Translation of Original User's Manual, Module
Contents
1. WERNER Contents Safety 5 1 1 Definition of the Alerts 5 1 2 General Safety Instructions 5 1 3 Special Hazard Warnings 6 Intended Use 2 1 Reasonably Foreseeable Misuse Installation Instructions 8 3 1 Installation Position 8 3 2 Overview of Motor Installation Variants 8 3 2 1 Module 160 15 Installation Variant 1 9 3 2 2 Module 160 15 Installation Variant 5 9 3 3 Attachment 10 3 3 1 Installation of Actuators 12 3 4 Wiring 13 3 4 1 Motors 13 3 4 2 Initiators 13 3 4 2 1 Technical Data of Initiators 14 3 4 2 2 Limit Switch 15 3 4 2 3 Collision Switch 15 3 4 3 Cable Routing 15 3 5 Technical Data 16 3 5 1 Tightening Torques for Screw Connections 16 3 5 2 Technical Data of Module 160 15G 16 3 5 3 Type Label 17 3 5 4 Technical Data when Using a Planetary Gearbox 17 3 5 5 Distances between Axes and Number of Teeth 18 3 5 6 Load Cases 19 3 5 6 1 Torques and Carrying Capacities 19 Preventive Maintenance 20 Troubleshooting 21 Repair 23 6 1 Factory Setting of Axial Toothed Belt Tension 24 6 2 Changing the Axial Toothed Belt 24 6 3 Reference Side of Guide System 25 Parts Lists and Drawings 26 7 1 Module 160 15G with Toothed Belt Gearbox 26 June 2011 Transl of Original User s Manual MAN_EN_1102540_Module160 15G_R1a doc Module 160 15 G Page 3 of 37 i WERNER 7 2 Module 160 15G with Direct Drive 28 7 3 Carriage Module 160 15G Length 195 mm 30 7 4 Toothed Belt Gearbox 32 7 5 Flange 34 7 6 Assemblies Components Specific to th2. Readjust toothed belt tension on carriage part Align toothed belt on fastener pressure piece and gear segment evenly tighten M6 fillister head screws Replace toothed belt protect linear module from heavy soiling Replace toothed belt Replace motor Apply current to the brake if the brake still does not release replace motor Connect the cable Replace limit switch collision switch Check limit switch cable Solder wires Check and change connector assignment if required Replace motor June 2011 MAN_EN_1102540_Module160 15G_R1a doc Transl of Original User s Manual Troubleshooting Module 160 15 G Page 21 of 37 i M D WERN Continuation of troubleshooting Cause Correction Malfunction Linear drive unit does not move Play on reversal Linear drive unit moves mechanically against the stop during the reference run Error in power electronics or control unit Motor cable damaged Belt transmission Toothed disk slips Planetary gearbox Coupling between motor and planetary gearbox slips Motor with brake brake does not release Gearbox toothed belt not tensioned Toothed disk of motor has play parallel key connection Drive tooth belt without adequate pre tension Incorrect direction of rotation Broken motor cable Check the power electronics or the control unit Check motor cable replace cable if required Firmly tighten clamping set and sec
3. 3 as as J 2 2 a VaN ic e e p fant a fo any yo SZ 2 M6 16x 12 2 deep 16x Figure 7 Standard carriage drilling pattern Installation Instructions Transl of Original User s Manual Page 11 of 37 June 2011 Module 160 15 G MAN_EN_1102540_Module160 15G_R1a doc M WERNER Figure 8 shows a centering ring for mounting clamping elements 4 12 8 5 Figure 8 Centering ring Art No 1024021 With the M6 threaded holes on the carriage different axis configurations can be achieved possibly via an adapter plate The counterbores with 12 mm dia serve for centering of the clamping elements with possible adjustment 3 3 1 Installation of Actuators Actuators gripper modules cylinders attached to the linear module are normally attached via the drilling pattern on the carriage Figure 7 Page 11 to the linear drive unit Special drilling pattern available on request June 2011 Installation Instructions Transl of Original User s Manual Page 12 of 37 Module 160 15 G MAN_EN_1102540_Module160 15G_R1a doc i N M y M X 3 4 Wiring 3 4 1 Motors CAUTION The electrical connection of the motors is performed according to the motor data sheet For customer specific motors the data sheet must be requested from the respective manufacturer and the motor connected accordingly 3 4 2 Initiators Inductive p
