Bosch Rexroth MAD Technical manual

MAD / MAF
Asynchronous Housing Motors
Project planning manual
R911295781
Edition 11

MAD / MAF
Asynchronous Housing Motors
Project planning manual
DOK-MOTOR*-MAD/MAF****-PR11-EN-P
RS-217b481c84cf5c230a6846a001447b0d-9-en-US-4
This documentation ...
● explains product character and applications, technical data as well as
operating conditions and operating limits and
● provides information regarding product selection, handling and opera‐
tion.
Record of revisions Edition 11, 2022-02
See tab. 1-1 "Record of revisions" on page 1.
Copyright © Bosch Rexroth AG 2021
All rights reserved, also regarding any disposal, exploitation, reproduction,
editing, distribution, as well as in the event of applications for industrial prop‐
erty rights.
Liability The specified data is intended for product description purposes only and shall
not be deemed to be a guaranteed characteristic unless expressly stipulated
in the contract. All rights are reserved with respect to the content of this docu‐
mentation and the availability of the product.
Published by Bosch Rexroth AG
Dept. DC-AE/EPI5 (fs,mb)
Bgm.-Dr.-Nebel-Str. 2
97816 Lohr a.Main
Germany
Tel. [phone]
Fax [phone]
http://www.boschrexroth.com/electrics
Note This document has been printed on chlorine-free bleached paper.
Title
Type of Documentation
Document Typecode
Internal File Reference
Purpose of Documentation
MAD / MAF Asynchronous Housing Motors

Table of Contents
Page
1 Introduction to the product............................................................................................. 1
1.1 General................................................................................................................................................... 1
1.2 About this documentation....................................................................................................................... 1
1.2.1 Editions of this documentation............................................................................................................. 1
1.2.2 Document structure............................................................................................................................. 2
1.2.3 Further documentation........................................................................................................................ 2
1.2.4 Standards............................................................................................................................................ 2
1.2.5 Additional components........................................................................................................................ 3
1.3 Your feedback......................................................................................................................................... 3
2 Important instructions for use......................................................................................... 5
2.1 Intended use........................................................................................................................................... 5
2.1.1 Introduction.......................................................................................................................................... 5
2.1.2 Areas of use and application............................................................................................................... 5
2.2 Unintended use ...................................................................................................................................... 6
3 Safety notes for electric drives and controls.................................................................. 7
3.1 Term definition........................................................................................................................................ 7
3.2 General information................................................................................................................................ 8
3.2.1 Using the Safety instructions and passing them on to others.............................................................. 8
3.2.2 Requirements for safe use.................................................................................................................. 8
3.2.3 Hazards by improper use.................................................................................................................... 9
3.3 Danger-related notes............................................................................................................................ 10
3.3.1 Protection against touch of electric parts and housings.................................................................... 10
3.3.2 Protective extra-low voltage as protection against electric shock .................................................... 11
3.3.3 Protection against dangerous movements........................................................................................ 11
3.3.4 Protection against electromagnetic and magnetic fields during operation and mounting.................. 13
3.3.5 Protection against contact with hot parts........................................................................................... 13
3.3.6 Protection during handling and mounting.......................................................................................... 13
3.3.7 Battery safety..................................................................................................................................... 14
3.3.8 Protection against pressurized systems............................................................................................ 14
3.4 Explanation of signal words and the Safety alert symbol..................................................................... 15
4 Technical data.............................................................................................................. 17
4.1 Operation modes.................................................................................................................................. 17
4.1.1 General.............................................................................................................................................. 17
4.1.2 Duty cycle.......................................................................................................................................... 17
4.2 Operating behavior............................................................................................................................... 17
4.2.1 Description of the specified parameters............................................................................................ 17
4.2.2 Example characteristic curves........................................................................................................... 20
4.3 Technical data of MAD100................................................................................................................... 22
4.3.1 Data sheet of MAD100B.................................................................................................................... 22
4.3.2 Motor characteristic curves MAD100B.............................................................................................. 23
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4.3.3 Data sheet MAD100C........................................................................................................................ 26
4.3.4 Motor characteristic curves MAD100C.............................................................................................. 27
4.3.5 Data sheet MAD100D........................................................................................................................ 30
4.3.6 Motor characteristic curves MAD100D.............................................................................................. 31
4.3.7 Motor fan MAD100............................................................................................................................ 33
4.3.8 Holding Brake MAD/MAF100 (Optional)............................................................................................ 34
4.4 Technical data MAD130....................................................................................................................... 35
4.4.1 Data sheet MAD130B........................................................................................................................ 35
4.4.2 Motor characteristic curves MAD130B ............................................................................................. 36
4.4.3 Data sheet MAD130C........................................................................................................................ 38
4.4.4 Motor characteristic curves MAD130C.............................................................................................. 39
