Movorail Installation Edition
Contents
1. i slv wmf i i i i Figure 30 safety cable type SLV A trolley safety cable type SLV is supplied with each BUB and shall be installed together with it Two sizes exist SLV4 for rail SPR 85 and SLV6 for SPR 125 SPR 160A SPR 295B and SPR 295W Install the cable 1 trough the trolley and attach it to the rail using its loops and the two T slot bolts 2 Installation Manual DW110410gb 0710 Edition 4 27 Movorail MARCH 2007 THOMSON 12 3 Installation of flexible bolt connections type TBUB between trolleys and crane rail x Taos TBUB12 max 600 kg tbub wmf Figure 31 flexible bolt connection type TBUB 1 Nut 5 Plastic washer 9 Movorail profile 2 Washer 2 x 6 Beam whit pin 10 Trolley 3 Upper beam 7 T slot profile 11 Trolley load attachment beam 4 Distance sleeve 8 Bolt 12 Movorail profile TBUB s are used to connect a trolley to a rail Put the plastic washer a on to the trolley load attachment and put the upper beam b in place Then insert the T slot profiles c which are put on the bolts d in to the Movorail profile Adjust the bolts e so that the beam with the pin f and the distance sleeved can be placed on the bolts Push up the Movorail profile and fix it to the troll2. SBHX or SBVX or the turntable SBVS then this is installed as well Switches and turntables are operated pneumatically The air pressure must be at least 6 bar We recom mend only using filtered air When a switch or a turntable is installed it is important to adjust them so that the trolleys can pass them without problems 14 2 Switches type HXL and VXL Figure 33 installation of switch seen from above Switches come in a right HXL and a left VXL version The switches are suspended from the six suspen sion holes 1 The connection rail 2 must be used in order to connect the rail system to the curved rail section in the switch This rail is 1000 mm long and is included in the switch delivery 14 3 Turntables type VSL se Figure 34 installation of turntables Turntables are suspended from the four suspension holes 1 30 DW110410gb 0710 Edition 4 Installation Manual Movorail MARCH 2007 THOMSON 15 Cable loop 15 1 Installation of cable loop 1 Lt Lh 600 800 mm KBVA lt Ag H lt cables wmf Figure 35 cable loop Cable loop can be done with flat cable 1 round cable 2 or hose 2 The same calculations are used for all types of cables and hoses to calculate the necessary number of trolleys the buffer zone length and the length of the cables Always
3. Colour Natural aluminium X mm 85 125 160 295 295 135 C mm 68 8 71 5 73 5 73 5 73 5 70 Standard profile lengths m 4 5 6 8 4 5 6 8 4 5 6 8 4 5 6 8 4 5 6 8 3 6 4 6 5 6 Inertia 97 333 812 1368 3700 556 Weight meter kg m 3 5 7 8 14 14 1 6 2 Profile area cm 11 18 6 28 7 51 5 51 5 22 8 Modulus of elasticity N mm 70 000 70 000 70 000 70 000 70 000 70 000 Table 8 profile data SPR 85 SPR 125 SPR 160A SPR 295B SPR 295W SPF 135 Y T c L Figure 38 profile dimensions profiledata wmf 18 2 Tightening torque for bolts The table is valid for both normal bolts and T slot bolts The bolt grade is normally embossed on the bolt heads see the figure below We recommend using at least bolt grade 8 8 Use a calibrated torque wrench to gauge the torque Bolt dimension Grade Zinc pl dry Zinc pl oiled 6 8 8 9 4 Nm 8 4 Nm M8 8 8 23 0 Nm 20 6 Nm M10 8 8 45 1 Nm 40 4 Nm M12 8 8 77 8 Nm 69 7 Nm M16 12 9 319 6 Nm 286 3 Nm Table 9 tightening torque for bolts Figure 39 bolt grade 34 DW110410gb 0710 Edition 4 Installation Manual Movorail MARCH 2007 THOMSON 18 3 Load diagram for a rail with a single load Lmax m F loaddiagram wmf 4 SPR 295B F kg 50 100 150 200 250 300 350 400 450 500 550 600 Figure 40 diagram for max recommended distance between suspensions at a single load The diagram is based on a maximum deflection of 1 500 of the distan
4. KUL Cable trolley type KBV KUL is intended to be used to round cables The trolley must be completed with cable clamps of type KK in suitable dimension A maximum of two cable clamps can be installed to the trol ley Cable trolley type KBVA KUL Cable trolley type KBVA KUL is intended to be used to round cables The trolley must be completed with cable clamps of type KK in suitable dimension As many cable clamps as needed can be installed to the trolley as long as the load do not exceed 50 kg Cable trolley type KBVS Cable trolley type KBVS is intended to be used to round cables which is fixed by the strap Cable trolley type KBV KUL SB Cable trolley type KBV KUL SB is intended to be used to hoses that are fixed with the cable tie The cable tie accepts hoses with a diameter of 30 80 mm Cable clamps type KK Cable clamps type KK are available in three sizes for cables with a diameter of 10 16 mm 17 25 mm and 26 36 mm The clamps are installed on top of each other in the maximum amount that the trolley type accepts 14 DW110410gb 0710 Edition 4 Installation Manual Movorail MARCH 2007 THOMSON 6 5 Pick up trolleys type STV5 and STVG5 STV5 is intended for rail SPR 85 and can carry loads up to 50 kg STV5 can be connected to other trolley if needed STVG5 comes in two versions STVG5 125 for rail SPR 125 STVG5 160A for SPR 160A SPR 295 B and SPR 295W This trolley must always be connected to ano
