Bosch Rexroth ActiveMover

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Bosch Rexroth AG

Postfach 30 02 07

70442 Stuttgart

Germany

Fax +49 711 811–7777

info@boschrexroth.de

www.boschrexroth.com

Subject to changes

3 842 564 874/2021-04

3842564874

Main Page

Table of Contents3
About this Documentation7
Validity of the Documentation7
Required and Supplementary Documentation7
Presentation of Information7
Safety Instructions7
Symbols8
Designations9
Safety Instructions9
About this Section9
Intended Use9
Improper Use9
Personnel Qualifi Cations10
General Safety Instructions10
Product-Specifi C Safety Instructions11
Personal Protective Equipment14
Owner Responsibilities14
General Notes on Property and Product Damage15
Scope of Delivery15
Condition on Delivery15
About this Product15
Specifi Cations15
Using Activemover Linear Motor System15
Product Description16
Base Frames18
Section Module Connection Kit 3 842 559 45219
Curve Module Connection Kit 3 842 559 45320
Fixing Plates 3 842 559 45421
Fixing Plate 3 842 559 45522
Module Holder 3 842 559 42923
Section Module 3 842 559 42624
Curve Module 3 842 559 43029
Workpiece Pallet 3 842 559 433 (2 Magnets)/3 842 559 434 (3 Magnets)33
IR ID System40
Power Supply 3 842 559 43541
Control Cabinet 3 842 564 861 and 3 842 564 86442
Connection Kit 3 842 55943
Interface Modules45
Removal Tool 3 842 559 43946
Calibration Set 3 842 559 45647
Identifi Cation of the Product48
Transport and Storage48
Transporting the Product48
Transport Suggestion for Conveyor/Curved Units49
Storing the Product49
Installation50
Unpacking50
Installation Requirements50
Installation Position50
Required Tools50
Mechanical System50
Electrical System50
Symbols Used51
Assembling the Product52
Assembly Procedure52
Customer Base Frames54
Assembly Without Fi Xing Plates on Customer Base Frames54
Positioning and Aligning the Base Frame55
Assembling the Section Module on a Base Frame57
Assembling the Curve Module on a Base Frame64
Attaching and Connecting System Sections66
Aligning Section Modules (Rough Adjustment)71
Assembling the Profi Le Connector for 2 Section Modules74
Assembling the Profi Le Connector for Curve Module and Section Module75
Aligning the Upper V-Rail, Section Module to Section Module (Fi Ne Adjustment)76
Aligning the Upper V-Rail, Section Module to Curve Module (Fi Ne Adjustment)79
Assembling and Aligning the Guide Rails82
Mounting/Removing Workpiece Pallets83
Assembling, Adjusting and Connecting the IR Reading Head ID System86
Assembling the Power Supply88
Electrical Connection of the Product89
Assembling the EMC Cable Glands and Cable Guard Pipe91
Inserting the Connection Cable92
Inserting the Power Supply Line into Section/Curve Module93
Connecting Grounding and Power Cables (28 V) (from Left Section/Curve Module)94
Connecting Grounding and Power Cables (28 V) (from Right Section/Curve Module)95
Connecting Network and Cable Control Voltage (24 V) (from Left Section/Curve Module)96
Connecting Network and Cable Control Voltage (24 V) (from Right Section/Curve Module)97
Connecting the Network Connections and Power Supplies in the Control Panel97
IR Reading Head ID System (Optional)98
Connecting Network - Printed Circuit Boards (Gateway)99
Network Connection Left Network and Right Network101
Connect Power Supply in Section Module102
Connect Power Supply in Curve Module103
Connect Power Supply in the Control Cabinet104
Ethernet POWERLINK105
Ethernet Port (Windows PC)106
Plc107
Emergency Safety Circuit108
Line Voltage109
Commissioning110
Measurements before Starting up the System for the Fi Rst Time110
Resistance between the Motor Cable Connections110
Resistance between Motor Cable (0 V) and Ground (Base Frame)111
Resistance between Motor Cable (0 V) and Control Voltage (24 V)112
Resistance between Motor Cable (28 V) and Control Voltage (24 V)113
Initial Commissioning114
Residual Risks116
Life Stages of the Machine117
Re-Commissioning after a Standstill117
Ampro Confi Guration Software117
Operation118
Information on Operation118
Wear118
Measures to Reduce Wear118
Loading the Workpiece Pallet118
Environmental Factors118
Maintenance and Repair120
Cleaning and Care122
Upper V-Rail and Guide Rails for Section/Curve Module122
Base Frames of Section/Curve Module123
Workpiece Pallets123
Measuring System123
Control Panel Fan123
Inspection124
Workpiece Pallets124
Inspection of Upper V-Rails/Guide Rails125
Testing the Connection Block (Magnetic Connector Section/Curve Module)126
Control Panel Fan126
Control Panel Air Fi Lter126
Air Fi Lter of Power Supply126
All Screws126
Checking the Measuring System (Magnetic Strip)127
Maintenance128
Lubricating the Workpiece Pallet128
Repair129
Required Mechanical Tools129
Required Electrical Tools129
Replacing the Rubber Buffer131
Replacing Discharge Brushes132
Replacing the Measuring System133
Replacing the Felt (Lubrication Device for WT)134
Replacing the Contact Pressure Springs135
Replacing the Magnetic Kit136
Replacing the Guide Rollers (Fl At)137
Replacing the V-Guide Rollers138
Replacing the Upper V-Rail (Section Module)139
Replacing the Upper V-Rail (Curve Module)140
Replacing the Guide Rails (Section Module)141
Replacing the Cover of the Coil (Section and Curve Module)142
Replacing the Power Supply143
Replacing the Printed Circuit Board (Coil Driver) (Section Module)144
Replacing the Printed Circuit Board (Coil Driver) (Curve Module)146
Replacing the Printed Circuit Board (Gateway) (Section Module)147
Replacing the Printed Circuit Board (Gateway) (Curve Module)149
Replacing the Drive Thermistors151
Replacing the Section/Curve Module Main Fuse152
Replacing the Section/Curve Module Coil Fuse153
Replacing the Measuring System (Encoder) (Section Module)154
Replacing the Measuring System (Encoder) (Curve Module)155
Replacing the Activemover Power Supply Air Fi Lter156
Adjustment and Calibration157
Checking and Adjusting the Measuring System Distance157
Primary and Secondary Measuring System159
Encoder Numbering and Order160
Assembling and Aligning the Calibration Set (Optional)161
Checking Position of the Calibration Set167
Referencing the Encoder Position169
Adjusting the Primary Measuring System170
Adjusting the Secondary Measuring System172
Installing/Removing the WT Mounting (Optional)175
Troubleshooting176
Localizing and Remedying Short Circuits176
Communication Error178
Operating Mode Error178
Diagnostic Leds179
Activemover Controller179
Printed Circuit Board (Coil Driver)179
Printed Circuit Board (Gateway)180
Decommissioning181
Disassembly and Replacement182
Preparing the Product for Storage/Later Use182
Disposal183
Upgrading and Modifi Cation183
Technical Data184
Mechanical Data184
Electrical Data184
Dimensions and Weight184
IR ID System186
Ambient Conditions186
Appendix186
Trademark Information186

Bosch Rexroth ActiveMover - Page 188

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