user manual electrical rotary unit dae-60 ba-100074
Contents
1. plug of encoder flat Flange of the toothed disk cable Encoder Item 50 Encoder Motor wires Motor Toothed disk flat cable end Item 50 Item 50 Introduction The motor with toothed disk item 50 is a unit consisting of the following components A motor with 8 wires An encoder with flat cable and multipoint connector plug A toothed disk In order to replace the motor the DAE must be dismantled and possibly even the add on units During operation the surfaces of the motor and permanent magnet brake can reach 100 C Do not touch the parts until they have cooled to below 40 C measure the surface temperature During work on the DAE 60 it must be ensured that the unit energy of the EC Motor Controller ECMR is switched off and cannot be switched on by unauthorized persons Preparation 1 Stop all travel jobs 2 Disable the EC Motor Controller ECMR 3 Switch off the voltage of the EC Motor Controller ECMR and ensure that it cannot be switched on by unauthorized persons Dismantle the DAE 60 and if necessary also the add on units Loosen the 2 screws item 530 and the screw item 540 and remove the cover item 20 Unplug the encoder multipoint connector plug item 50 Loosen the 2 screws item 520 and remove the terminal group item 150 Loosen the screw item 360 and remove the cover item 40 ae Se 21 MON ECH User Manual Electrical Rotary Unit DAE 60 Replacing the m2. Toothed belt tension gt Chapter 4 4 from point 6 23 MON ECH User Manual Electrical Rotary Unit DAE 60 4 4 Toothed belt tension Reference exploded view in chapter 5 During operation the surfaces of the motor and permanent magnet brake can reach 100 C Do not touch the parts until they have cooled to below 40 C measure the surface temperature A During work on the DAE 60 it must be ensured that the unit energy of the EC Motor Controller ECMR is switched off and cannot be switched on by unauthorized persons Excessively strong tensioning of the toothed belt item 400 can lead to destruction of the motor bearing Preparation 1 2 3 Stop all travel jobs Disable the EC Motor Controller ECMR Switch off the voltage of the EC Motor Controller ECMR and ensure that it cannot be switched on by unauthorized persons Toothed belt tension X M W L a Loosen the screw item 360 and remove the cover item 40 Slightly loosen the 4 screws item 390 The motor item 50 can be moved but is not loose Move the motor item 50 so that the toothed belt item 400 is lightly tensioned Hold the motor item 50 and tighten the 4 screws item 390 Fix the cover item 40 with the screw item 360 on the housing item 30 Final work 9 10 11 12 13 24 Switch on the voltage of the EC Motor Controller ECMR Enable the EC Motor Controller ECMR Carry out the
3. G 2 2 II EA 2 2 22 BU 2 r UE ij Eh 0 b 0 Oe i DM cu 0Q 40 Designation Electrical rotary unit DAE 60 complete Housing Cover one part Housing gear Cover gear coated Motor with toothed disk Flange bottom Guide Output shaft Flange internal Crown wheel z130 Encoder terminal group Motor sensor terminal group Clamping piece for proximity switch Clamping screw for 47906 Toothed disk GT 2MR 80S Flange for clamping set 7x10x4 5 Shaft gear Gear ring Nameplate CE Nameplate cover Cylinder head screw hex socket M4x12 vz BN3 Circlip shaft 8x0 8 sw BN818 Deep groove ball bearing 1r 8x22x7 608 2RSR Circlip bore 22x1 sw BN822 Cylinder head screw hex socket M8x8 sw BN1206 Ribbed washer M4x7x0 5 vz BN792 Cylinder head screw hex socket M4x18 vz BN3 Cable lug fork M3 0 5 1 insulated Ribbed washer M3x5 5x0 45 sw BN 791 Cylinder head screw hex socket M3x6 sw BN272 Toothed belt GT 2MR 208x9 Protective stopper 4x6x4 PE black Cylinder head screw hex socket M4x14 vz BN3 Cylinder head screw hex socket M3x14 vz BN3 Cylinder head screw hex socket M3x20 vz BN3 Deep groove ball bearing 1r 25x47x12 6005 2RSR Shrink disk 24x21 M5x16 TLK603 half S Deep groove ball bearing 1r 20x37x9 6904 RS Cable screw union M12x1 5 short Cable PU 18x0 14mm2 Ref No 57835 57509 57510 57507 57587 57475 57317 57382 57319 57312 57504 57085 57281 47906 47904 5
4. and remove the cover item 10 Additional operation Vent the permanent magnet brake gt Chapter 4 7 Additional operation Loosen the 2 screws item 190 and carefully remove the holder item 20 The following should be noted The 2 wires of the permanent magnet brake item 100 should not be subjected to mechanical stress Replaces the description in the chapter 4 4 Fix the holder item 20 with the 2 screws item 190 on the housing item 30 In this operation the following should be noted The wires of the permanent magnet brake item 100 must be lightly tightened during mounting so that no loop forms behind the holder item 20 Additional operation Check the air gap gt Chapter 4 7 3 Additional operation Switch off voltage of the permanent magnet brake Additional operation Carefully fold the 2 wires item 100 and fix the cover item 10 with the screw item 110 4 7 8 Zero point adjustment DAE 60 with permanent magnet brake All relevant information is mentioned in the chapter 4 5 37 MONECH User Manual Electrical Rotary Unit DAE 60 4 7 9 Gear play adjustment DAE 60 with permanent magnet brake All relevant information is mentioned in the chapter 4 6 it being necessary to take into account the following differences Specific operation for DAE 60 with permanent magnet brake gt Reference exploded view in chapter 5 1 4 4a 4b 12 12a 12b 12c 38 Replaces the
5. 2 3 MONECH User Manual Electrical Rotary Unit DAE 60 DAE 60 travel time Travel times were determined under the following conditions Symbol J wm 1000 V s SP Position of the horizontal vertical horizontal vertical horizontal vertical drive shaft Value 250 400 variable 300 500 2500 ___ 3o00 Beginning of the measurement with the Start motion task signal on ECMR terminal X5 6 End of the measurement with the INPOS in position signal on ECMR terminal X7 3 The travel time is measured between the signals Start motion task and INPOS In position window setting ECMR software 250 1000 plk Nav u 350 gl 250 200 4 i 180 100 5 1 ae 1 Y p BED T SE E S N DE Ez a 100 150 200 250 200 350 400 450 500 550 800 850 rog 750 ago 850 00 950 1000 1050 1100 1150 1200 1250 1300 1350 t ms m horizontal vertical Symbol Unit Designation J Kgcm2 Mass moment of inertia of add ons and or load t ms Travel time per rotation angle 0 Rotation angle or stroke W s Rotational speed q s a angular acceleration a angular delay MON ECH User Manual Electrical Rotary Unit DAE 60 2 4 Dimensions 2 4 1 Dimensions of DAE 60 Direction of rotation from reference point f 0 Reference number DAE 60 10 MONECH User Manual Electrical Rotary Unit DAE 60 2 4 2 Dimensions of DAE 60 with permanent ma
