Vertical Actuator HTR- Brochure

HTR We reserve the right to make technical changes. The data correspond to the technical state at the time of printing. 05/08 Art. Nr.: 192-530813N4 HTR - Product manual Project planning, assembly, commissioning, maintenance, repairs DIN EN ISO 9001 CE R TI F I E D QUA L I T Y S Y ST EMReg. Nr. 36 38 - 01 Parker Hannifin GmbH & Co. KG Electromechanical Automation Robert-Bosch-Straße 22 D-77656 Offenburg, Germany Phone +49 (0)781 / 509-0 Fax +49 (0)781 / 509-98176 sales.automation@parker.com www.parker-automation.com Table of Contents1 Product description....................................... 1-12 Technical data................................................ 2-12.1 Permissible loading of the rollers forvertical axle construction .............................. 2-12.1.1 Roller load based on static side load (Fv; Fw) ........2-22.1.2 Roller load based on existing torque (Mu; Mv;Mw).......................................................................2-22.1.3 Roller load based on dynamic side load (Fa) ........2-32.2 Permissible toothed belt load ........................ 2-32.3 Construction dimensions HTR80 (HTR50).... 2-42.4 Application examples for the diagrams ........ 2-52.4.1 Application example 1. Working load centredbelow the HTR80 .................................................2-52.4.1.1 Determine roller loading: ................................2-52.4.1.2 Determine toothed belt load: ..........................2-62.4.2 Application example 2. Working load eccentricbelow the HTR80 .................................................2-82.4.2.1 Determine roller loading: ................................2-82.4.2.2 Determine toothed belt load: ........................2-103 Safety .............................................................. 3-13.1 Correct use ...................................................... 3-13.2 Identification of other dangers and dangerareas ................................................................ 3-13.3 General dangers in the event of non-observance of the safety notices .................. 3-23.4 Safe working practices ................................... 3-23.4.1 Observe the notes.................................................3-23.4.2 Operating personnel..............................................3-23.5 Safety instructions for the user company..... 3-23.6 Safety instructions for the operatingpersonnel ........................................................ 3-23.7 Note regarding special dangers..................... 3-33.8 Unauthorised conversions ormodifications are forbidden .......................... 3-33.9 Transport ......................................................... 3-34 Assembly ........................................................ 4-14.1 General remarks.............................................. 4-14.2 Assembly on the flange plate......................... 4-14.2.1 Removal of the rotor station, lower centralsection .................................................................4-14.2.2 Removal of the rotor station, lower outer section...4-24.2.3 Installation of the HTR in the flange plate..............4-24.2.4 Installation of the rotor station, lower outersection .................................................................4-24.2.5 Intallation of the rotor station, lower centralsection .................................................................4-35 Commissioning.............................................. 5-15.1 General remarks.............................................. 5-15.2 Setting limit stops ........................................... 5-16 Maintenance ...................................................6-17 Repairs ............................................................7-17.1 Safety instructions .......................................... 7-17.2 General remarks .............................................. 7-17.3 Toothed belts ................................................... 7-17.3.1 General remarks regarding toothed belts.............. 7-17.3.2 Tensioning toothed belts, guidelines..................... 7-27.3.2.1 Toothed belt tension, measurement............... 7-37.3.3 Replacing, tensioning and aligning the maindrive toothed belt ................................................. 7-47.3.3.1 Determine axle stroke .................................... 7-47.3.3.2 Replace main drive toothed belts ................... 7-47.3.3.3 Tension main drive toothed belt ..................... 7-77.3.3.4 Aligning main drive toothed belts ................... 7-77.3.4 Replacing, tensioning and aligning thetransmission drive toothed belt ............................ 7-87.3.4.1 Replace transmission drive toothed belt ........ 7-87.3.4.2 Tensioning toothed belts of thetransmission drive ....................................... 7-127.3.4.3 Aligning the transmission drive toothedbelts ............................................................ 7-127.4 Setting and aligning rollers. ......................... 7-137.4.1 Adjusting rollers of the rotor station lower outersection............................................................... 7-137.4.2 Adjusting rollers of the rotor station upper outersection............................................................... 7-147.4.3 Adjusting rollers of the rotor station lower outersection............................................................... 7-187.4.4 Adjusting rollers of the rotor station upper innersection............................................................... 7-197.5 Replace rollers............................................... 7-237.5.1 General remarks................................................. 7-237.5.2 Replace fixed rollers ........................................... 7-247.5.3 Replace eccentric rollers .................................... 7-247.6 Replace belt tensioner .................................. 7-267.6.1 Replace main drive belt tensioner....................... 7-267.6.2 Replace transmission drive belt tensioner .......... 7-277.7 Replace gears ................................................ 7-307.8 Change motor ................................................ 7-318 HTR wearing parts, replacement parts andparts lists .......................................................8-18.1 HTR80 ............................................................... 8-18.1.1 HTR80 wearing parts............................................ 8-18.1.2 HTR80 replacement parts..................................... 8-18.1.3 Component overview with position numbers......... 8-28.1.4 Component diagrams with position numbers forHTR80................................................................. 8-38.2 HTR50 ............................................................. 8-128.2.1 HTR50 wearing parts.......................................... 8-128.2.2 HTR50 replacement parts................................... 8-128.2.3 Component overview with HTR50 positionnumbers ............................................................ 8-138.2.4 Component diagrams with HTR50 positionnumbers ............................................................ 8-14Product description1 - 11 Product description73415628Great lifting power with small constructionheightSpecially designed for applications that require alarge vertical lifting path in limited space, thetelescopic axle has been developed by HAUSER.With the wear-proof, high strength toothed belt,the main drive (1) and transmission drive (2) pro-vide optimal power transfer to the load attach-ment (8).Maintenance free, plastic rollers mounted onroller bearings combined with surface treatedaluminium extruded sections guarantees mini-mum wear with optimal running smoothness.A newly developed guiding principle, consisting ofthe 3 guide profiles and the relevant rotor sta-tions (3), (4), (5) and (6), provides self-stabilisingproperties.The hollow shafts and flange design of the drivestation (7) are identical to the flange dimensionsof HAUSER servo drives, offering optimal combi-nations with HAUSER drive technology.HTR connection possibilities are compatible withthe HAUSER modular system so that modularapplication specific handling technology can beprovided in combination with linear units.These proven HAUSER construction principlesgive the user many advantages which are alsoapplicable to the telescopic axle.1 Main drive 7 Drive station2 Transmission drive 8 Connection for outer load (e.g. Gripper)3 Rotor station, upper central section4 Rotor station, upper inner section5 Rotor station, lower outer section6 Rotor station, lower central sectionProduct descriptionTechnical data / Project planning2 - 12 Technical dataHTR Units HTR50 HTR80Cross-section outer profile mm x mm x mm 125 x 125 x 6 180 x 180 x 10Cross-section central profile mm x mm x mm 80 x 80 x 6 125 x 125 x 6Cross-section inner profile mm x mm x mm 50 x 50 x 5 80 x 80 x 6Moment of inertia about the outer profile cm4 674 3261Moment of inertia about the central profile cm4 163 674Moment of inertia about the inner profile cm4 31 163Travel speed, maximum m/s 5.0 5.0Travel path, maximum mm 2500 2500Maximum permissible acceleration m/s2 5 5Path travelled per rotation 1) mm/U 340 480Tooth lock washer diameter 1) mm 108.2 152.8Driving torque, maximum Nm 40 108Belt tensile force, maximum at retract speed N Æ Diagram 2-4 Æ Diagram 2-4Roller load, maximum N Æ Table 2- 2 Æ Table 2- 2Pos. repeat accuracy in one direction (DIN EN 29283) mm ±0.2 ±0.2Mass base unit, no lifting kg 12.8 35.3Mass additional length kg/m 8.6 16.2Moving mass, without lifting kg 2.8 7.4Moving mass, additional length kg/m 2.4 4.5Basic mass moment of inertia, based on the driveshaft, without lifting kgcm2 52.4 302.8Additional mass moment of inertia, based on the driveshaftkgcm2m49.2 202.3Table 2-1: Technical data of HTR axle2.1 Permissible loading of the rollers for vertical axle constructionApproach/retract speed (Vu) [m/s] 0 - 2 2-3 3-4 4-5Maximum permissible roller load [N]HTR50 210 170 145 125HTR80 388 316 268 232Table 2- 2: Maximum permissible roller load in relation to HTR speedAn additional safety factor of 1.5 must be taken into account with the given val-ues If it is unavoidable that this safety factor may be undershot, please contactHAUSER.Technical data, as of 10/98, safety based on S=1, different technical data on request. The dataapplies for a temperature range from -10°C to + 40°C. 1) calculated value, take into account telescope ratio 1:2Technical data / Project planning2 - 2FwMwFuMuFvMvThe total load on a single roller is calculated using the superposition principlefrom the sum of all resultant forces (FRoller, Æ see Diagrams 2-1 to 2-3). I.e. thesum of all resultant forces (FTotalRoller) must be smaller that the maximum per-missible roller load (Æ Table 2- 2). Meaning:FTotalRoller = FRoller (Fav) + FRoller (Fv) + FRoller (Mw) + FRoller (Mu)Equation 2-1a: Composition of the total roller load (direction 1)FTotalRoller = FRoller (Faw) + FRoller (Fw) + FRoller (Mv) + FRoller (Mu)Equation 2-1b: Composition of the total roller load (direction 2)Dimensioning is based on the higher value from equation 2-1a or 2-1b2.1.1 Roller load based on static side load (Fv; Fw)10 20 30 40 50 100 200 300 400 500 1000Fv, FwNFRollerN10203040501002003004005001000150020003000retracted, optional strokeHTR5010 20 30 40 50 100 200 300 400 500 1000Fv, FwNFRollerN102030405010020030040050010001500200030004000retracted, optional strokeHTR80Dia. 2-1: Resultant force FRoller based on Fv or Fw. Vertical installation position. Each of the curves 500 - 4000denotes a telescope with that stroke [mm], fully extended. Safety taken into consideration S=1.2.1.2 Roller load based on existing torque (Mu; Mv; Mw)1 2 3 4 5 10 20 30 40 50 100MNmFRollerN1020304050100200300400Mv, MwMuHTR5010 20 30 40 50 100 200 300 400 500 1000MNmFRollerN1020304050100200300400Mv, MwMuHTR80Dia. 2-2: Resultant force FRoller based on Mu or Mv or Mw. Vertical installation position. Safety-factor