Rexroth MAD and MAF Motors - CMA/Flodyne/Hydradyne PDFs/BRC/Motors/MAF/Rexroth MAD_MAF...series of IndraDyn A motors of Rexroth. The designation of a motor in Ex-design is made at

Electric Drivesand Controls Pneumatics Service

Linear Motion and Assembly TechnologiesHydraulics

Court

esy

of CM

A/F

lodyn

e/H

ydra

dyn

e ▪

Motion C

ontr

ol ▪

Hyd

raulic

▪ P

neu

mat

ic ▪

Ele

ctrica

l ▪

Mec

han

ical

▪ (

800)

426-5

480 ▪

ww

w.c

maf

h.c

om

Rexroth MAD and MAF Motorsin EX px d Design according tothe 94/9/EG (ATEX95) Directive

Operating Instructions

DOK-MOTOR*-IDYN*A*EXPD-IB01-EN-P

RS-46405ff26e8daec40a6846a00056a6e6-1-en-US-13

This documentation …● explains special product features regarding explosion protection, possi‐

bilities for use, operating conditions and operational limits● provides information regarding product installation and operation

Edition Release Date Notes

DOK-MOTOR*-IDYN*A*EXPD-IB01-EN-P

02/2009 1. Edition (replacementfor DOK-MOTOR*-IDYN*A*ATEX-IBxx-D5-P, MNR R911312072)

© Bosch Rexroth AG, 2009Copying this document, giving it to others and the use or communication of thecontents thereof without express authority, are forbidden. Offenders are liablefor the payment of damages. All rights are reserved in the event of the grant ofa patent or the registration of a utility model or design (DIN 34-1).The specified data is for product description purposes only and may not bedeemed to be guaranteed unless expressly confirmed in the contract. All rightsare reserved with respect to the content of this documentation and the availa‐bility of the product.Bosch Rexroth AGBgm.-Dr.-Nebel-Str. 2 ■ 97816 Lohr a. Main, GermanyPhone +49 (0)93 52 / 40-0 ■ Fax +49 (0)93 52 / 40-48 85http://www.boschrexroth.com/Dept. BRC/EDM1 (fs)This document has been printed on chlorine-free bleached paper.

Title

Type of Documentation

Document Typecode

Internal File Reference

Purpose of Documentation

Record of Revision

Bosch Rexroth AG | Electric Drivesand Controls

Rexroth MAD and MAF Motors | Operating Instructions

Copyright

Validity

Published by

Note

Court

esy

of CM

A/F

lodyn

e/H

ydra

dyn

e ▪

Motion C

ontr

ol ▪

Hyd

raulic

▪ P

neu

mat

ic ▪

Ele

ctrica

l ▪

Mec

han

ical

▪ (

800)

426-5

480 ▪

ww

w.c

maf

h.c

om

Table of ContentsPage

1 Operating Instructions.................................................................................................... 31.1 Introduction............................................................................................................................................. 31.2 Safety Instructions for Electric Drives and Controls................................................................................ 31.3 Appropriate Use...................................................................................................................................... 41.4 Application Conditions............................................................................................................................ 41.4.1 General Information............................................................................................................................. 41.4.2 Internal Motor Brake (if existing)......................................................................................................... 51.5 Residual Risks........................................................................................................................................ 61.6 Designation of Motors ............................................................................................................................ 61.7 Additional Components........................................................................................................................... 81.7.1 General Information............................................................................................................................. 81.7.2 Motor Fan ........................................................................................................................................... 81.7.3 Ex-p Controllers for Motor Purging ..................................................................................................... 81.7.4 Connection Cable................................................................................................................................ 91.8 Mechanical Attachment.......................................................................................................................... 91.9 Connection Techniques ....................................................................................................................... 111.9.1 General Information........................................................................................................................... 111.9.2 Power Connection............................................................................................................................. 111.9.3 Power Connection (Double Cabling)................................................................................................. 181.9.4 Encoder Connection.......................................................................................................................... 191.9.5 Equipotential Bonding Conductor...................................................................................................... 191.9.6 Cooling MAD Motors ........................................................................................................................ 201.9.7 Cooling Connection MAF Motors ..................................................................................................... 231.9.8 Operating Pressure .......................................................................................................................... 261.9.9 Purge Gas Connection ..................................................................................................................... 271.10 Commissioning..................................................................................................................................... 291.10.1 General Information........................................................................................................................... 291.10.2 Purging Time of the Overall System.................................................................................................. 291.10.3 Preparation........................................................................................................................................ 301.10.4 Execution........................................................................................................................................... 301.11 Disassembly......................................................................................................................................... 311.12 Maintenance / Repair............................................................................................................................ 32

2 Appendix...................................................................................................................... 352.1 Declaration of Conformity..................................................................................................................... 352.2 Service and Support............................................................................................................................. 37

Index............................................................................................................................ 39

Operating Instructions | Rexroth MAD and MAF Motors Electric Drivesand Controls

| Bosch Rexroth AG I/II

Table of Contents

Court

esy

of CM

A/F

lodyn

e/H

ydra

dyn

e ▪

Motion C

ontr

ol ▪

Hyd

raulic

▪ P

neu

mat

ic ▪

Ele

ctrica

l ▪

Mec

han

ical

▪ (

800)

426-5

480 ▪

ww

w.c

maf

h.c

om

II/II Bosch Rexroth AG | Electric Drivesand Controls


Court

esy

of CM

A/F

lodyn

e/H

ydra

dyn

e ▪

Motion C

ontr

ol ▪

Hyd

raulic

▪ P

neu

mat

ic ▪

Ele

ctrica

l ▪

Mec

han

ical

▪ (

800)

426-5

480 ▪

ww

w.c

maf

h.c

om

1 Operating Instructions1.1 Introduction

MAD and MAF motors in Ex-design according to directive 94/9/EC enhance theseries of IndraDyn A motors of Rexroth.The designation of a motor in Ex-design is made at the 15th column of the typecode with the classification number "6".● MAD□□□□-□□□□-□□-□6-□□□-□□-□□● MAF□□□□-□□□□-□□-□6-□□□-□□-□□This operating instruction provides special notes regarding selection, commis‐sioning, operation, dismantling and maintenance of motors in ATEX design.

CAUTION

The Ex motors must only be commissioned in an explosive environment,if:● All the following notes regarding commissioning and application of the

project planning manual DOK-MOTOR*-MAD/MAF****-PR□□-□□-P havebeen understood and put into practice.

● The overall system, consisting of motor, purging equipment, protectivedevices, and motor cooling equipment is inspected, accepted and loggedaccording to the requirements of the relevant standards.

These operating instructions form a part of the product and must bekept by the user of the motors over the entire operation and lifetimeof the product. If the product is passed on or sold, these instructionsmust also be passed on to each new owner or user.Is this product operated and used in another country or anotherlinguistic area, it is only allowed to forward this product, if operatinginstructions written in the national language or in the language ofthe linguistic area in which the product is used are supplied with theproduct.

1.2 Safety Instructions for Electric Drives and ControlsThe persons responsible for the safety of persons involved in the work or af‐fected by it must act in accordance with the national legislation.All persons working on, with or in the vicinity of an electrical system must beinformed of the relevant safety requirements, safety guidelines and internal in‐structions (source: EN 50110-1:2004).Taking the relevant national regulations into account, ATEX motors may becommissioned only by a skilled and competent electrician for ATEX protection.In order to indicate dangers that can occur especially during the operation ofATEX motors, the following warning symbols and key words are used in theseoperating instructions. Signal words describe the degrees of hazard serious‐ness. The degree of hazard seriousness identifies the risk that exists if thesafety information is not observed. In addition to the notes regarding safetylisted here, please also observe the general safety notes in the project planninginstructions for these motors.


| Bosch Rexroth AG 3/41


Personell

Warning Symbols

Court

esy

of CM

A/F

lodyn

e/H

ydra

dyn

e ▪

Motion C

ontr

ol ▪

Hyd

raulic

▪ P

neu

mat

ic ▪

Ele

ctrica

l ▪

Mec

han

ical

▪ (

800)

426-5

480 ▪

ww

w.c

maf

h.c

om

Warning symbols with signal word Hazard classification (according to ANSI Z535)

Caution

Bodily injury or damage may occur.

Warning

Death or severe bodily harm may occur.

Danger

Death or severe bodily harm will occur.

Fig.1-1: Fig. 1-1: Hazard classification (according to ANSI Z 535)

1.3 Appropriate UseEx-motors are certified as explosion-protected devices. However,please observe the notes in chapter 1.7 "Additional Components"on page 8. Additionally required safety precautions have to beestablished by the user.

The motors described here (devices for group II, category 2G, directive 94/9/EC, appendix II, chapter 2.2.1) may only be used in an environment in which● an explosive atmosphere results seldom or on a short-term basis due to

gases, vapors or fog● an explosive atmosphere may result occasionally due to gases, vapors or

fog.The system and the components must thus be designed and manufactured bythe user in such a manner that sources of ignition are avoided assuming thatdevice malfunctions occur frequently and that operating states occur that areusually unexpected.