6. Inductive proximity switch Inside device Output cable 18x0 14mm Designation Wire color Terminal Wire color Terminal U ind proximity switch Brown a Red b GND ind proximity switch Blue a OV Blue b OV Output Black a 11 Black b 11 Note U ind proximity switch is connected internally to U Hall sensors GND ind proximity switch is connected internally to GND Hall sensors 3 3 4 Permanent magnet brake Inside device Output cable 18x0 14mm Designation Wire color Terminal Wire color Terminal GND Blue b OV Blue b OV permanent magnet brake U Red a 12 Violet b 12 permanent magnet brake Note GND permanent magnet brake is connected internally to GND Hall sensors 3 4 Wiring the controller ECMR Please refer to Operating Instructions BA 100078 ECMR EC Motor Controller electrical and software part 19 MONFECH User Manual Electrical Rotary Unit DAE 60 4 Mechanical design 4 1 Lubrication Reference exploded view in chapter 5 Shaft teeth item 200 DAE 60 without lubrication stopper item 340 ANI Bi Output shaft item 90 Only the miter gears item 120 and item 200 require subsequent lubrication It is essential to use only Kl ber grease Staburags NBU12 300KP Montech ref no 508501 Lubrication interval 800 operating hours During operation the surfaces of the motor and permanent magnet brake can reach 100
7. Manual Electrical Rotary Unit DAE 60 Replacing the toothed belt Reference exploded view in chapter 5 During operation the surfaces of the motor and permanent magnet brake can reach 100 C Do not touch the parts until they have cooled to below 40 C measure the surface temperature A During work on the DAE 60 it must be ensured that the unit energy of the EC Motor Controller ECMR is switched off and cannot be switched on by unauthorized persons Excessively strong tensioning of the toothed belt item 400 can lead to destruction of the motor bearing Preparation 1 2 3 4 Stop all travel jobs Disable the EC Motor Controller ECMR Switch off the voltage of the EC Motor Controller ECMR and ensure that it cannot be switched on by unauthorized persons Loosen the screw item 360 and remove the cover item 40 Replacement of toothed belt eS E 10 Remove the 4 screws item 390 so that the motor item 50 is free Tilt the motor item 50 as obliquely as possible Remove the toothed belt item 400 First push the new toothed belt item 400 onto the toothed disk of the motor item 50 Carefully push the toothed belt over the toothed disk item 180 Slowly position the motor item 50 perpendicular to the housing item 30 Fix the motor item 50 with the 4 screws item 390 on the housing item 30 Only slightly tighten the 4 screws item 390 so that the motor can still be moved
8. The play should be checked approximately every 90 over a full revolution of the output shaft item 90 Due to the manufacturing tolerances the backlash cannot always be completely eliminated over a whole turn of the driving shaft Pos 90 The adjustment is complete as soon as a free backlash adjustment is reached in any position of the driving shaft Pos 90 Final work 11 Tighten the 4 screws item 360 12 Fix the cover item 40 with screw item 360 on the housing item 30 13 Switch on the voltage of the EC Motor Controller ECMR 14 Enable the EC Motor Controller ECMR 15 Carry out the reference travel 28 MON ECH User Manual Electrical Rotary Unit DAE 60 4 7 Option permanent magnet brake During operation the surfaces of the motor and permanent magnet brake can reach 100 C Do not touch the parts until they have cooled to below 40 C measure the surface temperature During work on the DAE 60 it must be ensured that the unit energy of the EC Motor Controller ECMR is switched off and cannot be switched on by unauthorized persons The air gap must not exceed or be less than the specified value gt Chapter 4 7 3 The mounted components in particular the friction surfaces must be free of grease Note The chapter 1 up to and including 3 is also applicable to the permanent magnet brake Permanent magnet brake actuation in the automatic mode The scope of delivery of the DAE 60 r
9. 7611 57508 57304 57506 41620 48508 502506 502446 520117 520286 520267 502606 508473 520345 502363 501602 520357 520348 508472 520057 520107 504916 520327 508130 520197 520261 Material Al Al Al Al Diverse Al Steel Steel Al Steel Diverse Diverse Steel Steel Al Steel Steel Al Polyester Polyester Steel Steel Steel Steel Steel Steel Steel Diverse Steel Steel Polyurethane PE Steel Steel Steel Steel Steel Steel Brass Diverse 510 520 530 540 550 560 570 ol co EA Tol 2 2 2 sd Cable PU 3x0 5mm2 screened Thread grooving cheesehead screw M3x6 vz BN13916 Countersunk screw hex socket M4x35 vz BN21 Countersunk screw hex socket M4x12 vz BN21 Inductive proximity switch PNP 6 5x22x2000 Clamping set 7x10x4 5 Cable screw union M12x1 5 short EC Motor Controller ECMR e These are wearing parts and are available from stock Not available from stock individually upon request o Price listed items available from stock MON ECH User Manual Electrical Rotary Unit DAE 60 520260 506341 520284 506845 508842 520268 520406 57332 Diverse Steel Steel Steel Diverse Steel Brass Diverse 41 MONFECH User Manual Electrical Rotary Unit DAE 60 5 1 Parts list for DAE 60 permanent magnet brake option Exploded view 30 100 170 180 20 100 140 160 140 120 160 120 150 150 150 110 130 10 120 120 120 Item Sym Designation Ref no Material a DAE 60
