Bosch Rexroth MKE Series Technical manual

Rexroth MKE Synchronous Motors
for Potentially Explosive Areas
according to ATEX and UL/CSA
R911297663
Edition 04
Electric Drives
and Controls Pneumatics Service
Linear Motion and
Assembly Technologies
Hydraulics
Project Planning Manual

Rexroth MKE Synchronous Motors
for Potentially Explosive Areas
according to ATEX and UL/CSA
Project Planning Manual
DOK-MOTOR*-MKE*GEN2***-PR04-EN-P
RS-e18d46620a6846ac01e65e1ec364402b-1-en-US-8
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
Note on industrial property rights © Bosch Rexroth AG, 2007.
Unless expressly authorized, any copying of this document, utilization and dis‐
closure of its content is not allowed. Damages will be payable in case of
contravention. All rights are reserved in the event of the granting of a patent or
the registration of a utility model or design (DIN 34-1).
Legal validity The data listed in this document only describe the product; they must not be
understood as guaranteed properties in the legal sense.
We reserve the right to modify the contents of this documentation and the
availability of the products.
Published by Bosch Rexroth AG
Electric Drives and Controls
Bgm.-Dr.-Nebel-Str. 2 • 97816 Lohr a. Main / Germany
Phone [phone] / 40-0 • Fax [phone] / 40-48 85
http://www.boschrexroth.com/
Dpt. EDM (jw)
Note This documentation is printed on bleached chlorine-free paper.
Title
Type of Documentation
Document Typecode
Internal File Reference
Record of Revision
Bosch Rexroth AG | Electric Drives
and Controls
Rexroth MKE Synchronous Motors |Project Planning Manual

Deutsch Diese Dokumentation muss vom Anwender während der gesamten
Einsatz- bzw. Lebensdauer des Produktes aufbewahrt, bei Verkauf
weitergegeben werden.
Bewahren Sie diese Anleitung auf.
English This documentation must be kept by the user during the whole pe‐
riod of use and lifetime of the product and be passed on in case of
sale.
Save these instructions.
Project Planning Manual |Rexroth MKE Synchronous Motors Electric Drives
and Controls
|Bosch Rexroth AG I/VI

II/VI Bosch Rexroth AG | Electric Drives
and Controls
Rexroth MKE Synchronous Motors |Project Planning Manual

Table of Contents
Page
1 Introduction to the Product............................................................................................. 7
1.1 MKE........................................................................................................................................................ 7
1.1.1 General................................................................................................................................................ 7
1.1.2 Versions............................................................................................................................................... 8
1.2 About this Documentation....................................................................................................................... 9
1.2.1 Structure of this Document Edition...................................................................................................... 9
1.2.2 Additional Documentation.................................................................................................................... 9
1.2.3 Standards............................................................................................................................................ 9
1.2.4 External Systems............................................................................................................................... 10
1.2.5 Your Feedback.................................................................................................................................. 10
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
3.2.4 Explanation of Safety Symbols and Hazard Classification................................................................ 16
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.............. 20
3.3.5 Protection Against Contact with Hot Parts......................................................................................... 20
3.3.6 Protection During Handling and Mounting......................................................................................... 21
3.3.7 Battery Safety.................................................................................................................................... 21
3.3.8 Protection Against Pressurized Systems........................................................................................... 21
4 Technical Data ............................................................................................................ 23
4.1 Definition of Parameters....................................................................................................................... 23
4.1.1 Parameters on the Data Sheet.......................................................................................................... 23
4.1.2 Parameters of the Characteristic Curves........................................................................................... 24
4.2 MKE037................................................................................................................................................ 26
4.3 MKE047................................................................................................................................................ 28
4.4 MKE098................................................................................................................................................ 30
4.5 MKE118................................................................................................................................................ 33
Project Planning Manual |Rexroth MKE Synchronous Motors Electric Drives
and Controls
|Bosch Rexroth AG III/VI
Table of Contents