taken intoconsideration S=1.Technical data / Project planning2 - 32.1.3 Roller load based on dynamic side load (Fa)mNaFaFaTmT1020304050100200300400FRollerN10 20 30 40 50 100 200 300 400 500FaN5001000150020003000retracted, optional strokeHTR50Diagram appliesfor acceleration < 5m/s21020304050100200300400FRollerN10 20 30 40 50 100 200 300 400 500 1000FaN50010001500200030004000retracted, optional strokeHTR80Diagram appliesfor acceleration < 10m/s2Dia. 2-3: Resultant force FRoller based on dynamic side loads. The diagram already takes into account the ownmass of the moving telescope sections (mT). Each of the curves 500 - 4000 is based on a telescopewith this stroke [mm], fully extended. Safety taken into consideration S=1.Fa = mN • a (mN = Mass of the working load moved in kg; a = Horizontal acceleration of the HTR withworking load in m/s2)2.2 Permissible toothed belt loadHTR80HTR500,1 0,2 0,3 0,4 0,5 1 2 3 4 5vum/s1002003004005001000FZR_zul.NDia. 2-4: Maximum permissible belt tensile force dependent on the traversing speed of the HTR. Installationposition vertical, stroke as required between 0 - 4000 mm, acceleration < 5 m/s2.Technical data / Project planning2 - 42.3 Construction dimensions HTR80 (HTR50)684 (434) + 0,5 x Stroke0,5 x Stroke0,5 xStroke125 x 680 x 6180 x 1010 2030258,5175 (109)10170250 Stroke234 (162)450 (272)28,5 (5)57 (43)(4,5)(16)(18) (10) (15)(170) (8)180 x 10Limit switch gearbox (accessory) 70 (49)140(90)Ø100(Ø100)68(68)234 (159)103,5(69,5)X - XM 1:2Key complying withDIN 6885/1 Ø 110 H7658Ø130 (Ø100)Ø 25 H7Ø 20 H7(47,5) (Ø 80 H7)(4) 4xM8x30(4xM6x12)(125 x 6)(80 x 6)(50 x 5)(123)290(190)Mounting angle (accessory)HTR80:MW140/290 (Art.Nr.: 500-000524)HTR50:MW90/190 (Art.Nr.: 500-000513)233 + 0,5xStroke *1(147,5 + 0,5xStroke) *1*1: The angle bracket can be fixed in other positions. Please contact HAUSER.67,5(48,5)15 (0)A - A86 (76)(112,5)160138(88)90(60)30 (20)120(80)4 x Ø11(4 x Ø9)Dimensions in ( ): HTR50Technical data / Project planning2 - 52.4 Application examples for the diagrams2.4.1 Application example 1. Working load centred below the HTR80This shows the moment that occurs during the greatest axle loading: HTR fully extended, accelera-tion of working load upwards and simultaneous acceleration of the HTR in the horizontal direction.mNFg + Fuvuaw FawauEquation symbols used:mN = Mass of working load [kg]vu = Approach speed of the HTR [m/s]au = Maximum acceleration while HTR isapproaching [m/s2]Fu = Inertia force on the HTR produced byacceleration and mass [N]. Fu = mNxauFg = Gravity based loading of the HTR [N]aw = Maximum acceleration while HTR istravelling [m/s2]Faw = Inertia force on the HTR produced byacceleration and mass [N]. Fw =mNxawg = Acceleration due to gravity (9.81 m/s2)Required results:Mass of working load on the HTR: mN = 36.5 kgMaximum stroke of the HTR: Stroke = 1000 mmApproach speed of the HTR: vu = 3 m/sAcceleration during approach of HTR: au = 3 m/s2Horizontal acceleration of the total system (HTR + working load): aw = 4.5 m/s22.4.1.1 Determine roller loading:Step 1: Calculate resulting forces:Faw = mN y aw = 36.5 kg y 4.5 m/s2 = 164 NFv, Fav, Fw, Mu, Mv, Mw = 0Step 2: Determine resultant forces with the help of the diagrams:1020304050100300400FRollerN20010 20 30 40 50 100 200 300 400 500 1000FaN50010001500200030004000retracted, optional strokeFawFRoller (Faw)= 260 NFrom diagram 2-3:FRoller (Faw) = 260NFrom equation 2-1b:FTotalRoller = FRoller (Faw) = 260NFrom Table 2- 2:FRollerPerm. (vu = 3 m/s) = 316NSafety factor:FRollerPerm. / FTotalRoller= 316N / 260 N = 1.2.Technical data / Project planning2 - 6Step 3: Back-calculate to permissible output valueThe safety factor obtained is too low at 1.2 It should be at least 1.5. To achieve this, there are three possibili-ties:a) Reduce acceleration aw;b) Reduce working loadc) First fully approach the HTR and then accelerate horizontally.The following is calculated using possibility a) to determine how large aw maximum can be:From FRollerPerm. / FTotalRoller = 1.5:FTotalRoller = FRollerPerm. / 1.5 = 316 N / 1.5 = 211 N1020304050100200300400FRollerN10 20 30 40 50 100 200 300 400 500 1000FaN50010001500200030004000retracted, optional strokeFaw =130 NFRoller (Faw)= 211 NFrom diagram 2-3:Faw = 130NFrom Faw = mN y aw :aw = Faw / mNaw = 130 N / 36.5 kg = 3.6 m/s22.4.1.2 Determine toothed belt load:Step 1: Determine maximum permissible toothed belt load at the required approach speed:0,1 0,2 0,3 0,4 0,5 1 2 3 4 5vum/s1002003004005001000FZR_zul.NFZR_zul.=600 NHTR80HTR50From diagram 2-4:FTB_per = 600 NThe safety factor of minimum 1.5must also be taken into accounthere:FTB_max. = FTB_per / SFTB_max = 600N / 1.5 = 400NTechnical data / Project planning2 - 7Step 2: Determine maximum possible vertical acceleration:The toothed belt load is composed of:Fg + Fu = mN y g + mN y auFrom Fg + Fu = FTB_max:au = (FTB_max - mN y g) / mNau = (400N - 36.5 kg y 9.81 m/s2) / 36.5 kgau = 1.1 m/s2The maximum possible vertical acceleration is less than required (required: au = 3 m/s2). To increase thisvalue, there are two possibilities:a) Reduce approach speed;b) Reduce working loadThe following is calculated using possibility a) to determine how large vu maximum can be:FTB_max = mN y g + mN y au = 36.5 kg y 9.81 m/s2 + 36.5 kg y 3 m/s2 = 468 NFTB_per = FTB_max y S = 468 N y 1.5 = 702 NFZR_zul.=702 N0,1 0,2 0,3 0,4 0,5 1 2 3 4 5vum/s1002003004005001000FZR_zul.NHTR50HTR80From diagram 2-4:vu_max = 2 m/sWhen vu is reduced to 2 m/s,the permissible roller loadingincreases from 316 N to 388N (Æ Table 2- 2) - the originalrequired horizontal accelera-tion of aw = 4.5 m/s2 is thenpermissible.Total result, Example 1:The required performance ratings are achievable if the approach speed of the telescope (vu) is reduced from3 m/s to 2 m/sTechnical data / Project planning2 - 82.4.2 Application example 2. Working load eccentric below the HTR80This shows the moment that occurs during the greatest axle loading: HTR fully extended,acceleration of working load upwards and simultaneous acceleration of the HTR in thehorizontal direction.Fg + FumNvuaw FawauL Mu MwEquation symbols used:mN = Mass of working load [kg]vu = Approach speed of the HTR [m/s]au = Maximum acceleration while HTR isapproaching [m/s2]Fu = Inertia force on the HTR produced byacceleration and mass [N]. Fu = mNxauFg = Gravity based loading of the HTR [N]aw = Maximum acceleration while HTR istravelling [m/s2]Faw = Inertia force on the HTR produced byacceleration and mass [N]. Fw =mNxawg = Acceleration due to gravity (9.81 m/s2)L = Lever arm for centre of mass of outerloadRequired results:Mass of working load on HTR: mN = 12 kgMaximum stroke of HTR: Stroke = 1500 mmApproach speed of HTR: vu = 3.5 m/sAcceleration during approach of HTR: au = 3 m/s2Horizontal acceleration of the total system (HTR + working load): aw = 2 m/s2Lever arm for centre of mass of outer load: L = 0.4 m2.4.2.1 Determine roller loading:Step 1: Calculate resulting forces:Faw = mN y aw = 12 kg y 2 m/s2 = 24 NFg + Fu = mN y g + mN y au = 12 kg y 9.81 m/s2 + 12 kg y 3 m/s2 = 153.7 NMu = Faw y L = 24 N y 0.4 m = 10 NmMw = (Fg + Fu) y L = 153.7 N y 0.4 m = 61.5 NmFv, Fav, Fw, Mv= 0Step 2: Determine resultant forces with the help of the diagrams:1020304050100200300400FRollerN10 20 40 50 100 200 300 400500 1000FaN50010001500200030004000retracted, optional strokeFRoller (Faw)= 57 NFaw=24 NFrom diagram 2-3:FRoller (Faw) = 57NTechnical data / Project planning2 - 910 20 30 40 50 100 200 300 400 500 1000MNm1020304050Mv, MwMuFRoller(Mu) = 95FRoller(Mw) = 100Mu = 10 Mw = 61,5300400200150From diagram 2-2:FRoller (Mu) = 95 NFRoller (Mw) = 100 NFrom equation 2-1a: FTotalRollera = FRoller (Fav) + FRoller (Fv) + FRoller (Mw) + FRoller (Mu):FTotalRollera = 0 N + 0 N + 100 N + 95 N = 195 NFrom equation 2-1b: FTotalRollerb = FRoller (Faw) + FRoller (Fw) + FRoller (Mv) + FRoller (Mu):FTotalRollerb = 57 N + 0 N + 0 N + 95 N = 152 NThe higher roller total load results from equation 2-1a.From Table 2- 2:FRollerPerm. (vu = 3.5 m/s) = 268NSafety factor:FRollerPerm. / FTotalRollera = 268N / 195 N = 1.37.Step 3: Back-calculate to permissible output valueThe safety factor obtained is too low at 1.37 It should be at least 1.5. To achieve this, there are four possibili-ties:a) Reduce acceleration aw and/or acceleration au.b) Reduce working loadc) Reduce lever armd) First fully approach the HTR and then accelerate horizontally.The following is calculated using possibility a) to determine how large aw maximum can be:From FRollerPerm. / FTotalRoller = 1.5:FTotalRollera = FRollerPerm. / 1.5 = 268 N / 1.5 = 178.7 NFrom equation 2-1a: FTotalRollera = FRoller (Fav) + FRoller (Fv) + FRoller (Mw) + FRoller (Mu):FRoller (Mu) = FTotalRollera - FRoller (Fav) - FRoller (Fv) - FRoller (Mw)FRoller (Mu) = 178.7 N - 0 N - 0 N - 100 N = 78.7 NTechnical data / Project planning2 - 1010 20 30 40 50 100 200 300 400500 1000MNm20304050100Mv, MwMuFRoller(Mu) = 78,7200400300Mu = 8From diagram 2-2:Mu (FRoller) = 8 NmFrom Mu = Faw y L:Faw = Mu / L = 8 Nm / 0.4 m = 20 NFrom Faw = mN y aw :aw = Faw / mN = 20 N / 12 kg = 1.7 m/s22.4.2.2 Determine toothed belt load:Step 1: Determine maximum permissible toothed belt load at the required approach speed:FZR_zul.=550 N0,1 0,2 0,3 0,4 0,5 1 3 5vum/s100200300400FZR_zul.Nvu =3,5 m/sHTR50HTR807002From diagram 2-4:FTB_per = 550 NThe safety factor of minimum 1.5must also be taken into accounthere:FTB_max. = FTB_per / SFTB_max = 550N / 1.5 = 367NStep 2: Determine maximum possible vertical acceleration:The toothed belt load is composed of:Fg + Fu = mN y g + mN y auFrom Fg + Fu = FTB_max:au = (FTB_max - mN y g) / mNau = (367N - 12 kg y 9.81 m/s2) / 12 kgau = 20.8 m/s2The maximum possible vertical acceleration for the toothed belt is theoretically 20.8 m/s2. It must be notedhowever that diagram 2-4 only applies up to an acceleration of 10 m/s2. Based on the resulting roller loading,au must not exceed 3 m/s2.Total result, Example 2:The required performance ratings are achievable if the horizontal acceleration (aw) is reduced from 2 m/s2 to1.7 m/s2 Safety instructions 3 - 1 3 Safety 3.1 Correct use The HTR is used for many purposes, including: positioning, transporting, feeding, removing, palletting, loading, unloading, handling and manipulating workpieces or tools. As it can be used in the most widely differing areas, the responsibility for use in specific pur-poses is handed over to the user. The user must ensure that when mounting workpieces or tools on the load attachment of the HTR, that personnel and/or property cannot be injured or damaged. The HTR may only be used in areas which are not accessible by personnel during operation. Where the HTR is used in areas accessible to personnel, it must be installed in such a way that personnel are not endangered during operation. The HTR must not be driven against the limit damper (Block). For prevention, our safety limit switches or limit switch gears can be installed. Note that for vertical installation, the rotors can fall downwards if the belt breaks. If the HTR has been driven up to the block, the axle must not be operated. Notify our Service Department immediately: Parker Hannifin GmbH Service Department ? +49-(0)7 81 / 5 09-43 81 3.2 Identification of other dangers and danger areas If other dangers still exist for personnel or property despite the structurally secure application of the HTR, the user must indicate these other dangers by means of signs and written behaviour regulations. The safety instructions given in these operating instructions are summarised in Table 3.1. STOP Danger; means that death, serious physical injury or damage to property may occur unless prevented by corresponding safety measures. Caution; means that physical injury or damage to property may occur unless prevented by corresponding safety measures. Note; important information which must be observed regarding the product, the opera-tion of the product