REXROTH GTE Series Technical manual

Project Planning Manual
Electric Drives
and Controls Pneumatics Service
Linear Motion and
Assembly Technologies
Hydraulics
Rexroth GTE
Planetary Gearboxes
R911308842
Edition 08

Rexroth GTE
Planetary Gearboxes
Project Planning Manual
DOK-GEAR**-GTE********-PR08-EN-P
RS-20ad79a1d989be610a6846a0004ed7c2-5-en-US-7
Edition Release Date Notes
DOK-GEAR**-GTE********-PR01-EN-P 12/2004 First edition
DOK-GEAR**-GTE********-PR02-EN-P 04/2005 Revision
DOK-GEAR**-GTE********-PR03-EN-P 01/2006 Revision
DOK-GEAR**-GTE********-PR04-EN-P 07/2009 Revision
DOK-GEAR**-GTE********-PR05-EN-P 11/2009 Revision
DOK-GEAR**-GTE********-PR06-EN-P 01/2010 Revision type code
DOK-GEAR**-GTE********-PR07-DE-P 11/2012 Revision type code,
technical data
DOK-GEAR**-GTE********-PR08-DE-P 04/2013 Revision technical data
Copyright © Bosch Rexroth AG 2012
This document, as well as the data, specifications and other information set
forth in it, are the exclusive property of Bosch Rexroth AG. It may not be re‐
produced or given to third parties without its consent.
Liability The specified data is intended for product description purposes only and shall
not be deemed to be a guaranteed characteristic unless expressly stipulated
in the contract. All rights are reserved with respect to the content of this docu‐
mentation and the availability of the product.
Published by Bosch Rexroth AG
Bgm.-Dr.-Nebel-Str. 2 ■ 97816 Lohr a. Main, Germany
Phone [phone] ■ Fax [phone]
http://www.boschrexroth.com/
Dept. DC-IA/EDM3 (JW;AR; 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-GEAR**-GTE********-PR08-EN-P
Rexroth GTE Planetary Gearboxes

Table of Contents
Page
1 Introduction to the Product............................................................................................. 5
1.1 GTE Planetary Gearboxes...................................................................................................................... 5
1.2 About this Documentation....................................................................................................................... 7
1.2.1 General Information............................................................................................................................. 7
1.2.2 Standards............................................................................................................................................ 7
2 Important Instructions on Use........................................................................................ 9
2.1 Intended Use.......................................................................................................................................... 9
2.1.1 General Information............................................................................................................................. 9
2.1.2 Areas of Use and Application.............................................................................................................. 9
2.2 Non-Intended Use................................................................................................................................. 10
3 Safety Instructions for Electric Drives and Controls..................................................... 11
3.1 Definitions of Terms.............................................................................................................................. 11
3.2 General Information.............................................................................................................................. 12
3.2.1 Using the Safety Instructions and Passing Them on to Others......................................................... 12
3.2.2 Requirements for Safe Use............................................................................................................... 12
3.2.3 Hazards by Improper Use.................................................................................................................. 13
3.3 Instructions with Regard to Specific Dangers....................................................................................... 14
3.3.1 Protection Against Contact With Electrical Parts and Housings........................................................ 14
3.3.2 Protective Extra-Low Voltage as Protection Against Electric Shock ................................................ 15
3.3.3 Protection Against Dangerous Movements....................................................................................... 16
3.3.4 Protection Against Magnetic and Electromagnetic Fields During Operation and Mounting.............. 17
3.3.5 Protection Against Contact With Hot Parts........................................................................................ 18
3.3.6 Protection During Handling and Mounting......................................................................................... 18
3.3.7 Battery Safety.................................................................................................................................... 18
3.3.8 Protection Against Pressurized Systems........................................................................................... 19
3.4 Explanation of Signal Words and the Safety Alert Symbol................................................................... 19
4 Dimensioning and Selection........................................................................................ 21
4.1 Dimensioning........................................................................................................................................ 21
4.2 Selection............................................................................................................................................... 22
5 Application Notes......................................................................................................... 25
5.1 Operating Conditions............................................................................................................................ 25
5.1.1 General Information........................................................................................................................... 25
5.1.2 Operating Mode S5 (Intermitted Operation)...................................................................................... 26
5.1.3 Operating Mode S1 (Continuous Operation ) ................................................................................... 26
5.2 Operating Gearboxes or Motor-Gearbox Combinations in Hazardous Areas (ATEX).......................... 27
5.3 Mechanical Features............................................................................................................................ 27
5.4 Combination Possibilities of GTE Planetary Gearboxes with Motors................................................... 29
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Table of Contents

