FP-1 To 5

MODULES ROBOTICS SYSTEMS COMPONENTS
OPERATING MANUAL
FP Size 1-5
Project:
Bill of materials:
Axxxxxxx
09xxxxx
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OPERATING 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 info@ch.gudel.com
www.gudel.com
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Table of contents
Table 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.4.2 Tightening torques for HV sets . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.4.3 Tightening torques for roller holders . . . . . . . . . . . . . . . . . . . . . . . . 11
1.4.4 Tightening torques for roller supports . . . . . . . . . . . . . . . . . . . . . . . 12
2 Product description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.1 Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.1.1 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.1.2 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.1.2 Operating personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.1.3 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 . . . . . . . . . . . . . . . . . . . . . 20
Hazard warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Warning symbols. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Special symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.3.2 Hazard symbols on the product . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.4 Fundamentals of safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
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3.4.1 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.4.2 Safety and monitoring equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.4.3 Product-specific hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Danger due to electric current. . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Danger 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5.1.2 Personnel qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5.2 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5.3 Positioning, assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.3.1 Prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.3.2 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.3.3 Positioning, fastening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Base fixing with adhesive anchor . . . . . . . . . . . . . . . . . . . . . . . . . 35
Base fixing with welded joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
5.3.4 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5.3.5 Transport securing device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
5.4 Function check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
6 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
7 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
7.1.1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
7.2 Consumables and auxiliary agents . . . . . . . . . . . . . . . . . . . . . . . . . . 53
7.2.1 Cleaning agents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
7.2.2 Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
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Markings at the lubricating points. . . . . . . . . . . . . . . . . . . . . . . . . 53
Oils. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Greases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
7.3 Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
7.4 Maintenance tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
7.4.1 General prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
7.4.2 Maintenance tasks 100 hours after commissioning . . . . . . . . . . . . . 57
7.4.3 Maintenance tasks every 150 hours . . . . . . . . . . . . . . . . . . . . . . . . . 58
Lubricating the guideways, racks and pinions . . . . . . . . . . . . . . . 58
7.4.4 Maintenance tasks every 500 hours . . . . . . . . . . . . . . . . . . . . . . . . . 59
General inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
7.4.5 Maintenance tasks every 2000 hours . . . . . . . . . . . . . . . . . . . . . . . . 61
Replacing the lubricating pinion . . . . . . . . . . . . . . . . . . . . . . . . . . 61
7.4.6 Maintenance tasks every 10000 hours . . . . . . . . . . . . . . . . . . . . . . . 63
Oil change in type NA / NH / FA / FH / AE gearboxes . . . . . . . 63
8 Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
8.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
8.1.1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
8.2 Special tools, testing and measuring instruments . . . . . . . . . . . . . . . 70
8.3 Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
8.3.1 General prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
8.3.2 Replacing the bumper unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
8.3.3 Replacing the wiper and lubrication unit . . . . . . . . . . . . . . . . . . . . . 72
8.3.4 Replacing the rollers and guideways . . . . . . . . . . . . . . . . . . . . . . . . . 75
Replacing the eccentric rollers . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Replacing the guideways . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
8.3.5 Setting the roller and tooth flank backlash . . . . . . . . . . . . . . . . . . . 83
8.3.6 Replacing the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
8.3.7 Setting the gear backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
8.3.8 Replacing the motor and coupling . . . . . . . . . . . . . . . . . . . . . . . . . . 92
8.4 Other documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
8.5 Service departments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
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9 Decommissioning, storage . . . . . . . . . . . . . . . . . . . . . . . . . . 95
9.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
9.1.1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
9.2 Storage conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
9.3 Decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
9.3.1 Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
9.3.2 Cleaning / rust-proofing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
9.3.3 Transport securing device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
9.3.4 Labeling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
9.4 Recommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
10 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
10.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
10.1.1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
10.2 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
10.3 Waste management compliant assemblies . . . . . . . . . . . . . . . . . . . . 99
10.3.1 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
10.3.2 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
11.1.2 Parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
11.2 Service departments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
12 Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
13 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
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General
1 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 for
partly 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
Service personnel
NOTE
