Bosch MSK030B-0900-NN Technical manual

Synchronous Servomotors
MSK
Project planning manual
R911296289
Edition 12

Synchronous Servomotors
MSK
Project planning manual
DOK-MOTOR*-MSK********-PR12-EN-P
RS-d170bab768c990d90a6846a500789bc3-5-en-US-2
This documentation
● explains the features of the product, possibilities for use, operating con‐
ditions and operational limits of MSK motors.
● contains technical data regarding available MSK motors.
● provides information regarding product selection, handling and opera‐
tion.
Record of revisions Edition 12, 2018-06
See "Editions of this documentation" on page 7
Copyright © Bosch Rexroth AG 2018
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.
Title
Type of Documentation
Document Typecode
Internal File Reference
Purpose of Documentation
Bosch Rexroth AG DOK-MOTOR*-MSK********-PR12-EN-P
Synchronous Servomotors MSK

Table of Contents
Page
1 About this documentation.............................................................................................. 7
1.1 Introduction............................................................................................................................................. 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 notes for electric drives and controls................................................................ 13
3.1 Term definition...................................................................................................................................... 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 Danger-related notes............................................................................................................................ 16
3.3.1 Protection against Touch of Electric Parts and Housings.................................................................. 16
3.3.2 Protective extra-low voltage as protection against electric shock .................................................... 17
3.3.3 Protection against dangerous movements........................................................................................ 17
3.3.4 Protection against electromagnetic and magnetic fields during operation and mounting.................. 19
3.3.5 Protection against contact with hot parts........................................................................................... 19
3.3.6 Protection during handling and mounting.......................................................................................... 19
3.3.7 Battery safety..................................................................................................................................... 20
3.3.8 Protection against pressurized systems............................................................................................ 20
3.4 Explanation of signal words and the Safety alert symbol..................................................................... 21
4 Technical data.............................................................................................................. 23
4.1 Description of the specified parameters............................................................................................... 23
4.2 IndraSize............................................................................................................................................... 26
4.3 Technical data encoder MSK motors.................................................................................................... 27
4.4 Technical data holding brakes.............................................................................................................. 28
4.5 MSK030B Technical data..................................................................................................................... 30
4.6 MSK030C Technical data..................................................................................................................... 31
4.7 MSK040B Technical data..................................................................................................................... 32
4.8 MSK040C Technical data..................................................................................................................... 34
4.9 MSK043C Technical data..................................................................................................................... 36
4.10 MSK050B Technical data..................................................................................................................... 38
4.11 MSK050C Technical data..................................................................................................................... 40
4.12 MSK060B Technical data..................................................................................................................... 42
4.13 MSK060C Technical data..................................................................................................................... 44
4.14 MSK061B Technical data..................................................................................................................... 46
4.15 MSK061C Technical data..................................................................................................................... 47
4.16 MSK070C Technical data..................................................................................................................... 50
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Page
4.17 MSK070D Technical data..................................................................................................................... 53
4.18 MSK070E Technical data..................................................................................................................... 56
4.19 MSK071C Technical data..................................................................................................................... 59
4.20 MSK071D Technical data..................................................................................................................... 62
4.21 MSK071E Technical data..................................................................................................................... 65
4.22 MSK075C Technical data..................................................................................................................... 68
4.23 MSK075D Technical data..................................................................................................................... 71
4.24 MSK075E Technical data..................................................................................................................... 74
4.25 MSK076C Technical data..................................................................................................................... 77
4.26 MSK100A Technical data..................................................................................................................... 79
4.27 MSK100B Technical data..................................................................................................................... 82
4.28 MSK100C Technical data..................................................................................................................... 85
4.29 MSK100D Technical data..................................................................................................................... 88
4.30 MSK101C Technical data..................................................................................................................... 91
4.31 MSK101D Technical data..................................................................................................................... 94
4.32 MSK101E Technical data..................................................................................................................... 97
4.33 MSK103A Technical data................................................................................................................... 100
4.34 MSK103B Technical data................................................................................................................... 101
4.35 MSK103D Technical data................................................................................................................... 102
4.36 MSK131B Technical data................................................................................................................... 103
4.37 MSK131D Technical data................................................................................................................... 105
4.38 MSK133B Technical data................................................................................................................... 107
4.39 MSK133C Technical data................................................................................................................... 110
4.40 MSK133D Technical data................................................................................................................... 113
4.41 MSK133E Technical data................................................................................................................... 117
