Page 1 ActiveMover Linear motor system Replaces: Assembly instructions 3842559521/2018-07 3 842 564 874/2021-04 ENGLISH...
Page 2 Our products are subject to natural wear and aging. © All rights reserved by Bosch Rexroth AG, also for the registration of industrial property rights. This document may not be reproduced or distributed to third parties without our consent.
Page 3: Table Of Contents
Removal tool 3 842 559 439 5.2.17 Calibration set 3 842 559 456 Identiﬁ cation of the product Transport and storage Transporting the product 6.1.1 Transport suggestion for conveyor/curved units Storing the product 3 842 564 874/2021-04, MIT: ActiveMover, Bosch Rexroth AG...
Page 4 Network connection Left Network and Right Network 7.6.12 Connect power supply in section module 7.6.13 Connect power supply in curve module 7.6.14 Connect power supply in the control cabinet 7.6.15 Ethernet POWERLINK 7.6.16 Ethernet port (Windows PC) Bosch Rexroth AG, MIT: ActiveMover, 3 842 564 874/2021-04...
Page 5 10.4.5 Replacing the measuring system 10.4.6 Replacing the felt (lubrication device for WT) 10.4.7 Replacing the contact pressure springs 10.4.8 Replacing the magnetic kit 10.4.9 Replacing the guide rollers (ﬂ at) 3 842 564 874/2021-04, MIT: ActiveMover, Bosch Rexroth AG...
Page 6 Preparing the product for storage/later use Disposal Upgrading and modiﬁ cation Technical data 16.1 Mechanical data 16.2 Electrical data 16.3 Dimensions and weight 16.4 IR ID system 16.5 Ambient conditions Appendix 17.1 Trademark information Bosch Rexroth AG, MIT: ActiveMover, 3 842 564 874/2021-04...
Page 7: About This Documentation
3 "General notes on property and product damage", as well as before any sequence of actions or any required action which involves a risk of personal injury or property damage. Be sure to observe all safety precautions. 3 842 564 874/2021-04, MIT: ActiveMover, Bosch Rexroth AG...
Page 8: Symbols
Meaning If this information is not observed, the product cannot be used and/or operated as designed.  Single, independent action Numbered steps: The numbers indicate that the action steps are sequential. Bosch Rexroth AG, MIT: ActiveMover, 3 842 564 874/2021-04...
Page 9: Designations
The intended use also includes having read and understood these instructions, especially section 2 "Safety instructions". 2.3 Improper use Any use other than that described in the section "Intended use" is considered improper and is not permitted. 3 842 564 874/2021-04, MIT: ActiveMover, Bosch Rexroth AG...
Page 10: Personnel Qualifi Cations
10/188 Safety instructions Bosch Rexroth AG is not liable for any damage resulting from improper use. The user alone bears any risks associated with improper use. The following foreseeable misuses also constitute improper use: • Transporting goods other than those speciﬁ ed.
Page 11: Product-Specifi C Safety Instructions
After shutting down the power supply, access needs to be blocked by means of separately locked protective equipment with guard locking so that the energy present in the capacitors can dissipate. 3 842 564 874/2021-04, MIT: ActiveMover, Bosch Rexroth AG...
Page 12 (e.g. ﬁ nger, hand, foot etc.) can be freed. To do this, drive the wedges into the separating gap using the hammer so that the trapped body parts can be freed. Bosch Rexroth AG, MIT: ActiveMover, 3 842 564 874/2021-04...
Page 13 • Following an EMERGENCY STOP or in the event of a fault or other irregularity, turn the product off and secure it against being switched back on. • Do not reach into moving parts. 3 842 564 874/2021-04, MIT: ActiveMover, Bosch Rexroth AG...
Page 14: Personal Protective Equipment
• Provide safety-related instructions to the operating personnel before initial commissioning or re-commissioning, and then at regular intervals. Bosch Rexroth AG, MIT: ActiveMover, 3 842 564 874/2021-04...
Page 15: General Notes On Property And Product Damage
Using ActiveMover linear motor system • For transporting products on speciﬁ c workpiece pallet assemblies in short-cycle operation • For positioning products on speciﬁ c workpiece pallet assemblies in short-cycle operation 3 842 564 874/2021-04, MIT: ActiveMover, Bosch Rexroth AG...
Page 16: Product Description
Connection kit 3 842 559 449 Interface modules 3 842 559 444, 3 842 559 445, 3 842 559 446 Removal tool 3 842 559 439 Calibration set 3 842 559 456 Bosch Rexroth AG, MIT: ActiveMover, 3 842 564 874/2021-04...
Page 17 About this product 17/188 557 186-01 Fig. 1: ActiveMover linear motor system – components 3 842 564 874/2021-04, MIT: ActiveMover, Bosch Rexroth AG...
Page 18: Base Frames
Base frame (short, only for curve module) 3 842 559 451 Leveling foot 16/12 mm SW36 (45,5 ... 163,5) SW24 557 186-02 Fig. 2: Base frames for section and curve modules Bosch Rexroth AG, MIT: ActiveMover, 3 842 564 874/2021-04...
Page 19: Section Module Connection Kit 3 842 559 452
32 x 3 842 559 450 with section M10 x 40 modules. 12.9 ISO8375 16 x 40 – A – ST 557 186-03 Fig. 3: Connection kit 3 842 559 452 3 842 564 874/2021-04, MIT: ActiveMover, Bosch Rexroth AG...
Page 20: Curve Module Connection Kit 3 842 559 453
3 842 559 450 12.9 or 3 842 559 451 with curve ISO8375 16 x 40 – A – ST module. 557 186-04 Fig. 4: Connection kit 3 842 559 453 Bosch Rexroth AG, MIT: ActiveMover, 3 842 564 874/2021-04...
Page 21: Fixing Plates 3 842 559 454
3 842 559 450. ISO8375 M10 x 40 10 x 40 – A – ST 12.9 ISO8734 6 x 20 557 186-05 Fig. 5: Connection kit 3 842 559 454 3 842 564 874/2021-04, MIT: ActiveMover, Bosch Rexroth AG...
Page 22: Fixing Plate 3 842 559 455
3 842 559 430 on a base 12.9 frame 3 842 559 450 or 3 842 559 451. DIN7349 10,5x25x4 Fixing plate Cable hole 557 186-06 Fig. 6: Fixing plate 3 842 559 455 Bosch Rexroth AG, MIT: ActiveMover, 3 842 564 874/2021-04...
Page 23: Module Holder 3 842 559 429
Sliding blocks (4x) M6 x 45 12.9 Headless setscrew (4x) 8 mm M6 x 14 M8 x 40 12.9 M6 x 45 557 186-07 Fig. 7: Module holder 3 842 559 429 3 842 564 874/2021-04, MIT: ActiveMover, Bosch Rexroth AG...
Page 24: Section Module 3 842 559 426
M6 x 8 Electronics box Measuring system (encoder) left Measuring system (encoder) right Upper V-rail Section proﬁ le 10 x ø7,4 Cable guide Centering piece Magnet 557 186-08 Fig. 8: Section module Bosch Rexroth AG, MIT: ActiveMover, 3 842 564 874/2021-04...
Page 25 About this product 25/188 Electronics box Printed circuit board (coil driver) Printed circuit board (gateway) Printed circuit board (coil driver) 557 186-09 Fig. 9: Section module with open electronics box 3 842 564 874/2021-04, MIT: ActiveMover, Bosch Rexroth AG...
