fp-1 to 5

MODULES ROBOTICS SYSTEMSCOMPONENTS

OPERATING MANUAL

FP Size 1-5

Project: Bill of materials:

Axxxxxxx09xxxxx

2OPERATING MANUAL FP

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by GDEL 2010

Translation of the original operating manual

Version a

Author robman

GDEL 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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Table of contentsTable of contents

1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1.1 Purpose of the document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1.2 Target readership . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1.3 Characters / Explanation of abbreviations . . . . . . . . . . . . . . . . . . . . . 8

1.4 Torque tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

1.4.1 Tightening torques for screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81.4.2 Tightening torques for HV sets . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101.4.3 Tightening torques for roller holders . . . . . . . . . . . . . . . . . . . . . . . . 111.4.4 Tightening torques for roller supports . . . . . . . . . . . . . . . . . . . . . . . 12

2 Product description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

2.1 Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

2.1.1 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132.1.2 Non-intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

2.2 Product designation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

2.3 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

2.4 Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

3 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

3.1.1 Product safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173.1.2 Operating personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173.1.3 Failure to comply with safety regulations . . . . . . . . . . . . . . . . . . . . . 18

3.2 Declaration of incorporation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

3.3 Hazard symbols and instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

3.3.1 Hazard symbols in the operating manual . . . . . . . . . . . . . . . . . . . . . 20Hazard warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20Warning symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21Special symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

3.3.2 Hazard symbols on the product . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

3.4 Fundamentals of safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243

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Table of contents3.4.1 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243.4.2 Safety and monitoring equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . 243.4.3 Product-specific hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Danger due to electric current. . . . . . . . . . . . . . . . . . . . . . . . . . . 24Danger due to falling axes/workpieces . . . . . . . . . . . . . . . . . . . . . 25

3.4.4 Safety data sheets (MSDS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

4 Design and function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

4.1 Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

4.2 Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

5 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

5.1.1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285.1.2 Personnel qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

5.2 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

5.3 Positioning, assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

5.3.1 Prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305.3.2 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305.3.3 Positioning, fastening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Base fixing with adhesive anchor . . . . . . . . . . . . . . . . . . . . . . . . . 35Base fixing with welded joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

5.3.4 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 385.3.5 Transport securing device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

5.4 Function check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

6 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

7 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51


7.2 Consumables and auxiliary agents . . . . . . . . . . . . . . . . . . . . . . . . . . 53

7.2.1 Cleaning agents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 534

7.2.2 Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

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Table of contentsMarkings at the lubricating points. . . . . . . . . . . . . . . . . . . . . . . . . 53Oils. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54Greases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

7.3 Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

7.4 Maintenance tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

7.4.1 General prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 577.4.2 Maintenance tasks 100 hours after commissioning . . . . . . . . . . . . . 577.4.3 Maintenance tasks every 150 hours . . . . . . . . . . . . . . . . . . . . . . . . . 58

Lubricating the guideways, racks and pinions . . . . . . . . . . . . . . . 587.4.4 Maintenance tasks every 500 hours . . . . . . . . . . . . . . . . . . . . . . . . . 59

General inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 597.4.5 Maintenance tasks every 2000 hours . . . . . . . . . . . . . . . . . . . . . . . . 61

Replacing the lubricating pinion . . . . . . . . . . . . . . . . . . . . . . . . . . 617.4.6 Maintenance tasks every 10000 hours . . . . . . . . . . . . . . . . . . . . . . . 63

Oil change in type NA / NH / FA / FH / AE gearboxes . . . . . . . 63

8 Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

8.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68


8.2 Special tools, testing and measuring instruments . . . . . . . . . . . . . . . 70

8.3 Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

8.3.1 General prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 718.3.2 Replacing the bumper unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 718.3.3 Replacing the wiper and lubrication unit . . . . . . . . . . . . . . . . . . . . . 728.3.4 Replacing the rollers and guideways . . . . . . . . . . . . . . . . . . . . . . . . . 75

Replacing the eccentric rollers . . . . . . . . . . . . . . . . . . . . . . . . . . 75Replacing the guideways . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

8.3.5 Setting the roller and tooth flank backlash . . . . . . . . . . . . . . . . . . . 838.3.6 Replacing the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 878.3.7 Setting the gear backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 918.3.8 Replacing the motor and coupling . . . . . . . . . . . . . . . . . . . . . . . . . . 92

8.4 Other documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

8.5 Service departments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 945

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Table of contents9 Decommissioning, storage . . . . . . . . . . . . . . . . . . . . . . . . . . 95

9.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95


9.2 Storage conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

9.3 Decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

9.3.1 Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 969.3.2 Cleaning / rust-proofing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 979.3.3 Transport securing device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 979.3.4 Labeling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

9.4 Recommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

10 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

10.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98


10.2 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

10.3 Waste management compliant assemblies . . . . . . . . . . . . . . . . . . . . 99

10.3.1 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9910.3.2 Material groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

10.4 Disposal facilities, authorities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

11 Spare part supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

11.1 Explanations regarding the spare parts list . . . . . . . . . . . . . . . . . . . 101

11.1.1 Positioning drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10111.1.2 Parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

11.2 Service departments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

12 Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

13 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1076

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General1 General

1.1 Purpose of the document

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

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 FP prod-uct. 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 manual forpartly completed

machinery

This operating manual serves as "Assembly manual for partly completed machin-ery" in acc. with the Machinery Directive 2006/42/EC.