Read 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 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 Page
Fig. 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 567.0 804.0 945.0
M24 714.0 1017.0 1190.0
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Tab. 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 3607.0
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General
1.4.2 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 3800
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General
1.4.3 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 holder
C Tighten screw with hexagonal socket wrench (tightening torque A2)
The following tightening torques apply to roller holders:
Tab. 1-5 Tightening torques: Roller holders
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7
7
2
A2
A1
A B C
Size
A1 A2
40 1.5 4
52 2 4
62 3 15
72 4.5 15
90 7 15
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General
1.4.4 Tightening torques for roller supports
Fig. 1-2 Tightening torques for roller supports
A Roller supports size 72 and 90
B Move roller with hexagonal socket wrench (tightening torque A1)
C Roller supports size 40 and 52
D 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
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0
9
4
1
A1
A2
A2
A1
A B C B
D D
Size
A1 A2
40 1 87
52 2 120
72 3 220
90 5.5 450
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Product description
2 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.
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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, type
B Project, sales order
C 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.
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A C D B
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Product description
Position of the type
plate
The type plate is attached in acc. with the following illustration:
Fig. 2-2 Position of the type plate
A Type plate
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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, 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 +40C
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Safety
3 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.
NOTE
Read 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
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
DANGER
Disregarding 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: 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 /
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 four following hazard levels:
DANGER
DANGER
DANGER refers to hazards with a high risk of severe physical injury or im-
mediate fatality.
WARNING
WARNING
WARNING refers to hazards with a moderate risk of severe physical injury
or potential fatality.
CAUTION
CAUTION
CAUTION refers to hazards with a slight risk of moderate physical injury.
NOTE
NOTE
NOTE refers to a hazard that can lead to property damage.
NOTE
Note 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
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 must
be secured from motion
before removing the
rack lock or other
locking device used for
transportation!
Vor dem Entfernen der
Transportsicherung
Z-Achse(n) gegen
herunterfallen Sichern!
WARNING! ACHTUNG!
Remove all rack locks or
other locking devices
used for transportation
on all axes before
attempting to move any
axis!
Vor dem Bewegen der
Achsen smtliche
Transportsicherungen
entfernen!
0
1
5
6
5
3
8
D
0
0
0
0
9
5
0
1
5
6
5
3
9
2
X
X
X
D
0
0
1
4
0
1
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3.4 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
NOTE
Never remove or modify any of the safety and monitoring equip-
ment! Be sure to close all of the protective equipment during op-
eration!
DANGER
Hazardous 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 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 Internet
Example: 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.
WARNING
Falling 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
In the standard configuration, the FP product consists of the following assem-
blies:
.
Fig. 4-1 Design
A X-drive
B Y-axis
C Z-drive
D Z-axis
E X-axis
F X-carriage
G Y-drive
H Y-carriage
D
0
0
1
5
2
1
F G
C
E
A D B
H
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Design and function
4.2 Functional description
The FP product can move along the following axes:
Fig. 4-2 Axis names
D
0
0
1
4
1
9
Y
Z
X
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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, 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.
WARNING
Suspended loads
Improper handling of suspended loads can lead to severe injuries or death!
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 Fragile
B This side up
C Keep dry
D 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
NOTE
Improper 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
D
0
0
0
0
9
8
D
0
0
0
0
9
9
CRAINT L'HUMIDITE
D
0
0
0
1
0
0
HANDLE
WITH CARE
D
0
0
0
1
0
1
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 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.
NOTE
The anti-rust oil protects the components. We recommend not remov-
ing the oil.
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5.3.3 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 cradle
B Hook
C Lifting belts
D Transport aids
E Screws
WARNING
Heavy 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.
D
0
0
1
4
0
3
A
D
E
B C
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Attach 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 Locknuts
B Beam leveling screws
C Floor leveling screws
D Column
2
5
D
0
0
1
5
3
0
2
5
B
A
C
D
A
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Set 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 Beam
B Beam leveling screw and locknut
C Washers
D Screws
E Column
Mount the beam as follows:
1 Lift beam onto column
2 Mount the beam to the column by means of screws and washers
3 Align the beam by means of the beam leveling screw
D
0
0
1
5
3
6
E
D
C
B
A
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4 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 Screw
B Sunk key
C HV sets
D Fixed beam
E Spacer sheet metal
F 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.
D
0
0
0
1
0
5
A B
C D E F
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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, 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 screw
B Column/frame
C Anchor
D Adhesive capsule
NOTE
Only anchor the product after it has been correctly positioned
and aligned!
Only use anchors approved by Gdel!
D
0
0
0
1
0
6
d
h
m
b
r
A
B
C
D
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Tab. 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
NOTE
The welding work described below may only be performed by
certified personnel!
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Fig. 5-7 Welded base fixing
A Screw
B Floor levelling screw
C Column/frame
D Bottom plate
E 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.
The product is anchored to the floor.
D
0
0
0
1
0
7
k n
m
b
r
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
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5.3.4 Assembly
Installing the
guideway