1.4 Application Conditions1.4.1 General Information

DANGER

Explosion hazard!● Do only use Ex p purging devices (see chapter 1.7.3 "Ex-p Controllers for

Motor Purging " on page 8) with an appropriate or higher Ex protectionclass according to the motor, to ensure the Ex-protection.

● The values indicated on the identification label (fig. 1-3 "Ex-designationlabel on the motors in Ex-design" on page 7) for example for the purginggas volume, the purge gas, the initial pressure and the over pressure mustbe ensured and monitored by the purging device.

The motors may only be operated with Bosch Rexroth drive control devices andconnection cables of the IndraDrive series. Control devices from other manu‐facturers are not permitted. The connector terminals in the terminal box mustbe screwed on tightly. Do not disconnect or connect connectors when they areenergized due to the danger of sparking within the explosive atmospheres!Speed-controlled drive systems contain unavoidable discharge currents flow‐ing through the earth. For this reason the motors have to be grounded over the

4/41 Bosch Rexroth AG | Electric Drivesand Controls



Connection Specifications

Grounding

Court

esy

of CM

A/F

lodyn

e/H

ydra

dyn

e ▪

Motion C

ontr

ol ▪

Hyd

raulic

▪ P

neu

mat

ic ▪

Ele

ctrica

l ▪

Mec

han

ical

▪ (

800)

426-5

480 ▪

ww

w.c

maf

h.c

om

motor cable and over a separate ground wire with a cross-section. Please, ob‐serve the notes in chapter 1.9.5 "Equipotential Bonding Conductor" on page19. Check that the position of the grounded conductor is fixed before com‐missioning.If the grounding connector in the motor cable and the second separate ground‐ing conductor on the motor housing are not connected or are interrupted dueto corrosion or other defects during their lifetime, the discharge current flows(as leakage current) over conducting housing parts. This must be preventedusing the measures mentioned above (directive 94/9/EC, appendix II, chapter1.3.3, and 1.4).The corrosion of the motor housing due to aggressive substances (such ascertain coolants, lubricants, cutting oils or salt mists) is to be prevented.Stored energy in the drive devices circuit has to be degraded or isolated assoon as possible via pressing the emergency stop, so that in the case of failurethe risk of an effect into the danger zone is reduced. (directive 94/9/EC, ap‐pendix II, section 1.6.2)The following options exist for the activation of the emergency stop device:● discharge of the energies via an intermediate circuit short-circuit● Insulation of energies before the transition to the potentially explosive area

through disconnection of cables and motors situated in the potentially ex‐plosive areas.

At improper pressure loss or temperature rise within the motor during operationswitch off the motor all-pole. Therefore, notice the details in the documentationabout the Ex p controller.Heed the application notes in the project planning manual regarding risks dueto outer influences, like:● Operation only inside the specified ambient conditions● Maximum vibration and impact loads● Protection of the grounding conductor connection from dirt, corrosion, hu‐

midity and/or aggressive substances etc.● ...The housing paint of the motors consists of a black (RAL9005) 2K epoxy resincoating based on epoxy-polyamide resin in water.Overcoating the motors in ATEX design is not admissible in order to not to effectthe surface properties (such as insulation resistance, electrostatic charge) ad‐versely.

1.4.2 Internal Motor Brake (if existing)In normal operation, the brake located within the motor must only be used atstandstill and for the realization of the drive-internal brake check. In these ca‐ses, only low temperatures (<100° C) occur and no sparks are generatedbecause critical grinding of the brake linings does not occur.The brake’s control mechanism must ensure this function in normal operation.Particularly under the least favorable installation conditions for the power supplycables to the brake and under the least favorable load condition for the powersupply, a supply voltage of 24 V +/- 10 % must still be applied to the motor. Ifa voltage divergence occurs due to a failure during operation, this failure mustbe identified and corrected immediately. The failure can be identified, for ex‐ample, using a monitoring device for undervoltage.Only during a malfunction, i.e. in the case of a fault in the system, may the brakebe activated when the motor is turning to, for example, prevent dangerousdropping of vertical axes. In this case, sparks may be generated in the brake




Risks of Corrosion

Emergency Stop

Pressure Loss / Temperature Rise

Other Environmental Influences

Surface of the Motor Housing

Brake Control

Malfunction

Court

esy

of CM

A/F

lodyn

e/H

ydra

dyn

e ▪

Motion C

ontr

ol ▪

Hyd

raulic

▪ P

neu

mat

ic ▪

Ele

ctrica

l ▪

Mec

han

ical

▪ (

800)

426-5

480 ▪

ww

w.c

maf

h.c

om

and increased temperatures may occur within the motor. When a fault occurs,the operator must eliminate it immediately.Before commissioning and, during operation, at periodic intervals (e.g. every 8hours), the function of the brake is to be checked in the framework of an ap‐propriate brake test. Through the application of a defined motor torque, thebrake is tested for slippage. In case of certain drive control devices, it is possibleto carry out an integrated brake test using the Brake Monitor command. Furtherinformation can be found in the respective firmware operation manual for thedrive control device.

1.5 Residual RisksIf the purging device and the monitor for maintaining the protective measuresfail simultaneously, explosion protection in an explosive atmosphere is no lon‐ger ensured and a danger of explosion exists.When the motor is overloaded, including cases where errors in the mechanicalor electrical equipment of the machine cause such overloading, high tempera‐tures may occur that result in explosion hazards.Variable-speed drive systems cause unavoidable discharge currents. If thegrounding connector in the motor cable and the second separate groundingconnector on the motor housing are not connected as specified or are inter‐rupted due to corrosion or other defects during their lifetime, the dischargecurrent flows as leakage current over conducting housing parts, resulting in therisks of sparking at transfer points and, if explosive materials are present, ex‐plosions. Therefore, check the proper conditions of both grounded conductorsin regular intervals.The periods of action and penetration of explosive materials depend on theapplication. They depend on the aging of the seals, the mechanical design ofthe motor, the characteristics of the explosive materials and the average tem‐perature that occurs during the operating time as a consequence of the loadcycles.

1.6 Designation of Motors Motors in ATEX design have an additional label that is located on the side ofthe motor housing, next to the motor type label. The identification plate is lo‐cated laterally at the motor housing next to the name plate and shows:● the classification of the motor according to ATEX● important details for adjusting the motor scavenging device.

Fig.1-2: Motor name plate (example: MAD-motor)




Functional Test

Failure of the Protective Equipment

Overload

Grounding and Discharge Currents

Material Aging

Motor Name Plate

Court

esy

of CM

A/F

lodyn

e/H

ydra

dyn

e ▪

Motion C

ontr

ol ▪

Hyd

raulic

▪ P

neu

mat

ic ▪

Ele

ctrica

l ▪

Mec

han

ical

▪ (

800)

426-5

480 ▪

ww

w.c

maf

h.c

om

Ⓐ Designation label on motors of frame size 100...180Ⓑ Designation label on motors of frame size 225Ex ATEX symbolII Device Group II, which is suitable for all ATEX atmospheres except

mines susceptible to firedamp2G Device Category 2: the device is suitable only for ATEX atmospheres

that are caused by gas that can occur occasionallyEx The European Standard for ATEX protection has been appliedpx Ignition protection class px means that an ATEX atmosphere is kept

away from the ignition source (EN 60079-2), considering the special re‐quirements in the construction sample test certificate

d Ignition protection class D means that the transmission of an explosionto external areas is ruled out (EN 60079-1)

IIB Explosion subgroup for certain gases and vaporsT3 The max. permitted surface temperature (inside and outside of the

housing) is 155° CTPS*** Motor registration number① Scavenging volume: 5 liter② scavenging gas to be used: Instrument air③ Technique: Adjust the leakage loss④ Minimum initial pressure (scavenging gas): 2 bar overpressure⑤ Minimum purging time: 60 seconds per motor⑥ Minimum overpressure: 1 mbar⑦ Maximum overpressure: 23 mbar⑧ Maximum leakage loss: 10 liter/min⑨ Max. ambient temperature: 0°C to +40°C⑩ Scavenging volume: 19 liter⑪ Minimum purging time: 360 seconds per motorFig.1-3: Ex-designation label on the motors in Ex-design




Additional Designation Label withDetails about Motor Purging

Court

esy

of CM

A/F

lodyn

e/H

ydra

dyn

e ▪

Motion C

ontr

ol ▪

Hyd

raulic

▪ P

neu

mat

ic ▪

Ele

ctrica

l ▪

Mec

han

ical

▪ (

800)

426-5

480 ▪

ww

w.c

maf

h.c

om

The motors have been presented to and approved by the UL authorities ”Un‐derwriters Laboratories Inc.®” according to UL1004 and CSA22.2., No. 100.The corresponding identification is done on the motor name plate.A declaration of conformity confirming the design and compliance with the validEN standards and directives is available for the motors. A copy of the declara‐tion of conformity can be found in chapter 6 "Appendix".