1.2 Target readership

This operating manual is aimed at the following target readership:

Specialists Technicians Forwarding agents

Operating companies

Operating personnel

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.7

Service personnel

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General1.3 Characters / Explanation of abbreviations

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

Tab. 1-1 Explanation of symbols/abbreviations

1.4 Torque tables

1.4.1 Tightening torques for screws

If no other specifications have been made, the following tightening torques apply for oiled and unlubricated screws:

Symbol/Abbreviation Use Explanation

For cross-reference PageFig. Designates drawings Figure

Tab. Designates tables Table

Thread size

Tightening torque [Nm]

8.8 10.9 12.9

M4 3 4.6 5.1

M5 5.9 8.6 10.0

M6 10.1 14.9 17.4

M8 24.6 36.1 42.2

M10 48.0 71.0 83.0

M12 84.0 123.0 144.0

M14 133.0 195.0 229.0

M16 206.0 302.0 354.0

M20 415.0 592.0 692.0

M22 567.0 804.0 945.08

M24 714.0 1017.0 1190.0

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GeneralTab. 1-2 Torque table: oiled and unlubricated screws

If no other specifications have been made, the following tightening torques apply for screws lubricated with moly grease:

Tab. 1-3 Torque table: screws lubricated with moly grease

M27 1050.0 1496.0 1750.0

M30 1420.0 2033.0 2380.0

M36 2482.0 3535.0 4136.0

Thread size


8.8 10.9 12.9

Thread size


8.8 10.9 12.9

M4 2.6 3.9 4.5

M5 5.2 7.6 8.9

M6 9.0 13.2 15.4

M8 21.6 31.8 37.2

M10 43.0 63.0 73.0

M12 73.0 108.0 126.0

M14 117.0 172.0 201.0

M16 180.0 264.0 309.0

M20 363.0 517.0 605.0

M22 495.0 704.0 824.0

M24 625.0 890.0 1041.0

M27 915.0 1304.0 1526.0

M30 1246.0 1775.0 2077.0

M36 2164.0 3082.0 3607.09

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General1.4.2 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 380010

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General1.4.3 Tightening torques for roller holders

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 1511

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General1.4.4 Tightening torques for roller supports

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

SizeTightening torque [Nm]

A1 A2

40 1 87

52 2 120

72 3 220

90 5.5 45012

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Product description2 Product description

2.1 Purpose

2.1.1 Intended use

The FP product is intended exclusively for moving and positioning workpieces and goods.

Any other or additional use is not considered to be use in the intended manner. The manufacturer assumes no liability for any resulting damages. All risks are carried solely by the user!

2.1.2 Non-intended use

The FP 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.13

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Product description2.2 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.

D00

0102

A C DB14

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Product descriptionPosition of the typeplate

The type plate is attached in acc. with the following illustration:

Fig. 2-2 Position of the type plate

A Type plate

D00

0510

A15

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Product description2.3 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, 107: Dimensions Weight Strokes of the individual axes Gearbox type Gearbox ratios Motors

Temperature ranges The following temperature ranges apply:

2.4 Options

The following options are supplied with separate documentation:

Automatic lubrication system, battery or external 24 V DC, oil or grease Manual lifting and safety unit: vertical axis Holding brake Rotary axis Telescope axis Pneumatic load balance

This documentation can be found in chapter 13 Appendix, 107.

Transport -10 to +60C

Operation +12 to +40C

Storage -10 to +40C16

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Safety3 Safety

3.1 General

3.1.1 Product safety

Residual danger The FP 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 FP prod-uct and other property.

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

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, 13.

