BA TMF 1-4 - Сервотехника Нева20TMF$201-4$20english.pdf · TMF Size 1-4 Project:...

MODULES ROBOTICS SYSTEMSCOMPONENTS

OPERATING MANUAL

TMF Size 1-4

Project: Bill of materials:Year of manufacture:

Axxxxxxx09xxxxx2012

OPERATING MANUAL TMF

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© by GÜDEL 2012

Translation of the original operating manual

This operating manual contains standard illustrations that may deviate from the original. In the case of special models, options, or technical changes, the scope of delivery may differ from the descriptions here. Any reproduction of this operating manual, in whole or in part, requires our express permission. Subject to change in the course of technical improvements.

Version a

Author chrgal

GÜDEL AG

Industrie Nord

CH-4900 Langenthal

Switzerland

phone +41 (0)62 916 91 91

fax +41 (0)62 916 91 50

e-mail [email protected]

www.gudel.com

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Tab. 0-1 Revision history

Version Date Specification / Description

a 21.05.2012 Basic version

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Table of contents

Table of contents

1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

1.1 Further applicable documentation. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

1.2 Purpose of the document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

1.3 Target readership . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

1.4 Characters / Explanation of abbreviations . . . . . . . . . . . . . . . . . . . . 10

1.5 Torque tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1.5.1 Tightening torques for screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111.5.2 Tightening torques for HV sets . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131.5.3 Tightening torques for roller holder . . . . . . . . . . . . . . . . . . . . . . . . 141.5.4 Tightening torques for roller support . . . . . . . . . . . . . . . . . . . . . . . 15

1.6 Thread rolling screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

2 Product description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

2.1 Purpose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

2.1.1 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172.1.2 Non-intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

2.2 Product designation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

2.3 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

2.4 Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

3 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

3.1.1 Product safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203.1.2 Operating personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203.1.3 Failure to comply with safety regulations . . . . . . . . . . . . . . . . . . . . . 213.1.4 Installation instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

3.2 Declaration of incorporation in acc. with Machinery Directive 2006/42/EC22

3.3 Hazard symbols and instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

3.3.1 Hazard symbols in the operating manual . . . . . . . . . . . . . . . . . . . . . 23Hazard warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

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Warning symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24Special symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

3.3.2 Hazard symbols on the product . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

3.4 Fundamentals of safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

3.4.1 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273.4.2 Safety and monitoring equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . 273.4.3 Product-specific hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Danger from electric current . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27Danger from falling axles/workpieces . . . . . . . . . . . . . . . . . . . . . . 28

3.4.4 Safety data sheets (MSDS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

4 Design and function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

4.1 Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

4.1.1 Standard configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294.1.2 Option FullCover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304.1.3 Planetary gear option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314.1.4 Double roller support option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

4.2 Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

5 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

5.1.1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345.1.2 Personnel qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

5.2 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

5.3 Positioning, assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

5.3.1 Prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365.3.2 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365.3.3 Positioning, fastening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Base fixing with adhesive anchor . . . . . . . . . . . . . . . . . . . . . . . . . 42Base fixing with welded joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

5.3.4 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 455.3.5 Transport securing devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

5.4 Functional check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

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6 Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

6.2 Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

7 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58


7.2 Consumables and auxiliary agents . . . . . . . . . . . . . . . . . . . . . . . . . . 60

7.2.1 Cleaning agents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 607.2.2 Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Markings at the lubricating points. . . . . . . . . . . . . . . . . . . . . . . . . 60Oils. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61Greases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

7.3 Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

7.4 Maintenance tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

7.4.1 General prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 657.4.2 Maintenance tasks 100 hours after commissioning . . . . . . . . . . . . . 657.4.3 Maintenance tasks every 150 hours . . . . . . . . . . . . . . . . . . . . . . . . . 66

Lubricating guideways, racks and pinions . . . . . . . . . . . . . . . . . . 667.4.4 Maintenance tasks every 500 hours . . . . . . . . . . . . . . . . . . . . . . . . . 67

General inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 677.4.5 Maintenance tasks every 2000 hours . . . . . . . . . . . . . . . . . . . . . . . . 69

Replacing the lubricating pinion . . . . . . . . . . . . . . . . . . . . . . . . . . 697.4.6 Maintenance tasks every 10000 hours . . . . . . . . . . . . . . . . . . . . . . . 71

Oil change in type NA / NH / FA / FH / AE gearboxes . . . . . . . 71

8 Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

8.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76


8.2 Special tools, testing and measuring instruments . . . . . . . . . . . . . . . 77

8.3 Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

8.3.1 General prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 798.3.2 Replacing the bumper unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

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8.3.3 Replacing the wiper and felt insert . . . . . . . . . . . . . . . . . . . . . . . . . . 808.3.4 Replacing the rollers and guideways . . . . . . . . . . . . . . . . . . . . . . . . . 83

Replacing guideways . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 868.3.5 Setting rollers and tooth flank backlash . . . . . . . . . . . . . . . . . . . . . . 908.3.6 Replacing the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 968.3.7 Setting the gear backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 998.3.8 Replacing motor and coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

8.4 Other documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

8.5 Service departments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

9 Decommissioning, storage . . . . . . . . . . . . . . . . . . . . . . . . . 104

9.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

9.1.1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1049.1.2 Personnel qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

9.2 Storage conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

9.3 Decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

9.3.1 Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1059.3.2 Cleaning / rust-proofing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1069.3.3 Transport securing device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1069.3.4 Labeling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

9.4 Recommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

10 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

10.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

10.1.1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10810.1.2 Personnel qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

10.2 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

10.3 Waste management compliant assemblies . . . . . . . . . . . . . . . . . . . 109

10.3.1 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10910.3.2 Material groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

10.4 Disposal facilities, authorities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

11 Spare part supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

11.1 Explanations regarding the spare parts list . . . . . . . . . . . . . . . . . . . 111

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11.1.1 Positioning drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11111.1.2 Parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

11.2 Service departments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

12 Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

13 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

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General

1 General

1.1 Further applicable documentation

All documents in the appendix of this operating manual are further applicable documentation. They must be observed in addition to this operating manual for the safe handling of the product.

1.2 Purpose of the document

This operating manual describes all product life phases of the product TMF:

• Transport• Repairs• Commissioning• Operation• Maintenance• Disposal

The operating manual contains the required information on how to operate the product in the intended manner. It is an important component of the product TMF. The operating manual must be available at the product site throughout its entire service life. If the product is sold, it has to be transferred to the new owner with the machine.

Assembly instruc-tions for partly

completedmachinery

This document serves as the "Assembly instructions for partly completed machinery" in acc. with the Machinery Directive 2006/42/EC, and is in this respect an "Operating Manual".

NOTERead the entire operating manual before working with the prod-uct! It contains important information for your personal safety. The operating manual must be read and understood by all per-sons who work on the product in any of the product life phases.

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General

1.3 Target readership

This operating manual is aimed at the following target readership:

• Construction

• Specialists• Technicians• Forwarding agents

• Operating companies

• Operating personnel

• Service personnel

1.4 Characters / Explanation of abbreviations

The following symbols and abbreviations are used in this operating manual:

Tab. 1-1 Explanation of symbols/abbreviations

Symbol/Abbreviation Use Explanation

For cross-reference Page

Fig. Designates drawings Figure

Tab. Designates tables Table

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General

1.5 Torque tables

1.5.1 Tightening torques for screws

If no other specifications have been made, the following tightening torques apply for zinced screws lubricated with Molykote(MoS2) grease or secured with Loc-tite 242:

Tab. 1-2 Torque table for zinced screws lubricated with Molykote(MoS2) grease

NOTEScrew connections on moving parts have to be secured with Loctite medium strength 242. The adhesive has to be applied onto the nut thread, not onto the screw!

Thread size

Tightening torque [Nm]

8.8 10.9 12.9

M3 1.1 1.7 2.0

M4 2.6 3.9 4.5

M5 5.2 7.6 8.9

M6 9 13 15

M8 22 32 37

M10 42 62 72

M12 74 108 126

M14 117 172 201

M16 180 264 309

M20 363 517 605

M22 495 704 824

M24 625 890 1041

M27 915 1304 1526

M30 1246 1775 2077

M36 2164 3082 3607

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General

If no other specifications have been made, the following tightening torques apply for black oiled and unlubricated screws, or screws secured with Loctite 242:

Tab. 1-3 Torque table for black oiled and unlubricated screws

Thread size


8.8 10.9 12.9

M4 3 4.6 5.1

M5 5.9 8.6 10

M6 10.1 14.9 17.4

M8 24.6 36.1 42.2

M10 48 71 83

M12 84 123 144

M14 133 195 229

M16 206 302 354

M20 415 592 692

M22 567 804 945

M24 714 1017 1190

M27 1050 1496 1750

M30 1420 2033 2380

M36 2482 3535 4136

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General

1.5.2 Tightening torques for HV sets

The following tightening torques apply to DIN6914/15/16-10.9 HV sets:

Tab. 1-4 Tightening torques: HV sets

Thread size


Lubricated with moly grease Slightly oiled

M12 100 120

M16 250 350

M20 450 600

M22 650 900

M24 800 1100

M27 1250 1650

M30 1650 2200

M36 2800 3800

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General

1.5.3 Tightening torques for roller holder

Fig. 1-1 Tightening torques for roller holders

A Move roller with hexagonal socket wrench (tightening torque A1)B Roller holderC Tighten screw with hexagonal socket wrench (tightening torque A2)

The following tightening torques apply to roller holders:

Tab. 1-5 Tightening torques: Roller holders

D00

0772

A2

A1

A B C

SizeTightening torque [Nm]

A1 A2

40 1.5 4

52 2 4

62 3 15

72 4.5 15

90 7 15

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General

1.5.4 Tightening torques for roller support

Fig. 1-2 Tightening torques for roller supports

A Roller supports size 72 and 90B Move roller with hexagonal socket wrench (tightening torque A1)C Roller supports size 40 and 52D Tighten nut and locknut with hexagonal key (tightening torque A2)

The following tightening torques apply to roller supports:

Tab. 1-6 Tightening torques: Roller supports

D00

0941

A1

A2A2

A1

A B C B

D D


A1 A2

40 1 87

52 2 120

72 3 220

90 5.5 450

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General

1.6 Thread rolling screws

Thread rolling screws are mainly used for guideways, mounting plates, as well as for cable tray brackets.

Fig. 1-3 Use of thread rolling screws

A LabelB Thread rolling screwsC Mounting plateD Cable tray bracketE Guideways

Thread rolling screws, recognizable with Güdel by a Torx drive, can be screwed in directly in the core hole. It is not necessary to cut the thread in advance. After the first use of a thread-cutting screw, a metric screw can also be employed.Drill holes without thread need to be furrowed. No thread may be cut in. This can also be read on the label.

The following tightening torques apply to thread rolling screws when turned in the first time:

Tab. 1-7 Tightening torques for thread rolling screws

3

2

1

0181

843

MA max

M8 30NmM10 60NmM12 100Nm

Nicht GewindeschneidenNo tapping!

GewindefurchendeSchraubenThread grooving screw

MA

.

.

.

.

.

.

.

3

21

0181

843

D

A

B

C

BBE


Steel S355J2 Aluminum

M8x30 30 35

M10x45 63 71

M12x40 108 123

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Product description

2 Product description

2.1 Purpose

2.1.1 Intended use

The TMF product is intended exclusively for moving and positioning of robots.

Other use or use that goes beyond the described purpose does not fall under the intended use. The manufacturer assumes no liability for any resulting dam-ages. All risks are carried solely by the user!

2.1.2 Non-intended use

The TMF product is not intended for:

• Movement of poisonous goods• Movement of explosive goods• Operation in explosive areas

Any other use shall be considered improper use and is forbidden!

Do not modify the product in any way.

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Product description

2.2 Product designation

Each product has a type plate. It contains the following information:

Fig. 2-1 Type plate

A Product, typeB Project, sales orderC Serial number (parts list)D Year of manufacture

In the declaration of conformity and declaration of incorporation, the terms are used in acc. with the legend above.

Position of the typeplate

The type plate is attached in accordance with the following illustration:

Fig. 2-2 Position of the type plate

A Type plate

D00

1120

A C DB

D00

1453

A

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Product description

2.3 Technical Data

The technical data is valid for temperatures between +25 and +30 °C.

The emitted sound pressure level depends on how the product is used.

For the following data, refer to the layout(s) in chapter 13 ’Appendix’, 117:

• Dimensions• Weight• Strokes of the individual axes• Gearbox type• Gearbox ratios• Motors

Temperature ranges The following temperature and air humidity ranges apply:

2.4 Options

The following options are available for the product TMF:

• Automatic lubrication system• Planetary gear• Double roller support• FullCover

In general, in these operating instructions the complete covering option is called FullCover.

Information on any available options can be found in the spare parts lists and the layout in chapter 13 ’Appendix’, 117. You may also find relevant docu-mentation in the same chapter under "Options".