10. C Do not touch the parts until they have cooled to below 40 C measure the surface temperature When working on the DAE 60 it is necessary to ensure that the unit energy of the EC Motor Controller ECMR is switched off and cannot be switched on by unauthorized persons Preparation 1 Stop all travel jobs 2 Disable the motor control 3 Switch off the voltage of the EC Motor Controller ECMR and ensure that it cannot be switched on by unauthorized persons Lubrication 4 Remove the lubrication stopper item 340 5 Lubricate the teeth of the shaft item 200 by means of a thin and long object e g a screwdriver gt approx 5ml Kluber grease Staburags NBU12 300KP 6 Turn the shaft item 90 through approx 45 7 Carry out the lubrication again as described above 8 Repeat the lubrication process until a full revolution of the output shaft item 90 has been achieved Install the lubrication stop item 340 again and tighten 10 If possible move the output shaft item 90 manually back and forth through 360 so that the grease is uniformly distributed Final work 11 Switch on the voltage of the EC Motor Controller ECMR 12 Enable the EC Motor Controller ECMR 13 Carry out the reference travel 20 MONECH User Manual Electrical Rotary Unit DAE 60 4 2 Replacing the motor Reference exploded view in chapter 5 Motor with toothed disk Ran Encoder Multipoint connector flat cable
11. CMR 3 Switch off the voltage of the EC Motor Controller ECMR and ensure that it cannot be switched on by unauthorized persons 4 Build up the DAE 60 on a firm substructure unless this has already been done 5 Remove the add on units if necessary 6 Switch on the voltage of the EC Motor Controller ECMR again Zero point adjustment 7 Start the reference travel with the software and wait until the output shaft item 90 finally remains stationary 8 Using the software check that the reference travel is complete 9 Switch off the voltage of the EC Motor Controller ECMR and ensure that it cannot be switched on by unauthorized persons 10 Mount the add on units again Ensure that the output shaft item 90 is moved as little as possible Final work 11 Switch on the voltage of the EC Motor Controller ECMR 12 Start the reference travel with the software again Ensure that the add on units permit reference travel and that there is no obstacle in the way 13 Small positional corrections can be made with the function reference offset in the software If larger corrections to the position are required the load can be repositioned 25 MONFECH User Manual Electrical Rotary Unit DAE 60 4 6 Adjustment of gear play Reference exploded view in chapter 5 Isometric view from above without cover item Isometric view from below 40 Bore access to item 190 Bores in item 190 Side view ze oe
12. Density a cm Length b cm Width d cm Diameter h cm Height 13 MON ECH User Manual Electrical Rotary Unit DAE 60 2 8 Calculation of mass moments of inertia of add on units Total mass moments of inertia Z Jz1 m1 J J 2 J m a 2 Tot 2 J J m a J m b Tot 2 2 2 Jie J tm a J m b J m d a b c d cm Length J kgcm Total mass moment of inertia of add on units with axis of rotation Z Z Ja J J kgcm Mass moment of inertia of the individual parts m m m kg Mass of the individual parts Z Z Axis of rotation 14 MONECH User Manual Electrical Rotary Unit DAE 60 3 Commissioning 3 1 Installation position and assembly Reference Exploded view in chapter 5 As a rule the housing item 10 is fixed and the rotational movement is performed by the output shaft item 90 The position of the output shaft item 90 provides information about the DAE 60 version which is to be used The output shaft item 90 is vertical Device DAE 60 reference number 57490 is suitable The drive shaft pos 90 is not vertical the DAE 60 device article no 57490 with the optional permanent magnet brake article no 57550 is suitable Properties of the permanent magnet brake Inthe case of a currentless torque free motor the load is held by the permanent magnet brake A movement of the load is thus prevented This is important especiall
13. MON ECH USER MANUAL ELECTRICAL ROTARY UNIT DAE 60 Mechanical Part BA 100074 Starting from serial number 430044 English Edition 02 2008 MON ECH User Manual Electrical Rotary Unit DAE 60 Contents 1 Important information 3 1 1 Introduction 3 1 2 EU conformance to EU Directive on Machine Appendix II A 3 1 3 Product description and application 3 1 4 Dangers 4 1 5 Additional information 4 1 6 Validity of User Manual 5 2 Technical data 6 2 1 Technical data for DAE 60 6 2 2 Option permanent magnet brake 8 2 3 DAE 60 travel time 9 2 4 Dimensions 10 2 4 1 Dimensions of DAE 60 10 2 4 2 Dimensions of DAE 60 with permanent magnet brake 11 2 5 Scope of delivery 12 2 6 Load calculation 12 2 7 Calculation of mass moments of inertia of parts 13 2 8 Calculation of mass moments of inertia of add on units 14 3 Commissioning 15 3 1 Installation position and assembly 15 3 2 Mounting of the add on units load 16 3 3 Internal wiring and cable connections 17 3 3 1 Motor 18 3 3 2 Encoder 18 3 3 3 Inductive proximity switch 19 3 3 4 Permanent magnet brake 19 3 4 Wiring the controller ECMR 19 4 Mechanical design 20 4 1 Lubrication 20 4 2 Replacing the motor 21 4 3 Replacing the toothed belt 23 MON ECH User Manual Electrical Rotary Unit DAE 60 4 4 4 5 4 6 4 7 4 7 1 4 7 2 4 7 3 4 7 4 4 7 5 4 7 6 4 7 7 4 7 8 4 7 9 5 5 1 Toothed belt tension Zero poi
14. QU e Bores in item 190 30 440 10 200 10 N z NE SNA WE El a 2 pe e 4 E F ail i Ra E 10 300 80 180 190 350 re a Bs Bores in item 190 26 MONECH User Manual Electrical Rotary Unit DAE 60 Note The gear play has already been set at the factory and usually does not need to be adjusted Overview The housing item 10 contains a miter gear consisting of a crown wheel item 120 and a pinion shaft item 200 The gear play is adjusted by moving the housing item 30 with the screws item 430 and 440 The screws item 430 and item 440 are used for adjusting the gear play and must never be tightened The screw item 430 is reached through a bore in the flange item 60 The housing is guided by 2 guides item 70 and is screwed tight by means of 4 screws item 360 In order to reach the 4 screws item 360 through the bores in the flange item 190 and the pinion item 180 the pinion item 180 is turned until the position according to the above drawing side view is reached During operation the surfaces of the motor and permanent magnet brake can reach 100 C Do not touch the parts until they have cooled to below 40 C measure the surface temperature During work on the DAE 60 it must be ensured that the unit energy of the motor control is switched off and cannot be switched on by unauthorized persons The adjus