Page 26 Flat ribbon cable (section module) top left Flat ribbon cable (section module) bottom left Cable entry point 557 186-10 Fig. 10: Printed circuit board (coil driver) left (here with connected voltage supply) Bosch Rexroth AG, MIT: ActiveMover, 3 842 564 874/2021-04...
Page 27 Control voltage connection (24 V) Network cable connection Flat ribbon cable (section module) top right Flat ribbon cable 557 186-11 (section module) Fig. 11: Printed circuit board (gateway) bottom right 3 842 564 874/2021-04, MIT: ActiveMover, Bosch Rexroth AG...
Page 28 Flat ribbon cable (section module) bottom right Flat ribbon cable (section module) top right Motor cable connection (0 V) Connection for grounding cable 557 186-12 Fig. 12: Printed circuit board (coil driver) right Bosch Rexroth AG, MIT: ActiveMover, 3 842 564 874/2021-04...
Page 29: Curve Module 3 842 559 430
M: Guide rail 500 mm (2x) Network cable (Ethernet) Control voltage cable (24 V) Power cable (28 V DC) Grounding cable Power cable (0 V) Cable protective pipe 557 186-13 Fig. 13: Curve module 3 842 564 874/2021-04, MIT: ActiveMover, Bosch Rexroth AG...
Page 30 Thermal resistance Motor cable connection (0 V) Flat ribbon cable (section module) top left Flat ribbon cable (section module) bottom left 557 186-14 Fig. 14: Printed circuit board (coil driver) left Bosch Rexroth AG, MIT: ActiveMover, 3 842 564 874/2021-04...
Page 31 Control voltage connection (24 V) Network cable connection Flat ribbon cable (section module) top right Flat ribbon cable (section module) bottom right 557 186-15 Fig. 15: Printed circuit board (gateway) 3 842 564 874/2021-04, MIT: ActiveMover, Bosch Rexroth AG...
Page 32 Flat ribbon cable (section module) bottom right Flat ribbon cable (section module) top right Motor cable connection (0 V) Connection for grounding cable 557 186-16 Fig. 16: Printed circuit board (coil driver) right Bosch Rexroth AG, MIT: ActiveMover, 3 842 564 874/2021-04...
Page 33: Workpiece Pallet 3 842 559 433 (2 Magnets)/3 842 559 434 (3 Magnets)
Observe the relevant regulations valid in the speciﬁ c country. For Germany, the speciﬁ cations of the German trade association with respect to "Electromagnetic ﬁ elds" in BGV B11 and BGR B11 must be observed. 3 842 564 874/2021-04, MIT: ActiveMover, Bosch Rexroth AG...
Page 34  The above persons should consult the doctor in charge of their treatment before accessing such areas.  Observe the occupational health and safety guidelines valid at the site of operation. Bosch Rexroth AG, MIT: ActiveMover, 3 842 564 874/2021-04...
Page 35 • Nickel allergies may develop in case of permanent contact with objects containing nickel.  Avoid permanent skin contact with magnets.  Avoid handling magnets if you already suffer from a nickel allergy. 3 842 564 874/2021-04, MIT: ActiveMover, Bosch Rexroth AG...
Page 36 Magnets have a maximum operating temperature. At temperatures from 80 °C, most magnets will permanently lose part of their adhesion strength.  Do not store the magnets in places where they are exposed to high heat. Bosch Rexroth AG, MIT: ActiveMover, 3 842 564 874/2021-04...
Page 37 When the workpiece pallets are not assembled, the corresponding protective plates must be attached. Assembly instructions see page 84.  Also observe the safety instructions in chapter "General safety instructions for magnets" on page 33. 3 842 564 874/2021-04, MIT: ActiveMover, Bosch Rexroth AG...
Page 38 38/188 About this product Base body Measuring system (holder and magnetic strip) Positioning Rubber buffer Locking screw Cover Protective cap Dowel pin 557 186-17 Fig. 17: Workpiece pallet (front view) Bosch Rexroth AG, MIT: ActiveMover, 3 842 564 874/2021-04...
Page 39 (2 magnets) Guide roller (ﬂ at) Positioning Lubrication system (lubricating felt + holder + ﬁ xing element) Magnetic kit (3 magnets) Protective plate 557 186-18 Fig. 18: Workpiece pallet (rear view) 3 842 564 874/2021-04, MIT: ActiveMover, Bosch Rexroth AG...
Page 40: Ir Id System
• The IR data carrier has a permanently assigned number and cannot be reprogrammed. The number is engraved at the edge of the IR data carrier. 557 186-19 Fig. 19: IR ID system components Bosch Rexroth AG, MIT: ActiveMover, 3 842 564 874/2021-04...
Page 41: Power Supply 3 842 559 435
Alternative plug connector (230 V AC) PLC monitoring connection output (24 V DC) Filter Fixing plate Mounting bracket Connection cable (0 V, 28 V DC) 557 186-20 Fig. 20: Power supply 3 842 564 874/2021-04, MIT: ActiveMover, Bosch Rexroth AG...
Page 42: Control Cabinet 3 842 564 861 And 3 842 564 864
Door lock (2x) Main switch PLC controller connection AMpro connection Filter Power port Port connection kit 3 842 559 449 PLC controller connection (optional) Power supply connection 557 186-21 Fig. 21: Control cabinet Bosch Rexroth AG, MIT: ActiveMover, 3 842 564 874/2021-04...
Page 43: Connection Kit 3 842 559
Power cable (28 V DC, blue) Grounding cable Power cable (0 V, blue/white) Cable protective pipe Control voltage cable (24 V) 557 186-22 Fig. 22: Connection kit 3 842 559 438 3 842 564 874/2021-04, MIT: ActiveMover, Bosch Rexroth AG...
Page 44 Network cable (7600 mm) Control voltage cable (24 V DC/0 V) Network cable (1000 mm) Ferrite Cable protective pipe (6500 mm) 557 186-23 Fig. 23: Connection kit 3 842 559 449 Bosch Rexroth AG, MIT: ActiveMover, 3 842 564 874/2021-04...
Page 45: Interface Modules
• Ethernet interface module EtherNet/IP 3 842 559 444 • Interface module PROFINET® 3 842 559 445 • Interface module EtherCAT® 3 842 559 446 557 186-24 Fig. 24: Interface modules 3 842 564 874/2021-04, MIT: ActiveMover, Bosch Rexroth AG...
Page 46: Removal Tool 3 842 559 439
About this product 5.2.16 Removal tool 3 842 559 439 Tool for disassembly/ assembly of workpiece pallets. Removal tool Locking hook 557 186-25 Fig. 25: Removal tool 3 842 559 439 Bosch Rexroth AG, MIT: ActiveMover, 3 842 564 874/2021-04...
Page 47: Calibration Set 3 842 559 456
The calibration set is required for adjusting/ calibrating the measuring system on the WT. Position indicator Reference system Alignment block Knurled screw Fixing element Knurled screw 557 186-26 Fig. 26: Calibration set 3 842 564 874/2021-04, MIT: ActiveMover, Bosch Rexroth AG...
Page 48: Identifi Cation Of The Product
Make sure the lifting straps are correctly fastened before lifting the product!  Secure the product against tipping over when lifting!  Make sure that no one but the operator is in the danger zone during lifting and lowering! Bosch Rexroth AG, MIT: ActiveMover, 3 842 564 874/2021-04...
