Module 105(S)/142(S)
Contents
1. Version 1 F F p gt lO Ho ol Figure 24 Belt gear version 1 e Remove the motor see section Motor replacement module 105 page 24 e Remove motor flange by loosening the connection screws F e Replace gear toothed belt e Attach motor flange again but do not screw it on yet e Install motor e Push motor and motor flange away from the basic body The toothed belt is tensioned e Screw on motor flange see Figure 21 page 24 F Version 2 ele G D Figure 25 Belt gear version 2 e Remove motor flange cover G see section Motor replacement module 105 page 24 e Loosen motor attachment screws X The motor can then be easily pushed towards the basic body The toothed belt is relieved e Replace toothed belt e Push the motor away from the basic body The toothed belt is tensioned Tighten motor attachment screws X e Attach the motor flange cover G Repair instructions Translation of the original instructions April 2013 Page 26 of 43 Modul 105 S 142 S MAN_EN_1040573_Modul105 142_R2b doc WERNE 6 1 5 Motor replacement module 142 Disassembly sequence e Remove the motor flange cover by loosening the screws see Figure 26 bottom X X go O PEI O Q2. o D ag OJ S gt z Figure 33 Top view linear unit end plate on spindle with the recessed head screw N end plate side mounting bore in the spindle for fastening Screw on end plate tighten recessed head screws and secure with threadlocker Tension cover belt and install retention plate see Figure 30 page 32 or Figure 31 page 32 Replace motor Loosen attachment screws for motor and pull motor out to the rear Install new motor always observe section Replace coupling version 1 stiff coupling page 35 CAUTION Do not impact the motor shaft Screw on motor Repair instructions Page 34 of 43 April 2013 Translation of the original instructions MAN_EN_1040573_Modul105 142_R2b doc Modul 105 S 142 S IFE WERNER 6 2 5 Replace coupling version 1 stiff coupling e Loosen attachment screws for motor and pull motor out to the rear e Remove recessed head screw N see Figure 32 page 33 end plate side mounting bore in the spindle for fastening e Push carriage towards motor flange spindle and coupling protrude from the basic body see e Figure 34 page 35 e Remove old coupling install new one use extractor e Push back carriage pull spindle back into the end plate by recessed head screw e Tighten recesse
3. X Figure 26 Belt gear of module 142 e Loosen motor attachment screws e the toothed belt is relieved e Remove the motor e Remove motor toothed disc see Figure 22 page 24 from the motor shaft and then install new motor CAUTION Do not impact the motor shaft Assembly sequence e Wire the new motor according to the motor data sheet Check direction of rotation e Install motor to motor flange e Push the motor away from the basic body the gear toothed belt is tensioned Then tighten the motor attachment screws e Attach the motor flange cover again 6 1 6 Replace gear toothed belt module 142 e Remove motor flange by loosening the attachment screws X see Figure 26 page 27 e Loosen the motor attachment screws the toothed belt is relieved e Replace defective gear toothed belt with new gear toothed belt e Push the motor away from the basic body the gear toothed belt is tensioned Then tighten the motor attachment screws e Attach the motor flange cover again April 2013 Translation of the original instructions Repair instructions MAN_EN_1040573_Modul105 142_R2b doc Modul 105 S 142 S Page 27 of 43 WERN E 6 1 7 Replacing the initiator Remove the motor side front sheet with plug see Figure 27 bottom H ar ll Figure 27 Belt gear motor side view Desolder the initiator cable from the installation plug Then pull out the cover st
4. Connect the toothed belt to the tappet E see Figure 20 page 23 Attach end plate see Figure 19 page 22 C D Connect the carriage unit to the tappet see Figure 18 page 21 A Translation of the original instructions Modul 105 S 142 S Repair instructions Page 29 of 43 E WERN 6 1 10 Replacing drive set module 142 Disassembly sequence e Disconnect the carriage unit from the tappet by loosening the two screws centrally installed in running direction see Figure 18 Page 21 A e Remove the deflection side end plate by loosening the four connection screws The toothed belt is relieved see Figure 19 page 22 C NOTE Pay particular attention to ensure that the two spacer sleeves are not lost e Loosen the toothed belt by opening the tappet screws see Figure 20 page 23 E e Remove motor flange cover by loosening the screws of the motor flange see Figure 26 page 27 X e Loosen the motor attachment screws the gear toothed belt is relieved Remove gear toothed belt and motor e Remove the motor side angle sheet see Figure 27 page 28 H e Remove the toothed belt from the shaft of the drive set by loosening the screws see Figure 29 bottom Y LS Figure 29 Drive set module 142 open and cut view e Remove motor flange from the linear unit by loosening the screws Z e Remove defective drive set from the guid
5. D 78120 Furtwangen Telefon 0 77 23 9 25 0 Service IEF Werner de IFE WERNER Module 105 142 EO M Type designation 166596 17 500 mm N Feed motor revs Verurs Nr Order number VorschubiMetorumdrehung Ser Nr 10540 0 Geers Serial number Figure 17 Type label example Assembly instructions Page 16 of 43 Translation of the original instructions April 2013 Modul 105 S 142 S MAN_EN_1040573_Modul105 142_R2b doc IFE WERNER 3 5 3 Technical data when using a planetary gear Before commissioning observe the possible input speeds of the gear manufacturers Too high input speeds can lead to increased wear at the gear and or thermal problems The accuracy of the linear unit is influenced by the reverse play of the gears Example The gear reverse play S is 9 angle minutes How high is the reverse play at the carriage of the linear unit Infeed constant of the linear unit Vk 140 mm Reverse play at the carriage Vk S 360 x 60 140 mm 9 360 x 60 0 058 mm Consider the information of the respective gear manufacturer in any case e g http Awww neugart de index php de Produkte Standardgetriebe http www wittenstein alpha de spielarme planetengetriebe htm April 2013 Translation of the original instructions Assembly instructions MAN_EN_1040573_Modul105 142_R2b doc Modul 105 S 142 S Page 17 of 43 IFE WERNER 4 Maintenance During the design of the lin
