Bosch 3 842 998 760 Assembly Instructions Manual Download Page 8

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8/56 Safety

instructions

Bosch Rexroth AG

, MIT: HD 2/H, 3 842 358 796/2015-01

• The transport of persons on the product or the cargo.

• Persons climbing onto the product

– the product is not accessible.

• Private use.

2.4

Personnel qualiﬁ cations

The activities described in this documentation require basic knowledge of

mechanical, electrical and pneumatic systems, as well as knowledge of the

appropriate technical terms. Additional knowledge in dealing with a hoist and the

associated slings are required for transport and handling of the product. In order to

ensure safe use, these activities may only be carried out by authorized personnel or

an instructed person under the supervision of a qualiﬁ ed person.

An expert is someone who can evaluate the work assigned to them due to their

professional training, knowledge and experience as well as knowledge of the relevant

provisions, recognize potential hazards and take appropriate safety measures.

Qualiﬁ ed personnel must comply with the relevant technical regulations and have the

necessary expertise.

Bosch Rexroth offers training to support activities in speciﬁ c areas. You can ﬁ nd an

overview of the training content online at http://www.boschrexroth.de/didactic.

2.5

General safety instructions

• Observe the current regulations for accident prevention and environmental

protection.

• Observe the safety rules and regulations of the country in which the product is

used / applied.

• Only use Rexroth products which are in technically perfect condition.

• Follow all instructions printed on the product.

• Persons who install, operate, disassemble or service Rexroth products may

not be under the inﬂ uence of alcohol, drugs or medications that affect their

responsiveness.

• Use only original accessories and spare parts from Rexroth to prevent hazards to

persons due to improper spare parts.

• Observe the ambient conditions speciﬁ ed in the product documentation and

technical data.

• You may operate the product only when it was found that the ﬁ nal product (such as

a machine or system), in which the Rexroth products are installed, is in accordance

with the respective national provisions, safety regulations and the standards for the

application.

358732_2015_01_EN.indd 8

29.05.2015 08:32:50

Summary of Contents for 3 842 998 760

Page 1: ...structions 3 842 358 796 2015 01 Replaces ENGLISH HD 2 H Lift rotate unit 3 842 998 760 3 842 998 761 3 842 998 762 ENGLISH 358732_2015_01_EN indd 1 358732_2015_01_EN indd 1 29 05 2015 08 32 38 29 05 2015 08 32 38 ...

Page 2: ...tare il codice 3 842 358 798 nel campo di ricerca Search in alto a destra quindi fare clic su Search ES Las presentes instrucciones de montaje están disponibles en los idiomas indicados Hay más idiomas a petición Las instrucciones están disponibles como versión impresa print o como archivo PDF media para descargar del archivo de medios www boschrexroth com mediadirectory En el buscador en la parte...

Page 3: ...tate unit HD 2 H design 11 5 2 Product description 12 5 3 Identiﬁcation of the product 16 6 Transportation and storage 16 6 1 Transporting the product 16 6 2 Storing the product 16 7 Installation 17 7 1 Unpacking the product 17 7 2 Installation conditions 17 7 2 1 Installation position 17 7 2 2 Fixing with T head bolts 17 7 3 Required tools 17 7 4 Symbols used 18 7 5 Installing the product 19 7 5 ...

Page 4: ...itted center of gravity on the workpiece carrier 42 9 1 5 Environmental inﬂuences 42 10 Maintenance and repair 44 10 1 Cleaning and care 44 10 2 Inspection 45 10 3 Maintenance 46 10 4 Replacement of worn parts 47 10 4 1 Replace the pressure point of the ﬁngers in the rotary table only sizes 1 and 2 47 10 4 2 Replace damper for rotary table 48 10 4 3 Spare parts 49 11 Decommissioning 49 12 Disassem...

Page 5: ... in possession of the documentation marked with the book symbol and you have understood and observed this Table 1 Required and supplementary documentation Title Document number Document type Safety related information for staff 3 842 527 147 MTparts 3 842 529 770 Spare part list available on CD 1 3 Presentation of information In order for you to work with your product quickly and safely using this...

Page 6: ...ation which will result in death or serious injury if not avoided WARNING Indicates a hazardous situation which can result in death or serious injury if not avoided CAUTION Indicates a hazardous situation which can result in minor or moderate injury if not avoided NOTICE Damage to property The product or the surrounding environment can be damaged 1 3 2 Symbols The following icons indicate informat...