Page 49: Transport Suggestion For Conveyor/Curved Units
• Protect the product from mechanical stress. • Protect the product from environmental inﬂ uences, such as dirt and moisture. • Pay attention to the ambient conditions, see technical data on page 184. 3 842 564 874/2021-04, MIT: ActiveMover, Bosch Rexroth AG...
Page 50: Installation
• 3 lifting straps/round slings, load capacity per 100 kg min. (for transporting the conveyor/curved units) 7.3.2 Electrical system • Various screwdrivers with insulating handles • Side cutter with insulating handles • Stripping tool with insulating handles • Multimeter Bosch Rexroth AG, MIT: ActiveMover, 3 842 564 874/2021-04...
Page 51: Symbols Used
Graphical depiction of the designation of components. The letters denote the components mentioned in the accompanying text. Detail view from a different direction, for example, the back or the bottom side of the product. 3 842 564 874/2021-04, MIT: ActiveMover, Bosch Rexroth AG...
Page 52: Assembling The Product
Then assemble additional system sections with section/curve modules symmetrically on the left and right.  Align all other assembled system sections vertically, horizontally and vertically in accordance with the reference system section. Bosch Rexroth AG, MIT: ActiveMover, 3 842 564 874/2021-04...
Page 53 Assemble the proﬁ le connectors on the rear side at the connection point between the section/curve modules.  Adjust the transition of the upper V-rails using the proﬁ le connector.  Check the transition between the section/curve modules using a workpiece pallet. 3 842 564 874/2021-04, MIT: ActiveMover, Bosch Rexroth AG...
Page 54: Customer Base Frames
Dimensional drawings for this can be found in the ActiveMover sales catalog. Assembly of the section/curve modules is carried out in the same way as described in chapters 7.5.4 to 7.5.13. Bosch Rexroth AG, MIT: ActiveMover, 3 842 564 874/2021-04...
Page 55: Positioning And Aligning The Base Frame
= 0,02 mm/m SW36 (45,5 ... 163,5) SW24 557 186-30 Fig. 31: Positioning and aligning the base frame 3 842 559 450 3 842 564 874/2021-04, MIT: ActiveMover, Bosch Rexroth AG...
Page 56 The base frame 3 842 559 451 (short, only for curve module) must be mounted on machine water level. a base frame 3 842 559 450 on the right or left. The installation is mirrored in each case (see ﬁ g. 32). Bosch Rexroth AG, MIT: ActiveMover, 3 842 564 874/2021-04...
Page 57: Assembling The Section Module On A Base Frame
ﬁ xing plates. ISO8375 – 16 x 40 – A – ST ISO8375 – 12 x 40 – A – ST 557 186-32 Fig. 33: Assembling the ﬁ xing plates (1) 3 842 564 874/2021-04, MIT: ActiveMover, Bosch Rexroth AG...
Page 58 Hammer down the 4 M10 x 40 cylinder pins half into =80 Nm the ﬁ xing plates. M6 x 40 557 186-33 Fig. 34: Assembling the ﬁ xing plates (2) Bosch Rexroth AG, MIT: ActiveMover, 3 842 564 874/2021-04...
Page 59 Screw the headless setscrews through the sliding blocks into the section proﬁ le. =7 Nm 557 186-34 Fig. 35: Assembling the module holder on the section module (1) 3 842 564 874/2021-04, MIT: ActiveMover, Bosch Rexroth AG...
Page 60 3 842 559 429. =16 Nm =16 Nm 3 842 559 429 3 842 559 429 600,00 199,75 199,75 4 , 5 4 , 5 557 186-35 Fig. 36: Assembling the module holder on the section module (2) Bosch Rexroth AG, MIT: ActiveMover, 3 842 564 874/2021-04...
Page 61 Press the section module against the cylinder pin. Tighten the ﬁ xing screws. ISO8734 6 x 20 =40 Nm 557 186-36 Fig. 37: Assembling the section module on the base frame (1) 3 842 564 874/2021-04, MIT: ActiveMover, Bosch Rexroth AG...
Page 62 =7 Nm module!  Install the second section module on the base frame accordingly. =7 Nm 557 186-37 Fig. 38: Assembling the section module on a base frame (2) Bosch Rexroth AG, MIT: ActiveMover, 3 842 564 874/2021-04...
Page 63 ﬁ g. 36. If necessary, repeat/check the complete assembly. = 0,02 mm/m 557 186-38 Fig. 39: Checking the alignment of the section modules 3 842 564 874/2021-04, MIT: ActiveMover, Bosch Rexroth AG...
Page 64: Assembling The Curve Module On A Base Frame
Fixing screw M8 x 75 Spring washer M6 Setting screw Lock nut 557 186-39 Fig. 40: Assembling the curve module on a base frame (1) Bosch Rexroth AG, MIT: ActiveMover, 3 842 564 874/2021-04...
Page 65 ﬁ xing plate. Install the covers on the =10 Nm module holders. Install the cover of the curve module. 557 186-40 Fig. 41: Assembling the curve module on a base frame (2) 3 842 564 874/2021-04, MIT: ActiveMover, Bosch Rexroth AG...
Page 66: Attaching And Connecting System Sections
Loosen the top locknut SW24 (D) and extend or retract the leveling foot (F) accordingly. Tighten the upper lock nut. (4x) 557 186-41 Fig. 42: Checking the alignment of the system sections Bosch Rexroth AG, MIT: ActiveMover, 3 842 564 874/2021-04...
Page 67 (A) and ﬁ x them with cylinder pins. Tighten both upper connection plates. 557 186-42 Fig. 43: Mounting the upper connection plate 3 842 564 874/2021-04, MIT: ActiveMover, Bosch Rexroth AG...
Page 68 Screw on the upper connection plate loosely. Mount the side connection plates (on both sides). (4x) =80 Nm 557 186-43 Fig. 44: Connecting system sections, using the example of 2 section modules (1) Bosch Rexroth AG, MIT: ActiveMover, 3 842 564 874/2021-04...
Page 69 • Plastic feeler gage 0.5 mm Make sure that all modules have a distance of X = 0.5 mm. X = 0,5 mm X = 0,5 mm 557 186-44 Fig. 45: Connecting system sections (2) 3 842 564 874/2021-04, MIT: ActiveMover, Bosch Rexroth AG...
Page 70 Screw down the side connection plates (on both sides).  All other system sections are mounted in the same way. =80 Nm 557 186-134 Fig. 46: Connecting system sections (3) Bosch Rexroth AG, MIT: ActiveMover, 3 842 564 874/2021-04...
Page 71: Aligning Section Modules (Rough Adjustment)
X = 0.5 mm. X = 0,5 mm Tighten the ﬁ xing screws. =40 Nm 557 186-45 Fig. 47: Setting the lateral offset of the section modules (rough setting) 3 842 564 874/2021-04, MIT: ActiveMover, Bosch Rexroth AG...
Page 72 X = 0.5 mm. Tighten the ﬁ xing SW13 =21 Nm screws. =16 Nm X = 0,5 mm 557 186-46 Fig. 48: Setting the height offset of the section modules (rough setting) Bosch Rexroth AG, MIT: ActiveMover, 3 842 564 874/2021-04...