6. There is a high danger of injury WARNING OF HOT SURFACE During operation heating of the motor in particular of stepper motors can cause burns of the skin when touching the motor Install a protective device if possible Do not touch the marked areas or wait for an adequate cooling time CAUTION Motor connectors must not be inserted or disconnected when live Risk of burning of the contacts and risk of flying sparks Translation of the original instructions Safety April 2013 Modul 105 S 142 S Page 5 of 43 MAN_EN_1040573_Modul105 142_R2b doc M S M X M Pe CAUTION Linear modules always have to be operated in connection with suitable safety devices e g safety cell protective room protective housing light curtain Observe the Declaration of Incorporation see section Declaration of NOTE incorporation page 43 Special hazard warnings 1 3 In addition this Original User s Manual also contains the following special hazard warning DANGER FROM CRUSHING These places of the components pose the danger of crushing limbs in operation April 2013 MAN_EN_1040573_Modul105 142_R2b doc Translation of the original instructions Modul 105 S 142 S Safety Page 6 of 43 7 WERNER 2 Intended use The linear units module 105 and module 142 see Figure 1 are precise linear adjustment units with circumfering toothed belt drive The types module 1
7. End plate spindle bearing e Remove the end plates by loosening the four attachment screws O e Replace end plate side spindle bearing e Insert and tighten threaded ring M and secure with threadlocker e Install end plate on spindle with the groove nut N end plate side groove nut mounting bore in the spindle for fastening e Screw on end plate e Tighten groove nut N and secure with threadlocker e Tension cover belt and install retention plate April 2013 Translation of the original instructions Repair instructions MAN_EN_1040573_Modul105 142_R2b doc Modul 105 S 142 S Page 33 of 43 E R N E 6 2 3 6 2 4 Replacement of linear bearing Remove retention plate for cover belt on the end plate side see Figure 30 page 32 and Figure 31 page 32 Remove groove nut see Figure 32 page 33 N End plate side groove nut mounting bore in the spindle for fastening Remove end plates by loosening the four attachment screws O see Figure 32 page 33 Remove clamping blocks by loosening the attachment screws P see Figure 33 page 34 Replace linear bearings push on clamping blocks again and connect to the carriage plate see Figure 32 page 33 Install CAUTION As of July 1999 the linear bearings are secured with threaded pins Remove threaded pins before uninstalling the linear bearings After replacement of the linear bearings install the threaded pins again as safety device P o e O O 1 A
8. and slave axis can be removed and re installed without disassembly of one of the two axes see Figure 38 page 39 Figure 38 Cut view shaft coupling of the parallel drive e Loosen the attachment screws T of the shaft couplings integrated into the connection shaft see Figure 38 e The connection shaft can be removed in one piece e Loosen the clamping screw see Figure 38 U The tension cone comes loose e Shaft coupling and connection pipe can be disconnected e Assemble new shaft coupling and connection pipe e Tighten clamping screw U with 12 Nm e If the carriages of master and slave are not mechanically connected push the carriages of master and slave to the stop on the end plate or motor side e Install connection shaft e Tighten attachment screws see Figure 38 T with 8 5 Nm April 2013 Translation of the original instructions Repair instructions MAN_EN_1040573_Modul105 142_R2b doc Modul 105 S 142 S Page 39 of 43 E WERWN 6 3 2 Replacing the slave drive set Disassembly sequence e Loosen the attachment screws T of the shaft couplings integrated into the connection shaft see Figure 38 page 39 e Remove connection shaft
9. e Disconnect the carriage unit of the slave axis from the tappet by loosening the two connection screws centrally installed in running direction see Figure 18 Page 21 A e Remove the end plate of the slave axis by loosening the four connection screws C The toothed belt is relieved see Figure 19 page 22 e Remove the drive side angle sheet of the slave axis e Open the tappet of the slave axis by loosening the connection screws see Figure 20 page 23 E e Remove retention ring V module 105 or pressure plate W module 142 see Figure 39 page 40 y Module 105 o Say rs 7 T T 75 dy gt fh fe Module 142 W Figure 39 Slave drive set module 105 and module 142 Assembly sequence e Replace the slave axis drive set e Install the retention ring module 105 or pressure plate module 142 e Connect the toothed belt to the tappet e Install the angle plate again e Install end plate e Connect the carriage unit to the tappet e Install connection shaft e Tighten the attachment screws T Repair instructions Translation of the original instructions April 2013 Page 40 of 43 Modul 105 S 142 S MAN_EN_1040573_Modul105 142_R2b doc 7 Replacement wear parts 7 1 Module 105 Designation Article number Type 16 linear bearing 1000466 Deflection unit 525137 Drive unit customer specific Drive unit parallel drive slave 525822 Toothed belt tooth 732766 Guide shaft 16mm Gear toothed belt Torsion coupling module