4. M M a M a 3 3 Attachment In most applications the Module 160 15 G is attached with clamping profiles clamping elements see Figure 5 below to a flat assembly surface The carriage moves freely Other types of attachment of the linear module for example with additional drilled holes in the basic profile should be avoided In almost all cases these drilled holes cause tension in the guide basis and the damaging of inner parts of the module CAUTION The clamping area should have a planeness of 0 1 mm m Clamping p Clamping element Figure 5 Crosswise cut with clamping elements and dimensions Module 160 15 For an overview of the different clamping elements see Section Overview of NOTE Clamping Elements page 36 Installation Instructions Transl of Original User s Manual June 2011 Module 160 15 G MAN_EN_1102540_Module160 15G_R1a doc Page 10 of 37 M d M d W RISK OF CRUSHING Risk of limb crush injuries during operation at these component positions Risk of crushing exists at the start and end of the stroke as well as between both movable carriages see Figure 6 Figure 6 Potential crushing positions Figure 7 shows the drilling pattern of a standard carriage 195 0 10 179 0 10 99 A ADN K a gt gt TO
5. Transl of Original User s Manual Page 17 of 37 June 2011 Module 160 15 G MAN_EN_1102540_Module160 15G_R1a doc a M W E 3 5 5 Distances between Axes and Number of Teeth Z1 218 88 AA Z2 A a lA AeA 38 88 lt 1 Figure 16 Explanation of the table of distances between axes subassembly No 1000475 Maintain the following distances between axes for the specified standard gear ratios The gearbox toothed belt tension motor installation variants 1 6 see Figure 2 page 8 is 150 N Z1 Z2 Drilled Length of AA Feed constant output drive hole drive toothed belt mm mm 42 120 140 1 142 Aon 450 mm 21 1 42 20 a eae 390mm 116 18 66 667 2 625 1 42 16 Pe 390mm 120 73 53 33 3 1 42 14 a 375mm 115 35 46 667 June 2011 Installation Instructions Page 18 of 37 Transl of Original User s Manual Module 160 15 G MAN_EN_1102540_ Module160 15G_R1a doc M J M Be 3 5 6 Load Cases 3 5 6 1 Torques and Carrying Capacities Figure 17 Torques and carrying capacities
6. Extract from technical data Figure 14 page 16 Torque Mx 100 Nm Torque My 100 Nm Torque Mz 100 Nm Carrying capacity C1 1500 N 800 N Carrying capacity C2 Figure 18 Table of torques and carrying capacities Transl of Original User s Manual Installation Instructions June 2011 Module 160 15 G Page 19 of 37 MAN_EN_1102540_Module160 15G_R1a doc fE WERN M d 4 Preventive Maintenance During the design of Module 160 15 G great importance was placed on the use of maintenance free components All roller elements are provided with lifetime lubrication in the factory The guide carriages are equipped with auxiliary lubrication elements An operating performance of 10000 km is therefore achieved with the initial lubrication In single shift operation with a stroke of 500 mm and 20 cycles per minute this is equivalent to an operating performance of almost 5 years After reaching the specified operating performance the guide carriage can be relubricated with a special grease gun IEF Werner Art No 1055123 see Figure 19 The grease gun is filled with high performance lubricant Dynalub One side of the carriage unit has a funnel shaped lubrication nipple External lubrication by means of the hand held grease gun can be performed directly at the carriage On the opposite side the toothed belt must be released for lubrication of the guide carriages to access the grease nipples of the guide carriages NOTE Do no us
7. The fields of application for the Module 160 15 G are correspondingly versatile They range from component insertion systems for SMD components insertion and pressing in processes in precision engineering loading and unloading stations of machine tools to manipulators for the packaging industry 2 1 Reasonably Foreseeable Misuse The Module 160 15 G is not to be used for certain applications such as the transport of persons and animals or as a pressing bending device for cold working of metal The use of the linear module without additional measures is also not possible in special fields of application such as the chemical or food industry or in explosive atmospheres In case of doubt consult the manufacturer Intended Use Transl of Original User s Manual Page 7 of 37 June 2011 Module 160 15 G MAN_EN_1102540_Module160 15G_R1a doc IFE WERNER 3 Installation Instructions 3 1 Installation Position The installation position is optional i e the Module 160 15 G can be installed horizontally as well as vertically CAUTION For a vertical installation position use motors with spring operated brake to prevent the lowering of the drive in de energized condition 3 2 Overview of Motor Installation Variants Installation variant 2 Installation variant 4 Installation variant 6 Figure 2 Installation Variants of Module 160 15 G June 2011 Installation Instructions Transl of Original