Transport -10 to +60°C

Operation +5 to +40°C Up to and with 85%, condensation formation not permissible

Storage -10 to +40°C up to 75%

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3 Safety

3.1 General

3.1.1 Product safety

Residual danger The TMF product corresponds to the state of the art. It was designed and con-structed according to the recognized safety regulations. However, some resid-ual danger remains during its operation.

There is danger to the personal safety of the operator, as well as to the TMF product and other property.

Operation Always adhere to the instructions in this manual when operating the TMF prod-uct, and ensure that it is always in perfect working order.

3.1.2 Operating personnel

Persons who work with the TMF product must be technically qualified and trained. They must be familiar with all hazards associated with using the TMF product.

NOTERead this chapter prior to working with the product! It contains important information for your personal safety. This chapter must be read and understood by all persons who work on the product in any of the product life phases.

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3.1.3 Failure to comply with safety regulations

Liability Güdel shall not be held liable under any of the following circumstances:

• The installation regulations were disregarded• Included protective equipment was not installed• Included protective equipment was modified

3.1.4 Installation instructions

Protective measures The operator is responsible for ensuring safe conditions in the vicinity of the product TMF, in particular, for complying with all general safety regulations, guidelines and standards . This includes implementing all of the safety measures before commissioning the system. These must cover all hazards. This is the only way to ensure that operation of the product conforms with CE regulations.

As stipulated by the machinery directive, the protective measures must:

• Correspond to best practices• Comply with the required safety category

Changes The product must never be modified or used in a manner contrary to its intended use. Intended use and non-intended use is described in Chapter 2 ’Product description’, 17.

General rules foroccupational safety

The generally accepted occupational safety rules have to be observed and fol-lowed.

DANGERDisregarding safety regulations

Disregarding the safety regulations can be very hazardous for personnel and the surroundings!

Always comply with the safety regulations!

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3.2 Declaration of incorporation in acc. with Machinery Directive 2006/42/EC

The manufacturer: GÜDEL AG, Industrie Nord, CH-4900 Langenthal

herewith declares that the partly completed machinery:

Product, type / serial number (parts list) / year of manufacture

TMF Size 1-4 / 09xxxxx / 2012

corresponds to the fundamental requirements of the Machinery Directive (2006/42/EC), Annex 1.

The special technical documents as per Annex VII Part B have been drawn up.

The partly completed machinery complies with the following other EC direc-tives:

• Low Voltage Directive 2006/95/EC• EMC Directive 2004/108/EC

The following harmonized standards have been applied:EN ISO12100; EN ISO 13850; EN 60204-1; EN 1088; EN ISO 4413; EN ISO 4414; EN ISO 13849-1

Authorized representative responsible for compiling the technical documents: Martin Knuchel Tel. +41 (0)62 916 92 40

The special technical documents are submitted in electronic form, depending on the respective regulations of the national bodies.

The partly completed machinery may only be commissioned after it has been determined that the machinery into which the partly completed machinery is to be incorporated complies with the stipulations of the Machinery Directive (2006/42/EC).

Langenthal, 01/01/2012 Walter Zulauf Martin Knuchel

Director of Development Director of Systems / Robotics

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3.3 Hazard symbols and instructions

3.3.1 Hazard symbols in the operating manual

Hazard warnings

The hazard warnings are defined for the following four types of danger levels:

DANGERDANGER

DANGER refers to hazards with a high risk of severe physical injury or im-mediate fatality.

WARNINGWARNING

WARNING refers to hazards with a moderate risk of severe physical injury or potential fatality.

CAUTIONCAUTION

CAUTION refers to hazards with a slight risk of moderate physical injury.

NOTENOTE

NOTE refers to a hazard that can lead to property damage.

NOTENote refers to helpful information and tips for users.

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Warning symbols

Symbol Use

Danger, warning, caution, note

Refers to hazards resulting from automatic operation of the plant

Danger, note

Refers to electrical hazards

Danger, warning

Refers to hazards from falling beams

Warning, caution

Refers to crushing hazards from gears


Refers to hazards from industrial trucks

Warning, caution

Refers to hand injury hazards

Warning, caution

Refers to hazards from heavy components


Refers to environmental pollution hazards

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Tab. 3-1 Warning symbols

Special symbols

Tab. 3-2 Special symbols


Refers to hazards from suspended loads

Danger, note

Refers to hazards from electromagnetic fields


Refers to hazards from crushing

Danger

Refers to hazards from explosion


Refers to hazardous locations

Warning, caution, note

Refers to hazards from heat

Symbol Use

Symbol Use

Note

Helpful information and other tips

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3.3.2 Hazard symbols on the product

The following labels are attached to the product:

The "Danger sign" label warns against:

• Axles falling after the transport securing device is removed• Moving the axles before the transport securing device is removed

Fig. 3-1 Danger sign label

The "Transport information" label provides information on correctly attaching transport equipment.

Fig. 3-2 Transport information label

DANGER! GEFAHR!The vertical axis mustbe secured from motionbefore removing therack lock or otherlocking device used fortransportation!

Vor dem Entfernen derTransportsicherungZ-Achse(n) gegenherunterfallen Sichern!

WARNING! ACHTUNG!Remove all rack locks orother locking devicesused for transportationon all axes beforeattempting to move anyaxis!

Vor dem Bewegen derAchsen sämtlicheTransportsicherungenentfernen!

0156

538

D00

0095

0156

539

2X

X

X

D00

1401

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Safety

3.4 Fundamentals of safety

3.4.1 Intended use

The intended use is described in chapter 2.1.1 ’Intended use’, 17.

3.4.2 Safety and monitoring equipment

For information on the safety and monitoring equipment, refer to the docu-mentation on the complete system. More details can be found in the supplied risk analysis.

3.4.3 Product-specific hazards

Danger from electric current

NOTENever remove or modify any of the safety and monitoring equip-ment! Be sure to close all of the protective equipment during op-eration!

DANGERHazardous voltage

The product contains components that are energized with hazardous volt-ages. Touching these components will cause an electric shock. Electric shocks can be fatal.

Before working in the danger area:• Switch off the main power supply and secure it against being switched on

again (main switch of complete plant)• Ground the equipment• Before switching on the product again, make sure that no one is located

in the danger area

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Danger from falling axles/workpieces

3.4.4 Safety data sheets (MSDS)

Safety data sheets contain safety information about the materials. The operator is responsible for obtaining safety data sheets for all materials used, such as oils, greases, cleaning agents etc.

Safety data sheets can be obtained as follows:

• Chemical vendors usually deliver their substances with safety data sheets.

• Safety data sheets are available on the InternetExample: Enter "msds" plus the name of the material to find safety informa-tion for the material.

Read the safety data sheets closely and follow all instructions. We recommend that you store the safety data sheets for future reference.

WARNINGFalling axles/workpieces

Falling axles or workpieces can cause severe or fatal injuries!

Observe the following:• Secure suspended axles using the stipulated equipment and deposit any

workpieces before working in the danger area• Never enter the area below suspended axles and workpieces• Check the belts of the telescope axes for signs of breakage and tears

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Design and function

4 Design and function

4.1 Design

4.1.1 Standard configuration

In the standard configuration, the TMF product consists of the following assem-blies:

Fig. 4-1 Design

A Energy chainB Y-carriageC Y-drive (gearbox)D Lubricating pinion unitE Roller supportF Y-axisG Bumper unit

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CA B

DG F E

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Design and function

4.1.2 Option FullCover

The TMF product with the FullCover option consists of the following assem-blies:

Fig. 4-2 FullCover option design

A Complete coveringB Y-axisC Y-drive (gearbox or planetary gear)D Y-carriage

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3145

DB CA

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Design and function

4.1.3 Planetary gear option

The TMF product with the planetary gear option consists of the following assemblies:

Fig. 4-3 Planetary gear option design

A Y-axisB Y-carriageC Y-drive (planetary gear)

D00

3236

CA B

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Design and function

4.1.4 Double roller support option

The TMF product with the double roller support option consists of the follow-ing assemblies:

Fig. 4-4 Double roller support design

A Y-axisB Y-carriage with double roller supportC Y-drive (gearbox)D Double roller support

D00

3235

DA B C

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Design and function

4.2 Functional description

The TMF product can move along the following axes:

Fig. 4-5 Axis names

D00

1459

Y

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Commissioning

5 Commissioning

5.1 Introduction

Various options are available for your product. This chapter provides informa-tion on several available options. It therefore describes components with which your product is not equipped.

5.1.1 Safety

Only perform the tasks described in this chapter after you have read and under-stood chapter 3 ’Safety’, 20. It concerns your personal safety!

5.1.2 Personnel qualifications

Only appropriately trained and authorized personnel are allowed to commis-sion the TMF product.

WARNINGSuspended loads

Improper handling of suspended loads can lead to severe injuries or death!

Observe the following:• Use appropriate lifting units• Wear appropriate protective clothing• Always keep sufficient distance to suspended loads• Never enter the area below a suspended load

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5.2 Transport

The product is transported by air, land or water. The packaging depends on the means of transport.

Packaging symbols Depending on the contents, the packaging units are marked with the symbols shown below. Observe these at all times.

Fig. 5-1 Packaging symbols

A FragileB This side upC Keep dryD Handle with care

Remove the packaging only to the degree necessary for company-internal trans-port.

Transport the pallet, crate or case to the planned installation location. Use appropriate transport devices.

Truck = Shipped on a transport pallet

Aircraft = Shipped in a crate

Ship = Shipped in a case or container

NOTEImproper transport

Improper handling of the package can lead to transport damage!

Do not tip over the package. Avoid heavy vibrations and shocks. Observe the symbols on the packaging.

FRAGILE

D00

0098

D00

0099

CRAINT L'HUMIDITE

D00

0100

HANDLEWITH CARE

D00

0101

A B C D

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5.3 Positioning, assembly

5.3.1 Prerequisites

Base The base has to fulfill the requirements of the application. For information on the load per surface and the surface properties, please refer to the layout or the documentation of the complete system.

Lines The supply lines have to meet the requirements of the application. For informa-tion on the required capacities, please consult the documentation of the com-plete system.

Lifting unit Lifting units are required for positioning and installing the product or plant. Make sure that appropriately dimensioned devices (crane etc.) are available.

5.3.2 Unpacking

Accessories and small parts are packaged in a separate case or directly with the product itself.

The components have been treated with anti-rust oil (spray) and wrapped in oil paper. Remove packaging carefully.

Dispose of the packaging in accordance with the local disposal regulations.For more information on disposal, refer to chapter 10 ’Disposal’, 108.

DeliveryChecking Check the content of the delivery by comparing it with the accompanying papers.Check the product for damage. Report transport damage immediately.

NOTEThe anti-rust oil protects the components. We recommend not removing the oil.

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5.3.3 Positioning, fastening

This chapter describes the steps for setting up and fastening the TMF product.If no other specifications have been made, the tightening torques as per chapter 1.5.1 ’Tightening torques for screws’, 11 apply.

Before you position the product at the installation site, the requirements listed in chapter 5.3.1 ’Prerequisites’, 36 have to be fulfilled.

WARNINGHeavy components

Components can be very heavy. Improper handling can cause severe or fatal injuries!

Use suitable means to secure the components against tipping over. Only re-move the tip-over protection after the product has been completely assem-bled.

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Attaching slings This section describes the steps for attaching the slings.

Fig. 5-2 Attaching the slings

A Transportation cradleB HookC Lifting belts

Attach the slings as follows:

1 Position the lifting belts as shown in the drawing(Symmetric arrangement according to the figure)

2 Hang the ends of the lifting belts into the hooks of the transportation cra-dle

The slings are in place.

D00

1467

X

X

2X

A

B

C

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Commissioning

Positioning theproduct

This section describes the steps for positioning and aligning the product.

Fig. 5-3 Positioning the product

A Floor leveling screwsB Locknuts

Position the product as follows:

1 Set floor levelling screws to the specified mass

2 Position the product as shown in the layout

3 Align the product horizontally and vertically by means of floor leveling screws (use guideways as reference)Flatness along overall length of the axis: up to 10 meters = 0.5 mm, up to 20 meters = 0.6 mm,up to 30 meters = 0.7 mm, etc.(max 0.1 mm tolerance for every 10 m extension)

4 Lock the floor leveling screws

The product has been completely positioned and aligned.

25

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A B

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Commissioning

Connecting theprofiles

This section describes the steps for connecting and aligning the profiles.

Fig. 5-4 Connecting the profiles

A Cover plateB RacksC Profile CD ScrewsE Profile EF Guideways

D00

3152

F E

A B C

D

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Connect the profiles as follows:

1 Align profile E with profile C. Distance between: 5 mmAlignment on the overall length of the axis: up to 10 meters = 0.5 mm, up to 20 meters = 0.6 mm,up to 30 meters = 0.7 mm, etc.(max 0.1 mm tolerance for every 10 m extension)

2 Connect the profiles

2.1 Mount the guideway and rack as per Section ’Installing the guide-way’, 45

2.2 Mount the cover plates

3 Realign the product horizontally and vertically, by means of the floor lev-eling screws (use as reference guideways)Flatness along overall length of the axis: up to 10 meters = 0.5 mm, up to 20 meters = 0.6 mm,up to 30 meters = 0.7 mm, etc.(max 0.1 mm tolerance for every 10 m extension)

The profiles are connected and aligned.

