Bosch Rexroth MKE E Series Technical manual

Rexroth MKE Synchronous Motors
for Potentially Explosive Areas
acc. to ATEX and UL/CSA
R911297663
Edition 06
Electric Drives
and Controls Pneumatics Service
Linear Motion and
Assembly Technologies
Hydraulics
Project Planning Manual
LSA Control S.L. www.lsa-control.com [email protected] ([phone]

Rexroth MKE Synchronous Motors
for Potentially Explosive Areas
acc. to ATEX and UL/CSA
Project Planning Manual
DOK-MOTOR*-MKE*GEN2***-PR06-EN-P
RS-e18d46620a6846ac01e65e1ec364402b-3-en-US-9
Edition Release Date Notes
DOK-MOTOR*-MKE*GEN2***-PR01-EN-
P
06/2003 First edition
DOK-MOTOR*-MKE*GEN2***-PR02-EN-
P
02/2004 Revision
DOK-MOTOR*-MKE*GEN2***-PR03-EN-
P
03/2004 Revision
DOK-MOTOR*-MKE*GEN2***-PR04-EN-
P
08/2007 Introduction IndraDrive
Encoder, revision
DOK-MOTOR*-MKE*GEN2***-PR05-EN-
P
11/2010 Standards EN 60079 ff.
DOK-MOTOR*-MKE*GEN2***-PR06-EN-
P
07/2012 Standards EN
60079:2009.
Copyright © Bosch Rexroth AG 2012
Copying this document, giving it to others and the use or communication of
the contents thereof without express authority, are forbidden. Offenders are
liable for the payment of damages. All rights are reserved in the event of the
grant of a patent or the registration of a utility model or design (DIN 34-1).
Validity The specified data is for product description purposes only and may not be
deemed to be guaranteed unless expressly confirmed in the contract. All
rights are reserved with respect to the content of this documentation and the
availability of the product.
Published by Bosch Rexroth AG
Electric Drives and Controls
Bgm.-Dr.-Nebel-Str. 2 ■ 97816 Lohr a. Main, Germany
Phone [phone] ■ Fax [phone]
http://www.boschrexroth.com/electrics
Dept. DC-IA/EDM3 (jw/mb)
Note This document has been printed on chlorine-free bleached paper.
Title
Type of Documentation
Document Typecode
Internal File Reference
Record of Revision
Bosch Rexroth AG DOK-MOTOR*-MKE*GEN2***-PR06-EN-P
Rexroth MKE Synchronous Motors for Potentially Explosive Areas acc. to ATEX and UL/CSA
LSA Control S.L. www.lsa-control.com [email protected] ([phone]

Table of Contents
Page
1 Introduction to the Product............................................................................................. 5
1.1 MKE........................................................................................................................................................ 5
1.1.1 General Information............................................................................................................................. 5
1.1.2 Design................................................................................................................................................. 7
1.2 About this Documentation....................................................................................................................... 8
2 Important Instructions on Use ..................................................................................... 11
2.1 Intended Use ....................................................................................................................................... 11
2.1.1 Introduction........................................................................................................................................ 11
2.1.2 Areas of Use and Application............................................................................................................ 11
2.2 Inappropriate Use................................................................................................................................. 12
3 Safety Instructions for Electric Drives and Controls..................................................... 13
3.1 Definitions of Terms.............................................................................................................................. 13
3.2 General Information.............................................................................................................................. 14
3.2.1 Using the Safety Instructions and Passing Them on to Others......................................................... 14
3.2.2 Requirements for Safe Use............................................................................................................... 14
3.2.3 Hazards by Improper Use.................................................................................................................. 15
3.3 Instructions with Regard to Specific Dangers....................................................................................... 16
3.3.1 Protection Against Contact With Electrical Parts and Housings........................................................ 16
3.3.2 Protective Extra-Low Voltage as Protection Against Electric Shock ................................................ 17
3.3.3 Protection Against Dangerous Movements....................................................................................... 18
3.3.4 Protection Against Magnetic and Electromagnetic Fields During Operation and Mounting.............. 19
3.3.5 Protection Against Contact With Hot Parts........................................................................................ 20
3.3.6 Protection During Handling and Mounting......................................................................................... 20
3.3.7 Battery Safety.................................................................................................................................... 20
3.3.8 Protection Against Pressurized Systems........................................................................................... 21
3.4 Explanation of Signal Words and the Safety Alert Symbol................................................................... 21
4 Technical Data ............................................................................................................ 23
4.1 Characteristics...................................................................................................................................... 23
4.1.1 General Information........................................................................................................................... 23
4.1.2 Operating Modes............................................................................................................................... 23
4.1.3 Duty Cycle......................................................................................................................................... 23
4.1.4 Definition of Parameters.................................................................................................................... 24
4.2 UL File Number..................................................................................................................................... 27
4.3 Technical Data Encoder for MKE Motors............................................................................................. 28
4.4 Technical Data Holding Brakes............................................................................................................ 29
4.5 MKE037B Technical Data..................................................................................................................... 30
4.6 MKE047B Technical Data..................................................................................................................... 32
4.7 MKE098B Technical Data..................................................................................................................... 34
4.8 MKE118B Technical Data..................................................................................................................... 38
4.9 MKE118D Technical Data.................................................................................................................... 42
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Table of Contents
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Page
5 Specifications............................................................................................................... 47
5.1 MKE037 Specifications......................................................................................................................... 47
5.2 MKE047 Specifications......................................................................................................................... 50
5.3 MKE098 Specifications......................................................................................................................... 53
5.4 MKE118 Specifications......................................................................................................................... 56
6 Type Codes.................................................................................................................. 59
6.1 Description............................................................................................................................................ 59
6.2 MKE037................................................................................................................................................ 61
6.3 MKE047................................................................................................................................................ 62
6.4 MKE098................................................................................................................................................ 63
6.5 MKE118................................................................................................................................................ 64
7 Accessories and Options............................................................................................. 65
7.1 Motor Encoder...................................................................................................................................... 65
7.2 Holding Brakes..................................................................................................................................... 66
7.3 Gearboxes............................................................................................................................................ 67
8 Connection Technique................................................................................................. 69
8.1 Variants................................................................................................................................................. 69
8.2 Motor Connection According to European Standard (EN).................................................................... 72
8.3 Connection According to American Standard (UL)............................................................................... 73