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 Rack
B Mounting aid
D
0
0
1
0
1
8
A B
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X-axis This section describes the steps for installing the guideway. X-axis.
Fig. 5-9 Installing the guideway X-axis
A Mounting aid
B Screw clamps
C Guideways
D Torque wrench
E 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
D
0
0
1
4
3
9
A
B C
B D E C
D
C
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Commissioning
4 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 surfaces
B Guideways
C Mounting aid
D Screw clamps
E Torque wrench
1 Clean the reference surfaces and guideways thoroughly and rub an oil
stone across them
D
0
0
0
1
0
8
A
E D B
B
C
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2 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)
allel
Inspecting the rack
transition
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
rack
Soft
rack
X 6 7 (only FP2-5)
Y 6 7 (only FP2-5)
Z 6 -
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Fig. 5-11 Inspect rack transition with micrometer
A Rack transition
B Measurement bolt
C Micrometer position C
D Micrometer position D
E 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)
The rack transition has been set
D
0
0
1
0
6
0
E D C
A B
Rack quality
Permissible
deviation [mm]
4 0.01
6 0.03
7 0.08
8 0.20
9 0.20
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Installing the Y-axis This section describes the steps for installing the Y-axis.
Fig. 5-12 Installing the Y-axis
A Lubricating pinion units
B Wiper and lubrication units
C X-axis
D Bumper units
E Clamping sets
F Y-axis
G X-carriages
H Drive pinions
I 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)
D
0
0
1
5
4
1
C D
E F H I G
A B
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Commissioning
6 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 motor
and 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).
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Fig. 5-13 Installing the motor and coupling
A Gearbox
B Motor flange
C Measuring instrument
D Coupling
E Coupling screws
F Motor screws
G 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
D
0
0
0
1
1
1
A B C D G F E
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Attaching 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 the
product
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.
NOTE
Wear 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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5.3.5 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 securing
device 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 Screws
B 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
Transport securing device has been removed.
WARNING
Falling 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!
D
0
0
0
1
1
4
A B
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Transport securing
device 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 screws
B Screws
C Cover
D 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
D
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1
1
3
B D C A
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Commissioning
Transport securing
device 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 Screws
B 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.
D
0
0
0
0
9
7
A
B
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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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Maintenance
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, 101.
Options and
third-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 apply
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7.1.1 Safety
Only appropriately trained and authorized personnel are allowed to work on
the FP product.
WARNING
Automatic 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!
Secure vertical axles (if equipped) against falling
Before switching on the plant again, make sure that no one is in the dan-
ger area.
WARNING
WARNING
Heavy components
injuries!
Use appropriate lifting units!
53
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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 marking disc below the grease nipple shows the type of lubricant.
Fig. 7-1 Markings at the lubricating points
A Marking disc
B Grease nipple
NOTE
Unsuitable lubricants
Using unsuitable lubricants can lead to machine damage!
Only use the lubricants listed below. If uncertain, please contact our service
departments!
D
0
0
0
3
1
4
A
B
Yellow marking disc Grease
Red marking disc Oil
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Oils
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 plate
55
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Maintenance
Greases
Grease types for
gearbox 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 for
bearings 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
grease
Arcanol
LOAD150
DIN 51825-KP2N-20
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7.3 Maintenance schedule
Fig. 7-2 Maintenance schedule
D
0
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1
5
4
2
2000 h
500 h
150 h
150 h
500 h
2000 h
10000 h
10000 h
Grease Replace Oil change
Oil Clean 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, 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 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, 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.
NOTE
Incompatible 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 5-6
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General inspection
During the general inspection, the entire product is subjected to an overall
check.
Performing a general
inspection
Perform the general inspection as follows:
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 table
Inspection 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
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
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 Measures
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Maintenance
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 Axle
B Lubricating pinion
C Carriage
D Grease nipple
E Casing
F Headless set screw with hexagonal socket wrench
G Screws
Replace the lubricating pinion as follows:
again
2 If there is an automatic lubrication, disconnect the supply
3 Remove the screws
4 Remove the lubricating pinion unit
D
0
0
0
4
9
8
A
B
F G E
D
C
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Maintenance
5 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.
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Maintenance
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 a
drive with pinion
This section describes the steps for disassembling the drive.
WARNING
Falling axles
NOTE
Do not change the position of the coupling on the motor shaft!
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Maintenance
Fig. 7-4 Disassembling the drive
A Motor
B Motor screws
C Gearbox
D Gearbox screws
Disassemble the drive as follows:
again
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.
D
0
0
0
2
6
8
B
C
A
D
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Maintenance
Disassembling a
drive with drive shaft