Page 7: ...e product is an incomplete machine You may use the product as follows for installation in a Rexroth transfer system TS 2plus For lifting and rotating Rexroth workpiece carriers WT 2 from the conveyor section Maximum load line load See technical data on page 51 For the environmental conditions see page 54 The product is strictly intended for professional use and not for private use The intended use...

Page 8: ...ssary expertise Bosch Rexroth offers training to support activities 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 the current regulations for accident prevention and environmental protection Observe the safety rules and regulations of the country in which the product is used applied Only use Rexr...

Page 9: ...t all pertinent product safety devices are on hand properly installed and fully functional You must not change the position of circumvent or disable safety devices Do not touch any moving parts Inspect the product for malfunctioning Make sure that only authorized personnel start operate or modify the functional sequence in the context of the intended use of the product or make adjustments to compo...

Page 10: ...8 Responsibilities of the end user Before ﬁrst use or re commissioning of a conveyor system run a risk assessment in accordance with DIN EN ISO 12100 Please also refer to the further risks of the individual components see chapter 8 2 Further risks on page 36 Before initial commissioning ensure that there are no protruding or sharp edged parts that may endanger personnel working or moving in the ar...

Page 11: ...ance description 5 1 1 Lift rotate unit HD 2 H use Installation in conveyor belt BS 2 or conveyor section ST 2 Lifting and rotating 90 180 workpiece carriers WT2 from the conveyor section 45 mm via conveyor level see Fig 1 detail X 5 1 2 Lift rotate unit HD 2 H design Extremely compact construction Suitable for limited installation space Pneumatic drive Please note Only 180 horizontal rotation for...

Page 12: ...0 the reverse rotation of the rotary table is performed below the belt section A Lift rotate unit HD 2 H size 1 For possible workpiece carrier sizes see Page 15 A1 Protective case kit not included in the delivery D Rotary table E Lifting plate F Base plate G Threaded hole position query rotation position H Damper I Mounting frame w Width in conveyor direction lT Length in conveyor direction 358732...

Page 13: ...ormed below the belt section B Lift rotate unit HD 2 H size 2 For possible workpiece carrier sizes see Page 15 B1 Protective case kit not included in the delivery D Rotary table E Lifting plate F Base plate G Threaded hole position query rotation position H Damper I Mounting frame J Additional support with loads of 50 kg not included in the delivery w Width in conveyor direction lT Length in conve...

Page 14: ...table is performed above the belt section C Lift rotate unit HD 2 H size 3 For possible workpiece carrier sizes see Page 15 C1 Protective case kit not included in the delivery D Rotary table E Lifting plate F Base plate G Threaded hole position query rotation position H Damper I Mounting frame J Additional support is absolutely necessary w Width in conveyor direction lT Length in conveyor directio...

Page 15: ...00 320 Size 2 3 842 998 761 l T b Load up to 128 kg Additional support with loads of 50 kg not included in delivery WT 2 WT 2 F 400 400 480 480 400 480 640 800 640 480 640 800 1040 800 640 Size 3 3 842 998 762 b l T Load up to 240 kg Additional support is absolutely necessary WT 2 H WT 2 F H 800 800 1040 1040 800 1040 1200 1200 1200 The maximum conveyor belt line load is to be observed see chapter...

Page 16: ...ct weight see shipping documents Check if the carrying straps are attached properly before lifting the product The product must always be prevented from tipping over when lifting During raising and lowering pay attention that nobody other than the operator is in the danger zone 6 2 Storing the product Only set the product down onto a level surface Protect the product from mechanical inﬂuences Prot...

Page 17: ... axis This ensures proper functioning and prevents premature wear and tear 7 2 2 Fixing with T head bolts Mount the transfer systems TS 1 TS 2plus TS 2pv TS 4plus TS 5 and the chain conveyor systems VarioFlow and VarioFlow S with T head bolt and collar nut When inserting and tightening make sure the T head is in the correct position in the collar nut The notch at the end of the screw indicates the...