10. suggestions for improvements and information about errors April 2013 IEF Werner GmbH Translation of the original instructions April 2013 Page 2 of 43 Modul 105 S 142 S MAN_EN_1040573_Modul105 142_R2b doc M al M Table of Contents 1 Safety 1 1 Definition or warning notes 1 2 General warning notes 1 3 Special hazard warnings 2 Intended use 2 1 Reasonably foreseeable misuse 3 Assembly instructions 3 1 Installation position 3 2 Module attachment 3 3 Installation of actuators 3 4 Wiring 3 4 1 Motors 3 4 2 _ Initiators 3 4 2 1 Technical data of the limit switches 3 4 3 Cable routing 3 5 Technical data 3 5 1 Critical spindle speed 3 5 2 Type label 3 5 3 Technical data when using a planetary gear 4 Maintenance 5 Troubleshooting 6 Repair instructions 6 1 Module 105 and Module 142 6 1 1 Replacement of the linear bearings 6 1 2 Replacement of the deflection unit 6 1 3 Motor replacement module 105 6 1 4 Replace gear toothed belt module 105 6 1 5 Motor replacement module 142 6 1 6 Replace gear toothed belt module 142 6 1 7 Replacing the initiator 6 1 8 Replacing the drive toothed belt 6 1 9 Replacing drive set module 105 6 1 10 Replacing drive set module 142 6 2 Module 105 S and Module 142 S April 2013 Translation of the original instructions MAN_EN_1040573_Modul105 142_R2b doc Modul 105 S 142 S Page 3 of 43 O aAa ua N 11 12 12 12 13 14 15 16 16 17 18 19 21 21 21 23 24 26
11. this type of attachment see Figure 8 page 10 lt lt _ LI Carriage Figure 7 Attachmnet of the linear module to the carriage Module 68 easyLINE M105 M105S M6 Module 142 Module 142 S M8 Figure 8 Connection screw A bs D 4x a oO Y He c Linear module A B Cc Thread D Module 105 Module 105S 124mm 124mm 140 mm M6 Module 142 Module 142S 168mm 168mm 190 mm M8 Figure 9 Mounting bores in the carriage Assembly instructions Translation of the original instructions April 2013 Page 10 of 43 Modul 105 S 142 S MAN_EN_1040573_Modul105 142_R2b doc IFE WERNER 3 3 Installation of actuators Actuators to be installed on the linear module pick up modules cylinders are usually attached to the linear unit using the drill template on the carriage see Figure 9 page 10 If a setup according to Figure 7 page 10 is used actuators may be attached according to the illustration in Figure 10 page 11 Only very light weight attachments lt 1 kg may also be attached directly to the end plate In this case apply the end plate with a suitable drill template Adapter plate Se Clamping element Type 140 Module 105 resp Type 190 Modul
12. 05 S and module 142 S are equipped with spindle drives ball roller or trapezoid spindle All linear units named are used as installation parts in connection with other components in the commercial area In combination with many standardised installation elements and the other linear modules of IEF Werner GmbH e g module 68 module 68 D module 142 and module 142 S complex multi axis handling systems can be developed as well Figure 1 Module 142 The areas of use of these linear units are accordingly diverse They range from e Stop adjustment in the wood industry e Equipment systems for SMD components e Joining and press in processes in precision mechanics e Loading and unloading station of tool machines up to e Manipulators for the packaging industry 2 1 Reasonably foreseeable misuse The linear module M105 S M142 S is not to be used for certain applications and in particular not for such as the transport of persons and animals or as a pressing bending device for cold working of metal Use of the linear units without additional measures is also not possible in special fields of application such as the chemical or food industry or in explosive atmospheres In case of doubt consult the manufacturer April 2013 Translation of the original instructions Intended use MAN_EN_1040573_Modul105 142_R2b doc Modul 105 S 142 S Page 7 of 43 E WERN 3 Assembly instructions 3 1 Installation position The installation position is option
13. 105 PA Initiator ind PNP normally closed contact Initiator ind PNP normally open contact Special grease for linear axes 50 gr 7 2 Module 105S Designation Spindle Coupling Guide shaft 16mm Article number April 2013 Initiator ind PNP normally closed contact Initiator ind PNP normally open contact Project related replacement and wear parts lists must be observed Translation of the original instructions Replacement wear parts MAN_EN_1040573_Modul105 142_R2b doc Modul 105 S 142 S Page 41 of 43 E WERN 7 3 Module 142 Designation Article number Deflection unit Drive unit standard Drive unit parallel drive master Drive unit parallel drive slave Toothed belt tooth Guide shaft 20mm 025794 Gear toothed belt customer specific Torsion coupling for parallel drive only 1063253 Initiator ind PNP normally closed contact 025165 Initiator ind PNP normally open contact 726744 Special grease for linear bearing 50 gr 732934 7 4 Module 142 S Designation Article number Type 20 linear bearing 1000469 Spindle customer specific Coupling customer specific Guide shaft 20mm 025794 Initiator ind PNP normally closed contact Initiator ind PNP normally open contact Special grease for linear bearing 50 gr Special grease for spindles 50 gr Project related replacement and wear parts list must be observed Replacement wear parts Translation of the original instruc