Page 73 Installation 73/188 ∆ ≤ 70 µm 557 186-132 Fig. 49: Example of measurement of height offset 3 842 564 874/2021-04, MIT: ActiveMover, Bosch Rexroth AG...
Page 74: Assembling The Profi Le Connector For 2 Section Modules
M6 x 35 modules and tighten the screws. Tighten the locking =16 Nm screws of the sliding blocks. =16 Nm 557 186-47 Fig. 50: Assembling the proﬁ le connector on 2 section modules Bosch Rexroth AG, MIT: ActiveMover, 3 842 564 874/2021-04...
Page 75: Assembling The Profi Le Connector For Curve Module And Section Module
Tighten the locking screws of the sliding blocks. =16 Nm M8 x 45 =35 Nm =16 Nm 557 186-48 Fig. 51: Assembling the proﬁ le connector for curve module and section module 3 842 564 874/2021-04, MIT: ActiveMover, Bosch Rexroth AG...
Page 76: Aligning The Upper V-Rail, Section Module To Section Module (Fi Ne Adjustment)
77). Adjust the lateral offset (see ﬁ g. 54 on page 77). 557 186-49 Fig. 52: Checking the vertical and horizontal offset of the upper V-rail, section module to section module Bosch Rexroth AG, MIT: ActiveMover, 3 842 564 874/2021-04...
Page 77 Right inward Left outward Tighten the ﬁ xing screws of the proﬁ le connector. 557 186-51 Fig. 54: Setting the lateral offset ≤ ±0.05 mm, section module to section module 3 842 564 874/2021-04, MIT: ActiveMover, Bosch Rexroth AG...
Page 78  Install upper V-rail and measuring system (encoder) in reverse order. =16 Nm 557 186-52 Fig. 55: Setting the lateral offset > ±0.05 mm, section module to section module Bosch Rexroth AG, MIT: ActiveMover, 3 842 564 874/2021-04...
Page 79: Aligning The Upper V-Rail, Section Module To Curve Module (Fi Ne Adjustment)
=18 Nm and proﬁ le connectors and tighten the setting screw. 557 186-123 Fig. 56: Setting the height offset ≤ ±0.05 mm, section module to curve module 3 842 564 874/2021-04, MIT: ActiveMover, Bosch Rexroth AG...
Page 80 Tighten the ﬁ xing screws of the module holder and proﬁ le connectors and tighten the setting screw. 557 186-124 Fig. 57: Setting the lateral offset ≤ ±0.05 mm, section module to curve module Bosch Rexroth AG, MIT: ActiveMover, 3 842 564 874/2021-04...
Page 81  Install upper V-rail and measuring system (encoder) in reverse order. =16 Nm 557 186-125 Fig. 58: Setting the lateral offset > ±0.05 mm, section module to curve module 3 842 564 874/2021-04, MIT: ActiveMover, Bosch Rexroth AG...
Page 82: Assembling And Aligning The Guide Rails
Tighten the screws of the adjustment unit (C). Install the cover caps. 557 186-53 Fig. 59: Assembling and aligning the guide rails Bosch Rexroth AG, MIT: ActiveMover, 3 842 564 874/2021-04...
Page 83: Mounting/Removing Workpiece Pallets
Be prepared for high forces of attraction.  Place the protective plate with the plastic cover on the magnetic kit!  Keep body parts away from between the protective plate and the magnetic kit. 3 842 564 874/2021-04, MIT: ActiveMover, Bosch Rexroth AG...
Page 84 (A). Install the removal tool (short arm left). Secure the removal tool with the locking hook (B) and the locking screws (C). 557 186-54 Fig. 60: Assembling the workpiece pallet (1) Bosch Rexroth AG, MIT: ActiveMover, 3 842 564 874/2021-04...
Page 85 Check the distance of the measuring system (encoder and magnetic strips), see chapter 10.5.1.  Disassembly is done in the reverse order. 557 186-55 Fig. 61: Assembling the workpiece pallet (2) 3 842 564 874/2021-04, MIT: ActiveMover, Bosch Rexroth AG...
Page 86: Assembling, Adjusting And Connecting The Ir Reading Head Id System
To do this, loosen the ﬁ xing screws (E) and move the holder of the IR reading head. =5 Nm 1,0 mm 557 186-56 Fig. 62: Assembling and adjusting the IR reading head Bosch Rexroth AG, MIT: ActiveMover, 3 842 564 874/2021-04...
Page 87 Connect the connection cable of the IR reading head to the printed circuit board (gateway). Fig. 63: Connecting the IR reading head ID system 3 842 564 874/2021-04, MIT: ActiveMover, Bosch Rexroth AG...
Page 88: Assembling The Power Supply
Prepare 4 ﬁ xing holes according to the drawing dimensions. Assemble the mounting plate. Install the power supply. =7 Nm =10 Nm 557 186-58 Fig. 64: Assembling the power supply Bosch Rexroth AG, MIT: ActiveMover, 3 842 564 874/2021-04...
Page 89: Electrical Connection Of The Product
Uninterruptible power supply UPS! Voltage may be present even when the main switch is in the OFF position! Coming in contact with electrical components can result in injury or burns from electric shocks. 3 842 564 874/2021-04, MIT: ActiveMover, Bosch Rexroth AG...
Page 90 • Take account of the electrical power requirement shown on the nameplate, see ﬁ g. 27 on page 48. • Take account of the circuit diagram included in the scope of delivery. Bosch Rexroth AG, MIT: ActiveMover, 3 842 564 874/2021-04...
Page 91: Assembling The Emc Cable Glands And Cable Guard Pipe
Push the cable protective pipe (C) into the cable glands between the section modules/curve modules. Tighten the cable glands. 557 186-59 Fig. 65: Assembling the EMC cable glands and cable guard pipe 3 842 564 874/2021-04, MIT: ActiveMover, Bosch Rexroth AG...
Page 92: Inserting The Connection Cable
Power cable (28 V DC) Grounding cable Power cable (0 V) Control voltage cable (24 V) 557 186-60 Fig. 66: Inserting the connection cable (here the example of the section module) Bosch Rexroth AG, MIT: ActiveMover, 3 842 564 874/2021-04...
Page 93: Inserting The Power Supply Line Into Section/Curve Module
Remove the caps. Assemble the cable glands. Lead the power supply connection line through the cable gland. Tighten the cable glands. 557 186-61 Fig. 67: Inserting the power supply line into section/curve module 3 842 564 874/2021-04, MIT: ActiveMover, Bosch Rexroth AG...
Page 94: Connecting Grounding And Power Cables (28 V) (From Left Section/Curve Module)
Connect the power cable (0 V, blue/white) to terminal H. =11 Nm =2,7 Nm =11 Nm 557 186-62 Fig. 68: Connecting grounding and power cables (from left section/curve module) without connected power supply Bosch Rexroth AG, MIT: ActiveMover, 3 842 564 874/2021-04...
Page 95: Connecting Grounding And Power Cables (28 V) (From Right Section/Curve Module)
(28 V DC, blue) to terminal D. =11 Nm =11 Nm Connect the power cable 557 186-63 (0 V, blue/white) Fig. 69: Connecting grounding and power cables (right section/curve module) to terminal I. 3 842 564 874/2021-04, MIT: ActiveMover, Bosch Rexroth AG...