5. meter R 1 mm 0 0175 1 5 0 0116 2 5 mm 0 0070 Table 11 resistivity Example If Ustart 24 V L 40 m conductor area 1 5 mm2 Imax 1 5 A Then Uend 24 2 x 40 x 0 0116 x 1 5 22 608 V Ufactor 22 608 24 0 94 0 94 lt 0 95 not OK the voltage drop is to large Conclusion a larger conductor cross section is necessary e g try with 2 5 mm 36 DW110410gb 0710 Edition 4 Installation Manual Movorail page intentionally left blank Installation Manual MARCH 2007 DW110410gb 0710 Edition 4 THOMSON 37 Movorail MARCH 2007 THOMSON page intentionally left blank 38 DW110410gb 0710 Edition 4 Installation Manual Movorail page intentionally left blank Installation Manual MARCH 2007 DW110410gb 0710 Edition 4 THOMSON 39 Movorail Sales and Service MARCH 2007 THOMSON Danaher Motion products are available world wide through an extensive authorised Distributor network These distributors offer literature technical assistance and a wide range of models off the shelf for fastest possible delivery Danaher Motion sales engineers are conveniently located to provide prompt attention to customers needs Call the nearest office listed for ordering United Kingdom Danaher Motion Chartmoor Road Chartwell Business Park Leighton Buzzard Bedfordshire LU7 4WG United Kingdom Phone 44 0 1525 243 243 Fax 44 0 1525 243 244 E mail sales uk dana
6. 35 18 4 Technical data for current track type SB u 35 18 5 Voltage drop in SablesS u e un ham uha wa cacti eines a 36 4 DW110410gb 0710 Edition 4 Installation Manual Movorail MARCH 2007 THOMSON 1 Introduction Thomson Movorail is a light weight rail system made of extruded aluminium profiles for loads up to 600 kg which is designed and manufactured by Danaher Motion to meet the latest national and international stan dards Product quality is assured by our ISO 9001 certified quality system Read trough this manual carefully and study all the instructions supplied with the delivery of the compo nents before starting the installation work Do not hesitate to contact us for more information Important e Read trough all installation instructions and all other diagrams and documents supplied with the delivery before commencing the installation in order to ensure that the work is carried out in a safe manner No mechanical electrical or pneumatic equipment delivered by Danaher Motion may be modified or be used in any other way than what is described in this manual without the written permission from Danaher Motion Never walk or stand under a hanging load Ensure that all ladders lifting and climbing aids used during the installation are in good condition and that they are securely fas tened Make sure that only authorised people enter the working area Never use any components that appear to be
7. 7 THOMSON Movorail Installation Manual Edition 4 DW110410gb 0710 Solutions by DANAHER MOTION Movorail Version History Edition Number Edition Date 1 n a 2 n a 3 2005 02 18 4 2007 03 09 MARCH 2007 THOMSON Reason for Revision manual created Changed content Changed content and new style Added instruction for adjustment of bogie trolleys DANAHER MOTION is a registered trademark of Danaher Corporation Danaher Motion makes every at tempt to ensure accuracy and reliability of the specifications in this publication Specifications are subject to change without notice Danaher Motion provides this information AS IS and disclaims all warranties ex press or implied including but not limited to implied warranties of merchantability and fitness for a particular purpose It is the responsibility of the product user to determine the suitability of this product for a specific application 2 DW110410gb 0710 Edition 4 Installation Manual Movorail MARCH 2007 THOMSON 2005 Danaher Printed in Sweden All rights reserved Table of contents Wis JIMMOGUCTION A 5 2 components of the Movorail system u u uu u u u u 6 22 Singl e girder ystem9ex ETETE O AET A E 7 3 The Movorail rais III ii aaa a aAa aa EEA AEAEE EA Eaa aa aa 8 3 1 Rall See ya gay SE EA E aa
8. AE E A E EA 8 3 2 Attachment of reinforcement profile type SPF 135_ u 8 4 gt Go ectio of raile u SD ma fu ee Tec maaa ap a ua a ee pei iaaa usss 9 4 1 Connection of straight rails type SPR u 9 4 2 Connection of o rvestype SPB u u a as u s Saa aS uu u aba 9 5 5 i a w 10 5 1 Installation and inspection of service sections type SSKT 10 6 Trolleys and accessories for trolleys l u u u uu u u u u J T 11 6 1 TrelleySg annuun a Hered Su ede ee a haut kulia upaku 11 62 Installation of rail and trolley attachments type KFFB KFKK KFVS and 12 6 3 Adjustment of bogie trolleys type BGV 300 HSE with support rollers 13 64 Cable trolleys type KBV KBVA and KBVS a 14 6 5 Pick up trolleys type STV5 STVG5 U 15 6 6 Installation of motor trolleys type TMT 16 67 Adjustment of centre of gravity on motor trolley type TMT u 16 6 8 Electrical connection and adjustment of motor trolleys type 17 End plates end stops
9. MARCH 2007 THOMSON 6 6 Installation of motor trolleys type TMT Figure 13 installation of motor trolleys Installation order for motor trolleys 1 Lower the drive wheel see point 6 8 5 Attach the load to the trolley never attach any 2 Set the correct profile size see point 6 8 load to the motor trolley itself 3 Connect possible trolley to the motor trolley 6 Check the centre of gravity see point 6 7 using the cardan joint Use MBE1B if curved 7 Connect the supply and the motor rails are used and MBE3 if only straight rails 8 Adjust the drive wheel contact pressure see are used point 6 7 4 Insert the motor trolley into the rail 9 Test run see point 6 8 6 7 Adjustment of centre of gravity on motor trolley type TMT 16418 Figure 14 centre of gravity adjustment Adjust the counter weight so that the trolley hangs perpendicular 16 DW110410gb 0710 Edition 4 Installation Manual Movorail MARCH 2007 THOMSON 6 8 Electric