14. 105 S 142 S Page 37 of 43 IFE WERNER Assembly sequence e Install the tappet on the new spindle nut The tappet opening points towards the end plate side e Install the pressure plate for module 105 S and the threaded ring for module 142 S and secure with threadlocker e Re install the coupling of the defective spindle on the new spindle see e Figure 34 page 35 or Figure 35 page 36 e Insert spindle into the basic body from the end plate side e Connect the carriage plate to the tappet e Install end plate on spindle with the recessed head screw N end plate side mounting bore in the spindle for fastening e Screw on end plate tighten recessed head screws and secure with threadlocker see Figure 32 page 33 e Tension cover belt and install retention plate Figure 30 page 32or Figure 31 page 32 e Move the carriage manually back and forth across the entire stroke The carriage must move evenly and easily throughout the range e Install motor Repair instructions Translation of the original instructions April 2013 Page 38 of 43 Modul 105 S 142 S MAN_EN_1040573_Modul105 142_R2b doc ee lt WERNE 6 3 Module 105 and module 142 parallel drive The following section explains the deviations between parallel drive systems and single linear module oP Figure 37 Parallel drive 6 3 1 Replace shaft coupling connection shaft The connection shaft between master
15. 27 27 28 28 29 30 32 S M X M 6 2 1 Replacing the cover belt 32 6 2 2 Replace end plate side spindle bearing 33 6 2 3 Replacement of linear bearing 34 6 2 4 Replace motor 34 6 2 5 Replace coupling version 1 stiff coupling 35 6 2 6 Replace coupling version 2 Elastomer coupling 36 6 2 7 Replacing the initiator 36 6 2 8 Replacement of spindle 37 6 3 Module 105 and module 142 parallel drive 39 6 3 1 Replace shaft coupling connection shaft 39 6 3 2 Replacing the slave drive set 40 Replacement wear parts 41 7 1 Module 105 41 7 2 Module 105 S 41 7 3 Module 142 42 7 4 Module 142 S 42 Declaration of incorporation 43 Translation of the original instructions April 2013 Page 4 of 43 Modul 105 S 142 S MAN_EN_1040573_Modul105 142_R2b doc ee 1 Safety 1 1 Definition or warning notes WARNING Indicates potential danger Non observance of the safety provisions may cause death or severe injury CAUTION Indicates potential danger Non observance of the safety provisions may cause property damage or injury NOTE Offers additional information 1 2 General warning notes The module must only be commissioned by specialists who received safety technical instruction and are able to assess potential dangers Furthermore all chapters of these operating instructions must have been read and understood completely WARNING The system must be powered down for all assembly disassembly or repair work
16. 2b doc 7 WERNER Replacing drive set module 105 Disassembly sequence Disconnect the carriage unit from the tappet by loosening the two connection screws centrally installed in running direction see Figure 18 Page 21 A Remove the deflection side end plate by loosening the four connection screws The toothed belt is relieved see Figure 19 page 22 C Remove the motor see section Motor replacement module 105 page 24 or Replace gear toothed belt module 105 page 26 Remove the motor side angle plate see Figure 27 page 28 Open the tappet by loosening the connection screws see Figure 20 page 23 E Push out the drive set by loosening the four attachment screws one by one see Figure 28 bottom X mE A S ef F o Figure 28 Cut view drive set module 105 Assembly sequence April 2013 MAN_EN_1040573_Modul105 142_R2b doc Install new drive set and tighten attachment screws Install angle plate again Install motor flange and motor again see section Motor replacement module 105 page 24 or Replace gear toothed belt module 105 page 26
17. 3850 EN 60201 1 Commissioning of the incomplete machine delivered by us is not permitted until it has been determined that the overall system into which the incomplete machine is installed meets the basic safety and health protection requirements according to Annex of the above EC directive 2006 42 EC Name of the documentation officer Frank Reichelt technical editor Address of the documentation officer see manufacturer s address Furtwangen 06 February 2010 Manfred Bar manager April 2013 Translation of the original instructions Declaration of incorporation MAN_EN_1040573_Modul105 142_R2b doc Modul 105 S 142 S Page 43 of 43
18. I and K see Figure 30 bottom e Pull out the old cover belt insert new greased cover belt e Install both blank holders and the retention plate on the motor side e Tension cover belt install retention plate on the end plate side cut off protruding piece oO Figure 30 Top view linear unit module 105 S Module 142 e Remove retention plates by loosening the attachment screws L see Figure 31 bottom e Pull out the old cover belt insert new greased cover belt e Install the retention plate on the motor side e Tension cover belt install retention plate on the end plate side cut off protruding piece O Figure 31 Top view linear unit module 142 S Repair instructions Translation of the original instructions April 2013 Page 32 of 43 Modul 105 S 142 S MAN_EN_1040573_Modul105 142_R2b doc 7 WERNER 6 2 2 Replace end plate side spindle bearing e Remove retention plate for cover belt on the end plate side see Figure 30 page 32 or Figure 31 page 32 e Remove recessed head screw N and threaded ring M see Figure 32 page 33 end plate side mounting bore in the spindle for fastening M N Figure 32