4.4.5 Data sheet MAD130D........................................................................................................................ 42
4.4.6 Motor characteristic curves MAD130D.............................................................................................. 43
4.4.7 Motor fan MAD130............................................................................................................................ 45
4.4.8 Holding Brake MAD/MAF130 (Optional)............................................................................................ 46
4.5 Technical data MAD160....................................................................................................................... 47
4.5.1 Data sheet MAD160B........................................................................................................................ 47
4.5.2 Motor characteristic curves MAD160B.............................................................................................. 48
4.5.3 Data sheet MAD160C........................................................................................................................ 50
4.5.4 Motor characteristic curves MAD160C.............................................................................................. 51
4.5.5 Motor fan MAD160............................................................................................................................ 53
4.5.6 Holding Brake MAD/MAF160 (Optional)............................................................................................ 53
4.6 Technical data MAD180....................................................................................................................... 54
4.6.1 Data sheet MAD180C........................................................................................................................ 54
4.6.2 Motor characteristic curves MAD180C.............................................................................................. 55
4.6.3 Data sheet MAD180D........................................................................................................................ 57
4.6.4 Motor characteristic curves MAD180D.............................................................................................. 58
4.6.5 Motor fan MAD180............................................................................................................................ 60
4.6.6 Holding Brake MAD/MAF180 (Optional)............................................................................................ 60
4.7 Technical data MAD225....................................................................................................................... 61
4.7.1 Data sheet MAD225C........................................................................................................................ 61
4.7.2 Motor characteristic curves MAD225C.............................................................................................. 62
4.7.3 Motor fan MAD225............................................................................................................................ 63
4.8 Technical data MAF100........................................................................................................................ 64
4.8.1 Data sheet MAF100B........................................................................................................................ 64
4.8.2 Motor characteristic curves MAF100B............................................................................................... 65
4.8.3 Data sheet MAF100C........................................................................................................................ 68
4.8.4 Motor characteristic curves MAF100C.............................................................................................. 69
4.8.5 Data sheet MAF100D........................................................................................................................ 72
4.8.6 Motor characteristic curves MAF100D.............................................................................................. 73
4.8.7 Holding brake MAD/MAF100 (optional)............................................................................................. 76
4.9 Technical data MAF130........................................................................................................................ 78
4.9.1 Data sheet MAF130B........................................................................................................................ 78
4.9.2 Motor characteristic curves MAF130B............................................................................................... 79
4.9.3 Data sheet MAF130C........................................................................................................................ 82
4.9.4 Motor characteristic curves MAF130C.............................................................................................. 83
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Bosch Rexroth AG R911295781_Edition 11

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4.9.5 Data sheet MAF130D........................................................................................................................ 86
4.9.6 Motor characteristic curves MAF130D.............................................................................................. 87
4.9.7 Holding Brake MAD/MAF130 (Optional)............................................................................................ 90
4.10 Technical data MAF160........................................................................................................................ 92
4.10.1 Data sheet MAF160B........................................................................................................................ 92
4.10.2 Motor characteristic curves MAF160B............................................................................................... 93
4.10.3 Data sheet MAF160C........................................................................................................................ 96
4.10.4 Motor characteristic curves MAF160C.............................................................................................. 97
4.10.5 Holding Brake MAD/MAF160 (Optional)............................................................................................ 99
4.11 Technical data MAF180...................................................................................................................... 100
4.11.1 Data sheet MAF180C...................................................................................................................... 100
4.11.2 Motor characteristic curves MAF180C............................................................................................ 101
4.11.3 Data sheet MAF180D...................................................................................................................... 104
4.11.4 Motor characteristic curves MAF180D............................................................................................ 105
4.11.5 Holding Brake MAD/MAF180 (Optional).......................................................................................... 107
4.12 Technical data MAF225...................................................................................................................... 108
4.12.1 Data sheet MAF225C...................................................................................................................... 108
4.12.2 Motor characteristic curves MAF225C............................................................................................ 109
5 Dimensional sheets MAD/MAF.................................................................................. 111
5.1 Frame size MAD100........................................................................................................................... 111
5.1.1 MAD100 without brake.................................................................................................................... 111
5.1.2 MAD100 with brake 1 or 5............................................................................................................... 112
5.1.3 MAD100 with fan shroud, without brake.......................................................................................... 113
5.1.4 MAD100 with fan shroud, brake 1 or 5............................................................................................ 114
5.2 Frame size MAD130........................................................................................................................... 115