Page 18: ...driver size ISO FLEX TOPAS NCA 52 Klüber Struktovis GHD Lubricate Lubricate with speciﬁc grease ISO FLEX TOPAS NCA 52 www klueber com Klüber Struktovis GHD www klueber com Loctite 243 Loctite 601 Secure the screws with Loctite 243 medium strength detachable www loctite de Loctite 601 high strength screw retention non detachable www loctite de The marked parts are not required for the assembly desc...

Page 19: ...ize 1 in section ST 2 example shown here size 1 180 Please note Because of its low weight size 1 can be installed into the section proﬁle directly from below without dismantling 1 Mark the installation position of HD 2 H 2 Install the T head bolts 3 Install the lift rotate unit HD 2 H to the section proﬁle from below Please note Use a lifting aid to lift the product For example the eye bolts X in ...

Page 20: ...ze 1 can be installed as described in chapter 1 1 9 on page 21 NOTICE Improper adjustment can result in property damage The product can be damaged the service life may be adversely affected During commissioning the angle of rotation must be checked and precisely set Not performing this work may result in the lift rotate unit being damaged or cause premature wear See chapter 8 4 Check and adjust th...

Page 21: ...es the mounting frame of the HD 2 H to be installed from below and the HD 2 H to be added from above 1 Mark the position of the lift rotate unit on the mounting frame 2 Remove the lift rotate unit from the mounting frame Please note Use a lifting aid to lift the product For example the ring bolts X in the base plate serve as lifting points for a round sling see Fig 8 3 Mark the installation positi...

Page 22: ...s 11 With size 3 ensure that the additional supports are installed mandatory For size 2 with loads of 50 kg For size 2 3 842 993 324 For size 3 3 842 993 325 NOTICE Improper adjustment can result in property damage The product can be damaged the service life may be adversely affected During commissioning the angle of rotation must be checked and precisely set Not performing this work may result in...

Page 23: ... supports Please note With size 3 ensure that the additional supports are installed mandatory For size 2 with loads of 50 kg 1 Pre install the lock nuts 2 Lubricate the threaded spindle 3 Install the plates 4 Screw in the articulated feet with a screwdriver 5 Mount the remaining parts of the support ENGLISH 358732_2015_01_EN indd 23 358732_2015_01_EN indd 23 29 05 2015 08 32 54 29 05 2015 08 32 54...

Page 24: ...h ST6 PN M12R 030 SENSOR 0 830 100 433 Proximity switch short IEC EN 60947 5 2 2004 3 842 549 811 1 Mount the cylinder switch A to the cylinder proﬁle Please note For sizes 1 2 3 angle of rotation 180 and size 3 angle of rotation 90 two switches per cylinder For sizes 1 and 2 angle of rotation 90 three switches per cylinder multiple position cylinder 2 Install 2 proximity switches B to the lifting...

Page 25: ... S 2 S 3 on the section proﬁle Check functionality 1 Starting position Pre separating stop A open main separating stop B closed lift rotate unit in the lower end position 2 S 1 actuated by passing WT2 VE A closes 3 S 2 actuated by passing WT2 Cylinder moves to upper end position WT2 is lifted 4 Switch upper end position actuated Rotation 90 or 180 5 Rotation end position reached If required start ...

Page 26: ...Pre separating stop A open main separating stop B closed lift rotate unit in the lower end position 2 S 1 actuated by passing WT2 VE A closes 3 S 2 actuated by passing WT2 Cylinder moves to upper end position WT2 is lifted 4 Switch upper end position actuated Rotation 90 or 180 5 Rotation end position reached If required start operation 6 If required complete operation external signal Cylinder mov...

Page 27: ...connection 1 If present remove the protective ﬁlm from the sheet metal 2 Install the edge protection pieces in the cable recess 3 Install the side walls B in the base A The side walls connect with an audible click 4 Install the covers with the inspection openings C Please note The requirements of the Machinery Directive 2006 42 EC on captive screws are only fulﬁlled if the locking wasters X 384254...

Page 28: ...ective case example shown here size 2 180 6 Insert the connecting cable through the opening in the base of the protective case 7 Slide the protective case over the HD 2 H from below Screw the protective case to the mounting frame 358732_2015_01_EN indd 28 358732_2015_01_EN indd 28 29 05 2015 08 32 56 29 05 2015 08 32 56 ...