15. Reference Exploded view in chapter 5 The terminal groups are located under the cover item 20 Loosen the 2 screws item 530 and the screw item 540 in order to remove the cover item 20 Legend Item 130c terminal strip c Item 150a terminal strip a Item 150b terminal strip b Item 370 screen connection 17 MON ECH User Manual Electrical Rotary Unit DAE 60 3 3 1 Motor Inside device Output cable 3x0 5mm Wire color White Brown Green Screen Terminal b 1 b 2 b 3 Item 370 Output cable 18x0 14mm Wire color White Brown Green Yellow Grey Pink Blue Red Designation Wire color Terminal Motor winding 1 Red a 1 Motor winding 2 Black a 2 Motor winding 3 White a 3 Screen connection n c n c Inside device Designation Wire color Terminal n c n c n c n c n c n c n c n c n c Hall sensor 1 Yellow a8 Hall sensor 2 Brown a9 Hall sensor 3 Grey a 10 GND Hall sensor Blue a 0V U Hall sensor Green a Note n c Not connected 3 3 2 Encoder Inside device Designation Wire color Terminal Vcc Encoder GND Encoder A emer A N B emer nada Mulk we B emer 18 Terminal n c n c n c b 8 b9 b 10 b OV b Output cable 18x0 14mm Wire color Grey pink Red blue White green Brown green White yellow Yellow brown White grey Grey brown Terminal c2 c3 c5 c c c8 c9 c 10 MON ECH User Manual Electrical Rotary Unit DAE 60 3 3 3
16. and permanent magnet brake can reach 100 C Do not touch the parts until they have cooled to below 40 C measure the surface temperature During work on the DAE 60 it must be ensured that the unit energy of the EC Motor Controller ECMR is switched off and cannot be switched on by unauthorized persons DAE 60 with permanent magnet brake without cover item 10 sectional view from above fo Installation site of 60 the screws item Air gap item 100 adjustable nts wee Ye Item 100 SSS N Qt Ft hub SZ zl N N N a e SS Item 100 ww NA IN me Zal s em 100 au 2 wires TY _ Parts list sarin Chapter Fehler Varnaraicaualla Lannta nicht Preparation 1 Stop all travel jobs 2 Disable the EC Motor Controller ECMR 3 Switch off the voltage of the EC Motor Controller ECMR and ensure that it cannot be switched on by unauthorized persons gt Reference exploded view in chapter 5 4 Loosen the 2 screws item 530 and the screw item 540 and remove the cover item 20 5 Loosen the screw item 360 and remove the cover item 40 These parts are no longer required 6 Remove stopper item 410 This part is no longer required 30 MON ECH User Manual Electrical Rotary Unit DAE 60 Mounting the permanent magnet brake gt Reference exploded view in chapter 5 1 1 2 3 4 oF 6 Loosen the screw item 110 and remove the cover item 10 Remove the hub
17. annot be switched on by unauthorized persons 4 Loosen the screw item 110 and remove the cover item 10 34 MON ECH User Manual Electrical Rotary Unit DAE 60 Adjustment 5 Vent the permanent magnet brake gt Chapter 4 7 6 Turn the output shaft item 90 exploded view in chapter 5 until both screws item 180 are visible in one opening each of the cover item 30 7 The air gap between the brake surfaces of the permanent magnet brake item 100 reachable through the openings of the cover item 30 should be within the tolerance Air gap tolerance Nominal value mm 0 3 Minimum value mm 0 15 Maximum value mm 0 35 7 Slightly loosen the 2 screws item 180 9 Adjust the air gap and tighten the 2 screws item 180 10 Check the air gap 11 Switch off the voltage of the permanent magnet brake Final work 11 Carefully fold the 2 wires item 100 and fix the cover item 10 with the screw item 110 12 Switch on the voltage of the EC Motor Controller ECMR 13 Enable the EC Motor Controller ECMR 14 Carry out the reference travel 4 7 4 Lubrication DAE 60 with permanent magnet brake All relevant information is mentioned in the chapter 4 1 it being necessary to take into account the following differences Specific operation for DAE 60 with permanent magnet brake 5a Additional operation Vent the permanent magnet brake gt Chapter 4 7 10a Additional operation Switch off the v
18. apter 4 3 it being necessary to take into account the following differences Specific operation for DAE 60 with permanent magnet brake gt Reference exploded view in chapter 5 1 5 ba 5b Replaces the description in the chapter 4 3 Loosen the screw item 110 and remove the cover item 10 Additional operation Vent the permanent magnet brake gt Chapter 4 7 Additional operation Loosen the 2 screws item 190 and carefully remove the holder item 20 The following should be noted The 2 wires of the permanent magnet brake item 100 should not be subjected to mechanical stress Replaces the description in the chapter 4 3 Carefully push the toothed belt over the holder item 20 and the cover item 30 and remove Replaces the description in the chapter 4 3 First carefully push the new toothed belt over the holder item 20 and the cover item 30 and then push onto the toothed disk of the motor item 50 Toothed belt tension gt Chapter 4 7 7 36 MONECH User Manual Electrical Rotary Unit DAE 60 4 7 7 Toothed belt tension DAE 60 with permanent magnet brake All relevant information is mentioned in the chapter 4 4 it being necessary to take into account the following differences Specific operation for DAE 60 with permanent magnet brake gt Reference exploded view in chapter 5 1 4 4a 4b 8a 8b 8c Replaces the description in the chapter 4 4 Loosen the screw item 110
