Electromechanical Cylinders EMC

Transcription

1 Electromechanical Cylinders EMC R / Instructions

2 The data specified only serves to describe the product. Statements concerning condition or suitability for a certain application cannot be derived from this information. The information does not constitute the user's own judgment and verification. It is important to note that our products are subject to a natural process of wear and aging. All rights reserved by, even in cases of proprietary rights applications. Copying and distribution to third parties is only permitted with our explicit consent. The illustration on the front page represents an example configuration. The delivered product may thus deviate from the illustration. The original instructions were prepared in German. Distribution of the product is only permitted together with this manual. Die vorliegende Anleitung ist in folgenden Sprachen verfügbar. These instructions are available in the following languages. Les présentes instructions sont disponibles dans les langues suivantes. Le presenti istruzioni sono disponibili nelle lingue seguenti. Las presentes instrucciones están disponibles en los siguientes idiomas. As presentes instruções estão disponíveis nas seguintes línguas. 本说明书具有下列语言版本 DE Deutsch (original version) English FR Français IT Italiano ES Español PT Português ZH 中文

3 R / EMC 3 Contents 1 About these instructions Safety instructions Scope of supply Product description Transport and storage Mounting Initial operation Operation Cleaning and care Maintenance and repair Disassembly and replacement Disposal Technical data Operating conditions...56

4 4 EMC R / About these instructions 1.1 Scope and purpose of the documentation This documentation applies to the following products: Electromechanical Cylinders (EMC) as described in the Electromechanical Cylinders EMC catalog. This documentation is intended for assembly/installation personnel, line operators and machinery/plant users. This documentation contains important information for proper and safe installation, operation, maintenance and disassembly of the product and for troubleshooting simple errors oneself. XX Before commencing any work with the product, be sure to read these instructions and the Safety Instructions for Linear Motion Systems carefully and completely. 1.2 Required documentation Documentation which is indicated by the book symbol before handling the product and must be adhered to. must be obtained Table 1: Title Required documentation Document number Description Safety Instructions for Linear Motion Systems R Safety instructions Electromechanical Cylinders EMC R Catalog IndraDrive C for Linear Motion Systems R Catalog IndraDrive Cs for Linear Motion Systems R Catalog Material safety data sheet for Dynalub 510 R Safety instructions Product data sheet for Dynalub 510 R Catalog System documentation of the machinery/ system manufacturer Manuals for the other machine/system components The Rexroth documentation is available for download at:

5 R / EMC Presentation of information To enable users to work rapidly and safely with the product while following these instructions, this documentation uses standardized safety instructions, symbols, terms and definitions, and abbreviations. For clearer understanding, these are explained in the following sub-sections Safety notices in these instructions These instructions contain safety (warning) notices preceding any actions that involve a risk of personal injury or damage to property. The safety precautions described must be adhered to. Warning notices are structured as follows: SIGNAL WORD Type of hazard! Consequences if ignored. Hazard avoidance precautions. Warning sign: draws attention to the hazard Signal word: indicates the severity of the hazard Type of hazard: indicates the type or source of the hazard Consequences: describes the consequences that may occur if the hazard avoidance precautions are ignored Hazard avoidance precautions: indicates how to avoid the hazard The warning notices cover the following hazard levels. The hazard level describes the risks involved if the warning notice is ignored. Hazard levels as per ANSI Z535: Warning sign, signal word NOTE DANGER WARNING CAUTION Meaning Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. Damage to property: Risk of damaging the product or the surrounding environment.

6 6 EMC R / Symbols The following symbols designate notes or cross-references that are not safetyrelevant but increase the clarity of the documentation. Table 2: Symbol X X 1. Meaning of the symbols Meaning If this information is not observed, the product will not be used or operated optimally. Single, independent work step Numbered work steps 2. The sequence of the work steps is indicated by the numbers. 3.! 7 See section 7! Fig. 7.1 See figure 7.1 Screw with strength class... u Tightening torque m Friction factor for screws Abbreviations The following abbreviations are used in this document: Table 3: Abbreviations and definitions Abbreviation Meaning EMC ElectroMechanical Cylinder Ball screw Ball screw drive

7 R / EMC 7 2 Safety instructions The general safety instructions for this product can be found in the documentation Safety Instructions for Linear Motion Systems. You must have read and understood these before handling the product. 3 Scope of supply The scope of supply includes: Electromechanical Cylinders EMC, and any ordered motors, controllers, control systems and accessories 1 Instruction manual Electromechanical Cylinders EMC 3.1 Accessories The following accessories are available: Mounting elements Switches Motor mounting kit (flange, coupling, timing belt side drive) Load sensor Cover screws Plug-in connectors Dimensions and part numbers of the accessories as well as additional mounting accessories! Electromechanical Cylinders EMC catalog.