8. 1000588 drawing see Figure 23 page 29 poate ee Bibs snl O moesenation eh 10 1000478 0 Basic profile 160 15 20 1000688 0 Ball rail guide type 15 V 30 1061034 1 Toothed belt 32ATL5 V 40 626061 1 Fillister head screw DIN 912 M4x16 12 9 50 1023994 1 Groove slide block L 70mm 60 731466 1 Groove slide block 70 1025262 1 Housing with damper 80 626037 1 Fillister head screw DIN 912 M6x20 8 8 90 627581 1 Cylindrical pin ISO 8734 5m6x20 A 100 1034373 1 Plastic cover 110 626124 1 Hexagon socket head countersunk screw ISO 10642 M4x10 8 8 120 1045543 1 Shim DIN 988 36x45x0 1 130 1019278 1 Bearing cover 140 028585 1 Limit switch holder 150 025165 1 Inductive switch PNP NC E 160 726744 1 Inductive switch PNP NO E 170 030887 1 Special screw M4x7 180 725164 1 Angular coupling 190 725163 1 Round plug 200 025626 1 Retaining sheet metal 210 627630 1 Oval head screw ISO 7380 M3x8 8 8 220 626056 1 Fillister head screw DIN 912 M6x16 8 8 230 1044440 1 Plastic clip 240 1018820 1 Drive unit V i 1077831 1 Standard drive unit V 250 1042984 1 Pulley V 260 1018827 1 Stop 270 1056053 1 Carriage unit 160 15 G L 195mm V 280 1000041 0 Motor V 290 1000886 0 Planetary gearbox V 310 1050247 1 Flange 626049 1 Fillister head screw DIN 912 M6x35 8 8 626061 Fillister head screw DIN 912 M4x16 8 8 330 1024065 1 Switch rail collision switch 340 1024068 1 Distance washer usage depending on version E replacement part V wearing part Parts Lists an
9. B and can be transmitted in response to a reasoned request by the appropriate national authorities in electronic form List of some harmonized standards used EN ISO 12100 1 2 EN ISO 13857 EN ISO 13850 EN 60204 1 The incomplete machine supplied by us must not be put into service until the final machine into which the incomplete machinery is to be incorporated has been declared in conformity with the fundamental safety and health requirements according to Annex of EC Directive 2006 42 EC referred to above Name of person responsible for documentation Frank Reichelt Technical Writer Address of person responsible for documentation See Manufacturer s address Furtwangen 21 June 2011 Manfre d Bar Managing Director June 2011 Transl of Original User s Manual Declaration of Incorporation MAN_EN_1102540_Module160 15G_R1a doc Module 160 15 G Page 37 of 37
10. the guide carriages have an increased slide resistance After a short run in period 1 to 2 days the slide resistance is reduced to normal The adapter plates are each placed on the guide carriage at the guide carriage reference side NOTE Do not interchange the carriage plate and the adapter plates with the carriage plates and or adapter plates of other linear drive units Module 160 15 G Do not interchange adapter plates within the same linear drive unit Reference side carriages Reference mark Slide plate WP A TI a RA PA N Z 7 D cy A PA S Z N PENG ESS Put rail to edge pa NEN F N SAN BONE OU Figure 21 Guide system Transl of Original User s Manual Repair Page 25 of 37 June 2011 MAN_EN_1102540_Module160 15G_R1a doc Module 160 15 G IFE WERNER 7 Parts Lists and Drawings 7 1 Module 160 15 G with Toothed Belt Gearbox Subassembly 1000588 drawing see Figure 22 page 27 ee ieee Pie a 0 oe gnation Eh 10 1000478 0 Basic profile 160 15 20 1000688 0 Ball rail guide type 15 V 30 1061034 1 Toothed belt 32ATL5 V 40 626061 1 Fillister head screw DIN 912 M4x16 12 9 50 1023994 1 Groove slide block L 70mm 60 731466 1 Groove slide block 70 1025262 1 Housing with damper 80 626037 1 Fillister head screw DIN 912 M6x20 8 8 90 627581 1 Cylindrical pin ISO 8734 5m6x20 A 100 1034373