1.7 Additional Components1.7.1 General Information

To operate a motor as part of an overall system within an explosion-protectedarea, further components are necessary. Not all required components are inthe scope of delivery of Bosch Rexroth. Components that are not available fromBosch Rexroth are signified as additional components and have to be orderedby the manufacturer of the system.An overall system mainly consists of:Bosch Rexroth devices and components● MAD/MAF motors in Ex-design● IndraDrive controller● Connecting Cables Provided additional components● Purging equipment and monitoring unit with connection hoses, accepted

as an overall system and certified for the required protection class.● For MAF motors: External cooling system for liquid cooling. For specifi‐

cation refer to the motor project planning manual● For MAD motors: External cooling system (fan) For specification refer to

motor project planning manual and the following notes.

1.7.2 Motor FanCool the MAD motors for ATEX atmospheres during operation with a forcedventilation. We recommend using a radial fan, which must be mounted outsideof the hazardous area (seefig. 1-21 "Example of use about fan connection ofthe MAD motor in Ex-area" on page 23). Mounting a fan directly on the motoris not permitted within explosive atmospheres. Observe the information in theproject planning manual regarding motor cooling when calculating and select‐ing a suitable motor fan.

Fans, an air hose and the small parts required for connection (hoseclamps, etc.) do not belong to the Bosch Rexroth scope of delivery.

1.7.3 Ex-p Controllers for Motor PurgingThe IndraDyn A motor in ATEX design is merely a part of a drive system whichprovides explosion protection only in combination with an Ex p control devicefor motor purging.The control device, which is required to safely operate the motor in an ATEXatmosphere, does not belong to the Bosch Rexroth scope of delivery and mustbe provided by the machine manufacturer.




UR, cUR Identification

Declaration of Conformity

Court

esy

of CM

A/F

lodyn

e/H

ydra

dyn

e ▪

Motion C

ontr

ol ▪

Hyd

raulic

▪ P

neu

mat

ic ▪

Ele

ctrica

l ▪

Mec

han

ical

▪ (

800)

426-5

480 ▪

ww

w.c

maf

h.c

om

WARNING

Explosion hazard! Danger to life and high material damage by improperhandling!The motor within ATEX atmospheres may only be commissioned as an overallsystem in connection with an Ex-p controller for motor purging. The necessarycontroller must be classified and certified according to the same or a highercategory of the motor.

Certification of the motors according to the ignition protection class● Ex d (encoder housing)● Ex p (motor housing)according to EN 60079-1:2004 bzw. EN 60079-2:2004 was made using a con‐trol device of type 07-3711-2213/1002 manufactured by● BARTEC GmbH

Max-Eyth-Str. 1697980 Bad Mergentheim, GermanyP.O.Box 1166, D-97961 Bad Mergentheim, GermanyTel +49 (0)7931 597-0, Fax +49 (0)7931 597-119e-mail [email protected]

Observe the notes of the manufacturer about motor purging whenselecting and commissioning the control device when designing thedrive system.

1.7.4 Connection CableOnly Bosch Rexroth connection cables are to be used to operatethe motors in explosive atmospheres.

Bosch Rexroth provides suitable ready-made connection cables for the motors.They are checked for conformity with the directives and relevant DIN and ENstandards. When selecting cables, use the following documentation:● DOK-CONNEC-CABLE-INDRV-AUxx-DE-P, R911322948● DOK-CONNEC-CABLE-INDRV-AUxx-EN-P, R911322949

1.8 Mechanical AttachmentBefore installing the motor, check whether the required information is presenton the designation label of the motor, such as the● Equipment group and category,● Explosion subgroup,● Maximum permitted surface temperature,correspond to the locally permitted conditions for use in potentially explosiveareas.Check the components for visible damage. Defective components must not bemounted.Before the installation, make sure that the environmental conditions on site,such as the ambient temperature, the humidity, the vibration and shock envi‐ronment do not exceed the details specified in the project planning manual ofthe motor.




Preparation

Court

esy

of CM

A/F

lodyn

e/H

ydra

dyn

e ▪

Motion C

ontr

ol ▪

Hyd

raulic

▪ P

neu

mat

ic ▪

Ele

ctrica

l ▪

Mec

han

ical

▪ (

800)

426-5

480 ▪

ww

w.c

maf

h.c

om

At the factory, the motors are produced either for flange mounting (frame shape05) or for foot mounting (frame shape 35). You will find details about the fas‐tening threads in the motor dimension sheet in the motor project planningmanual. For the fastening, the following general assignment applies:

① Holes for flange assembly② Assembly feet (existing on both sides) for foot assemblyFig.1-4: Motor fastening holes

MAD/MAF

B05 (Flange assembly) B35 (Foot assembly)

Hole Screw 1) Hole Screw 1)

Ø [mm] Type MGA [Nm] Ø [mm] Type MGA [Nm]

100 14 M12 87 11 M10 50

130

18 M16 215

12 M10 50

160 14M12 85

180 14.5

225 21 M18 270

1) Type and torques as recommendations for screws of property class 8.8.MGA = tightening torque in newtonmeters.

Fig.1-5: Fixing hole

● When mounting the motor, avoid clamping or jamming thecentering bundle on the motor side.

● Avoid damage to the insertion fitting on the system side.● Use for all kinds of mounting the existing motor fastening holes

to fasten the motor safely onto the machine.Check the property and accuracy of the connection before you dothe electric connection.




Mounting

Court

esy

of CM

A/F

lodyn

e/H

ydra

dyn

e ▪

Motion C

ontr

ol ▪

Hyd

raulic

▪ P

neu

mat

ic ▪

Ele

ctrica

l ▪

Mec

han

ical

▪ (

800)

426-5

480 ▪

ww

w.c

maf

h.c

om

1.9 Connection Techniques1.9.1 General Information

DANGER

Explosion hazard due to improper handling during the connection of themotor!● Ensure that the power is off and that the motor is connected only in an

atmosphere that is not capable of explosions.● Before working on the system, always use a suitable measuring instru‐

ment (e.g. multimeter) to assure that the parts no longer have a residualvoltage (e.g. due to the residual energies of capacitors in filters, drive de‐vices, etc.). Wait for their discharging time.

● The connection between the ground-reference lug and the grounding con‐ductor must be made before any other connections.

● In particular, make sure that the connection cables are installed in theterminal box orderly and free of tension to avoid abrasion or pressuremarks on the cables.

● The connection points to or on the control device must be located outsideof the explosive atmosphere.

● The ATEX motors may be operated only with Rexroth IndraDrive drivecontrollers and connection cables. Control devices or cables from othermanufacturers are not permitted.

The motors have to be grounded over the motor cable and over a separategrounding wire (see " Grounding" on page 4 and fig. 1-12 "Connection overviewof standard cabling for Ex-areas" on page 17).The power connection is located on top and is provided only as a terminal boxin the case of ATEX motors.The following connections must be made to ensure safe operation of the mo‐tors:● Power connection (incl. temperature sensor and holding brake, if appli‐

cable)● Encoder connection● Equipotential bonding connection● Cooling connection● Connect the purge gas with safety monitoring

1.9.2 Power ConnectionThe following description of the power connection refers to the connection ofthe motor with a power cable. Depending from the motor power, it can be nec‐essary to use two power cables (double cabling). Please, observe the notes inchapter 1.9.3 "Power Connection (Double Cabling)" on page 18 about doublecabling.We recommend keeping the following standard tools at hand to connect themotors:● 1 torque screwdriver 1/4" (adjustable)● 1 torque wrench 1/2" (with adjustment scale)● 1 socket wrench set 1/4" + 1/2"● 1 set of Allen keys● 1 set of combination wrenches




Court

esy

of CM

A/F

lodyn

e/H

ydra

dyn

e ▪

Motion C

ontr

ol ▪

Hyd

raulic

▪ P

neu

mat

ic ▪

Ele

ctrica

l ▪

Mec

han

ical

▪ (

800)

426-5

480 ▪

ww

w.c

maf

h.c

om

Proceed as follows when connecting the power cable within the terminal box ofthe motor:The required outlet direction of the power cable is selected in the type code ofthe motor. In accordance with the specification of the outlet direction by theuser, the terminal box is factory-mounted at the motor.

By selecting the connection option "terminal box rotatable", the usercan adapt the cable outlet direction to a new or modified connectionsituation directly at the installation site simply by "turning" the ter‐minal box.

The connection of the power cable to terminal boxes of the type code option"D, E, G, H" requires the following steps:

1. Open the lid of the terminal box ①.Open and remove the fastening screws (4 screws).

① Terminal box lid② Seal terminal box lid③ Fastening screws for terminal box (4 screws)④ Terminal box of the option ""D, E, G, H"⑤ Adapter plate for screwed cable connection⑥ Fastening screws for adapter plate (4 screws)⑦ Protection cover of screwed cable connection⑧ O-ring⑨ Purging connections

Fig.1-6: Terminal box rotatable (options "D, E, G, H").