This section describes the steps for disassembling the drive together with the
drive shaft
A Gearbox screws
B Coupling screws
C Drive shaft
D Motor with coupling
E Motor screws
F Gearbox
again
2 Secure vertical axles against falling
3 Loosen the motor screws
5 Loosen the coupling screws
NOTE
D
0
0
0
2
8
8
A B
E
C
D
F
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Maintenance
6 Loosen the gearbox screws
Changing the
gearbox oil
This section describes the steps for changing the gearbox oil.
Fig. 7-6 Oil change
A Bleed screw
B Filler screw
C Drain screw
CAUTION
Oils/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.
D
0
0
0
2
7
0
A B
C
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Maintenance
Change the gearbox oil as follows:
1 Position the gearbox:
Drain screw at the bottom
Filler 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, 83
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
NOTE
Calibrate 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!
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Repairs
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, 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
WARNING
Automatic 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!
Secure vertical axles (if equipped) against falling
Before switching on the plant again, make sure that no one is in the dan-
ger area.
69
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Repairs
the FP product.
WARNING
WARNING
Heavy components
injuries!
Use appropriate lifting units!
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Repairs
8.2 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 rollers
Size 10, 15, 20
999 756
Adjusting the rollers
Size 25, 35
999 758
Micrometer Checking parallelism at
the guideways
Inspecting the rack
transition
Screw clamps Installing the guideways
Mounting aid Installing the guideways
Size 10
902 410
Installing the guideways
Size 15, 20
902 401
Size 25
902 402
Size 35
902 403
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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, 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
WARNING
Weak 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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Repairs
8.3.3 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 wiper
and lubrication unit
of 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 Cover
B Grease nipple
C Identification disc
D Felt insert
E Casing
F Wiper
Replace the wiper and lubrication unit as follows:
again
D
0
0
0
1
0
9
A
B
C
D
E
F
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Repairs
3 Only for oil lubrication:
Submerge new felt insert in oil for several minutes
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
Lubricate guideways
7.1 Connect lubrication lines
7.2 Start lubrication procedure
The wiper and lubrication unit has been replaced.
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Replacing the wiper
and lubrication unit
of 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 insert
B Grease nipple
C Identification disc
D Casing
E Wiper
Replace the wiper and lubrication unit as follows:
again
3 Only for oil lubrication:
Submerge new felt insert in oil for several minutes
4 Assemble the wiper and lubrication unit as shown in the figure above.
5 Replace the wiper and lubrication unit
D
0
0
0
1
0
9
A
B
C
D
E
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Repairs
Lubricate guideways
7.1 Connect lubrication lines
7.2 Start lubrication procedure
The wiper and lubrication unit of the flat guideway has been replaced.
Preparing the felt
insert
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 hole
B 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
and tooth flank backlash.
3
D
0
0
1
0
6
1
A
B
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Repairs
Fig. 8-4 Roller positions
A Position 1
B Position 0
C 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 rollers
B Screws
C Pin-type face spanner
D Hexagonal socket wrench
Replace the rollers as follows:
again
D
0
0
0
2
7
5
A
B
C
D
0
0
1
5
5
5
A C B
A
D
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Repairs
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
9 Move carriage onto axle or insert Z-axis (see Inserting the Z-axis, 44)
11 Set roller and tooth flank backlash as per chapter 8.3.5, 83
The rollers have been replaced.
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Y-/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 rollers
B Screws
C Pin-type face spanner
D Hexagonal socket wrench
E Guideway rollers
Replace the rollers as follows:
again
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
D
0
0
0
2
7
4
A C B
E
A
D
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8.2 Guideway rollers: position -1
9 Move carriage onto axle or insert Z-axis (see Inserting the Z-axis, 44)
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:
Guideway
removal
The designations refer to fig. 8-7, 80.
Remove the guideway as follows:
again
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.
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X-axis This section describes the steps for installing the guideway. X-axis.
Fig. 8-7 Installing the guideway X-axis
A Mounting aid
B Screw clamps
C Guideways
D Torque wrench
E 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
D
0
0
1
4
3
9
A
B C
B D E C
D
C
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4 Inspect transition according to section Inspecting the rack transition,
41
allel
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 surfaces
B Guideways
C Mounting aid
D Screw clamps
E Torque wrench
1 Clean the reference surfaces and guideways thoroughly and rub an oil
stone across them
D
0
0
0
1
0
8
A
E D B
B
C
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Repairs
2 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)
allel
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
4 If necessary, adjust the rollers
The final tasks have been performed.
The guideway has been replaced.
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8.3.5 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 wrench
B Supporting roller B
C Screws
D Carriage
E Supporting roller E
F Dial gauge
G Axle
Set the roller and tooth flank backlash as follows:
(For descriptions, see also chapter Fig. 8-4 Roller positions, 76)
NOTE
Always set the roller backlash and tooth flank backlash with load
attached and at operating temperature!
D
0
0
0
5
1
3
C B F E D
G
A
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Repairs
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, 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.
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Y-/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 wrench
B Supporting roller B
C Screws
D Carriage
E Supporting roller E
F Dial gauge
G Axle
H 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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C B
H
F E D
G
A
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4 At the eccentric, move supporting roller B closer, in the direction of the
arrow; check the parallelism between the carriage and axle
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
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.