3.1.2 Operating personnel

Persons who work with the FP product must be technically qualified and trained. They must be familiar with all hazards associated with using the FP 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.17

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Safety3.1.3 Failure to comply with safety regulations

Protective measures The operator is responsible for ensuring safe conditions in the vicinity of the FP product. In particular, it is mandatory to comply with all general safety regula-tions. This includes implementing all of the safety measures before commission-ing 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 safety measures must:

Correspond to the state of the art Comply with the required safety category

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

Failure to implement safety measures Included protective equipment was not installed Included protective equipment was modified

DANGERDisregarding safety regulations

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

Always comply with the safety regulations!18

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Safety3.2 Declaration of incorporation in acc. with Machinery Directive 2006/42/EC

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

herewith declares that the partly completed machinery:

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

FP Size 1-5 / 09xxxxx / 2010

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 ISO12100-1; EN-ISO 1200-2; EN ISO 1421-1; EN ISO 13850; EN 60204-1; EN 1088; EN 982; EN 983; 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, 01/01/2010 Walter Zulauf Martin Knuchel

Director of Development Director of Systems / Robotics19

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Safety3.3 Hazard symbols and instructions

3.3.1 Hazard symbols in the operating manual

Hazard warnings

The hazard warnings are defined for the four following hazard 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.20

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SafetyWarning 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 hazards21

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SafetyTab. 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

Symbol Use

Symbol Use

Note

Helpful information and other tips22

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Safety3.3.2 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 smtlicheTransportsicherungenentfernen!

0156

538

D00

0095

0156

539

2X

X

X

D00

140123

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Safety3.4 Fundamentals of safety

3.4.1 Intended use

The intended use is described in chapter 2.1.1 Intended use, 13.

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 due to 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 area24

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SafetyDanger due to falling axes/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 tears25

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Design and function4 Design and function

4.1 Design

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

.

Fig. 4-1 Design

A X-driveB Y-axisC Z-driveD Z-axisE X-axisF X-carriageG Y-driveH Y-carriage

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FG

C

E

A DB

H26

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Design and function4.2 Functional description

The FP product can move along the following axes:

Fig. 4-2 Axis names

D00

1419

Y

Z

X27

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Commissioning5 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, 17. It concerns your personal safety!

5.1.2 Personnel qualifications

Only appropriately trained and authorized personnel are allowed to commis-sion the FP 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 load28

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Commissioning5.2 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

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 D29

appropriate transport devices.

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Commissioning5.3 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 assembling 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, 98.

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 remov-ing the oil.30

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Commissioning5.3.3 Positioning, fastening

This chapter describes the steps for positioning and fastening the FP product.If no other specifications have been made, the tightening torques as per chapter 1.4.1 Tightening torques for screws, 8 apply.

Before you position the product at the installation site, the requirements as per chapter 5.3.1 Prerequisites, 30 have to be fulfilled.

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

Fig. 5-2 Attaching the slings

A Transportation cradleB HookC Lifting beltsD Transport aidsE Screws

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.

D00

1403

A

D

E

B C31

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CommissioningAttach the slings as follows:

1 Fasten the transport aid by means of the screw(Symmetric arrangement according to the figure)

2 Position the lifting belts as shown in the drawing

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

The slings are in place.

Setting up a column For the FP product, the following fastening methods are possible:

Gdel columns Other columns Directly onto a machine Directly onto a steel beam construction

If you are not using Gdel columns, contact the respective manufacturer.

Fig. 5-3 Setting up a column

A LocknutsB Beam leveling screwsC Floor leveling screwsD Column

25

D00

1530

25

B

A

C

D

A32

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CommissioningSet up the column as follows:

1 Set the beam leveling screws to the specified dimensions(not for size 1)

2 Set the floor leveling screws to the specified dimensions

3 Set up the column as shown in the layout

4 Align the column horizontally and vertically by means of floor leveling screws

5 Lock the floor leveling screws

6 Secure the column against falling over

The column has been completely set up and aligned.

Mounting beams This section describes the steps for mounting a beam to the Gdel supports. For other models, please contact the respective manufacturer.

Fig. 5-4 Mounting beams

A BeamB Beam leveling screw and locknutC WashersD ScrewsE Column

Mount the beam as follows:

1 Lift beam onto column

2 Mount the beam to the column by means of screws and washers

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EDCBA33

3 Align the beam by means of the beam leveling screw

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Commissioning4 Lock the beam leveling screw

The beam has been mounted and aligned.

Connecting beams This section describes the steps for connecting and aligning the beams.

Fig. 5-5 Connecting beams

A ScrewB Sunk keyC HV setsD Fixed beamE Spacer sheet metalF Loose beam

Connect beams as follows:

1 Mount the sunk key to the fixed beam

2 Lift the loose beam to the height of the fixed beam(the beams have to be flush)

3 If equipped, insert the spacer sheet metal

4 Connect the beam with the HV set(For the tightening torque, refer to tab. 1-4, 10)

5 Connect the loose beam with the column

6 Realign the product horizontally and vertically, by means of the levelling screws

The beams are connected and aligned.

D00

0105

A B

CDEF34

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CommissioningBase 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, 107.

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). The minimum concrete thickness and edge distance can be found in the table below.

Fig. 5-6 Anchored base fixing

A Floor levelling screwB Column/frameC AnchorD Adhesive capsule

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

Only use anchors approved by Gdel!