Base fixing The base can be fastened either with adhesive anchors or with a welded joint.

You can find the corresponding anchor type in the layout in chapter 13 ’Appen-dix’, 117.

NOTEOnly anchor the product after it has been correctly positioned and aligned!

Only use anchors approved by Güdel!

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Base fixing with adhesive anchor

This section describes the base fixing with adhesive anchor.

This fastening requires uncracked concrete with a quality of at least C20/25 (ENV 206) with ideal stiffness. Deviations can be found in the layout in the appendix. The minimum concrete thickness, edge distance and maximum per-missible tensile and compressive loads can be found in the table below.

Fig. 5-5 Anchored base fixing

A Floor levelling screwB Column/frameC AnchorD Adhesive capsule

Tab. 5-1 Anchored base fixing

D00

0106

d

h

m

b

r

A

B

C

D

m (anchor size) M12 M20 M27 M30

b (concrete thickness) [mm] 140 220 300 340

r (edge distance) [mm] 110 180 240 270

d (drill diameter) [mm] ø14 ø24 ø30 ø35

h (drilling depth) [mm] 110 170 240 270

Tightening torque [Nm] 50 160 270 300

Permissible tensile load [kN] 12.8 36.5 78 101.6

Permissible compressive load [kN]

34 60 80 135

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Anchor the column as follows:

1 Make a bore hole as per the table above

2 Clean the bore hole

3 Insert the adhesive capsule

4 Screw in the anchor rod with the hammer drill

5 Wait until the hardening period specified by the manufacturer has passed

6 Screw the column tight(For the tightening torque, refer to the table above.)

7 Remove the safety devices

The column is anchored.

Base fixing with welded joint

This section describes the base fixing with welded joint.

Prior to welding the joint, you have to fasten the base plate to the floor.This fastening requires cracked or uncracked concrete with a quality of at least C20/25 (ENV 206) with ideal stiffness. Deviations can be found in the layout in the appendix. The minimum concrete thickness, edge distance and maximum permissible tensile and compressive loads can be found in the table below.

NOTEThe welding work described below may only be performed by certified personnel!

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Fig. 5-6 Welded base fixing

A ScrewB Floor levelling screwC Column/frameD Bottom plateE Base plate

Tab. 5-2 Welded base fixing

D00

0107

k n

m

br

A

B

C

D

E

m (floor levelling screw) M24x2 M36x2 M48x3 M56x3

b (concrete thickness) [mm] 120 160 250 340

r (edge distance) [mm] 90 130 185 255

k (throat dimension) [mm] a 4 a 4 a 5 a 5

n (joint length) [mm] 140 190 190 330

Permissible tensile load [kN] 12.8 36.5 78 101.6

Permissible compressive load [kN]

34 60 80 135

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Perform the weld joint as follows:

1 Connect the floor levelling screw and bottom plate by means of the screw

2 Weld the bottom plate to the base plate(weld joint in acc. with the table above)

3 Tighten the screw

4 Remove the safety devices

The weld joint has been applied.

The product is anchored to the floor.

5.3.4 Assembly

Installing theguideway

Proper installation of the guideways in accordance with the regulations is pre-requisite for low-wear use of the product.

Mounting aid The start and end of the rack form a half tooth gap. For precise and low-noise transition, we recommend using a mounting aid geared in the opposite direction (see chapter 8.2 ’Special tools, testing and measuring instruments’, 77).

Fig. 5-7 Mounting aid for rack assembly

A RackB Mounting aid

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1018

A B

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This section describes the steps for installing the guideway.

For axes over 20 meters, the assembly of the guideways must be performed from the middle.

Fig. 5-8 Installing the guideway

A Reference surfacesB ScrewsC Screw clampD Mounting aidE RackF Torque wrenchG ScrewsH Guideway

D00

3156

A H G F

A B A C D E

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Install the guideway as follows:

1 Clean the reference surfaces and guideways thoroughly and rub an oil stone across them

2 Lay first pair of guideways and racks on the reference surface. Lightly tighten with outermost screws (all holes must be aligned)

3 Mount next pair of guides and rack as in step 2

4 Clamp mounting aid to guides and racks with screw clamp

5 Install the rest of the screws and tighten with all the others

6 Inspect transition:

6.1 For guideways with gears, transition according to section ’Inspect-ing rack transition’, 48

6.2 For guideways without gears(gap dimension < 0.02 mm)

7 Use a suitable measuring instrument to check that the guideways are par-allel(tolerance: ±0.04 mm)

8 If deviations occur (transition/parallelism):

8.1 Remove screws and guideway

8.2 Repeat the procedure

The guideway has been installed.

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Inspecting racktransition

This section describes the inspection of the rack transition.

The racks correspond to the qualities in the following table:

Tab. 5-3 Rack quality

Hardened racks can be recognized by the engraved Güdel logo.

Fig. 5-9 Inspect rack transition with micrometer

A Rack transitionB Measurement boltC Micrometer position CD Micrometer position DE Micrometer position E

Rack quality

Standard configura-tion Planetary gear option

Q9 Q6

D00

1060

E D C

A B

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Tab. 5-4 Deviation method 1

Inspect the rack transition as follows:

1 Position the measurement bolt as shown in the illustration

2 Inspect the deviations in the height of positions C and E to position D via micrometer(Permissible deviation of position C and E to D, refer to table above)

The rack transition has been inspected.

Mounting motor andcoupling

This section describes the steps for assembly of the coupling and the motor.

Depending on the type of transport securing device used, you have to remove the device before installing the motor for the first time (see Section ’Transport securing device at the gearbox’, 55).

Permissible deviation [mm]

Rack quality Modulem ≤ 3

Module3 < m ≤ 8

Module8 < m ≤ 12

Q4 h21 0.014 0.016 0.022

Q5 h22 0.022 0.027 0.034

Q6 h23 0.034 0.041 0.055

Q7 h25 0.082 0.110 0.137

Q8 h27 0.220 0.275 0.343

Q9 h27 0.220 0.275 0.343

WARNINGDanger of being crushed

Incorrect tightening torques can lead to suddenly moving axes or workpiec-es. This can cause severe or fatal injuries!

Observe the following:• Calibrate and check the torque wrench periodically• Tighten all screws with a torque wrench to the specified tightening tor-

ques

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Fig. 5-10 Installing the motor and coupling

A GearboxB Motor flangeC Measuring instrumentD CouplingE Coupling screwsF Motor screwsG Motor

Install the motor and the coupling as follows:

1 Clean the coupling and motor shaft to ensure that they are free of grease

2 Measure distance X

3 Push the coupling onto the motor shaft(Dimension Y has to match dimension X, tolerance -0.2 to -0.4 mm)

4 Tighten the coupling screws For the tightening torque, refer to tab. 1-2, 11

5 Grease the gear rim of the coupling(For grease types, see 7.2.2 ’Lubricants’, 60)

6 Push the motor, with the mounted coupling, onto the gearbox

7 Tighten the motor screws

The motor and the coupling have been installed.

X

Y

D00

0111

A B C D GFE

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Attaching optionalcomponents

If equipped, attach the following optional components as per the separate doc-umentation:

• Automatic lubrication system• Manual lifting and safety unit: vertical axis• Safety brake system to vertical axle• Rotary axis• Telescope axis• Pneumatic load balance

Attaching the load Attach the load (gripper, robot, etc.) to the TMF product. Set the roller and tooth flank backlash again. This procedure is described in chapter 8.3.5 ’Setting rollers and tooth flank backlash’, 90.

NOTEWear on the guideways!

Incorrectly adjusted roller and tooth flank backlash increase the wear on the guideways.

After attaching the load, set the roller backlash and tooth flank backlash again!

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Mounting the robot This section describes the steps for mounting the robot.

Fig. 5-11 Mounting the robot

A RobotB ScrewC PlateD Carriage

Mount the robot as follows:

1 With a lifting unit, place the robot on the carriage and align it

2 Screw robot tight(The screws have to go at least 1xd into the plate)

3 Remove the lifting unit

The robot has been mounted.

Integrating product Integrate the TMF product into the complete plant. Connect the product with the supply lines for energy and consumables. For this procedure, refer to the documentation of the complete system.

NOTEWhen installing the robot, use sufficiently long screws. The screws have to go at least 1xd into the plate.

D00

1499

1xd

d

A

B

C

D

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Cables and Lines This section provides information on the proper handling of cables and lines.

Fig. 5-12 Cables and lines

A Strain relief version cable fittingB Energy chainC Strain relief version ChainFixD Cable descriptionE Reel with dispenserF Vertical dividerG Fixed sideH Driver

NOTEImproper handling of cables

The improper handling of cables leads to cable damage, unnecessary maintenance work and stopped operation.

Observe the instructions for use of cables and lines.

D00

3044

A B C D

H G F E

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Observe the following when handling cables and lines:

• Use only highly flexible, energy chain capable lines! The maximum permissible bending radius of the line must not be larger than the minimum radius of the energy chain.

• Roll the cable off evenly, never take off in loops

• Layout cables without twisting for at least 24 hours before putting them into energy chains! The cable description will aid you in doing so.

• Prepare vertical dividers:• Cables are separated by vertical dividers, cables are not permitted to

be layed next to each other• Piled up cables with variant sheath materials must be separated from

each other (danger of sticking)• The vertical dividers are not allowed to be positioned in an offset man-

ner in the roll-off direction

• The cable must have play on all sides of the cable divider. At its mini-mum, it should be 10% of the cable diameter. However, it should not be less than one millimeter.

• Lay cables in, never pull them in!

• If the process paths of the energy chain are less than 50m:• Relieve cable strain at the driver and the fixed side

• The distance between the end of bend movement and strain re-lief is 10-30 times the diameter of the cable

• Strain relief version cable fitting: Two pieces 4.5mm wide on the appropriate holders, Do not damage the sheaths of the cables!

• Strain relief version ChainFix (IGUS energy chains): Do not exceed a tightening torque of 1 Nm!

• Run cable straight at least 20cm after the strain relief on the fixed side (length L)

• For process paths of the energy chain larger than 50m:• Relieve cable strain at the drive

• The distance between the end of bend movement and strain re-lief is 10-30 times the diameter of the cable

• Strain relief version cable fitting: Two pieces 4.5mm wide on the appropriate holders, Do not damage the sheaths of the cables!

• Strain relief version ChainFix (IGUS energy chains): Do not exceed a tightening torque of 1 Nm!

• Run cable straight at least 50cm after the strain relief on the fixed side (length L)

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• Pressure hoses from the hydraulic system and pneumatics have to be strain relieved at the driver and at the fixed side. Except if they expand under pres-sure (only fabric hoses).

• Before commissioning, label cables during strain relief so they can be read-justed during maintenance work

5.3.5 Transport securing devices

At delivery, a transport securing device is in effect at the gearbox. This has to be removed prior to assembling the motor.

Transport securingdevice at the

gearbox

This section describes the removal of the transport securing device at the gear-box.

Fig. 5-13 Transport securing device at the gearbox

A ScrewsB Transport securing device


After removing the transport securing device or the motor, the carriage may run off to the side. This can cause severe or fatal injuries!

Secure the carriage before removing the transport securing device or the motor!

D00

0097

A

B

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Remove the transport securing device at the gearbox as follows:

1 Fixate the carriage

2 Loosen the screw

3 Remove the transport securing device

Transport securing device has been removed.

5.4 Functional check

Prior to the functional check, ensure that:

• The Installation instructions were observed.

• The product is anchored to the floor.

• The safety equipment has been attached and closed.

• No persons are present in the danger area.

The procedure for the functional check is described in the documentation of the complete system.

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Operation

6 Operation

6.1 General

Operate the product only after the Installation instructions has been observed!

For information on how to operate the product TMF refer to the respective chapters of the documentation of the complete plant.

6.2 Personnel

WARNINGTraining of operating personnel

Wrong behavior of untrained or insufficiently trained operating personnel can lead to severe personal or material damage.

Before the operating personnel begins working with the product:• Train and instruct the operating personnel• Point out dangers in the work area to the operating personnel• Assess qualification of operating personnel before approving them• Keep the operating personnel trained in best practices. Inform them also

about technical progress, changes, etc.

If these measures are not complied with, you alone as operating company are liable for damages that may result!


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7 Maintenance

7.1 Introduction

This chapter describes all maintenance tasks.

Work sequences Perform the work sequences in the order described. Perform the described tasks at the specified times. This ensures a long service life for your product.

Original spare parts Use only original spare parts. For information on spare parts and wear items, refer to chapter 11 ’Spare part supply’, 111.

