Adjust clearance Cto the motor.
5. Mount the tensioning unit.
6. Pre-mounting the motor:
Pre-mount the motor with the two motor strips (3) as close as possible to the Feed Module.
Do not tighten the motor mounting screws yet.
7. Tensioning the belt. !6.5.3.
Fig. 16: Mounting the belt pulley for i=1.5 or 2
C
1
23

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6.5.3 Tensioning the belt:
The pretensioning force Fpr depends on the size of the unit, the motor, belt pulleys, and on the torque.
The pretensioning value is indicated on the inside of the gear cover. If the timing belt side drive is not
mounted horizontally, take account of the dead weight of the motor!
Table 9: Masses of motor and brake
Motor mm(kg) mbr (kg)
VKK 15-50 MSM019B
MSM031B 0,82 0,48
MSK030C 2,10 0,25
VKK 15-70 MSM031C 1,20 0,50
MSM041B
MSK030C 2,10 0,25
MSK040C
VKK 25-110 MSM041B 2,30 0,80
MSK050C 5,40 0,70
mm= mass of motor without brake
mbr= mass of brake
1. Loosen the motor mounting screws.
2. Screw a suitable cross plate (4) to the two motor strips (3).
3. Pull the cross plate (4) away from the protective profi le with pretensioning force Fpr and tighten the mounting
screws !„12.1“.
Fig. 17: Tensioning the belt
Fpr Fpr
3
4