Page 96: Connecting Network And Cable Control Voltage (24 V) (From Left Section/Curve Module)
H on the printed circuit board (gateway). Connect the control voltage (24 V) cable to terminal G. 557 186-64 Fig. 70: Connecting network cables (from left section/curve module) Bosch Rexroth AG, MIT: ActiveMover, 3 842 564 874/2021-04...
Page 97: Connecting Network And Cable Control Voltage (24 V) (From Right Section/Curve Module)
7.6.8 Connecting the network connections and power supplies in the additional information in control panel chapter 7.6.10.  Please refer to the corresponding information from the circuit diagram. 3 842 564 874/2021-04, MIT: ActiveMover, Bosch Rexroth AG...
Page 98: Ir Reading Head Id System (Optional)
Connect the connection cable of the IR reading head to the printed circuit board (gateway). 557 186-66 Fig. 72: Connecting the IR reading head ID system (optional) Bosch Rexroth AG, MIT: ActiveMover, 3 842 564 874/2021-04...
Page 99: Connecting Network - Printed Circuit Boards (Gateway)
Left Network Left Network circuit boards (gateway) in accordance with the adjacent connection plan. See next page for explanations of the positions. 557 186-67 Fig. 73: Connecting printed circuit boards (gateway) 3 842 564 874/2021-04, MIT: ActiveMover, Bosch Rexroth AG...
Page 100 RJ45 Left Network network cable to the controller Network end Right Network Network end Left Network Network start Left Network M: Cable entry point, network cable Curve module, network supply Connection cable network Left Network Control cabinet Bosch Rexroth AG, MIT: ActiveMover, 3 842 564 874/2021-04...
Page 101: Network Connection Left Network And Right Network
RJ45 Network cable Right Network RJ45 Network cable Left Network Network Right Network Curve module, network supply Network Left Network 557 186-68 Network connection Left Network and Right Network Fig. 74: 3 842 564 874/2021-04, MIT: ActiveMover, Bosch Rexroth AG...
Page 102: Connect Power Supply In Section Module
Connect the power cable (28 V DC, blue) to port B. Connect the power cable (0 V, blue/white) to terminal H. =11 Nm 557 186-69 Fig. 75: Connect power supply in section module Bosch Rexroth AG, MIT: ActiveMover, 3 842 564 874/2021-04...
Page 103: Connect Power Supply In Curve Module
Connect the power cable (28 V DC, blue) to port A. Connect the power cable (0 V, blue/white) to port B. =11 Nm 557 186-70 Fig. 76: Connect power supply in curve module 3 842 564 874/2021-04, MIT: ActiveMover, Bosch Rexroth AG...
Page 104: Connect Power Supply In The Control Cabinet
Connect the plug connector (230 V AC) of the connection line to the power supply. 557 186-71 Fig. 77: Connect power supply in the control cabinet Bosch Rexroth AG, MIT: ActiveMover, 3 842 564 874/2021-04...
Page 105: Ethernet Powerlink
 Connect the ActiveMover controller to the bus controller according to the circuit diagram. Ethernet POWERLINK port Ethernet POWERLINK port 557 186-72 Fig. 78: Ethernet POWERLINK connection 3 842 564 874/2021-04, MIT: ActiveMover, Bosch Rexroth AG...
Page 106: Ethernet Port (Windows Pc)
• The connection cable is not included in the scope of delivery.  Connect the Ethernet port according to the circuit diagram. Ethernet port 557 186-73 Fig. 79: Ethernet port connection Bosch Rexroth AG, MIT: ActiveMover, 3 842 564 874/2021-04...
Page 107: Plc
Ethernet/ IP™ and EtherCAT® bus protocols in the according to the circuit bus controller. diagram. Ethernet POWERLINK module Set the rotary switches Cable entry point according to the graphic. 3 842 564 874/2021-04, MIT: ActiveMover, Bosch Rexroth AG...
Page 108: Emergency Safety Circuit
PL = d. • It must not be possible to start up the ActiveMover with the safety door open!  Connect the emergency stop safety circuits according to the circuit diagram. Bosch Rexroth AG, MIT: ActiveMover, 3 842 564 874/2021-04...
Page 109: Line Voltage
(A). Connect the supply voltage according to the circuit diagram. Screw down the cable gland. 557 186-75 Fig. 81: Cable gland for supply voltage connection cable 3 842 564 874/2021-04, MIT: ActiveMover, Bosch Rexroth AG...
Page 110: Commissioning
(28 V) Motor cable connection (0 V)  Measurement OK  Short circuit present  Troubleshooting see chapter 11.1 [Ω] 557 186-126 Fig. 82: Resistance between the motor cable connections Bosch Rexroth AG, MIT: ActiveMover, 3 842 564 874/2021-04...
Page 111: Resistance Between Motor Cable (0 V) And Ground (Base Frame)
Resistance between motor cable (0 V) and housing (section/curve modules) Troubleshooting  Check the ground cable connection in the curve modules. 557 186-128 Fig. 84: Troubleshooting: No connection between motor cable (0 V) and housing (section/curve modules) 3 842 564 874/2021-04, MIT: ActiveMover, Bosch Rexroth AG...
Page 112: Resistance Between Motor Cable (0 V) And Control Voltage (24 V)
(0 V)  Measurement OK  Short circuit present  Troubleshooting see chapter 11.1 [Ω] 1000 557 186-129 Fig. 85: Resistance between motor cable (0 V) and control voltage (24 V) Bosch Rexroth AG, MIT: ActiveMover, 3 842 564 874/2021-04...
Page 113: Resistance Between Motor Cable (28 V) And Control Voltage (24 V)
Short circuit present  Troubleshooting see chapter 11.1 R > 1 MΩ R < 10 Ω 557 186-130 Fig. 86: Resistance between motor cable (28 V) and control voltage (24 V) 3 842 564 874/2021-04, MIT: ActiveMover, Bosch Rexroth AG...
Page 114: Initial Commissioning
• Before the initial commissioning or re-commissioning of a conveyor system, carry out a risk assessment in accordance with DIN EN ISO 12100. • According to EU Machinery Directive 2006/42/EC, you must equip the transfer system with EMERGENCY STOP control devices. Bosch Rexroth AG, MIT: ActiveMover, 3 842 564 874/2021-04...
Page 115 • Check the complete and correct assembly again (see chapter 7.5). • Check the correct and complete electrical connection again (see chapter 7.6). • Carry out the measurements before starting up the system for the ﬁ rst time (see chapter 8.1) 3 842 564 874/2021-04, MIT: ActiveMover, Bosch Rexroth AG...
Page 116: Residual Risks
1) Life stages of the machine according to DIN EN ISO 12100 Sect. 5.4 a /b (No. 1 -27), Sect. 5.4 a (see page 117) 6, 7 1, 2, 3, 4 557 186-198 557 186-199 Bosch Rexroth AG, MIT: ActiveMover, 3 842 564 874/2021-04...
Page 117: Life Stages Of The Machine
The AMpro conﬁ guration software is required for commissioning, conﬁ guration, parameterization, calibration and troubleshooting. For the description of the software, see the separate AMpro manual. You can download the manual on the Internet at: https://www.boschrexroth.com/de/de/myrexroth/share/ﬁ les 3 842 564 874/2021-04, MIT: ActiveMover, Bosch Rexroth AG...