Options andThird-party products

For information on maintenance of options and third-party products, read the appropriate documents in the appendix.

Lubrication This chapter describes the steps for manually lubricating the product. If your product has an automatic lubrication system, manual lubrication of guideways, racks and pinions is not necessary. However, perform lubrication work when the first signs of tribocorrosion (reddish discoloration of the track) show.

Tightening torques If no other specifications have been made, the tightening torques as per chapter 1.5.1 ’Tightening torques for screws’, 11 apply.

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7.1.1 Safety



Only appropriately trained and authorized personnel are allowed to work on the TMF product.

WARNINGAutomatic startup

When work is being performed on the product, there is danger of the ma-chine starting up automatically. This can cause severe or fatal injuries!

Before working in the danger area:• Secure vertical axles (if equipped) against falling• Switch off the main power supply and secure it against being switched on

again (main switch of complete plant)• Before switching on the plant again, make sure that no one is in the dan-

ger area.







Use appropriate lifting units!

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7.2 Consumables and auxiliary agents

7.2.1 Cleaning agents

For cleaning tasks, have a grease-dissolving cleaning agent (e.g. acetone) at hand.

7.2.2 Lubricants

Markings at the lubricating points

The identification disc below the grease nipple shows the type of lubricant.

Fig. 7-1 Markings at the lubricating points

A Identification discB Grease nipple

NOTEUnsuitable lubricants

Using unsuitable lubricants can lead to machine damage!

Only use the lubricants listed below. If uncertain, please contact our service departments!

D00

0314

A

B

Yellow identification disc

Grease

Red identification disc Oil

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Oils

If special oils have been delivered from the factory at the request of the cus-tomer, you can find the relevant specifications in the spare parts list. Otherwise, the following lubricants apply:

Oil types The following oil is used ex works by default:

The following types of oil can be used alternatively:

Oil quantities Refer to the table below for the required oil quantities for the gearbox.

Tab. 7-1 Oil quantity for gearbox

Mobil Glygoyle 460

Aral Degol GS 460

BP Enersyn SG-XP-460

Texaco Pinnacle 460

Shell Tivela S 460

Klüber Klübersynth GH6-220

Type Quantity [cm3]

AE030 40

AE045 100

AE060 250

AE090 700

AE120 1400

AE180 as per type plate

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Greases

If special greases have been delivered from the factory at the request of the cus-tomer, you can find the relevant specifications in the spare parts list. Otherwise, the following lubricants apply:

Grease types forrack/pinion teeth

The following grease is used ex works for manual lubrication of the rack and pinion teeth:

The following grease types can be used alternatively:

The following grease is used ex works for automatic lubrication of the rack and pinion teeth:

Grease types forteeth

Gearbox coupling

The following grease is used ex works for the gear teeth of the gearbox cou-pling:


Mobil Mobilux EP 2

Aral Aralup HLP 2

BP Energrease LS-EP 2

Texaco Multifak EP 2

Shell Gadus S2 V220 2

Klüber Centoplex EP-2

Castrol Longtime PD2 Lubrication system Memolub

Güdel Güdel H1 Lubrication system FlexxPump

Motorex Grease 218 M

Mobil Mobilith SCH 1000 Special

OtherManufac-turer

Specifications: KPF2K-20

in acc. with DIN 51502 MoS2 content minimum 3%

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Grease type forbearings of the

rollers

For the rollers, you must use a high quality lithium soap greaseDIN 51825-KP2N-20.For rollers the following grease is used from the factory:


INA Arcanol LOAD150

Shell Gadus S4V150KP2

ExxonMobil Beacon EP2

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7.3 Maintenance schedule

Fig. 7-2 Maintenance schedule

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2000 h

500 h

150 h

150 h

500 h

2000 h

10000 h

10000 h

Grease Replace Oil change

Oil Cleaning Visual inspection

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7.4 Maintenance tasks

7.4.1 General prerequisites

Prior to performing repair and maintenance tasks, do the following:

• If vertical axles are present, secure them against falling

• Switch off the plant and padlock it to secure it against being switched on again

• Make sure that all spare parts and wear items are at hand(For information on spare parts and wear items, refer to chapter 11 ’Spare part supply’, 111)

7.4.2 Maintenance tasks 100 hours after commissioning

To ensure smooth operation, certain maintenance tasks have to be performed after commissioning.

Perform the following tasks 100h after commissioning the product:

• General inspection as per chapter ’General inspection’, 67

• Check the base fixing:• Check the tightening torques of the screws and nuts, retighten if re-

quired• Check the anchor connection, place new anchor if required

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7.4.3 Maintenance tasks every 150 hours

For more information on the lubricants, refer to chapter 7.2 ’Consumables and auxiliary agents’, 60.

Lubricating guideways, racks and pinions

Lubricate all guideways, racks and pinions every 150 hours.

Tab. 7-2 Number of shots with the grease gun

Lubricate the guideways, racks and pinions as follows:

1 Switch off the system and padlock it to secure it against being switched on again

2 Use a grease gun to manually inject full shots of lubricant at the lubricating point of all wiper and lubrication units and all lubricating pinions(Number of shots according to table above)

The guideways, racks and pinions are lubricated.

NOTEIncompatible lubricant!

Mixing different lubricants affects their properties.

Never mix different types of lubricant!Before using another type of lubricant, exchange the wiper and lubrication units and the lubricating pinions! Rinse the lines with fresh lubricant!

Product size Roller size Number of shots with the grease gun (1 shot = 1.5 cm3)

TMF-1 40 5-6

TMF-2 52 5-6

TMF-3 72 8-10

TMF-4 90 8-10

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General inspection

During the general inspection, the entire product is subjected to an overall check.

Performing a generalinspection

Perform the general inspection as follows:

1 Switch off the plant and padlock it to secure it against being switched on again

2 Check the inspection points as described in the inspection table

3 Take measures as described in the inspection table

The general inspection has been performed.

Inspection tableInspection cri-terion

Specification / Description Measures

Dirt Check the components for dirt:• Wipers• Rollers• Guideways

Immediately clean away any dirt

Damage Check the plant for dam-age:• Paint damage• Bent attachments (e.g.

cover plates)• Cracks in the cast

parts• Cracks at welding

seams

Immediately remedy all dis-covered damage

Loose compo-nents

Check the seating of the components:• Screws• Nuts • Attachments

• Immediately tighten loose screws to the re-quired torque

• Align and fasten loose attachments

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Tab. 7-3 Inspection table

Loss of oil Check the plant and its surroundings for signs of the following:• Puddles of oil and oil

spills on the floor or in the drip sheets

• Leaks, torn or pinched lines

• Leakage at the gearbox

• Replace defective and pinched lines

• Repair or replace the gearbox

• Remove puddles of oil and oil spills on the floor or in the drip sheets

Components Check the condition of the components:• Carriage• Rollers• Guideways• Racks• Cog belt

Replace worn components

Backlash Check for correct amount of backlash in the components:• Pinions• Rollers

Correct the backlash

Tension Correct cog belts for cor-rect tension

Correct the tension

Energy chain and cable

Check the energy chain:• Mobility• Wear• Damage• Position of the cables

and lines• Condition of the cables

and lines• Tightening torques,

strain relief(e.g. 1Nm at IGUS Chainfix)

• Look for cause• Replace defective or

worn energy chains• Correct the position of

cables and lines• Replace worn or defec-

tive cables• Correct the tightening

torque

Inspection cri-terion

Specification / Description Measures

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Replacing the lubricating pinion

A pinion soaked in lubrication runs along next to the drive pinion. It ensures a continuous lubrication of the rack and the drive pinions.

Replace the lubricating pinion to ensure uniform lubrication.

This section describes the steps for replacing the lubricating pinion.

Fig. 7-3 Replacing the lubricating pinion

A Lubrication pointB Holder of the axle to the lubricating pinionC Axle to the lubricating pinionD Lubricating pinionE Gasket

Replace the lubricating pinion as follows:


2 If there is an automatic lubrication, disconnect the supply

3 Remove the entire lubricating pinion unit

4 Replace the lubricating pinion: For oil lubrication, submerge the new lubricating pinion in oil for several minutes(Oil quality, see chapter 7.2 ’Consumables and auxiliary agents’, 60)

5 If necessary, replace the gasket

6 To install the entire lubricating pinion unit, reverse the removal steps

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A

E D C

B

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7 Lubricate the lubricating pinion at the lubrication point

7.1 For manual lubrication:Lubricate the lubricating pinion according to the chapter "Lubricat-ing the rack and pinion"

7.2 For automatic lubrication:Connect supply line, start lubrication procedure(See separate operating manual on automatic lubrication)

The lubricating pinion has been replaced.

This section describes the steps for greasing the roller.

Fig. 7-4 Greasing the roller

A Grease nippleB Covering

Tab. 7-4 Roller relubrication quantity

D00

0722

A

B

Product size Roller size Relubrication

quantity [g]

TMF-1 40 1.1

TMF-2 52 2.4

TMF-3 72 7.3

TMF-4 90 7.3

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Grease the roller as follows:


2 Remove the covering

3 Use a grease gun to press in the grease(Relubrication quantity according to table above)

The roller has been greased.


Oil change in type NA / NH / FA / FH / AE gearboxes

Always replace the gearbox oil within the specified intervals.

For more information on the oil qualities, refer to chapter 7.2 ’Consumables and auxiliary agents’, 60.

Perform the oil change as follows:

Disassembling adrive with pinion

This section describes the steps for disassembling the drive.




NOTEDo not change the position of the coupling on the motor shaft!

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Fig. 7-5 Disassembling the drive

A Gearbox screwsB GearboxC Motor screwsD MotorE Eccentric ringF Headless set screw

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A B C D

F E

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Disassemble the drive as follows:


2 Secure carriage or axle with transport securing device or lifting device

3 Remove coverings if necessary

4 Remove lubricating pinion if necessary

5 Mark eccentric position

6 Remove the motor, together with the coupling

7 Remove headless set screw

8 Remove the gearbox

The drive has been disassembled.

Changing gearbox oil This section describes the steps for changing the gearbox oil.

CAUTIONOils/greases

Oils and greases are harmful to the environment!

The oils and greases may not get into the drinking water supply:• Take appropriate measures.• Observe the country-specific safety data sheets.• Oils and greases must be disposed of as hazardous waste, even if the to-

tal quantity is small.

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Fig. 7-6 Oil change

A Bleed screwB Filler screwC Drain screw

Change the gearbox oil as follows:

1 Position the gearbox: Drain screw at the bottomFiller and bleed screw at the top

2 Position a suitable container below the drain screw

3 Remove the bleed, filler and drain screw

4 Drain the oil

5 Rinse the gearbox with fresh oil(for oil types, see the Oils chapter)

6 Allow the gearbox to drain

7 Screw in the drain screw

8 Fill up the gearbox through the filler screw(for oil types and quantity, see the Oils chapter)

9 Screw in the bleed and filler screws

The gearbox oil has been changed.

D00

0270

A B

C

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Assembling the drive This section describes the steps for assembling the drive.

Assemble the drive as follows:

1 To assemble the drive, reverse the disassembly steps in section ’Disas-sembling a drive with pinion’, 71

2 Set the tooth flank backlash according to chapter 8.3.5, 90

3 Calibrate the measurement reference plane of the motor (This procedure is described in the documentation of the complete plant or of the motor)

The drive has been assembled.

The oil change has been completed

NOTECalibrate the measurement reference plane after each drive as-sembly.This procedure is described in the documentation of the com-plete system or of the motor!

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8 Repairs

8.1 Introduction

This chapter describes all repair tasks.

Work sequences Perform the work sequences in the order described.

Original spare parts Use only original spare parts. For information on spare parts and wear items, refer to chapter 11 ’Spare part supply’, 111.

Tightening torques If no other specifications have been made, the tightening torques as per chapter 1.5.1 ’Tightening torques for screws’, 11 apply.

8.1.1 Safety


WARNINGAutomatic startup

When work is being performed on the product, there is danger of the ma-chine starting up automatically. This can cause severe or fatal injuries!

Before working in the danger area:• Secure vertical axles (if equipped) against falling• Switch off the main power supply and secure it against being switched on

again (main switch of complete plant)• Before switching on the plant again, make sure that no one is in the dan-

ger area.

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8.2 Special tools, testing and measuring instruments

For repairs, make sure that you have the following special tools, testing and measuring instruments at hand:







Use appropriate lifting units!