Page
5 Specifications............................................................................................................... 39
5.1 Specifications MKE037......................................................................................................................... 39
5.2 Specifications MKE047......................................................................................................................... 42
5.3 Specifications MKE098......................................................................................................................... 45
5.4 Specifications MKE118......................................................................................................................... 48
6 Type Codes.................................................................................................................. 51
6.1 Description............................................................................................................................................ 51
6.2 MKE037................................................................................................................................................ 53
6.3 MKE047................................................................................................................................................ 55
6.4 MKE098................................................................................................................................................ 57
6.5 MKE118................................................................................................................................................ 59
7 Options and Accessories............................................................................................. 61
7.1 Motor Encoder...................................................................................................................................... 61
7.2 Holding Brakes..................................................................................................................................... 62
7.3 Gearboxes............................................................................................................................................ 63
7.3.1 General.............................................................................................................................................. 63
7.3.2 Planetary Gearbox ............................................................................................................................ 63
8 Connection Technique................................................................................................. 65
8.1 Variants................................................................................................................................................. 65
8.2 Motor Connection according to European Standard (EU).................................................................... 67
8.3 Connection according to American Standard (UL)............................................................................... 68
8.4 Dimensioning Power Cable.................................................................................................................. 69
8.5 Cable – Handling and Installation Recommendations ......................................................................... 69
9 Operating Conditions and Application Notes............................................................... 73
9.1 Potentially Explosive Areas ................................................................................................................. 73
9.1.1 Terms and Definitions ....................................................................................................................... 73
General........................................................................................................................................... 73
The following terms are used in the European Standard EN 50014: 1992.................................... 74
Zones.............................................................................................................................................. 76
Degree of ignition protection, groups and temperature classes..................................................... 76
9.1.2 Application Conditions for MKE Motors............................................................................................. 77
General........................................................................................................................................... 77
Motor-internal holding brake (if applicable)................................................................................... 78
9.1.3 Type Test of the Motors according to European Standard (EN)....................................................... 78
9.1.4 Type Test of the Motors according to American Standard (UL)........................................................ 79
9.2 Setup Height and Ambient Temperature.............................................................................................. 81
9.3 Degree of Protection............................................................................................................................. 81
9.4 Compatibility......................................................................................................................................... 82
9.5 Designs and Installation Positions........................................................................................................ 82
9.6 Housing Varnish................................................................................................................................... 83
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Table of Contents

Page
9.7 Vibration................................................................................................................................................ 83
9.8 Shock.................................................................................................................................................... 84
9.9 Output Shaft and Shaft Sealing Ring.................................................................................................... 84
9.9.1 Plain Shaft......................................................................................................................................... 84
9.9.2 Output Shaft with Key........................................................................................................................ 84
9.9.3 Output Shaft with Shaft Sealing Ring................................................................................................ 85
9.10 Bearings and Shaft Load...................................................................................................................... 86
9.10.1 General.............................................................................................................................................. 86
9.10.2 Radial Load, Axial Load..................................................................................................................... 86
9.10.3 Attachment of Drive Elements........................................................................................................... 87
9.10.4 Bearing Lifetime................................................................................................................................. 89
9.11 Holding Brakes (Ex).............................................................................................................................. 90
9.11.1 Holding Brake Electrically Releasing................................................................................................. 90
9.11.2 Holding Brakes Notes Regarding Safety........................................................................................... 90
9.11.3 Holding Brakes Note Regarding the System's Safety....................................................................... 91
9.11.4 Layout of Holding Brakes.................................................................................................................. 92
9.11.5 Holding Brake–Commissioning and Maintenance Instructions.......................................................... 92
9.12 Acceptances and Authorizations.......................................................................................................... 93
9.12.1 Motors in EU Version......................................................................................................................... 93
9.12.2 Motors in UL Version......................................................................................................................... 93
10 State of Delivery, Identification, Handling, Transport and Storage.............................. 95
10.1 State of Delivery................................................................................................................................... 95
10.1.1 Packaging.......................................................................................................................................... 95
10.1.2 High-voltage Test.............................................................................................................................. 95
10.2 Identification ......................................................................................................................................... 95
10.2.1 Shipping Documents and Delivery Note............................................................................................ 95
10.2.2 Name Plate........................................................................................................................................ 95
10.3 Handling, Transport and Storage.......................................................................................................... 96
11 Installation.................................................................................................................... 99
11.1 Safety.................................................................................................................................................... 99
11.2 Skilled Personnel.................................................................................................................................. 99
11.3 Mechanical Mounting – Motor Assembly.............................................................................................. 99
11.3.1 Flange Connection............................................................................................................................ 99
11.3.2 Preparation...................................................................................................................................... 100
11.3.3 Assembly......................................................................................................................................... 100
11.4 Electrical Connection.......................................................................................................................... 100
11.4.1 Notes Regarding Safety.................................................................................................................. 100
11.4.2 Motor Connection according to European Standard (EN)............................................................... 101
MKE037, -047, -098..................................................................................................................... 101
MKE118........................................................................................................................................ 104
11.4.3 Motor Connection according to American Standard (UL)................................................................ 108
MKE037, -047, -098..................................................................................................................... 108
MKE118........................................................................................................................................ 109
Project Planning Manual |Rexroth MKE Synchronous Motors Electric Drives
and Controls
|Bosch Rexroth AG V/VI
Table of Contents