Page
6 Technical Data............................................................................................................. 31
6.1 Technical Data for Intermittent and Continuous Operation................................................................... 31
6.1.1 GTE040............................................................................................................................................. 31
6.1.2 GTE060............................................................................................................................................. 32
6.1.3 GTE080............................................................................................................................................. 33
6.1.4 GTE120............................................................................................................................................. 34
6.1.5 GTE160............................................................................................................................................. 35
6.2 Maximum Transferable Output Torque................................................................................................. 36
6.3 Thermal Specifications for S1 Operation.............................................................................................. 37
6.4 Technical Data at Increased Lifetime................................................................................................... 38
6.5 Limiting Temperature Curves to Determine Higher S1-Speed............................................................. 39
6.5.1 General.............................................................................................................................................. 39
6.5.2 GTE040............................................................................................................................................. 40
6.5.3 GTE060............................................................................................................................................. 41
6.5.4 GTE080............................................................................................................................................. 42
6.5.5 GTE120............................................................................................................................................. 43
6.5.6 GTE160............................................................................................................................................. 44
6.6 Permitted Shaft Load............................................................................................................................ 45
6.6.1 General.............................................................................................................................................. 45
6.6.2 GTE040............................................................................................................................................. 46
6.6.3 GTE060............................................................................................................................................. 47
6.6.4 GTE080............................................................................................................................................. 48
6.6.5 GTE120............................................................................................................................................. 49
6.6.6 GTE160............................................................................................................................................. 50
7 Specifications............................................................................................................... 51
7.1 GTE040................................................................................................................................................ 51
7.2 GTE060................................................................................................................................................ 52
7.3 GTE080................................................................................................................................................ 53
7.4 GTE120................................................................................................................................................ 54
7.5 GTE160................................................................................................................................................ 55
8 Type Codes.................................................................................................................. 57
8.1 Notes on Connecting a Motor acc. to ATEX Standard......................................................................... 57
8.2 Type Code GTE040.............................................................................................................................. 58
8.3 Type Code GTE060.............................................................................................................................. 59
8.4 Type Code GTE080.............................................................................................................................. 60
8.5 Type Code GTE120.............................................................................................................................. 61
8.6 Type Code GTE160.............................................................................................................................. 62
9 Handling, Transport and Storage................................................................................. 63
9.1 Handling................................................................................................................................................ 63
9.1.1 Identifying the Goods......................................................................................................................... 63
9.1.2 Name Plates...................................................................................................................................... 63
9.2 Transport and Storage.......................................................................................................................... 64
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Table of Contents

Page
10 Assembly..................................................................................................................... 67
10.1 Skilled Personnel.................................................................................................................................. 67
10.2 Motor Mounting..................................................................................................................................... 67
10.2.1 General Information........................................................................................................................... 67
10.2.2 Mounting Procedure.......................................................................................................................... 68
10.3 Gearbox Mounting................................................................................................................................ 70
11 Commissioning, Operation and Maintenance.............................................................. 71
11.1 Start-Up................................................................................................................................................ 71
11.1.1 General Information........................................................................................................................... 71
11.1.2 Preparation........................................................................................................................................ 71
11.1.3 Bulk Head Connector........................................................................................................................ 71
11.2 Deactivation.......................................................................................................................................... 72
11.3 Disassembly......................................................................................................................................... 72
11.4 Maintenance......................................................................................................................................... 72
11.4.1 General Information........................................................................................................................... 72
11.4.2 Measures........................................................................................................................................... 73
11.5 Troubleshooting ................................................................................................................................... 73
11.5.1 General Information........................................................................................................................... 73
11.5.2 Excess Temperature of Gearbox Housing........................................................................................ 73
11.5.3 Gearbox-Motor Unit Generates Vibrations........................................................................................ 74
11.5.4 Specified Position is not Attained...................................................................................................... 74
12 Ordering Designations................................................................................................. 75
12.1 General Information.............................................................................................................................. 75
12.2 Notes on Connecting a Motor acc. to ATEX Standard......................................................................... 75
13 Environmental Protection and Disposal ...................................................................... 77
13.1 Environmental Protection...................................................................................................................... 77
13.2 Disposal................................................................................................................................................ 77
14 Service and Support.................................................................................................... 79
Index............................................................................................................................ 81
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Table of Contents