Tool Use Item number

Pin-type face spanner Setting the tooth flank backlash (TMF 1)

999 758

Dial gauge Setting the tooth flank backlash

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Tab. 8-1 Special tools, testing and measuring instruments

Micrometer Checking parallelism at the guideways

Inspecting the rack transition

Screw clamps Assembly of the racks

Mounting aid Assembly of rack mod-ule 2.5helical

902282

Assembly of rack mod-ule 3helical

902283

Assembly of rack mod-ule 4helical

902284

Fastening device Blocking the drive pin-ion AE030

0917452

Blocking the drive pin-ion AE045

0917453


0917454


0917447


0917455


0917456

Adjusting tool Adjusting the rollersSize 40/52

0919690

Adjusting the rollersSize 72/90

0915289

Tool Use Item number

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8.3 Repairs

8.3.1 General prerequisites

Prior to performing repair and maintenance tasks, do the following:

• If vertical axles are present, secure them against falling

• Switch off the plant and padlock it to secure it against being switched on again

• Make sure that all spare parts and wear items are at hand(For information on spare parts and wear items, refer to chapter 11 ’Spare part supply’, 111)

8.3.2 Replacing the bumper unit

The bumper unit is a safety component.Replace the entire bumper unit after a crash has occurred.

The buffer unit consists of the following components:

• Bumper

• Bumper block or bumper bracket

• Screws

• Sleeves and/or heavy-duty spring tension pins

WARNINGWeak safety component

After a crash, it is not immediately apparent whether bumper unit elements have been weakened or are defective. Another crash can cause severe or fatal injuries.

Always replace the entire bumper unit!

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8.3.3 Replacing the wiper and felt insert

Continuous lubrication of the guideways at operating temperatures under 0 °C or with grease requires a modification to the wiper and felt insert. This proce-dure is described in the sections:

• ’Preparing the wiper’, 81• ’Preparing the felt insert’, 82

This section describes the steps for replacing the wiper and the felt insert.

Fig. 8-1 Wiper and felt insert

A ScrewsB WiperC Felt insert

Replace the wiper and felt insert as follows:


2 If there is an automatic lubrication, disconnect the supply

3 Remove the screws

4 Replace the wiper

5 Replace the felt insert

6 Only for oil lubrication:Submerge new felt insert in oil for several minutes

D00

0349

A B C

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Repairs

(Oil quality, see chapter 7.2 ’Consumables and auxiliary agents’, 60)

7 To install the wiper and felt insert, reverse the removal steps

8 Only for manual lubrication: Lubricate guideways (See chapter ’Lubricating guideways, racks and pinions’, 66)

9 Only for automatic lubrication:(See separate operating manual on automatic lubrication)

9.1 Connect lubrication line

9.2 Start lubrication procedure(See separate operating manual on automatic lubrication)

The wiper and felt insert have been replaced.

Preparing the wiper This section describes the steps for preparing the wiper. This applies for oil lubrication, operating temperature under 0 °C or grease lubrication.

Fig. 8-2 Preparing the wiper

A WiperB Recess

Prepare the wiper as follows:

1 Attach recess(Mass according to figure)

The wiper has been prepared.

10...12

2.5.

..3

8...10D00

1053

B

A

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Repairs

Preparing the feltinsert

This section describes the steps for preparing the felt insert. This applies for oil lubrication, operating temperature under 0 °C or grease lubrication.

Fig. 8-3 Preparing the felt insert

A ReductionB Slot

Prepare the felt insert as follows:

1 Shorten the felt insert to the 5 mm dimension

2 Increase dimension S by 1 mm(Only for oil lubrication, operating temperature below 0 °C)

The felt insert has been prepared.

5D

0010

35

S +

1

A

B

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8.3.4 Replacing the rollers and guideways

The rollers, guideways and racks are designed for continuous use. Certain ambi-ent conditions can increase the wear on these components.

Replacing the rollers, guideways and racks involves a considerable amount of work. Always replace these components simultaneously.

Roller holder instal-lation types

The roller holders have installation types for setting the roller backlash and tooth flank backlash.

Fig. 8-4 Roller holder installation types

A Installation type (E1): Eccentric zero position, fixed with positioning screwB Installation type (E2): Eccentric infinitely adjustable, fixed with flangeC Installation type (E3): Eccentric adjustable in increments, fixed with positioning screw

D00

0759

+

-

+

-

A B C

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Roller holderarrangement

The roller holders are to be arranged according to the following figure:

Fig. 8-5 Roller holder arrangement

A Roller holder E2 unloadedB Roller holder E1 loadedC Roller supportD E1 roller holderE Gearbox sideF Direction of loadG E2 roller holderH Fastening screws and flange

FullCover option:For this option the roller supports are installed rotated by 90°.Roller holder (A) corresponds thus to the installation type E1 loaded and Roller holder (B) to installation type E2.

Double roller support option:The double roller support has two loaded (B) and two unloaded (A) roller hold-ers.

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3190

A B

D F E D

C

GH

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This chapter describes the steps for replacing the roller.

Fig. 8-6 Replacing the roller

A ScrewB PegC Supporting rollerD Roller holderE CoveringF Positioning screwG FlangeH Fastening screws

Replace the roller as follows:


2 Secure vertical axis, if equipped

3 Support the carriage or secure it to a lifting device

4 Remove fastening screws and flange

5 If there is a positioning screw, remove it

6 Remove the covering

7 Remove the entire roller holder

7.1 Remove screw and peg

7.2 Replace the roller

D00

0753

A B C D E F

G

H

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7.3 To assemble the roller holder, reverse the disassembly steps(Secure screw with Loctite 242, tightening torque according to tab. 1-5, 14)

8 Install E1 roller holder:(Type and arrangement of installation, see chapter ’Roller holder instal-lation types’, 83)

8.1 Fix roller holder in eccentric zero position with positioning screw

8.2 Mount flange

8.3 Tighten fastening screws

9 Install E2 roller holder:

9.1 Turn roller holder to eccentric minimum setting

9.2 Mount flange

9.3 Move fastening screws slightly

10 If it is present, turn E3 roller holder to eccentric minimum setting

11 Remove the securing element, support or lifting device

12 Set roller and tooth flank backlash as per chapter 8.3.5, 90

The roller has been replaced.

Replacing guideways

Replace the guideways as soon as the surfaces show signs of wear.

The term "guideway" includes:

• Guideway• Rack

Replace the guideways as follows:

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Guidewaydisassembly

The designations refer to fig. 8-8, 88.

Remove the guideway as follows:


2 Attach the carriage or axle to a lifting device

3 Expose guideway:

3.1 Remove coverings if necessary

3.2 Move the carriage off the guideway or axle to be replaced if neces-sary

3.3 Extend the vertical axis, if required

4 Remove all screws(See fig. 8-8, 88)

5 Remove the guideways

The guideway has been removed.

Installing theguideway

Proper installation of the guideways in accordance with the regulations is pre-requisite for low-wear use of the product.

Mounting aid The start and end of the rack form a half tooth gap. For precise and low-noise transition, we recommend using a mounting aid geared in the opposite direction (see chapter 8.2 ’Special tools, testing and measuring instruments’, 77).

Fig. 8-7 Mounting aid for rack assembly

A RackB Mounting aid

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A B

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This section describes the steps for installing the guideway.

For axes over 20 meters, the assembly of the guideways must be performed from the middle.

Fig. 8-8 Installing the guideway

A Reference surfacesB ScrewsC Screw clampD Mounting aidE RackF Torque wrenchG ScrewsH Guideway

D00

3156

A H G F

A B A C D E

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Install the guideway as follows:

1 Clean the reference surfaces and guideways thoroughly and rub an oil stone across them

2 Lay first pair of guideways and racks on the reference surface. Lightly tighten with outermost screws (all holes must be aligned)

3 Mount next pair of guides and rack as in step 2

4 Clamp mounting aid to guides and racks with screw clamp

5 Install the rest of the screws and tighten with all the others

6 Inspect transition:

6.1 For guideways with gears, transition according to section ’Inspect-ing rack transition’, 48

6.2 For guideways without gears(gap dimension < 0.02 mm)

7 Use a suitable measuring instrument to check that the guideways are par-allel(tolerance: ±0.04 mm)

8 If deviations occur (transition/parallelism):

8.1 Remove screws and guideway

8.2 Repeat the procedure

The guideway has been installed.

Final tasks The following tasks must be performed after assembly of the guideway.

Perform these final tasks as follows:

1 Move the carriage onto the axle if necessary

2 Retract the vertical axis, if required

3 Remove the lifting device

4 If necessary, adjust the rollers

The final tasks have been performed.

The guideway has been replaced.

The guideways have been replaced.

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8.3.5 Setting rollers and tooth flank backlash

Reset the roller and tooth flank backlash after each roller, guideway or gearbox change.

Blocking the drivepinion

This section describes the steps for blocking the drive pinion. Block the drive pinion in order to check the tooth flank backlash.

Unblock the drive pinion after repair work has been finished. For this purpose, remove the fastening device and place the plug back onto the gearbox.

Fig. 8-9 Blocking the drive pinion

A MotorB CarriageC GearboxD Fastening deviceE Plug

NOTEAlways set the roller backlash and tooth flank backlash with load attached and at operating temperature!

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A

D

B

C

E

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Block the drive pinion as follows:


2 Remove the plug

3 Attach fastening device to gearbox

The drive pinion is blocked.

Setting rollers This section describes the steps for setting the roller

The designations refer to section "Roller holder arrangement".

Adjust the rollers as follows:

1 You may need to make the following preparations:

1.1 Slightly loosen the fastening screws of all E2 roller holders

1.2 Loosen flanges of the E2 roller holders

1.3 Remove coverings if necessary

2 Move the E2 roller holders closer by rotating them clockwise uniformly(For the tightening torque, refer to tab. 1-5, 14)

3 Fixate the position with the flange and the securing screws

4 If there are deviations:

4.1 Check zero position of E1 roller holder

4.2 Repeat process from step 2

5 Move the unloaded E2 roller holders closer by rotating them clockwise uniformly(For the tightening torque, refer to tab. 1-5, 14)

6 Fixate the position with the flange and the securing screws

7 Install coverings if necessary

The rollers have been set.

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Setting the toothflank backlash

This section describes the steps for setting the tooth flank backlash.

Inspect the tooth flank backlash according to the section "Checking the tooth flank backlash". Only adjust if a deviation is detected.

Fig. 8-10 Setting the tooth flank backlash

A GearboxB ScrewC Marking boreD Headless set screwE RackF Eccentric ringG Drive pinions

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3209

A B C D

F EG

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Set the tooth flank backlash as follows:



3 Loosen headless set screw

4 Slightly loosen the gearbox screws

5 Turn eccentric ring with bolt remover or pin-type face wrench (Marking bore near the rack = minimum play; marking bore far away = maximum play)

6 Tighten the gearbox screws

7 Inspect tooth flank backlash according to section "Checking the tooth flank backlash"

8 If there are deviations:

8.1 Slightly loosen the gearbox screws

8.2 Backlash too large: Turn marking bore closer to the rack

8.3 Backlash too small: Turn marking bore away from the rack

8.4 Repeat process from step 6

The tooth flank backlash has been set.

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Checking the toothflank backlash

This section describes the inspection of the tooth flank backlash.

If the axis is not driven with Güdel gearbox type NA / NH / FA / FH / AE, then use the procedure described in the operating manual of the gearbox!

Fig. 8-11 Checking the tooth flank backlash

A CarriageB AxisC GuidewayD RackE GearboxF Drive pinionsG Dial gauge

NOTEThe inexact measurement method described here can lead to in-correct interpretation and subsequent damage of any kind!

Only use it when the exact method is not possible!

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3176

b

A

F

DCB

G E

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The rack quality can be found in tab. 5-3, 48, the module from the rack of the spare parts list in the appendix.

Tab. 8-2 Tooth flank backlash

Check the tooth flank backlash as follows:

1 Measurement method 1 (exact measurement method):

1.1 Block the drive pinion according to the section "Blocking the drive pinion"

1.2 Mount the dial gauge to the guideway

1.3 Mount dial gauge in the direction of travel aligned with the center of the drive pinion

1.4 Zero the dial gauge

1.5 Move the carriage or axle in the direction of travel

1.6 Read the tooth flank backlash on the dial gauge

Tooth flank backlash [mm]

Rack quality Modulem ≤ 3

Module3 < m ≤ 8

Module8 < m ≤ 12

Q4 h21 0.010 0.012 0.016

Q5 h22 0.016 0.019 0.025

Q6 h23 0.025 0.03 0.04

Q7 h25 0.059 0.079 0.099

Q8 h27 0.158 0.198 0.247

Q9 h27 0.158 0.198 0.247

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2 Measurement method 2 (inexact measurement method only when necessary due to weight rea-sons):

2.1 Insert paper strip from DIN A4 80 g/cm3 with width b between drive pinion and rack

2.2 Move carriage or axis with auxiliary agents(Paper strip is "turned through")

2.3 Paper strip worn:Tooth flank backlash <0.05 mm

2.4 Paper strip cut, partially disconnected pieces: Tooth flank backlash ~ 0.05 mm

2.5 Paper strips mildly cut, no disconnected pieces: Tooth flank back-lash ~ 0.07 mm

2.6 Paper strip wavy:Tooth flank backlash ~ 0.1 mm

2.7 Paper strip undamaged:Tooth flank backlash >0.1 mm

3 Interpret tooth flank backlash according to previous table

The tooth flank backlash has been checked.