Power Cable Connection at "Termi‐nal Box Rotatable" (Options "D, E,

G, H")

Court

esy

of CM

A/F

lodyn

e/H

ydra

dyn

e ▪

Motion C

ontr

ol ▪

Hyd

raulic

▪ P

neu

mat

ic ▪

Ele

ctrica

l ▪

Mec

han

ical

▪ (

800)

426-5

480 ▪

ww

w.c

maf

h.c

om

2. Check the direction of the outgoing cable and turn the terminal box if nec‐essary.● Detach the terminal box.

Open the fastening ③ and turn the terminal box ④ to the requiredoutlet direction in 90° increments.

● Fasten the terminal box.Screw in and tighten the fastening screws ③.Tightening torque of the screws: 6.5 Nm (±10%)#

CAUTION

Improperly inserted or missing seals may cause loss of motor pro‐tection class and danger of explosion of ATEX motors!A seal is located between terminal box and motor housing. Check theterminal box after turning or re-fastening for proper condition and correctposition of the seal.

3. Unscrew the protection cover of the screwed cable connection ⑦.4. Detach the adapter plate ⑤ at the terminal box ④.5. Tightly screw the adapter plate to the metric cable connection at the power

cable.

① Positioning the O-RingFig.1-7: O-ring at the screwed cable connection#

CAUTION

Improperly inserted or missing seals may cause loss of motor pro‐tection class and danger of explosion of ATEX motors!Conduct a visual inspection to check the O-ring for proper state and po‐sition at the screwed connection of the power cable before attaching theadapter plate to the power cable.If the O-ring is missing, do not use the power cable. In this case, contactyour Rexroth sales or service partner.

6. Run the power cable through the opening into the terminal box up to theadapter plate. Refasten the adapter plate to the terminal box.Tightening torque of the screws: 9 Nm (±10%)#

CAUTION

Improperly inserted or missing seals may cause loss of motor pro‐tection class and danger of explosion of ATEX motors!Check the O-ring inserted into the adapter plate for proper state and po‐sition before attaching the adapter plate to the terminal box.

7. Connect the wires in accordance with the connection diagram for standardor double cabling.Observe the following tightening torques:




Court

esy

of CM

A/F

lodyn

e/H

ydra

dyn

e ▪

Motion C

ontr

ol ▪

Hyd

raulic

▪ P

neu

mat

ic ▪

Ele

ctrica

l ▪

Mec

han

ical

▪ (

800)

426-5

480 ▪

ww

w.c

maf

h.c

om

Screw tightening torques in NM (±10%) for power connection MAD/MAF to terminal boxes of the options "D, E, G, H"

Terminal box rotatableOption "D, E, G, H"

U-V-W PE

M6 M12 M8 M12

MAx100MAx130MAx160

2.5 - / - 3.5 - / -

MAx180MAx225

- / - 14.0 - / - 20.0

Fig.1-8: Screw tightening torques in Nm in the MAx terminal box "D, E, G,H"

8. Close and fasten the lid of the terminal box.Moisten the thread of the fastening screws for the lid ① with liquid screwfastener Loctite 243 and fasten the lid with all the fastening screws.Tightening torque of the screws: 6.5 Nm (±10%)#

CAUTION

Improperly inserted or missing seals may cause loss of motor pro‐tection class and danger of explosion of ATEX motors!Check the attached seal at the terminal box lid for proper state and positionbefore attaching the terminal box lid to the terminal box.

The required outlet direction of the power cable is selected in the type code ofthe motor. In accordance with the specification of the outlet direction by theuser, the terminal box is mounted to the motor in the factory and must not bemodified afterwards.

As opposed to the connection option "terminal box rotatable", theoutlet direction must not be modified upon delivery and during theinstallation of the motors respectively.

The connection of the power cable to terminal boxes of the type code option"F, K, S, T" requires the following steps:

1. Open terminal box lid.




Power Cable Connection at Termi‐nal Box of Option "F, K, S, T"

Court

esy

of CM

A/F

lodyn

e/H

ydra

dyn

e ▪

Motion C

ontr

ol ▪

Hyd

raulic

▪ P

neu

mat

ic ▪

Ele

ctrica

l ▪

Mec

han

ical

▪ (

800)

426-5

480 ▪

ww

w.c

maf

h.c

om

① Terminal box of Option "F, K, S, T"② Protection cover of screwed cable connection

Fig.1-9: Terminal box (option "F, K, S, T")2. Unscrew the protection cover of the screwed cable connection ②.3. Run the power cable through the opening into the terminal box up to the

screwed cable connection and attach the screwed cable connection to theterminal box.There is an O-ring at the screwed cable connection of the power cable.Ensure that the O-ring is actually situated in the screwed connection ofthe power cable during assembly.

① Positioning the O-RingFig.1-10: O-ring at the screwed cable connection#

CAUTION

Improperly inserted or missing seals may cause loss of motor pro‐tection class and danger of explosion of ATEX motors!Conduct a visual inspection to check the O-ring for proper state and po‐sition at the screwed connection of the power cable before attaching thepower cable to the terminal box.If the O-ring is missing, do not use the power cable. In this case, contactyour Rexroth sales or service partner.

4. Connect the wires in accordance with the connection diagram for standardor double cabling.Observe the following tightening torques:




Court

esy

of CM

A/F

lodyn

e/H

ydra

dyn

e ▪

Motion C

ontr

ol ▪

Hyd

raulic

▪ P

neu

mat

ic ▪

Ele

ctrica

l ▪

Mec

han

ical

▪ (

800)

426-5

480 ▪

ww

w.c

maf

h.c

om

Screw tightening torques in NM (±10%) for power connection MAD/MAF to terminal boxes of the options "F, K, S, T"

Terminal Box"F, K, S, T"

U-V-W PE

M4 M6 M6 M8 M10 M12

MAx100 1.5 -/- 2.5 -/- -/- -/-

MAx130B-xxxxMAx130C-xxxxMAD130D-0050MAD130D-0100MAD130D-0150MAD130D-0200MAF130D-0050MAF130D-0100MAF130D-0200

1.5 -/- -/- 3.5 -/- -/-

MAD130D-0250MAF130D-0150MAF130D-0200MAx160

-/- 3.2 -/- 3.5 -/- -/-

MAx180 -/- 6 -/- -/- 12 -/-

MAx225 -/- 6 -/- -/- -/- 20

Fig.1-11: Screw tightening torques in NM in the MAx terminal box "F, K, S,T"

5. Close and fasten the lid of the terminal box.Moisten the thread of the fastening screws for the lid with liquid screwfastener Loctite 243 and fasten the lid using all the fastening screws.Tightening torque of the screws: 6.5 Nm (±10%)Before tightening the screws, make sure that the seal between the lid andthe terminal box housing is positioned properly.#

CAUTION

Improperly inserted or missing seals may cause loss of motor pro‐tection class and danger of explosion of ATEX motors!Check the attached seal at the terminal box lid for proper state and positionbefore attaching the terminal box lid to the terminal box.




Court

esy

of CM

A/F

lodyn

e/H

ydra

dyn

e ▪

Motion C

ontr

ol ▪

Hyd

raulic

▪ P

neu

mat

ic ▪

Ele

ctrica

l ▪

Mec

han

ical

▪ (

800)

426-5

480 ▪

ww

w.c

maf

h.c

om

① Motor② Terminal box③ Holding Brake (Option)④ Backup temperature sensor. Connect the backup sensor only if neces‐

sary.⑤ Shield connection via cable clamp of strain relief in the screwed con‐

nection.⑥ Equipotential bonding motor⑦ Equipotential bonding machine⑧ Purge gas duct to the controller of the motor scavenging⑨ Connection designations at the Rexroth drive controllerFig.1-12: Connection overview of standard cabling for Ex-areas

● The brake connections are assigned only if the motor wasmanufactured with the "brake" option.

● Only one of the PTC thermistor connector pairs (3-4 or 5-6) inthe motor cable should be connected to the motor; the otherone pairs serves a spare.

● Do not remove or damage the seal glued into the cover.● Observe the size of the threaded cable connection and con‐

nection thread for the cable inlet into the terminal box.● The connections of the motor-windings in the terminal box

must not be removed.● The through hole into the motor housing should not be closed

or sealed.




Connection overview standard ca‐bling

Court

esy

of CM

A/F

lodyn

e/H

ydra

dyn

e ▪

Motion C

ontr

ol ▪

Hyd

raulic

▪ P

neu

mat

ic ▪

Ele

ctrica

l ▪

Mec

han

ical

▪ (

800)

426-5

480 ▪

ww

w.c

maf

h.c

om

1.9.3 Power Connection (Double Cabling)

① Motor② Terminal box③ Holding Brake (Option)④ Equipotential bonding motor⑤ Equipotential bonding machine⑥ Connection designations at the Rexroth drive controller⑦ Purge gas duct to the controller of the motor scavengingFig.1-13: Connection scheme for double cabling in Ex-areas

● The brake connections are assigned only if the motor wasmanufactured with the "brake" option.