19. _Modul105 142_R2b doc M Pal M a 3 4 2 1 April 2013 MAN_EN_1040573_Modul105 142_R2b doc brown 24VDC m gt black Signal blue ov Figure 13 Connection designation PNP normally open contact Technical data of the limit switches Parameter Value Operating voltage 10 30 VDC incl residual ripple lt 15 Current load capacity l lt 200 mA Voltage drop at l max lt 2 5 V Switching frequency lt 1 000 Hz Own current consumption lt 15 mA Nominal switching distance on 1 5 mm 410 steel Switching hysteresis 3 20 Reproducibility U const 0 01 mm Operating temperature 25 70 C Protection class IP 65 Short circuit proof yes Protected against polarity yes reversal Pin no assignment IEF cable 1 24V brown 2 limit switch movement green 3 OV white 4 limit switch movement yellow 5 Reference switch grey Figure 14 Plug assignment Translation of the original instructions Modul 105 S 142 S Assembly instructions Page 13 of 43 E WERN 3 4 3 Cable routing For all moving cables suitable cable routing has to be used to effectively prevent cable breaks The minimum radius rmin for cable carriers results from the following formula For IEF cables rmin 2 10 x cable diameter When different cables are used EN 60204 must be observed In addition it must be en
20. al i e the linear modules module 105 and module 142 can be used horizontally as well as vertically CAUTION In the vertical installation position use only motors with spring operated brake to prevent the lowering of the drive in de energized condition 3 2 Module attachment Use of clamping elements permits assembly friendly attachment of the linear units module 105 and module 142 on a level installation surface The drilling distance for installation surface depends on the construction series For cross installation of the linear units there are clamping elements in standard lengths that are equipped with the system drill template of the respective construction size see Attachment of linear modules Figure 2 to Figure 9 on pages 8 to 10 For attachment of a linear module on an installation surface continuous clamping profiles are preferable to clamping elements for safety reasons This avoids shear points likely to cause accidents CAUTION The clamping surface should have a levelness of 0 1 mm m Do not use attachment bores installed in the basic body because this may cause damage to internal parts and tension on the guide basis Hole distance s Figure 2 Attachment of the linear modules with clamping elements clamping profile April 2013 Assembly instructions Translation of the origin
21. al instructions Page 8 of 43 Modul 105 S 142 S MAN_EN_1040573_Modul105 142_R2b doc WERNER Linear module Hole distance s Thread Module 105 124 mm M6 Module 142 168 mm M8 a E Figure 3 Scaled drawing clamping element clamping profile Linear module A B C D Module 105 Module 105 S 24mm 14 3mm 7 7mm 7mm Module 142 Module 142 S 30mm 15 5mm 7 9mm 7 5mm Figure 4 Dimensions of the clamping elements or clamping profiles crushing position s ee p MIM ser Se a oN Pa Se ie lt gt SS al Sai S meee ae ot Sy r wo en gee ae Le shear points Figure 5 Attachment of the linear modules with standard clamping elements crushing position FS LSA Q L Figure 6 Attachment of the linear modules with continuous clamping profiles Assembly instructions Page 9 of 43 Translation of the original instructions Modul 105 S 142 S April 2013 MAN_EN_1040573_Modul105 142_R2b doc IFE WERNER Another version is attachment of the linear modules to their carriage The basic body moves freely However the motor motor brake and limit switch cables as well as the encoder or resolver cables have to be moved along There are special connection screws for
22. d head screw end plate side groove nut mounting bore in the spindle for fastening and secure with threadlocker e Install motor on sliding seat e Screw on motor Coupling Fitted keys Drive shaft Module 1058 gt oS LIL _ Flange Z 7 7 Z7 Basic unit ry Drive shaft Fitted keys AJ Module 1428 gt ee ae Flange Basic unit Figure 34 Cut view coupling version 1 April 2013 Translation of the original instructions Repair instructions MAN_EN_1040573_Modul105 142_R2b doc Modul 105 S 142 S Page 35 of 43 E WERWN 6 2 6 Replace coupling version 2 Elastomer coupling E Figure 35 Cut view coupling version 2 e Loosen attachment screws for motor and pull motor out to the rear e Loosen clamping screws e Remove old coupling halves e Install new coupling halves e Tighten clamping screws CAUTION Tightening torque 11 Nm e Install motor and tighten attachment screws 6 2 7 Replacing the initiator e Desolder the initiator cable from the sleeve e Loosen threaded pin of the ini
23. e 142 Figure 10 Installation example April 2013 Translation of the original instructions Assembly instructions MAN_EN_1040573_Modul105 142_R2b doc Modul 105 S 142 S Page 11 of 43 IFE WERNER 3 4 Wiring 3 4 1 Motors CAUTION Wire the motors according to the motor data sheet When using customer specific motors inquire at the respective manufacturer for the cable suitable for this motor 3 4 2 Initiators Inductive proximity switches PNP normally closed contacts article number 025165 are used as standard stroke limit switches These stroke limit switches are not safety limit switches according to EN60204 1 Optionally an additional reference point switch PNP normally open contact article no 726744 can be installed The active button is marked with a coloured circle Normally closed contacts are marked with a green normally open contacts with a red dot The initiators and their supply lines are protected in a cable channel integrated in the basic body and are centrally wired to a plug A AR L q me a ie Oe ii le 40 20 _ V pt 5 ia active area Figure 11 Initiator dimensions brown 24VDC black Signal 6 F blue OV Figure 12 Connection designation PNP normally closed contact Assembly instructions Translation of the original instructions April 2013 Page 12 of 43 Modul 105 S 142 S MAN_EN_1040573