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8.3.6 Replacing the gearbox
This section describes the steps for replacing the gearbox.
Disassemble the drive to replace the gearbox.
Disassembling a
drive with pinion
This section describes the steps for disassembling the drive.
WARNING
Falling axles
NOTE
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A Motor
B Motor screws
C Gearbox
D Gearbox screws
again
2 Secure carriage or axle with transport securing device or lifting device
3 Remove the motor screws
5 Remove the gearbox screws
Disassembling a
drive with drive shaft
This section describes the steps for disassembling the drive together with the
drive shaft
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6
8
B
C
A
D
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A Gearbox screws
B Coupling screws
C Drive shaft
D Motor with coupling
E Motor screws
F Gearbox
2 Secure vertical axles against falling
6 Loosen the gearbox screws
NOTE
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8
8
A B
E
C
D
F
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Replacing the
gearbox
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, 83
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.
NOTE
sembly.
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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 shaft
B Screws
C Casing cover
Set the gear backlash as follows:
again
2 Disassemble the drive according to section Replacing the gearbox, 90
3 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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1
7
A
B
C
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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 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 fig. 8-14, 93):
Removing the motor
and coupling
This section describes the steps for removing the coupling and the motor.
Remove the motor and the coupling as follows:
again
5 Pull the coupling off the motor shaft
The motor and the coupling have been removed
NOTE
sembly.
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Installing the motor
and 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).
Fig. 8-14 Installing the motor and coupling
A Gearbox
B Motor flange
C Measuring instrument
D Coupling
E Coupling screws
F Motor screws
G 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.
The motor and the coupling have been replaced.
X
Y
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1
1
1
A B C D G F E
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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, 102.
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Decommissioning, storage
9 Decommissioning, storage
9.1 Introduction
9.1.1 Safety
the FP product.
9.2 Storage conditions
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 +40C. Make
sure that the product is not subjected to large temperature fluctuations.
Air humidity The air humidity must be below 75%.
CAUTION
Leaking fluids
During storage, substances that are hazardous to the environment could
leak!
Hazardous substances may not get into the drinking water supply:
Fluids must be disposed of as hazardous waste, even if the total quantity
is small.
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9.3 Decommissioning
9.3.1 Shutdown
This chapter provides information on shutting down the product.
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.
WARNING
NOTE
Do not empty the lubrication lines and the gearbox when shut-
ting down the product!
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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
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, 57. 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
NOTE
Dispose 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, 98.
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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
the FP product.
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, 96.
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
5 Dismount fixed assemblies
(axes/columns)
6 Take the assemblies apart and separate the different materials.
The product has been disassembled.
WARNING
Suspended loads
Improper handling of suspended loads can lead to severe injuries or death!
Use appropriate lifting units
Wear appropriate protective clothing
Always keep sufficient distance to suspended loads
Never enter the area below a suspended load
CAUTION
Oils/greases
Oils and greases are harmful to the environment!
The oils and greases may not get into the drinking water supply:
Oils and greases must be disposed of as hazardous waste, even if the to-
tal quantity is small.
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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 point
Disposal in accordance with the safety data
sheets 3.4.4 Safety data sheets (MSDS), 25
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, 107. 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 of
symbols
Fig. 11-1 Explanation of symbols
A Spare part status
B Availability
14.07.2008 / Page 1 of 1
BCH034580 VS0035 2-Amod ZP-4 M MO mec 3.10 10947-001A
W E t i n U y t i t n a u Q g n i w a r D t x e T r e b m u n m e t I n o i t i s o P
300 V000134 Y k t S 1 2 3 0 - 3 2 5 8 0 0 2 9 = L V 5 2 - 0 2 2 / 0 2 2 P L s i x A -
E k t S 7 7 0 . 0 0 2 . 7 1 . 0 9 3 S U G I 0 . 0 0 2 . 7 1 . 0 9 3 n i a h c y g r e n E 4 0 0 1 4 1 0 2 0 3 A
400 0916667 Y k t S 2 0 3 0 - 3 2 5 8 4 - P Z e g a i r r a C -
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 130/110 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
40.6x20, Modul m=2.387 pitch P=7.5, Z=15
8102-039d 1 Stk V A
Gdel AG
Insustrie Nord
CH-4900 Langnethal
phone +41 62 916 91 91
fax +41 62 916 91 50
info@ch.gudel.com
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4
A
B
Spare part status (column E): E
V
=
=
Spare part
Wear item
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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:
Product, type
Project no., order no.
Serial no.
Drawing no.
Availability (column W): A
B
C
=
=
=
Available from stock
Delivery time approx. 2 - 3 weeks
Delivery time upon request
Germany: +49 6291 6446 41
Great Britain: +44 24 7669 5444
India: +91 20 5622 7165
Italy: +39 0292 170920
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
A
Appendix . . . . . . . . . . . . . . . . . . . . . . . 107
Assembly
Beams . . . . . . . . . . . . . . . . . . . . . . . . 33
Drive . . . . . . . . . . . . . . . . . . . . . . . . . 67
Motor . . . . . . . . . . . . . . . . . . . . .44, 93
Assembly manual for partly completed
machinery . . . . . . . . . . . . . . . . . . . . . 7
Attaching
Load . . . . . . . . . . . . . . . . . . . . . . . . . 46
Options . . . . . . . . . . . . . . . . . . . . . . 46
Slings . . . . . . . . . . . . . . . . . . . . . . . . . 31
Authorities . . . . . . . . . . . . . . . . . . . . . 100
Auxiliary agents . . . . . . . . . . . . . . . . . . 53
Axis names . . . . . . . . . . . . . . . . . . . . . . 27
B
Base fixing . . . . . . . . . . . . . . . . . . . . . . . 35
Adhesive anchor . . . . . . . . . . . . . . . 35
Welded joining . . . . . . . . . . . . . . . . 36
Beam
Mounting . . . . . . . . . . . . . . . . . . . . . 33