D00

0106

d

h

m

b

r

A

B

C

D35

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CommissioningTab. 5-1 Anchored base fixing

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). The minimum concrete thickness and edge distance can be found in the table below.

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] 14 24 30 35

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

Tightening torque [Nm] 50 160 270 300

NOTEThe welding work described below may only be performed by certified personnel!36

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CommissioningFig. 5-7 Welded base fixing

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

Tab. 5-2 Welded base fixing

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.

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 33037

The product is anchored to the floor.

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Commissioning5.3.4 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, 70).

Fig. 5-8 Mounting aid for rack assembly

A RackB Mounting aid

D00

1018

A B38

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CommissioningX-axis This section describes the steps for installing the guideway. X-axis.

Fig. 5-9 Installing the guideway X-axis

A Mounting aidB Screw clampsC GuidewaysD Torque wrenchE Reference surfaces

Install the guideway as follows:

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

2 Clamp guideway to reference surfaces with screw clamp and mounting aid

3 Tighten all screws

D00

1439

A

B C

B D E C

D

C39

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Commissioning4 Inspect transition according to section Inspecting the rack transition, 41

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

6 If deviations occur (transition/parallelism):

6.1 Remove screws and guideway

6.2 Repeat the procedure

The guideway has been installed.

Y-/Z-axis This section describes the steps for installing the Y-/Z-axis guideway.

Fig. 5-10 Installing the Y-/Z-axis guideway

A Reference surfacesB GuidewaysC Mounting aidD Screw clampsE Torque wrench


1 Clean the reference surfaces and guideways thoroughly and rub an oil

D00

0108

A

E D B

B

C40

stone across them

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Commissioning2 Use clamp screws to clamp the guideways against the reference surfaces


4 Inspect transition:

4.1 For guideways with gears, transition according to section Inspect-ing the rack transition, 41

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






Inspecting the 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 Gdel logo.

Rack quality

Axle Hardened rackSoftrack

X 6 7 (only FP2-5)

Y 6 7 (only FP2-5)

Z 6 -41

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CommissioningFig. 5-11 Inspect rack transition with micrometer

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

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 with a micrometer(Permissible deviation of position C and E to D, refer to table above)

D00

1060

E D C

A B

Rack quality Permissibledeviation [mm]

4 0.01

6 0.03

7 0.08

8 0.20

9 0.2042

The rack transition has been set

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CommissioningInstalling the Y-axis This section describes the steps for installing the Y-axis.

Fig. 5-12 Installing the Y-axis

A Lubricating pinion unitsB Wiper and lubrication unitsC X-axisD Bumper unitsE Clamping setsF Y-axisG X-carriagesH Drive pinionsI Plastic safety devices

Install the Y-axis as follows:

1 Remove the bumper units of the X-axis

2 Release the clamping sets(drive pinions have to be able to rotate independent of the drive)

3 Remove the wiper and lubrication units, lubricating pinion units and plastic safety devices of the X-carriages

4 Turn all rollers of the X-carriages to eccentric minimum setting

5 Raise the Y-axis with a suitable lifting unit(see chapter Attaching the slings, 31)

D00

1541

C D

EFHI G

A B43

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Commissioning6 Align the Y-axis and carefully shift it onto the X-axis

7 Mount the bumper units and lubricating pinion unions

8 Move the Y-axis to the middle of the X-axis

9 Set the roller and tooth flank backlash as described in chapter 8.3.5 Set-ting the roller and tooth flank backlash, 83

10 Mount the wiper and lubrication units and plastic safety devices

11 Tighten the clamping sets

12 Manually move the Y-axis across the entire X-axis once, and check that it is moving smoothly and evenly

The Y-axis has been mounted.

Inserting the Z-axis This section describes the steps for inserting the Z-axis.

In some cases, the Z-axis is loose at delivery. Depending on the available space, the Z-axis can be inserted into the carriage from the top or the bottom.

Insert the Z-axis as follows:

1 Remove the upper and lower bumpers of the Z-axis

2 Remove the holding brake (optional) and rotary axis (optional) as described in the separate documentation

3 Attach a lifting device to the Z-axis:Shackle shape A, DIN 82101 (nominal size 0.4 for ZP-3 / nominal size 1 for ZP-4 and ZP-5)

4 Insert the Z-axis into the carriage

5 Attach the bumpers, energy chain, rotary axis (optional) and holding brake (optional)

6 Secure the Z-axis by means of a transport securing device, holding brake or manual lifting and safety unit

7 Remove the lifting device

The Z-axis has been inserted.