or the relevant section of the manual. Table 3.1: Safety symbols and their significance 3.3 General dangers in the event of non-observance of the safety notices The machine components are built according to the state of the art and is safe in use. Dangers may, however, be generated by the machine if it is used by personnel who are not trained or at least instructed, or is used incorrectly or for purposes other than those intended. As a consequence, there may be a risk of: ) Danger to life and limb of the user or a third party ) Damage to the machine and the user's other property Safety instructions3 - 23.3 General dangers in the event of non-observance of the safety noticesThe machine components are built according to the state of the art and is safe in use. Dangersmay, however, be generated by the machine if it is used by personnel who are not trained or atleast instructed, or is used incorrectly or for purposes other than those intended.As a consequence, there may be a risk of:) Danger to life and limb of the user or a third party) Damage to the machine and the user's other propertyWhen installing the HTR in a machine plant, the safety instructions given in these operating in-structions must be sensibly integrated with those in the machine plant operating instructions.3.4 Safe working practices3.4.1 Observe the notesThe notes in these operating instructions and shutdown procedures must be observed in allwork relating to the installation, start-up, setting up, operation, modifications to conditions of useand methods of operation, maintenance, inspections and repair.3.4.2 Operating personnelThe following work should only be carried out by trained and authorised personnel.) Assembly and calibration work on the HTR) Installation of safety limit switches) Installation of the drives and testing the direction of rotation3.5 Safety instructions for the user companyManagement must be familiar with the whole of Chapter "Safety" and the necessary operationson the HTR.Management must ensure that the Chapter "Safety" and the descriptionsof the appropriateoperations are read, understood and complied with by the assembly and operating personnel.The HTR must only be operated when in faultless condition.3.6 Safety instructions for the operating personnelRefrain from any method of working which is prejudicial to the safety of the HTR.The operating or supervisory personnel are obliged to inspect the HTR or the machine plant atleast once per shift for outerly detectable damage and defects, any changes detected (includingthe operating performance) which could affect safety must be reported immediately.Components and accessories have been specially designed for the product. Only use our origi-nal parts when purchasing replacement parts and wearing parts. We would like to make you ex-pressly aware that genuine parts and accessories not supplied by us have also not beenchecked and released by us. The installation and/or use of such products can therefore, undercertain circumstances, have a negative effect on the constructional characteristics of the ma-chine and thus affect active and/or passive operating safety.We accept no liability as manufacturers for damages arising through the use of non-genuineparts and accessories.On no account may any safety fixtures be removed or put out of operation.Protective fixtures may not be made ineffective or circumvented.The relevant requirements and national accident-prevention regulations are always to be com-plied with when installing and operating our mechanical linear units.Safety instructions3 - 33.7 Note regarding special dangersThe HTR must be fixed or supported in accordance with the indications in these operating in-structions with the prescribed minimum distances.Ensure that the movement of the HTR does not result in any danger.If the HTR moves in danger areas, these areas can be secured with safety limit switches.3.8 Unauthorised conversions or modifications are forbiddenThe HTR may not be altered structurally or safety-wise without our express authorisation. Anyunauthorised alteration of this sort excludes any liability on our part.3.9 TransportSTOP Danger When transporting components, never move under the suspended load.This can be fatalBefore transportation, secure axle against independent extension. Block the axle with a bolt (b).Only use transport equipment with adequate lifting capacity. When using ropes, ensure thatthese are not twisted or knotted. If several ropes are used, all should be under equal tension.The HTR housing is fitted with eyebolts or threaded holes suitable for eyebolts for attachingtransportation ropes (HTR80: M10; HTR50: M6).b a aa aKey:a: Threaded hole transportationeyeboltsb: Axle extension safety boltFig. 3-1: Transporting the HTRSafety instructionsAssembly( ): Position numbers for HTR80; [ ]: Position numbers for HTR504 - 14 Assembly4.1 General remarksThe HTR standard axle is always fully assembled and delivered mechanically operational.If no HAUSER drive is provided, fit your motor-gear combination according to the applicablemanufacturer's instructions.The installation position of the HTR is always vertical, unless specially designed otherwise. Attention The HTR may only be fitted / removed by specialists.4.2 Assembly on the flange plate123456 Key:1. HTR2. Assembly angle bracket3. Flange plate4. Robot system (for example, two HAUSER linear units)5. Threaded holes (HTR80: M10; HTR50: M6)6. Threaded holes (for eyebolts to „suspend" the axle HTR80:M10; HTR50: M6)The HTR is fixed by at least 2 assembly angle brackets (2) and aflange plate suitable for the current application purposes.The HTR standard axle is fitted for this purpose on three sides re-spectively with 8 (HTR50) or 10 (HTR80) threaded holes M10x10(HTR80) or M6x6 (HTR50). Pos. 5Fig. 4-1: Flange plate assembly) Fix the flange plate where present in your robot system - the flange plate must be fitted sothat the axle can be inserted without having to remove the lower rotor stations.4.2.1 Removal of the rotor station, lower central section(Pos-Nos. see Figure 4-2, Page 4-3)only necessary, if the axle with rotor station attached cannot pass through flange plateopening) Remove outer attachments (Gripper, etc.).) Extend linear axle (min. 50 mm).) Remove the cover plate (295)/[375] of the lower central section of the rotor station by re-moving the fixing screws (296)/[376].) Mark the position of the tensioning station (44)/[44] against the guide profile of the centralsection (40)/[40].The marking ensures that at a later date the toothed belt tension can be reset to thecorrect level - if it is accidentally changed. (Adjustment, see Chapter 7.3.3)Assembly( ): Position numbers for HTR80; [ ]: Position numbers for HTR504 - 2) Set screws (61)/[45] must be firmly tightened so that the toothed belt tension does notchange.) Completely unscrew set screw (58)/[63].) Completely unscrew fixing screws (60)/[55].) Pull rotor station out of the guide profile central section (40)/[40].4.2.2 Removal of the rotor station, lower outer section(Pos-Nos. see Figure 4-2, Page 4-3)only necessary, if the axle with rotor station attached cannot pass through flange plateopening) Remove the toothed belt cover (14)/[31] from the main drive by unscrewing the fixingscrews (23)/[32].) Remove the cover plate (215)/[295] of the lower central section of the rotor station by re-moving the fixing screws (216)/[296].) Mark the position of the tensioning station (4)/[600] against the guide profile of the outersection (1)/[1].The marking ensures that at a later date the toothed belt tension can be reset to the cor-rect level - if it is accidentally changed. (Adjustment, see Chapter 7.3.2)) Set screws (26)/[8] must be firmly tightened so that the toothed belt tension does notchange.) Completely unscrew set screws (27)/[10].) Remove fixing screws (25+21)/[4].) Pull rotor station out of the guide profile outer section (1)/[1].4.2.3 Installation of the HTR in the flange plate) Attach the assembly angle brackets to the HTR, loosely tighten the screws so that thebrackets can still be adjusted.) Block the HTR rotors against independent extension using the transportation bolts (see Fig-ure 3-1).) Feed the HTR from above into the flange plate and loosely screw on the assembly anglebrackets.STOP Keep the HTR suspended until all fixing screws are firmly tightened) Align the HTR at right angles to the flange plate.) Firmly tighten the screws between the HTR <> assembly angle brackets and assembly anglebracket <> flange plate.4.2.4 Installation of the rotor station, lower outer section(Pos-Nos. see Figure 4-2, Page 4-3)) Carefully insert lower outer section of rotor station over the central section guide profile(40)/[40] into the outer section guide profile (1)/[1].Insert the rotor station so that the holes for the toothed belt tensioning screws (27)/[10]are on the side of the main drive.) Fix the rotor station with fixing screws (21)/[28], e.g. attach to the tension station of themain drive at Pos. (25)/[8] inc. screw locking devices.) Fit the set screws (27)/[10] of the main drive.) Fit the cover plate (215)/[295].Assembly( ): Position numbers for HTR80; [ ]: Position numbers for HTR504 - 34.2.5 Intallation of the rotor station, lower central section(Pos-Nos. see Figure 4-2, Page 4-3)) Carefully insert lower central section of rotor station over the inner section guide profile(80)/[80] into the central section guide profile (40)/[40].Insert the rotor station so that the holes for the toothed belt tensioning screws (58)/[63]are on the side of the main drive.) Fix rotor station with fixing screws (60)/[55], inc. screw locking devices.) Fit the set screws (58)/[63] of the transmission drive.) Fit the cover plate (295)/[375].) Remove the extension block.236080215844 61 402952962714425 26 1216215Fig. 4-2: Removal and installation of the rotor station lower central section and outer section.(Pos-Nos. for HTR80)AssemblyCommissioning5 - 15 Commissioning5.1 General remarksThe HTR standard axle is always fully assembled and delivered mechanically operational.If no HAUSER drive is provided, fit your motor-gear combination according to the applicablemanufacturer's instructions.The installation position of the HTR is always vertical, unless specially designed otherwise.If, following commissioning, it is noted that the travel range selected is too big or that there areproblem edges lying in the regular safety path, Chapter 5.2 shows how to adjust the equipment.5.2 Setting limit stops The following working steps are best carried out with the drive switched on. Theyshould therefore only be carried out by trained and authorised personnel. Onlymove at creep speed (< 2m/min) and - if possible - limit the driving torque. Checkthat there are no unauthorised people in the danger area1 2440Key:1: Rotatable control cam2: Limit switch440: Housing coverFig. 