8.3.6 Replacing the gearbox

This section describes the steps for replacing the gearbox.

Disassemble the drive to replace the gearbox.

Disassembling adrive with pinion

This section describes the steps for disassembling the drive.




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Fig. 8-12 Disassembling the drive

A Gearbox screwsB GearboxC Motor screwsD MotorE Eccentric ringF Headless set screw

NOTEDo not change the position of the coupling on the motor shaft!

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A B C D

F E

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Disassemble the drive as follows:


2 Secure carriage or axle with transport securing device or lifting device



5 Mark eccentric position

6 Remove the motor, together with the coupling

7 Remove headless set screw

8 Remove the gearbox

The drive has been disassembled.

Replacing thegearbox

This section describes the steps for replacing and installing the new gearbox.

Replace and install the gearbox as follows:

1 Replace the gearbox

2 To assemble the drive, reverse the disassembly steps

3 Set the tooth flank backlash according to chapter 8.3.5, 90

4 Calibrate the measurement reference plane of the motor(This procedure is described in the documentation of the complete plant or of the motor)

The gearbox has been replaced and installed.


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8.3.7 Setting the gear backlash

Ex works, the gear backlash is set to a value lower than 6‘. If the backlash increases, it has to be readjusted.

Fig. 8-13 Setting the gear backlash

A Worm shaftB ScrewsC Casing cover

NOTE• Do not remove the casing cover, else the gearbox oil will leak

out!• Always align both casing covers in the identical position!

2

3

4

1

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0317

A

B

C

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Set the gear backlash as follows:


2 Disassemble the drive according to section ’Disassembling a drive with pinion’, 96

3 Remove all screws on both sides

4 Rotate both covers to the next higher, cast-in number

5 Tighten two screws on each of the two sides

6 Check the gear backlash:Rotate the worm shaft 360° by hand

6.1 The shaft does not resist rotation:Repeat from step 3

6.2 The shaft resists rotation:Remove the screws, set both gearbox covers one level lower

7 Insert all screws on both sides and tighten crosswise

8 Check the gear backlash:Rotate the worm shaft 360° by hand

8.1 The shaft resists rotation:Repeat from step 3

The gear backlash has been set.

8.3.8 Replacing motor and coupling

This chapter describes the steps for replacing the motor and the coupling.

Replace the motor and coupling as follows (for descriptions, see fig. 8-14, 102):


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Disassemblingmotor and coupling

This section describes the steps for removing the coupling and the motor.

Remove the motor and the coupling as follows:


2 Loosen the motor screws

3 Pull the motor, together with the coupling, off the gearbox

4 Loosen the coupling screws

5 Pull the coupling off the motor shaft

The motor and the coupling have been removed

Assembling theMotor and coupling

This section describes the steps for assembly of the coupling and the motor.

Depending on the type of transport securing device used, you have to remove the device before installing the motor for the first time (see Section ’Transport securing device at the gearbox’, 55).

WARNINGFalling axes / workpieces

Incorrect tightening torques can lead to falling axes or workpieces. This can cause severe or fatal injuries!

Observe the following:• Calibrate and check the torque wrench periodically• Tighten all screws with a torque wrench to the specified tightening tor-

ques

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Fig. 8-14 Installing the motor and coupling

A GearboxB Motor flangeC Measuring instrumentD CouplingE Coupling screwsF Motor screwsG Motor

Install the motor and the coupling as follows:

1 Clean the coupling and motor shaft to ensure that they are free of grease

2 Measure distance X

3 Push the coupling onto the motor shaft(Dimension Y has to match dimension X, tolerance -0.2 to -0.4 mm)

4 Tighten the coupling screws For the tightening torque, refer to tab. 1-2, 11

5 Grease the gear rim of the coupling(For grease types, see 7.2.2 ’Lubricants’, 60)

6 Push the motor, with the mounted coupling, onto the gearbox

7 Tighten the motor screws

The motor and the coupling have been installed.

The motor and the coupling have been replaced.

X

Y

D00

0111

A B C D GFE

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8.4 Other documents

For information on the available options, read the appropriate documents in the appendix.

8.5 Service departments

If you have questions, please contact the service departments. For a list with their contact information, see chapter 11.2 ’Service departments’, 112.

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Decommissioning, storage

9 Decommissioning, storage

9.1 Introduction

9.1.1 Safety




9.2 Storage conditions

CAUTIONLeaking fluids

During storage, substances that are hazardous to the environment could leak!

Hazardous substances may not get into the drinking water supply:• Take appropriate measures.• Observe the country-specific safety data sheets.• Fluids must be disposed of as hazardous waste, even if the total quantity

is small.

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Room Store the product in a dry location. For information on the required space and the floor capacity, refer to the machine layout or general layout.

Use a covering to protect the product against dust and dirt.

Temperature The ambient storage temperature must remain between -10 and +40°C. Make sure that the product is not subjected to large temperature fluctuations.

Air humidity The air humidity must be below 75%.

9.3 Decommissioning

9.3.1 Shutdown

This chapter provides information on shutting down the product.





NOTEDo not empty the lubrication lines and the gearbox when shut-ting down the product!

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To shut down the product, proceed as follows:

1 Fixate the axles

2 Shut down the plant(main switch of complete system)

3 Disconnect the supply lines for energy and consumables

4 Automatic lubrication system (optional): Unscrew the lubricator and remove the batteries

The product has been decommissioned.

9.3.2 Cleaning / rust-proofing

Prior to performing rust-proofing, clean away any dirt and dust from the prod-uct. Clean the product thoroughly.

Apply corrosion protection to all parts.

9.3.3 Transport securing device

On unbraked motors, mount the transport securing devices.

9.3.4 Labeling

Label the product with the following data:

• Date of decommissioning

• Internal machine number/name

• Further data as per internal guidelines

NOTEDispose of any cloths soaked in oils and/or greases in an environ-mentally friendly manner! For more information on disposal, re-fer to chapter 10 ’Disposal’, 108.

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9.4 Recommissioning

For recommissioning, follow the steps described for commissioning.

Prior to recommissioning, perform the general inspection as set out in chapter 7.4 ’Maintenance tasks’, 65. Perform the required maintenance tasks and repairs.

If the machine has been standing still for more than one year, perform the fol-lowing tasks:

• Change the gearbox oil

• Rinse the lubrication lines with fresh lubricant

• Replace the felt inserts and lubricating pinions

• Check the gaskets and replace if necessary

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Disposal

10 Disposal

10.1 Introduction

Observe the following during disposal:

• Adhere to the country-specific regulations• Separate the material groups• Dispose of the materials in an environmentally friendly way• Recycle waste if possible

10.1.1 Safety




10.2 Disposal

Your product consists of the following units:

• Packaging • Contaminated materials /auxiliary agents (oil paper)• Wood• Plastic (film)

• Consumables• Lubricants (oils/greases)• Batteries

• Base unit• Metals (steel/aluminum)• Plastics (thermoplasts/duroplasts)• Contaminated materials/auxiliary agents (felt/cleaning cloths)• Electrical material (cables)

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10.3 Waste management compliant assemblies

10.3.1 Disassembly

This chapter describes how to disassemble the product.

Prior to disassembly, shut down product as described in chapter 9.3.1 ’Shut-down’, 105.

Disassemble the product as follows:

1 Remove connecting elements(cables / energy chains)

2 Dismount mobile axes

3 Remove the gearbox and drain the oil

4 Dismount the carriage

WARNINGSuspended loads

Improper handling of suspended loads can lead to severe injuries or death!

Observe the following:• Use appropriate lifting units• Wear appropriate protective clothing• Always keep sufficient distance to suspended loads• Never enter the area below a suspended load

CAUTIONOils/greases

Oils and greases are harmful to the environment!

The oils and greases may not get into the drinking water supply:• Take appropriate measures.• Observe the country-specific safety data sheets.• Oils and greases must be disposed of as hazardous waste, even if the to-

tal quantity is small.

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5 Dismount fixed assemblies(axes/columns)

6 Take the assemblies apart and separate the different materials.

The product has been disassembled.

10.3.2 Material groups

Dispose of the material groups in accordance with the following table.

Tab. 10-1 Disposal: material groups

10.4 Disposal facilities, authorities

The disposal facilities and authorities differ from country to country. Observe the local laws and regulations on disposal.

Material Disposal route

Contaminated mate-rials/auxiliary agents

Hazardous waste

Wood Municipal waste

Plastic Collecting point or municipal waste

Lubricants Collecting pointDisposal in accordance with the safety data sheets 3.4.4 ’Safety data sheets (MSDS)’, 28

Batteries Battery collection

Metals Scrap metal collection

Electrical material Electrical rubbish

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Spare part supply

11 Spare part supply

11.1 Explanations regarding the spare parts list

The spare parts list can be found in chapter 13 ’Appendix’, 117. It contains position drawings and the complete parts list of your product.

11.1.1 Positioning drawings

The positions of the spare parts can be seen on the drawings. These are stand-ard drawings. Individual positions or images might differ from your product.

11.1.2 Parts list

The parts list contains all parts of your product. The spare parts and wear items are indicated as described in the explanation of symbols.

Explanation ofsymbols

Fig. 11-1 Explanation of symbols

A Spare part statusB Availability

14.07.2008 / Page 1 of 1

BCH034580 VS0035 2-Amod ZP-4 M MO mec 3.10 10947-001A

WEtinUytitnauQgniwarDtxeTrebmun metInoitisoP

300 V000134 Y ktS1230-32580029=L V 52-022/022PL sixA-

EktS770.002.71.093SUGI 0.002.71.093 niahc ygrenE4001410203 A

400 0916667 Y ktS2030-32584-PZ egairraC-900 406015-10.00 Worm gear unit AE060/L left

Ratio i=10.00

AE060 2 Stk E B

910 406089 Motor flange 060 18x116x116 ø130/110 8030-018a 2 Stk E C

1000 0910499 Mechanical multi limit switch accessories 750 Y 8523-024 2 Stk

1100 230803 Felt pinion for lubrication

ø40.6x20, Modul m=2.387 pitch P=7.5, Z=15

8102-039d 1 Stk V A

Güdel AGInsustrie Nord

CH-4900 Langnethalphone +41 62 916 91 91fax +41 62 916 91 [email protected]

D00

0094

A

B

Spare part status (column E): EV

==

Spare partWear item

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Spare part supply

The information on availability is given without warranty. The delivery times might in some cases differ.

11.2 Service departments

If you have questions on service, please use the service form at www.gudel.com or contact the offices in the appropriate country:

For urgent service requests, our Helpdesk provides after-hour assistance (24-hour support):

Please have the following information, as labeled on the type plate, at hand:

• Serial no.• Part list no. • Drawing number (if applicable)

Availability (column W): ABC

===

Available from stockDelivery time approx. 2 - 3 weeksDelivery time upon request

Germany: +49 6291 6446 41

Great Britain: +44 24 7669 5444

India: +91 20 5622 7165

Italy: +39 02 9217021

South Korea: +82 2168 98 00

Taiwan: +88 635 97 8808

USA: +1 734 214 0000

All other countries and Switzerland:+41 62 916 91 91

Europe/Asia: +41 62 916 9170

USA: +1 248 456 0440

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Index

12 Index

AAppendix . . . . . . . . . . . . . . . . . . . . . . . 117Arrangement

Roller holder . . . . . . . . . . . . . . . . . . 84Assembly . . . . . . . . . . . . . . . . . . . . .36, 45

Coupling . . . . . . . . . . . . . . . . . .49, 101Drive . . . . . . . . . . . . . . . . . . . . . . . . . 75Guideway . . . . . . . . . . . . . . . . . .45, 87Motor . . . . . . . . . . . . . . . . . . . . . . . . 49Robot . . . . . . . . . . . . . . . . . . . . . . . . 52

Assembly instructions for partly completed machinery . . . . . . . . . . . 9

AttachingOptional components . . . . . . . . . . 51Slings . . . . . . . . . . . . . . . . . . . . . . . . . 38

Authorities . . . . . . . . . . . . . . . . . . . . . 110Auxiliary agents . . . . . . . . . . . . . . . . . . 60Axis names . . . . . . . . . . . . . . . . . . . . . . 33

BBase fixing . . . . . . . . . . . . . . . . . . . . . . . 41

Adhesive anchor . . . . . . . . . . . . . . . 42Welded joint . . . . . . . . . . . . . . . . . . 43

BlockingDrive pinion . . . . . . . . . . . . . . . . . . . 90

Bumper unitReplacing . . . . . . . . . . . . . . . . . . . . . 79

CCables and lines . . . . . . . . . . . . . . . . . . 53Change

Gearbox oil . . . . . . . . . . . . . . . . . . . 73Changes . . . . . . . . . . . . . . . . . . . . . . . . . 21Checking

Delivery . . . . . . . . . . . . . . . . . . . . . . 36Cleaning . . . . . . . . . . . . . . . . . . . . . . . . 106Cleaning agents . . . . . . . . . . . . . . . . . . . 60Commissioning . . . . . . . . . . . . . . . . . . . 34Connecting