24. e profile Repair instructions Translation of the original instructions April 2013 Page 30 of 43 Modul 105 S 142 S MAN_EN_1040573_Modul105 142_R2b doc Assembly sequence e Insert new drive set e Attach motor flange to the linear unit by tightening the screws Z e Connect the drive toothed belt to the tappet see Figure 20 page 23 E e Remove end plate see Figure 19 page 22 C D CAUTION The two spacer sleeves D must be installed as shaft stop to reproducibly limit the clamping path of the toothed belt e Attach angle plate see Figure 27 page 28 H e Install motor flange see Figure 29 page 30 Z e Connect toothed disc with drive set shaft by clamping set Push the clamping set all the way to the rear Observe that the screws Y see Figure 29 page 30 are tightened evenly in sequence Check that the toothed disc turns freely e Install motor to motor flange e Install gear toothed belt e Push the motor away from the basic body the gear toothed belt is tensioned Then tighten the motor attachment screws e Attach motor flange cover again see Figure 26 page 27 X April 2013 Translation of the original instructions Repair instructions MAN_EN_1040573_Modul105 142_R2b doc Modul 105 S 142 S Page 31 of 43 IFE WERNER 6 2 Module 105 S and Module 142 S 6 2 1 Replacing the cover belt Module 105 e Remove retention plates and blank holders by loosening the attachment screws
25. ear module series great importance was placed on the use of low maintenance components All roller elements were provided with lifetime lubrication in the factory To avoid danger of over lubrication of the linear bearings no external lubrication nipples were attached to the carriage part However to achieve a high service life of the wipers we recommend moistening the guide shafts with special grease at regular intervals Proceed accordingly when using a ball screw The lubricant may be procured from IEF in tubes of 50 gram each special grease for linear bearings Article no 732934 special grease for spindles article no 729148 If a bellows is used it should also be regularly cleaned from gross contamination The recommended maintenance intervals add up to approx 200 operating hours under regular ambience conditions Under difficult conditions high dust share high humidity high temperature the maintenance intervals should be reduced NOTE Never use compressed air for cleaning Maintenance Translation of the original instructions April 2013 Page 18 of 43 Modul 105 S 142 S MAN_EN_1040573_Modul105 142_R2b doc ee WERNE 5 Troubleshooting Interference Reason Correction Increased Nominal service life of linear bearing Replace all linear bearings running noise exceeded Linear bearing worn from overload Replace all linear bearings reduce load too high torque etc Linear bearing worn from s
26. eeves see Figure 19 top D must be installed as shaft stop to reproducibly limit the clamping path of the toothed belt e Tighten the connection screws see Figure 18 page 21 B between carriage plate and clamping block Connect tappet and carriage unit see Figure 18 page 21 A April 2013 Repair instructions Translation of the original instructions Page 22 of 43 Modul 105 S 142 S MAN_EN_1040573_Modul105 142_R2b doc W M a M 6 1 2 Replacement of the deflection unit Disassembly sequence e Disconnect the carriage unit from the tappet by loosening the two connection screws centrally installed in running direction see Figure 18 Page 21 A e Remove the end plate by loosening the four connection screws C The toothed belt is relieved see Figure 19 page 22 e Open the tappet by loosening the connection screws see Figure 20 bottom E Figure 20 Belt parts fastener tappet e Replacement of the conversion unit old spacer sleeves are reused see Figure 19 page 22 D CAUTION Ensure that the axial bearing unit has enough play inside the basic body e Connect the toothed belt to the tappet see Figure 20 top E e Attach end plate see Figure 19 page 22 C NOTE The two spacer sleeves D must be installed as shaft stop to reproducibly limit the clamping path of the toothed belt The old spacer sleeves should be reused e Connect carriage unit and tappet see Figure 18 pa
27. ge 21 A April 2013 Translation of the original instructions Repair instructions MAN_EN_1040573_Modul105 142_R2b doc Modul 105 S 142 S Page 23 of 43 E WERN 6 1 3 Motor replacement module 105 Version 1 Disassembly sequence Remove loosen the connection screws of the motor flange the gear toothed belt is relieved see Figure 21 bottom F CHO IO Ol O 7 3 Y Figure 21 Linear unit and belt gear drive version 1 Loosen connection screws between motor and motor flange Take out motor by tilting up and pulling towards the back Remove motor toothed disc from the motor shaft and then install it on the new motor Motor toothed disc is built differently depending on order see Figure 22 bottom e Type 1 Toothed disc with separate clamping set Type 2 Toothed disc with integrated clamping set and central clamping e Type 3 Toothed disc with integrated clamping cone and 5 clamping screws e Type 4 Toothed disc with keyway a Type 4 HV p KA NS V OS o YA SS F b SIX ane O Figure 22 Motor toothed disc designs Repair instructions Translation of the original instructions April 2013 Page 24 of 43 Modul 105 S 142 S MAN_EN_1040573_Modul105 142_R2b doc ee CAUTION Do not impac