5.2.1 MAD130 without brake.................................................................................................................... 115
5.2.2 MAD130 with brake 1 or 5............................................................................................................... 116
5.2.3 MAD130 with fan shroud, without brake.......................................................................................... 117
5.2.4 MAD130 with fan shroud, brake 1 or 5............................................................................................ 118
5.3 Frame size MAD160........................................................................................................................... 119
5.3.1 MAD160 without brake.................................................................................................................... 119
5.3.2 MAD160 with brake 1 or 5............................................................................................................... 120
5.3.3 MAD160 with brake 3...................................................................................................................... 121
5.3.4 MAD160 with fan shroud, without brake.......................................................................................... 122
5.3.5 MAD160 with fan shroud, brake 1 or 5............................................................................................ 123
5.3.6 MAD160 with fan shroud and brake 3............................................................................................. 124
5.4 Frame size MAD180........................................................................................................................... 125
5.4.1 MAD180 without brake.................................................................................................................... 125
5.4.2 MAD180 with brake 2 or 5............................................................................................................... 126
5.4.3 MAD180 with fan shroud, without brake.......................................................................................... 127
5.4.4 MAD180 with fan shroud, brake 2 or 5............................................................................................ 128
5.5 Frame size MAD225........................................................................................................................... 129
5.5.1 MAD225 without brake.................................................................................................................... 129
5.5.2 MAD225 with fan shroud, without brake.......................................................................................... 130
5.6 Frame size MAF100........................................................................................................................... 131
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5.6.1 MAF100 without brake..................................................................................................................... 131
5.6.2 MAF100 with brake 1 or 5............................................................................................................... 132
5.7 Frame size MAF130........................................................................................................................... 133
5.7.1 MAF130 without brake..................................................................................................................... 133
5.7.2 MAF130 with brake 1 or 5............................................................................................................... 134
5.8 Frame size MAF160........................................................................................................................... 135
5.8.1 MAF160 without brake..................................................................................................................... 135
5.8.2 MAF160 with brake 1 or 5............................................................................................................... 136
5.9 Frame size MAF180........................................................................................................................... 137
5.9.1 Threaded holes in MAF180 motor housing..................................................................................... 137
5.9.2 MAF180 without brake..................................................................................................................... 138
5.9.3 MAF180 with brake 2 or 5............................................................................................................... 139
5.10 Frame size MAF225........................................................................................................................... 140
5.10.1 Threaded holes in MAF225 motor housing..................................................................................... 140
5.10.2 MAF225C without brake.................................................................................................................. 141
6 Type codes................................................................................................................ 143
6.1 Introduction......................................................................................................................................... 143
6.1.1 General............................................................................................................................................ 143
6.1.2 Definition.......................................................................................................................................... 143
6.2 Type code MAD100............................................................................................................................ 148
6.3 Type code MAD130............................................................................................................................ 150
6.4 Type code MAD160............................................................................................................................ 152
6.5 Type code MAD180............................................................................................................................ 154
6.6 Type code MAD225............................................................................................................................ 156
6.7 Type code MAF100............................................................................................................................ 158
6.8 Type code MAF130............................................................................................................................ 160
6.9 Type code MAF160............................................................................................................................ 162
6.10 Type code MAF180............................................................................................................................ 164
6.11 Type code MAF225............................................................................................................................ 166
7 Accessories................................................................................................................ 169
7.1 Sealing air connection........................................................................................................................ 169
7.2 Gear ................................................................................................................................................... 171
7.3 Order designations for thread reductions at terminal boxes............................................................... 171
8 Connection techniques.............................................................................................. 173
8.1 Notes.................................................................................................................................................. 173
8.2 Power connection .............................................................................................................................. 173
8.2.1 General............................................................................................................................................ 173
8.2.2 Additional ground conductor on motors........................................................................................... 174
8.3 Power connection with connector socket............................................................................................ 174
8.3.1 Motors with connector socket.......................................................................................................... 174
