Bosch 3 842 998 067 Assembly Instructions Manual Download Page 1

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Assembly instructions

3 842 564 350/2020-06

Replaces: –

ENGLISH

PE 2/X, PE 2/H, PE 4

Positioning unit

3 842 998 324

3 842 999 000

3 842 998 067

GLISH

Summary of Contents for 3 842 998 067

Page 1: ...Assembly instructions 3 842 564 350 2020 06 Replaces ENGLISH PE 2 X PE 2 H PE 4 Positioning unit 3 842 998 324 3 842 999 000 3 842 998 067 ENGLISH ...

Page 2: ...duzca 3 842 564 353 a continuación haga clic en Search PT O presente manual de montagem está disponível nos idiomas aqui indicados Demais idiomas sob consulta Como versão impressa ou o arquivo PDF para download no diretório de mídias www boschrexroth com mediadirectory Insira a máscara de pesquisa parte superior direita em Search 3 842 564 354 e clique em Search ZH 本安装说明书有这里给出的语言版本还可按照需求提供其他语言版本 ...

Page 3: ...tions 11 5 1 1 Positioning unit PE 2 X PE 2 H and PE 4 application 11 5 1 2 PE 2 X PE 2 H and PE 4 positioning unit design 11 5 2 Product description 12 5 3 Identiﬁcation of the product 14 6 Transport and storage 14 6 1 Transporting the product 14 6 2 Storing the product 14 7 Assembly 15 7 1 Unpacking 15 7 2 Installation requirements 15 7 2 1 Installation position 15 7 3 Required tools 15 7 4 Symb...

Page 4: ...tal factors 29 10 Maintenance and repair 30 10 1 Cleaning and care 30 10 2 Inspection 30 10 3 Maintenance 30 10 4 Replacing positioning pins 31 10 5 Spare parts 34 11 Decommissioning 34 12 Disassembly and replacement 34 12 1 Preparing the product for storage later use 35 13 Disposal 35 14 Upgrading and modiﬁcation 35 15 Troubleshooting and repair 36 16 Technical data 36 16 1 Ambient conditions 37 ...

Page 5: ...tion marked with the book symbol is available and you have understood and followed the instructions in it Table 1 Required and supplementary documentation Title Document number Document type Instructing employees on safety 3 842 527 147 Declaration of incorporation 3 842 358 424 MTpro 1 3 842 539 057 With list of spare parts 1 Download from www boschrexroth com mtpro 2 Not available in print Downl...

Page 6: ...ng DANGER Indicates a hazardous situation that will result in serious injury or death if not avoided WARNING Indicates a hazardous situation that may result in severe injury or death if not avoided CAUTION Indicates a hazardous situation that may result in minor to moderate injury if not avoided NOTICE Property damage The product or the surrounding area could be damaged 1 3 2 Symbols The following...

Page 7: ...to all users at all times Always include them when giving the product to a third party 2 2 Intended use The product is an incomplete machine You may use the product as follows for installation in a Rexroth transfer system TS 2plus for positioning the Rexroth workpiece carriers WT 2 WT 2 H WT 4 Maximum load section load see the Technical Data on page 36 For the environmental conditions see page 37 ...

Page 8: ...ith the relevant rules speciﬁc to his her occupation and have the necessary expertise Bosch Rexroth offers measures to support training in speciﬁc areas You can ﬁnd an overview of the training content online at http www boschrexroth de didactic 2 5 General safety instructions Observe applicable accident prevention and environmental protection regulations Observe the safety rules and regulations of...

Page 9: ... safety equipment which forms part of the product is present has been properly installed and is fully functional Do not move bypass or disable any safety equipment Do not reach into moving parts Check the product for malfunctions Make sure that only authorized personnel perform the following tasks as part of the intended use of the product Starting or operating the system or interfering with its n...

Page 10: ...uct is being used All pieces the personal protective equipment must be intact 2 8 Owner responsibilities Before initially starting up or restarting any conveyor system run a risk assessment in accordance with DIN EN ISO 12100 Please also observe the residual risks of the individual components see section 8 1 Residual risks on page 25 Before initial start up make sure there are no protruding or sha...

Page 11: ... or PE 2 H or PE 4 positioning unit preassembled 5 About this product 5 1 Speciﬁcations Fig 1 554 089 01 Performance description of the PE 2 X PE 2 H and PE 4 positioning unit 5 1 1 Positioning unit PE 2 X PE 2 H and PE 4 application Installation in belt sections BS 2 ST 2 BS 4 For lifting conveyor media and positioning workpiece pallets WT in a manual automatic processing station with high requir...

Page 12: ...oth AG MIT PE 2 X PE 2 H PE 4 3 842 564 350 2020 06 5 2 Product description Fig 2 554 089 02 D C B A A B C D PE 2 X PE 4 PE 2 H PE 2 X PE 2 H PE 4 positioning unit A Positioning pins B Lifting frame C Supporting bolts D Mounting bracket ...