11. 1 Plastic cover 110 626124 1 Hexagon socket head countersunk screw ISO 10642 M4x10 8 8 120 1045543 1 Shim DIN 988 36x45x0 1 130 1019278 1 Bearing cover 140 028585 1 Limit switch holder 150 025165 1 Inductive switch PNP NC E 160 726744 1 Inductive switch PNP NO E 170 030887 1 Special screw M4x7 180 725164 1 Angular coupling 190 725163 1 Round plug 200 025626 1 Retaining sheet metal 210 627630 1 Oval head screw ISO 7380 M3x8 8 8 220 626056 1 Fillister head screw DIN 912 M6x16 8 8 230 1044440 1 Plastic clip 240 1018820 1 Drive unit 160 15 32 V 1077831 1 Drive unit 80 15 32 FLG V 250 1042984 1 Pulley V 260 1018827 1 Stop 270 1056053 1 Carriage unit 160 15 G L 195mm V 1000041 0 Motor V 290 1000475 0 Toothed belt gearbox V 330 1024065 1 Switch rail collision switch 340 1024068 1 Distance washer usage depending on version E replacement part V wearing part Parts Lists and Drawings Transl of Original User s Manual June 2011 Page 26 of 37 Module 160 15 G MAN_EN_1102540_Module160 15G_R1a doc X YP ine gt p MW A ig S Figure 22 Linear drive unit 160 15 G with toothed belt gearbox 260 Stopper zur Hubbegrenzung stop for stroke limitation June 2011 Transl of Original User s Manual MAN_EN_1102540_Module160 15G_R1a doc Module 160 15 G Parts Lists and Drawings Page 27 of 37 i WERN M d 7 2 Module 160 15 G with Direct Drive Subassembly
12. M N M X M J Translation of Original User s Manual Module 160 15 G Edition June 2011 Article No 1102540 IEF Werner GmbH Wendelhofstra e 6 78120 Furtwangen Germany Phone 49 7723 925 0 Fax 49 7723 925 100 www lEF Werner de info IEF Werner de June 2011 Transl of Original User s Manual MAN_EN_1102540_Module160 15G_R1a doc Module 160 15 G Page 1 of 37 i M yD M aD Change History Initial release of this English document originated from German document MAN_DE_1077858_ Modul160 June 2011 15G_R3b doc MAN_EN_1102540_Module160 15G_R1a doc Trademarks and trade names are used without an assurance of their free usability Although the texts and examples were created with great thoroughness errors can not be fully excluded IEF Werner GmbH does not assume legal responsibility nor any liability for missing or incorrect statements and their consequences IEF Werner GmbH reserves the right to modify or improve without previous notice the software or hardware or parts of it was well as the supplied documentation or parts of it IEF Werner GmbH expressly reserves all rights for duplication and photomechanical reproduction including extracts We are always grateful for suggestions for improvements and information about errors June 2011 IEF Werner GmbH June 2011 Transl of Original User s Manual Module 160 15 G MAN_EN_1102540_Module160 15G_R1a doc Page 2 of 37 i
13. User s Manual MAN_EN_1102540_Module160 15G_R1a doc Page 8 of 37 Module 160 15 G i N M X M J Module 160 15 G Installation Variant 1 3 2 1 L stroke 424 20 stroke 20 2 x 195 20 A c B L 195 e oos O L d oft wo Fe S R Taral 92 92 Mounting measurement 179 3 124 195 0 10 179 010 99 z EE A B C stroke limitation limit switch al L 7 7 ai 2 A Reference point 2 e e A c A e Me 16x 2 12 2 deep 16x 3 Figure 3 Module 160 15 G subassembly No 1000477 installation variant 1 3 2 2 Module 160 15 G Installation Variant 5 stroke 424 stroke 20 2 x 195 195 20 195 c COPE m F 2 2 T me 3 92 Mounting measurement 179 S 195 195 010 179 010 99 l bel 16 3 ES e E m6069 Jl 12 2 deep 16x 64 010 A B C stroke limitation limit switch A Reference point Figure 4 Module 160 15 G subassembly No 1000477 installation variant 5 Installation Instructions June 2011 MAN_EN_1102540_Module160 Transl of Original User s Manual Page 9 of 37 15G_R1a doc Module 160 15 G
14. a of Initiators Parameter Value Operating voltage including ripple Current load capacity Voltage drop at l max Switching frequency Self current consumption Nominal operating distance on steel Switch hysteresis Reproducibility U const Operating temperature Protection class Short circuit proof Protected against polarity reversal 10 30 VDC lt 15 lg lt 200 mA lt 2 5V lt 1000 Hz lt 15mA 2 0 mm 10 3 20 0 01 mm 25 C 70 C IP 65 yes yes Figure 12 Technical data of initiators Installation Instructions Page 14 of 37 Transl of Original User s Manual Module 160 15 G June 2011 MAN_EN_1102540_Module160 15G_R1a doc i M X M ms 3 4 2 2 Limit Switch The pin assignment of the limit switch is as follows see Figure 13 1 24V Brown 2 Limit switch negative direction of G movement carriage 1 RRN 3 oV White 4 Limit switch negative direction of Yellow movement carriage 2 5 Reference switch optional Gray Figure 13 Pin assignment of limit switch 3 4 2 3 Collision Switch The collision switch is located on one of the movable carriages This switch is supplied with open cable end The switch signal of the collision switch must be wired on both carriages as function Limit switch of positive direction of movement 3 4 3 Cable Routing Suitable cable routing has to be used for all moving cables to effectively prevent cable breaks The mi