5-1: Principle of the limit switch mechanismSetting the positive limit stop (Retracted condition)) Check that the travel path of the axle is free.) Remove the cover from the limit switch mechanism (440)) Set linear axle to machine datum.) In manual mode, carefully travel up against the positive limit stop (fully retracted).) If the linear axle is in contact with the mechanical limit stop and the positive limit stop is notrecognised: Rotate the control cam against the limit switch for the positive limit stop until thisis activated.) If the linear axle recognises the positive limit stop too early, rotate the control cam away fromthe limit switch and repeat the process described above until the required end position isreached.Setting the negative limit stop (Extended condition)) In manual mode, carefully travel up against the negative limit stop (fully extended).) If the linear axle is in contact with the mechanical limit stop and the negative limit stop hasnot been recognised, rotate the control cam against the limit switch for the negative limit stopuntil this is activated.) If the linear axle recognises the negative limit stop too early, rotate the control cam awayfrom the limit switch and repeat the process described above until the required end position isreached.Commissioning5 - 2) Fit the cover of the limit switch mechanism (440)) Set linear axle to machine datum.) Where possible, set the software limit stops (see commissioning instructions for the installedposition controller).Maintenance6 - 16 Maintenance) After commissioning as well as every 6 months, check the rotor play, toothed belt tension,positioning and wear. (see maintenance schedule, below)) In addition, depending on the level of contamination, all relevant components (guides, rotors,tension station, drive station) should be cleaned in rotation.) With high levels of contamination (e.g. drilling chips, etc.) the HTR must be fitted with a cover(e.g.: concertina walls, protective plate between gripper/tool and HTR).Maintenance schedule:What Action DescriptionRotors / Rollers Check rotor play:Rock the lower and central HTR profilesections manually - there should not beany play.Chapter 7.4Setting and adjusting rollers.Toothed belt Check positioning (alignment):The toothed belt must always run to theopposite flanged wheel when travel is re-versed, i.e. it must always travel fromright to left.Chapter 7.3.3.4 and 7.3.4.3Align toothed belts on themain and transmissiondrives.Check pre-tension:Press the toothed belt in the centre. Thebelt must be tautly tensioned whenloaded and unloaded.Chapter 7.3.3.3 and 7.3.4.2Tensioning toothed belts ofthe main and transmissiondrives.Check wear:Evaluate wear of the toothed belt by avisual check.Chapter 7.3.3.2 and 7.3.4.1Replace the toothed belts ofthe main and transmissiondrives if there is abnormalwear.Causes of abnormal toothed belt wearCertain wear appearances can have various causes, so a clear cause is often difficult to deter-mine. The following table shows possible causes in typical faults:Error type Cause RemovalAbnormal wear on the loaded toothprofiles of the beltIncorrect belt tensionOverloadAdjust pre-tension cor-rectlyCheck whether the load iswithin the permittedrange.Abnormal wear in the tooth gullet ofthe beltPre-tension too greatDrive torque too highReduce pre-tensionCheck the drive dimen-sioningAbnormal wear on the side profiles ofthe beltIncorrect toothed beltorientationEdge of the roller/toothlock washer deformedAlign toothed beltChange the roller/toothlock washerBelt teeth sheared off Pre-tension too lowOverload (by collision)Adjust pre-tensionMaintenance6 - 2Error type Cause RemovalCracks on the belt teeth Incorrect belt tension Adjust pre-tension cor-rectlyOverload Check whether the load iswithin the permittedrange.Ageing of the belt mate-rialReplace beltToothed belt break Incorrect belt tension Adjust pre-tension cor-rectlyOverload Check whether the load iswithin the permittedrange.Toothed belt material softening Operating temperaturetoo highLower operating tempera-tureContact with solvents Do not clean the belt us-ing solventsGearing jumping, loss of machine da-tum pointPre-tension too low Adjust pre-tension cor-rectlyRepairs( ): Position numbers for HTR80; [ ]: Position numbers for HTR507 - 17 RepairsHelp with problemsParker Hannifin GmbHService Department? +49 (0)7 81 / 509-43 81 7.1 Safety instructionsSTOPSwitch main switch to '0' and secure against re-start by means of a padlock be-fore maintenance and repair work.Particular caution is advised if the machine must be ready for operation duringcertain repair tasks: Make sure that there is no possibility of persons staying in thedanger area; if necessary, secure against unauthorized persons by additional bar-riers or fences.Repairs may only be carried out by engineers or by HAUSER personnel.Work on the electrical equipment must only be carried out by engineers qualified for this task;the relevant requirements shall be observed (IEC..., EN..., national accident prevention regula-tions)Where it is necessary to dismantle safety devices during set up, repair and maintenance work,the safety devices must be refitted immediately on conclusion of the work. The machine must bedisabled before disassembly.7.2 General remarks) For optimal working conditions (easier access) and for personal safety, it is recommendedthat the HTR is completely removed, i.e. removal of all attachments and dismount the teles-copic axle from the robot systemIncorrect repairs will invalidate any claim against HAUSER under the guarantee. Screw lockingdevices must be used for all screw connections. Old safety plates must be replaced after sev-eral applications. If safety plates are not available use a suitable adhesive (e.g. Loctite 243).7.3 Toothed belts7.3.1 General remarks regarding toothed belts) Unpack new toothed belts immediately. They must be stored, laid out in a circle, at roomtemperature in dry rooms.) Toothed belts must not be kinked.) The distribution of toothed belts and synchronizing disks must coincide.) Long-term temperatures of a maximum of 80° C are permitted. In the short term, the tem-perature can reach 120° C.) The drives must be protected from dust, dirt, hot water and steam as well as acids and lyes.) The pre-tension must be adapted to the operating loads, but must not exceed the maximumpermissible tensile force (Æ Table 7-1).Repairs( ): Position numbers for HTR80; [ ]: Position numbers for HTR507 - 27.3.2 Tensioning toothed belts, guidelinesNote:The toothed belt tension must be adapted to the operating loads, but must not ex-ceed the maximum permissible tension values given in Table 7-1.The toothed belt tension is based on the force being transmitted by the toothed belt Fu(Fu = Fstatic + Fdynamic).To avoid the toothed belt coming off, the toothed belt tension (operating tension) must lieapprox. 10% above the force Fu being transmitted.In the case of new or old slackened toothed belts, the pre-tension will reduce by about20% a short time after first being tensioned. Therefore, on tensioning the belt, a tensionmust be set which is 1.25 times greater than the operating tension. This tension is definedin Table 7-1 as the tension to be set.If the tension of a toothed belt, in operation for over a week, is less than 0.9 x operatingtension, then the toothed belt tension must be increased to 1.1 x operating tension.Default values all in [N]HTR Toothed belt Fumax Tension to be setOperatingtensionpre-tension for max. force transmittedby toothed beltnew/ old slack-ened beltsAftertensioning adjusts with time80 Main drive unloaded --- 1500 1320 1200loaded --- 500 440 400Transmis- unloaded --- 656 578 525sion drive loaded 700 219 193 17550 Main drive unloaded --- 731 644 585loaded --- 244 215 195Transmis- unloaded --- 310 273 248sion drive loaded 330 104 91,3 83Table 7-1: Toothed belt tension of the HTR with vertical installation0501001502002503000 500 1000 1500 2000 2500Stroke / mmFp / NMain drive belt unloadedMain drive belt loadedTransmission drive belt unloadedTransmission belt drive loadedDiagram 7-1: Test force for vertically installed HTR80 toothed belt tension, fully extended for 10mm depth of impressionRepairs( ): Position numbers for HTR80; [ ]: Position numbers for HTR507 - 30501001502002500 500 1000 1500 2000 2500Stroke / mmFp / NMain drive belt unloadedMain drive belt loadedTransmission drive belt unloadedTransmission drive belt loadedDiagram 7-2: Test force for vertically installed HTR50 toothed belt tension, fully extended for 8mm depth of impression7.3.2.1 Toothed belt tension, measurementThe following measuring procedure is currently the only way to measure the toothed belttension at the required tolerance of +/- 5% .Belt tension measuring device RSMThe belt tension measuring device RSM determines,with known data (specifically belt mass, free runningbelt length) and belt oscillation frequency, the currentbelt tension .The belt tension measuring device can be obtainedthrough HAUSER (Art. No. 037- 000200).Repairs( ): Position numbers for HTR80; [ ]: Position numbers for HTR507 - 47.3.3 Replacing, tensioning and aligning the main drive toothed belt7.3.3.1 Determine axle strokeMany HTR parameters, such as toothed belt length, dimensions and weights, are de-pendent on the stroke. These parameters will recur frequently in the following equations.The stroke of a axle can be measured from its block dimension. To do this, fully retractthe axle carefully and slowly (up to the inner limit stops).Block dimension The block dimension is the total length of the retractedtelescope.Fig. 7-1: Determine HTR block dimensionHTR80: Stroke = 2xBlock dim. [mm] - 1368 mm / HTR50: Stroke = 2xBlock dim. [mm] - 870 mmEquation 7-1: Calculate HTR stroke7.3.3.2 Replace main drive toothed beltsM0 ) Remove outer attachments (Gripper, etc.).) If possible; position linear axle on the machine datumand record this point by marking or measuring the dis-tance from the lower outer section of the M0 rotor sta-tion to the gripper / lower end of the inner section guideprofile.Marking or recording the machine datum point facili-tates subsequent commissioning.Figure 7-2: Mark machine datum) If possible; extend linear axle (min. 50 mm)) If present; switch off drive and secure against accidental start-up.) Remove outer attachments (Gripper, etc.).) Secure the linear axle with safety bolts against falling out whenthe axle is vertically positioned.STOP Gravity can cause the linear axle to fall down if not secured.This may harm personnel or propertyFigure 7-3: Block telescopeRepairs( ): Position numbers for HTR80; [ ]: Position numbers for HTR507 - 523 14752127425 26216215) Remove the toothed belt covers(14)/[31] from the main drive by un-screwing the fixing screws (23)/[32].) Remove the cover plate (215)/[295] ofthe lower central section of the rotorstation by removing the fixing screws(216)/[296].) Unscrew set screws (25+26)/[8] on thebelt tensioner outer section (4)/[600].) Slacken off main drive toothed belt (75)/[65] by rotating the set screw (27)/[10]anticlockwise, ( ).) Unscrew fixing screws (25)/[4] and letdown the lower rotor station outer sec-tion until it reaches the lower rotor sta-tion central section.Figure 7-4:Slacken the main drive toothed belt (Pos. No. for HTR80)22,315621 107) Open sealing piece (5-7)/[16-18] on themain drive toothed belt (75)/[65] by re-moving the set screws (22)/[19].) Remove the mechanical limit stop(10)/[26] by removing the fixing screws(21)/[28].) Remove set screws (25+26-Fig. 7-4)/[8]and belt tensioner outer section.Figure 7-5: Remove toothed belt sealing piece and mechanical limit stop (Pos. No. for HTR80)20 46) Undo adjustment device (46)/[58] (sea-ling piece for transmission drive) of theguide profile inner section by removingthe fixing screws (20)/[4].Figure 7-6: Undo transmission drive - outer housing section connection. (Pos-Nos. for HTR80)) Carefully remove auxilliary structure andslowly remove the complete central sec-tion telescope from the outer sectionguide profile.The mass of the part removed is: (Ge-neral equation) (Determine stroke: Chap-ter 7.3.3.1)HTR80: m~15 *kg + 9 *kg/per metre strokeHTR50: m~7 *kg + 3 *kg/per metre strokeEquation 7-2: Complete central section massFigure 7-7: Remove telescope central section and inner sectionRepairs( ): Position numbers for HTR80; [ ]: Position numbers for HTR507 - 660 50-52) Place complete telescope central sec-tion - with the main drive upwards - onsuitable, level blocks.) Open the clamping piece of the maindrive (50-52)/[68-70] by removing theset screws (60)/[71].) Remove old gear belt.Figure 7-8: Remove old toothed belt (Pos. Nos. for HTR80)) Cut new toothed belt to the correct length.Find the correct length l from the piece list. General equation:HTR80: l = 980 + stroke; HTR50: l = 620 + strokeEquation 7-3: Toothed belt length(Determine stroke: Chapter 7.3.3.1)Simple method:Lay old and new toothed belt together and use the length to cut the new