● Only one of the PTC thermistor connector pairs (3-4 or 5-6) inthe motor cable should be connected to the motor; the otherone pairs serves a spare.

● Do not remove or damage the seal glued into the cover.● Observe the size of the threaded cable connection and con‐

nection thread for the cable inlet into the terminal box.● The connections of the motor-windings in the terminal box

must not be removed.● The through hole into the motor housing should not be closed

or sealed.




Court

esy

of CM

A/F

lodyn

e/H

ydra

dyn

e ▪

Motion C

ontr

ol ▪

Hyd

raulic

▪ P

neu

mat

ic ▪

Ele

ctrica

l ▪

Mec

han

ical

▪ (

800)

426-5

480 ▪

ww

w.c

maf

h.c

om

1.9.4 Encoder ConnectionA 15 meter-long connection cable is connected with the explosion-protectedmotors. This connection cable has been connected with the encoder at thefactory. The connection cable has been connected to the encoder in the factoryand has to be connected to the controller after the motor has been mounted.

DANGER

Explosion hazard due to improper handling during the connection of themotor!The junction to/on the motor drive device must be located outside of the ex‐plosive atmosphere.

Observe the following when connecting the encoder:● The encoder housing on the motor may no longer be opened

in principle! Do not remove any of the screws on the encoderhousing.

● Work may be carried out only if the electrical system is notunder power.

● Please observe the detailsl of the project planning manual ofthe drive device and the details about pin assignment in themotor project planning manual DOK-MOTOR*-MAD/MAF****-PRxx-xx-P in chapter 8.7 "Encoder Connection".

1.9.5 Equipotential Bonding Conductor

WARNING

Explosion hazard due to improper handling during the connection of themotor!The equipotential bonding on the motor has to be connected according to EN60079-0:2004, chapter. 15.4 in addition to the grounding wire with a separatecable with min. 4 mm² cross-section (MAF225C-0150 with min. 25 mm²)

To connect the equipotential bonding conductor, the motors have the followingconnection possibilities on the motor flange:

Frame size Clamping mode Comment

100...180 Terminal For cable cross-sections upto 10mm²

225 Brass screw M12 To connect a cable via ringterminal for thread M12

Fig.1-14: Clamping mode for equipotential bonding conductor




Court

esy

of CM

A/F

lodyn

e/H

ydra

dyn

e ▪

Motion C

ontr

ol ▪

Hyd

raulic

▪ P

neu

mat

ic ▪

Ele

ctrica

l ▪

Mec

han

ical

▪ (

800)

426-5

480 ▪

ww

w.c

maf

h.c

om

① Terminal for equipotential bondingFig.1-15: Equipontential bonding on MAD100Connect the equipotential bonding on the motor via the cable having the equi‐potential bonding of the machine or installation and tighten the screwed con‐nection according to the following table.

Frame size Necessary cable cross-sec‐tion Tightening torque (±10%)

100...180 min 4 mm² 3.5 Nm225 min 25 mm² 20 Nm

Fig.1-16: Cable cross-section and tightening torque for equipotential bonding onthe motor

1.9.6 Cooling MAD Motors MAD motors in ATEX design are equipped with a fan cover with fan cowl foroperation with an external fan. With view ofn the A-side of the motor, the output direction of the fan cowl is onthe RIGHT side of the motor at delivery. Dependend from the installation, theoutput direction of the fan cowl or the fan cover can be adjusted.The following table gives an overview about the possible output directions de‐pending from the motor size:

Motor frame size Possible output directions CommentMAD100 right / left ⇒ fan cowl can be mounted in 2 directions

MAD130 ... 160 right / left / bottom / top ⇒ complete fan cover is rotatable in 4 directionsMAD180 ... 225 right / left / bottom ⇒ complete fan cover is rotatable in 3 directions

Fig.1-17: Possible output directions of the fan cowl The output direction of the fan cowl on the MAD100 can be changed withoutdisassemble the fan cover from the motor. The following figure gives a betteroverview about the significant parts of the fan cover without the motor.




Fan Cover with Fan Cowl onMAD100

Court

esy

of CM

A/F

lodyn

e/H

ydra

dyn

e ▪

Motion C

ontr

ol ▪

Hyd

raulic

▪ P

neu

mat

ic ▪

Ele

ctrica

l ▪

Mec

han

ical

▪ (

800)

426-5

480 ▪

ww

w.c

maf

h.c

om

① Fan Adapter② Cover sheet③ Fastening ScrewsFig.1-18: Fan cover on the MAD100 designed with fan cowlWhen changing the output direction of the fan cowl proceed as follows:

1. Loosen the fastening screws ③ on the fan cowl ① and on the cover sheet②.

2. Change the position of the fan cowl and the cover.3. Fasten the fan cowl and the cover into the changed position with all fas‐

tening screws again. The output direction of the fan cowl on the MAD130 and MAD160 can bechanged by rotating the complete fan cover. Possible output directions - right /left / bottom / top. To rotate the output direction, disassamble the fan cover offthe motor. The following figure gives a better overview about the disassembledfan cover without the motor.

① Fan cover - fastening screws (4 pieces) on MAD130② Fan cover - fastening screws (8 pieces) on MAD160Fig.1-19: Fan cover on the MAD130 (left) and MAD160 (right) designed with fan

cowl.When changing the output direction of the fan cowl proceed as follows:

Before working safe the fan cover against falling down!

1. Loosen and remove the fastening screws ① or ② of the fan cover.2. Turn the fan cover in steps of each 90° into the required output direction.3. Fasten the fan cover in the changed position again with all fastening

screws.




Fan Cover with Fan Cowl onMAD130 and MAD160

Court

esy

of CM

A/F

lodyn

e/H

ydra

dyn

e ▪

Motion C

ontr

ol ▪

Hyd

raulic

▪ P

neu

mat

ic ▪

Ele

ctrica

l ▪

Mec

han

ical

▪ (

800)

426-5

480 ▪

ww

w.c

maf

h.c

om

The output direction of the fan cowl on the MAD180 and MAD225 can bechanged by rotating the complete fan cover. To rotate the output direction, dis‐assamble the fan cover off the motor. Possible output directions - right / left /bottom. The following figure gives a better overview about the disassembledfan cover without the motor.

① Cable duct (rubber grommet) for encoder cables② Fan cover - fastining screws (4 for MAD180, 8 for MAD225)③ Filler plug (on hole for alternative output direction of the encoder cable)Fig.1-20: Fan cover with fan cowl on MAD180 and MAD225 in Ex-design.

Before working safe the fan cover against falling down!

Change the fan cowl - output direction1. Loosen and remove the fastening screws ② of the fan cover.2. Turn the fan cover in steps of each 90° into the required output direction.

Possible output directions - right / left / bottom.

Heed that the encoder cable should never be stressed or tensionedwhen changing the output direction of the fan cowl.

3. Fasten the fan cover in the changed position again with all fasteningscrews.

Change the encoder cable - output direction1. Loosen and remove the fastening screws ② of the fan cover.2. Tighten the encoder cable with the respective cable duct (rubber grommet)

completely inwards through the fan cover.3. Remove the filler plug in the required output direction and lead the encoder

cable through this opened hole from inwards to outwards.4. Re-position the cable duct (rubber grommet) on the encoder cable that the

hole is sealed by the rubber grommet.5. Fasten the fan cover with all fastening screws. Then, pull the encoder

cable outside through the cable duct that it is not stressed or tensioned.Close the orginal hole of the cable duct with a filler plug.




Fan Cover with Fan Cowl onMAD180 and MAD225 in Ex-De‐

sign.

Court

esy

of CM

A/F

lodyn

e/H

ydra

dyn

e ▪

Motion C

ontr

ol ▪

Hyd

raulic

▪ P

neu

mat

ic ▪

Ele

ctrica

l ▪

Mec

han

ical

▪ (

800)

426-5

480 ▪

ww

w.c

maf

h.c

om

The required fan and corresponding connection materials (air hose,connection clamps, etc.) do not belong to the scope of delivery ofthe motor; these must be provided by the machine manufacturer.

CAUTION

Danger of explosion due to electrostatic charge"Please observe the following when selecting and mounting the air hoseRadialfanAir hose between motor and fan,● the hose has to be approved for the use in ATEX atmospheres on the

basis of its properties.● there must be no electrostatic charge.

MAD motors may be operated only if the fan provides the specified minimumamount of air flow on the motor side. Therefore, when selecting radial fans orcentral ventilation systems, take into account the length of the air duct to beinstalled, as well as the air baffles. Also observe the notes regarding "radialventilation in intense polluted or hazardous areas" in chapter 9.8.2 of the motorproject planning manual.