15. anual June 2011 Page 30 of 37 Module 160 15 G MAN_EN_1102540_Module160 15G_R1a doc Cs xc ly c ly Figure 24 Carriage 160 15 G exploded view Page 31 of 37 Parts Lists and Drawings Transl of Original User s Manual Module 160 15 G MAN_EN_1102540_Module160 15G_R1a doc June 2011 i WERN M 7 4 Toothed Belt Gearbox Subassembly 1000475 drawing see Figure 25 page 33 geese Article Part 1 Use Designation os No Subassembly 0 10 1021557 1 Housing 20 029690 1 Toothed disk AT5 42 0 30 1007376 1 Toothed disk AT5 42 2 40 028722 1 Toothed disk AT5 42 2 50 1006664 1 Toothed disk AT5 42 2 60 732770 1 Clamping set 16 32 70 732770 1 Clamping set 16 32 80 732294 1 Clamping set 20 38 90 734168 1 Clamping set 22 40 95 526735 1 Toothed disk AT5 20 2 including clamping set 12 98 525983 1 Toothed disk AT5 20 2 including clamping set 14 100 525984 1 Toothed disk AT5 20 2 including clamping set 16 110 1005790 1 Toothed disk AT5 14 2 including clamping set 10 120 1005756 1 Toothed disk AT5 14 2 including clamping set 12 130 1003999 1 Belt transmission cover 140 028574 1 Gliding block 150 626072 1 Oval head screw ISO 7380 M4 x 8 8 8 160 1004001 1 Push in cover 170 730353 1 Toothed belt 25AT5 390 180 732286 1 Toothed belt 25AT5 375 190 908243 1 Toothed belt 25AT5 450 usage depending on version Parts Lists and Drawings Transl of Origina
16. avity 1196016 mm 8689482 mm Figure 14 Technical data Installation Instructions Page 16 of 37 Transl of Original User s Manual June 2011 Module 160 15 G MAN_EN_1102540_Module160 15G_R1a doc i S M X M X 3 5 3 Type Label IEF Werner GmbH Wendelhofstrate 6 D 78120 Furtwangen Teleton 0 77 23 9250 WERNER ServicesPiEF WVerner de Module 160 15 G Type Designation 17 500 mm Verurs Nr 166596 Order number 70540 nainii N Feedrate motor revolution Ser Nr focdrate motorrevolition Serial number Figure 15 Type label example 3 5 4 Technical Data when Using a Planetary Gearbox Before start up pay attention to the possible input speeds specified by the gearbox manufacturers Excessive input speeds could cause higher gearbox wear and or thermal problems The precision of the linear drive unit is influenced by the play on reversal of the gearbox Example The play on reversal of the gearbox P is 9 angular minutes What is the play on reversal at the carriage of the linear drive unit Feed constant of linear drive unit Fc 140 mm Fc e P 360 x 60 140 mm 9 360 x 60 0 058 mm By all means pay attention to the specifications of the respective gearbox manufacturer For example _ http www neugart de index php de Produkte Standardgetriebe http www wittenstein alpha de 896 htm Play on reversal at the carriage Installation Instructions
17. d Drawings Transl of Original User s Manual June 2011 Page 28 of 37 Module 160 15 G MAN_EN_1102540_Module160 15G_R1a doc ise 5 Hl R f A POE D Y 3 il SIZAS Gi mae p Figure 23 Linear drive unit 160 15 G with direct drive Parts Lists and Drawings Page 29 of 37 Transl of Original User s Manual Module 160 15 G June 2011 MAN_EN_1102540_Module160 15G_R1a doc i WERN M 7 3 Carriage Module 160 15 G Length 195 mm Article No 1056053 drawing see Figure 24 page 31 SS ase Babee sie O mpoesemation aN 10 1029382 1 Guide carriage size 15 V 20 1046583 1 Guide carriage size 15 for external V lubrication 30 1059202 1 Toothed quadrant 40 1023935 1 Pressure piece 50 1041818 1 Adapter plate 60 1056056 1 Carriage plate 160 15 G 70 1023944 1 Cover 80 626484 1 Fillister head screw DIN 912 M4 x 25 8 8 90 626500 1 Fillister head screw DIN 912 M6 x 18 8 8 100 626049 1 Fillister head screw DIN 912 M6 x 35 8 8 110 626115 1 Hexagon socket head countersunk screw DIN 7991 M3 x 8 120 626190 1 Threaded pin DIN 913 M6 x 10 8 8 130 1023942 1 Threaded bush 140 626317 1 Cylindrical pin ISO 8734 4x20 A 150 1031602 1 O ring type 1 80 1 80 E 160 1028704 1 Funnel shaped grease nipple DIN 3405 type D4 170 1062938 1 Adapter plate 160 15 G 180 626487 1 Fillister head screw DIN 912 M5 x 10 8 8 E replacement part V wearing part Parts Lists and Drawings Transl of Original User s M