8 8 EMC R / Product description 4.1 Description of features An Electromechanical Cylinder EMC consists of the following parts: 1 Piston rod (stainless steel) 2 Hex socket head cap screw on the cover with internal thread for mounting accessories 3 Protective profile 4 Hex socket head cap screw on the base with internal thread for mounting accessories, motor flange or timing belt side drive 5 Drive journal 6 Hexagon nut Fig. 1: Structural design of the EMC

9 R / EMC Identification of the product The name plate of the product carries the following information: Table 4: Details given on the name plate 1 MNR Part number 2 TYP Short product name Size 4 CS Customer information 5 FD Date of manufacture Manufacturing location 7 s max Maximum travel range 8 u Lead constant without motor mounting 9 v max Maximum speed 10 a max Maximum acceleration 11 M1 max Maximum drive torque at motor journal 12 d Direction of rotation of the motor for travel in positive (+) direction 13 i Transmission ratio XX When ordering replacement parts, please always state all data given on the name plate D Schweinfurt MNR: R Made in Germany TYP: EMC-080-NN-2 FD: CS: s max (mm) u (mm/u) v max (m/s) a max (m/s 2 ) M1 max (Nm) d i Fig. 2: Name plate

10 10 EMC R / Transport and storage Observe the environmental conditions! 14 on page 56 and Electromechanical Cylinders EMC catalog. For special environmental conditions, please consult us. 5.1 Transporting the EMC Electromechanical Cylinders are pre-assembled as ready-to-install units. WARNING Risk of product crashing down due to inadequate load hoisting equipment! Serious injury or even death. Use only safety-inspected and suitable load hoisting equipment. Attach load hoisting equipment only to the frame (main body) or at the designated points. Do not stand under hoisted loads. NOTE Risk of damage to motor attachment by vibrations! Motor may break o. When transporting the product with attached motor, always provide support for the motor, or Remove the motor before transporting the product.

11 R / EMC ! Fig. 3: Transporting the EMC

12 12 EMC R / NOTE Damage to the product due to improper transport! Fig. 3 on page 11! Damage to the EMC. Retract the piston rod (1). Lift the EMC only by its protective profile.(2). Do not lift the EMC by the piston rod (3). The ball screw is not self-locking. Use eyebolts only on the round-neck nuts on the cover of the EMC. Subject these to tensile stress only (4). Prevent the EMC from swinging during lifting operations (5). 1. Before hoisting the EMC, note the weight! Electromechanical Cylinders EMC catalog, Technical Data section. 2. Hoist the EMC. 5.2 Storing the EMC NOTE Risk of damage due to incorrect storage! Potential corrosion of product parts. Store the product only in dry, roofed areas. Protect the product against humidity and corrosive agents.

13 R / EMC 13 6 Mounting Dimensions and part numbers of the individual components! Electromechanical Cylinders EMC catalog. WARNING Risk of product crashing down due to inadequate load hoisting equipment! Serious injury or even death. Use only safety-inspected and suitable load hoisting equipment. Attach load hoisting equipment only to the frame (main body) or at the designated points. Do not stand under hoisted loads. Risk of product crashing down in vertical or hanging installations due to lack of protection against falling loads. Serious injury or even death. Secure the product against dropping. Do not stand under the product in the hazard zone. XX Before hoisting the EMC, note the weight! Electromechanical Cylinders EMC catalog, Technical Data section. 6.1 Installation conditions Heed the operating conditions! 14 on page 56 and Electromechanical Cylinders EMC catalog. XX For special requirements, please contact us. NOTE Risk of damage due to non-permissible loads! Damage to the product. No overhanging loads (see catalog for maximum values) Do not subject the piston rod to torsion (it is not designed to absorb torque). The protective profile is not intended for attachment of other machine elements for absorbing force.