4.42 MSK133 Technical data fan................................................................................................................ 120
5 Specifications............................................................................................................. 121
5.1 Technical design ................................................................................................................................ 121
5.2 MSK030 Specifications....................................................................................................................... 122
5.3 MSK040 Specifications....................................................................................................................... 123
5.4 MSK043 Specifications....................................................................................................................... 124
5.5 MSK050 Specifications....................................................................................................................... 125
5.6 MSK060 Specifications....................................................................................................................... 126
5.7 MSK060 Specifications fan unit axial.................................................................................................. 127
5.8 MSK060 Specifications fan unit radial................................................................................................ 128
5.9 MSK061 Specifications....................................................................................................................... 129
5.10 MSK061 Specifications fan unit axial.................................................................................................. 130
5.11 MSK061 Specifications fan unit radial................................................................................................ 131
5.12 MSK070 Specifications....................................................................................................................... 132
5.13 MSK070 Specifications fan unit axial.................................................................................................. 133
5.14 MSK070 Specifications fan unit radial................................................................................................ 134
5.15 MSK071 Specifications....................................................................................................................... 135
5.16 MSK071 Specifications liquid cooling................................................................................................. 136
5.17 MSK071 Specifications fan unit axial.................................................................................................. 137
5.18 MSK071 Specifications fan unit radial................................................................................................ 138
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5.19 MSK075 Specifications....................................................................................................................... 139
5.20 MSK075 Specifications liquid cooling................................................................................................. 140
5.21 MSK075 Specifications axial fan unit.................................................................................................. 141
5.22 MSK075 Specifications fan unit radial................................................................................................ 142
5.23 MSK076 Specifications....................................................................................................................... 143
5.24 MSK076 Specifications fan unit axial.................................................................................................. 144
5.25 MSK076 Specifications fan unit radial................................................................................................ 145
5.26 MSK100 Specifications....................................................................................................................... 146
5.27 MSK100 Specifications fan unit axial.................................................................................................. 147
5.28 MSK100 Specifications radial fan unit................................................................................................ 148
5.29 MSK101 Specifications....................................................................................................................... 149
5.30 MSK101 Specifications liquid cooling................................................................................................. 150
5.31 MSK101 Specifications fan unit axial.................................................................................................. 151
5.32 MSK101 Specifications radial fan unit................................................................................................ 152
5.33 MSK103 Specifications....................................................................................................................... 153
5.34 MSK131 Specifications....................................................................................................................... 154
5.35 MSK131 Specifications fan unit axial.................................................................................................. 155
5.36 MSK133 Specifications....................................................................................................................... 156
5.37 MSK133 Specifications liquid cooling................................................................................................. 157
6 Type code.................................................................................................................. 159
6.1 MSK type code - structure and description......................................................................................... 159
6.2 MSK030 Type code............................................................................................................................ 161
6.3 MSK040 Type code............................................................................................................................ 162
6.4 MSK043 Type code............................................................................................................................ 163
6.5 MSK050 Type code............................................................................................................................ 164
6.6 MSK060 Type code............................................................................................................................ 165
6.7 MSK061 Type code............................................................................................................................ 166
6.8 MSK070 Type code............................................................................................................................ 167
6.9 MSK071 Type code............................................................................................................................ 168
6.10 MSK075 Type code............................................................................................................................ 169
6.11 MSK076 Type code............................................................................................................................ 170
6.12 MSK100 Type code............................................................................................................................ 171
6.13 MSK101 Type code............................................................................................................................ 173
6.14 MSK103 Type code ........................................................................................................................... 175
6.15 MSK131 Type code............................................................................................................................ 176
6.16 MSK133 Type code............................................................................................................................ 177
7 Accessories................................................................................................................ 179
7.1 Transmission...................................................................................................................................... 179
7.2 Fan units for MSK motors................................................................................................................... 180
7.2.1 Fan units area of application........................................................................................................... 180
7.2.2 Fan unit type key............................................................................................................................. 181
7.2.3 Fan unit technical data ................................................................................................................... 182