28. i WERNER Translation of the original instructions Module 105 S 142 S Issue April 2013 Article no 1040573 IEF Werner GmbH WendelhofstraBe 6 78120 Furtwangen Germany Phone 49 7723 925 0 Fax 49 7723 925 100 www lEF Werner de April 2013 Translation of the original instructions MAN_EN_1040573_Modul105 142_R2b doc Modul 105 S 142 S Page 1 of 43 i M d M d Change History Document code Date Revision MAN_EN_1040573_Modul105_142_R1a doc May 2006 Release of the English document MAN_EN_1040573_Modul105_142_R2a doc pals Changes to the couplings for parallel drive Document updated regarding the new machinery directive MRL 2006 42 EC April 2013 Translation from German Document MAN_EN_ 1040573 Modul105_ 142 _R2b doc MAN_DE_1040545_Modul105_ 142 R4a doc Formal changes Trademarks and trade names are used without any warranty of their free usability Texts and examples were created with great care Nevertheless errors cannot be excluded IEF Werner GmbH does not assume legal responsibility nor any liability for missing or incorrect statements and their consequences IEF Werner GmbH reserves the right to modify or improve the software or hardware or parts of it as well as the supplied documentation or parts of it without previous notice IEF Werner GmbH expressly reserves all rights for replication and photomechanical reproduction including in extracts We are always grateful for
29. on screws in running direction to uncouple the carriage unit from the tappet toothed belt See Figure 18 bottom A fo S N MAN B o9 g aN Oo fe o m A I i se oe I ON i o o Go Figure 18 Top view linear unit Repair instructions Translation of the original instructions Page 21 of 43 April 2013 Modul 105 S 142 S MAN_EN_1040573_Modul105 142_R2b doc WERNER Remove the deflection side end plate by loosening the four connection screws C The toothed belt is relieved see Figure 19 bottom Figure 19 Deflection unit Pull the entire carriage unit from the guide shafts e Push the defective linear bearings from the fitting bores CAUTION As of 07 99 the linear bearings are secured with threaded pins Remove threaded pins before uninstalling the linear bearings After replacement of the linear bearings install the threaded pins again as safety device Assembly sequence Install new greased linear bearings Before installing the carriage unit the screw connection B between carriage plate and e e clamping block see Figure 18 page 21 must be loosened to avoid tensioning of the linear bearings during insertion into the guide e Install end plate NOTE Attention The two spacer sl
30. rip serving as profile groove cover and the defective initiator Insert the new initiator and cover strip again Insert initiator cable into the basic body through the bore Solder the initiator cable to the installation plug Attach the sheet again install the motor again if required 6 1 8 Replacing the drive toothed belt Disassembly sequence Disconnect the carriage unit from the tappet by loosening the two connection screws centrally installed in running direction see Figure 18 Page 21 A Remove the deflection side end plate by loosening the four connection screws C The toothed belt is relieved see Figure 19 page 22 Remove the motor side angle plate see Figure 27 page 28 H This may require removal of the motor see section Motor replacement module 105 page 24 or Motor replacement module 142 page 27 Open the tappet by loosening the connection screws see Figure 20 page 23 E Replace toothed belt Assembly sequence Connect the toothed belt to the tappet see Figure 20 page 23 Attach angled plate again see Figure 27 page 28 H Attach end plate see Figure 19 page 22 CAUTION The two spacer sleeves D must be installed as shaft stop to reproducibly limit the clamping path of the toothed belt Connect carriage unit and tappet see Figure 18 page 21 A Repair instructions Translation of the original instructions April 2013 Page 28 of 43 Modul 105 S 142 S MAN_EN_1040573_Modul105 142_R
31. s or control Check the power electronics or the control unit unit Motor cable defective Check motor cable replace cable if required April 2013 Translation of the original instructions Troubleshooting MAN_EN_1040573_Modul105 142_R2b doc Modul 105 S 142 S Page 19 of 43 IFE WERNER Troubleshooting continued Interference Reason Correction Reverse play Gearbox toothed belt not tensioned Tension gear toothed belt lee sarge Motor toothed disk has play key Replace motor toothed disc if motor shaft connection keyway is damaged replace motor Tension drive toothed belt Pull deflection unit to stop on spacer sleeves Linear drive unit Incorrect direction of rotation Change motor direction of rotation moves mechanically Broken motor cable Replace cable against the stop during the reference run Troubleshooting Translation of the original instructions April 2013 Page 20 of 43 Modul 105 S 142 S MAN_EN_1040573_Modul105 142_R2b doc 6 Repair instructions WARNING Always power down the system before starting repairs WARNING Any repairs must only be performed by specialist personnel who have read and understood the operating instructions CAUTION Only use original replacement parts otherwise IEF Werner GmbH will not accept any warranty 6 1 Module 105 and Module 142 6 1 1 Replacement of the linear bearings Disassembly sequence Loosen the two central connecti
32. sured that a space reserve of 30 is kept free within the routing chains A strain relief for the cables has to be attached at the outlet of the cable routing chain April 2013 MAN_EN_1040573_Modul105 142_R2b doc Translation of the original instructions Modul 105 S 142 S Assembly instructions Page 14 of 43 3 5 Technical data Module Module Module 105 105 S NV oye 0 E 2 142S Weight increase per 100 mm stroke Figure 15 Torques and carrying capacity module 105 and module 142 Translation of the original instructions Assembly instructions Page 15 of 43 April 2013 Modul 105 S 142 S MAN_EN_1040573_Modul105 142_R2b doc E ERN 3 5 1 Critical spindle speed While the maximum movement speed in linear modules with toothed belt drive is generally limited by the drive motor the critical spindle speed in linear modules with spindle drive require observation of the critical spindle speed It determines the maximum possible movement speed in particular for longer strokes see Figure 16 page16 movement speed calculated from the spindle speed according to the following equation v movement speed mm s n spindle speed rpm h spindle pitch mm 2500 2000 1500 1000 Spindle speed U min 500 3 5 2 Type label Stroke mm 500 1000 1500 Figure 16 Critical spindle speed IEF Werner GmbH Wendelhofstrabe 6