belt. If theold belt is torn or stretched, count the number of teeth and use this number to cutthe new belt.L1HTR80: L1 = 500 + 0.5 * strokeHTR50: L1 = 326 + 0.5 * strokeEquation 7-4: Toothed belt excess length L1 (Determinestroke: Chapter 7.3.3.1)The toothed belt must be mounted withthe excess length L1 for correct instal-lation.If the toothed belt is incorrectly moun-ted, the sealing piece may knockagainst the drive housing or belt ten-sioner and damage important func-tional parts of the HTR.Figure 7-9: Toothed belt installation475) Position the guide profile outer sectionopening for the belt tensioner of themain drive belt facing upwards on levelblocks.) Insert the telescope central section andtransmission drive belt from below intothe guide profile outer section. Feed themain drive belt (75)/[65] up out throughthe guide profile outer section orthrough the opening for the belt ten-sioner (4)/[600].) Loosely tighten the belt tensioner outersection (4)/[600] with set screws (25+26- Figure 7-4)[8]Figure 7-10: Insert telescope central section into the housing (Pos. Nos. for HTR80)) Replace lower rotor station outer section on the profile outer section and screw tight.) Prevent linear axle from extending (Æ Figure 7-3).) Close sealing piece of the main drive belt (5-7)/[16-18] using screws (22)/[19] (Pos. Nos. Fig.7-5).) Fit mechanical limit stop (10)/[26]) Insert set screws (27)/[10] of the main drive and pre-tension toothed belt by rotating the setscrews clockwise ( ), as described in the operating instructions (Æ Page 7-7: Tensionmain drive toothed belt).Repairs( ): Position numbers for HTR80; [ ]: Position numbers for HTR507 - 7 The pre-tension must be adapted to the loading.General guideline: Toothed belt tension >= maximum operating force Unnecessarily high pre-tension only puts pressure on the bearings and othercomponents. Too high pre-tension can cause damage to the mechanics) Fit cover plate (215)/[295] (Æ Figure 7-4).) Fit the toothed belt cover (14)/[31] of the main drive using screws (23)/[32].) Fit gears (Æ Page 7-30)) Fit motor (Æ Page 7-31)) Remove auxilliary structures.) Fit attachments) Set machine datum (see operating manual of the controller being used)7.3.3.3 Tension main drive toothed beltThe diagrams 7-1 and 7-2, Page 7-2 are only applicable for vertical hoist positions. Thetoothed belts can be lightly pre-tensioned during assembly of the axle in the horizontalposition. If the axle is then positioned vertically: readjust tension) Move linear axle up to 50 mm in the upper end position.) Remove cover plate (14)/[31] (Æ Figure 7-4) by undoing the fixing screws.) Press centre of toothed belt using the test force (Æ Diagram 7-1 or 7-2) and determine depthof impression. The tension is correct, when the depth of impression is 10 mm for the HTR80or 8 mm for the HTR50.) When the depth of impression or tension is not correct:) Unscrew cover plate (215)/[295] (Æ Figure 7-4) and displace until the screw, Pos. (27)/[10],can be reached.) Undo the fixing screws (25+26)/[8] (Æ Figure 7-4) until the belt tensioner (4)/[600] can bestraightened out.) Depth of impression too big ==> tension too low: Tension toothed belt by tightening the setscrew (27)/[10].) Depth of impression too low ==> tension too high: Slacken toothed belt by releasing the setscrew (27)/[10].) Checking the pre-tension or depth of impression) Tighten or slacken tension until the tension or depth of impression (Æ Table 7-1, Diagram 7-1 or 7-2) is correct.) Clamp down belt tensioner by tightening the fixing screws (25+26)/[8].7.3.3.4 Aligning main drive toothed belts Precise alignment is only possible while the telescopic axle is travelling. Thetoothed belt must always run to the opposite flanged wheel when travel is re-versed, i.e. when correctly adjusted it must always travel from left to right.Repairs( ): Position numbers for HTR80; [ ]: Position numbers for HTR507 - 823 14752127425 26216215) Remove the toothed belt covers (14)/[31]by unscrewing the fixing screws (23)/[32].) Remove the cover plate (215)/[295] byremoving the fixing screws (216)/[296].) Undo the fixing screws (25 + 26)/[8] untilthe belt tensioner (4)/[600] can be movedin a straight line.) Carefully undo set screw (27)/[10] on theside that the toothed belt continuallycontacts and rotate anticlockwise ( )until the toothed belt runs in according tothe above definition.) Tighten fixing screws (25+26)/[8].) Refit cover plate (215)/[295]) Refit toothed belt cover (14)/[31]Figure 7-11: Align the toothed belt of the main drive (Pos. Nos. for HTR80)7.3.4 Replacing, tensioning and aligning the transmission drive toothed belt7.3.4.1 Replace transmission drive toothed beltM0 ) Remove outer attachments (Gripper, etc.).) If possible; position linear axle on the machine datumand record this point by marking or measuring the dis-tance from the lower outer section of the M0 rotor sta-tion to the gripper / lower end of the inner section guideprofile.Marking or recording the machine datum point facili-tates subsequent commissioning.Fig. 7-12: Mark machine datum) If possible; extend linear axle (min. 50 mm)) if present; switch off servo drive) Remove outer attachments (Gripper, etc.).) Secure the linear axle with safety bolts against falling out whenthe axle is vertically positioned.STOP Gravity can cause the linear axle to fall down if not secured.This may harm personnel or propertyFig. 7-13: Block telescope173) Open housing cover (173)/[177] of the drive stationMark the belt position on the drive plate so that the belt canbe correctly re-installed at a later date - this retains the pre-vious settings.Figure 7-14: Mark toothed belt position on the drive plate (Pos. Nos. for HTR80)Repairs( ): Position numbers for HTR80; [ ]: Position numbers for HTR507 - 923 14752127425 26216215) Remove the toothed belt covers(14)/[31] by unscrewing the fixingscrews (23)/[32].) Remove the cover plate (215)/[295] byremoving the fixing screws (216)/[296].) Mark the position of the belt tensioner(4)/[600] against the guide profile. Themarking ensures that at a later date thetoothed belt tension can be reset to thecorrect level.) Unscrew set screws (25+26)/[8] on thebelt tensioner (4)/[600].) Slacken off main drive toothed belt (75)/[65] by rotating the set screw (27)/[10]anticlockwise, ( ).) Unscrew fixing screws (25)/[4] and letdown the lower rotor station outer sec-tion.Figure 7-15: Slacken the main drive toothed belt (Pos. No. for HTR80)22,315621 107) Mark the toothed belt position in theclamping plate) Open sealing piece (5-7)/[16-18] on themain drive toothed belt (75)/[65] by re-moving the set screws (22)/[19].) Remove the mechanical limit stop(10)/[26] by removing the fixing screws(21)/[28].) Remove set screws (25+26 - see Figure7-15)/[8] and belt tensioner outer sec-tion.Figure 7-16: Remove toothed belt sealing piece and mechanical limit stop (Pos. No. for HTR80)20 46) Undo adjustment device (46)/[58] (sea-ling piece for transmission drive) of theguide profile inner section by removingthe fixing screws (20)/[61].Figure 7-17: Undo transmission drive - outer housing section connection. (Pos. Nos. for HTR80)Repairs( ): Position numbers for HTR80; [ ]: Position numbers for HTR507 - 10) Carefully remove auxilliary structure andslowly remove the complete centralsection telescope from the central sec-tion guide profile.The mass of the part removed is:(General equation) (Determine stroke:Chapter 7.3.3.1)HTR80: m | 15 *kg + 9 *kg / per metre strokeHTR50: m | 7 *kg + 3 *kg / per metre strokeEquation 7-5: Complete central section massFigure 7-18: Remove telescope central section and inner section295 296 58 44 46 5961 40 110) Place complete telescope central sec-tion on level blocks.) Remove the cover plate (295)/[375] byremoving the fixing screws (376)/[296].) Undo the set screws (61)/[45] until thebelt tensioner (44)/[640] can be movedin a straight line.) Slacken off transmission drive toothedbelt (110)/ [93] by rotating the set screw(58)/[63] anticlockwise, ( ).) Open sealing piece (46)/[58] by remov-ing the set screws (59)/[61].) Remove belt tensioner (44)/[640] by un-doing the set screws (61)/[45]Figure 7-19: Remove telescope inner section (Pos. Nos. for HTR80)) Carefully remove telescope "complete inner section" from the guide profile central section.L285-87 90 ) Place complete telescope inner sectionon level blocks.) Open the clamping piece of the maindrive (85-87)/[87-89] by removing theset screws (90)/[90].) Remove old gear belt.Figure 7-20: Remove transmission drive toothed belt (Pos. Nos. for HTR80)) Cut new toothed belt to the correct length.Find the correct length l from the piece list. General equation:HTR80: l = 865 + stroke; HTR50: l = 560 + strokeEquation 7-6: Transmission drive toothed belt length(Determine stroke: Chapter 7.3.3.1)Simple method:Lay old and new toothed belt together and use the length to cut the new belt. If theold belt is torn or stretched, count the number of teeth and use this number to cutthe new belt (applies to belts with same gauge).Repairs( ): Position numbers for HTR80; [ ]: Position numbers for HTR507 - 11The toothed belt must be mounted with the excess length L2 for correct installa-tion (Æ Figure 7-20). If the toothed belt is incorrectly mounted, the sealing piecemay knock against the drive housing or belt tensioner and damage importantfunctional parts of the HTR. General equation:HTR80: L2 = 450 + 0.5 * stroke / HTR50: L2 = 355 + 0.5 * strokeEquation 7-7: Excess length L2 for transmission drive toothed belts (Determine stroke: Chapter7.3.3.1)110 ) Insert complete telescope inner sectionin the guide profile central section.) Feed the toothed belt (110)/[93] up outthrough the guide profile inner sectionor through the opening for the belt ten-sioner.) Loosely tighten belt tensioner centralsection with set screws (61 - Figure 7-19)/[45]Figure 7-21: Thread in transmission drive toothed belt (Pos. Nos. for HTR80)) Close the sealing piece (46)/[58] for the transmission drive belt with screws (59)/[61] (Pos.Nos.: Figure 7-19).) Insert set screws (58)/[63] (Æ Figure 7-19), of the transmission drive and pre-tension toothedbelts by rotating the set screws clockwise ( ), following the marking (see above) or operat-ing instructions (Æ Page 7-12). The pre-tension must be adapted to the loading.General guideline: Toothed belt tension >= maximum operating force Unnecessarily high pre-tension only puts pressure on the bearings and components. Too high pre-tension can cause damage to the mechanics) Fit cover plate (295)/[375] (Æ Figure 7-19).475) Position the guide profile outer sectionopening for the belt tensioner of themain drive belt facing upwards on levelblocks.) Insert the telescope central section andtransmission drive belt from below intothe guide profile outer section. Feed themain drive belt (75)/[65] up out throughthe guide profile outer section orthrough the opening for the belt ten-sioner (4)/[600].) Loosely tighten belt tensioner outersection (4)/[600] with set screws (25+26- Figure 7-15, Page 7-9)/[8]Figure 7-22: Insert telescope central section into the housing (Pos. Nos. for HTR80)) Secure the linear axle with safety bolts against falling out whenthe axle is vertically positioned.STOP Gravity can cause the linear axle to fall down if not secured.This may harm personnel or propertyFigure 7-23: Block telescopeRepairs( ): Position numbers for HTR80; [ ]: Position numbers for HTR507 - 12) Close sealing piece of the main drive belt (5-7)/[16-18] using screws (22)/[19] (Pos. Nos. Fig-ure 716).) Refit mechanical limit stop (10)/[26].) Insert set screws (27)/[10] (Æ Figure 7-15) of the main drive and pre-tension toothed belt byrotating the set screws clockwise ( ) following the marking or operating instructions (seePage 7-7: Tension main drive toothed belt). The pre-tension must be adapted to the loading.General guideline: Toothed belt tension >= maximum operating force Unnecessarily