7.2.4 Fan unit selection table.................................................................................................................... 184
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7.2.5 Fan units electrical connection........................................................................................................ 186
7.2.6 Fan units ordering............................................................................................................................ 188
7.2.7 Fan units assembly.......................................................................................................................... 188
7.3 Sealing air connection........................................................................................................................ 188
7.3.1 Description....................................................................................................................................... 188
7.3.2 Technical data................................................................................................................................. 188
7.3.3 Ordering data and assignment........................................................................................................ 189
7.3.4 Assembly instructions...................................................................................................................... 189
8 Connection technique................................................................................................ 191
8.1 Overview of the electrical connection technique................................................................................. 191
8.2 Plug-in power connector..................................................................................................................... 192
8.3 Encoder plug connector...................................................................................................................... 195
8.4 Plug connector, rotatable.................................................................................................................... 196
8.5 RLK1200 Terminal box....................................................................................................................... 198
8.6 Terminal box RLK1300....................................................................................................................... 199
8.7 Connection cables.............................................................................................................................. 199
8.8 Liquid cooling connection .................................................................................................................. 201
9 Operating conditions and application notes............................................................... 203
9.1 Environmental conditions ................................................................................................................... 203
9.1.1 Installation altitude and ambient temperature.................................................................................. 203
9.1.2 Humidity / temperature ................................................................................................................... 204
9.1.3 Vibration.......................................................................................................................................... 205
9.1.4 Shock............................................................................................................................................... 206
9.2 Degree of protection........................................................................................................................... 207
9.3 Design and installation positions........................................................................................................ 208
9.4 Compatibility with foreign materials.................................................................................................... 210
9.5 Motor paint.......................................................................................................................................... 211
9.6 Output shaft........................................................................................................................................ 212
9.6.1 Plain shaft........................................................................................................................................ 212
9.6.2 Output shaft with keyway................................................................................................................. 212
9.6.3 Output shaft with shaft sealing ring................................................................................................. 212
9.7 Bearing and shaft load........................................................................................................................ 214
9.7.1 Radial load, axial load..................................................................................................................... 214
9.8 Bearing lifetime................................................................................................................................... 219
9.9 Attachment of drive elements............................................................................................................. 220
9.10 Holding brakes.................................................................................................................................... 221
9.10.1 Holding brake electrically releasing................................................................................................. 221
9.10.2 Holding brakes safety instructions................................................................................................... 221
9.10.3 Design of holding brakes................................................................................................................. 222
9.10.4 Holding brake - commissioning and maintenance instructions........................................................ 223
9.11 Acceptances and approvals................................................................................................................ 224
9.11.1 CE.................................................................................................................................................... 224
9.11.2 cURus.............................................................................................................................................. 224
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Page
9.11.3 EAC ................................................................................................................................................ 224
9.11.4 RoHS .............................................................................................................................................. 224
9.11.5 China RoHS 2.................................................................................................................................. 225
9.12 Motor cooling...................................................................................................................................... 226
9.12.1 Natural convection........................................................................................................................... 226
9.12.2 Fan units.......................................................................................................................................... 226
9.12.3 Liquid cooling................................................................................................................................... 227
9.13 Motor temperature monitoring............................................................................................................ 234
9.13.1 General information......................................................................................................................... 234
9.13.2 Temperature sensor........................................................................................................................ 234
9.14 Operation on external controllers........................................................................................................ 235
10 Transport and storage................................................................................................ 237
10.1 Transport Instructions......................................................................................................................... 237
10.2 Storage instructions............................................................................................................................ 238
10.2.1 Storage conditions........................................................................................................................... 238
10.2.2 Storage times.................................................................................................................................. 239
11 Delivery condition, identification, handling................................................................. 241