① Hazardous area② Neutrally area③ MAD motors in Ex-design④ e.g. radial fan (not in the scope of delivery)Fig.1-21: Example of use about fan connection of the MAD motor in Ex-area

Fan adapter at the MAD... Connection diameter for airhose [mm]

Necessary air amount on themotor [m³/h]

100 80 300130 100 1000160

1501000

180 1500225 2000

Fig.1-22: Connection diameter fan cowl

1.9.7 Cooling Connection MAF Motors For liquid-cooled motors, the following connections are available:




Court

esy

of CM

A/F

lodyn

e/H

ydra

dyn

e ▪

Motion C

ontr

ol ▪

Hyd

raulic

▪ P

neu

mat

ic ▪

Ele

ctrica

l ▪

Mec

han

ical

▪ (

800)

426-5

480 ▪

ww

w.c

maf

h.c

om

● Coolant connection using the connection threads at the motor● Coolant connection using quick couplers

To supply the MAF motors with cooling liquid, you will need addi‐tional installation material as e.g. hoses and fixing clamps (notincluded in the delivery).

Inflow (IN) and outflow (OUT) can be assigned at the user's discre‐tion. The assignment does not affect the performance data of themotor.

Motor MAF ...

Connection via …

NoteThread

Quick coupler[Ø di Hose]

100...130 G1/4" 9 mm Selection of con‐nection type by type

code160...225 G1/2" 13 mm

Fig.1-23: Overview coolant connectionsOn delivery, the connection threads at the motor are covered with protectivestoppers. These protective stoppers must only be removed shortly beforescrewing-in the coolant lines or the quick couplers to avoid the intrusion of dirtinto the cooling system.Depending on the type of selected connection threaded joint, the maximumadmissible tightening torque of the motor-side threaded joint may not be appliedto the full extent, but has to be reduced to the admissible value of the customers'connection threaded joint. For this, please note the information of the manu‐facturer of the connection threaded joint you selected.The following table provides an overview of the values the motor-side connec‐tion threads may be loaded with. Exceeding the tightening torque or depth ofengagement can lead to irreversible motor damage.

Frame size MAF… Connecting threadMax. permissible

depth of engagement[mm]

Permissible tighten‐ing range [Nm]

100...130 G1/4" 14 18...20160...225 G1/2" 18 27...30

Fig.1-24: Coolant connection thread, admissible tightening torques and threaddepths

The motor-sided coolant connections are designed for coolant connectionthreads with axial sealing.Bosch Rexroth recommends to use connection threads, which contain an O-Ring for axial sealing of the screw connection.Not suited is a sealing using hemp bred, teflon tape or even with conical threadsas this kind of sealing can stress and/or even damage the connection threadon the motor

The impermeability of the coolant connection is in the responsibilityof the machine manufacturer and has to be tested and acceptet byhim after installing the motor.Furthermore, a regular test of correct state of the coolant connectionshould be stored in the maintenance plan of the machine.




Coolant Connection Threads

Court

esy

of CM

A/F

lodyn

e/H

ydra

dyn

e ▪

Motion C

ontr

ol ▪

Hyd

raulic

▪ P

neu

mat

ic ▪

Ele

ctrica

l ▪

Mec

han

ical

▪ (

800)

426-5

480 ▪

ww

w.c

maf

h.c

om

The quick coupler is another option for the coolant connection. It has a leakprotection at both sides and can be released also under full pressure of thecoolant system.If a motor having this coolant connection is ordered, all parts of the quick couplerare included in the motor delivery. In accordance with the ambient conditionsof the motor, the user can select one of two mounting options for the quickcoupler.1. Option A: Sealing nipple mounted at motor side2. Option B: Coupling mounted at motor side

① Connection threads at the motor②④⑦ Seal③ Double nipple⑤ Sealing nipple⑥ Coupling⑧ Threaded nozzle for hose

Fig.1-25: Mounting options of the quick coupler

First, connect the double nipple of the quick coupling with the cou‐pling or the sealing nipple of the quick coupling. After that, screwthe double nipple into the connection thread at the motor. This pro‐cedure prevents any multiple stress on the connection thread in themotor during mounting.

When mounting the quick coupler, observe● the correct position of the seals and● the tightening torques between the individual coupler components speci‐

fied below.

Thread sizes of the quick coupler Permissible tightening range [Nm] betweenthe components of the quick coupler

1/8"...1/4" 23...251/2" 28...30

Fig.1-26: Permissible tightening torque of the quick coupler● on permitted screw-in depths and tightening torques on the motor




Quick Coupler

Court

esy

of CM

A/F

lodyn

e/H

ydra

dyn

e ▪

Motion C

ontr

ol ▪

Hyd

raulic

▪ P

neu

mat

ic ▪

Ele

ctrica

l ▪

Mec

han

ical

▪ (

800)

426-5

480 ▪

ww

w.c

maf

h.c

om

Frame size MAF… Connecting threadMax. permissible

depth of engagement[mm]

Permissible tighten‐ing range [Nm]

100 G1/8" 14 14...15130 G1/4" 14 18...20

160...225 G1/2" 18 27...30

Fig.1-27: Coolant connection thread, admissible tightening torques and threaddepths

Once the quick coupler has been attached to the motor, the coolant hose canbe slipped over the threaded nozzle and fastened.When selecting the coolant hose , observe the required inner diameter of thehose di pursuant to fig. 1-23 " Overview coolant connections" on page 24.

Fig.1-28: Example for connection of a coolant hose Basic procedure for assembly:

1. Remove the protective covers of the coolant connection threads at themotor and screw in the pre-mounted quick coupler.

2. Slip the hose on the connection element (threaded nozzle). Avoid anybending or damaging of the screwed connection at the motor side.

3. Screw down the hose end over the connection element with the fixingclamp.● For service purposes, the quick coupling may be removed from the

sealing nipple using the coupler. It is not necessary to open the hoseconnection.

If you use another connection technology at the hose side, other assemblysteps may be required. Refer to the manufacture for information on assembly.

1.9.8 Operating PressureA maximum coolant supply pressure of 3bar applies to all MAF motors, regard‐ing the pressure effectively existing directly at the coolant connection of themotor.Please note that additional screwed or branch connections in the cooling circuitcan reduce the flow and supply pressure of the coolant.




Court

esy

of CM

A/F

lodyn

e/H

ydra

dyn

e ▪

Motion C

ontr

ol ▪

Hyd

raulic

▪ P

neu

mat

ic ▪

Ele

ctrica

l ▪

Mec

han

ical

▪ (

800)

426-5

480 ▪

ww

w.c

maf

h.c

om

1.9.9 Purge Gas Connection The connection of both purge gas ducts is on the appropriate thread on themotor. The connection threads are factory-made closed with protective plugs.Remove the protective plugs just before assembly.When connecting the purge gas ducts heed the prescribed flow directions:● Inlet (IN) is done via the purge gas hole on the terminal box.● Outlet (OUT) is done via the purge gas hole on the motor housing.

① Purge gas hole on the motor housing (OUT)② Purge gas hole on the terminal box (IN)Fig.1-29: Purge gas connections on the Ex-motorTo connect an Ex-motor with the Ex p controlle for motor scavenging use a pipeor tube with a maximum inner diameter of 8 mm.When using a plastic pipe, the maximum outer diameter is 13 mm.

CAUTION

Possible electrostatic discharge of plastic tubes!Use only plastic tubes which are authorized for use in Ex-areas.

Observe the permitted bending radius of the plastic tubes according to fig.1-30 "Scavenging gas connection scheme" on page 28 when connecting thepneumatic scavenging gas ducts.




Court

esy

of CM

A/F

lodyn

e/H

ydra

dyn

e ▪

Motion C

ontr

ol ▪

Hyd

raulic

▪ P

neu

mat

ic ▪

Ele

ctrica

l ▪

Mec

han

ical

▪ (

800)

426-5

480 ▪

ww

w.c

maf

h.c

om

p Maximum permitted input pressure on the BARTEC-Ex p controller 3bar

Fig.1-30: Scavenging gas connection scheme

If several motors should be operated with a controller, connect themin series when connecting the scavenging gas tubes (fig. 1-30"Scavenging gas connection scheme" on page 28)!

Proceed as follows when connecting the scavenging gas tube:1. Remove the protective stoppers of the scavenging bores on the motor.2. Fasten the scavenging gas tubes via the scavenging gas connections into

the appropriate connection threads on the motor (heed the flow direction).3. Heed the following details about the permitted screw-in depth of the scav‐

enging gas connections and tighten them with a tightening torque accord‐ing to the details of the manufacturer.

Motor frame size Connecting thread permitted screw-indepth

100...225 G1/4”min. 12 mmmax. 14 mm

Fig.1-31: Connection threads of the scavenging gas bores on the motorOnly inert gas or cleaned and dried industrial air are permitted as scavenginggas. In any case, connect a filter, if the quality regarding foreign particles cannotbe ensured.