10. in the reinforcement profile must be fixed so that it can not move Installing T slot bolts on both sides of the reinforcement profile prevents it from moving 8 DW110410gb 0710 Edition 4 Installation Manual Movorail MARCH 2007 THOMSON 4 Connection of rails 4 1 Connection of straight rails type SPR Figure 5 connection of straight rails 1 2 3 4 5 6 Assemble the connection Push the connection on to the rail Glue the locating pins to the rail using the glue supplied with the connection Also see below table Push the other rail on to the locating pins Do not glue the locating pins in this end Pull over the connection 6 from the first rail to the other until the connection is exactly in the middle and then tighten all bolts according to the table in point 18 2 Note Keep in mind that each connection must be supported by a suspension SPR 85 SPR 125 SPR 160A SPR 295B SPR 295W L mm 30 40 Table 1 projecting length of the locating pins 4 2 Connection of curves type SPB Connection of curves is done the same way as for straight but with special curve connections SK 85R B and SK 125 160AR B Note Keep in mind that both the connections and the curve must be supported by a suspension This means that at least three suspensions must be used per curve SK 85R B SK 125 160AR B SPB 85 SPB 125 SPB 160A 7 curve wmf Figure 6 connection of curved rails
11. rails End stop End plate support a component used to attach the end plate to when the end stop is not placed in the end of the rail Installation Manual DW110410gb 0710 Edition 4 7 Movorail MARCH 2007 THOMSON 3 The Movorail rails 3 1 Rails There are five different straight rail sizes SPR 85 SPR 125 SPR160A SPR295B with reinforcement pro file and SPR295W with welded reinforcement profile Further to this sizes 85 125 and 160A also comes in a curved versions SPB The reinforcement profile SPF 135 can also be delivered separately be installed afterwards on top of a SPR 160A with the aid of the T slot profile TSS to create a rail of type SPR295B The max allowed load for each profile depends on the distance between the suspensions see point 18 3 For installations to the T slots of the rails there is a series of T slot bolts in different lengths Size TBM 8 is used for SPR 85 while TBM 12 is used for the others Note Only this type of bolt may be used for attach ments to the rail T slots SPR 85 SPR 125 SPR 160A SPR 295B SPR 295W LO LO N O 3 DE DE SPF 135 TSS J LSS SPB 85 SPB 125 SPB 160A TBM profiles wmf Figure 3 profiles and T slot bolts 3 2 Attachment of reinforcement profile type SPF 135 ee i P sees x tbm wmf Figure 4 how to secure the T slot profile At SPR295B or at installation of reinforcement profile
12. Installation Manual DW110410gb 0710 Edition 4 9 Movorail MARCH 2007 THOMSON 5 Service sections 5 1 Installation and inspection of service sections type SSKT 4 Lmax 2 2 service wmf 9 o o o o o i bana C S te vs apu Figure 7 installation of service section 1 gt o N 10 Suspend the service section using one suspension on each side Maximum allowed distance Lmax is 400 mm for SPR 85 and 500 mm for SPR 125 SPR 160A Remove the indicated socket head cap screws Test the function of the hatch Adjust if necessary Put back the socket head cap screws Test the function of the section by running the types of trolleys that will be used trough the section The hatch can when it is open be completely removed by knocking out the hinge pins from the hatch to the sides of the hatch DW110410gb 0710 Edition 4 Installation Manual Movorail MARCH 2007 THOMSON 6 Trolleys and accessories for trolleys 6 1 Trolleys STVG5 125 STVG5 160A Figure 8 trolleys 1 Crab trolleys this type of trolley is used when only hanging loads the force pointing downwards shall be moved i e as for hoists 2 Bogie trolleys this type of trolley is used when both hanging loads
13. MSON 9 4 Flexible suspensions type DBSU DBSU 85 100 DBSU 125 160A 600 suspension2 wmf Figure 22 installation of DBSU Flexible suspensions are installed either to the T slot of the rail as shown for DBSU 85 100 or on a con nection as shown for DBSU 125 160A 600 Two of the bolts of the connection are used in the later case to fit the bracket to the connection The suspension is then attached to a beam flange This type of suspension can be installed in any angle in relation to the rail Max load for DBSU 85 100 is 1000 N while it for DBSU 125 160A 600 is 6000 N Fit the cube 1 and the spacer sleeve 2 to the suspension profile 3 Then fit the l beam clamps 4 to the suspension profile Attach the suspension profile to the beam flange with the l beam clamps Fit the bracket 5 to the Movorail profile or to the connection Fit the bracket to the cube with the aid of the cylindri cal pin 6 Secure the pin with the split cotter pins If this type of suspension is installed both directly on to the rail and on connections in the same system the supplied washers must be placed between the rail and the bracket on those suspensions installed directly on the rail to keep the rail horizontally aligned over the whole length 9 5 Adjustable suspensions type ASU suspension3 wmf 1 Figure 23 installation of ASU Adjustab
14. W110410gb 0710 Edition 4 25 Movorail MARCH 2007 THOMSON 11 5 Electrical connection of current tracks with power supply track type ATSA 5 ATSA 5 63 mo ow gt trackconnection wmf x 2 me A Figure 28 electrical connection of current track The power supply track ATSA 5 has five connection points for cable clips The two outer are for screw con nection while the three in the centre are for pin connection Proper earthing is important for the safety Connect earth to the pre drilled M3 Hole in the end plate 1 and to the profile 2 At every connection 3 an earth cable 4 should be installed over the connection in order to earth the whole rail This requires the drilling of a hole in the beginning of each rail and at each side of a connection Clean the end plate and the profile from any oxide and anodising before the earth leads are connected to ensure good contact Carry out the connections to the current track according to the figure and the table At last affix a warning sign 5 at both ends of the rail If the track has been stored before it is installed it may be need to be cleaned from oxide before it is used Spray along the track with a contact spray e g Electrolube SOB Scotch 1607 or equivalent Let the spray work for a while before using the track Never spray with the power on A B C D E Sup