14 14 EMC R / F F M Fig. 4: Non-permissible loads 6.2 Mounting orientation The EMC can be mounted in any orientation. WARNING For vertical or inclined installation risk of the piston rod crashing due to lack of self-locking! Serious injury or even death. In vertical or slanting installations, secure the piston rod so that it cannot drop out. Do not stand in line with the direction in which the piston rod could fall. Fig. 5: Dropping of the piston rod

15 R / EMC Required accessories Required mounting accessories! Electromechanical Cylinders EMC catalog, Mounting Elements section. 6.4 Mounting options 1 By the cover 2 By the timing belt side drive 3 By the base 4 By the piston rod end Fig. 6: Mounting options

16 16 EMC R / Mounting elements Overview of mounting elements Befestigungselemente Table 5: Overview of mounting elements Befestigungselement Mounting element Ausführung Version ohne Flange-less Flansch OF01 Gruppe Group Without ohne 00 Without ohne 00 Without ohne 00 Without ohne Gabelbefestigung Clevis mount with force mit measurement Kraftmessbolzen bolts Stainless Edelstahl steel mit With Flansch flange und and coupling Kupplung MF EMC-32 - EMC With mit timing Riemenvorgelege belt side drive RV01 RV01 bis to RV03 RV03 05 EMC-63 - EMC- 100XC 06 Stainless Edelstahl steel

17 R / EMC Ausführung Version Gruppe Group Without ohne 00 Without ohne 01 1) mit With Flansch flange und and coupling Kupplung MF ) 05 1) EMC-32 - EMC-50 EMC-63 - EMC-100XC 06 EMC-32 - EMC-50 EMC-63 - EMC-100XC EMC-32 - EMC With mit Riemenvorgelege timing belt side drive RV01 RV01 bis to RV03 RV03 EMC-63 - EMC-100XC EMC-32 - EMC EMC-63 - EMC-100XC 05 Gabelbefestigung Clevis mount with force mit measurement Kraftmessbolzen bolts Hinweis: Befestigungselemente liegen bei 1) Befestigungselemente bei Ausführung mit Flansch und Kupplung bereits angebaut

18 18 EMC R / Permitted forces when installing the unit using mounting elements CAUTION The attainable forces may vary according to the version, mounting orientation and maximum travel! Injuries. Ensure that the actual load does not exceed the maximum axial force values! Section Maximum Axial Loading of Mechanical Cylinder System F max EMC in the Electromechanical Cylinders EMC catalog. F max EMC can be attained with suitably designed customer-built mounting elements.

19 R / EMC Fastening the mounting elements NOTE Risk of twisting the piston rod due to incorrect assembly! Damage to the EMC due to application of torque. Take care not to subject the piston rod to torsion when tightening and loosening the hex nuts. Use the wrench contact surface as a holding point only. Fig. 7: Fastening the swivel head The EMC is supplied with the ordered mounting elements. Except for the foot mount, these mounting elements are not pre-assembled to the EMC on delivery. The foot mount is pre-assembled on delivery. The mounting elements can also be ordered separately as accessories.

20 20 EMC R / XX Remove the set screws (if present) from the bearing plate on the timing belt side drive before mounting it. XX Fasten the mounting elements as shown in the illustration! Fig. 8. Tighten the fastening bolts evenly, taking care not to exceed the maximum screw-in depth B G and the tightening torque M A max. Table 6: Tightening torques M A max EMC 32, 40 50, 63 80, XC 8.8, µ = M6 M8 M10 M12 B G (mm) u M A max (Nm) B G Fig. 8: Fastening the mounting elements

21 R / EMC Installing the EMC NOTE Risk of warping due to incorrect mounting! Product malfunction Avoid subjecting the cover/base and the protective profile to tension! Fig. 9. F F F Fig. 9: Warping of cover/base and protective profile 1. Bring the EMC into position (extend/retract piston rod). 2. Tighten the fastening bolts evenly. Take care not to exceed the maximum permitted tightening torques M A max! Table 18 on page 55.