Purging Connections

Scavenging Gas

Court

esy

of CM

A/F

lodyn

e/H

ydra

dyn

e ▪

Motion C

ontr

ol ▪

Hyd

raulic

▪ P

neu

mat

ic ▪

Ele

ctrica

l ▪

Mec

han

ical

▪ (

800)

426-5

480 ▪

ww

w.c

maf

h.c

om

1.10 Commissioning1.10.1 General Information

WARNING

Explosion hazard due to non-acceptance of the overall system!● Commissioning in ATEX atmospheres is prohibited until it has been as‐

certained that the overall system corresponds to the demands and certif‐ication conditions for ATEX protection.

● After repair, disassembly or for setup of security relevant parts, do theroutine test of the Ex protective system in connection with the motor ac‐cording to EN 60079-0 and EN 60079-2, again.

CAUTION

Damage to property due to errors in the controls of motors and movingelements!● Do not carry out commissioning if connections, operating states or product

data are unclear or faulty!● Do not carry out commissioning if the safety and monitoring equipment of

the system is damaged or not in operation.● Check the holding brake (option) functions before commissioning.● Contact Bosch Rexroth for missing information or support during com‐

missioning!● Observe the notes regarding startup of the controller for motor scaveng‐

ing.

1.10.2 Purging Time of the Overall SystemKeep the stipulated purging time of the whole system before every startup ofthe motors. The purging time can be determined according to the following de‐tails:● Frame Size 100 ... 180

– 60 seconds purging time per motor● Size 225

– 360 seconds purging time per motor for 20 l/min purging volumeor

– 180 seconds purging time per motor for 40 l/min purging volume● 30 seconds purging time per each 10 m connection hoseExample:

Connected motors: 2 x MAD130 Purging time

2 x 60 seconds 120 sec.

Length of scavenging gas tube: 14 m Purging time

2 x 30 seconds 60 sec.

Minimum purging time to be adjusted on the controller 180 sec.

Fig.1-32: Worked sample about purging timeThe controller of BARTEC with type 07-3711-2213/1002 is initialized for motorsof frame size 100 ... 180. With this initialization, a drive system consisting of ● up to 5 motors of frame size 100 ...180 with




Identify the Purging Time

Adjustable Pressure Switching Val‐ue

Court

esy

of CM

A/F

lodyn

e/H

ydra

dyn

e ▪

Motion C

ontr

ol ▪

Hyd

raulic

▪ P

neu

mat

ic ▪

Ele

ctrica

l ▪

Mec

han

ical

▪ (

800)

426-5

480 ▪

ww

w.c

maf

h.c

om

● up to 20 m purging gas tubes can be operated.

CAUTION

Risk of explosion due to incorrect adjusted pressure switching values!The initialization of the BARTEC controller cannot be accepted for the motorswith frame size 225. Are motors used with frame size 225 or controller fromother manufacturers, the appropriate pressure switching values for motor purg‐ing must be adjusted manually.Heed the details in fig. 1-33 "Pressure switching value" on page 30, "Identifythe Purging Time" on page 29 and fig. 1-3 "Ex-designation label on the motorsin Ex-design" on page 7 to adjust the pressure switching values.In general, the locally test of the pressure switching values and before startupmust be ensured by the user of the total system.

Designation Pressure switching value

DIFF A / DIFF B (traverse value on the pressure moni‐toring module)

2.0 mbar

MIN A / MIN B (minimum housing inner pressure, de‐activation value)

1.0 mbar

MIN P (arbitrary prewarning) 2.0 mbar

DP 1 (minimum or nominal operating pressure) 2.5 mbar

MAX (maximum housing inner pressure) 23.0 mbar

MAX 1 (maximum scavenging pressure) 20.0 mbar

Fig.1-33: Pressure switching value

1.10.3 Preparation1. Keep the documentation of all products you are using ready.2. Check the products for damage.3. Check all mechanical and electrical connections (incl. the potential equal‐

ization line!).4. Activate the safety and monitoring equipment of the system.

1.10.4 ExecutionWhen all prerequisites have been fulfilled, proceed as follows:1. Activate the fan for the MAD motor or the external cooling system to cool

the MAF motor.2. Check the given values on the designation plate on the motor , like scav‐

enging gas volumen, scavenging gas, purging time, etc. (see fig. 1-3 "Ex-designation label on the motors in Ex-design" on page 7). The values mustbe adjusted, reached and kept. Thereby, notice the details of the manu‐facturer of the controller.

3. Activate the controller of the motor scavenging.4. Carry out the commissioning of the drive system according to the instruc‐

tions of the corresponding product documentation. You can find the re‐spective information in the functional description of the drive controldevices.

5. Log all measures taken in the commissioning report.




Court

esy

of CM

A/F

lodyn

e/H

ydra

dyn

e ▪

Motion C

ontr

ol ▪

Hyd

raulic

▪ P

neu

mat

ic ▪

Ele

ctrica

l ▪

Mec

han

ical

▪ (

800)

426-5

480 ▪

ww

w.c

maf

h.c

om

The commissioning of drive control devices and the control unit may requireadditional steps. The inspection of the functioning and performance of the sys‐tems is not object of these operating instructions; instead, it is carried out withinthe framework of the commissioning of the machine as a whole. Observe theinstructions and regulations given by the machine manufacturer.

1.11 Disassembly

DANGER

Explosion hazard!Fatal injury due to errors during the control of motors or works on movingelements!● Do not work on unsecured and operating machines.● Before accessing motors after having switched them off, let them cool

down for a sufficiently long time. Cooling down can require up to 140 mi‐nutes!

● Make sure that the motor is only dismantled in the de-energized state anda non-explosive atmosphere.

● Before working on the system, always use a suitable measuring instru‐ment (e.g. multimeter) to assure that the parts no longer have a residualvoltage (e.g. due to the residual energies of capacitors in filters, drive de‐vices, etc.). Wait for their discharging time.

● Secure the machine against accidental movements and against unau‐thorized operation.

● Before dismantling, secure the motor and power supply against falling ormovement before disconnecting the mechanical connections.

● Observe the notes regarding dismantling in the documentation of the mo‐tor purging control device.

In the case of malfunctions, maintenance or deactivation of the motors, proceedas follows:1. Use the control commands to bring the drive to a controlled standstill.2. Switch off the power and control voltage of the drive device.3. For MAD only: Switch off the motor protection switch for the motor fan.For MAF only: Switch off the supply of the external cooling system.1. Switch off the controller for motor scavenging (observe the notes of the

manufacturer regarding switch off!).2. Switch off the main switch of the machine.3. Secure the machine against accidental movements and against unau‐

thorized operation.4. Wait for the cooldown times of the motor and the discharge time of the

electrical systems to elapse.5. Disconnect all electrical connections. Disconnect the scavenging gas

ducts on the connection threads of the motor.6. Before dismantling, secure the motor and power supply against falling or

movement before disconnecting the mechanical connections.7. Dismantle the motor from the machine. At the MAF motor, also empty the

coolant channels.8. Log all measures taken in the commissioning report.




Court

esy

of CM

A/F

lodyn

e/H

ydra

dyn

e ▪

Motion C

ontr

ol ▪

Hyd

raulic

▪ P

neu

mat

ic ▪

Ele

ctrica

l ▪

Mec

han

ical

▪ (

800)

426-5

480 ▪

ww

w.c

maf

h.c

om

1.12 Maintenance / RepairIncrease availability with regular preventive maintenance measures. Notice theinformation in the maintenance schedule of the machine manufacturer and thefollowing details regarding maintenance measures and intervals for the motor.

WARNING

Explosion hazard!Death by electrocution possible due to live parts with more than 50 V!● Working on parts that are under power while the danger of explosions

exists is strictly prohibited.● Before starting work that has to be carried out, observe the important

safety regulations according to DIN VDE 530, such as releasing the power;securing against restarting; ensuring that the system is not under power;grounding and short-circuiting; and covering or fencing off neighboringparts that are under power.

● Ensure that the measures mentioned above cannot be repealed beforethe work is completed.

Measure Interval

For MAF only: Check the functioning of thecoolant system

According to the guidelines in the machinemaintenance plan, but at least every 1,000operating hours.

For MAD only: Check the functioning of thefan and the air circulation.


Check the mechanical and electrical con‐nections.


Check the air hoses for motor scavengingdevice for proper seat and tightness.

According to the guidelines in the machinemaintenance plan, but at least every 1,000operating hours. Note: An error messageof the controller regarding pressure loss inthe over pressure encapsulation can be asign of deterioration of the radial shaftsealing ring on the motor.

Check the machine for smooth running, vi‐brations and bearing noises.


Remove dust, chips and other dirt from themotor housing, cooling fins and the con‐nections.

According to the guidelines in the machinemaintenance plan or according to the pol‐lution severty, at least every 1,000 oper‐ating hours.