11.1 Delivery condition............................................................................................................................... 241
11.1.1 General information......................................................................................................................... 241
11.1.2 Factory inspection........................................................................................................................... 241
11.1.3 Customer inspection........................................................................................................................ 241
11.2 Identification ....................................................................................................................................... 242
11.2.1 Scope of delivery............................................................................................................................. 242
11.2.2 Type plate........................................................................................................................................ 242
11.3 Handling.............................................................................................................................................. 244
12 Installation.................................................................................................................. 247
12.1 Safety.................................................................................................................................................. 247
12.2 Specialist personnel............................................................................................................................ 248
12.3 Mechanical attachment....................................................................................................................... 249
12.3.1 Flange attachment........................................................................................................................... 249
12.3.2 Foot attachment............................................................................................................................... 249
12.3.3 Preparation...................................................................................................................................... 250
12.3.4 Motor mounting................................................................................................................................ 250
12.4 Electrical connection - connect motor................................................................................................. 252
12.4.1 General information......................................................................................................................... 252
12.4.2 Connecting the plug-in connector.................................................................................................... 253
12.5 MSK133 with terminal box type RLK1200, RLK1300......................................................................... 254
13 Commissioning, operation and maintenance ............................................................ 259
13.1 Commissioning................................................................................................................................... 259
13.2 Operation............................................................................................................................................ 260
13.3 Shutdown............................................................................................................................................ 260
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13.4 Maintenance....................................................................................................................................... 261
13.4.1 General information......................................................................................................................... 261
13.4.2 Cleaning.......................................................................................................................................... 261
13.4.3 Bearings.......................................................................................................................................... 262
13.4.4 Connecting cables........................................................................................................................... 262
13.5 Information in case of malfunctions ................................................................................................... 263
13.6 Disassembly....................................................................................................................................... 265
14 Environmental protection and disposal ..................................................................... 267
14.1 Environmental protection.................................................................................................................... 267
14.2 Disposal.............................................................................................................................................. 267
15 Appendix.................................................................................................................... 269
15.1 EU Declaration of conformity.............................................................................................................. 269
16 Service and support................................................................................................... 273
Index.......................................................................................................................... 275
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1 About this documentation
Editions of this documentation
Edition State Note
01 2004-06 First edition
02 2004-10 Revision, supplements
04 2005-06 Revision, supplements
06 2006-12 Revision, supplements
07 2008-06 Revision, supplements
08 2008-09 Revision, supplements
09 2010-12 Revision, supplements
10 2013-10 Revision, supplements
11 Not published
12 2018-06 MSK050: correction of technical data holding brakes M4 (6 Nm)
MSK133: revision of characteristic curves, specifications
New: Fan unit LEM-RB-192T-x1-NNNA, specifications MSK100, MSK101
Editorial revision
Tab. 1-1: Change history
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About this documentation

1.1 Introduction
MSK synchronous servo motors
for all requirements
The MSK motor series is characterized in particular by its wide performance
spectrum and fine size gradation. The high torque density of these synchro‐
nous servo motors enables a particularly compact design with a maximum
torque of up to 631 Nm.
Depending on the required accuracy, you can choose between encoder sys‐
tems with low, medium or high resolution. All encoder variants are available
in single-turn or multi-turn versions.
With numerous other options, the MSK motors can be upgraded and precise‐
ly tailored to the desired requirements. The MSK series is therefore also suit‐
able for applications that go beyond the classic areas of application for servo
motors.
The wide performance spectrum of the MSK motor series is supplemented by
a large number of functional options.
In addition to the various encoder systems, numerous other options such as
keyway, holding brake and increased concentricity accuracy can be selected.
Fan units for axial and radial mounting are available for applications with in‐
creased continuous performance.
Just like the MSK motors themselves, the fan motors are also designed with
IP65 protection and equipped with an integrated temperature sensor. This not
only increases the reliability of the motors. The certified intrinsic safety of the
fans ("Thermally Protected F" according to UL) also eliminates the need for
external motor protection switches. The motors cover the highest perform‐
ance requirements with the aid of liquid cooling, which is available for selec‐
ted sizes.
Document structure This documentation focuses on the following topics:
Chap‐
ter Title Content
1 About this documentation General information
2 Important instructions for use Safety
3 Safety notes for electric drives and controls
4 Technical data
Product description
(for planners and designers)
5 Specifications
6 Type code
7 Accessories
8 Connection technique
9 Operating conditions and application notes
10 Transport and storage
Practical application
(for operating and mainte‐
nance personnel)
11 Delivery condition, identification, handling
12 Installation
13 Commissioning, operation and maintenance
14 Environmental protection and disposal
General information
15 Appendix
16 Service & support
Index
Tab. 1-2: Document structure
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About this documentation

Further documentation For the project planning of drive systems with motors of the MSK series, you
will require further documentation, depending on the devices used. Rexroth
provides the entire product documentation in the Bosch Rexroth media direc‐
tory in PDF format.