33. t the motor shaft Assembly sequence Wire the new motor according to the motor data sheet Check direction of rotation Install motor to motor flange Push motor and motor flange away from the basic body the gear toothed belt is tensioned then tighten connection screws see Figure 21 page 24 F Version 2 Disassembly sequence Remove the motor flange cover by loosening the attachment screws G see Figure 23 bottom Figure 23 Linear unit and belt gear drive version 2 Uncouple the motor and motor flange plate by loosening the attachment screws Remove motor toothed disc see Figure 22 page 24 from the motor shaft Assembly sequence April 2013 Install motor toothed disc see Figure 22 page 24 on the new motor Wire the new motor according to the motor data sheet Check direction of rotation Install motor to motor flange plate Before tightening the attachment screws push the motor away from the basic body the gear toothed belt is tensioned then Tighten the attachment screws Attach the motor flange cover again Translation of the original instructions Repair instructions MAN_EN_1040573_Modul105 142_R2b doc Modul 105 S 142 S Page 25 of 43 E WERN 6 1 4 Replace gear toothed belt module 105
34. tiator e Replace cover strip and defective initiator through the provided bores in the end plate e Solder the initiator cable to the sleeve Repair instructions Translation of the original instructions April 2013 Page 36 of 43 Modul 105 S 142 S MAN_EN_1040573_Modul105 142_R2b doc 6 2 8 Replacement of spindle Disassembly sequence April 2013 Caution Never turn the spindle nut off of the spindle Remove the motor Remove retention plate for cover belt on the end plate side see Figure 30 page 32 or Figure 31 page 32 Remove recessed head screw N see Figure 32 page 33 end plate side mounting bore in the spindle for fastening Remove end plate by loosening the four attachment screws O see Figure 32 page 33 Disconnect carriage from the tappet by loosening the attachment screws Q see Figure 33 page 34 Remove spindle with tappet from the basic body towards the end plate side Disconnect tappet from spindle nut for module 105 S the pressure plate R and for module 142 S the threaded ring S see Figure 36 page 37 must be removed from the tappet Remove the tappet from the spindle nut Module 105 S Module 142 S Figure 36 Tappet module 105S and module 142S Translation of the original instructions Repair instructions MAN_EN_1040573_Modul105 142_R2b doc Modul
35. tions April 2013 Page 42 of 43 Modul 105 S 142 S MAN_EN_1040573_Modul105 142_R2b doc IFE WERNER 8 Declaration of incorporation EC declaration of incorporation in the sense of the EC directive 2006 42 EC machinery Annex Il B The manufacturer IEF Werner GmbH WendelhofstraBe 6 78120 Furtwangen Germany hereby declares that the following products the incomplete machines partial machines IEF Werner parts group numbers Module 105 105S Module 105 TG1000012 module 105S TG1000014 Module 142 142S module 142 TG1000015 module 142S TG1000017 where possible based on the scope of delivery correspond to the following basic requirements of the directive on Machinery 2006 42 EC e Annex I item 1 1 2 1 1 3 1 1 5 1 3 2 1 3 4 1 5 1 1 7 3 The incomplete machines also correspond to the following further directives Directive 2004 108 EC of the council dated 15 December 2004 for harmonisation of the legal provisions of the member states on electromagnetic compatibility Directive 2006 95 EC of the council dated 12 December 2006 for harmonisation of the legislation of the member states regarding electrical equipment for use within specified voltage thresholds The technical documents were generated according to Annex VII part B and may be electronically submitted to the national authorities upon justified request List of some applied harmonised standards EN ISO 12100 1 2 EN ISO 13857 EN ISO 1
36. trong Replace all linear bearings clean guide contamination elements guide shafts more often if required or use bellows Guide shafts worn Replace guide shafts replace all linear bearings check load protect linear module from strong contamination use bellows if required Guide shafts corroded Replace guide shafts replace linear bearing if required lubricate guide shafts more often Deflection unit worn Replace deflection unit Toothed belt runs dry Slightly lubricate toothed belt on the toothed inner side Toothed belt tension too high Install reconciled spacer sleeves as shaft stop Toothed belt runs diagonally Align toothed belt with belt fastener carriage plate and tappet install reconciled spacer sleeves Toothed belt strongly contaminated Replace toothed belt protect linear module on the toothed inner side from strong contamination Toothed belt defective Replace toothed belt Motor motor bearing defective Replace motor Motor with brake brake does not Apply current to the brake if the brake still open does not open replace motor Linear drive unit Limit switch cable not connected Connect the cable does not move Limit switch defective Replace limit switch Limit switch cable defective Check limit switch cable Solder connection on socket has Solder on wires come loose Motor connected incorrectly Check and change connector assignment if required Motor defective Replace motor Error in power electronic
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