18. e Version 35 7 6 1 Installation of Flange Gearbox e g Planetary Gearbox Type PLFE64 35 7 6 2 Overview of Clamping Elements 36 8 Declaration of Incorporation 37 Transl of Original User s Manual June 2011 Page 4 of 37 Module 160 15 G MAN_EN_1102540_Module160 15G_R1a doc i M X M D 1 Safety 1 1 NOTE Definition of the Alerts WARNING Indicates a potentially hazardous situation Read the warnings before performing the task CAUTION Indicates a potentially hazardous situation which if not avoided could result in minor or moderate injury damage to equipment or material Read the cautions before performing the task Gives additional information 1 2 General Safety Instructions The module may be put into operation only by specialist personnel who have received technical safety instructions and can assess potential hazards In addition all chapters of the User s Manual have to be read and understood completely WARNING The system has to be de energized for all installation disassembly or repair work High risk of injuries WARNING OF HOT SURFACE During operation the heating of the motor in particular of stepper motors can cause the burning of the skin when touching the motor Install a protective device if possible Do not touch the marked areas or only after an adequate cooling time CAUTION Motor connectors may not be inserted or disconnected under live conditi
19. e gearbox toothed belt tension motor installation variants 1 6 see Figure 2 page 8 is 150 N 6 2 Changing the Axial Toothed Belt For explanation see Figure 22 page 27 and Figure 24 page 31 To change the axial toothed belt proceed as follows Figure 24 page 31 Loosen the screws M6 x 35 pos 100 remove pressure piece Pos 40 remove toothed quadrant Pos 30 Figure 22 page 27 remove plastic covers Pos 100 Remove defective toothed belt install new toothed belt Insert toothed belt in the middle of toothed quadrant Pos 30 and pressure piece Pos 40 The pressure piece and the toothed quadrant can be wrapped with a thin adhesive tape This makes it easier to insert these parts into the carriage Tension the pressure piece with screws M6 x 35 pos 100 on block Belt tension adjusted in factory Do not remove the safety lacquer on the screws pos 120 Figure 24 page 31 Re install plastic covers pos 100 Figure 22 page 27 Repair Transl of Original User s Manual June 2011 Page 24 of 37 Module 160 15 G MAN_EN_1102540_Module160 15G_R1a doc i X M X W E 6 3 Reference Side of Guide System Both guide rails are each positioned at the outward pointing edges of the basic profile The reference side of the carriage plate which is indicated by two locating pins which are attached one sided is on the same side as the reference side of the basic profile marked by a 90 notch When new
20. e grease containing ester oils Figure 19 Lubrication of the guide carriage Preventive Maintenance Transl of Original User s Manual June 2011 Page 20 of 37 Module 160 15 G MAN_EN_1102540_Module160 15G_R1a doc M W M y M ms 5 Troubleshooting Increased running noise Linear drive unit does not move Nominal service life of guide carriages exceeded Guide carriages worn by overload excessive torques etc Guide carriages worn by excessive soiling Guide rails worn Guide rails corroded Reversing unit worn Drive unit worn Toothed belt runs dry Excessive toothed belt tension Toothed belt runs canted Heavy soiling of toothed belt on the toothed inner side Toothed belt damaged Motor motor bearing damaged Motor with brake brake does not release Limit switch cable not connected Limit switch collision switch defective Limit switch cable damaged Soldered connection on socket became loose Incorrect motor connection Motor damaged Replace all guide carriages Replace all guide carriages reduce load Replace all guide carriages clean guide rails more frequently and relubricate guide carriage Replace guide rails replace all guide carriages check load protect linear module from excessive soiling Replace guide rails replace guide carriages as required Replace reversing unit Replace drive unit Lightly grease toothed belt on the toothed inner side