Profiles . . . . . . . . . . . . . . . . . . . . . . . 40

Consumables . . . . . . . . . . . . . . . . . . . . 60Coupling

Assembling . . . . . . . . . . . . . . . . . . 101Assembly . . . . . . . . . . . . . . . . . . . . . 49Disassembly . . . . . . . . . . . . . . . . . 101Replacing . . . . . . . . . . . . . . . . . . . . 100

DDeclaration of incorporation . . . . . . 22Decommissioning . . . . . . . . . . . 104, 105Delivery

Checking . . . . . . . . . . . . . . . . . . . . . 36Design . . . . . . . . . . . . . . . . . . . . . . . . . . 29Disassembly . . . . . . . . . . . . . . . . . . . . 109

Coupling . . . . . . . . . . . . . . . . . . . . 101Drive with pinion . . . . . . . . . . . 71, 96Guideway . . . . . . . . . . . . . . . . . . . . 87Motor . . . . . . . . . . . . . . . . . . . . . . 101

Disposal . . . . . . . . . . . . . . . . . . . . . . . . 108Disposal facilities . . . . . . . . . . . . . . . . 110Drive

Assembly . . . . . . . . . . . . . . . . . . . . . 75Disassembly with pinion . . . . . 71, 96

Drive pinionBlocking . . . . . . . . . . . . . . . . . . . . . . 90

EExplanation

Abbreviation . . . . . . . . . . . . . . . . . . 10Symbols . . . . . . . . . . . . . . . . . . . . . . 10

Explanation of abbreviations . . . . . . . 10Explanation of symbols . . . . . . . . . . . . 10

FFastening . . . . . . . . . . . . . . . . . . . . . . . . 37Felt insert

Preparing . . . . . . . . . . . . . . . . . . . . . 82Final tasks . . . . . . . . . . . . . . . . . . . . . . . 89Function . . . . . . . . . . . . . . . . . . . . . . . . 29

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Functional check . . . . . . . . . . . . . . . . . . 56Functional description . . . . . . . . . . . . . 33Fundamentals of safety . . . . . . . . . . . . 27

GGearbox

Oil change . . . . . . . . . . . . . . . . . . . . 73Replacing . . . . . . . . . . . . . . . . . .96, 98Setting the backlash . . . . . . . . . . . . 99

General inspection . . . . . . . . . . . . . . . . 67General rules for occupational safety .

21Greases . . . . . . . . . . . . . . . . . . . . . . . . . 62Guideway

Assembly . . . . . . . . . . . . . . . . . .45, 87Disassembly . . . . . . . . . . . . . . . . . . . 87Lubricating . . . . . . . . . . . . . . . . . . . . 66Replacing . . . . . . . . . . . . . . . . . . . . . 86

HHazard symbols

Operating manual . . . . . . . . . . . . . . 23Product . . . . . . . . . . . . . . . . . . . . . . 26

Hazard warningCaution . . . . . . . . . . . . . . . . . . . . . . 23Danger . . . . . . . . . . . . . . . . . . . . . . . 23Note . . . . . . . . . . . . . . . . . . . . . . . . . 23Warning . . . . . . . . . . . . . . . . . . . . . . 23

IIdentification

Lubrication points . . . . . . . . . . . . . 60Improper handling of cables . . . . . . . . 53Inspecting

Rack transition . . . . . . . . . . . . . . . . 48Installation instructions . . . . . . . . . . . . 21

LLabeling . . . . . . . . . . . . . . . . . . . . . . . . 106Liability . . . . . . . . . . . . . . . . . . . . . . . . . . 21Load

Attaching . . . . . . . . . . . . . . . . . . . . . 51

Lubricants . . . . . . . . . . . . . . . . . . . . . . . 60Lubricating

Guideways . . . . . . . . . . . . . . . . . . . . 66Pinions . . . . . . . . . . . . . . . . . . . . . . . 66Racks . . . . . . . . . . . . . . . . . . . . . . . . 66

Lubricating pinionReplacing . . . . . . . . . . . . . . . . . . . . . 69

MMaintenance . . . . . . . . . . . . . . . . . . 58, 76

10000 hours . . . . . . . . . . . . . . . . . . 71150 hours . . . . . . . . . . . . . . . . . . . . 662000 hours . . . . . . . . . . . . . . . . . . . 69500 hours . . . . . . . . . . . . . . . . . . . . 67Schedule . . . . . . . . . . . . . . . . . . . . . 64Tasks . . . . . . . . . . . . . . . . . . . . . . . . 65

Maintenance schedule . . . . . . . . . . . . 64Maintenance tasks 100 hours after

commissioning . . . . . . . . . . . . . . . . 65Material groups . . . . . . . . . . . . . . . . . 110Measuring instruments . . . . . . . . . . . . 77Monitoring equipment . . . . . . . . . . . . 27Motor

Assembling . . . . . . . . . . . . . . . . . . 101Assembly . . . . . . . . . . . . . . . . . . . . . 49Disassembly . . . . . . . . . . . . . . . . . 101Replacing . . . . . . . . . . . . . . . . . . . . 100

Mounting aid . . . . . . . . . . . . . . . . . . 45, 87

OOil change

Gearbox . . . . . . . . . . . . . . . . . . . . . 71Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61Operating personnel . . . . . . . . . . . . . . 20Operation . . . . . . . . . . . . . . . . . . . . . . . 57Optional components

Attaching . . . . . . . . . . . . . . . . . . . . . 51Options . . . . . . . . . . . . . . . . . . . . . . . . . 19Other documents . . . . . . . . . . . . . . . 103

PPackaging symbols . . . . . . . . . . . . . . . . 35Parts list . . . . . . . . . . . . . . . . . . . . . . . 111

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Index

Personnel qualification .34, 59, 77, 104, 108

PinionLubricating . . . . . . . . . . . . . . . . . . . . 66

Position drawings . . . . . . . . . . . . . . . . 111Preparing

Felt insert . . . . . . . . . . . . . . . . . . . . . 82Wiper . . . . . . . . . . . . . . . . . . . . . . . . 81

Prerequisites . . . . . . . . . . . . . . . . . . . . . 36Base . . . . . . . . . . . . . . . . . . . . . . . . . . 36Lifting unit . . . . . . . . . . . . . . . . . . . . 36Lines . . . . . . . . . . . . . . . . . . . . . . . . . 36Maintenance, repair . . . . . . . . .65, 79Positioning . . . . . . . . . . . . . . . . . . . . 36

ProductDescription . . . . . . . . . . . . . . . . . . . 17Designation . . . . . . . . . . . . . . . . . . . 18Integrating . . . . . . . . . . . . . . . . . . . . 52Positioning . . . . . . . . . . . . . . . . . . . . 39Safety . . . . . . . . . . . . . . . . . . . . . . . . 20

Product-specific hazards . . . . . . . . . . . 27Profiles

Connecting . . . . . . . . . . . . . . . . . . . 40Protective measures . . . . . . . . . . . . . . 21Purpose of the document . . . . . . . . . . . 9

RRack

Inspecting transition . . . . . . . . . . . . 48Lubricating . . . . . . . . . . . . . . . . . . . . 66

Recommissioning . . . . . . . . . . . . . . . . 107Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . 79Replacing

Bumper unit . . . . . . . . . . . . . . . . . . . 79Coupling . . . . . . . . . . . . . . . . . . . . . 100Gearbox . . . . . . . . . . . . . . . . . . .96, 98Guideway . . . . . . . . . . . . . . . . . . . . . 83Guideways . . . . . . . . . . . . . . . . . . . . 86Lubricating pinion . . . . . . . . . . . . . . 69Motor . . . . . . . . . . . . . . . . . . . . . . . 100Roller . . . . . . . . . . . . . . . . . . . . . . . . 83

Residual danger . . . . . . . . . . . . . . . . . . 20Robot

Mounting . . . . . . . . . . . . . . . . . . . . . 52Roller backlash

Setting . . . . . . . . . . . . . . . . . . . . . . . . 90Roller holder

Arrangement . . . . . . . . . . . . . . . . . . 84

Installation types . . . . . . . . . . . . . . 83Roller holder installation types . . . . . 83Rust-proofing . . . . . . . . . . . . . . . . . . . 106

SSafety . . . . . . . . . 20, 34, 59, 76, 104, 108Safety data sheets . . . . . . . . . . . . . . . . 28Safety equipment . . . . . . . . . . . . . . . . . 27safety regulations

disregarding . . . . . . . . . . . . . . . . . . . 21Screw locked . . . . . . . . . . . . . . . . . . . . 11Service departments . . . . . . . . . . . . . 112Setting

Gear backlash . . . . . . . . . . . . . . . . . 99Roller backlash . . . . . . . . . . . . . 90, 91Tooth flank backlash . . . . . . . . 90, 92

Setting the roller backlash . . . . . . . . . 91Setting the tooth flank backlash . . . . 92Setup . . . . . . . . . . . . . . . . . . . . . . . . 36, 37Shutdown . . . . . . . . . . . . . . . . . . . . . . 105Slings

Attaching . . . . . . . . . . . . . . . . . . . . . 38Spare part supply . . . . . . . . . . . . . . . . 111Spare parts list . . . . . . . . . . . . . . . . . . 111

Explanation of symbols . . . . . . . . 111Explanations . . . . . . . . . . . . . . . . . 111

Special symbols . . . . . . . . . . . . . . . . . . 25Special tools . . . . . . . . . . . . . . . . . . . . . 77Storage . . . . . . . . . . . . . . . . . . . . . . . . 104Storage conditions . . . . . . . . . . . . . . 104

TTarget readership . . . . . . . . . . . . . . . . 10Technical data . . . . . . . . . . . . . . . . . . . 19Temperature ranges . . . . . . . . . . . . . . 19Testing instruments . . . . . . . . . . . . . . 77Thread rolling screws . . . . . . . . . . . . . 16Tightening torques

HV sets . . . . . . . . . . . . . . . . . . . . . . 13Roller holders . . . . . . . . . . . . . . . . . 14Roller support . . . . . . . . . . . . . . . . 15Screws . . . . . . . . . . . . . . . . . . . . . . . 11

Tooth flank backlashInspecting . . . . . . . . . . . . . . . . . . . . 94Setting . . . . . . . . . . . . . . . . . . . . . . . 90

Torque tables . . . . . . . . . . . . . . . . . . . . 11

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Index

Training of operating personnel . . . . 57Transport . . . . . . . . . . . . . . . . . . . . . . . 35Transport securing devices . . . .55, 106Type plate . . . . . . . . . . . . . . . . . . . . . . . 18

UUnpacking . . . . . . . . . . . . . . . . . . . . . . . 36Use

Improper . . . . . . . . . . . . . . . . . . . . . 17Intended . . . . . . . . . . . . . . . . . . . . . . 17Purpose . . . . . . . . . . . . . . . . . . . . . . 17

WWarning symbols . . . . . . . . . . . . . . . . . 25Waste management compliant assemblies 109Wiper

Preparing . . . . . . . . . . . . . . . . . . . . . 81

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Appendix

13 Appendix

The appendix of this operating manual contains the following documents:

• Hazard analysis / Risk analysis

• Layout

• Options

• Third-party products

• Spare parts list

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Hazard analysis / Risk analysis

Hazard analysis / Risk analysis

Ligh

t

Med

ium

Sev

ere

Rar

e

Ofte

n

Fre

quen

t

A B C D E F G H I J K L M 1 4 10 1 2 3 The following should be prevented:

1.1 x x x x x x x x x x x x x x

Processing of hazardous materials.Fire and danger of explosionThermal factors

All Noncompliance with the intended use Persons are injured or killed x x 10 3/d Intended use of the product.

A Güdel device is only used to bring objects to a specific position, hold them there or to move simultaneously with other machine movements.No hazardous (e.g. poisonous or explosive) objects may be moved. A Güdel device may not be operated in a potentially explosive area. The ambient temperature during operation must be between 12° and 40 °C.

If the intended use is modified, hazards can results that are not covered by the safety concept.

x J

1.2 x x x x x x x x Suspended loads

TechniciansCommissio

ning technicians

Improper use of lifting equipmentPerson is surprised by unexpected movement and injured or killed as a result.

x x 10 3/d No persons may be injured by falling parts.Use appropriate lifting equipment. Wear protective

clothing. Keep a safe distance.Do not walk under suspended loads. x J

1.3 x

Movement of the axes.Suspended loads(Z-axis and workpieces)

OperatorMaintenance

personnel

Gripper problemsDefective motor brakeGeneral problems in the drive train

Person is surprised by vertical movement and injured as a result. x x 20 3/d

The areas of movement must be secured so that neither operating personnel nor third parties can reach or walk into the hazardous locations where automatic movements are performed.

The areas of movement must be enclosed by light grids,

light curtains as well as mechanical safety fences so that

it is impossible to enter this area from any direction.

There must be door elements or light curtains that allow

entry into the danger area or to a portion of the danger

area.