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Rexroth GTE Planetary Gearboxes
IV/83

1 Introduction to the Product
1.1 GTE Planetary Gearboxes
Fig.1-1: Mounting example: GTE planetary gearboxes mounted on IndraDyn S
motors
Application area In combination with the drive and control system of Rexroth, GTE planetary
gearboxes provide a low-cost automation system for various sectors of indus‐
try.
They are well-suited for use with gear racks or toothed belts in handling sys‐
tems with high speed and accelerations (e.g.: loader and robots).
The low-backlash with shave-grinded (honed) planet wheels permits the exe‐
cution of exact positioning tasks. Furthermore, the gearboxes are suited for
S1-operation-required for application in e.g. the printing sector.
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Introduction to the Product

Gradations
Fig.1-2: Nominal torque gradation of GTE planetary gearboxes
Mode of functioning The GTE series of planetary gearboxes offers a coaxial input and output. The
output shaft of the motor is connected to the sun gear with a non-positive
compression clamp coupling. This sun gear drives three planetary wheels,
which roll off on an internal gear with internal gear teeth, as a single-stage
gearbox and four planetary wheels as a two-stage gearbox. The planetary
gears are fixed in the planet carrier, which acts as the output. By dividing the
load among the planetary gear on three or four planetary wheels, a balanced
force splitting occurs. This allows for a very compact gearbox with a high
power density.
High operational reliability ● Maintenance-free operation through lifetime lubrication
● Use under adverse environmental conditions is possible due to the com‐
pletely enclosed IP54 design.
● Safe and lasting sealing by abradant bearing sealants.
● Hermetically sealed housing
● Non-positive from backlash-free torque transmission via the compres‐
sion coupling
High performance data ● High accuracy via shave grinded (honed) planetary wheels, low back‐
lash gearing with low torque play.
● High efficiency, low temperature and minimum power loss made possi‐
ble by using the smallest possible seal diameters.
● Low running noise by optimized gear profiles.
● High emergency stop torque made possible by internal transferred pow‐
er.
● Highly dynamic because of inertia
● Low weight through compact type of construction
Easy to mount to machine ● The high radial-load capability and tilt resistance makes it possible to di‐
rectly mount a pinion or pulley.
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Introduction to the Product

● The design of the output shaft with a solid shaft shoulder makes axial
tightening of output elements simple.
● The gearbox can be mounted in any position. Due to the defined bear‐
ing position and pump current a sufficient lubricant supply is always en‐
sured.
● The output elements can be mounted in two different ways:
– non-positive shaft-hub connection by means of a plain output hol‐
low shaft, or
– connection by means of an output shaft with keyway
1.2 About this Documentation
1.2.1 General Information
This document contains safety regulations, technical data, and operating in‐
structions for gearboxes. 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 Dimensioning and Selection
Product Description (for
planners and designers)
5 Application Notes
6 Technical Data
7 Specifications
8 Type Codes
9 Handling, Transport and Storage
Practise(for operating and
maintenance personnel)
10 Assembly
11 Commissioning, Operation and Mainte‐
nance
12 Ordering Data
13 Appendix
General Information
14 Service & Support
15 Index
Tab.1-3: Document Structure
1.2.2 Standards
This documentation refers to German, European and international technical
standards. Documents and sheets on standards underlie the protection by
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Bosch Rexroth AG 7/83
Introduction to the Product

copyright and may not be passed on to third parties by REXROTH INDRA‐
MAT. 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.be/beuth
Email: [email protected]
Your Feedback
Your experiences are an essential part of the process of improving both the
product and the documentation.
Please do not hesitate to inform us of any error you detect in this documenta‐
tion or of any modifications you might desire. We would appreciate your feed‐
back.
Please send your remarks to:
Bosch Rexroth AG
Dept. DC-IA/EDM3 (jw/mb)
Buergermeister-Dr.-Nebel-Strasse 2
97816 Lohr am Main, Germany
Email: [email protected]
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8/83
Introduction to the Product