9 Operating Conditions and Application Notes............................................................... 75
9.1 Permitted Areas of Use for MKE Motors............................................................................................... 75
9.1.1 Motors with Housing Design "E"........................................................................................................ 75
9.1.2 Application Conditions ATEX Device Group II, Category 2............................................................... 76
9.1.3 Motors with Housing Design "U",....................................................................................................... 78
9.2 Installation Altitude and Ambient Temperature..................................................................................... 79
9.3 Degree of Protection............................................................................................................................. 79
9.4 Compatibility with Foreign Materials..................................................................................................... 79
9.5 Design and Installation Positions.......................................................................................................... 80
9.6 Motor Paint........................................................................................................................................... 80
9.7 Vibration................................................................................................................................................ 80
9.8 Shock.................................................................................................................................................... 81
9.9 Output Shaft.......................................................................................................................................... 81
9.9.1 Plain Shaft......................................................................................................................................... 81
9.9.2 Output Shaft with Keyway................................................................................................................. 81
9.9.3 Output Shaft with Shaft Sealing Ring................................................................................................ 82
9.10 Bearings and Shaft Load...................................................................................................................... 84
9.10.1 Radial Load, Axial Load..................................................................................................................... 84
9.10.2 Shaft Load MKE Motors.................................................................................................................... 86
9.10.3 Bearing Lifetime................................................................................................................................. 88
9.11 Attaching Drive Elements..................................................................................................................... 89
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Page
9.12 Holding Brakes (Ex).............................................................................................................................. 90
9.12.1 Holding Brake Electrically-Released................................................................................................. 90
9.12.2 Holding Brakes - Notes Regarding Safety......................................................................................... 90
9.12.3 System Safety for Holding Brakes .................................................................................................... 91
9.12.4 Layout of Holding Brakes.................................................................................................................. 92
9.12.5 Holding Brake–Commissioning and Maintenance Instructions ......................................................... 92
10 Transport and Storage................................................................................................. 95
10.1 Transport Instructions........................................................................................................................... 95
10.2 Storage Instructions.............................................................................................................................. 97
10.2.1 Storage Conditions............................................................................................................................ 97
10.2.2 Storage Times................................................................................................................................... 98
11 Delivery Status, Identification, Handling...................................................................... 99
11.1 State of Delivery................................................................................................................................... 99
11.1.1 General Information........................................................................................................................... 99
11.1.2 Inspection at the Factory................................................................................................................... 99
11.1.3 Test Realized by the Customer......................................................................................................... 99
11.2 Identification ....................................................................................................................................... 100
11.2.1 Scope of Delivery............................................................................................................................ 100
11.2.2 Rating Plate..................................................................................................................................... 100
11.3 Handling.............................................................................................................................................. 103
12 Installation.................................................................................................................. 105
12.1 Safety.................................................................................................................................................. 105
12.2 Skilled Personnel................................................................................................................................ 106
12.3 Mechanical Mounting – Motor Assembly............................................................................................ 107
12.3.1 Flange Assembly............................................................................................................................. 107
12.3.2 Preparation...................................................................................................................................... 107
12.3.3 Assembly......................................................................................................................................... 108
12.4 Electrical Connection.......................................................................................................................... 109
12.4.1 Safety Instructions........................................................................................................................... 109
12.4.2 Electric Connection MKE037, MKE047, MKE098 Housing Design "E" .......................................... 109
12.4.3 Electric Connection MKE118 Housing Design "E" ......................................................................... 112
12.4.4 Electric Connection Motor Types MKE037 ... 098 Housing Design "U".......................................... 117
12.4.5 Electric Connection MKE118 Housing Design "U".......................................................................... 118
13 Commissioning, Operation and Maintenance ........................................................... 119
13.1 Commissioning................................................................................................................................... 119
13.2 Operation............................................................................................................................................ 120
13.3 Maintenance / Dismantling / Repair.................................................................................................... 121
13.3.1 Dismantling...................................................................................................................................... 121
13.3.2 Maintenance / Repair...................................................................................................................... 122
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Bosch Rexroth AG III/135
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Page
14 Environmental Protection and Disposal .................................................................... 123
14.1 Environmental Protection.................................................................................................................... 123
14.2 Disposal.............................................................................................................................................. 123
15 Appendix.................................................................................................................... 125
15.1 List of Standards................................................................................................................................. 125
15.2 Selection of Connection Cable........................................................................................................... 127
15.2.1 Power Cable IndraDyn S MKE........................................................................................................ 127
15.2.2 Encoder cable IndraDyn S MKE...................................................................................................... 128
15.3 Declaration of Conformity .................................................................................................................. 129
16 Service and Support.................................................................................................. 131
Index.......................................................................................................................... 133
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1 Introduction to the Product
1.1 MKE
1.1.1 General Information
The MKE servo motors fulfill the specifications according to ATEX and
UL/CSA in one class. This permitts the worldwide use of Rexroth MKE mo‐
tors with one machine design only.