8.3.2 Connection diagram........................................................................................................................ 175
8.4 Power connection with terminal box................................................................................................... 175
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Bosch Rexroth AG R911295781_Edition 11

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8.4.1 Overview of motors with terminal box.............................................................................................. 175
8.4.2 Cable connecting thread on terminal box........................................................................................ 175
8.4.3 Connection diagram........................................................................................................................ 177
8.4.4 Terminal box details........................................................................................................................ 178
8.4.5 Power connection............................................................................................................................ 178
8.5 Double cabling.................................................................................................................................... 181
8.6 Encoder connection ........................................................................................................................... 182
8.7 Temperature sensor .......................................................................................................................... 184
8.8 Holding brake ..................................................................................................................................... 184
8.9 Motor cooling...................................................................................................................................... 185
8.9.1 Fan connection................................................................................................................................ 185
8.9.2 Coolant connection ......................................................................................................................... 185
8.9.3 Coolant input pressure ................................................................................................................... 188
9 Application notes ....................................................................................................... 189
9.1 Operating conditions .......................................................................................................................... 189
9.1.1 Installation altitude and ambient temperature.................................................................................. 189
9.2 Humidity.............................................................................................................................................. 190
9.3 Vibration and shock............................................................................................................................ 190
9.3.1 Vibration.......................................................................................................................................... 190
9.3.2 Shock............................................................................................................................................... 191
9.4 Compatibility test................................................................................................................................ 191
9.5 Degree of protection........................................................................................................................... 192
9.6 Frame shape and Installation position ............................................................................................... 193
9.6.1 General............................................................................................................................................ 193
9.6.2 Foot mounting.................................................................................................................................. 194
9.6.3 Vertical installation positions........................................................................................................... 195
9.7 Motor paint.......................................................................................................................................... 196
9.8 Motor cooling...................................................................................................................................... 196
9.8.1 Fan.................................................................................................................................................. 196
9.8.2 Radial ventilation in heavily soiled atmospheres............................................................................. 198
9.8.3 Coolants ......................................................................................................................................... 200
9.8.4 Coolant additives............................................................................................................................. 201
9.8.5 Materials used................................................................................................................................. 202
9.8.6 Coolant inlet temperature ............................................................................................................... 203
9.9 Motor temperature monitoring............................................................................................................ 203
9.10 Holding brake (option)........................................................................................................................ 204
9.10.1 General............................................................................................................................................ 204
9.10.2 Holding brakes safety instructions................................................................................................... 205
9.10.3 Selecting holding brakes................................................................................................................. 206
9.10.4 Layout of holding brakes................................................................................................................. 207
9.11 Motor encoder .................................................................................................................................... 207
9.11.1 Options............................................................................................................................................ 207
9.11.2 Compatibility ................................................................................................................................... 208
9.11.3 Accuracy.......................................................................................................................................... 208
9.11.4 Encoder connection......................................................................................................................... 209
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Page
9.12 Output shaft ....................................................................................................................................... 209
9.12.1 Plain shaft........................................................................................................................................ 209
9.12.2 Output shaft with key....................................................................................................................... 209
9.12.3 Output shaft with shaft sealing ring................................................................................................. 210
9.12.4 Output shaft with labyrinth seal....................................................................................................... 211
9.13 Bearing variants and shaft load.......................................................................................................... 212
9.13.1 Bearing variants............................................................................................................................... 212
9.13.2 Selection tips................................................................................................................................... 215
9.13.3 Radial load, axial load..................................................................................................................... 215
9.14 Attaching drive elements.................................................................................................................... 222
9.14.1 General............................................................................................................................................ 222