Fig.1-34: Maintenance measures




Maintenance

Court

esy

of CM

A/F

lodyn

e/H

ydra

dyn

e ▪

Motion C

ontr

ol ▪

Hyd

raulic

▪ P

neu

mat

ic ▪

Ele

ctrica

l ▪

Mec

han

ical

▪ (

800)

426-5

480 ▪

ww

w.c

maf

h.c

om

WARNING

Danger of explosion due to improper repair or maintenance!● Repairs on ATEX motors may only be carried out by Bosch Rexroth Elec‐

tric Drives and Controls GmbH or workshop that has been authorized byBosch Rexroth.

● Are Ex-motors repaired, changed or reconverted, an addition plate mustbe brought on the motor after each repair of maintenance according to EN60034-1:2004 which names the work shop or the person, the year of themaintenance and the done changes.

● After repair, disassembly or for setup of security relevant parts, do theroutine test of the Ex protective system in connection with the motor ac‐cording to EN 60079-0:2004 and EN 60079-2:2004, again.

Defective ATEX motors must be sent back to the place of manufacture or to aBosch Rexroth authorized workshop for ATEX motors for repairs such as● Replacing the motor encoder● Replacing the radial shaft sealing ring. In no case may they be dismantled or repaired by a workshop not authorizedby Bosch Rexroth.




Court

esy

of CM

A/F

lodyn

e/H

ydra

dyn

e ▪

Motion C

ontr

ol ▪

Hyd

raulic

▪ P

neu

mat

ic ▪

Ele

ctrica

l ▪

Mec

han

ical

▪ (

800)

426-5

480 ▪

ww

w.c

maf

h.c

om



Court

esy

of CM

A/F

lodyn

e/H

ydra

dyn

e ▪

Motion C

ontr

ol ▪

Hyd

raulic

▪ P

neu

mat

ic ▪

Ele

ctrica

l ▪

Mec

han

ical

▪ (

800)

426-5

480 ▪

ww

w.c

maf

h.c

om

2 Appendix2.1 Declaration of Conformity

Fig.2-1: Declaration of conformity (1/2)



Appendix

Court

esy

of CM

A/F

lodyn

e/H

ydra

dyn

e ▪

Motion C

ontr

ol ▪

Hyd

raulic

▪ P

neu

mat

ic ▪

Ele

ctrica

l ▪

Mec

han

ical

▪ (

800)

426-5

480 ▪

ww

w.c

maf

h.c

om

Fig.2-2: Declaration of conformity (2/2)



Appendix

Court

esy

of CM

A/F

lodyn

e/H

ydra

dyn

e ▪

Motion C

ontr

ol ▪

Hyd

raulic

▪ P

neu

mat

ic ▪

Ele

ctrica

l ▪

Mec

han

ical

▪ (

800)

426-5

480 ▪

ww

w.c

maf

h.c

om

2.2 Service and SupportOur service helpdesk at out headquarters in Lohr, Germany, will assist you withall kinds of enquiries. Out of helpdesk hours please contact our German servicedepartment directly.

Helpdesk Service HotlineGermany

Service HotlineWorldwide

Time 1) Mo-Fr 7:00 am - 6:00 pm CET Mo-Fr 6:00 pm - 7:00 am CETSa-Su 0:00 am - 12:00 pm CET

Outwith Germany please con‐tact our sales/service office inyour area first.For hotline numbers refer to thesales office addresses on theInternet.

Phone +49 (0) 9352 40 50 60 +49 (0) 171 333 88 26or+49 (0) 172 660 04 06

Fax +49 (0) 9352 40 49 41 –

e-mail [email protected] –

Internet http://www.boschrexroth.comYou will also find additional notes regarding service, maintenance (e.g. delivery addresses) andtraining.

1) Central European Time (CET) For quick and efficient help please have the following information ready:● detailed description of the fault and the circumstances● information on the type plate of the affected products, especially type co‐

des and serial numbers● your phone, fax numbers and e-mail address so we can contact you in

case of questions.



Appendix

Preparing Information

Court

esy

of CM

A/F

lodyn

e/H

ydra

dyn

e ▪

Motion C

ontr

ol ▪

Hyd

raulic

▪ P

neu

mat

ic ▪

Ele

ctrica

l ▪

Mec

han

ical

▪ (

800)

426-5

480 ▪

ww

w.c

maf

h.c

om

mailto:[email protected]

http://www.boschrexroth.com



Court

esy

of CM

A/F

lodyn

e/H

ydra

dyn

e ▪

Motion C

ontr

ol ▪

Hyd

raulic

▪ P

neu

mat

ic ▪

Ele

ctrica

l ▪

Mec

han

ical

▪ (

800)

426-5

480 ▪

ww

w.c

maf

h.c

om

IndexAAdditional components.......................................... 8Application conditions........................................... 4

Connection specifications .............................. 4Emergency Stop ............................................. 5Pressure loss / temperature rise .................... 5Risk of corrosion ............................................ 5

Application ConditionsGrounding ...................................................... 4

Appropriate use..................................................... 4

BBrake..................................................................... 5

Control ............................................................ 5Brake fault............................................................. 5

CConnection cable.................................................. 9Connection overview double cabling.................. 18Connection overview standard cabling............... 17Connection technique

Motor cooling, fan ......................................... 20Motor cooling, liquid ..................................... 23Purge gas connection ................................. 27

Connection techniques....................................... 11Coolant connection threads ......................... 24Coolant inflow ............................................... 24Coolant outflow ............................................ 24Inner diameter of hose ................................. 26Operating pressure ...................................... 26Power connection ......................................... 11Quick coupler ............................................... 25

DDesignation of motors........................................... 6Disassembly........................................................ 31Discharge currents................................................ 6discharge time..................................................... 31

EEncoder connection............................................ 19Environmental influences

Environmental influences ............................... 5Equipotential bonding conductor......................... 19Ex-p controller....................................................... 8Ex-p controller, supplier........................................ 9

FFan cover............................................................ 20Fan cowl.............................................................. 20

FFunctional test, brake............................................ 6

GGrounding............................................................. 6

HHolding brake........................................................ 5

Control ............................................................ 5Functional test ................................................ 6

IIgnition protection class........................................ 9

MMaintenance / repair........................................... 32Mechanical mounting

Flange mounting (B05) ................................. 10foot mounting (B35) ...................................... 10

Motor fan............................................................... 8Motor name plate.................................................. 6Motor type plate, additional designation label....... 7

PPressure switching value.................................... 29Property.............................................................. 10Purge gas connection......................................... 27Purging time........................................................ 29

RResidual risks........................................................ 6

Aging .............................................................. 6Failure of the protective equipment ................ 6Overload ......................................................... 6

SSafety instructions for electric drives and con‐trols....................................................................... 3Safety notes

Personell ........................................................ 3Warning symbols ............................................ 3

Service Hotline.................................................... 37Support

see Service Hotline ...................................... 37

TTerminal box....................................................... 11



Index

Court

esy

of CM

A/F

lodyn

e/H

ydra

dyn

e ▪

Motion C

ontr

ol ▪

Hyd

raulic

▪ P

neu

mat

ic ▪

Ele

ctrica

l ▪

Mec

han

ical

▪ (

800)

426-5

480 ▪

ww

w.c

maf

h.c

om



Court

esy

of CM

A/F

lodyn

e/H

ydra

dyn

e ▪

Motion C

ontr

ol ▪

Hyd

raulic

▪ P

neu

mat

ic ▪

Ele

ctrica

l ▪

Mec

han

ical

▪ (

800)

426-5

480 ▪

ww

w.c

maf

h.c

om

Notes



Court

esy

of CM

A/F

lodyn

e/H

ydra

dyn

e ▪

Motion C

ontr

ol ▪

Hyd

raulic

▪ P

neu

mat

ic ▪

Ele

ctrica

l ▪

Mec

han

ical

▪ (

800)

426-5

480 ▪

ww

w.c

maf

h.c

om

Printed in GermanyDOK-MOTOR*-IDYN*A*EXPD-IB01-EN-PR911323997

Bosch Rexroth AGElectric Drives and ControlsP.O. Box 13 5797803 Lohr, GermanyBgm.-Dr.-Nebel-Str. 297816 Lohr, GermanyTel. +49 (0)93 52-40-0Fax +49 (0)93 52-48 85www.boschrexroth.com

Court

esy

of CM

A/F

lodyn

e/H

ydra

dyn

e ▪

Motion C

ontr

ol ▪

Hyd

raulic

▪ P

neu

mat

ic ▪

Ele

ctrica

l ▪

Mec

han

ical

▪ (

800)

426-5

480 ▪

ww

w.c

maf

h.c

om

mailto:[email protected]

http://www.boschrexroth.de

Documents

Rexroth MAD and MAF Motors - CMA/Flodyne/Hydradyne PDFs/BRC/Motors/MAF/Rexroth MAD_MAF...series of IndraDyn A motors of Rexroth. The designation of a motor in Ex-design is made at