15. al connection and adjustment of motor trolleys type TMT 1 IO TO PE L1 12 L3 PE L1 L2 L3 3 x 230 Vac 3 x 400 Vac 4 1 5 mm Q sPR125 SPR160A h Figure 15 connection and adjustment Connect the motor cable Adjust the spring pressure to obtain slip free drive wheel operation Set the eccentric screw to the correct position for the profile size being used If pneumatic release is being used make sure the operating pressure is max 5 bar Install the pneumatic release cylinder sensor bracket as shown SY P S Installation Manual DW110410gb 0710 Edition 4 17 Movorail MARCH 2007 THOMSON 7 End plates end stops motion limiters and Walter bolts 7 1 End stops type STP end plates type TPL and end plate supports type EPF Figure 16 installation of end stop end plate and end plate support All rails should be equipped with end plates 1 and end stops 2 in both ends If the end stop is installed a bit from the end 3 an end plate support 4 can be installed in the rail as a support for the end
16. and lateral forces can be present i e as for crane rails or systems with curves 3 Bogie trolleys with lower support rollers this type of trolley can manage hanging loads lateral forces and upward forces 4 Pick up trolleys this type of trolley is used when a rail is equipped with current track STV5 can be used alone while STVG5 must be connected to another trolley with the help of the cardan joint see point 6 4 5 Motor trolleys this type of trolley is used to motorise the movement in X or Y direction and is available in several speed versions 6 Cable trolley this type of trolley is used to move cables along a rail The cable trolley is at the delivery equipped with a cable clamp a strap or a cable tie for round cables flat cables or hoses Installation Manual DW110410gb 0710 Edition 4 11 Movorail MARCH 2007 THOMSON 6 2 Installation of rail and trolley attachments type KFFB KFKK KFVS and KFSB 1 i oo cabieparts wmf AS IL Figure 9 installation of rail and trolley attachments 1 Install the trolley cable attachment a to the installation holes of the trolley The picture shows a cable attachment with a flat cable clamp Cable attachments with other clamp types exist however they are all installed in the same way Also install the motion limiter plate
17. at a test of a Movorail system Figure 36 inspection of the system Check the system against the drawing if any is available Make sure the system is marked with an adequate number of max load sign Check the span a Max permissible parallel deviation between the rails is 2 mm Check so that there is no gap between the rails at the connections b Check so that no rails are deformed or that they are subjected to any twisting or bending forces OP ON eRe GON Check the tightening torque for all bolt connections BUB s suspensions connections and safety ca bles 7 Test any electrical systems Perform at least a continuity check of the bonding circuit an insulation re sistance test and a voltage test Also make sure that the system is equipped with a lockable main switch placed beside it and that warning signs for electrical equipment are applied 8 Run the system without load Check all functions Adjust 9 Run the system with 25 overload Check all functions Check all critical components after the test especially bolt connections 10 If rails of type SPR 295W are used check so that there is no cracks in the weldings between the upper and the lower rail 11 At last check all rail and trolley tolerances again Adjust if necessary 32 DW110410gb 0710 Edition 4 Installation Manual Movorail MARCH 2007 THOMSON 17 Training and user instructions 17 1 General about training All operators should have the suf
18. b to the trolley if a motion limiter will be used see point 7 2 2 Therail cable attachment is installed on the end stop a or to the end plate support b depending on how the rail is equipped 3 Examples of complete installations Also see point 7 1 and 7 2 for instructions on the installation of end stops end plate supports and motion limiters 12 DW110410gb 0710 Edition 4 Installation Manual Movorail MARCH 2007 THOMSON 6 3 Adjustment of bogie trolley type BGV 300 HSE with support rollers bogie_trolley_adjustment wmf Figure 10 adjustment of bogie trolley support rollers The position of the support rollers on bogie trolleys type BGV 300 HSE must be checked after installation If the distance between the support rollers is less than 0 1 mm anywhere along the entire length of the rail the roller positions must be adjusted To adjust loosen the lock screws 1 and turn the eccentric shaft of the rollers 2 until the distance between the rollers is within the limit all along the rail Tighten the lock screw when the adjustment is done The tightening torque of the lock screws should be 5 Nm Installation Manual DW110410gb 0710 Edition 4 13 Movorail MARCH 2007 THOMSON 6 4 Cable trolleys type KBV KBVA and KBVS KBV FB KBV KUL KBVA KUL cabletrolleys wmf Figure 11 cable trolleys Cable trolley type KBV FB Cable trolley tyoe KBV FB is intended to be used to flat cables Cable trolley type KBV
19. ce between the suspensions Lmax and shows the maximum recommended distance between the suspensions at a given load 18 4 Technical data for current track type SB Max voltage 400 V Current track conductor cross section 9 mm Protection class IP 21 Max current track 55A Ambient temperature 20 C 55 C Max current connection 25A Voltage drop 0 103 V m 25A Max current power supply track 25A Max speed straight rails 2 m s Max current pick up 60 ED 10 Max speed curved rails 0 5 m s Max current pick up 100 ED 6A Table 10 technical data for current track Installation Manual DW110410gb 0710 Edition 4 35 Movorail MARCH 2007 18 5 Voltage drop in cables THOMSON Long cables may lead to a significant voltage drop that may lead to malfunctioning To avoid this it may be necessary to increase the conductor cross section The formulas below can be used to calculate the voltage drop If the voltage drop exceeds 5 Ufactor less than 0 95 of the nominal voltage a larger cross sectional area is necessary Formula 1 Uend Ustart 2 L x R x Imax Formula 2 Uend Ustart Ufactor Formula 3 Ufactor gt 0 95 OK Ufactor lt 0 95 not OK Imax current to be transmitted in cable Ufactor voltage drop coefficient Uend voltage at the end of the cable Ustart voltage at the start of the cable L length of cable R resistance per meter see table below Conductor area Resistance