2 Important Instructions on Use
2.1 Intended Use
2.1.1 General Information
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.
The products must only be used as intended. If they are inappropriate used,
situations may arise resulting in injuries to property and persons.
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 the Bosch Rexroth products, the following condition precedent
must be fulfilled 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.
● If the products are hardware, they must be kept in their original state,
i.e. no constructional modifications must be made. Software products
must not be decompiled; their source codes must not be modified.
● Damaged or improperly working products must 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
Typical application ranges of the GTE planetary gearboxes are:
● Handling and Mounting systems,
● Packaging and Food-processing machines,
● Printing and Paper-processing machines and
Controlling and monitoring of the motor/-gearbox combination may require
connection of additional sensors and actuators.
The gearboxes may only be used with the accessories specified
in the documentation. Components that are not explicitly men‐
tioned must neither be attached nor connected. The same is true
for cables and lines.
The operation must only be carried out in the explicitly mentioned
configurations and combinations of the component and with the
software and firmware specified in the corresponding functional
description.
Any drive controller must be programmed before startup, in order to ensure
that the motor executes the functions specific to the particular application.
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Important Instructions on Use

The gearboxes 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, and the like)
specified in this documentation.
2.2 Non-Intended Use
Any use of gearboxes 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".
Planetary gearboxes may not be used if . . .
● They are subject to operating conditions which do not comply with the
ambient conditions described above. E.g. operation under water, under
extreme variations in temperature or extreme maximum temperatures is
not permitted.
● the intended application is not explicitly released by Bosch Rexroth.
Please make absolutely sure that the instructions given in the general
safety notes are also complied with!
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Important Instructions on Use

3 Safety Instructions for Electric Drives and Controls
3.1 Definitions of Terms
Application 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: User Guide, Operation Manual,
Commissioning Manual, Instruction Manual, Project Planning Manual, Appli‐
cation Manual, etc.
Component 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.
Control System A control system comprises several interconnected control components
placed on the market as a single functional unit.
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.
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.
Electric 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.
Installation 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.
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.
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.
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 Persons 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 Instructions 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
User A user is a person installing, commissioning or using a product which has
been placed on the market.
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 Instructions 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 must take into account
● 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 Instructions 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 Instructions with Regard to Specific Dangers
3.3.1 Protection Against Contact With Electrical Parts and Housings
This section concerns components of the electric drive and con‐
trol system with voltages of more than 50 volts.
Contact with parts conducting voltages above 50 volts can cause personal
danger and electric shock. When operating components of the electric drive
and control system, it is unavoidable that some parts of these components
conduct dangerous voltage.
High electrical voltage! Danger to life, risk of injury by electric shock or seri‐
ous injury!
● Only qualified persons are allowed to operate, maintain and/or repair the
components of the electric drive and control system.
● Follow the general installation and safety regulations when working on
power installations.
● Before switching on, the equipment grounding conductor must have
been permanently connected to all electric components in accordance
with the connection diagram.
● Even for brief measurements or tests, operation is only allowed if the
equipment grounding conductor has been permanently connected to the
points of the components provided for this purpose.
● Before accessing electrical parts with voltage potentials higher than
50 V, you must disconnect electric components from the mains or from
the power supply unit. Secure the electric component from reconnec‐
tion.
● With electric components, observe the following aspects:
Always wait 30 minutes after switching off power to allow live capacitors
to discharge before accessing an electric component. Measure the elec‐
trical voltage of live parts before beginning to work to make sure that the
equipment is safe to touch.
● Install the covers and guards provided for this purpose before switching
on.
● Never touch electrical connection points of the components while power
is turned on.
● Do not remove or plug in connectors when the component has been
powered.
● Under specific conditions, electric drive systems can be operated at
mains protected by residual-current-operated circuit-breakers sensitive
to universal current (RCDs/RCMs).
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Safety Instructions for Electric Drives and Controls

● Secure built-in devices from penetrating foreign objects and water, as
well as from direct contact, by providing an external housing, for exam‐
ple a control cabinet.
High housing voltage and high leakage current! Danger to life, risk of injury
by electric shock!
● Before switching on and before commissioning, ground or connect the
components of the electric drive and control system to the equipment
grounding conductor at the grounding points.
● Connect the equipment grounding conductor of the components of the
electric drive and control system permanently to the main power supply
at all times. The leakage current is greater than 3.5 mA.
● Establish an equipment grounding connection with a minimum cross
section according to the table below. With an outer conductor cross sec‐
tion smaller than 10 mm2 (8 AWG), the alternative connection of two
equipment grounding conductors is allowed, each having the same
cross section as the outer conductors.
Cross section outer con‐
ductor
Minimum cross section equipment grounding conductor
Leakage current ≥ 3.5 mA
1 equipment grounding
conductor
2 equipment grounding
conductors
1,5 mm2 (AWG 16)
10 mm2 (AWG 8)
2 × 1,5 mm2 (AWG 16)
2,5 mm2 (AWG 14) 2 × 2,5 mm2 (AWG 14)
4 mm2 (AWG 12) 2 × 4 mm2 (AWG 12)
6 mm2 (AWG 10) 2 × 6 mm2 (AWG 10)
10 mm2 (AWG 8) -
16 mm2 (AWG 6)
16 mm2 (AWG 6)
-
25 mm2 (AWG 4) -
35 mm2 (AWG 2) -
50 mm2 (AWG 1/0) 25 mm2 (AWG 4) -
70 mm2 (AWG 2/0) 35 mm2 (AWG 2) -
... ... ...
Tab.3-1: Minimum Cross Section of the Equipment Grounding Connection
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 between 5 and 50 volts are PELV
("Protective Extra-Low Voltage") systems. It is allowed to connect devices
equipped with basic insulation (such as programming devices, PCs, note‐
books, display units) to these connections.
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Rexroth GTE Planetary Gearboxes
Bosch Rexroth AG 15/83
Safety Instructions for Electric Drives and Controls