Page 13: ...itioning unit Applicable belt sections and section proﬁles Applicable workpiece carriers PE 2 X 3 842 998 324 Load up to 100 kg BS 2 ST 2 WT 2 WT 2 F PE 2 H 3 842 999 000 Load up to 250 kg BS 2 ST 2 WT 2 H WT 2 F H PE 4 3 842 998 067 Load up to 250 kg BS 4 ST 4 WT 4 WT 4 F Observe the maximum conveyor section load see section 16 Technical data on page 36 ENGLISH ...

Page 14: ...r walk under suspended loads Make sure no one is in the danger zone Only use suitable and inspected lifting gear slings and forklifts Observe bearing load for product weight see shipping documents Check that the slings are securely fastened Secure the load against toppling before you lift it 6 2 Storing the product Only set the product down on a ﬂat surface Protect the product from mechanical stre...

Page 15: ...rial in accordance with the applicable regulations in your country 7 2 Installation requirements During installation be sure to maintain the ambient conditions speciﬁed in the Technical Data see page 37 7 2 1 Installation position Install the product level and plumb at right angles and axially parallel This ensures proper functioning and prevents premature wear 7 3 Required tools Open end wrench S...

Page 16: ...S NCA 52 Klüber Struktovis GHD Lubricate lubricate with speciﬁc grease lubricant ISO FLEX TOPAS NCA 52 www klueber com Klüber Struktovis GHD www klueber com GHD V 68 Oil Oil Oil Lubricate lubricate with speciﬁc mineral oil GHD Structovis GHD www klueber com V 68 mineral oil with a viscosity of 68 Loctite 243 Loctite 601 Secure the screws with Loctite 243 medium strength detachable www loctite de L...

Page 17: ...ng bracket Required accessories Mounting bracket for PE 2 X and PE 2 H on BS 2 ST 2 3 842 531 350 Mounting bracket for PE 4 on ST 4 R 3 842 530 775 1 Mark the installation position of the 4 mounting brackets 2 Suspend the mounting brackets in the section proﬁle 3 Insert the T bolts into the section proﬁles and gently pull on the collar nuts mounting brackets can still be moved lT Workpiece pallet ...

Page 18: ...D 25 Nm SW13 2 Assembling the positioning unit shown here on PE 2 H and PE 2 X Please note Use a lift aid to lift the product The positions indicated with a Z in the drawing are used for example as lifting points for a round sling 1 Set the positioning unit onto the section proﬁle 2 After aligning the positioning unit tighten all mounting bracket screws ...

Page 19: ...53 819 IEC EN 60947 5 2 2004 proximity switches 3 842 537 995 Please note The proﬁle height is marked in mm A on the switching ﬂags on the bracket plate 1 Do not break the required switching ﬂags on the bracket plate 2 Install the bracket plate on the positioning unit 3 Install the distance place in the bottom slot of the section proﬁle 4 Install the switch brackets on the spacer plate 5 Install t...

Page 20: ... 4 Required accessories Position monitoring kit 3 842 535 726 IEC EN 60947 5 2 2004 proximity switches 3 842 537 995 Please note The proﬁle height is marked in mm A on the switching ﬂags on the bracket plate 1 Do not break the required switching ﬂags on the bracket plate 2 Install the bracket plate on the positioning unit 3 Install the 2 switch holders from below in the slot in the section proﬁle ...

Page 21: ... S 3 on the section proﬁle Testing functionality 1 Starting position Pre stop gate A open main stop gate B closed lift positioning unit in the lower end position 2 S 1 actuated by passing WT VE A closes 3 S 2 actuated by passing WT Positioning unit moves to upper end position WT is lifted 4 Switch upper end position actuated and operation starts 5 If required complete operation external signal Pos...

Page 22: ... TS 2plus catalog VE 4 stop gate see TS 4plus catalog IEC EN 60947 5 2 2004 proximity switches 3 842 537 995 1 Install the stop gates 2 x VE 2 D H and 2 x VE 4 and the proximity switches S 1 S 2 S 3 on the section proﬁle Testing functionality 1 Starting position Pre stop gate A open main stop gate B closed lift positioning unit in the lower end position 2 S 1 actuated by passing WT VE A closes 3 S...

Page 23: ...Ventilate the pneumatic circuit of the relevant system component Secure the system against being unintentionally switched on again Wear safety goggles For the compressed air speciﬁcation see section 16 2 Fig 10 Pneumatic connection shown here on PE 2 H and pneumatic diagram 554 089 11 Y X 1 3 5 2 4 1 D8 D8 D8 D8 Y X Please note Use connections X and Y This charges the system more quickly and evenl...

Page 24: ...t equip the transfer system with EMERGENCY STOP devices The surfaces of motors and gears can reach temperatures of over 65 C under certain load and operating conditions In these cases you must comply with the respective applicable accident prevention regulations UVV by taking appropriate constructive measures safety guards or by afﬁxing displaying appropriate warning signs Make sure that all the e...

Page 25: ...nent and workpiece pallet Body parts can be caught when retracting the workpiece pallet Dismemberment 3 Lifting frame Between component and workpiece pallet Body parts can be caught during lifting Crushing 4 Lifting frame Between component and section proﬁle Body parts can be caught during lowering 5 Conveyor medium Between conveyor medium and workpiece carrier Body parts can be caught during lowe...