The height of the safety fences is described in EN ISO

13857.

Safety shutdown situation:

The vacuum system remains active in a de-energized

state.

Door elements: when opening the danger area, a safety

shutdown is performed for at least the drives that pose a

hazard in this area.

The door elements are also locked electromechanically.

Light barriers: these are to be monitored so that when

contact is broken, at least the drives that pose a hazard

in this area are shutdown. The distance between the

source of the danger and the light barriers is described

in EN 999 Art. 6.

In normal operation, all protective hoods must be closed, removable protective hoods must be screwed securely.Required behavior:Inspect the protective hoods before starting normal operation. Safety shutdown situation: do not walk under suspended workpieces and Z-axes.

x J

1.4 xManual workstations

Operator Automatic movements at the manual workstationPerson is surprised by the automation, body parts are crushed and injuries result.

x x 20 3/d

It must be ensured that neither operating personnel nor third parties are injured during manual insertion and ejection of the workpieces.

Insertion or ejection axes may only be moved in jog

mode or with two-hand operation. The drive

configuration is such that at the maximum speed of the

drive motor only a slow axis speed is achieved. The

operating elements for insertion and ejection must be

configured so that the operator has a clear view onto

the movement and cannot be endangered. Areas where

body parts could be crushed are to be prevented with

design measures to the greatest possible extent.

Extra attention is required of the operator at manual workstations.Only perform movements if no other person is in the danger area and none of your own body parts are in the line of danger of the corresponding axis

x J

1.5 x Parts that are flung outOperator

Third parties

Parts clamped improperlyBreakage of rotating tools

Person is surprised by parts flying away and injured as a result x x 10 3/dIt must be ensured that neither operating personnel nor third parties are injured by parts that become loose and fly off.

Mechanical guards must be placed in the possible flight

path of parts that could fly off.

Safety devices are inspected using calculations and

trials.

In normal operation, all protective hoods must be closed, removable protective hoods must be screwed securely.Required behavior: Inspect the protective hoods before starting normal operation.

x J

1.6 x x x x x x x Electrical hazard

OperatorMaintenance

personnel

Technicians

Touching the machineDefective insulationImproper el. installationUnsuitable components

Person suffers an electric shock and is injured or killed as a result. x x 10 3/dIt must be ensured that neither operating personnel nor third parties are injured by direct or indirect electrical contact.

Only contact-protected components are to be used.Before working on electrical installations, always disconnect the system (plug/main switch) and double check.Work on electrical installations, switch cabinets and devices may only be performed by authorized specialists.Control cabinet fuses

Work on electrical installations requires expertise and extra care.

x J

1.7 x Disruption of the energy supply

OperatorMaintenance

personnel Power failure, lightning Person is surprised by unexpected movement and injured as a result. x x 10 3/dThe effects of a power failure must not be dangerous for the operator or for third parties.

The movement of the drives is mechanically limited in case the supply voltage fails (mechanical stops and holding brakes).The movement of the drives is braked if the supply

voltage fails

The operator and third parties are outside the danger

area.

After a crash, defective elements of the mechanical stops cannot necessarily be recognized immediately. The entire bumper unit must always be replaced.

x J

1.8 x Malfunction of the control system

OperatorMaintenance

personnel Failure of control unit components Person is surprised by unexpected movement and injured as a result. x x 10 3/dThe effects of a control system malfunction must not be dangerous for the operator or for third parties.

The areas of movement are to be encompassed by

mechanical safety fences and light curtains and light

grids so that it is not possible to enter this area from any

side.

Movements must transition to static states as quickly as

possible.

In normal operation, all protective hoods must be closed, removable protective hoods must be screwed securely.Required behavior: Inspect the protective hoods before starting normal operation.

x J

Hazard analysis / risk assessment

Safety goal

(negation of the event)

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Risk assessment/safety goals/protective measures/residual risks1)

Solution suggested to the customer (cursive, Times New Roman)

Güdel solution (Arial)

Saf

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requ

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[Y/N

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Residual risks

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Customer:

Machine type: all modules without control system

Project no.:

Document no.:

Copyright © 2009 by GÜDEL AG Process owner: M. Knuchel Version 30 / Risikobeurteilung_en.xls Page1 / 3

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Customer:


Project no.:

Document no.:

1.9 x x x x x Malfunction of protection measures

OperatorMaintenance

personnelAging, fatigue fracture, failure due to vibration or overloading

Person is surprised by unexpected situation and injured as a result. x x 10 3/d Averting an emerging hazard

The plant is equipped with emergency stop devices,

which trigger an emergency stop of the plant. A lock-out

(overview of the switch off locations) draws attention to

the switch-off devices.

Do not walk under suspended workpieces or Z-axes. Only possible in setup mode.Permanent workstations are not permitted in the direction of movement of the axes.

x J

1.1 x

Movement of the axes.Suspended loads(Z-axis and workpieces)

TechniciansRemoval of transport securing device without supporting suspended loads and axes.

Person is surprised by unexpected movement and injured as a result. x x 10 3/dIt must be ensured that suspended loads do not fall down.

Before removing the transport securing device, support

the suspended loads or axis.Do not walk under suspended loads. x J

1.11 x x x xMovement of the axes.Parts that are flung out

OperatorMaintenance

personnelCleaning

personnel

Unexpected start Person is surprised by unexpected situation and injured as a result. x x 10 3/dIt must be ensured that an expected start of moving parts is prevented.

A start-up of the plant without the permissive button

being pressed must be prevented.

With the permission device pressed, moving plant parts

can be moved in a controlled manner, even if the plant

is unsecured.

When the permissive button is pressed, it must not be

possible for the operator to be endangered by an

automatic movement triggered by a third party.

Do not walk under suspended workpieces and Z-axes.

In confirmation mode, the operator must pay great attention and have a high level of individual responsibility.

x J

1.12 x Movement of the axes. Setters Unexpected start Person is surprised by unexpected situation and injured as a result. x x 10 3/d

When the permissive button is pressed, it must not be possible for the operator to be endangered by an automatic movement triggered by a third party.

Axes can only be moved individually by one two-hand

operating device in jog mode. For multiple carriages on

one gantry, the individual carriages must be selected

using a key switch. The permissive button is a "shock

button".

For the permissive button to be activated, only one

safety door may be open and the others must be closed

and reset. Safety-relevant parts of the control are

inspected in appropriate time intervals by the machine

control system.

In confirmation mode, the operator must pay great attention and have a high level of individual responsibility. Only perform movements if no other person is in the danger area and none of your own body parts are in the line of danger of the corresponding axis.

x J

1.13 xSuspended loads.(Z-axes, telescopic axes, counter balance cylinders and workpieces)

Setters

Gripper problemsDefective motor brakeTorn belt (telescopic axis)Pressure drop (load balancing)General problems in the drive train

Person is surprised by unexpected situation and injured as a result. x x 10 3/d

It must be ensured that no persons can be endangered by Z-axes, telescopic axes and workpieces that fall down when the permissive button is not pressed.

Grippers must remain in the de-energized state in the

clamp position.

For very frequent set-up under Z-axes, Z-axes can be

secured redundantly with an additional brake on the

pinion and the motor brake.

Telescopic axes: and load balancing cylinders: Special

attention is required here. The axis (for a telescopic

axis, the 2nd stage) is to be secured with a mechanism.

Operation in setup mode only when the safety area is

closed off.

Do not walk under suspended workpieces or Z-axes. Take especial care with telescopic axes. Inspect belts before every setup procedure for cracks and tears.

x J

1.14 xSuspended loads.(Z-axes, telescopic axes, counter balance cylinders and workpieces)

Setters Inattention and/or careless operation by operator Person is surprised by unexpected situation and injured as a result. x x 10 3/dWorkpieces must not be dropped accidentally.

Grippers can only be operated in the storage position.

Do not walk under suspended workpieces or Z-axes. Take especial care with telescopic axes. Inspect belts before every setup procedure for cracks and tears.

x J

1.15 x Parts that are flung outSetters

Third parties

Gripper problemsDefective motor brakeTorn belt (telescopic axis)Pressure drop (load balancing)General problems in the drive train

Person is surprised by parts flying away and injured as a result x x 10 3/d No parts may be flung out.The axes can only be moved with reduced speed.

Rotating parts must be shut down securely.

Work in this mode requires a high level of individual responsibility from the operator. Only perform movements if no other person is in the danger area and none of your own body parts are in the line of danger of the corresponding axis.

x J

1.16 x x Disruption of the energy supply Setters Power failure, lightning Person is surprised by unexpected situation and injured as a result.The effects of a power failure must not be dangerous for the operator or for third parties.

The movement of the drives is limited by mechanical stops in case the supply voltage fails. The drives have already been switched off in case of a

power failure (safety shutdown situation). The

movement of the drives is braked in case of supply

voltage failure by the motor brake or holding brake in

the drive train.

After a crash, defective elements of the mechanical stops cannot necessarily be recognized immediately. The entire bumper unit must always be replaced.

x J

1.17 x Malfunction of the control system Setters Failure of control unit components Person is surprised by unexpected movement and injured as a result. x x 10 3/dThe risk of possible hazard must be kept as low as possible.

Only drive systems are used. They comply with the state

of the art and the standards referenced in the machine

directives.

Work in this mode requires a high level of individual responsibility from the operator. There is no way to completely ensure that a malfunction of the control system does not create a dangerous situation by moving the axes.The operator must therefore try to never be in the possible direction of travel of the axes and ensure that no third parties are in the possible danger zones.

x J


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Residual risks

Ope

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Protective measures


Affe

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Customer:


Project no.:

Document no.:

1.18 x x xMovement of the axes.Parts that are flung out

Service personnelCleaning personnel

Unexpected start Person is surprised by unexpected situation and injured as a result. x x 10 3/d Starting up the plant must be prevented.The lockable main plant switch breaks all main and

control circuits.

If motors or gearboxes are removed, vertical axes must always be secured or supported.

x J

1.19 x x x

Suspended loads(Z-axes, telescopic axes, counter balance cylinders and workpieces)

Service personnelCleaning personnel

Unexpected startDefective motor brakeTorn belt (telescopic axis)Pressure drop (load balancing)General problems in the drive trainDisassembly of the Z-axis motor

Person is surprised by unexpected situation and injured as a result. x x 10 3/d Z-axes falling down must be prevented.

Workpieces must be deposited beforehand in automatic

or setup mode.

Z-axes must be secured with the Z-axes device or with

the transport securing device.

Telescopic axes must be secured against falling down

with appropriate auxiliary means (cables, auxiliary

supports, etc.).

Avoid walking under suspended workpieces or Z-axes. Take especial care with telescopic axes. Inspect belts before every maintenance procedure for cracks and tears.Workpieces must be deposited beforehand in automatic or setup mode.Z-axes must be secured with the Z-axes device or with the transport securing device.Telescopic axes must be secured against falling down with appropriate auxiliary means (cables, auxiliary supports, etc.).

x J

1.20 x x Incorrect assembly All Incorrectly assembled plant Person is surprised by unexpected situation and injured as a result. x x 10 3/d Incorrect assembly must be prevented. The content of the operating manual is known.

Before a Güdel device is transported to the location of use, unpacked, assembled and commissioned, the operating manual must first be read and understood.

x J

1.21 x x Loss of stability All Inattention and/or careless operation Machine/plant tips over x x 10 3/dTipping over or falling down of equipment must be prevented.

Equipment without base supports:To connect to customer supports, the specified screw configuration according to the Güdel layout must be used with the corresponding screws.Equipment with base supports:The supplied screws for assembly must be used.For the connection of the supports to the floor, the anchoring suggestion according to the Güdel layout must be taken into consideration.Fall protection must be mounted for surface gantries.

Check the connections that are responsible for the stability of the device before starting the plant. The operating manual must be read and understood.

x J

1.22 xImproper disposal can cause environmental damage.

All Disposal regulations are not observed Environmental hazard x x 10 3/dThe device and its consumables must be disposed of accordingly after the end of its service life.

Statewide regulations regarding disposal of the plant must be observed.

x J

1) Protective measures (comments):

The suggested solutions printed in italics are binding suggestions for achieving CE conformity.We point out, however, that before commissioning of the plant, suitable protective measures must be implemented for all hazards to ensure CE-compliant use of the Güdel devices. According to the CE Machinery Directive 2006/42/EC, these suitable protective measures, including all modifications, must comply with the "state of the art" and ensure the necessary safety category. If not all protective measures are implemented for any reason, or if any protective measures supplied and/or installed by Güdel have been been modified or not installed, Güdel will not commission the plant and will not assume liability or provide a warranty relating to any resulting events.



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Layout

Layout


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Options

Options


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Third-party products

Third-party products


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Spare parts list

Spare parts list

BA TMF 1-4 - Сервотехника Нева20TMF$201-4$20english.pdf · TMF Size 1-4 Project:...

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Transcript of BA TMF 1-4 - Сервотехника Нева20TMF$201-4$20english.pdf · TMF Size 1-4 Project:...