21. gy qo qa q 5 g9 A g 4 Typ 16 D o A m AN 4 g Typ 65 Bi o Typ 80 R Typ 105 m e AN Typ 115 SZ o Typ 140 Typ 160 Clamping element L customer specific Figure 28 Overview of clamping elements June 2011 MAN_EN_1102540_Module160 15G_R1a doc Transl of Original User s Manual Module 160 15 G Parts Lists and Drawings Page 36 of 37 M W M X M X 8 Declaration of Incorporation EC Declaration of Incorporation in accordance with the EC Directive 2006 42 EC Machinery Annex II B We the manufacturer IEF Werner GmbH Wendelhofstrake 6 78120 Furtwangen Germany hereby declare that the following product the incomplete machine partly completed machine Module 160 15 G 61000588 operating in opposing directions complies with all essential requirements of Directive Machinery 2006 42 EC as far as the scope of delivery allows e Annex Article 1 1 2 1 1 3 1 1 5 1 3 2 1 3 4 1 5 1 1 7 3 In addition the partly completed machinery is in conformity with the following Directives Directive 2004 108 EC of the Council of 15 December 2004 on the approximation of the laws of the Member States relating to electromagnetic compatibility Directive 2006 95 EG of the Council of 12 December 2006 on the approximation of the laws of the Member States relating to electrical equipment designed for use within certain voltage limits The technical documentation is compiled in accordance with Annex VII Part
22. ion to the list of parts subject to wear specific to the order which is enclosed with the delivery Parts Lists and Drawings Page 34 of 37 Transl of Original User s Manual June 2011 Module 160 15 G MAN_EN_1102540_Module160 15G_R1a doc i M J M Be W Assemblies Components Specific to the Version Installation of Flange Gearbox e g Planetary Gearbox Type PLFE64 7 6 The following drive unit for flange gearboxes is used Part No 7 6 1 1077831 Description Drive unit 80 15 32 FLG Figure 27 Installation of flange gearbox example with drive unit 1077831 Parts Lists and Drawings Page 35 of 37 Transl of Original User s Manual Module 160 15 G June 2011 MAN_EN_1102540_Module160 15G_R1a doc M counterbore DIN74 Km 6 2x 7 6 2 Overview of Clamping Elements Dimensional drawing of clamping element Article number Clamping element example type 105 L2 in mm Clamping element type 16 0 16 220701 65 49 65 1062169 80 64 80 1021641 105 89 105 28674 115 99 115 1054491 140 124 140 220702 160 64 160 1039032 Undrilled Customer specific 1019192 8 8 8 Sy 8 N 4 8 TOSSE ELS Se J ae X oe 7 ANKAS
23. l User s Manual June 2011 Page 32 of 37 Module 160 15 G MAN_EN_1102540_Module160 15G_R1a doc M M J 140 20 170 180 190 60 Y i 150 130 160 10 a pt gt Pe N gt 7 N S _ SS lt 130 a 150 30 40 50 Transl of Original User s Manual 95 98 100 Module 160 15 G 410 120 70 80 90 Figure 25 Belt transmission of Module 160 15 exploded view Parts Lists and Drawings Page 33 of 37 June 2011 MAN_EN_1102540_Module160 15G_R1a doc i WE re M 7 5 Flange Subassembly 1000476 drawing see Figure 26 below Drawing Article Pos 10 100 110 120 130 No 1022105 1022129 734161 626037 626244 627215 1022199 1022203 1022201 1022202 1006530 1007310 1008886 1022206 Part 1 Subassembly 0 1 h b h h b h h Se Ce i Ml usage depending on version 100 110 120 130 70 80 90 Use Designation it it i Flange axial Flange plate axial Plastic cover Fillister head screw DIN 912 M6 x 20 8 8 Fillister head screw DIN 912 M6 x 60 8 8 Locking ring DIN 472 47 1 75 Coupling dia 16 Toothed ring red Coupling dia 20 Coupling dia 22 Sleeve 12 16 Sleeve 15 20 Sleeve 14 16 Sleeve 19 22 Figure 26 Flange Module 160 15 i 1 1 CAUTION Also please pay attent
24. nimum radius fmin for cable routing chains is calculated for IEF Werner cables according to the following formula fmin 2 10 x cable diameter When different cables are used EN 60204 must be observed In addition it must be ensured that a space reserve of 30 is kept free within the routing chains A strain relief for the cables has to be attached at the outlet of the cable routing chain We recommend to also order cables and cable routing chains at IEF Werner GmbH June 2011 Transl of Original User s Manual Installation Instructions Module 160 15 G Page 15 of 37 MAN_EN_1102540_Module160 15G_R1a doc WERNER 3 5 Technical Data 3 5 1 Tightening Torques for Screw Connections Tightening torque Nm M3 M4 M5 M6 M8 M10 M12 1 1 2 5 5 0 8 5 21 0 41 0 71 0 Screw 12 9 Tightening torque Nm M4 attachment of guide rail 4 9 3 5 2 Technical Data of Module 160 15G Parameter Value Repetition accuracy 0 05 mm Weight without motor 14 kg Weight increase per 100 mm stroke 1 4 kg Maximum movement speed 5 m s Maximum acceleration 40 m s Maximum transferable feed force with maximum movement speed 5 m s 810 N Torque Mx see Figure 17 page 19 100 Nm Torque My see Figure 17 page 19 100 Nm Torque Mz see Figure 17 page 19 100 Nm Carrying capacity C1 see Figure 17 page 19 1500 N Carrying capacity C2 see Figure 17 page 19 800 N Geometrical moment of inertia of profile cross section at center of gr