19. d movements The electrical rotary units are equipped with a hollow shaft internal diameter 15 mm Usually the electrical rotary units are fixed to the housing The scope of delivery includes a EC Motor Controller ECMR This is preset at the factory and covers the whole operating range Accordingly subsequent adjustment is unnecessary The electrical rotary units are obtainable in the following versions Standard version electrical rotary units 60 DAE 60 The electrical rotary drives DAE 60 in the standard version are assembled with vertical drive shafts Option DAE 60 permanent magnet brake Equipped with a permanent magnet brake can be mounted in any installation position The load limits which were specified by the technical data must be complied with in all circumstances Overloading can lead to faults and failure of the device MON ECH User Manual Electrical Rotary Unit DAE 60 1 4 Dangers The use of DAE 60 in installations is only permissible when they are guarded by moveable isolating protective devices according to EN 292 2 section 4 2 2 3 Failure to comply with this safety measure can result in injuries due to crushing and impact particularly in machines which start up automatically It is essential to comply with the operating conditions and safety instructions described in the controller User Manual It is essential to comply with the stated load limits During operation the surfaces of motor and
20. ded view in chapter 5 gt chapter 3 3 4 gt Reference exploded view in chapter 5 1 7 Carefully pull the 2 wires item 100 out of the bore 4 0 mm in the holder item 20 8 Vent the permanent magnet brake gt Chapter 4 7 9 Loosen the 3 screws item 140 and remove the cover item 30 The armature item 100 is present in the cover item 30 10 Switch off the voltage of the permanent magnet brake 11 Loosen the 6 screws item 120 and remove the armature item 100 12 Loosen the 2 screws item 180 and remove the hub item 100 from the shaft item 200 Mounting the new permanent magnet brake 13 Lead the 2 wires of the permanent magnet brake item 100 through the lateral opening of the cover item 30 The wires are led from the inside to the outside 14 Guide the permanent magnet brake item 100 into the cover item 30 In this operation the following should be noted During the introduction of the permanent magnet brake item 100 hold the 2 wires close to the armature housing item 100 The wires must not form a loop in the cover item 30 Note the positioning of the armature item 100 The wires should be led straight to the lateral opening of the cover item 30 and not wound around the armature item 100 15 Fix the armature item 100 with the 6 screws item 120 in the cover item 30 16 Fix the cover item 30 with the new permanent magnet brake item 100 using the 3 screws item 140 on the ho
21. description in the chapter 4 6 Loosen the screw item 110 and remove the cover item 10 Additional operation Vent the permanent magnet brake gt Chapter 4 7 Additional operation Loosen the 2 screws item 190 and carefully remove the holder item 20 The following should be taken into account The 2 wires of the permanent magnet brake item 100 should not be subjected to mechanical stress Replaces the description in the chapter 4 6 Fix the holder item 20 with the 2 screws item 190 on the housing item 30 In this operation the following should be taken into account The wires of the permanent magnet brake item 100 must be lightly tightened during mounting so that no loop forms behind the holder item 20 Additional operation Check the air gap gt Chapter 4 7 3 Additional operation Switch off the voltage of the permanent magnet brake Additional operation Carefully fold the 2 wires item 100 and fix the cover item 10 with the screw item 110 MON ECH User Manual Electrical Rotary Unit DAE 60 5 Parts list for DAE 60 Exploded view 300 190 560 180 170 160 550 150 56 56 530 20 540 530 370 56 56 130 490 510 lt gt i 39 MON ECH User Manual Electrical Rotary Unit DAE 60 Item Sym 10 20 30 40 50 60 70 90 100 120 130 150 160 170 180 190 200 210 220 230 300 310 320 330 340 350 360 370 380 390 400 410 420 430 440 460 470 480 490 500
22. ef no 57490 includes a EC Motor Controller ECMR with housing ref no 57332 The EC Motor Controller ECMR is preset at the factory and autonomously performs the actuation of the permanent magnet brake Permanent magnet brake actuation in manual mode In the next operations the permanent magnet brake is to be manually vented while the EC Motor Controller ECMR is switched off For this purpose it is necessary to provide a switch which makes it possible to switch the voltage supply of the permanent magnet brake manually on and off Function 1 Voltage applied gt permanent magnet brake vented gt air gap between armature and hub of the permanent magnet brake gt shaft torque free 2 No voltage applied gt permanent magnet brake fixed gt no air gap between armature and hub of the permanent magnet brake shaft fixed 29 MON ECH User Manual Electrical Rotary Unit DAE 60 4 7 1 Mounting the permanent magnet brake Reference exploded view in chapter 5 1 Validity For retrofitting an existing DAE 60 device ref no 57490 with a DAE 60 permanent magnet brake ref no 57550 State on delivery of DAE 60 permanent magnet brake ref no 57550 The permanent magnet brake DAE 60 is completely assembled A protective transport foil is present between the 2 brake surfaces of the permanent magnet brake item 100 This protective transport foil must be removed before installation During operation the surfaces of the motor
23. gnet brake Direction of rotation from reference point f 0 Reference number DAE 60 permanent magnet brake 57835 57550 11 MON ECH User Manual Electrical Rotary Unit DAE 60 2 5 Scope of delivery Mechanical part including 3 m cable with loose ends for connecting to the ECMR controller 3m power cable shielded and towable 3m data cable unshielded and towable ECMR controller completely configured with all counter connection terminals for connecting the loose wires CD ROM with Windows commissioning software and Operating Instructions in German English French and Italian 2 6 Load calculation In Section 2 1 the maximum values are listed They must not be exceeded This means Add ons and Condition Maximum Unit Remark load value Section 2 1 lt a s Angular acceleration J lt NERS Kgcm Mass moment of inertia M lt M pra Nm Torque dynamic M lt M gt Nm Holding moment static M lt M ax Nm Tilting moment static IF lt F N Max axial force static identical for a amax tractive and compressive 12 2 7 Calculation of mass moments of inertia generally d MONECH User Manual Electrical Rotary Unit DAE 60 Calculation of mass moments of inertia of parts J kgcm Mass moment of inertia with axis of rotation z z J kgcm Mass moment of inertia with axis of rotation x x m kg Mass p kg cm