high pre-tension only puts pressure on the bearings and othecomponents. Too high pre-tension can cause damage to the mechanics) Fit cover plate (215)/[295] (Æ Figure 7-15).) Fit the toothed belt cover (14)/[31] using screws (23)/[32].) Close drive station with housing cover (173 - see Figure 7-14)/[177]) Fit gears (Æ Page 7-31)) Fit motor (Æ Page 7-31)) Remove the extension block.) Fit attachments) Set machine datum (see operating manual of the controller)7.3.4.2 Tensioning toothed belts of the transmission driveThe diagrams 7-1 and 7-2, Page 7-2 are only applicable for vertical hoist positions. Thetoothed belts can be lightly pre-tensioned during assembly of the axle in the horizontaposition. If the axle is then positioned vertically: readjust tension) Move the linear axle to the lower end position (extend).) Press toothed belt with the test force (Æ Diagram 7-1 or 7-2, Page 7-2) and determine depthof impression. The depth of impression must be 10 mm for the HTR80 or 8 mm for theHTR50.) If the depth of impression, and therefore the tension, is incorrect:) Remove cover plate (295)/[375] (Æ Figure 7-19) or displace until the screw, Pos. (58)/[63],can be reached.) Loosen or tighten the fixing screws (61)/[45] (Æ Figure 7-19) until the belt tensioner can justbe moved.) Depth of impression too big ==> tension too low: Tension toothed belt by tightening the setscrew (58)/[63].) Depth of impression too low ==>tension too high: Tension toothed belt by loosening the setscrew (58)/[63].) Checking the pre-tension or depth of impression) Tighten or slacken tension until the tension or depth of impression is correct.) Clamp down belt tensioner by tightening the fixing screws (61)/[45].) Fit cover plate (295)/[375].7.3.4.3 Aligning the transmission drive toothed beltsThe transmission drive belt is only possible in specific conditions. Precise alignment is only possible while the telescopic axle is travellingtoothed belt must always run to the opposite flanged wheel when travelversed, i.e. when correctly adjusted it must always travel from left to right.) Move the linear axle to the lower end position.Repairs( ): Position numbers for HTR80; [ ]: Position numbers for HTR507 - 13) Remove the cover plate (295)/[375] of the lower central section of the rotor station by remov-ing the fixing screws (296)/[376].Æ Figure 7-19).) Loosen fixing screws (61)/[45].) Carefully move belt tensioner by displacing it from the front sideusing the bore tolerance (e.g. by lightly tapping with a rubberhammer), always on the opposite side to where the toothed belttouches. Repeat process until the toothed belt runs as definedabove.Fig. 7-24: Aligning toothed belts) Tighten fixing screws (61)/[45].) Fit the cover plate (295)/[375] of the lower central section of the rotor station with the fixingscrews (296)/[376].7.4 Setting and aligning rollers.7.4.1 Adjusting rollers of the rotor station lower outer section) Extend linear axle (min. 100 mm).) Check roller action:) To check the roller action of the rotor station lower outer section from below, unscrew thecover plate (215)/[295] (Æ Figure 7-11). The roller action can only be checked while the telescopic axle is travelling.Danger of injury - special care must be taken here If possible, move the shaftmanually (if necessary, remove motor and gears first and position shaft horizon-tally). If not, then move the shaft in the creep mode using the jog button (Speed <2m/min).) All rollers must rotate during the movement.) To check the pressure acting against it, prevent the wheels from turning using your indexfinger; the wheels should be able to be stopped with minimal force.Jockey wheels which are adjusted too tightly develop pressure marks which lead torunning noise. Replace defective rollers (Æ Chapter 7.5)) Adjusting the rollersbacabaa: Eccentric rollers; b: Fixed rollers;c: Opening (HTR80)) First adjust the eccentric rollers opposite the two fixed roll-ers. Do not exceed the maximum permissible screw tight-ening torque:Fixed rollers: HTR80: 42.3 Nm / HTR50: 40.0 NmEccentric rollers: HTR80: 26.5 Nm / HTR50: 23.1 Nm) Adjust the jockey wheels using the hexagon of the eccen-tric bush in small steps so that the guide profile / rotors canbe easily moved without any play. Lock in position using anAllen key - ensure that the adjusted setting is not changed) Fit the cover plate (215)/[295].Fig. 7-25: Rollers of the rotor station lower outer sectionRepairs( ): Position numbers for HTR80; [ ]: Position numbers for HTR507 - 147.4.2 Adjusting rollers of the rotor station upper outer sectionThe central section of the rotor station cannot be adjusted when fitted. Adjustmentscan only be carried out when the linear shaft is removed and partially disassembled.M0 ) Remove outer attachments (Gripper, etc.).) If possible; position linear axle on the machine datumand record this point by marking or measuring the dis-tance from the lower outer section of the M0 rotor sta-tion to the gripper / lower end of the inner section guideprofile.Marking or recording the machine datum point facili-tates subsequent commissioning.Figure 7-26: Mark machine datum) If possible; extend linear axle (min. 50 mm)) if present; switch off servo drive) Remove outer attachments (Gripper, etc.).) Secure the linear axle with safety bolts against falling out whenthe axle is vertically positioned.STOP Gravity can cause the linear axle to fall down if not secured.This may harm personnel or propertyFigure 7-27: Block telescope173) Open housing cover (173)/[177] of the drive stationMark the belt position on the drive plate so that the belt canbe correctly re-installed at a later date - this retains the pre-vious settings.Figure 7-28: Mark toothed belt position on the drive plate (Pos. Nos. for HTR80)) Remove motor (Æ Page 7-31).) Remove the HTR from the robot system) Place the HTR on level blocks ensuring that it is accessible from all sides.Repairs( ): Position numbers for HTR80; [ ]: Position numbers for HTR507 - 1523 14752127425 26216215) Remove the toothed belt cover(14)/[31] from the main drive by un-screwing the fixing screws (23)/[32].) Remove the cover plate (215)/[295] ofthe lower outer section of the rotor sta-tion by removing the fixing screws(216)/[296].) Mark the toothed belt position in theclamping plate) Mark the position of the belt tensioner(4)/[600] against the guide profile. Themarking ensures that at a later date thetoothed belt tension can be reset to thecorrect level.) Unscrew set screws (25+26)/[8] on themain drive belt tensioner (4)/[600].) Slacken off main toothed belt (75)/[65]by rotating the set screws (27)/[10] an-ticlockwise ( ).Figure 7-29:Slacken the main drive toothed belt. (Pos. Nos. for HTR80)22,3156726425 75) Open sealing piece (5-7)/[16-18] on themain drive toothed belt (75)/[65] by re-moving the set screws (22)/[19].Figure 7-30:Remove main drive toothed belt and belt tensioner (Pos. Nos. for HTR80)23 15253) Remove the drive housing (3)/[160] byunscrewing the fixing screws (25)/[4].) Remove the cover plate (15)/[22] by un-screwing the screws (23)/[23].Figure 7-31:Remove drive housing (Pos. Nos. for HTR80)20 46) Undo adjustment device (46)/[58] (sea-ling piece for transmission drive) of theguide profile inner section by removingthe screws (20)/[61].Figure 7-32: Undo transmission drive - outer housing section connection (Pos. Nos. for HTR80)Repairs( ): Position numbers for HTR80; [ ]: Position numbers for HTR507 - 16605844 61 40295296) Remove the cover plate (295)/[375] ofthe lower central section of the rotorstation by removing the screws(296)/[376].) Mark the position of the belt tensioner(44)/[640] against the guide profile ofthe central section (40)/[40].The marking ensures that at a laterdate the toothed belt tension can bereset to the correct level - if it is acci-dentally changed. (Adjustment: Chap-ter 7.3.4, Page 7-8)) Set screws (61)/[45] must be firmlytightened so that the toothed belt ten-sion does not change.) Remove set screws (58)/[63].) Remove fixing screws (60)/[55].) Pull rotor station out of the guide profilecentral section (40)/[40].Figure 7-33: Remove rotor station lower central section (Pos. Nos. for HTR80)) To check the roller action of the rotor station upper central section from the drive side, movethe complete telescope central section backwards and forwards manually in the guide profileouter section.) All rollers must rotate during the movement.) To check the pressure acting against it, prevent the wheels from turning using your index fin-ger; the wheels should be able to be stopped with minimal force.Jockey wheels which are adjusted too tightly develop pressure marks which lead torunning noise. Replace defective rollers (Æ Chapter 7.5)) Adjusting the rollersHTR80:a: Eccentric rollers; b:Fixed rollers:abHTR50:a: Eccentric rollers at minimum po-sition; b: Eccentric rollers at centralposition) Remove complete telescope central section from the guideprofile outer section on the drive side.) HTR80: First adjust the eccentric rollers opposite the twofixed rollers. HTR50: First set the two eccentric rollers a tothe minimum position, then the roller b to the central posi-tion and leave them as they are. Do not exceed the maxi-mum permissible screw tightening torque:Fixed rollers: HTR80: 42.3 Nm / HTR50: 40.0 NmEccentric rollers: HTR80: 26.5 Nm / HTR50: 23.1 Nm) Adjust the remaining jockey wheels using the hexagon ofthe eccentric bush in small steps so that the guide profile /rotors can be easily moved without any play. Lock in posi-tion using an Allen key - ensure that the adjusted setting isnot changedFigure 7-34: Adjust the rollers of the rotor station upper central section) Carefully insert complete telescope central section in the guide profile outer section andcheck the correct settings of the rollers. Carelessness during insertion can damage the rollers on the rotor station.Repairs( ): Position numbers for HTR80; [ ]: Position numbers for HTR507 - 17) Repeat process described above until all eccentric rollers are adjusted.475) Position the guide profile outer sectionopening for the tension station of themain drive belt (4)/[600] facing upwardson level blocks.) Insert the pre-assembled telescopecentral section (Rotor station lowercentral section), with the transmissiondrive belt facing downwards, into theguide profile outer section. Feed themain drive belt (75)/b [65] up outthrough the guide profile outer sectionor through the opening for the tensionstation.) Fit the cover (15)/[22] using screws(23)/[32].) Fit the drive housing (3)/[160] usingscrews (25)/[4].Figure 7-35: Insert telescope central section into the housing (Pos. Nos. for HTR80)22,315621 107) Close sealing piece of the main drivebelt (5-7)/[16-18] using screws.Figure 7-36: Fit main drive belt (Pos. Nos. for HTR80)) Block HTR rotors against undesired movement.) Secure the linear axle with safety bolts against falling out whenthe axle is vertically positioned.STOP Gravity can cause the linear axle to fall down if not secured.This may harm personnel or propertyFigure 7-37: Block telescopeRepairs( ): Position numbers for HTR80; [ ]: Position numbers for HTR507 - 1880296586129540) Carefully insert lower central section ofrotor station over the inner sectionguide profile (80)/[80] into the centralsection guide profile (40)/[40].Insert the rotor station so that the holesfor the toothed belt tensioning screws(58)/[63] are on the side of the maindrive.) Fix rotor station with two fixing screws,inc. screw locking devices (61)/[45] oneach side.Figure 7-38: Fit rotor station lower central section (Pos. Nos. for HTR80)) Insert set screws (58)/[63] of the transmission drive and pre-tension toothed belts by rotatingthe set screws clockwise ( ), following the marking (see above) or operating instructions(Æ Page 7-12). The pre-tension must be adapted to the loading.General guideline: Toothed belt tension >= maximum operating force Unnecessarily high pre-tension