http://www.boschrexroth.com/various/utilities/mediadirectory/index.jsp
Standards This documentation refers to German, European and international technical
standards. Standard typefaces and standard sheets are protected by copy‐
right and may not be passed on by Rexroth. If need be, please contact the
authorized sales outlets or, in Germany, directly:
BEUTH Verlag GmbH
Burggrafenstrasse 6
10787 Berlin
Phone [phone], Fax [phone]
Internet: http://www.din.de/beuth
Email: [email protected]
External systems Documentation for external systems connected with Rexroth components is
not part of the scope of delivery and must be requested directly from these
manufacturers.
Feedback For us, your experience is an important part of the improvement process for
product and documentation.
Please send your comments to [email protected].
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About this documentation

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2 Important instructions on use
2.1 Intended use
2.1.1 Introduction
Rexroth products are developed and manufactured according to the state of
the art. Before they are delivered, they are inspected to ensure that they op‐
erate safely.
Improper product handling may result in per‐
sonal injury and property damage!
WARNING
The products must only be used as intended. If they are not used as inten‐
ded, situations may arise that result in personal injuries or damage to proper‐
ty.
Rexroth, as the manufacturer, does not provide any warranty, as‐
sume any liability, or pay any damages for damage caused by
products not being used as intended. Any risks resulting from the
products not being used as intended are the sole responsibility of
the user.
Before using Rexroth products, the following condition precedent must be ful‐
filled so as to ensure that they are used as intended:
● Everyone who in any way whatsoever handles one of our products must
read and understand the corresponding notes regarding safety and re‐
garding the intended use.
● The motors must be left in their original state. It is not allowed to do any
constructional modifications. Software products may not be decompiled;
their source codes may not be modified.
● Damaged or improperly working products may not be installed or put in‐
to operation.
● It must be ensured that the products are installed according to the regu‐
lations specified in the documentation.
2.1.2 Areas of use and application
Rexroth IndraDyn A series asynchronous motors ApplicationsMSK are de‐
signed to be used as rotary main and servo drive motors. The following are
typical fields of application:
● Machine tools
● Printing and paper-processing machines,
● Packaging and Food-processing machines,
● Metal-forming machines
● Robotics
Device types with different driving powers and different interfaces are availa‐
ble for an application-specific use of the motors.
Controlling and monitoring of the motors may require connection of additional
sensors and actuators.
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Important instructions on use

MSKThe motors must only be used with the accessories specified
in this documentation. Components that are not explicitly men‐
tioned may neither be attached nor connected. The same is appli‐
cable for cables and lines.
Operation is only allowed in the explicitly mentioned configura‐
tions and combinations of the component and with the software
and firmware specified in the corresponding functional descrip‐
tion.
Any connected drive controller must be programmed before startup in order
to ensure that the motor executes the functions specifically to the particular
application.
MSKThe motors may only be operated under the assembly, mounting and in‐
stallation conditions, in the normal position, and under the environmental con‐
ditions (temperature, degree of protection, humidity, EMC etc.) specified in
this documentation.
2.2 Inappropriate use
Any use MSKof motors outside of the fields of application mentioned above
or under operating conditions and technical data other than those specified in
this documentation is considered as "non-intended use".
MSK motors may not be used if . . .
● they are subject to operating conditions which do not comply with the
ambient conditions described above; for example, they may not be oper‐
ated under water, under extreme temperature fluctuations or extreme
maximum temperatures;
● the intended application is not explicitly released by Bosch Rexroth.
Please be absolutely sure to comply with the instructions given in the
general safety instructions!
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Important instructions on use

3 Safety notes for electric drives and controls
3.1 Term definition
System An installation consists of several devices or systems interconnected for a
defined purpose and on a defined site which, however, are not intended to be
placed on the market as a single functional unit.
Electrical drive system An electric drive system comprises all components from mains supply to mo‐
tor shaft; this includes, for example, electric motor(s), motor encoder(s), sup‐
ply units and drive controllers, as well as auxiliary and additional compo‐
nents, such as mains filter, mains choke and the corresponding lines and ca‐
bles.