24. item 100 and take away the protective transport foil in the air gap Loosen the 2 screws item 180 but do not remove Mount the hub item 100 on the shaft item 200 The hub should be pushed on to the shaft by approx 2 mm so that it is not flush Tighten the 2 screws item 180 Lead the 2 wires of the permanent magnet brake item 100 through the bore 4 0 mm of the housing item 30 gt Reference exploded view in chapter 5 14 The 2 wires are laid further between the motor item 50 and the housing item 10 In the DAE 60 below the cover item 20 the 2 wires are led with the motor wires item 50 to the terminal item 150 Connect wires to the terminal group item 150 gt Chapter 3 3 4 15 Fix the cover item 20 with the 2 screws item 530 and the screw item 540 on the housing item 10 gt Reference exploded view in chapter 5 1 16 Fix the holder item 20 with the 2 screws item 190 on the housing item 30 The following should be noted in this operation The wires of the permanent magnet brake item 100 must be lightly tightened during mounting so that no loop forms behind the holder item 20 Adjustment or checking of the air gap gt Chapter 4 7 1 from point 5 31 MON ECH User Manual Electrical Rotary Unit DAE 60 4 7 2 Replacement of the permanent magnet brake Reference exploded view in chapter 5 1 DAE 60 with permanent magnet brake without cover item 10 ISO view Sec
25. lder item 20 Note the positioning of the cover item 30 on the holder item 20 17 Lead the 2 wires item 100 through the bore 4 0 mm in the holder item 20 Further work gt Chapter 4 7 1 from point 9 33 MON ECH User Manual Electrical Rotary Unit DAE 60 4 7 3 Air gap adjustment of the permanent magnet brake Reference exploded view in chapter 5 1 DAE 60 with permanent magnet brake without cover item 10 ISO view Sectional view viewed from above 3 openings offset 120 on item 30 lt 1 Adjustment of air gap of item 100 6oo 60 Installation site 20 of screws item 180 Air gap item 100 adiustable SS Item 100 SSSA N z sath ZL NI A oN KS 7 Ki ANT mnie AZZAN armature eal NT N tem 100 nm Ne gt 7 2 wires nay Z2 Parts list Prin chapter 5 DAE 60 a G0 100 Lateral opening of Wires item 100 item 30 for the 2 wires from item 100 During operation the surfaces of the motor and permanent magnet brake can reach 100 C Do not touch the parts until they have cooled to below 40 C measure the surface temperature During work on the DAE 60 it must be ensured that the unit energy of the EC Motor Controller ECMR is switched off and cannot be switched on by unauthorized persons Preparation 1 Stop all travel jobs 2 Disable the EC Motor Controller ECMR 3 Switch off the voltage of the EC Motor Controller ECMR and ensure that it c
26. lete units but dismantled into components and disposed of according to the type of material The type of material used for each part is shown in the spare parts lists Material which cannot be recycled should be appropriately disposed of 43 MONAECH more than technology MONTECH AG Gewerbestrasse 12 CH 4552 Derendingen Fon 41 32 681 55 00 Fax 41 32 682 1977 info montech com www montech com
27. name DAE 60 permanent magnet brake Short name DAE 60 Short name Reference number 57835 Reference number 57550 MONFECH User Manual Electrical Rotary Unit DAE 60 2 Technical data 2 1 Technical data for DAE 60 Max rotation angle max S Max mass moment of inertia Max torque dynamic Dmax Max holding moment static Hmax Max tilting moment static Kmax w S SE Max axial force static A Max rotational speed U Max angular acceleration a Weight Drive Motor rated power Encoder system Protective class Repeat precision Play Supply voltage current Reference point proximity switch Noise pressure level Ambient Temperature Rel humidity Purity of the air kgcm Nm Nm Nm N s s kg W dBA C Horizontal drive shaft 6 Vertical drive shaft 3600 10 rotations 400 250 2 4 3 0 4 5 4 5 10 10 450 450 500 300 3000 2500 2 20 Brushless electronic commutated DC motor toothed belt and angular gear 60 Encoder IP 40 0 01 Low backlash and adjustable 24VDC 4A Integrated inductive proximity switch PNP lt 63 10 50 5 85 without condensation Normal workshop atmosphere MON ECH User Manual Electrical Rotary Unit DAE 60 Maintenance Grease miter gear Warranty period 2 years from date of delivery Material Steel aluminum plastic 1 Measured at max mass moment of i
28. nertia max rotational speed and max angular acceleration gt see travel time diagram Section 2 3 2 Torque or movement moment Corresponds to the moment which is available on the drive shaft in order to move a load gt Section 2 6 Load calculation 3 Holding moment or load of the drive due to a load on the drive shaft at standstill without it moving gt Section 2 6 Load calculation 4 Tilting moment or load of the drive shaft due to a radial force element gt Section 2 6 Load calculation 5 Measured at constant motor temperature max mass moment of inertia max rotational speed max angular acceleration and 100 successive rotary movements in the same direction 6 For use with drive horizontal drive shaft a permanent magnet brake should be used gt Section 2 2 Optional permanent magnet brake MON ECH User Manual Electrical Rotary Unit DAE 60 Electrical rotary unit DAE 60 installation position vertical drive shaft 2 2 Option permanent magnet brake With integrated permanent magnet brake 0 4 Nm including housing and fixing screws The permanent magnet brake is recommended when the driving shaft of the DAE 60 is not oriented vertically Reference number 57550 Weight without DAE 60 kg 0 18 Type Permanent magnet single surface brake for dry running Rated power W 6 2 Voltage 24VDC Electrical rotary unit DAE 60 with Permanent magnet brake installation position horizontal drive shaft MS