25. on Risk of burning of the contacts and risk of flying sparks June 2011 Transl of Original User s Manual Safety Module 160 15 G Page 5 of 37 MAN_EN_1102540_Module160 15G_R1a doc i M yD M CAUTION Linear modules always have to be operated in connection with suitable safety devices e g safety cell protective room protective housing light curtain Observe the Declaration of Incorporation see Section Declaration of NOTE Incorporation page 37 Special Hazard Warnings 1 3 In addition this User s Manual also contains the following special hazard warning RISK OF CRUSHING Risk of limb crush injuries during operation at these component positions Transl of Original User s Manual Module 160 15 G June 2011 MAN_EN_1102540_Module160 15G_R1a doc Safety Page 6 of 37 i M J M Be W 2 Intended Use The linear drive unit Module 160 15 G G means Gegenlaufig in opposing directions see Figure 1 was designed for industrial applications The use of a high quality guide ensures high dynamics and good running characteristics The guide elements have special seals which protect them from coarse dirt However the application of the linear drive unit Module 160 15G under conditions with increased dirt and abrasive dusts should be avoided because no further protective measures such as bellow cover etc are available Figure 1 Overview of Module 160 15 G
26. roximity switches PNP NC Article No 025165 see Figure 9 are used as standard limit switches for the distance traveled as well as for collision protection These switches are not safety limit switches according to EN60204 1 Optionally an additional reference point switch PNP NO Article No 726744 see Figure 10 can also be retrofitted in the Module 160 15 G The active switch area is marked with a colored circle symbol The NCs have a green dot the NOs have a red dot The initiators and their supply lines are protected in a cable duct which is integrated in the basic profile and are routed jointly to a connector A plastic strip serves to cover the cable duct The replacement of an initiator or its shifting is easily possible after removal of this plastic strip from the cable duct brown 24VDC A black Signal z blue OV Figure 9 Connection assignment PNP NC Art 025165 brown 24VDC p gt black Signal A ov A o blue Figure 10 Connection assignment PNP NO Art 726744 Transl of Original User s Manual Installation Instructions Page 13 of 37 June 2011 MAN_EN_1102540_Module160 15G_R1a doc Module 160 15 G WERNER A 9 9 q pee M4 40 20 active area Figure 11 Dimensional sketch of inductive proximity switch 3 4 2 1 Technical Dat
27. ure screws with safety lacquer Firmly tighten coupling and secure screws with safety lacquer Apply current to the brake if the brake still does not release replace motor Tension gearbox toothed belt Replace toothed disk of motor and if the parallel key groove of the motor is damaged replace motor Tension drive tooth belt Change motor direction of rotation Replace cable Troubleshooting Page 22 of 37 Transl of Original User s Manual June 2011 Module 160 15 G MAN_EN_1102540_Module160 15G_R1a doc i N M X M J 6 Repair WARNING Always de energize the system before beginning the repair WARNING Generally repairs must be performed by specialist personnel who have read and understood the User s Manual CAUTION Only when original parts are used can warranty claims be accepted by IEF Werner GmbH Transl of Original User s Manual Module 160 15 G Repair Page 23 of 37 June 2011 MAN_EN_1102540_Module160 15G_R1a doc M M d M 6 1 Factory Setting of Axial Toothed Belt Tension The toothed belt tension of the axial toothed belt is set with adjusting screws see Figure 20 When delivered the toothed belt tension is correct and the adjusting screws are secured in position with safety lacquer Adjusting screws Figure 20 Adjusting screws for belt tension NOTE Do not remove the safety lacquer at the adjusting screws Th
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