22 22 EMC R / Air equalization slit (optional) NOTE Malfunctioning caused by blocking of the air equalization slit! Product malfunction. Keep the area surrounding the air equalization slit free from obstruction. 1. Mount the EMC in such a way that the air equalization slit (1) remains unobstructed. 1 Fig. 10: Air equalization slit 6.7 Mounting the drive NOTE Risk of excessive torque and rotary speed if limits are exceeded! Damage to the product. Keep within specified maximum values. Technical data and maximum values! Electromechanical Cylinders EMC catalog. The Electromechanical Cylinder EMC has the following drive options! Fig. 11: Motor (1) with flange and coupling (2) Motor (1) with timing belt side drive (3)

23 R / EMC Fig. 11: Drive options Motor mounting kits for motors according to customer specification In order to determine the appropriate attachment kit, the connection geometry of the motor is crucial. For more information, see the catalog Electromechanical Cylinder EMC. The following table lists the recoding from the motor geometry code to the motor designation (required for motor mounting in the following section). Table 7: Third-party motor code Motor geometry code M M M M M M Motor designation M1002 M1004 M1005 M1006 M1007 M1008

24 24 EMC R / Mounting the motor via flange and coupling 1. Push the coupling (1) onto the drive journal of the EMC. While doing so keep the necessary (B) distance! Fig. 12. Clamp the coupling with clamping screw (3) terminals onto the motor pin with M A max Fig. 12: Mounting the motor via flange and coupling 2. Mount the coupling housing (4) with four screws (5) at the base of the cylinder. M A max 2! Table 9 please note. Pay attention to the alignment of the closing hole. 3. Mount the motor plate (8) with four / six screws (9) to the coupling housing (4). M A max 2! Table 9. B Fig. 13: Set dimensions B

25 R / EMC Slide the motor (6) with coupling (1) into the motor plate (8) and the clutch housing (4). Mount engine with four screws (7) on the motor plate with M A max 2. Clamp the clutch on the drive stud of the cylinder with M A max 1! Table 8 (2). 5. Close the clutch housing with the plug screw. Table 8: M A max 1 (steel steel) 8.8, µ = M4 M5 M6 M8 M10 M12 u M A max (Nm) Table 9: M A max 2 (steel alu / alu alu) 8.8, µ = M4 M5 M6 M8 M10 M12 u M A max (Nm) Table 10: Dimensions B for flange and coupling EMC Motor type Dimensions B (mm) 32 MSM019B, MSM031B 2.5 MSK030C, M MSM031C 3.5 MSK030C, MSK040C 4.0 M MSM031C, MSM041B 3.5 MSK040C 4.0 MSK050C, M MSM041B 15.5 MSK040C 17.5 MSK050C, MSK060C, M MSK050C, MSK060C 8.5 MSK076C 7.5 M MSK060C 9.5 MSK071D, MSK076C 8.5 M XC MSK071E 19.5 MSK101D 21.5 M

26 26 EMC R / Mounting the motor via timing belt side drive Timing belt side drive without support bearing During assembly, apply Loctite 242 to the threads of all screws/bolts that were not coated with threadlocking adhesive on delivery. The timing belt side drive can be attached in the following orientations: RV01 RV02 RV Fig. 14: Mounting orientations for the timing belt side drive 1 Lube fitting on EMC 2 Motor connector

27 R / EMC Fig. 15: Mounting the motor and timing belt side drive without support bearing 1 Base plate 2 Motor plate 3 Housing 4 Hex socket head cap screw 5 Hex socket head cap screw 6 Tensioning unit type 2 7 Hex socket head cap screw 8 Tensioning unit 9 Belt 10 System-side belt pulley 11 Motor-side belt pulley 12 Hex socket head cap screw 13 Centering plate (necessary for some motors) 14 Hex socket head cap screw 15 Motor 16 Hex socket head cap screw

28 28 EMC R / Assembling the base plate and system-side belt pulley 1. Screw-fasten the housing (1) of the timing belt side drive to the base of the EMC. When doing this, observe the specified tightening torques! Table 18 on page Push the belt pulley (10) with fitted toothed belt (9) onto the drive journal of the EMC. NOTE Insuicient lubrication by use of false lubricant! Damage to the product. Do not use oil with MoS 2 additives! 3. Lightly oil the tensioning elements. 4. Type 2: Push on the tensioning unit. The tensioning elements must be completely inserted into the bore of the belt pulley. Fig. 16: Tensioning unit type 2 5. Lightly tighten the screws (5).