User A user is a person installing, commissioning or using a product which has
been placed on the market.
User documentation Application documentation comprises the entire documentation used to in‐
form the user of the product about the use and safety-relevant features for
configuring, integrating, installing, mounting, commissioning, operating, main‐
taining, repairing and decommissioning the product. The following terms are
also used for this kind of documentation: Operating Instructions, Commis‐
sioning Manual, Instruction Manual, Project Planning Manual, Application De‐
scription, etc.
Electrical equipment Electrical equipment encompasses all devices used to generate, convert,
transmit, distribute or apply electrical energy, such as electric motors, trans‐
formers, switching devices, cables, lines, power-consuming devices, circuit
board assemblies, plug-in units, control cabinets, etc.
Device A device is a finished product with a defined function, intended for users and
placed on the market as an individual piece of merchandise.
Manufacturer The manufacturer is an individual or legal entity bearing responsibility for the
design and manufacture of a product which is placed on the market in the in‐
dividual's or legal entity's name. The manufacturer can use finished products,
finished parts or finished elements, or contract out work to subcontractors.
However, the manufacturer must always have overall control and possess
the required authority to take responsibility for the product.
Components A component is a combination of elements with a specified function, which
are part of a piece of equipment, device or system. Components of the elec‐
tric drive and control system are, for example, supply units, drive controllers,
mains choke, mains filter, motors, cables, etc.
Machine A machine is the entirety of interconnected parts or units at least one of
which is movable. Thus, a machine consists of the appropriate machine drive
elements, as well as control and power circuits, which have been assembled
for a specific application. A machine is, for example, intended for processing,
treatment, movement or packaging of a material. The term "machine" also
covers a combination of machines which are arranged and controlled in such
a way that they function as a unified whole.
Product Examples of a product: Device, component, part, system, software, firmware,
among other things.
Project planning manual A Project Planning Manual is part of the application documentation used to
support the sizing and planning of systems, machines or installations.
Qualified personnel In terms of this application documentation, qualified persons are those per‐
sons who are familiar with the installation, mounting, commissioning and op‐
eration of the components of the electric drive and control system, as well as
with the hazards this implies, and who possess the qualifications their work
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Safety notes for electric drives and controls

requires. To comply with these qualifications, it is necessary, among other
things,
1) to be trained, instructed or authorized to switch electric circuits and devi‐
ces safely on and off, to ground them and to mark them
2) to be trained or instructed to maintain and use adequate safety equipment
3) to attend a course of instruction in first aid
Control system A control system comprises several interconnected control components
placed on the market as a single functional unit.
3.2 General information
3.2.1 Using the Safety instructions and passing them on to others
Do not attempt to install and operate the components of the electric drive and
control system without first reading all documentation provided with the prod‐
uct. Read and understand these safety instructions and all user documenta‐
tion prior to working with these components. If you do not have the user doc‐
umentation for the components, contact your responsible Rexroth sales part‐
ner. Ask for these documents to be sent immediately to the person or per‐
sons responsible for the safe operation of the components.
If the component is resold, rented and/or passed on to others in any other
form, these safety instructions must be delivered with the component in the
official language of the user's country.
Improper use of these components, failure to follow the safety instructions in
this document or tampering with the product, including disabling of safety de‐
vices, could result in property damage, injury, electric shock or even death.
3.2.2 Requirements for safe use
Read the following instructions before initial commissioning of the compo‐
nents of the electric drive and control system in order to eliminate the risk of
injury and/or property damage. You must follow these safety instructions.
● Rexroth is not liable for damages resulting from failure to observe the
safety instructions.
● Read the operating, maintenance and safety instructions in your lan‐
guage before commissioning. If you find that you cannot completely un‐
derstand the application documentation in the available language,
please ask your supplier to clarify.
● Proper and correct transport, storage, mounting and installation, as well
as care in operation and maintenance, are prerequisites for optimal and
safe operation of the component.
● Only qualified persons may work with components of the electric drive
and control system or within its proximity.
● Only use accessories and spare parts approved by Rexroth.
● Follow the safety regulations and requirements of the country in which
the components of the electric drive and control system are operated.
● Only use the components of the electric drive and control system in the
manner that is defined as appropriate. See chapter "Appropriate Use".