29. nt adjustment Adjustment of gear play Option permanent magnet brake Mounting the permanent magnet brake Replacement of the permanent magnet brake Air gap adjustment of the permanent magnet brake Lubrication DAE 60 with permanent magnet brake Replacing the motor DAE 60 with permanent magnet brake Replacing the toothed belt DAE 60 with permanent magnet brake Toothed belt tension DAE 60 with permanent magnet brake Zero point adjustment DAE 60 with permanent magnet brake Gear play adjustment DAE 60 with permanent magnet brake Parts list for DAE 60 Parts list for DAE 60 permanent magnet brake option General information Environmental compatibility and disposal 24 25 26 29 30 32 34 35 36 36 37 37 38 39 42 43 43 MON ECH User Manual Electrical Rotary Unit DAE 60 1 Important information 1 1 Introduction This User Manual describes the mechanical design the technical data the load limits assembly maintenance and spare parts of the electrical rotary units 1 2 EU conformance to EU Directive on Machine Appendix II A Rules and standards complied with Machinery Directives 89 392 EEC 91 368 EEC Manufacturer Montech AG Gewerbestrasse 12 CH 4552 Derendingen Tel 41 32 681 55 00 Fax 41 32 682 19 77 1 3 Product description and application The electrical rotary units are electrically operated position controlled rotary units for executing regular rotational forward and backwar
30. oltage of the permanent magnet brake 35 MON ECH User Manual Electrical Rotary Unit DAE 60 4 7 5 Replacing the motor DAE 60 with permanent magnet brake All relevant information is mentioned in the chapter 4 2 it being necessary to take into account the following differences Specific operation for DAE 60 with permanent magnet brake gt Reference exploded view in chapter 5 1 8 8a 8b 20 20a 20b 4 7 Replaces the description in the chapter 4 2 Loosen the screw item 110 and remove the cover item 10 Additional operation Vent the permanent magnet brake gt Chapter 4 7 Additional operation Loosen the 2 screws item 190 and carefully remove the holder item 20 The following should be noted The 2 wires of the permanent magnet brake should not be subjected to mechanical stress Replaces the description in the chapter 4 2 Fix the holder item 20 with the 2 screws item 190 on the housing item 30 In this operation the following should be noted The wires of the permanent magnet brake item 100 must be lightly tightened during mounting so that no loop forms behind the holder item 20 Additional operation Check the air gap gt Chapter 4 7 3 Additional operation Carefully fold the 2 wires item 100 and fix the cover item 10 with the screw item 110 6 Replacing the toothed belt DAE 60 with permanent magnet brake All relevant information is mentioned in the ch
31. otor 10 11 12 13 14 15 16 17 Remove all wires of the motor item 50 from the terminal strip item 150 gt Chapter 3 3 1 Remove the 4 screws item 390 so that the motor item 50 is free Tilt the motor item 50 as obliquely as possible and remove carefully Insert the new motor item 50 obliquely into the housing item 30 Carefully push the toothed belt over the flange of the toothed disk item 50 Slowly position the motor item 50 perpendicular to the housing item 30 Fix the motor item 50 with the 4 screws item 390 on the housing item 30 Tighten the screws item 390 only lightly so that the motor can still be moved Connect all wires of the motor item 50 to the terminal strip item 150 gt Chapter 3 3 1 Fix the terminal group item 150 with the 2 screws item 520 on the housing item 10 Do not forget the screen connection item 370 or cable lug Insert the encoder multipoint connector plug item 50 on the terminal group item 130 Fix the cover item 20 with 2 screws item 530 and the screw item 540 on the housing item 10 Toothed belt tension 18 19 20 Remove the motor item 50 so that the toothed belt item 400 is slightly tensioned Hold the motor item 50 and tighten the 4 screws item 390 Fix the cover item 40 with the screw item 360 on the housing item 30 The zero point adjustment gt Chapter 4 5 from point 3 22 4 3 MON ECH User
32. permanent magnet brake option 57550 10 Cover gear PM brake coated 57547 Al 20 Holder permanent magnet brake 57548 Al 30 Cover permanent magnet brake 57549 Al 100 e Permanent magnet brake 0 4 Nm 510017 Diverse 110 Cylinder head screw hex socket M4x22 vz BN3 506183 Steel 120 Cylinder head screw hex socket M2x6 vz BN11 520335 Steel 130 Ribbed washer M4x7x0 5 vz BN792 502606 Steel 140 Cylinder head screw hex socket nK M3x6 vz BN17 520040 Steel 150 Ribbed washer M2x4x0 35 vz BN14083 520334 Steel 160 Ribbed washer M3x5 5x0 45 sw BN791 502363 Steel 170 Straight pin 3h6x6 bl hardened BN858 502018 Steel 180 0 Setscrew hex socket cone M3x4 sw BN24 501884 Steel 190 Cylinder head screw hex socket M3x10 vz BN3 502503 Steel e These are wearing parts and are available from stock Not available from stock individually upon request a Price listed items available from stock 42 6 General information 6 1 Environmental compatibility and disposal Materials used Aluminum Steel Copper PU polyurethane Brass Polyester Surface treatment Anodization of aluminum Nickel plating of brass Coating of aluminum Shaping processes Machining of aluminum and steel Aluminum casting Emissions during operation None Disposal MONECH User Manual Electrical Rotary Unit DAE 60 Devices which cannot be used anymore should be recycled not as comp
33. permanent magnet brake may reach up to 100 C The parts must not be touched if the temperature has exceeded 40 C measurement of surface temperature When working on the DAE 60 it must be ensured that the unit energy has been switched off and cannot be switched on by unauthorized persons 1 5 Additional information The aim of the present User Manual is to enable users to employ the DAE 60 correctly and safely Should further information be required in relation to your particular application please contact the manufacturer When reordering User Manuals it is essential to quote the reference number the product name and serial number This document can be obtained from our homepage www montech com Nameplate MONAECH CH 4552 DERENDINGEN 100000 000 GERWERBESTRASSE 12 Produkt CE Reference number Product name Serial number Montech AG Management Le A414 U D Wagner C Wullschleger 1 6 Validity of User Manual MONECH User Manual Electrical Rotary Unit DAE 60 Our products are continually updated to reflect the latest state of the art and practical experience In line with product developments our User Manuals are continually updated Every User Manual has a reference number e g BA 100074 and an edition number e g 02 2008 The reference number and the edition number are shown on the title page Validity Main device Full name Electrical rotary unit 60 Option Full