Beams
Connecting . . . . . . . . . . . . . . . . . . . 43
connecting . . . . . . . . . . . . . . . . . . . . 34
Bumper unit
Replacing . . . . . . . . . . . . . . . . . . . . . 71
C
Change
Gearbox oil . . . . . . . . . . . . . . . . . . . 66
Checking
Delivery . . . . . . . . . . . . . . . . . . . . . . 30
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . 97
Cleaning agents . . . . . . . . . . . . . . . . . . . 53
Column
Setting Up . . . . . . . . . . . . . . . . . . . . 32
Commissioning . . . . . . . . . . . . . . . . . . . 28
Connecting
Beams . . . . . . . . . . . . . . . . . . . . .34, 43
Consumables . . . . . . . . . . . . . . . . . . . . 53
Coupling
Installing . . . . . . . . . . . . . . . . . . . 44, 93
Removing . . . . . . . . . . . . . . . . . . . . 92
Replacing . . . . . . . . . . . . . . . . . . . . . 92
D
Declaration of incorporation . . . . . . 19
Decommissioning . . . . . . . . . . . . . 95, 96
Delivery
Checking . . . . . . . . . . . . . . . . . . . . . 30
Design . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Disassembly . . . . . . . . . . . . . . . . . . . . . 99
Coupling . . . . . . . . . . . . . . . . . . . . . 92
Drive with pinion . . . . . . . . . . . 63, 87
Guideways . . . . . . . . . . . . . . . . . . . . 79
Motor . . . . . . . . . . . . . . . . . . . . . . . 92
Disposal . . . . . . . . . . . . . . . . . . . . . . . . . 98
Disposal facilities . . . . . . . . . . . . . . . . 100
Drive
Assembly . . . . . . . . . . . . . . . . . . . . . 67
Disassembling with pinion . . . 63, 87
E
Explanation
Abbreviation . . . . . . . . . . . . . . . . . . . 8
Symbols . . . . . . . . . . . . . . . . . . . . . . . 8
Explanation of abbreviations . . . . . . . . 8
Explanation of symbols . . . . . . . . . . . . . 8
F
Fastening . . . . . . . . . . . . . . . . . . . . . . . . 31
Felt insert
preparation . . . . . . . . . . . . . . . . . . . 75
Final tasks . . . . . . . . . . . . . . . . . . . . . . . 82
Function . . . . . . . . . . . . . . . . . . . . . . . . 26
Functional check . . . . . . . . . . . . . . . . . 49
Functional description . . . . . . . . . . . . 27
Fundamentals of safety . . . . . . . . . . . . 24
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Index
G
Gear
Setting the backlash . . . . . . . . . . . . 91
Gearbox
Oil change . . . . . . . . . . . . . . . . . . . . 66
Replacing . . . . . . . . . . . . . . . . . .87, 90
General inspection . . . . . . . . . . . . . . . . 59
Greases . . . . . . . . . . . . . . . . . . . . . . . . . 55
Guideway
Disassembling . . . . . . . . . . . . . . . . . 79
Installing . . . . . . . . . . . . . . . . . . . . . . 38
Lubricating . . . . . . . . . . . . . . . . . . . . 58
Replacing . . . . . . . . . . . . . . . . . . . . . 79
H
Hazard symbols
Operating manual . . . . . . . . . . . . . . 20
Product . . . . . . . . . . . . . . . . . . . . . . 23
Hazard warning
Caution . . . . . . . . . . . . . . . . . . . . . . 20
Danger . . . . . . . . . . . . . . . . . . . . . . . 20
Note . . . . . . . . . . . . . . . . . . . . . . . . . 20
Warning . . . . . . . . . . . . . . . . . . . . . . 20
I
Inserting
Z-axis . . . . . . . . . . . . . . . . . . . . . . . . 44
Inspecting
Rack transition . . . . . . . . . . . . . . . . 41
Installation . . . . . . . . . . . . . . . . . . . .30, 38
Guideway . . . . . . . . . . . . . . . . . . . . . 38
Installing
Coupling . . . . . . . . . . . . . . . . . . .44, 93
Integrating
Product . . . . . . . . . . . . . . . . . . . . . . 46
L
Labeling . . . . . . . . . . . . . . . . . . . . . . . . . 97
Liability . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Load
Attaching . . . . . . . . . . . . . . . . . . . . . 46
Lubricants . . . . . . . . . . . . . . . . . . . . . . . 53
Lubricating
Guideways . . . . . . . . . . . . . . . . . . . . 58
Pinions . . . . . . . . . . . . . . . . . . . . . . . 58
Racks . . . . . . . . . . . . . . . . . . . . . . . . 58
Lubricating pinion
Replacing . . . . . . . . . . . . . . . . . . . . . 61
M
Maintenance . . . . . . . . . . . . . . . . . . . . . 51
10000 hours . . . . . . . . . . . . . . . . . . 63
150 hours . . . . . . . . . . . . . . . . . . . . 58
2000 hours . . . . . . . . . . . . . . . . . . . 61
500 hours . . . . . . . . . . . . . . . . . . . . 59
Schedule . . . . . . . . . . . . . . . . . . . . . 56
Tasks . . . . . . . . . . . . . . . . . . . . . . . . 57
Maintenance schedule . . . . . . . . . . . . 56
Maintenance tasks 100 hours after
commissioning . . . . . . . . . . . . . . . . 57
Markings
Lubricating points . . . . . . . . . . . . . 53
Material groups . . . . . . . . . . . . . . . . . 100
Measuring instruments . . . . . . . . . . . . 70
Monitoring equipment . . . . . . . . . . . . 24
Motor
Installing . . . . . . . . . . . . . . . . . . . 44, 93
Removing . . . . . . . . . . . . . . . . . . . . 92
Replacing . . . . . . . . . . . . . . . . . . . . . 92
Mounting aid . . . . . . . . . . . . . . . . . . . . . 38
O
Oil change
Gearbox . . . . . . . . . . . . . . . . . . . . . 63
Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Operating personnel . . . . . . . . . . . . . . 17
Operation . . . . . . . . . . . . . . . . . . . . . . . 50
Options . . . . . . . . . . . . . . . . . . . . . . . . . 16
Attaching . . . . . . . . . . . . . . . . . . . . . 46
Other documents . . . . . . . . . . . . . . . . 94
P
Packaging symbols . . . . . . . . . . . . . . . . 29
Parts list . . . . . . . . . . . . . . . . . . . . . . . 101
Personnel qualification 28, 52, 69, 95, 98
Pinion
Lubricating . . . . . . . . . . . . . . . . . . . 58
Position drawings . . . . . . . . . . . . . . . 101
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Index
Preparation
of the felt insert . . . . . . . . . . . . . . . 75
Prerequisites . . . . . . . . . . . . . . . . . . . . . 30
Base . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Lifting unit . . . . . . . . . . . . . . . . . . . . 30
Lines . . . . . . . . . . . . . . . . . . . . . . . . . 30
Maintenance, repair . . . . . . . . .57, 71
Positioning . . . . . . . . . . . . . . . . . . . . 30
Product
Description . . . . . . . . . . . . . . . . . . . 13
Designation . . . . . . . . . . . . . . . . . . . 14
Integrating . . . . . . . . . . . . . . . . . . . . 46
Safety . . . . . . . . . . . . . . . . . . . . . . . . 17
Product-specific hazards . . . . . . . . . . . 24
Protective measures . . . . . . . . . . . . . . 18
Purpose of the document . . . . . . . . . . . 7
R
Rack
Inspecting transition . . . . . . . . . . . . 41
Lubricating . . . . . . . . . . . . . . . . . . . . 58
Recommissioning . . . . . . . . . . . . . . . . . 97
Repairs . . . . . . . . . . . . . . . . . . . . . . .68, 71
Replacing
Bumper unit . . . . . . . . . . . . . . . . . . . 71
Coupling . . . . . . . . . . . . . . . . . . . . . . 92
Gearbox . . . . . . . . . . . . . . . . . . .87, 90
Guideways . . . . . . . . . . . . . . . . . . . . 79
Lubricating pinions . . . . . . . . . . . . . 61
Motor . . . . . . . . . . . . . . . . . . . . . . . . 92
Rollers . . . . . . . . . . . . . . . . . . . . . . . 75
Wiper and lubrication unit . . .72, 74
Replacing the wiper and lubrication unit
. . . . . . . . . . . . . . . . . . . . . . . . . . .72, 74
Residual danger . . . . . . . . . . . . . . . . . . 17
Roller backlash