only puts pressure on the bearings and othecomponents. Too high pre-tension can cause damage to the mechanics) Fit the toothed belt cover (14)/[31] of the main drive using screws (23)/[32].) If necessary, refit HTR in the robot system.) Fit gears (Æ Page 7-30)) Fit motor (Æ Page 7-31)) Tension the toothed belts of the main and transmission drives (Æ Page 7-7 and Page 7-12)) Screw on housing cover (173 - see Figure 7-28)/[177]) Fit the cover plate (295)/[375].7.4.3 Adjusting rollers of the rotor station lower outer section) To check the roller action of the rotor station lower outer section from below, unscrew thecover plate (295)/[375] (Æ Figure 7-38). The roller action can only be checked while the telescopic axle is travelling.Danger of injury - special care must be taken here If possible, move the shafmanually (if necessary, remove motor and gears first and position shaft horizontally). If not, then move the shaft in the creep mode using the jog button (Speed <2m/min).) All rollers must rotate during the movement.) To check the pressure acting against it, prevent the wheels from turning using your indexfinger; the wheels should be able to be stopped with minimal force.Jockey wheels which are adjusted too tightly develop pressure marks which lead torunning noise. Replace defective rollers (Æ Chapter 7.5)Repairs( ): Position numbers for HTR80; [ ]: Position numbers for HTR507 - 19) Adjusting the rollersbabaaa: Eccentric rollers;b:Fixed rollers:) First adjust the eccentric rollers opposite the two fixedrollers. Do not exceed the maximum permissible screwtightening torque:Fixed rollers: HTR80: 40.0 Nm / HTR50: 13.1 NmEccentric rollers: HTR80: 22.0 Nm / HTR50: 10.2 Nm) Adjust the jockey wheels using the hexagon of the eccen-tric bush in small steps so that the guide profile / rotors canbe easily moved without any play. Lock in position using anAllen key - ensure that the adjusted setting is not changed) Fit the cover plate (295)/[375].Figure 7-39: Adjust the rollers of the rotor station lower central section7.4.4 Adjusting rollers of the rotor station upper inner sectionThe inner section of the rotor station cannot be adjusted when fitted. Adjustmentscan only be carried out when the linear shaft is removed and partially disassembled.M0 ) Remove outer attachments (Gripper, etc.).) If possible; position linear axle on the machine datumand record this point by marking or measuring the dis-tance from the lower outer section of the M0 rotor sta-tion to the gripper / lower end of the inner section guideprofile.Marking or recording the machine datum point facili-tates subsequent commissioning.Figure 7-40: Mark machine datum) Where possible: Extend linear axle (min. 50 mm).) If present: switch off drive and secure against accidental start-up.) Secure the linear axle with safety bolts against falling out whenthe axle is vertically positioned.STOP Gravity can cause the linear axle to fall down if not secured.This may harm personnel or propertyFigure 7-41: Block telescope173) Open housing cover (173)/[177] of the drive stationMark the belt position on the drive plate so that the belt canbe correctly re-installed at a later date - this retains the pre-vious settings.Figure 7-42: Mark toothed belt position on the drive plate (Pos. Nos. for HTR80)Repairs( ): Position numbers for HTR80; [ ]: Position numbers for HTR507 - 2023 14752127425 26216215) Remove the toothed belt cover(14)/[31] from the main drive by un-screwing the fixing screws (23)/[32].) Remove the cover plate (215)/[295] ofthe lower outer section of the rotor sta-tion by removing the fixing screws(216)/[296].) Mark the toothed belt position in theclamping plate) Mark the position of the belt tensioner(4)/[600] against the guide profile. Themarking ensures that at a later date thetoothed belt tension can be reset to thecorrect level.) Loosen set screws (25+26)/[8] on themain drive belt tensioner (4)/[600].) Slacken off main drive toothed belt(75)/ [65] by rotating the set screw(27)/[10] anticlockwise ( ).) Remove fixing screws (25)/[4] and takeoff the lower rotor station outer section.Figure 7-43: Slacken the main drive toothed belt (Pos. No. for HTR80)22,315621 107) Open sealing piece (5-7)/[16-18] on themain drive toothed belt (75)/[65] by re-moving the set screws (22)/[19].) Remove the mechanical limit stop(10)/[26] by removing the fixing screws(21)/[4].) Remove the belt tensioner of the maindrive (4)/ [600] by undoing the setscrews (25+26 - see Figure 7-43)/[8].Figure 7-44: Remove toothed belt sealing piece and mechanical limit stop (Pos. No. for HTR80)20 46) Undo adjustment device (46)/[58] (sea-ling piece for transmission drive) of theguide profile inner section by removingthe fixing screws (20)/[61].Figure 7-45: Undo transmission drive - outer housing section connection. Pos. Nos. for HTR80)Repairs( ): Position numbers for HTR80; [ ]: Position numbers for HTR507 - 21) Carefully remove auxilliary structure andslowly remove the complete centralsection telescope from the outer sectionguide profile.The mass of the part removed is:(General equation) (Determine stroke:Chapter 7.3.3.1)HTR80: m~15 *kg + 9 *kg / per metre strokeHTR50: m~7 *kg + 3 *kg / per metre strokeEquation 7-8: Complete central section massFigure 7-46: Remove telescope central section and inner section) Place complete telescope central section on suitable, level blocks.295 296 58 44 46 59 40 11061 62 42) Remove the cover plate (295)/[375] ofthe lower central section of the rotorstation by removing the fixing screws(296)/[376].) Mark the position of the belt tensioner(44)/[640] against the guide profile ofthe central section (40)/[40]. The mark-ing ensures that at a later date thetoothed belt tension can be reset to thecorrect level.) Loosen set screws (61)/[45] on thetransmission drive belt tensioner (44)/[640].) Slacken off transmission drive toothedbelt (110)/ [93] by rotating the set screw(58)/[63] anticlockwise, ( ).) Open sealing piece (46)/[58] on thetransmission drive toothed belt by re-moving the set screws (59)/ [61].Figure 7-47: Remove old toothed belt (Pos. Nos. for HTR80)) Undo rotor station upper central section (42)/[48] by removing the fixing screws (62)/[49] andremove from the guide profile central section.) To check the roller action of the rotor station upper inner section from the rightÆ Fig.7-47,move the complete telescope inner section backwards and forwards manually in the guideprofile central section. .) All rollers must rotate during the movement.) To check the pressure acting against it, prevent the wheels from turning using your index fin-ger; the wheels should be able to be stopped with minimal force.Jockey wheels which are adjusted too tightly develop pressure marks which lead torunning noise. Replace defective rollers (Æ Chapter 7.5)Repairs( ): Position numbers for HTR80; [ ]: Position numbers for HTR507 - 22) Adjusting the rollersaabbcba: Eccentric rollers;b: Fixed rollers;c: Toothed belt side) Remove complete telescope inner section upwards out ofthe guide profile central section.) First adjust the eccentric rollers opposite the two fixedrollers. Do not exceed the maximum permissible screwtightening torque:Fixed rollers: HTR80: 40.0 Nm / HTR50: 13.1 NmEccentric rollers: HTR80: 22.0 Nm / HTR50: 10.2 Nm) Adjust the jockey wheels using the hexagon of the eccen-tric bush in small steps so that the guide profile / rotors canbe easily moved without any play. Lock in position using anAllen key - ensure that the adjusted setting is not changedFigure 7-48: Adjust the rollers of the rotor station upper inner section) Carefully insert complete telescope inner section into the guide profile complete. Carelessness during insertion can damage the rollers on the rotor station.) Repeat process until all eccentric rollers are adjusted.44 46 59 40 11061 241624 90) Place guide profile central section, withthe transmission drive belt (110)/[93]facing upwards, on level blocks so thatit is accessible from all sides.Use suitable blocks (spacers) to pro-vide optimal support.) Fit the rotor station upper central sec-tion, with the deflection roller for thetoothed belt (241)/[350] facing upwards,on the guide profile central section andsecure with the screws (62)/[49].) Close the sealing piece (46)/[58] for thetransmission drive belt with screws(59)/[61] as indicated by the markings.) Lightly pre-tension the transmissiondrive belt by manually operating the belttensioner (4)/[600]. (if necessary loosenthe screws (61)/[45] until the belt tensio-ner can just be moved manually)Figure 7-49:Prepare telescope central section for assembly (Pos. Nos. for HTR80)) Pre-tension toothed belt by rotating the set screw (58)/[63] clockwise ( ) following themarking (Æ Page 7-20) or operating instructions (Æ Page 7-12). The pre-tension must be adapted to the loading.General guideline: Toothed belt tension >= maximum operating force Unnecessarily high pre-tension only puts pressure on the bearings and othecomponents. Too high pre-tension can cause damage to the mechanicsRepairs( ): Position numbers for HTR80; [ ]: Position numbers for HTR507 - 23475) Position the guide profile outer sectionopening for the tension station of themain drive belt (4)/[600] facing upwardson level blocks.) Insert the pre-assembled telescopecentral section (without the rotor stationlower central section), with the trans-mission drive belt facing downwards,into the guide profile outer section.Feed the main drive belt (75)/ [65] upout through the guide profile outer sec-tion or through the opening for the ten-sion station.Figure 7-50:Insert telescope central section (Pos. Nos. for HTR80)22,315621 10727 14 23) Close sealing piece of the main toothedbelt (5-7)/[16-18] using screws (22)/[19].) Pre-tension toothed belt by rotating theset screw (27)/[10] clockwise ( ), fol-lowing the marking (Æ Page 7-20) oroperating instructions (Æ Page 7-7).Figure 7-51: Fit limit stop and tension main toothed belt (Pos. Nos. for HTR80) The pre-tension must be adapted to the loading.General guideline: Toothed belt tension >= maximum operating force Unnecessarily high pre-tension only puts pressure on the bearings and othecomponents. Too high pre-tension can cause damage to the mechanics) Screw on cover plate (215)/[295] (Æ Figure 7-43).) Fit the toothed belt cover (14)/[31] of the main drive using screws (23)/[32].7.5 Replace rollers7.5.1 General remarks) The HAUSER telescopic axle rollers are ball-bearing rollers with a synthetic coating.) With long downtimes, the rollers become slightly flattened, however this mainly disappearsduring subsequent continuous operation.) The ball-bearings used conform to the normal roller-bearing standards and have recieved alifetime lubrication. The seals used are Z-seals. The rollers should where possible be replaced only by HAUSER personnel.Repairs( ): Position numbers for HTR80; [ ]: Position numbers for HTR507 - 247.5.2 Replace fixed rollersEach rotor station has 3 fixed rollers. The rollers are always replaced in accordancewith the same procedure. In some cases where the removal of the rotor station is un-avoidable, follow the relevant recommendations. The example given is based on therotor station upper inner section.aab bbc330325a: Eccentric rollers; b: Fixed rollers;c: Toothed belt side) Remove fixing screws (330)/[410].) Replace the rollers (325)/[405]Figure 7-52: Replace fixed rollers following the example of the rotor station upper inner section(Pos. Nos. for HTR80)The roller must be screwed with the collar (smaller inner diameter) against the rotorstation. Locking rings must always be fitted between screw and bearing, and thereshould also be the appropriate number of plain washers between bearing and rotor sta-tion. Safety plates must always be replaced to maintain safety functions.) Tighten screw (330)/[410] with the correct tightness torque Ma (Æ Table 7-2).) Adjust rotor station according to the relevant setting