29 R / EMC Fig. 17: Mounting the system-side belt pulley 6. Adjust distance A to the base plate A Fig. 18: Adjust the systemside belt pulley distance Table 11: Clearance dimensions for belt pulley EMC Motor Clearances (mm) to the base plate to the Motor i = 1 i = 1,5 i = 2 A B C D 32 MSM019B 1 1 MSM031B, MSK030C M MSM031C MSK030C 2 12 MSK040C M MSM031C 4 14 MSM041B MSK040C 3 14 MSK050C 7 4 M MSM041B 5 18,0 MSK040C 5 7,5 MSK050C ,0 MSK060C 3 M ,0 80 MSK050C ,0 MSK060C 21,0 MSK076C 2 3 M ,0 100 MSK060C, MSK076C M ,0 M XC MSK071E, MSK101D M

30 30 EMC R / Evenly tighten the screws (7) cross-wise in several stages to the specified tightening torques! Table 12 on page 30. Table 12: Tightening torques for the tensioning units m = Type M2,5 M3 M4 M5 M6 u M A max (Nm) Mounting the second belt pulley and motor for i = 1 1. To make sure the second belt pulley can be easily inserted, pre-mount the motor as close to the EMC as possible. 2. Push the belt pulley and tensioning unit onto the motor journal. Fig. 19: Mounting the motor and motor-side belt pulley, i = 1 3. Adjust distance B! Table 11 on page 29. i = 1 B Fig. 20: Adjusting the clearance for the motor-side belt pulley, i = 1 4. Tighten the screws to the specified tightening torque! Table 12 on page 30.

31 R / EMC 31 Mounting the second belt pulley and motor for i = 1.5 and i = 2 1. Connect belt pulley (10) and clamping set type 1 (12) for i = 2 and type 2 (13) for i = 1.5 to the pins of the motor. Lightly tighten the screws (8). Fig. 21: Tensioning unit type 1 2. To make sure the second belt pulley can be easily inserted, pre-mount the motor as close to the EMC as possible. i = 1.5 i = Fig. 22: Mounting the motor and motor-side belt pulley, i = 1,5 and i = 2 3. Adjust distance for C and D! Table 11 on page 29. i = 1.5 i = 2 C D Fig. 23: Adjusting the clearance for the motor-side belt pulley, i = 1.5 and i = 2 4. Tighten the screws to the specified tightening torque! Table 12 on page Insert the pulley into the belt.

32 32 EMC R / Center the toothed belt on the belt pulley. 7. Screw the adjusting screw (14) through the base plate (1) into the motor plate (2). 8. Adjust belt frequency with frequency meter and adjusting screw as per Table Tighten the screws (16) in the motor plate with tightening torque! Table 18 on page Fig. 24: Preloading the timing belt side drive 10. Check belt frequency and adjust again if necessary. 11. Screw the housing tightly onto the (3) base plate. 3 Fig. 25: Mounting the housing 12. Perform a function check.

33 R / EMC 33 Table 13: Belt frequency EMC Motor i Frequency ±2 (Hz) P = MSM MSM031B MSK030 M MSM031C , MSK , MSK M1004 1, MSM031C MSM041B MSK040 1, MSK050 M MSM041B MSK MSK M MSK MSK MSK M MSK MSK M MSK M MSK070/ XC MSK071E MSK101D M1008 1, P = ball screw lead

34 34 EMC R / Mounting the switching system NOTE Potential collision due to false mounting of the switching system! Damage to product, adjoining structure and workpieces. The entire switching system must be mounted on one side of the product. The T-slot strip for switches(1), retaining bracket (2) and switch (3) (magnetic field sensors) need to be mounted by the customer. The necessary magnet (4) is factory-fitted Fig. 26: Mounting the switching system 1

35 R / EMC Mounting the T-slot strip for switches NOTE Potential collision due to false mounting of the switching system! Damage to product, adjoining structure and workpieces. The entire switching system must be mounted on one side of the product. 1. Align the T-slot strip for switches (1) with the leading edge (7) in the longitudinal groove (6) in the protection profile. Align the T-slot strip for switches between the base (8) and the cover (9). 2. Line up the supplied mounting bracket (2) evenly along the T-slot strip for switches. 3. Clamp mounting bracket with clamping screws (3/5) (tightening torque 1.9 Nm) in the protection profile. 4. Fix the T-slot strip for switches into place with clamping screws (4) against the protection profile. 5. Ensure that the T-slot strip for switches is firmly mounted Fig. 27: Mounting the T-slot strip for switches

36 36 EMC R / Mounting the switches Switches can be inserted into either or both of the two T-slots. NOTE Potential collision due to false mounting of the switching system! Damage to product, adjoining structure and workpieces. The entire switching system must be mounted on one side of the product. 1. Place the switches (magnetic field sensors) in the T-slot of the T-slot strip that the clamping screw (1) is facing outward! Fig Adjust the switches to the desired switch activation point. Take care to ensure that the active zone of the switch is between L 0 1Mag and L smax 1Mag.! Fig. 29 on page 37 and Table 14 on page Fig. 28: Mounting the switches