Installing the motorand coupling

This section describes the steps for installing 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, 49).44

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CommissioningFig. 5-13 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

5 Grease the gear rim of the coupling(For grease types, see 7.2.2 Lubricants, 53)

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 GFE45

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

Automatic lubrication system, battery or external 24 V DC, oil or grease Manual lifting and safety unit: vertical axis Holding brake Rotary axis Telescope axis Pneumatic load balance

Attaching the load Attach the load (gripper, robot, etc.) to the FP product. Set the roller and tooth flank backlash again. This procedure is described in chapter 8.3.5 Setting the roller and tooth flank backlash, 83.

Integrating theproduct

Integrate the FP product into the complete plant. Connect the product with the supply lines for energy and consumables. For this procedure, refer to the doc-umentation of the complete system.

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!46

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Commissioning5.3.5 Transport securing device

At delivery, a transport securing device is in effect at the rack or the gearbox.

Remove the transport securing device at the gearbox prior to assembling the motor. The transport securing device at the gearbox is only used for the hori-zontal axle.

Transport securingdevice at the

Y-rack

This section describes the removal of the transport securing device at the Y-rack:

Fig. 5-14 Transport securing device at the Y-rack

A ScrewsB Transport securing device

Remove the transport securing device at the Y-rack as follows:

1 Fixate the carriage

2 Loosen the screws

3 Remove the transport securing device

WARNINGFalling axles

After transport securing device or the motor has been removed, the verti-cal axle falls down and the carriage moves off to the side. This can cause severe or fatal injuries!

Secure the vertical axle and the carriage before removing the transport se-curing device or the motor!

D00

0114

A B47

Transport securing device has been removed.

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CommissioningTransport securingdevice at the

Z-rack

This section describes the removal of the transport securing device at the Z-rack:

Fig. 5-15 Transport securing device at the Z-rack

A Set screwsB ScrewsC CoverD Transport securing device

Remove the transport securing device at the Z-rack as follows:

1 Fixate the Z-axis

2 Loosen the screws

3 Remove the transport securing device assembly

4 Remove the set screws

5 Detach the transport securing device from the cover

6 Reinstall the cover with the screws


D00

0113

B DCA48

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CommissioningTransport securingdevice at the

gearbox

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

Fig. 5-16 Transport securing device at the gearbox

A ScrewsB Transport securing device

Remove the transport securing device at the gearbox as follows:

1 Fixate the carriage

2 Loosen the screw

3 Remove the transport securing device


5.4 Function check

Prior to the functional check, ensure that:

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.

D00

0097

A

B49

50

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Operation

6 Operation

For information on operating the FP, refer to the appropriate chapter of the documentation of the complete product.

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Maintenance7 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, 101.

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 machine. If your product is equipped with an automatic lubrication system, these tasks do not have to be performed.

Tightening torques If no other specifications have been made, the tightening torques as per chapter 1.4.1 Tightening torques for screws, 8 apply51

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Maintenance7.1.1 Safety


7.1.2 Personnel qualifications

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




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



Use appropriate lifting units!52

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Maintenance7.2 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 marking disc below the grease nipple shows the type of lubricant.

Fig. 7-1 Markings at the lubricating points

A Marking 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 marking disc Grease

Red marking disc Oil53

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MaintenanceOils

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

Information on deviating cases is contained in the spare parts list in the appen-dix.

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 Energol SG-XP-460

Texaco Pinnacle 460

Shell Tivela S 460

Klber Klbersynth GH6-220

Type Quantity [cm3]

AE030 40

AE045 100

AE060 250

AE090 700

AE120 1400

AE180 as per type plate54

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MaintenanceGreases

Grease types forgearbox coupling

and teeth

The following grease is used ex works for the gearbox coupling and the teeth (for manual lubrication):

Information on deviating cases is contained in the spare parts list in the appen-dix.

The following grease types can be used alternatively:

For automatic grease lubrication, the following grease is used ex works for the teeth:

Grease type forbearings of the

rollers

Always use the following grease for the rollers:

Mobil Mobilux EP 2

Aral Aralup HLP 2

BP Energol LS-EP 2

Texaco Multifak EP 2

Shell Alvania EP-2

Klber Centoplex EP-2

Castrol Longtime PD2

INA Lithium soap greaseArcanol

LOAD150DIN 51825-KP2N-2055

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Maintenance7.3 Maintenance schedule

Fig. 7-2 Maintenance schedule

D00

1542

2000 h

500 h

150 h

150 h

500 h

2000 h

10000 h

10000 h

Grease Replace Oil change

Oil Clean Visual inspection56

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Maintenance7.4 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, 101.)

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, 59 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 required57

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Maintenance7.4.3 Maintenance tasks every 150 hours

For more information on the lubricants, refer to chapter 7.2 Consumables and auxiliary agents, 53.