Page 29: ...exroth AG Fig 16 358 732 08 8 8 SW4 MD 4 Nm MD 25 Nm SW13 10x Install front protective covers example shown here size 2 180 8 Install the side protective sheets ENGLISH 358732_2015_01_EN indd 29 358732_2015_01_EN indd 29 29 05 2015 08 32 56 29 05 2015 08 32 56 ...

Page 30: ...protective covers example shown here size 2 180 9 Install the front protective sheets Please note Depending on the conﬁguration of the workpiece carrier and the separating stops used it may be necessary to separate the protection sheets at the perforation X Y saw 358732_2015_01_EN indd 30 358732_2015_01_EN indd 30 29 05 2015 08 32 56 29 05 2015 08 32 56 ...

Page 31: ...rapid rotational movements and falling objects Make sure that the rotating cylinder is in its original position and under pressure exhaust air before commissioning re commissioning and in particular before each restart of the system after shutdown malfunction breaks shift changes or rest periods For the speciﬁcation of the compressed air and the operating pressure see page 54 Fig 18 358 732 26 1 2...

Page 32: ... 3 2 1 3 2 1 3 2 D 6 D 6 Pneumatic diagrams A and B Use the pneumatic diagram A rotating cylinder for size1 2 3 rotation angle 90 and 180 B lifting cylinder for sizes 1 2 rotation angle 90 multiple position cylinder 358732_2015_01_EN indd 32 358732_2015_01_EN indd 32 29 05 2015 08 32 56 29 05 2015 08 32 56 ...

Page 33: ...6 D 6 1 3 2 1 3 2 1 3 2 1 3 2 D 12 D 12 Pneumatic diagrams C and D Use the pneumatic diagram C lifting cylinder for sizes 1 2 rotation angle 180 D rotating cylinder for size 3 rotation angle 180 ENGLISH 358732_2015_01_EN indd 33 358732_2015_01_EN indd 33 29 05 2015 08 32 57 29 05 2015 08 32 57 ...

Page 34: ...tion and adjusted if necessary see chapter 8 4 Check and adjust the rotation angle of the lift rotate unit on page 37 Before ﬁrst use or re commissioning of a conveyor system run a risk assessment in accordance with DIN EN ISO 12100 Before initial commissioning ensure that there are no protruding or sharp edged parts that may endanger personnel working or moving in the area According to EU Machine...

Page 35: ...rough other switching elements exists Only start up the product when all safety devices of the system are installed and are operational Only start up a fully assembled product Double check the correct adjustment of the lift rotate table in the section proﬁle see Fig 7 on page 20 and Fig 21 on page 37 ENGLISH 358732_2015_01_EN indd 35 358732_2015_01_EN indd 35 29 05 2015 08 32 57 29 05 2015 08 32 5...

Page 36: ...ody while lifting Crush injury 4 Lifting plate Between the component and the section proﬁle Trapping of parts of the body at lowering 5 Workpiece carrier Improper setting of the adjusting throttle will cause the lifting rotary table to strike the end stop hard Trapping of body parts from falling workpiece carriers Only relevant during the adjustment process Installation and service only by qualiﬁe...

Page 37: ...set Not performing this work may result in the lift rotate unit being damaged or cause premature wear Fig 21 358 732 31 Check and set the angle of rotation example shown here size 2 180 Please note Perform the test setting in both end positions with the rotating cylinder at operating pressure Only then are the end dampers fully retracted Perform the test setting under operating conditions rotation...

Page 38: ...oke speed mount the workpiece carrier WT working load On delivery the setting achieves an even smooth lifting and rotating movement of the lift rotate unit Set the check throttle valves for both lifting cylinders in the same position To adjust the speed for the stroke and rotation movement throttle the exhaust air Rotate in the direction The movement is slower Rotate in the direction The movement ...

Page 39: ...be damaged or can wear prematurely Fig 23 358 732 23 h1 h2 0 1 mm 2 SW A 3 SW A MD B h 1 1 3 4 h 2 Set the stroke over the conveyor level example shown here size 2 180 Please note It is recommended not to change the factory preset stroke If the hub is to nonetheless be reduced both stop screws must be precisely adjusted to the same height 0 1 mm Perform the adjustment of the stroke at lower end po...

Page 40: ...o be provided by the customer Final commissioning may only be performed with guards in place These must be provided and installed by the customer See also chapter 2 8 Responsibilities of the end user on page 10 A Contact protection from below B Contact protection from above 358732_2015_01_EN indd 40 358732_2015_01_EN indd 40 29 05 2015 08 32 59 29 05 2015 08 32 59 ...