Page 118: Operation
Rexroth representative if you have any doubts about resistance to speciﬁ c chemicals, such as test oil, doped oils, aggressive cleaning agents, solvents or brake ﬂ uid. • Avoid prolonged contact with highly reactive acidic or alkaline materials. Bosch Rexroth AG, MIT: ActiveMover, 3 842 564 874/2021-04...
Page 119 In such instances, special care must be taken when planning the system, and the maintenance intervals must be correspondingly shortened. 3 842 564 874/2021-04, MIT: ActiveMover, Bosch Rexroth AG...
Page 120: Maintenance And Repair
Risk of burns from touching hot surfaces above 65 °C.  Install appropriate guards.  Let the unit cool down for at least 30 minutes before performing maintenance and/or repair work. Bosch Rexroth AG, MIT: ActiveMover, 3 842 564 874/2021-04...
Page 121 Danger of crushing during assembly/removal of workpiece pallets! Additional workpiece pallets near the removal tool constitute a risk of crushing for hands and ﬁ ngers.  Remove all workpiece pallets in the area of the removal tool. 3 842 564 874/2021-04, MIT: ActiveMover, Bosch Rexroth AG...
Page 122: Cleaning And Care
(IPA) and a clean, soft cloth. After cleaning with isopropanol, a new lubricating ﬁ lm must be applied to the upper V-rail and the guide rails in order to prevent damage to the WT. Bosch Rexroth AG, MIT: ActiveMover, 3 842 564 874/2021-04...
Page 123: Base Frames Of Section/Curve Module
For test of the measuring system, see chapter 10.2.8 10.1.5 Control panel fan If necessary, clean deposits and contamination from the fan using a clean, soft cloth. If necessary, replace the ﬁ lter mats in case of coarse contamination. 3 842 564 874/2021-04, MIT: ActiveMover, Bosch Rexroth AG...
Page 124: Inspection
The lubricating felt must return to the starting position. Magnetic kit Check the magnetic kit visually If necessary, clean or for contamination, wear and replace the magnetic kit damage. (see chapter 10.4.8). Bosch Rexroth AG, MIT: ActiveMover, 3 842 564 874/2021-04...
Page 125: Inspection Of Upper V-Rails/Guide Rails
Check the upper V-rails and guide rails (ﬂ at) for damage and deposits. Slowly move a workpiece pallet manually over the section/curve modules. If resistance is noticeable during movement, check this position for possible damage and deposits. 3 842 564 874/2021-04, MIT: ActiveMover, Bosch Rexroth AG...
Page 126: Testing The Connection Block (Magnetic Connector Section/Curve Module)
Perform regular monthly checks of the air ﬁ lter of the power supply for dust and contamination. For replacing the air ﬁ lter see chapter 10.4.25. 10.2.7 All screws Perform regular monthly checks of all the ActiveMover components for loose mountings and loose screws. Bosch Rexroth AG, MIT: ActiveMover, 3 842 564 874/2021-04...
Page 127: Checking The Measuring System (Magnetic Strip)
All poles of the measuring system (magnetic strip) should be parallel to each other and be clearly visible. 557 186-76 Fig. 87: Checking the measuring system If individual poles are not visible or appear damaged, replace the measuring system (magnetic strip). 3 842 564 874/2021-04, MIT: ActiveMover, Bosch Rexroth AG...
Page 128: Maintenance
Thereafter, lubricate as required according to table 7 on page 124 Please note: The workpiece pallet must No-Tox®HD Food Grade not be disassembled for Oil 46 5 ... 10 lubrication. 557 186-77 Fig. 88: Lubricating the workpiece pallet Bosch Rexroth AG, MIT: ActiveMover, 3 842 564 874/2021-04...
Page 129: Repair
When the workpiece pallets are not assembled, the corresponding protective plates must be attached. Assembly instructions see page 84.  Also observe the safety instructions in chapter "General safety instructions for magnets" on page 33. 3 842 564 874/2021-04, MIT: ActiveMover, Bosch Rexroth AG...
Page 130 NOTICE There is a risk of destruction of electronic components/printed circuit boards by ESD  Always wear an anti-static wristband to prevent electrostatic charging when working on electronic components/printed circuit boards. Bosch Rexroth AG, MIT: ActiveMover, 3 842 564 874/2021-04...
Page 131: Replacing The Rubber Buffer
(see chapter 7.5.14). Place the protective plate with the plastic cover on the magnetic kit! Remove the rubber buffers. Assemble the new rubber buffers. 557 186-78 Fig. 89: Replacing the rubber buffer 3 842 564 874/2021-04, MIT: ActiveMover, Bosch Rexroth AG...
Page 132: Replacing Discharge Brushes
Replacing discharge brushes Remove the discharge brushes. Align the discharge brushes with the outer bores of the tilt device. Mount the ﬁ xing screws of the discharge brushes and tighten them. Bosch Rexroth AG, MIT: ActiveMover, 3 842 564 874/2021-04...
Page 133: Replacing The Measuring System
Install the new measuring system in the reverse order. Check the distance of the measuring system (encoder and magnetic strips), see chapter 10.5.1. Recalibrate the WT (see chapter 10.5.4 et sq). 3 842 564 874/2021-04, MIT: ActiveMover, Bosch Rexroth AG...
Page 134: Replacing The Felt (Lubrication Device For Wt)
Lubricate the WT 557 186-81 Fig. 92: Replacing the felt (lubrication device for WT) (see chapter 10.3.1). Please note: The V-groove of the felt must be placed horizontally on the V-guide rollers. Bosch Rexroth AG, MIT: ActiveMover, 3 842 564 874/2021-04...
Page 135: Replacing The Contact Pressure Springs
Remove the contact pressure springs. SW2,5 =2 Nm Install the new contact pressure springs and the lubricating felt holder in reverse order. 557 186-82 Fig. 93: Replacing the contact pressure springs 3 842 564 874/2021-04, MIT: ActiveMover, Bosch Rexroth AG...
Page 136: Replacing The Magnetic Kit
Remove the front plate =5,8 Nm of the WT. Remove the magnetic kit. Install the new magnetic kit and the front plate in reverse order. 557 186-83 Fig. 94: Replacing the magnetic kit Bosch Rexroth AG, MIT: ActiveMover, 3 842 564 874/2021-04...
Page 137: Replacing The Guide Rollers (Fl At)
Remove the guide rollers with washers. Assemble the new guide rollers with washers (2 per guide roller) in reverse order. 557 186-84 Fig. 95: Replacing the guide rollers (ﬂ at) 3 842 564 874/2021-04, MIT: ActiveMover, Bosch Rexroth AG...
Page 138: Replacing The V-Guide Rollers
Remove the shims. Remove the bearing pins. Remove the guide rollers. Install the new guide rollers in reverse order. SW3} =4,5 Nm 557 186-85 Fig. 96: Replacing the V-guide rollers Bosch Rexroth AG, MIT: ActiveMover, 3 842 564 874/2021-04...
Page 139: Replacing The Upper V-Rail (Section Module)
• The V-grooves on both sides of the upper V-rail prevent lifting of the rail. • The gap at both ends of the upper V-rail should be about 0.5 mm on both sides. 3 842 564 874/2021-04, MIT: ActiveMover, Bosch Rexroth AG...
Page 140: Replacing The Upper V-Rail (Curve Module)
V-rail in reverse order. If necessary, align the upper V-rail (see chapter 7.5.11). Calibrate the measuring system sensor units (see chapter 10.5). 557 186-87 Fig. 98: Replacing the upper V-rail (curve module) Bosch Rexroth AG, MIT: ActiveMover, 3 842 564 874/2021-04...