● The ambient and operating conditions given in the available application
documentation must be observed.
● Applications for functional safety are only allowed if clearly and explicitly
specified in the application documentation "Integrated Safety Technolo‐
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Safety notes for electric drives and controls

gy". If this is not the case, they are excluded. Functional safety is a safe‐
ty concept in which measures of risk reduction for personal safety de‐
pend on electrical, electronic or programmable control systems.
● The information given in the application documentation with regard to
the use of the delivered components contains only examples of applica‐
tions and suggestions.
The machine and installation manufacturers must
– make sure that the delivered components are suited for their indi‐
vidual application and check the information given in this applica‐
tion documentation with regard to the use of the components,
– make sure that their individual application complies with the appli‐
cable safety regulations and standards and carry out the required
measures, modifications and complements.
● Commissioning of the delivered components is only allowed once it is
sure that the machine or installation in which the components are instal‐
led complies with the national regulations, safety specifications and
standards of the application.
● Operation is only allowed if the national EMC regulations for the applica‐
tion are met.
● The instructions for installation in accordance with EMC requirements
can be found in the section on EMC in the respective application docu‐
mentation.
The machine or installation manufacturer is responsible for compliance
with the limit values as prescribed in the national regulations.
● The technical data, connection and installation conditions of the compo‐
nents are specified in the respective application documentations and
must be followed at all times.
National regulations which the user has to comply with
● European countries: In accordance with European EN standards
● United States of America (USA):
– National Electrical Code (NEC)
– National Electrical Manufacturers Association (NEMA), as well as
local engineering regulations
– Regulations of the National Fire Protection Association (NFPA)
● Canada: Canadian Standards Association (CSA)
● Other countries:
– International Organization for Standardization (ISO)
– International Electrotechnical Commission (IEC)
3.2.3 Hazards by improper use
● High electrical voltage and high working current! Danger to life or seri‐
ous injury by electric shock!
● High electrical voltage by incorrect connection! Danger to life or injury by
electric shock!
● Dangerous movements! Danger to life, serious injury or property dam‐
age by unintended motor movements!
● Health hazard for persons with heart pacemakers, metal implants and
hearing aids in proximity to electric drive systems!
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Safety notes for electric drives and controls

● Risk of burns by hot housing surfaces!
● Risk of injury by improper handling! Injury by crushing, shearing, cutting,
hitting!
● Risk of injury by improper handling of batteries!
● Risk of injury by improper handling of pressurized lines!
3.3 Danger-related notes
3.3.1 Protection against Touch of Electric Parts and Housings
This section concerns components of electric drive and control
systems with a voltage over 50 volt.
In the case of touching parts with a voltage higher than 50 volt, this can be
dangerous for personnell and can lead to electric shock. During operation of
components of electric drive and control systems, certain parts of these com‐
ponents are inevitably under dangerous voltage.
High electrical voltage! Danger of life, risk of injury due to electric shock or
heavy bodily harm.
● Operation, maintenance and/or repair of components of electric drive
and control systems may only be done by qualified personnel.
● Observe the general construction and safety instructions about work on
high voltage systems.
● Before switching on, establish the fixed connection of the protective con‐
ductor to all electric components according to the interconnection dia‐
gram.
● Operation, even for short-term measuring and testing purposes, is only
permitted with the protective conductor securely connected to the com‐
ponent points provided.
● Disconnect electric components from the mains or from the power sup‐
ply, before you have contact with electric parts with a voltage higher
than 50 V. Secure the electric components against restarting.
● Observe for electrical components:
Please, always wait 30 minutes, after switch-off, so live capacitors dis‐
charge before they have access to electric components. To exclude any
danger due to any contact, measure electric voltage of live parts before
working.
● Before switch-on install the provided covers and protective devices for
the touch guard.
● Do not touch any electric junctions of live components.
● Do not disconnect or connect connectors under voltage.
High housing voltage and high discharge current! Danger! Risk of injury due
to electric shock!
● Before switch-on and start-up, ground or connect the components of the
drive and control system with the protective conductors on the ground‐
ing points.
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Safety notes for electric drives and controls

● Connect the protective conductors of the electric drive and control sys‐
tems always fix and continuously with the external supply network.
● Do a protective conductor connection with a minimum cross section ac‐
cording to the following table.