Lubricating the 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 plant 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)

FP1-3 10-20 3-4

FP4-5 25-52 5-658

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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:


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 Description Measures

Dirt Check the components for dirt: Wiper 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 attachments59

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MaintenanceTab. 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

Look for cause Replace defective or

worn energy chains Correct the position of

cables and lines Replace worn or defec-

tive cables

Inspection cri-terion Description Measures60

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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 AxleB Lubricating pinionC CarriageD Grease nippleE CasingF Headless set screw with hexagonal socket wrenchG Screws

Replace the lubricating pinion as follows:


2 If there is an automatic lubrication, disconnect the supply

3 Remove the screws

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FG E D

C61

4 Remove the lubricating pinion unit

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Maintenance5 Loosen headless set screw

6 Remove axle

7 Remove lubricating pinion from the casing

8 For oil lubrication, submerge the new lubricating pinion in oil for several minutes(Oil quality, see chapter 7.2 Consumables and auxiliary agents, 53)

9 To assemble the lubricating pinion unit, reverse the disassembly steps

10 Check position of axle and pinion

11 Only for manual lubrication: Lubricate lubricating pinion (See chapter Lubricating the guideways, racks and pinions, 58)

12 Only for automatic lubrication: Connect lubrication line, start lubrication procedure(See separate operating manual on automatic lubrication)

The lubricating pinion has been replaced.62

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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, 53.

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!63

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MaintenanceFig. 7-4 Disassembling the drive

A MotorB Motor screwsC GearboxD Gearbox screws

Disassemble the drive as follows:


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

3 Remove the motor screws

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

5 Remove the gearbox screws

6 Remove the gearbox

The drive has been disassembled.

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B

C

A

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MaintenanceDisassembling adrive with drive shaft

This section describes the steps for disassembling the drive together with the drive shaft

Fig. 7-5 Disassembling the drive

A Gearbox screwsB Coupling screwsC Drive shaftD Motor with couplingE Motor screwsF Gearbox



2 Secure vertical axles against falling

3 Loosen the motor screws


5 Loosen the coupling screws

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

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E

C

D

F65

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Maintenance6 Loosen the gearbox screws



Changing thegearbox oil

This section describes the steps for changing the gearbox oil.

Fig. 7-6 Oil change

A Bleed screwB Filler screwC Drain screw

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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A B

C66

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MaintenanceChange 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.

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, 63

2 Set the tooth flank backlash according to chapter 8.3.5, 833 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.

NOTECalibrate the measurement reference plane after each drive as-sembly.This procedure is described in the documentation of the com-plete plant or of the motor!67

The oil change has been completed

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Repairs8 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, 101.

Tightening torques If no other specifications have been made, the tightening torques as per chapter 1.4.1 Tightening torques for screws, 8 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.68

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Repairs8.1.2 Personnel qualifications

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




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



Use appropriate lifting units!69

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Repairs8.2 Special tools, testing and measuring instruments

For repairs, ensure that you have the following special tools, testing and meas-uring instruments at hand:

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

Tool Use Item number

Pin-type face spanner Adjusting the rollersSize 10, 15, 20

999 756

Adjusting the rollersSize 25, 35

999 758

Micrometer Checking parallelism at the guideways

Inspecting the rack transition

Screw clamps Installing the guideways

Mounting aid Installing the guidewaysSize 10

902 410

Installing the guidewaysSize 15, 20

902 401

Installing the guidewaysSize 25

902 402

Installing the guidewaysSize 35

902 40370

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Repairs8.3 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, 101.)

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 bumper 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!71

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Repairs8.3.3 Replacing the wiper and lubrication unit

Continuous lubrication of the guideways at operating temperatures below 0 C or with grease requires a modification to the felt insert. This procedure is described in the section Preparing the felt insert, 75.

Replacing the wiperand lubrication unitof prism guideways

This section describes the steps for replacing the wiper and lubrication unit of prism guideways.

The wiper and lubrication unit is supplied as piece parts.

Fig. 8-1 Wiper and lubrication unit of prism guideways

A CoverB Grease nippleC Identification discD Felt insertE CasingF Wiper

Replace the wiper and lubrication unit as follows:



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C

D

E

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Repairs3 Only for oil lubrication:Submerge new felt insert in oil for several minutes(Oil quality, see chapter 7.2 Consumables and auxiliary agents, 53)

4 Assemble the wiper and lubrication unit as shown in the figure above.(Do not remove the cover again after it has been placed.)

5 Replace the wiper and lubrication unit

6 Only for manual lubrication:Lubricate guideways(See chapter Lubricating the guideways, racks and pinions, 58)

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

7.1 Connect lubrication lines

7.2 Start lubrication procedure

The wiper and lubrication unit has been replaced.73

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RepairsReplacing the wiperand lubrication unitof the flat guideway

This section describes the steps for replacing the wiper and lubrication unit of the flat guideway.

The wiper and lubrication unit is supplied as piece parts.