20. check so that the trolleys roll on their wheels and not are lifted up in the rail by the cables or the hose Always use flexible cables or hoses which are made for continuos motion and that can withstand the environment in question If in doubt contact your cable or hose supplier Select the conductor cross section area with respect to the power that will be transmitted Keep in mind that long cables may result in a voltage drop that necessitates the use of a greater conductor cross section See point 18 6 Avoid using cables with less conductor cross section than 1 mm as they may break due to the forces acting on the cable Number of trolleys Length of buffer zone Length of cables n Lt Lh x 2 Lc Lt Lb x 1 15 Lt total length of travel for cables Lb length of buffer zone n necessary trolley quantity Lc length of cables hoses in the loop Lh loop height 600 800 mm is recommended Lv length of cable trolley being used Installation Manual DW110410gb 0710 Edition 4 31 Movorail MARCH 2007 THOMSON 16 Testing the Movorail system 16 1 General about testing of the Movorail system The system must be tested when the installation is completed Follow all applicable instructions below Please note that national and international regulations may call for further tests The test area should be closed during all tests only persons who are involved in the testing procedures may enter the area 16 2 Inspection points
21. ed can carry the maximum load of the system max load to lift weight of system Furthermore may no suspension be exposed to higher side forces than 10 of the permissible max load Tighten all bolts according to the table in point 18 2 We recommend that each suspension and its attachments should be thoroughly inspected by someone with adequate knowledge before the system is tested or used 9 2 Z suspension type DZ 1 2 2 3 714 4 a zprofile wmf Figure 20 installation of DZ 1 2 3 4 5 Nut Washer Z profile Clamp Bolt Z suspensions are installed directly to the T slot in the rail and is attached to the roof or a roof beam Max load for DZ 85 is 1000 N while DZ 125 160A manage 6000 N 9 3 I beam clamps typ VBKLA VBKLA 85 VBKLA 125 160A o 2 a all 5 2 _ 1 5 m i suspension1 wmf i 6 s n o n 6 gt Figure 21 installation of VBKLA Nut Washer Sliding washer Clamp T slot profile Bolt OahwoN l beam clamps are installed directly to the T slot in the rail and are attached to a beam flange Max load for VBKLA 85 is 1000 N while VBKLA 125 160A manage 6000 N beam clamps type VBKLA accepts a beam flange thickness L from 5 20 mm l beam clamps type VBKLA can not be installed on a connection Installation Manual DW110410gb 0710 Edition 4 21 Movorail MARCH 2007 THO
22. ey by means of the washers i and nuts j Tighten the bolts with the correct torque For dry bolts use 77 8 Nm and for oiled 69 7 Nm 28 DW110410gb 0710 Edition 4 Installation Manual Movorail MARCH 2007 THOMSON 13 Crane distance trolley and distance girders 13 1 Flexible distance girder type DNS i i i 700 i i lt gt i i i i a 7 EP eS i 1 _ 2 7 1 1 L NPA PRS A u Q a ie Siete u Figure 32 flexible distance girder type DNS The flexible type of distance girder separates two crane rails of type SPR 125 SPR 160A SPR 295B or SPR 295W The rails may move around the BUB The distance girder a is attached by two BUB s 125 160A b For installation of BUB 125 160A see point 12 1 13 2 Rigid distance girder type SD The rigid type of distance girder separates two crane rails of type SPR 125 SPR 160A SPR 295B or SPR 295W The rails are fixed in relation to each other Except from this the rigid type of distance girder is in stalled and functioning in the same way as the flexible with the exception that four T slot bolts are used for the attachment instead for two BUB s Installation Manual DW110410gb 0710 Edition 4 29 Movorail MARCH 2007 THOMSON 14 Switches and turntables 14 1 General about switches and turntables Switches and turntables are delivered completely assembled If a current track kit is ordered to the switch
23. faulty or damaged Replace them immediately with the components of the same make and type The system must be labelled with a clearly visible max load sign All operators of the system should be instructed in using the system safely before using it Never work with any electricity or compressed air switched on during the installation The Movorail system may not be used before it complies with the EEC Machinery Directive 89 392 EEC with valid amend ments if it is to be used within the EEC area In such cases electrical equipment is a part of the system the system also must comply with the demands in the Low Voltage Directive 72 23 EEC and the directive for Electromagnetic Compatibility 89 336 EEC with valid amendments All equipment work and documentation must for both the electrical mechanical and pneumatic areas comply with all relevant national and international regulations standards and EEC directives Regular maintenance is necessary in order to obtain long life and to maintain a high safety level Service instructions can be found in the Movorail Service Manual which is included in the delivery Do not hesitate to contact Danaher Motion if you have any questions Installation Manual DW110410gb 0710 Edition 4 5 Movorail MARCH 2007 THOMSON 2 The components of the Movorail system 2 1 System with main girder rails Figure 1 system with main girder rails 1 l beam clamps type VBKLA used to suspend a rai