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.
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‐
Bosch Rexroth AG DOK-GEAR**-GTE********-PR08-EN-P
Rexroth GTE Planetary Gearboxes
16/83
Safety Instructions for Electric Drives and Controls

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.
3.3.4 Protection Against Magnetic and Electromagnetic Fields During Oper‐
ation and Mounting
Magnetic and electromagnetic fields generated by current-carrying conduc‐
tors or permanent magnets of electric motors represent a serious danger to
persons with heart pacemakers, metal implants and hearing aids.
Health hazard for persons with heart pacemakers, metal implants and hear‐
ing aids in proximity to electric components!
● Persons with heart pacemakers and metal implants are not allowed to
enter the following areas:
– Areas in which components of the electric drive and control sys‐
tems are mounted, commissioned and operated.
– Areas in which parts of motors with permanent magnets are stored,
repaired or mounted.
● If it is necessary for somebody with a heart pacemaker to enter such an
area, a doctor must be consulted prior to doing so. The noise immunity
of implanted heart pacemakers differs so greatly that no general rules
can be given.
● Those with metal implants or metal pieces, as well as with hearing aids,
must consult a doctor before they enter the areas described above.
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Rexroth GTE Planetary Gearboxes
Bosch Rexroth AG 17/83
Safety Instructions for Electric Drives and Controls

3.3.5 Protection Against Contact With Hot Parts
Hot surfaces of components of the electric drive and control system. Risk of
burns!
● Do not touch hot surfaces of, for example, braking resistors, heat sinks,
supply units and drive controllers, motors, windings and laminated
cores!
● According to the operating conditions, temperatures of the surfaces can
be higher than 60 °C (140 °F) during or after operation.
● Before touching motors after having switched them off, let them cool
down for a sufficient period of time. Cooling down can require up to 140
minutes! The time required for cooling down is approximately five times
the thermal time constant specified in the technical data.
● After switching chokes, supply units and drive controllers off, wait 15 mi‐
nutes to allow them to cool down before touching them.
● Wear safety gloves or do not work at hot surfaces.
● For certain applications, and in accordance with the respective safety
regulations, the manufacturer of the machine or installation must take
measures to avoid injuries caused by burns in the final application.
These measures can be, for example: Warnings at the machine or in‐
stallation, guards (shieldings or barriers) or safety instructions in the ap‐
plication documentation.
3.3.6 Protection During Handling and Mounting
Risk of injury by improper handling! Injury by crushing, shearing, cutting, hit‐
ting!
● Observe the relevant statutory regulations of accident prevention.
● Use suitable equipment for mounting and transport.
● Avoid jamming and crushing by appropriate measures.
● Always use suitable tools. Use special tools if specified.
● Use lifting equipment and tools in the correct manner.
● Use suitable protective equipment (hard hat, safety goggles, safety
shoes, safety gloves, for example).
● Do not stand under hanging loads.
● Immediately clean up any spilled liquids from the floor due to the risk of
falling!
3.3.7 Battery Safety
Batteries consist of active chemicals in a solid housing. Therefore, improper
handling can cause injury or property damage.
Risk of injury by improper handling!
● Do not attempt to reactivate low batteries by heating or other methods
(risk of explosion and cauterization).
● Do not attempt to recharge the batteries as this may cause leakage or
explosion.
● Do not throw batteries into open flames.
● Do not dismantle batteries.
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Rexroth GTE Planetary Gearboxes
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Safety Instructions for Electric Drives and Controls