Fig. 8-2 Wiper and lubrication unit of the flat guideway

A Felt insertB Grease nippleC Identification discD CasingE Wiper

Replace the wiper and lubrication unit as follows:



3 Only for oil lubrication:Submerge new felt insert in oil for several minutes(Oil quality, see chapter 7.2 Consumables and auxiliary agents, 53)

4 Assemble the wiper and lubrication unit as shown in the figure above.

5 Replace the wiper and lubrication unit

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B

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D

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Repairs6 Only for manual lubrication:Lubricate guideways(See chapter Lubricating the guideways, racks and pinions, 58)

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

7.1 Connect lubrication lines

7.2 Start lubrication procedure

The wiper and lubrication unit of the flat guideway has been replaced.

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 Drill holeB Felt insert

Prepare the felt insert as follows:

1 Drill a 3mm hole in the felt insert

The felt insert has been prepared.

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.

Replacing the eccentric rollers

The eccentric rollers have three home positions, for setting the roller backlash

3

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B75

and tooth flank backlash.

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RepairsFig. 8-4 Roller positions

A Position 1B Position 0C Position +1

X-axis This section describes the steps for replacing the rollers. X-axis

Fig. 8-5 Moving the rollers closer X-axis

A Supporting rollersB ScrewsC Pin-type face spannerD Hexagonal socket wrench

Replace the rollers as follows:

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

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A B C

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A CB

A

D76

again

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Repairs2 Attach the carriage or axle to a lifting device

3 Move the carriage off the axle or remove the Z-Axis

4 Remove the wiper and lubrication unit

5 Remove the screws

6 Replace the rollers

7 Slightly tighten the screws

8 Adjust the rollers (see fig. 8-4, 76):8.1 Supporting rollers: position +1

9 Move carriage onto axle or insert Z-axis (see Inserting the Z-axis, 44)10 Remove the lifting device

11 Set roller and tooth flank backlash as per chapter 8.3.5, 83

The rollers have been replaced.77

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RepairsY-/Z-axis This section describes the steps for replacing the rollers. Y-/Z-axis

Fig. 8-6 Moving the rollers closer Y-/Z-axis

A Supporting rollersB ScrewsC Pin-type face spannerD Hexagonal socket wrenchE Guideway rollers

Replace the rollers as follows:


2 Attach the carriage or axle to a lifting device

3 Move the carriage off the axle or remove the Z-Axis

4 Remove the wiper and lubrication unit

5 Remove the screws

6 Replace the rollers

7 Slightly tighten the screws

8 Adjust the rollers (see fig. 8-4, 76):8.1 Supporting rollers: position +1

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E

A

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Repairs8.2 Guideway rollers: position -1

9 Move carriage onto axle or insert Z-axis (see Inserting the Z-axis, 44)10 Remove the lifting device

11 Set roller and tooth flank backlash as per chapter 8.3.5, 83

The rollers have been replaced.

Replacing the guideways

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

The term "guideway" includes:

Guideway vee bar Guideway vee rack

Replace the guideways as follows:

Guidewayremoval

The designations refer to fig. 8-7, 80.

Remove the guideway as follows:


2 Attach the carriage or axle to a lifting device

3 Expose guideway:

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

3.2 Move out the Z-axis, if required

4 Remove all screws(See fig. 8-7, 80)

5 Remove the guideway

The guideway has been removed.79

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RepairsX-axis This section describes the steps for installing the guideway. X-axis.

Fig. 8-7 Installing the guideway X-axis

A Mounting aidB Screw clampsC GuidewaysD Torque wrenchE Reference surfaces


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

2 Clamp guideway to reference surfaces with screw clamp and mounting aid


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B C

B D E C

D

C80

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Repairs4 Inspect transition according to section Inspecting the rack transition, 41






Y-/Z-axis This section describes the steps for installing the Y-/Z-axis guideway.

Fig. 8-8 Installing the Y-/Z-axis guideway

A Reference surfacesB GuidewaysC Mounting aidD Screw clampsE Torque wrench


1 Clean the reference surfaces and guideways thoroughly and rub an oil

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E D B

B

C81

stone across them

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Repairs2 Use clamp screws to clamp the guideways against the reference surfaces


4 Inspect transition:

4.1 For guideways with gears, transition according to section Inspect-ing the rack transition, 41

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






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 Insert the Z-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.82

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Repairs8.3.5 Setting the roller and tooth flank backlash

Set the roller and tooth flank backlash again after each roller, guideway or gear-box change.

X-axis This section describes the steps for setting the roller and tooth flank backlash X-axis.