24. ficient training before the equipment is taken into use The training required depends on the type of equipment and has to be defined on a case to case basis The following instructions however apply to most types of equipment and are the basic information all users should be given Also make sure that all users fulfil the requirements below Only those who are at least 18 years old may use the equipment Only those who are authorised by their superiors may use the equipment Only those who have been trained may use the equipment Only those who know all safety devices and operating controls of the system may use the equipment PO 17 2 User instructions 9 instructions wmf Figure 37 user instructions 1 2 3 4 5 6 7 8 9 Installation Manual DW110410gb 0710 Edition 4 33 Never move people with the system Never lift loads above people Never force loads that are stuck or jammed to move Never apply overload to the system Avoid lifting loads higher than 1 5 m above floor level Never pull loads along the floor Never leave hanging loads unattended at any time Never push loads intentionally into the end stops Always try to lift loads from their centre of gravity Wear hard hat safety shoes and protective gloves at all times Movorail MARCH 2007 THOMSON 18 Technical data 18 1 Data for the Movorail profiles SPR 85 SPR 125 SPR160A SPR295B SPR 295W SPF 135 Material Anodised extruded aluminium
25. hermotion com Germany Danaher Motion GmbH Sales Office North Wacholderstr 40 42 40489 Dusseldorf Germany Phone 49 0 203 9979 214 Fax 49 0 203 9979 3214 E Mail iris tolusch danahermotion com Danaher Motion GmbH Sales Office South West BruckenfeldstraBe 26 1 75015 Bretten Germany Phone 49 0 7252 97390 56 Fax 49 0 7252 97390 55 E Mail kerstin muellere danahermotion com Danaher Motion GmbH Sales Office South East Kiesgrable 7 89129 Langenau Germany Phone 49 0 7471 62 23 23 Fax 49 0 7471 62 23 26 E Mail ursula koschak danahermotion com 40 DW110410gb 0710 Edition 4 France Danaher Motion C P 80018 12 Rue Antoine Becquerel Z I Sud F 72026 Le Mans Cedex 2 France Phone 33 0 243 50 03 30 Fax 33 0 243 50 03 39 E mail sales france tollo com Italy Danaher Motion srl Largo Brughetti 1 20030 Bovisio Masciago Italy Phone 39 0362 594260 Fax 39 0362 594263 E mail info danahermotion it Sweden Danaher Motion Box 9053 SE 291 09 Kristianstad Sweden Phone 46 0 44 24 67 00 Fax 46 0 44 24 40 85 E mail helpdesk kid danahermotion com Switzerland Danaher Motion SA La Pierreire 2 1029 Villars Ste Croix Switzerland Phone 41 0 21 631 33 33 Fax 41 0 21 636 05 09 E mail info danaher motion ch Installation Manual
26. ible to add safety cables to a system at any time without any disassembly The cable is 1 5 m long and is cut to fit the applica tion The cable should be installed with a minimum of slack so that the fall height is minimised Insert the L profiles a one by one in to the T slot of the profile Then put the cable b trough the holes in the L profiles and put the cable around the safe point beam roof beam etc Connect the ends of the cable using the cable locks Install the cable locks with a distance between them and with a length of the project ing ends corresponding at least to the figure above 1 Cable 2 Cable locks a minimum of two locks must be used 3 L profiles Rail Cable designation Cable diameter d SPR 85 SLU4 4mm SPR 125 SPR 160A SPR 295B SPR 295W SLU6 6 mm Table 5 cable diameter Installation Manual DW110410gb 0710 Edition 4 23 Movorail MARCH 2007 THOMSON 11 Installation of current track 11 1 General about current track The current track is installed in the Movorail rails The supply to the current track is connected to the power supply track that is installed in one of the rail ends Sometimes however it may be necessary to install power supply tracks in both ends of the current track due to the power required See below figure Carry out the electrical connections to the current track as described in point 11 5 Make sure that the voltage and current that will be transmitted in the curren
27. l directly to an l beam Single main girder rail Movorail rail load carrying profile which comes in five sizes SPR 85 SPR 125 SPR 160A SPR 295B and SPR 295W Flexible suspension type DBSU suspension type that allows some misalignment between the I beam and the rail Locating pin a pin that guides the rails at connections Reinforcement profile a profile that is used to reinforce profile SPR 160A Bogie trolley trolley with horizontal wheels for guidance that is used for hanging loads BUB attachment between bogie trolleys distance girders and rails Yoke frame in which a hoist or other loads can be suspended Down shop rails the non moving rails to which the suspensions are attached Span the c c distance between two down shop rails Current track rail with copper conductors installed inside of the Movorail profile Distance girder two types exist flexible or rigid End plate End stop Double main girder rails Connection DW110410gb 0710 Edition 4 Installation Manual Movorail MARCH 2007 THOMSON 2 2 Single down shop rail Figure 2 single down shop rail system 18 19 20 21 22 23 24 Rail and trolley cable attachment kit components that fix cables to the end of a rail and a trolley Cable the type of cable hose determines the type of cable trolley Cable trolley Crab trolley Service section a hatch that facilitates the service of trolleys and other components at long