instructions.Adjusting/Aligning the rotor station:Lower outer section: Chapter 7.4.1Upper central section: Chapter 7.4.2Lower central section: Chapter 7.4.3Upper inner section: Chapter 7.4.4Tightness torque [Nm]Rotor station HTR80 HTR50Lower outer section: 42.3 40.0Upper central section 42.3 40.0Lower central section 40.0 13.1Upper inner section 40.0 13.1Table 7-2: Tightness torque for fixed rollers7.5.3 Replace eccentric rollersEach rotor station has 5 eccentric rollers. The rollers are always replaced in accordancewith the same procedure. In some cases where dismantling of the linear axle is un-avoidable, follow the relevant recommendations. The example given is based on therotor station upper inner section.aabbbc331 326 325a: Eccentric rollers; b: Fixed rollers;c: Toothed belt side) Remove the fixing screws, (331)/[411] including the eccen-tric bushes) Replace the rollers (325)/[405]Fig. 7-53: Replace fixed rollers following the example of the rotor station upper inner section(Pos. Nos. for HTR80)Repairs( ): Position numbers for HTR80; [ ]: Position numbers for HTR507 - 25The roller must be screwed with the collar (smaller inner diameter) against the rotorstation. Locking rings must always be fitted between screw and eccentric bush, andthere should also be the appropriate number of plain washers between bearing and ro-tor station. Safety plates must always be replaced to maintain safety functions. If lock-ing rings are not used, suitable screw locking devices (e.g. Loctite 243) must be used.) Tighten screw (331)/[441] with the correct tightness torque Ma (Æ Table 7-3).RollerEccentricbushMarkingfor zeropositionMinimum positionThe eccentric bushes of the roller must be aligned so thatthe roller distance decreases when rotating clockwise ( ). The ideal position for the nominal size in this case isa horizontal alignment, i.e. zero-position of the cam.Figure 7-54: Adjusting the eccentric rollers) Adjust rotor station according to the relevant setting instructions.Adjusting/Aligning the rotor station:Lower outer section: Chapter 7.4.1Upper central section: Chapter 7.4.2Lower central section: Chapter 7.4.3Upper inner section: Chapter 7.4.4Tightness torque [Nm]Rotor station HTR80 HTR50Lower outer section: 26.5 23.1Upper central section 26.5 23.1Lower central section 22.0 10.2Upper inner section 22.0 10.2Table 7-3: Tightness torque for eccentric rollersRepairs( ): Position numbers for HTR80; [ ]: Position numbers for HTR507 - 267.6 Replace belt tensioner7.6.1 Replace main drive belt tensionerM0 ) Remove outer attachments (Gripper, etc.).) If possible; position linear axle on the machine datumand record this point by marking or measuring the dis-tance from the lower outer section of the M0 rotor sta-tion to the gripper / lower end of the inner section guideprofile.Marking or recording the machine datum point facili-tates subsequent commissioning.Figure 7-55: Mark machine datum) Where possible: Extend linear axle (min. 50 mm).) If present: switch off drive and secure against accidental start-up.) Secure the linear axle with safety bolts against falling out whenthe axle is vertically positioned.STOP Gravity can cause the linear axle to fall down if not secured.This may harm personnel or propertyFigure 7-56: Block telescope173) Open housing cover (173)/[177] of the drive stationMark the belt position on the drive plate so that the belt canbe correctly re-installed at a later date - this retains the pre-vious settings.Figure 7-57: Mark toothed belt position on the drive plate (Pos. Nos. for HTR80)23 14752127425 26216215) Remove the toothed belt cover(14)/[31] from the main drive by un-screwing the screws (23)/[32].) Remove the cover plate (215)/[295] ofthe lower central section of the rotorstation by removing the screws(216)/[296].) Mark the toothed belt position in theclamping plate) Loosen set screws (25+26)/[8] on themain drive belt tensioner (4)/[600].) Slacken off main drive toothed belt(75)/ [65] by rotating the set screw(27)/[10] anticlockwise ( ).Figure 7-58: Slacken the main drive toothed belt (Pos. No. for HTR80)Repairs( ): Position numbers for HTR80; [ ]: Position numbers for HTR507 - 2722,3156727 425 26) Open sealing piece (5-7)/[16-18] on themain drive toothed belt by removingthe set screws (22)/[19].) Unscrew set screws (27)/[10] on themain drive belt tensioner (4)/[600].) Remove set screws (25+26)/[8] on themain drive belt tensioner (4)/[600].) Replace main drive belt tensioner (4)/[600].) Insert and lightly tighten set screws(25+26)/[8] on the main drive belt ten-sioner (4)/ [600].) Close sealing piece of the main drivebelt (5-7)/[16-18] using screws (22)/[19].) Insert set screws (27)/[10] of the maindrive and pre-tension toothed belt byrotating the set screws clockwise ( ),following the marking or operating in-structions (Æ Page 7-7).Fig. 7-59:Replace belt tensioner (Pos. Nos. for HTR80) The pre-tension must be adapted to the loading.General guideline: Toothed belt tension >= maximum operating force Unnecessarily high pre-tension only puts pressure on the bearings and othercomponents. Too high pre-tension can cause damage to the mechanics) Remove auxilliary structures.) Fit the toothed belt cover (14)/[31] of the main drive using screws (23)/[32] (Pos. Nos.: Figure7-58).) Fit the cover plate (215)/[295] of the rotor station lower outer section using screws (216)/[296](Pos. Nos.: Figure 7-58).) Set machine datum (see operating manual of the controller being used)7.6.2 Replace transmission drive belt tensionerM0 ) Remove outer attachments (Gripper, etc.).) If possible; position linear axle on the machine datumand record this point by marking or measuring the dis-tance from the lower outer section of the M0 rotor sta-tion to the gripper / lower end of the inner section guideprofile.Marking or recording the machine datum point facili-tates subsequent commissioning.Figure 7-60: Mark machine datum) Where possible: Extend linear axle (min. 50 mm).) If present: switch off drive and secure against accidental start-up.Repairs( ): Position numbers for HTR80; [ ]: Position numbers for HTR507 - 28) Secure the linear axle with safety bolts against falling out whenthe axle is vertically positioned.STOP Gravity can cause the linear axle to fall down if not secured.This may harm personnel or propertyFigure 7-61: Block telescope173) Open housing cover (173)/[177] of the drive stationMark the belt position on the drive plate so that the belt canbe correctly re-installed at a later date - this retains the pre-vious settings.Figure 7-62: Mark toothed belt position on the drive plate (Pos. Nos. for HTR80)23 14752127425 26216215) Remove the toothed belt cover(14)/[31] from the main drive by un-screwing the fixing screws (23)/[32].) Remove the cover plate (215)/[295] ofthe lower outer section of the rotor sta-tion by removing the fixing screws(216)/[296].) Mark the toothed belt position in theclamping plate) Mark the position of the belt tensioner(4)/[600] against the guide profile. Themarking ensures that at a later date thetoothed belt tension can be reset to thecorrect level.) Loosen set screws (25+26)/[8] on themain drive belt tensioner (4)/[600].) Slacken off main drive toothed belt(75)/ [65] by rotating the set screw(27)/[10] anticlockwise ( ).Figure 7-63: Slacken the main drive toothed belt (Pos. No. for HTR80)22,315621 107) Open sealing piece (5-7)/[16-18] on themain drive toothed belt (75)/[65] by re-moving the set screws (22)/[19].) Remove the mechanical limit stop(10)/[26] by removing the fixing screws(21)/[28].) Remove set screws (25+26 - see Figure7-63)/[8] and belt tensioner outer sec-tion.Figure 7-64: Remove toothed belt sealing piece and mechanical limit stop (Pos. No. for HTR80)Repairs( ): Position numbers for HTR80; [ ]: Position numbers for HTR507 - 2920 46) Undo adjustment device (46)/[58] (sea-ling piece for transmission drive) of theguide profile inner section by removingthe fixing screws (20)/[61].Figure 7-65: Undo transmission drive - outer housing section connection. Pos. Nos. for HTR80)) Carefully remove auxilliary structure andslowly remove the complete centralsection telescope from the outer sectionguide profile.The mass of the part removed is:(General equation) (Determine stroke:Chapter 7.3.3.1)HTR80: m~15 *kg + 9 *kg / per metre strokeHTR50: m~15 *kg + 9 *kg / per metre strokeEquation 7-9: Complete central section massFigure 7-66: Remove telescope central section and inner section) Place complete telescope central section on suitable, level blocks.295 296 58 44 46 59 40 11061 62 42) Remove the cover plate (295)/[375] ofthe lower central section of the rotorstation by removing the fixing screws(296)/[376].) Loosen set screws (61)/[45] on thetransmission drive belt tensioner (44)/[640].) Slacken off transmission drive toothedbelt (110)/ [93] by rotating the set screw(58)/[63] anticlockwise, ( ).) Open sealing piece (46)/[58] on thetransmission drive toothed belt by re-moving the set screws (59)/ [61].Figure 7-67: Remove old toothed belt (Pos. Nos. for HTR80)) Remove set and locking screws (58+61)/[63+45] of the transmission drive belt tensioner(44)/[640].) Replace transmission drive belt tensioner (44)/ [640].) Close sealing piece (46)/[58] on the transmission drive toothed belt using the set screws(59)/[61].) Insert and lightly tighten the set screws (61)/[45] of the transmission drive belt tensioner(44)/[640].) Insert set screws (58)/[63] of the transmission drive and pre-tension toothed belts by rotatingthe set screws clockwise ( ), following the marking (see above) or operating instructions(Æ Page 7-12). The pre-tension must be adapted to the loading.General guideline: Toothed belt tension >= maximum operating force Unnecessarily high pre-tension only puts pressure on the bearings and othercomponents. Too high pre-tension can cause damage to the mechanicsRepairs( ): Position numbers for HTR80; [ ]: Position numbers for HTR507 - 30) Fit the cover plate (295)/[375].475) Position the guide profile outer sectionopening for the belt tensioner of themain drive belt facing upwards on levelblocks.) Insert the telescope central section andtransmission drive belt from below intothe guide profile outer section. Feed themain drive belt (75)/ [65] up out throughthe guide profile outer section orthrough the opening for the belt ten-sioner.Figure 7-68: Insert telescope central section into the housing (Pos. Nos. for HTR80)22,315621 10727 14 23) Close sealing piece of the main toothedbelt (5-7)/[16-18] using screws (22)/[19].) Pre-tension toothed belt by rotating theset screw (27)/[10] clockwise ( ), fol-lowing the marking (Æ Page 7-20) oroperating instructions (Æ Page 7-7).Figure 7-69: Fit limit stop and tension main toothed belt (Pos. Nos. for HTR80) The pre-tension must be adapted to the loading.General guideline: Toothed belt tension >= maximum operating force Unnecessarily high pre-tension only puts pressure on the bearings and othercomponents. Too high pre-tension can cause damage to the mechanics) Screw on cover plate (215)/[295] (Æ Figure 7-63).) Fit the toothed belt cover (14)/[31] of the main drive using screws (23)/[32].) Block HTR rotors against undesired movement.) Fit gears (Æ Page 7-30)) Fit motor (Æ Page 7-31)) Attach grippers if required.) Set machine datum (see operating manual of the controller being used)7.7 Replace gearsThe gears can be fitted at any time on the side opposite to the drive station on theHTR80 - the drive shaft is symmetric.In the HTR50, the drive shaft must first be removed and rotated by 180°Repairs( ): Position numbers for HTR80; [ ]: Position numbers for HTR507 - 31M0 ) Remove outer attachments (Gripper, etc.).) If possible; position linear axle on the machine datumand record this point by marking or measuring the dis-tance from the lower outer section of the M0 rotor sta-tion to the gripper / lower end of the inner section guideprofile.Marking or recording the machine datum point facili-