Page 141: Replacing The Guide Rails (Section Module)
For mounting the new guide rail, see ﬁ g. 59 on page 82. 557 186-88 Fig. 99: Replacing the guide rails (section module) 3 842 564 874/2021-04, MIT: ActiveMover, Bosch Rexroth AG...
Page 142: Replacing The Cover Of The Coil (Section And Curve Module)
Press out any air inclusions from the inside to the outside. 557 186-89 Fig. 100: Replacing the cover of the coil (here the example of the section module) Bosch Rexroth AG, MIT: ActiveMover, 3 842 564 874/2021-04...
Page 143: Replacing The Power Supply
Remove the power supply from the mounting plate.  Install and connect the new power supply in reverse order. =10 Nm 557 186-90 Fig. 101: Replacing the power supply 3 842 564 874/2021-04, MIT: ActiveMover, Bosch Rexroth AG...
Page 144: Replacing The Printed Circuit Board (Coil Driver) (Section Module)
Unplug the 2 ribbon cables from the printed circuit board. Unplug the 5 coil connectors. 557 186-91 Fig. 102: Replacing the printed circuit board (coil driver) (section module) Bosch Rexroth AG, MIT: ActiveMover, 3 842 564 874/2021-04...
Page 145 This could lead to short circuits. 557 186-92 Fig. 103: Replacing the printed circuit board (coil driver) (section module) 3 842 564 874/2021-04, MIT: ActiveMover, Bosch Rexroth AG...
Page 146: Replacing The Printed Circuit Board (Coil Driver) (Curve Module)
 Install the new printed circuit board in reverse order. Plastic =2 Nm 557 186-93 Fig. 104: Replacing the printed circuit board (coil driver) (curve module) Bosch Rexroth AG, MIT: ActiveMover, 3 842 564 874/2021-04...
Page 147: Replacing The Printed Circuit Board (Gateway) (Section Module)
Unplug the 2 plugs of the 24 V supply. Unplug the network cable (1 and 2) Unplug the 4 ribbon cables. 557 186-94 Fig. 105: Replacing the printed circuit board (gateway) (section module) 3 842 564 874/2021-04, MIT: ActiveMover, Bosch Rexroth AG...
Page 148 ﬁ xing screws of the new printed circuit board (gateway).  Install the new printed circuit board (gateway) in reverse order. =2 Nm 557 186-95 Fig. 106: Replacing the printed circuit board (gateway) (section module) Bosch Rexroth AG, MIT: ActiveMover, 3 842 564 874/2021-04...
Page 149: Replacing The Printed Circuit Board (Gateway) (Curve Module)
Unplug the 2 plugs of the 24 V supply. Unplug the 4 ribbon cables. Disconnect the 2 encoder cables. 557 186-96 Fig. 107: Replacing the printed circuit board (gateway) (curve module) 3 842 564 874/2021-04, MIT: ActiveMover, Bosch Rexroth AG...
Page 150 ﬁ xing screws of the new printed circuit board (gateway).  Install the new printed circuit board (gateway) in reverse order. =2 Nm 557 186-97 Fig. 108: Replacing the printed circuit board (gateway) (curve module) Bosch Rexroth AG, MIT: ActiveMover, 3 842 564 874/2021-04...
Page 151: Replacing The Drive Thermistors
Install the new thermistor in reverse order. Please note: The thermistor must be pushed all the way into the thermistor mounting. 557 186-100 Fig. 109: Replacing the drive thermistor 3 842 564 874/2021-04, MIT: ActiveMover, Bosch Rexroth AG...
Page 152: Replacing The Section/Curve Module Main Fuse
=2,7 Nm =2,7 Nm Please note: The main fuse must be installed using a screw, tooth lock washer and washer. 557 186-99 Fig. 110: Replacing the section/curve module main fuse Bosch Rexroth AG, MIT: ActiveMover, 3 842 564 874/2021-04...
Page 153: Replacing The Section/Curve Module Coil Fuse
Pull the coil fuse out of the fuse holder. Install the new coil fuse (15 A) in reverse order. 557 186-100 Fig. 111: Replacing the section/curve module coil fuse 3 842 564 874/2021-04, MIT: ActiveMover, Bosch Rexroth AG...
Page 154: Replacing The Measuring System (Encoder) (Section Module)
Install the new sensor SW2,5 unit in reverse order. =2 Nm Calibrate the new sensor unit (see chapter 10.5). 557 186-101 Fig. 112: Replacing the measuring system (encoder) (section module) Bosch Rexroth AG, MIT: ActiveMover, 3 842 564 874/2021-04...
Page 155: Replacing The Measuring System (Encoder) (Curve Module)
Pull off the connection cable. Install the new sensor units in reverse order. Calibrate the new sensor units (see chapter 10.5). 557 186-102 Fig. 113: Replacing the measuring system (encoder) (curve module) 3 842 564 874/2021-04, MIT: ActiveMover, Bosch Rexroth AG...
Page 156: Replacing The Activemover Power Supply Air Fi Lter
3 842 555 969 Remove the retaining clip from the air ﬁ lter. Replace the air ﬁ lter. Assemble the retaining clip. 557 186-103 Fig. 114: Replacing the ActiveMover power supply air ﬁ lter Bosch Rexroth AG, MIT: ActiveMover, 3 842 564 874/2021-04...
Page 157: Adjustment And Calibration
124. • the correct installation of the measuring system (see chapter 10.4.5). Check the distance (X) between measuring system and sensor unit. 557 186-104 Fig. 115: Checking the measuring system distance 3 842 564 874/2021-04, MIT: ActiveMover, Bosch Rexroth AG...
Page 158 Install a suitable spacer washer to maintain the distance X = 0.5 mm (± 0.3 mm). Assembly is done in the reverse order. 557 186-105 Fig. 116: Setting the measuring system distance Bosch Rexroth AG, MIT: ActiveMover, 3 842 564 874/2021-04...
Page 159: Primary And Secondary Measuring System
• The secondary measuring system is calibrated at the factory and normally no longer needs to be calibrated. Primary measuring system Secondary measuring system 557 186-106 Fig. 117: Primary and secondary measuring system 3 842 564 874/2021-04, MIT: ActiveMover, Bosch Rexroth AG...
Page 160: Encoder Numbering And Order
8 encoders. • Encoder numbering starts at the left sensor unit at 0 and ends at the right sensor right at 15. 557 186-107 Fig. 118: Encoder numbering and order Bosch Rexroth AG, MIT: ActiveMover, 3 842 564 874/2021-04...
Page 161: Assembling And Aligning The Calibration Set (Optional)
V-rail, insert appropriate intermediate layers between the ﬁ xing element and the sensor unit. 557 186-108 Fig. 119: Assembling the measuring system adjusting tool (1) 3 842 564 874/2021-04, MIT: ActiveMover, Bosch Rexroth AG...
Page 162 ﬁ xing element to the upper V-rail using a dial gage mounted on a WT. 557 186-109 Fig. 120: Assembling the calibration set (2) Bosch Rexroth AG, MIT: ActiveMover, 3 842 564 874/2021-04...
Page 163 Click on the Encoder with which the ﬁ xing element is centrally aligned (uneven number). Click on Accept. 557 186-110 Fig. 121: Aligning the ﬁ xing element with an encoder (1) 3 842 564 874/2021-04, MIT: ActiveMover, Bosch Rexroth AG...