37 R / EMC 37 L 0 1Mag L smax 1Mag L 0 2Mag L smax 2Mag Fig. 29: Setting the switching point Table 14: Setting the switching points EMC Size of ball screw Dimensions (mm) At travel range 0 mm At travel range s max mm d 0 x P (mm) L 0 1Mag L 0 2Mag L smax 1Mag L smax 2Mag 32 12x x x x x x x x x x x x x x x x x x x XC 50x x The dimensions given in the table show the position of the magnet depending on the maximum path s max. 3. Fasten in place using the clamping screw (1)! Fig. 28 on page 36. Hand tighten and check tightness of the switch.

38 38 EMC R / Connecting the switches 1. Connect the switches as illustrated Fig , M8x R R R R NO NC PNP - NO 3 - PNP - NC NPN - NO 3 - NPN - NC 3 - Fig. 30: Connecting the switches 1 Connection 2 Fastening screw 3 LED display 4 Position of sensor element : 2.0 mm

39 R / EMC 39 NOTE Collision between the ball nuts and base plate! Damage to product, adjoining structure and workpieces. Do not over-travel Table 14 on page 37 the indicated.positions. 2. After connecting, check the switching points at low speeds and adjust if necessary. Further technical data to the switches! Electromechanical Cylinders EMC catalog Connecting the EMC electronically WARNING Electrical shock from touching live parts! Serious injury or even death. Disconnect the power before working on the electrical installation and secure against reconnection. Observe the safety instructions in the documentation of the controller used. 1. While still disconnected from the power supply, switch on the relevant system component. 2. Connect the EMC to the power supply as illustrated. Fig. 31: Connecting the EMC electronically

40 40 EMC R / XX Observe the information on electromagnetic compatibility. XX Also note the information in the current publications. They can be ordered from your sales partner under or downloaded at XX Refer to the documentation for the controller used. It is available for download at

41 R / EMC 41 7 Initial operation XX Only initiate operation of the product when it has been verified that the final product (such as a machine or system), into which the Rexroth product is installed, complies with the national regulations, safety regulations and standards for the application. WARNING Risk of injury from moving parts (e.g. piston rod)! Contusions. During operation, do not reach into moving parts. Do not linger in dangerous zone in front of the piston rod. Before start-up, check that there are no persons in front of the piston rod. NOTE Short circuiting of the motor caused by missing fasteners! Engine damage due to ingression of liquids and debris. Prior to initial operation, ensure that all connectors are plugged in correctly. Prior to initial operation, ensure that all gaskets and seals of the connections are tight. NOTE Collision caused by incorrectly adjusted limit switches! Damage to the product. Do not run the product to the physical stop limit. If required by the application, the piston rod may be driven without force to a stop point in the final position for referencing purposes. Do not exceed the maximum approach speed of 0.01 m/sec. Observe the EMC's maximum travel range. Comply with all mounting positions for a two-sided safety distance (overflow).

42 42 EMC R / Checking the operating conditions XX Check the ambient temperature, load, rotational speed, travel speed and maximum travel range of the EMC! Table 19 on page 56 and Electromechanical Cylinders EMC catalog. XX For special requirements, please contact us. 7.2 Trial run, start-up XX Place the product into operation only after successful production-related tests. XX Proceed at a slow speed over the entire travel range. Most importantly, make sure that the limit switches are correctly set and properly functioning. XX If necessary, optimize interaction of mechanics and electronics. 7.3 Initial start-up WARNING Risk of injury from moving parts (e.g. piston rod)! Contusions. During operation, do not reach into moving parts. Do not linger in dangerous zone in front of the piston rod. Before start-up, check that there are no persons in front of the piston rod. To extend the working life of the seals, apply some lubricant to the piston rod in the vicinity of the seals prior to start-up.

43 R / EMC Make sure that the travel range is free from obstructions. On delivery, the piston rod is maximally retracted. NOTE Collision caused by incorrectly adjusted limit switches! Damage to the product. Do not run the product to the physical stop limit. Comply with all mounting positions for a two-sided safety distance (overflow). Observe the EMC's maximum travel range. First check to ensure that the spindle extends and retracts in the direction of rotation. Move the piston rod very slowly. Make sure that the travel range is free from obstructions. 2. To extend, rotate the drive journal of EMC to the left. It is recommended to turn the drive journal by hand. If the extension is to take place using a motor, then only at a low speed. Fig. 32: Extending the piston rod

44 44 EMC R / Restarting after dismantling 1. When restarting the system, proceed as described in section Start-up! 7.3 on page 42.