Page 26: ...u can adjust the lifting speed by throttling the exhaust air 1 Set the operating pressure of the maintenance unit to 4 6 bar 2 Mount the proper workpiece pallet operating load 3 Move the cylinder e g using the manual override on the directional control valve 4 Adjust the lifting speeds at the throttle non return valves Rotate in the direction The stroke becomes slower Rotate in the direction The s...

Page 27: ...by the customer Fig 12 554 089 16 B A A Example of a guard provided by the customer Final start up should only be performed with guards in place These must be provided by the customer See also section 2 8 Owner responsibilities on page 10 A Contact protection from below B Contact protection from above ENGLISH ...

Page 28: ...possible to guarantee their function 9 1 2 Measures to reduce wear The following commonsense measures will reduce wear Switch off the conveyor section when the system is not in use e g during breaks at night and on weekends Do not select a higher speed for the conveyor section than that required for the corresponding function Abrasive media and objects will greatly increase wear Clean the system r...

Page 29: ...oil Alloyed oils Corrosive cleaning agents Solvents Brake ﬂuid Abrasive media and objects will greatly increase wear These include Sand Silicates Pumice dust Glass fragments Metal shavings Loose items Resistance to media does not mean functional reliability is guaranteed under all circumstances Liquids that thicken as they evaporate and become highly viscous or sticky can lead to malfunctions Lubr...

Page 30: ...ors that are in motion or operation when the safety guards are in place Note DIN EN ISO 13857 when you remove or replace safety guards and or bypass safety equipment Test runs with open paneling should only be performed by a person with appropriate knowledge and experience using tip switches and if there is no possibility of interference from other switching devices 10 1 Cleaning and care NOTICE B...

Page 31: ...CE Positioning pin wear Malfunctions and possible damage to the positioning unit Replace the positioning pins every 2 million cycles 10 4 Replacing positioning pins Required tools Open end wrench SW13 Allen keys sizes 3 4 5 6 Phillips screwdriver PZ2 Caliper 500 mm Rubber mallet Strainer Hand lever press ENGLISH ...

Page 32: ...SW10 SW10 A B SW13 MD 25 Nm MD 25 Nm SW13 90 90 90 PE 2 X replacing positioning pins Required accessories Positioning pin 3 842 536 995 A Positioning pin 3 842 536 996 B Required tools Open end wrenches SW8 SW10 1 Remove the positioning pins 2 Install the new positioning pins Please observe the position of the chamfers on the positioning pin B ...

Page 33: ...ccessories Positioning pin 3 842 529 929 C Positioning pin 3 842 529 926 D Optional accessories Fitting screw 3 842 529 930 A Leveling washer 3 842 529 928 B Required tools Open end wrench SW13 Torque wrench Strainer Hand lever press 1 Remove the leveling washer B 2 Replace the positioning pin C 3 Insert the leveling washer B 4 Replace the positioning pin C Please note Do not damage the ﬁts in the...

Page 34: ...e Switch off the compressed air supply to the relevant system component before performing any maintenance or repairs Ventilate the pneumatic circuit of the relevant system component Secure the system against being unintentionally switched on again Wear safety goggles Falling and toppling loads Only qualiﬁed personnel should transport the product Never stand or walk under suspended loads Make sure ...

Page 35: ...dance with environmental protection regulations Never dispose of electrical components tools and accumulators batteries in household waste or commercial waste Only in EU countries According to the currently valid EU Directive on Waste Electrical and Electronic Equipment WEEE and its implementation into national law electrical components and devices that are no longer used must be collected separat...

Page 36: ...16 Technical data For dimensions see TS 2plus sales catalog 3 842 531 138 and TS 4plus sales catalog 3 842 527 530 Maximum section load Up to 2 0 kg cm bearing load depending on the belt section used Lift or conveyor media PE 2 X PE 2 H 3 mm PE 4 16 mm Position accuracy 0 1 mm Permissible vertical process force with center load 3500 N incl WT Maximum load PE 2 X 100 kg PE 2 H PE 4 250 kg Noise emi...

Page 37: ... sand or dust Do not install or operate in areas that are regularly subjected to high energy forces caused e g by presses or heavy machinery Resistant to many media that are commonly found in manufacturing such as water mineral oil grease and detergents Contact your Rexroth representative if you have any doubts about resistance to speciﬁc chemicals such as test oil doped oils corrosive detergents ...

Page 38: ...38 40 Technical data Bosch Rexroth AG MIT PE 2 X PE 2 H PE 4 3 842 564 350 2020 06 ...

Page 39: ...Technical data 39 40 3 842 564 350 2020 06 MIT PE 2 X PE 2 H PE 4 Bosch Rexroth AG ENGLISH ...

Page 40: ...Bosch Rexroth AG Postfach 30 02 07 70442 Stuttgart Germany Fax 49 711 811 7777 info boschrexroth de www boschrexroth com Subject to change 3 842 564 350 2020 06 ...

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