Fig. 8-9 Setting the roller and tooth flank backlash X-axis

A Hexagonal socket wrenchB Supporting roller BC ScrewsD CarriageE Supporting roller EF Dial gaugeG Axle

Set the roller and tooth flank backlash as follows:(For descriptions, see also chapter Fig. 8-4 Roller positions, 76)

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

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G

A83

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Repairs1 You may need to make the following preparations:

1.1 Slightly loosen the screws

1.2 Adjust the rollers as follows:(supporting rollers: position +1, see fig. 8-4, 76)

2 Block the drive pinions

3 At the eccentric, move supporting roller E closer, in the direction of the arrow

4 At the eccentric, move supporting roller B closer, in the direction of the arrow; check the parallelism between the carriage and axle (tolerance max. 0.05 mm)

5 Tighten screws(block the rollers by means of a pin-type face spanner)

6 Check the tooth flank backlash:

6.1 Mount the dial gauge

6.2 Move the carriage or axle in the direction of travel

6.3 Read the tooth flank backlash on the dial gauge (correct value: 0.05 mm)

7 Deviation:

7.1 Loosen the screws of the rollers

7.2 Move away the guideway rollers

7.3 Backlash is larger than 0.05 mm:Move the supporting rollers closer by rotating them in the direction of the arrow (See fig. 8-9, 83)

7.4 Backlash is less than 0.05 mm:Move the supporting rollers away by rotating them away from the direction of the arrow(See fig. 8-9, 83)

7.5 Check the parallelism between the carriage and axle(tolerance: max. 0.05 mm)

7.6 Repeat process from step 5

8 Install the wiper and lubrication unit

9 Unblock the drive pinions

The roller and tooth flank backlash has been set.84

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RepairsY-/Z-axis This section describes the steps for setting the roller and tooth flank backlash Y-/Z-axis.

Fig. 8-10 Setting the roller and tooth flank backlash Y-/Z-axis

A Hexagonal socket wrenchB Supporting roller BC ScrewsD CarriageE Supporting roller EF Dial gaugeG AxleH Guideway rollers

Set the roller and tooth flank backlash as follows:(For descriptions, see also chapter Replacing the eccentric rollers, 75)

1 You may need to make the following preparations:

1.1 Slightly loosen the screws

1.2 Adjust the rollers as follows:(Supporting rollers: position +1; guideway rollers: position -1.See fig. 8-4, 76)

2 Block the drive pinions

3 At the eccentric, move supporting roller E closer, in the direction of the arrow

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CB

H

FED

G

A85

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Repairs4 At the eccentric, move supporting roller B closer, in the direction of the arrow; check the parallelism between the carriage and axle (tolerance: max. 0.05 mm)

5 Move the guideway rollers at the eccentric closer in direction of arrow

6 Tighten screws(block the rollers by means of a pin-type face spanner)

7 Check the tooth flank backlash:

7.1 Mount the dial gauge

7.2 Move the carriage or axle in the direction of travel

7.3 Read the tooth flank backlash on the dial gauge (correct value: 0.05 mm)

8 Deviation:

8.1 Loosen the screws of the rollers

8.2 Move away the guideway rollers

8.3 Backlash is larger than 0.05 mm:Move the supporting rollers closer by rotating them in the direction of the arrow (See fig. 8-10, 85)

8.4 Backlash is less than 0.05 mm:Move the supporting rollers away by rotating them away from the direction of the arrow(See fig. 8-10, 85)

8.5 Check the parallelism between the carriage and axle(tolerance: max. 0.05 mm)

8.6 Repeat process from step 5

9 Install the wiper and lubrication unit

10 Unblock the drive pinions

The roller and tooth flank backlash have been set.86

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Repairs8.3.6 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.




NOTEDo not change the position of the coupling on the motor shaft!87

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RepairsFig. 8-11 Disassembling the drive

A MotorB Motor screwsC GearboxD Gearbox screws



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

3 Remove the motor screws


5 Remove the gearbox screws



Disassembling adrive with drive shaft

This section describes the steps for disassembling the drive together with the drive shaft

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B

C

A

D88

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RepairsFig. 8-12 Disassembling the drive

A Gearbox screwsB Coupling screwsC Drive shaftD Motor with couplingE Motor screwsF Gearbox


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

2 Secure vertical axles against falling

3 Loosen the motor screws


5 Loosen the coupling screws

6 Loosen the gearbox screws


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

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A B

E

C

D

F89


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RepairsReplacing 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, 834 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.

NOTECalibrate the measurement reference plane after each drive as-sembly.This procedure is described in the documentation of the com-plete plant or of the motor!90

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Repairs8.3.7 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

Set the gear backlash as follows:


2 Disassemble the drive according to section Replacing the gearbox, 903 Remove all screws on both sides

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

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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A

B

C91

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Repairs5 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 backlash again, as described in step 6.

The gear backlash has been set

8.3.8 Replacing the 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 fi

fp-1 to 5

Documents

maintenance tasks

fundamentals of safety

safety regulations

general prerequisites

maintenance schedule

operating personnel

hazard symbols

product description