45 R / EMC 45 8 Operation WARNING Electrical shock from touching live parts! Serious injury or even death. Disconnect the power before working on the electrical installation and secure against reconnection. Observe the safety instructions in the documentation of the controller used. Risk of injury from moving parts (e.g. piston rod)! Contusions. During operation, do not reach into moving parts. Do not linger in dangerous zone in front of the piston rod. NOTE Leaking lubricant due to vertical installation. Pollution Take appropriate measures to collect leaked grease and dispose of it properly. Engine overheating due to overload! Fire. Please note values, such as torque, maximum speed, motor data, etc. while in operating mode! EMC Electromechanical Cylinders X X Please note values, such as load ratings, torque, maximum speed, motor data, etc. while in operating mode! Electromechanical Cylinders EMC catalog.

46 46 EMC R / Cleaning and care NOTE Damage caused by the use of solvents and aggressive cleaning agents! Destruction of seals and malfunction of the product. Clean only with water and, if necessary, use a mild detergent. 1. Seal all openings with appropriate protective caps/devices. 2. Make sure all gaskets and seals of the connectors are firmly seated so that during cleaning no moisture can get into the EMC. 3. To extend the life of the seal, apply some lubricant on the piston rod in the vicinity of the seal after cleaning.

47 R / EMC Maintenance and repair The only maintenance required is greasing the ball screw drive with a commercially available hand press. The basic lubrication is done at the manufacturer. Nozzle pipes with suitable mouthpiece can be ordered under the order number R Lubrication XX Read the relevant safety data sheets and take notice before using lubricants. NOTE Damage due to insuicient lubrication! Drop in performance and corrosion. Lubricate product every two years or if the specified travel range is completed whichever limit is reached first! Table 15 on page 48. Insuicient lubrication by use of false lubricant! Damage to the product. Do not use any oil which contains MoS 2 additives! Use only recommended lubricants! Table 16 on page 49. Power change due to special operating conditions Damage to the product. Before starting-up the product under special operating conditions consult, particularly in cases involving glass fiber dust, wood dust, solvents, short stroke and extreme temperatures.

48 48 EMC R / Lubrication intervals When the specified travel range is completed or after two years, whichever limit is reached first. To ensure the lubrication is distributed equally, the specified quantity of grease per lubrication interval is to be applied. Limit conditions: Load = 0.2 C n min = 100 min 1 Installation position: arbitrary Mode of operation: no short stroke (> s min ) Sealant: Standard If the option ball screw only preserved, the double amount of lubrication is to be applied prior to start up. Table 15: Lubrication intervals, lubricant quantities EMC P 1) (mm) Dynalub 510 Dynalub 520 Dynalub 510 Dynalub 520 s min Rotations U (million) Travel range (km) Grease relubrication amount (cm 3 ) XC ) Ball screw lead XX Under normal operating conditions, relubricate according to Table 15. XX For special requirements, please contact us.

49 R / EMC Lubricant quantities The EMC is designed for grease lubrication only. Greases containing solid particles (e.g. graphite or MoS 2 ) S2) must not be used! Recommended lithium soap greases! Table 16. Table 16: Recommended lubricant Grease Dynalub 510 Dynalub 520 Part number R R Lubricating the EMC 1. In order to achieve the lubricating L Lub position, move the piston rod to stroke position S 2. For this purpose, move S 1 from the end position according to ttable 17 on page 50.! Fig. 33. S 1 L Lub S Fig. 33: Lubricating the EMC 2. Apply grease to the ball screw drive using the lube nipple. Use the entire amount of grease at once! Table 17 on page Extend and retract the piston rod the entire travel range with three double strokes.