Setting . . . . . . . . . . . . . . . . . . . . .83, 85
Roller positions . . . . . . . . . . . . . . .76, 78
Rollers
Replacing . . . . . . . . . . . . . . . . . . . . . 75
Rust-proofing . . . . . . . . . . . . . . . . . . . . 97
S
Safety . . . . . . . . . . . 17, 28, 52, 68, 95, 98
Safety data sheets . . . . . . . . . . . . . . . . 25
Safety equipment . . . . . . . . . . . . . . . . . 24
Safety regulations
Failure to comply . . . . . . . . . . . . . . 18
Service departments . . . . . . . . . . . . . 102
Setting
Gear backlash . . . . . . . . . . . . . . . . . 91
Roller backlash . . . . . . . . . . . . . . . . 83
Tooth flank backlash . . . . . . . . . . . 83
Setup . . . . . . . . . . . . . . . . . . . . . . . . 30, 31
Shutdown . . . . . . . . . . . . . . . . . . . . . . . 96
Slings
Attaching . . . . . . . . . . . . . . . . . . . . . 31
Spare part supply . . . . . . . . . . . . . . . . 101
Spare parts list . . . . . . . . . . . . . . . . . . 101
Explanation of symbols . . . . . . . . 101
Explanations . . . . . . . . . . . . . . . . . 101
Special symbols . . . . . . . . . . . . . . . . . . 22
Special tools . . . . . . . . . . . . . . . . . . . . . 70
Storage . . . . . . . . . . . . . . . . . . . . . . . . . 95
Storage conditions . . . . . . . . . . . . . . . 95
Symbols
Special symbols . . . . . . . . . . . . . . . 22
Warning symbols . . . . . . . . . . . . . . 21
T
Target readership . . . . . . . . . . . . . . . . . 7
Technical data . . . . . . . . . . . . . . . . . . . 16
Temperature ranges . . . . . . . . . . . . . . 16
Testing instruments . . . . . . . . . . . . . . 70
Tightening torques
HV sets . . . . . . . . . . . . . . . . . . . . . . 10
Roller holders . . . . . . . . . . . . . . . . . 11
Roller supports . . . . . . . . . . . . . . . 12
Screws . . . . . . . . . . . . . . . . . . . . . . . . 8
Tooth flank backlash
Setting . . . . . . . . . . . . . . . . . . . . . . . 83
Torque tables . . . . . . . . . . . . . . . . . . . . . 8
Transport . . . . . . . . . . . . . . . . . . . . . . . 29
Transport securing devices . . . . . 47, 97
Type plate . . . . . . . . . . . . . . . . . . . . . . . 14
U
Unpacking . . . . . . . . . . . . . . . . . . . . . . . 30
Use
Improper . . . . . . . . . . . . . . . . . . . . . 13
Intended . . . . . . . . . . . . . . . . . . . . . 13
Purpose . . . . . . . . . . . . . . . . . . . . . . 13
106
OPERATING MANUAL FP
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Index
W
Warning symbols . . . . . . . . . . . . . . . . . 21
Waste management compliant assemblies 99
Z
Z-axis
Inserting . . . . . . . . . . . . . . . . . . . . . . 44
107
OPERATING MANUAL FP
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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
OPERATING MANUAL FP
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ABCDEFGHIJKLM14
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123The 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 explosion
Thermal factors
All Noncompliance with the intended use Persons are injured or killed x x 10 3/d Intended use of the product.
A Gdel 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 Gdel device may not be
operated in a potentially explosive area. The
ambient temperature during operation must be
between 12and 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
Technicians
Commissio
ning
technicians
Improper use of lifting equipment
Person 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)
Operator
Maintenance
personnel
Gripper problems
Defective motor brake
General 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 x
Manual workstations
Operator Automatic movements at the manual workstation
Person 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 out
Operator
Third
parties
Parts clamped improperly
Breakage of rotating tools
Person is surprised by parts flying away and injured as a result x x 10 3/d
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.
Required behavior: Inspect the protective
hoods before starting normal operation.
x J
1.6 x x x x x x x Electrical hazard
Operator
Maintenance
personnel
Technicians
Touching the machine
Defective insulation
Improper el. installation
Unsuitable components
Person suffers an electric shock and is injured or killed as a result. x x 10 3/d
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
Operator
Maintenance
personnel
Power failure, lightning Person is surprised by unexpected movement and injured as a result. x x 10 3/d
The 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
Operator
Maintenance
personnel
Failure of control unit components Person is surprised by unexpected movement and injured as a result. x x 10 3/d
The 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.
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 risks
1)
Solution suggested to the customer (cursive, Times New Roman)
Gdel solution (Arial)
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Residual risks
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Protective measures
(existing protective measures)
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(Worst case)
(Without protective measures)
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Customer:
Machine type: all modules without control system
Project no.:
Document no.:
Copyright 2009 by GDEL AG Process owner: M. Knuchel Version 30 / Risikobeurteilung_en.xls Page1 / 3
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ABCDEFGHIJKLM14
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Safety goal
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Protective measures
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Customer:
Project no.:
Document no.:
1.9 x x x x x Malfunction of protection measures
Operator
Maintenance
personnel
Aging, 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
Suspended loads
(Z-axis and workpieces)
Technicians
Removal 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/d
It 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 x
Parts that are flung out
Operator
Maintenance
personnel
Cleaning
personnel
Unexpected start Person is surprised by unexpected situation and injured as a result. x x 10 3/d
It 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 x
Suspended loads.
(Z-axes, telescopic axes, counter balance
cylinders and workpieces)
Setters
Gripper problems
Torn belt (telescopic axis)
Pressure drop (load balancing)
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.
Z-axes. Take especial care with telescopic
axes. Inspect belts before every setup
procedure for cracks and tears.
x J
1.14 x
Suspended loads.
Setters Inattention and/or careless operation by operator Person is surprised by unexpected situation and injured as a result. x x 10 3/d
Workpieces must not be dropped
accidentally.
Grippers can only be operated in the storage position.
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 out
Setters
Third parties
Gripper problems
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/d
The 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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ABCDEFGHIJKLM14
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Safety goal
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u
s
t
o
m
e
r
Source of danger
E
x
t
e
n
t