In connection with the drive devices of Rexroth, the MKE motors generates
drive systems with high functionality for the use in hazardous areas.
Performance list MKE motors are available in the following power spectrum:
Fig.1-1: MKE power graduation
Performance feature MKE motors are characterized by the following advantages:
● Motor design according to EN 60079-0, EN 60079-1, EN 60079-31
● High operational reliability
● Maintenance-free operation (owing to the brushless design and use of
bearings grease-lubricated for their entire lifetime)
● Use under adverse environmental conditions is possible (owing to the
completely closed motor design in IP 65 degree of protection
● Overload protection (by means of motor-temperature control)
● High performance data
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Bosch Rexroth AG 5/135
Introduction to the Product
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● High dynamics (owing to the favorable ratio of torque to inertia mass)
● High overload capability (owing to the favorable heat dissipation from
the stator windings to the outside wall of the motor housing)
● Peak torque utilizable across a wide speed range (owing to electronic
commutation)
● Continuous start-stop operation possible with high repeat frequencies
(owing to electrical commutation)
● Easy attachment to the machine (owing to flange according to DIN
42948)
● Any installation position desired
● Simple and fast startup (by data memory)
Design and Components MKE motors are permanent-magnet motors with electronic commutation.
Special magnet materials permit the motors to be designed with low inertia
masses. The following figure shows the principal design of MKE motors.
(1) Drive shaft
(2) Stator with winding
(3) Bearings
(4) Motor encoder
(5) Connection unit
(6) Terminal box lid
(7) Holding brake (optional)
(8) Grounding clamp
(9) Shaft sealing ring
(10) Rotor with permanent magnets
Fig.1-2: Design of MKE motors
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Introduction to the Product
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1.1.2 Design
MKE motors are available in various designs. Conditional upon existing na‐
tional regulations and standards, the MKE motors have to be defferentiated
from the housing according to:
● Design "E" acc. to European Standard (EU with cURus conform insula‐
tion system)
● Design "U" according to American Standard (UL)
unterteilt werden.
The connection technology of the MKE motors is variously processed accord‐
ing to the national regulations.
Please heed the notes according to the valid national regulations
in the chapter ”Application Notes”.
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Bosch Rexroth AG 7/135
Introduction to the Product
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1.2 About this Documentation
Storage This documentation must be kept by the user during the whole
period of use and lifetime of the product and be passed on in
case of sale.
Save these instructions.
Structure of this document edition The present documentation contains safety regulations, technical data, and
operating instructions for MKE motors. The individual chapters can be
subdivided into the following focal points:
Chapter Title Content
1 Introduction to the Product General Information
2 Important Instructions on Use Safety
3 Safety Instructions
4 Technical Data
Product Description
(for planners and designers)
5 Specifications
6 Type Codes
7 Accessories and Options
8 Connection Technique
9 Operating Conditions and Application Notes
10 Transport and Storage
Practice
(for operating and maintenance personnel)
11 Delivery Status, Identification, Handling
12 Installation
13 Commissioning, Operation and Maintenance
14 Environmental Protection and Disposal
General Information
15 Appendix
16 Service & Support
Index
Fig.1-3: Document Structure
Additional documentation You might need additional documentation referring to the used devices to
project the drive systems of the MKE motor unit. Rexroth provides the entire
product documentation in the Bosch Rexroth media directory (in PDF format)
under http://www.boschrexroth.com/various/utilities/mediadirectory/index.jsp.
Standards This documentation refers to German, European and international technical
standards. Documents and sheets on standards are subject to copyright
protection and may not be passed on to third parties by Rexroth. If need be,
please contact the authorized sales outlets or, in Germany, directly:
BEUTH Verlag GmbH
Burggrafenstrasse 6
10787 Berlin, Germany
Phone [phone], Fax [phone]
Internet: http://www.din.de/beuth
Email: [email protected]
External systems Documentation for external systems which are connected to Rexroth
components are not included in the scope of delivery and must be ordered
directly from the respective manufacturers.
Your feedback Your experiences are an essential part of the process of improving both the
product and the documentation.
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Introduction to the Product
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