50 50 EMC R / Table 17: Lubrication positions EMC Dimensions (mm) P 1) LLub S 1 S s max /2 2) s max /2 2) s max /2 2) s max /2 2) s max /2 2) s max /2 2) s max /2 2) s max /2 2) s max /2 2) s max /2 2) s max /2 2) s max /2 2) s max /2 2) s max /2 2) s max /2 2) s max /2 2) s max /2 2) s max /2 2) s max /2 2) s max /2 2) s max /2 2) s max /2 2) s max /2 2) s max /2 2) s max /2 2) s max /2 2) s max /2 2) s max /2 2) s max /2 2) s max /2 2) s max /2 2) s max /2 2) s max /2 2) s max /2 2) s max /2 2) s max /2 2) s max /2 2) s max /2 2) s max /2 2) s max /2 2) s max /2 2) s max /2 2) s max /2 2) s max /2 2) s max /2 2) s max /2 2) s max /2 2) s max /2 2) s max /2 2) s max /2 2) s max /2 2) s max /2 2) s max /2 2) s max /2 2) s max /2 2) s max /2 2) s max /2 2) 100XC s max /2 2) s max /2 2) s max /2 2) s max /2 2) s max /2 2) s max /2 2) 1) Ball screw lead 2) s max : maximum travel range of the EMC (see name plate) NOTE Damage caused by incorrect parameters when approaching the rear end position! Damage to the product. Approaching the rear end position with the following parameters. Maximum speed: 10 mm/s Maximum force: 5% of F max EMC

51 R / EMC Disassembly and replacement Basically, the dismantling and replacing of modules must only be performed by Rexroth to ensure the accuracy of the EMC after replacement of modules. Excluded are the activities described in this chapter Dismantling the drive WARNING Electrical shock from touching live parts! Serious injury or even death. Disconnect the power before working on the electrical installation and secure against reconnection. For vertical or inclined installation risk of the piston rod crashing due to lack of self-locking! Serious injury or even death. When mounted vertically or on an inclined surface securely fasten product before removing the mounting screws securing the piston rod to prevent crashing. Do not stand in the direction of travel of the piston rod.

52 52 EMC R / Removing the motor flange and coupling 1. Open the plug screw in the clutch housing (4). Open the clamping screw (2) of the clutch. 2. Open the motor screws (7) and remove the motor (6) together with clutch from the clutch housing (4). 3. Loosen the screws (9) and remove the motor plate (8). 4. Loosen the screws (5) and remove the clutch housing (4) Fig. 34: Removing the motor flange and coupling

53 R / EMC Removing the motor and belt transmission 1. Disassemble the cover (3) from the base plate (1)! Fig. 35 on page 54. CAUTION Uncontrolled movements of the pre-tensioned belt when loosening the screws! Injuries. Loosen the fastening screws on the motor carefully. 2. Loosen the fastening screws (17) holding the motor (16). 3. Loosen the tensioning unit (7) on the motor side belt pulley (12), take o the tensioning unit and belt pulley. 4. Remove the belt (10). 5. Detach the tensioning unit (9) on the EMC belt pulley (11). To f facilitate disassembly, forcing threads are present in the tensioning units. 6. Loosen the motor mount (17), and remove the motor (16).

54 54 EMC R / Fig. 35: Removing the motor with belt transmission 10

55 R / EMC Disposal The EMC contains dierent substances: Aluminum, steel, plastics, grease and possibly electronic components. NOTE Environmentally hazardous substances can be released into the environment through improper disposal! Pollution. Collect and properly dispose of discharging lubricants. Dispose of the product and its components appropriately and in accordance with applicable national and international regulations and laws. 13 Technical data Technical data! Electromechanical Cylinders EMC catalog Tightening torque By default, screws of property class 8.8 are used. Deviations are marked accordingly. Table 18: Tightening torque 8.8 M2 M2,5 M3 M4 M5 M6 M8 M10 M12 u M A max (Nm) m =

56 56 EMC R / Operating conditions Table 19: Operating conditions Ambient temperature Cylinder mechanism: 10 C C Cylinder with Rexroth Servomotor: 0 C C, performance degradation over 40 C ϑ Travel speed max 1.6 m/s v Maximum travel range 100 to 1500 mm 14.1 Service and Support XX When ordering spare parts, mention all data on the name plate! Fig. 2 on page 9. XX Please contact your regional center of for ordering replacement parts. These can be found at In urgent cases, please contact the Bosch Rexroth service help-desk and hot line: Phone: +49 (0) servicelt@boschrexroth.de Return address: SERVICE Röntgenstraße Schweinfurt, Germany

57 R / EMC 57

58 Ernst-Sachs-Straße Schweinfurt, Germany Phone Fax Subject to modifications Printed in Germany R /