o
f

t
h
e

d
a
m
a
g
e
C
a
t
e
g
o
r
y

/

P
L
r

(
S
I
L
)

m
in
im
a
l
1)
S
a
f
e
t
y

r
e
q
u
ir
e
m
e
n
t

f
u
lf
ille
d

[
Y
/
N
]
Residual risks
O
p
e
r
a
t
in
g

m
a
n
u
a
l
Protective measures
A
f
f
e
c
t
e
d

p
e
r
s
o
n
(
s
)
C
o
r
r
e
s
p
o
n
d
in
g

o
p
e
r
a
t
in
g

m
o
d
e
Triggering factor
Event
(Worst case)
S
e
t
u
p
/
c
h
a
n
g
e
o
v
e
r
C
le
a
n
in
g
T
r
o
u
b
le
s
h
o
o
t
in
g

a
n
d

r
e
p
a
ir
M
a
in
t
e
n
a
n
c
e
D
is
a
s
s
e
m
b
ly
D
is
p
o
s
a
l
Customer:
Project no.:
Document no.:
1.18 x x x
Parts that are flung out
Service
personnel
Cleaning
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
Service
personnel
Cleaning
personnel
Unexpected start
Disassembly 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 Gdel 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/d
Tipping 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 Gdel 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 Gdel 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 x
Improper disposal can cause
environmental damage.
All Disposal regulations are not observed Environmental hazard x x 10 3/d
The 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 Gdel
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 Gdel have
been been modified or not installed, Gdel will not commission the plant and will not assume liability or provide a warranty relating to any resulting events.
OPERATING MANUAL FP
D
0
0
1
5
1
5
Layout
Layout
OPERATING MANUAL FP
D
0
0
1
5
1
5
Options
Options
OPERATING MANUAL FP
D
0
0
1
5
1
5
OPERATING MANUAL FP
D
0
0
1
5
1
5
Spare parts list
Spare parts list

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