28. le suspensions are installed either to the T slot of the rail A or on a connection B Two of the T slot bolts of the connection are used in the later case to fit the plate to the connection The suspension is then attached to a beam flange This type of suspension can be installed in any angle in relation to the rail and be adjusted 50 mm in height Max load is 6000 N Fit the socket head cap screw and the sleeve 1 to the suspension profile 2 Fit the two plates and the adjustment screws 3 to the suspension profile Then fit the l beam clamps 4 to the suspension profile Attach the suspension profile to the beam flange with the I beam clamps At installations directly on the rail the two T slot bolts 5 which is supplied with the suspension must be used to attach the rail to the suspen sion There must also be a washer 6 between the nuts and the lower plate At installations on a connection the two bolts in the centre of the connection are used instead and no washer should be installed between the nuts and the lower plate 22 DW110410gb 0710 Edition 4 Installation Manual Movorail MARCH 2007 THOMSON 10 Safety cables for suspensions 10 1 Safety cable type SLU min 5d min 3d Figure 24 installation of safety cable type universal Safety cables type SLU are used to enhance the safety of suspensions The safety cable is put around any safe point that can support the load such as a roof beam The L profiles makes it poss
29. meter of the hole Do not deform the rail when tightening the bolt SPR 85 SPR 125 SPR 160A SPR 295B SPR 295W L mm 49 52 56 mm 12 5 12 5 12 5 Table 4 drilling position of the hole for Walter bolts Installation Manual DW110410gb 0710 Edition 4 19 Movorail MARCH 2007 THOMSON 8 Location of suspensions 9 1 Location of suspensions positions wmf 1 N 1 Figure 19 suspension points The above figure shows at which points it is necessary to install suspensions for different types of systems It may also be necessary to use more suspensions in order to keep the deflection of the rails within the per missible limits See the diagram in point 18 3 1 Rail ends always install a suspension at the ends of each rail Connections each connection must be supported by a suspension placed directly on to the connec tion 3 Curves each curve must be suspended by at least one suspension in the centre of the curve 4 Service sections each service section must be suspended by at least two suspensions one on each side of the hatch Also see point 5 1 20 DW110410gb 0710 Edition 4 Installation Manual Movorail MARCH 2007 THOMSON 9 Suspensions 9 1 General about suspensions Never use any suspensions or fixing material in any other way than recommended in this manual Check that the beams and suspension points that will be us
30. motion limiters and Walter bolts 18 7 1 End stops type STP end plates type TPL and end plate supports type EPF 18 7 2 Motion limiters type BG Ris Zur a SR Ak yas aN ar eaa 18 73 19 8 Location Of 20 8 1 5 5 aan ay es 20 Os 2 SUSPENSIONS u E 21 9 1 nici al i 21 9 25 lt ZSUSPENSIONS type DZ a into eld eel icteric 21 9 3 beam clamps 1 21 9 4 Flexible suspensions type DB SU u n NR SSS 22 9 5 Adjustable suspensions type ASU u 22 10 Safety cables for suspensions U U 23 1041 Sately cabletypeSEDu u u T u S Gum 23 11 Installation of current track 24 434 2 2 eet enti uywa quisu Maqua aint aquy h ada 24 11 2 Installation of current track SB cii uuu au wau
31. ofile AARANI Figure 26 insertion of current track The current track is inserted in to the grooves in the profile Use the top grooves in SPR 125 Install the current tracks before any trolleys are inserted into the profile The track end of the first current track can be slightly chamfered to simplify the insertion Chalk can be used as lubricant to reduce the friction Never use any oil or silicone based products as lubricants 11 4 Connection of current tracks with current track connection type ATSK 5 O C 3 0 0 AANANT I rackjoint wmf Figure 27 connection of current tracks Insert the plastic pins LED 5 1 in the track end 2 Attach the track end with the aid of the two screws 3 to the end of the first current track power supply track 4 and then insert the track into the profile until the first connection Insert the four insulation pieces 5 in to the first current track and put together the next current track 6 with the first so that the insulation pieces enter both tracks Snap on the five collars 7 over the copper conductors and snap on the track connection plate 8 so that rails gets connected Insert the connection and the current track until the next connection and repeat the procedure until the whole current track is installed At last install a track end on the finishing current track power supply track Installation Manual D
32. plate 7 2 Motion limiter type BGR 1 B A 2 motionlimiter wmf 30 90 100 pasi _ s T KBVA Figure 17 installation of motion limiter Motion limiters 1 are used to create a buffer zone for cable trolleys in a rail end How long the buffer zone needs to be depends on the number and type of cable trolley being used For information on how to calcu late the number of cable trolleys see point 15 1 One or two holes needs to be drilled the number of holes depends on the rail type in the centre of the T slot of the rail to be able to install the motion limiter For drilling data see the table below On trolleys that will work against a motion limiter there must be a motion limiter plate 2 installed Also see point 6 2 Check that no suspension bolts will be located at the same place as the motion limiter BGR 85 BGR 125 BGR 160A A 38 mm 60 mm B 36 mm 1 9 mm 2 x 13 mm Table 3 drill measures for motion limiters 18 DW110410gb 0710 Edition 4 Installation Manual Movorail MARCH 2007 THOMSON 7 3 Walter bolt type WBM Ll iis 2 Figure 18 installation of Walter bolt and end stop Holder for the rubber bumper Lock plate Bolt Walter bolt bolt washer and nut End plate screws 2x ON Oo The Walter bolt is used to enhance the safety of the system as it will make it impossible to push the end stop out of the rail See the table below for the position and the dia