34. reference travel Check the position of the add on units Small positional corrections can be made with the function reference offset in the software If larger positional corrections are required the load can be repositioned MON ECH User Manual Electrical Rotary Unit DAE 60 4 5 Zero point adjustment Reference exploded view in chapter 5 Introduction In the zero point adjustment mechanical zero point reference of the DAE 60 is established In order to determine the zero point reference travel is initiated If the reference travel is started the following takes place The output shaft item 90 first rotates counter clockwise until the inductive proximity switch item 550 responds Once the inductive proximity switch item 550 has responded the output shaft item 90 stops and then rotates more slowly in the opposite direction On reaching the encoder index the output shaft item 90 stops again The reference travel is now complete The entire procedure takes place automatically During operation the surfaces of the motor and permanent magnet brake can reach 100 C Do not touch the parts until they have cooled to below 40 C measure the surface temperature During work on the DAE 60 it must be ensured that the unit energy of the EC Motor Controller ECMR is switched off and cannot be switched on by unauthorized persons Preparation 1 Stop all travel jobs 2 Disable the EC Motor Controller E
35. tional view viewed from above 3 openings offset 120 on item 30 1 Adjustment of air gap of item 100 6oo 60 Installation site 60 of the screws item Air gap item 100 adjustable N A j 17 Z Item 100 Sg N mk N ONT SSX Item 100 N Ne mg N armature Item 100 SEG 2 wires 2 f parts list bA chapter 5 DAE 60 E f n 0 100 Lateral opening of item 30 Wires item 10u for 2 wires from item 100 During operation the surfaces of the motor and permanent magnet brake can reach 100 C Do not touch the parts until they have cooled to below 40 C measure the surface temperature During work on the DAE 60 it must be ensured that the unit energy of the EC Motor Controller ECMR is switched off and cannot be switched on by unauthorized persons Preparation 1 Stop all travel jobs 2 Disable the EC Motor Controller ECMR 3 Switch off the voltage of the EC Motor Controller ECMR and ensure that it cannot be switched on by unauthorized persons 4 Loosen the screw item 110 and remove the cover item 10 gt Reference exploded view in chapter 5 5 Loosen the 2 screws item 530 and the screw item 540 and remove the cover item 20 32 MON ECH User Manual Electrical Rotary Unit DAE 60 Removing the existing permanent magnet brake 6 Remove the 2 wires item 100 ref exploded view in chapter 5 1 from the terminal group item 150 ref explo
36. tment of the gear play must be carried out carefully since otherwise premature wear of the teeth and or overloading of the motor may occur Preparation 1 Stop all travel jobs 2 Disable the motor control 3 Switch off the voltage of the motor control and ensure that it cannot be switched on by unauthorized persons 4 Loosen the screw item 360 and remove the cover item 40 5 Turn on the pinion item 180 until all 4 bores correspond to the positions of the screws item 360 6 Loosen the screws item 360 as far as they will go and then tighten again by two revolutions The screws item 360 cannot be removed 7 Slightly loosen the screws item 430 and 440 The screw item 430 cannot be removed The housing item 30 can now be pushed to and fro 27 MON ECH User Manual Electrical Rotary Unit DAE 60 The adjustment 8 Slightly tighten the screw item 440 until there is marked play Never tighten the screw item 440 firmly 9 Lightly tighten the screw item 430 until the housing item 30 can no longer move Never tighten the screw item 430 firmly 10 Alternately and in sequence loosen the screw item 440 by 1 6 turn tighten the screw item 430 by 1 6 turn check the play Use this procedure until play is no longer noticeable The play is best checked by the following procedure the output shaft item 90 is moved with one hand and the screws item 300 of the flange item 190 are held with the other hand
37. y if the output shaft item 90 is not positioned vertically and the load would move by itself to the lowest position The permanent magnet brake is not used by the motor for braking since otherwise premature wear of the permanent magnet brake would occur The permanent magnet brake becomes active only if the motor control unit is disabled or there is a power failure The DAE 60 is assembled by means of Quick Set fixing elements on the dovetail of the housing item 10 During assembly the total length of the dovetail should as far as possible be used as with a clamping element SLL 55 40 and a clamping element SLL 20 40 Installation position and assembly SLL 20 40 SLL 55 40 15 MON ECH User Manual Electrical Rotary Unit DAE 60 3 2 Mounting of the add on units load Reference Exploded view in chapter 5 While complying with the permissible loads see chapter 2 5 any add on units can be fixed to the DAE 60 The add on units load are mounted by means of Quick Set fixing elements SLR 15 40 on the output shaft item 90 Mounting of the load SLR 15 40 16 MON ECH User Manual Electrical Rotary Unit DAE 60 3 3 Internal wiring and cable connections Introduction The DAE 60 is delivered completely wired Only the cable ends have to be connected to the motor control Electrical terminal group Usually it is not necessary to carry out work on the terminal group item 130 and item 150
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