Page
12 Startup, Operation and Maintenance ........................................................................ 111
12.1 Commissioning................................................................................................................................... 111
12.2 Operation............................................................................................................................................ 111
12.3 Deactivation........................................................................................................................................ 111
12.4 Maintenance....................................................................................................................................... 112
12.4.1 General............................................................................................................................................ 112
12.4.2 Cleaning.......................................................................................................................................... 112
12.4.3 Bearings.......................................................................................................................................... 112
12.4.4 Connection Cables.......................................................................................................................... 112
12.4.5 Holding Brakes ............................................................................................................................... 113
12.4.6 Battery Change................................................................................................................................ 113
12.5 Troubleshooting.................................................................................................................................. 114
12.6 Dismantling......................................................................................................................................... 115
13 Environmental Protection and Disposal..................................................................... 117
13.1 Environmental Protection.................................................................................................................... 117
13.1.1 Production Processes...................................................................................................................... 117
13.1.2 Prohibited Substances..................................................................................................................... 117
13.1.3 No Release of Hazardous Substances............................................................................................ 117
13.1.4 Principal Components..................................................................................................................... 117
13.2 Disposal.............................................................................................................................................. 117
13.2.1 Return of Products........................................................................................................................... 117
13.2.2 Packaging Materials........................................................................................................................ 117
13.2.3 Recycling......................................................................................................................................... 118
14 Appendix.................................................................................................................... 119
14.1 List of Standards................................................................................................................................. 119
14.2 Selection of Connection Cable........................................................................................................... 121
14.2.1 Power Cable IndraDyn S MKE........................................................................................................ 121
14.2.2 Encoder Cable IndraDyn S MKE..................................................................................................... 122
14.3 Declaration of Conformity .................................................................................................................. 123
15 Service and Support.................................................................................................. 127
15.1 Helpdesk............................................................................................................................................. 127
15.2 Service Hotline.................................................................................................................................... 127
15.3 Internet................................................................................................................................................ 127
15.4 Helpful Information.............................................................................................................................. 127
Index.......................................................................................................................... 129
VI/VI Bosch Rexroth AG | Electric Drives
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Rexroth MKE Synchronous Motors |Project Planning Manual
Table of Contents

1 Introduction to the Product
1.1 MKE
1.1.1 General
The MKE servo motors of the second generation fulfill the specifications ac‐
cording to ATEX and UL/CSA in one series. This permits the worldwide use of
Rexroth MKE-motors with one machine design only.
In connection with the drive control devices offered by Rexroth, the MKE motors
are drive systems with a high functionality for the use in potentially explosive
areas.
Performance list MKE motors are available in the following power spectrum:
Fig.1-1: MKE power gradation
Performance features MKE motors are characterized by the following advantages:
● Motor construction in "Flameproof Enclosures" according to EN 50 014 :
1992
● 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)
Project Planning Manual |Rexroth MKE Synchronous Motors Electric Drives
and Controls
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Introduction to the Product

● High performance data
● 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)
11.65)
● Any installation position
● Simple and fast startup (thanks to data memory)
Structure and components MKE motors are permanent-magnet motors with electronic commutation. Spe‐
cial magnet materials permit the motors to be designed with low inertia masses.
The following figure shows the principal design of MKD 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
1.1.2 Versions
MHE motors are available in various designs. On the basis of existing national
regulations and standards, the MKE motors have to be subdivided into housing
types
● E according to European Standard (EU) and
● U according to American Standard (UL)
.
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Rexroth MKE Synchronous Motors |Project Planning Manual
Introduction to the Product