Cross-sectional area A of the live wires Minimum cross-sectional area APE of the
protective conductor
A ≤ 16 mm² A
25 mm² < A ≤ 50 mm² 25 mm²
50 mm² < A A / 2
Tab. 3-1: Minimum cross-section of protective conductor connection for motors
3.3.2 Protective extra-low voltage as protection against electric shock
Protective extra-low voltage is used to allow connecting devices with basic in‐
sulation to extra-low voltage circuits.
On components of an electric drive and control system provided by Rexroth,
all connections and terminals with voltages up to 50 volts are PELV ("Protec‐
tive Extra-Low Voltage") systems. It is allowed to connect devices equipped
with basic insulation (such as programming devices, PCs, notebooks, display
units) to these connections.
Danger to life, risk of injury by electric shock! High electrical voltage by incor‐
rect connection!
If extra-low voltage circuits of devices containing voltages and circuits of
more than 50 volts (e.g., the mains connection) are connected to Rexroth
products, the connected extra-low voltage circuits must comply with the re‐
quirements for PELV ("Protective Extra-Low Voltage").
3.3.3 Protection against dangerous movements
Dangerous movements can be caused by faulty control of connected motors.
Some common examples are:
● Improper or wrong wiring or cable connection
● Operator errors
● Wrong input of parameters before commissioning
● Malfunction of sensors and encoders
● Defective components
● Software or firmware errors
These errors can occur immediately after equipment is switched on or even
after an unspecified time of trouble-free operation.
The monitoring functions in the components of the electric drive and control
system will normally be sufficient to avoid malfunction in the connected
drives. Regarding personal safety, especially the danger of injury and/or
property damage, this alone cannot be relied upon to ensure complete safety.
Until the integrated monitoring functions become effective, it must be as‐
sumed in any case that faulty drive movements will occur. The extent of faulty
drive movements depends upon the type of control and the state of opera‐
tion.
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Safety notes for electric drives and controls

Dangerous movements! Danger to life, risk of injury, serious injury or property
damage!
A risk assessment must be prepared for the installation or machine, with its
specific conditions, in which the components of the electric drive and control
system are installed.
As a result of the risk assessment, the user must provide for monitoring func‐
tions and higher-level measures on the installation side for personal safety.
The safety regulations applicable to the installation or machine must be taken
into consideration. Unintended machine movements or other malfunctions
are possible if safety devices are disabled, bypassed or not activated.
To avoid accidents, injury and/or property damage:
● Keep free and clear of the machine’s range of motion and moving ma‐
chine parts. Prevent personnel from accidentally entering the machine’s
range of motion by using, for example:
– Safety fences
– Safety guards
– Protective coverings
– Light barriers
● Make sure the safety fences and protective coverings are strong enough
to resist maximum possible kinetic energy.
● Mount emergency stopping switches in the immediate reach of the oper‐
ator. Before commissioning, verify that the emergency stopping equip‐
ment works. Do not operate the machine if the emergency stopping
switch is not working.
● Prevent unintended start-up. Isolate the drive power connection by
means of OFF switches/OFF buttons or use a safe starting lockout.
● Make sure that the drives are brought to safe standstill before accessing
or entering the danger zone.
● Additionally secure vertical axes against falling or dropping after switch‐
ing off the motor power by, for example,
– mechanically securing the vertical axes,
– adding an external braking/arrester/clamping mechanism or
– ensuring sufficient counterbalancing of the vertical axes.
● The standard equipment motor holding brake or an external holding
brake controlled by the drive controller is not sufficient to guarantee per‐
sonal safety!
● Disconnect electrical power to the components of the electric drive and
control system using the master switch and secure them from reconnec‐
tion ("lock out") for:
– Maintenance and repair work
– Cleaning of equipment
– Long periods of discontinued equipment use
● Prevent the operation of high-frequency, remote control and radio equip‐
ment near components of the electric drive and control system and their
supply leads. If the use of these devices cannot be avoided, check the
machine or installation, at initial commissioning of the electric drive and
control system, for possible malfunctions when operating such high-fre‐
quency, remote control and radio equipment in its possible positions of
normal use. It might possibly be necessary to perform a special electro‐
magnetic compatibility (EMC) test.
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Safety notes for electric drives and controls