33. ply 1 x 230 VAC PE L1 N L1 PE Supply 3 x 400 VAG PE L1 L2 L3 PE Cable with number leads Yellow green 1 2 3 Yellow green Cable with colour leads Yellow green Brown Black Black white Yellow green Table 6 connection of power supply track 26 DW110410gb 0710 Edition 4 Installation Manual Movorail MARCH 2007 THOMSON 12 Flexible bolt connection for trolleys and trolley safety cable 12 1 Installation of flexible bolt connections type BUB between trolleys and crane rail BUB 85 BUB 125 160A SS 2 3 Wee 74 as Figure 29 flexible bolt connections type BUB 1 Split cotter pin 5 Plastic washer 2 Lock nut 6 Distance sleeve 3 Nut 7 Lower washer chamfer up 4 Upper washer BUB 85 chamfer up 125 160A chamfer down 8 T slot bolt BUB s should always be used to attach a trolley to a rail never replace them by another component Also always install the safety cable supplied with the BUB see below Note Check so that the chamfer of the washers are correctly positioned and that the plastic washer is not stuck between the upper washer and the distance sleeve Use the correct tightening torque See table 7 below Tightening torque BUB BUB 125 160A 85 Dry threads Nm 23 0 77 8 Oiled threads Nm 20 6 69 7 Table 7 BUB tightening torque 12 2 Installation of trolley safety cable type SLV
34. sis 30 15 2 i u aa 31 15 1 Installation oticable loop u u a e ats e clei ts vets chai Raves eet deed 31 gt gt gt Table of content continues on the next page gt gt gt Installation Manual DW110410gb 0710 Edition 4 3 Movorail MARCH 2007 THOMSON Table of contents 16 Testing the Movorail system U U u u u u uu uuu u 32 16 1 General about testing of the Movorail system L 32 16 2 Inspection points at a test of a Movorail system 32 17 Training and user instructions U u u u u u u uu u ul J J 33 UA Ge eral 3aboutaralnilB02 u l uA au taa ushushika asss as 33 17 2 ibaaddadasscatehdstacestarsiacsianaabaadessund s eacesueuspeeceoadncnaasucesdincasasuetedsedsansagadstsagey 33 18 Techh iG6al Gate i EATEN 4 18 1 Data for the Movorail 34 18 2 Tightening torque for bolt uu uuu uuu uuu iapa aiei aaa aa a Eaka eiae 34 18 3 Load diagram for a rail with a single load a
35. t track lies within the permissible limits See table in point 18 4 A qualified electrician must carry out all electrical connections 11 2 Installation of current track type SB 1 2 3 4 4 9 10 11 12 track1 wmf Figure 25 components to current track If the current track is not delivered from factory cut to fit the total length of the rails it may be necessary to cut one of the current tracks to make the total track length the same as the total rail length This operation is also necessary as the track ends only can be fitted to a straight track end and not to a track end used for track connections see point 11 4 Never cut a power supply track Also drill a hole in the aluminium profile at the power supply track to be used for earthing of the Movorail profile Also see point 11 5 Track end type EST 5 LED 5 Current tracks type SB cut Track connection type ATSK 5 Current track type SB uncut Power supply track type ATSA 5 Cable End plate type TPL Place of cut 9 Cable clip see point 11 5 10 Hole for earthing of the rail see point 11 5 11 Hole for earthing of the end plate see point 11 5 12 End plate type TPLH with cable gland PG16 13 Example of power supply at both ends 24 DW110410gb 0710 Edition 4 Installation Manual Movorail MARCH 2007 THOMSON 11 3 Insertion of current track in to the Movorail pr
36. ther trolley via the cardan joint which is included in the delivery Never exceed the current limits of the pick up brushes current track see point 18 4 Figure 12 connection of pick trolley A STV5 1 load carrying pin can be placed any of the holes h1 h2 or h3 Max load 50 kg 2 The strain relief plate can be placed any of the holes h1 h2 or h3 3 Adjustment screw for the contact pressure of the brushes Adjust the brushes to ensure good contact Clean if necessary the brushes from any oxide Connect the cable according to the below table 4 If needed connect STV5 to another trolley by means of the cardan joint MBE1B not included in STV5 5 Cable 4 x 1 5 mm B STVG5 1 Connect STVG5 to the load carrying trolley 2 Adjustment screw for the contact pressure of the brushes Adjust the brushes to ensure good contact Clean if necessary the brushes from any oxide Connect the cable according to the below table 3 Cable 4 x 1 5 mm C Connection of cable to pick up trolley a b c d e 1 x 230 VAC Earth PE L1 N L1 Earth PE 3 x 400 VAC Earth PE L1 L2 L3 Earth PE Cable lead Yellow green 1 2 3 _ Table 2 connection of cable on pick up trolley Installation Manual DW110410gb 0710 Edition 4 15 Movorail
37. u satin a qatun huuu Sukis his eea 24 11 3 Insertion of current track in to the Movorail profile u a 25 11 4 Connection of current tracks with current track connection type ATSK 5 25 11 5 Electrical connection of current track with power supply track type ATSA 5 26 12 Flexible bolt connection for trolleys and trolley safety cable 27 12 1 Installation of flexible bolt connection for trolleys type BUB between trolley and crane rail 27 12 2 Installation of trolley safety cable type SLV L 27 12 3 Installation of flexible bolt connection for trolleys type TBUB between trolley and crane rail 28 13 Crane distance trolley and distance girders u u u u u u 29 13 1 Flexible distance girder type DNS simsii misir L as a s ataqu niaaa 29 43 2 Rigid distance girder type SD missis veh are ieee 29 14 SWitches and turntables no L Na u au sa 30 14 1 General about switches and turntables u 30 14 2 Switchestype HXLILandiVXL L Lu l uqun Dee see saywa sbs 30 14 37 Turntables au asul aQ S
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