Page 164  and the arrow mean that the calibration set must be moved by 158 µm to the left. 557 186-111 Fig. 122: Aligning the ﬁ xing element with an encoder (2) Bosch Rexroth AG, MIT: ActiveMover, 3 842 564 874/2021-04...
Page 165 ﬁ xing element if necessary (steps 8 -22). 557 186-112 Fig. 123: Aligning the ﬁ xing element with an encoder (3) 3 842 564 874/2021-04, MIT: ActiveMover, Bosch Rexroth AG...
Page 166 ﬁ xing element. Tighten the locking 24 26 screw. Disassemble the position indicator. 24 26 557 186-113 Fig. 124: Aligning the ﬁ xing element with an encoder (4) Bosch Rexroth AG, MIT: ActiveMover, 3 842 564 874/2021-04...
Page 167: Checking Position Of The Calibration Set
Depending on the tightening torque of the knurled screw, the position may vary by ±5 µm. Always use a uniform tightening torque. Fig. 125: Checking position of the calibration set (1) 3 842 564 874/2021-04, MIT: ActiveMover, Bosch Rexroth AG...
Page 168 Click on the Encoder with which the ﬁ xing element is centrally aligned (uneven number). The display should be ±4 µm. 557 186-115 Fig. 126: Checking position of the calibration set (2) Bosch Rexroth AG, MIT: ActiveMover, 3 842 564 874/2021-04...
Page 169: Referencing The Encoder Position
Click on Save Parameters. The Save Conﬁ guration window is opened. 557 186-116 Encoder Conﬁ guration Fig. 127: Referencing the encoder position has already been selected. Click on OK. 3 842 564 874/2021-04, MIT: ActiveMover, Bosch Rexroth AG...
Page 170: Adjusting The Primary Measuring System
WT under the reference system. The WT must not hit the reference system! Fold the knurled screw downwards. Slightly press the WT to the left and tighten the knurled screw lightly. Bosch Rexroth AG, MIT: ActiveMover, 3 842 564 874/2021-04...
Page 171 Tighten the screws of the measuring system. Check the display again.  If the value has changed, repeat steps 6 to 9. 557 186-118 Fig. 129: Checking position of the calibration set (2) 3 842 564 874/2021-04, MIT: ActiveMover, Bosch Rexroth AG...
Page 172: Adjusting The Secondary Measuring System
The WT must not hit the reference system! Fold the knurled screw downwards. Slightly press the WT to the left and tighten the knurled screw lightly. 557 186-119 Fig. 130: Adjusting the secondary measuring system (1) Bosch Rexroth AG, MIT: ActiveMover, 3 842 564 874/2021-04...
Page 173 Repeat steps 6 to 8. Observe the ﬁ ne adjustment value and move the measuring system with the auxiliary screws until the display is green. 557 186-120 Fig. 131: Adjusting the secondary measuring system (2) 3 842 564 874/2021-04, MIT: ActiveMover, Bosch Rexroth AG...
Page 174 174/188 Maintenance and repair Tighten the screws on the measuring system. Check the display again. Click Finish. Remove the auxiliary screws. 557 186-121 Fig. 132: Adjusting the secondary measuring system (3) Bosch Rexroth AG, MIT: ActiveMover, 3 842 564 874/2021-04...
Page 175: Installing/Removing The Wt Mounting (Optional)
Gently tighten the knurled screw. The knurled screw is equipped with a friction clutch.  Disassembly is done in the reverse order. 557 186-122 Fig. 133: Installing/removing the WT mounting 3 842 564 874/2021-04, MIT: ActiveMover, Bosch Rexroth AG...
Page 176: Troubleshooting
5. Loosen the motor cable (28 V) connection in the middle of the half with the short-circuit. 6. Repeat step 4. 7. Repeat this until you have localized the section/curve module with the short-circuit. Bosch Rexroth AG, MIT: ActiveMover, 3 842 564 874/2021-04...
Page 177 3. Loosen the control voltage (24 V) connection in the middle of the half with the short-circuit. 4. Repeat step 2. 5. Repeat this until you have localized the section/curve module with the short-circuit. 3 842 564 874/2021-04, MIT: ActiveMover, Bosch Rexroth AG...
Page 178: Communication Error
Switch off main switch, wait 5 s and switch on the main switch again. Reboot ActiveMover controller and check whether controller starts in RUN mode. If the error is not remedied, repeat the process max. 4 - 5x, then contact Bosch Rexroth Service. Bosch Rexroth AG, MIT: ActiveMover, 3 842 564 874/2021-04...
Page 179: Diagnostic Leds
Normal state Possible error  Green Voltage supply deactivated • Switch on the voltage supply The A/D CPLD (Complex Programmable Logic Devices) is not programmed • Contact the customer service  3 842 564 874/2021-04, MIT: ActiveMover, Bosch Rexroth AG...
Page 180: Printed Circuit Board (Gateway)
Fast ﬂ ashing No coil current speciﬁ cations received  6 CURLIM Fast ﬂ ashing When motor Printed circuit board (coil driver) voltage defective 7 CURLIM supply is switched off  Bosch Rexroth AG, MIT: ActiveMover, 3 842 564 874/2021-04...
Page 181: Decommissioning
11 TEMP exceeded  Motor temperature in the permitted range 12 Decommissioning This product is a component which does not need to be decommissioned. Accordingly, this section has been left blank. 3 842 564 874/2021-04, MIT: ActiveMover, Bosch Rexroth AG...
Page 182: Disassembly And Replacement
• Protect the product from mechanical stress. • Protect the product from environmental inﬂ uences, such as dirt and moisture. • Pay attention to the ambient conditions, see technical data on page 184. Bosch Rexroth AG, MIT: ActiveMover, 3 842 564 874/2021-04...
Page 183: Disposal
15 Upgrading and modiﬁ cation • Do not modify the product. • The Bosch Rexroth warranty only applies to the conﬁ guration as delivered, and to approved upgrades. The manufacturer will not accept any warranty claims for systems with unapproved modiﬁ cations or upgrades.
Page 184: Technical Data
383.25 x 500 x 603 mm • Weight 62 kg Section module connection kit 3 842 559 452 • Weight 17 kg Curve module connection kit 3 842 559 453 • Weight 17 kg Bosch Rexroth AG, MIT: ActiveMover, 3 842 564 874/2021-04...
Page 185 Connection kit 3 842 559 438 • Weight 3.3 kg Connection kit 3 842 559 449 • Weight 5 kg Interface modules • Weight 0.06 kg Removal tool 3 842 559 439 • Weight 0.8 kg 3 842 564 874/2021-04, MIT: ActiveMover, Bosch Rexroth AG...
Page 186: Ir Id System
• PROFINET® is a registered trademark of PROFIBUS Nutzerorginisation e.V. • Ethernet POWERLINK is a trademark of B&R Industrial Automation GmbH • EtherCAT® is a registered trademark of Beckhoff Automation GmbH & Co. KG Bosch Rexroth AG, MIT: ActiveMover, 3 842 564 874/2021-04...
Page 187 Appendix 187/188 3 842 564 874/2021-04, MIT: ActiveMover, Bosch Rexroth AG...
Page 188 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...

Bosch rexroth ActiveMover Assembly Instructions Manual

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