9.14.2 Gearbox........................................................................................................................................... 223
9.14.3 Couplings......................................................................................................................................... 223
9.14.4 Skew bevel driving pinions.............................................................................................................. 225
9.14.5 Bevel gear pinions........................................................................................................................... 225
9.15 Bearing service life............................................................................................................................. 225
9.16 Grease service life.............................................................................................................................. 227
9.17 Vibration severity level........................................................................................................................ 231
9.18 Acceptances and approvals................................................................................................................ 234
9.18.1 CE mark........................................................................................................................................... 234
9.18.2 UR, cUR listing................................................................................................................................ 234
10 Handling and transport............................................................................................... 235
10.1 Delivery status ................................................................................................................................... 235
10.1.1 General............................................................................................................................................ 235
10.1.2 Factory test ..................................................................................................................................... 235
10.1.3 Customer test ................................................................................................................................. 235
10.2 Identification........................................................................................................................................ 235
10.3 Identification........................................................................................................................................ 236
10.4 Transport and storage........................................................................................................................ 237
10.4.1 General notes.................................................................................................................................. 237
10.4.2 Transport instructions...................................................................................................................... 237
10.4.3 Storage instructions......................................................................................................................... 239
11 Installation.................................................................................................................. 241
11.1 Safety.................................................................................................................................................. 241
11.2 Mechanical attachment....................................................................................................................... 241
11.2.1 Motor attachment............................................................................................................................. 241
11.2.2 Preparing assembly......................................................................................................................... 244
11.2.3 Assembling the motor...................................................................................................................... 244
11.3 Mount transmission elements............................................................................................................. 244
11.4 Electrical connection .......................................................................................................................... 245
11.4.1 General............................................................................................................................................ 245
11.4.2 Additional ground conductor on motors........................................................................................... 245
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Bosch Rexroth AG R911295781_Edition 11

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12 Operation of MAD/MAF motors.................................................................................. 247
12.1 Commissioning................................................................................................................................... 247
12.1.1 General............................................................................................................................................ 247
12.1.2 Preparation...................................................................................................................................... 247
12.1.3 Procedure........................................................................................................................................ 247
12.2 Operation with third-party controllers.................................................................................................. 247
12.3 Shutdown............................................................................................................................................ 248
12.4 Disassembly....................................................................................................................................... 248
12.5 Maintenance....................................................................................................................................... 249
12.5.1 General............................................................................................................................................ 249
12.5.2 Measures......................................................................................................................................... 249
12.5.3 Motor fan......................................................................................................................................... 250
12.5.4 Coolant supply ................................................................................................................................ 253
12.5.5 Servicing and commissioning holding brakes ................................................................................. 253
12.6 Troubleshooting ................................................................................................................................. 254
12.6.1 General............................................................................................................................................ 254
12.6.2 Excessive temperature of motor housing........................................................................................ 255
12.6.3 High motor temperature values, but housing temperature is normal............................................... 255
12.6.4 Motor or machine table generates vibrations.................................................................................. 256
12.6.5 Specified position is not reached..................................................................................................... 256
12.7 Environmental protection and disposal .............................................................................................. 256
12.7.1 Environmental protection................................................................................................................. 256
12.7.2 Disposal........................................................................................................................................... 257
13 Service and support................................................................................................... 259
Index.......................................................................................................................... 261
MAD / MAF Asynchronous Housing Motors VII
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R911295781_Edition 11 Bosch Rexroth AG

VIII MAD / MAF Asynchronous Housing Motors
Bosch Rexroth AG R911295781_Edition 11