Page 41: ...umatically activated components are overloaded it is not possible to guarantee their function 9 1 2 Measures to minimize wear The following measures will reduce wear Switch off the conveyor line when at standstill e g during breaks at night at weekends Do not select a higher speed for the conveyor line than that required for the corresponding function Avoid contamination due to abrasive media redu...

Page 42: ...ith bWT lWT Failure to comply with this requirement can compromise the conveyor safety particularly at higher conveyor speeds Maximum mass moment of inertia see Mass moment of inertia on page 51 9 1 5 Environmental inﬂuences Resistant to many conventional substances used in the manufacturing sector such as water oil grease and detergents If you are unsure about resistance against certain chemicals...

Page 43: ... highly viscous or adhesive can lead to malfunctions Media that have a lubricating effect can reduce the drive power that is transmitted via friction if these media are displaced on systems with rollers In cases like these particular care must be taken when planning the system and the maintenance intervals must be shortened appropriately ENGLISH 358732_2015_01_EN indd 43 358732_2015_01_EN indd 43 ...

Page 44: ... motion or in operation may only be inspected and adjusted once all required safeguards are in place Note EN ISO 13857 when you remove or replace safeguards and or nullify a safety guideline Test runs with open panels are only allowed if they are carried out by a competent person using tip switches and no interference through other switching elements exists 10 1 Cleaning and care NOTICE Failure of...

Page 45: ...ction of all pressure points regularly every 2000 hours or every 500000 cycles whichever is reached ﬁrst The spring action of the pressure points must be felt across the entire movement of the ﬁnger Fig 26 358 732 20 Check the spring action of the pressure point Worn pressure points must be replaced see chapter 10 4 Replacement of worn parts on page 47 ENGLISH 358732_2015_01_EN indd 45 358732_2015...

Page 46: ...sk of damage to property and the service life may be reduced if the maintenance intervals are not complied with Fig 27 358 732 22 Klüber Struktovis GHD 0 5 g Lubricate the load adapter damper Please note Perform the work at the upper end position of the lift rotate unit The rotating cylinder must be depressurized vented The rotary table must be rotated for disassembly assembly Lubricate the damper...

Page 47: ...AS NCA 52 2 5 4 2x SW6 MD 8 Nm 1 3 C A B 5 Exchange the pressure point of the ﬁngers in the rotary table only sizes 1 and 2 Please note Perform the replacement at the upper end position of the lift rotate unit The rotating cylinder must be depressurized vented Required tools Hex socket head cap screw SW6 Strainer 1 Remove the latch A from the rotary table 2 Remove the ﬁnger B 3 Replace the pressur...

Page 48: ...t The rotating cylinder must be depressurized vented The rotary table must be rotated for disassembly assembly 1 Remove the damper A 2 Install the new damper 3 Adjust the damper by screwing in out of the damper housing so that the rotary table is parallel to the belt section at the end position see chapter 8 4 Check and adjust the rotation angle of the lift rotate unit on page 37 4 Lubricate the l...

Page 49: ...ir work Secure the system against unintentional restarting Raised loads can fall down Serious injury or death can occur if the product falls down Use only slings with sufﬁciently high load capacity for product weight see shipping documents Check if the carrying straps are attached properly before lifting the product The product must always be prevented from tipping over when lifting During raising...

Page 50: ... with the national laws of your country 14 Extension and modiﬁcation You may not modify the product The Bosch Rexroth manufacturer s warranty only applies to the delivered conﬁguration and extensions that were included in the conﬁguration After a renovation or extension beyond the structural modiﬁcations or extensions described here the warranty will become null and void 15 Troubleshooting If you ...

Page 51: ...ation for the minimum rotation times for different moments of inertia Jges Please remember to observe the maximum moment of inertia for the sizes 1 to 3 Lift rotate unit HD 2 H 3 842 998 760 size 1 Mass max 50 kg mass moment of inertia max 1 8 kgm Fig 30 0 1 5 2 2 5 3 0 0 5 1 1 5 2 Time of rotary movement s Mass moment of inertia Jges kgm Permissible range Impermissible range Diagram mass moment o...

Page 52: ...e Impermissible range Mass moment of inertia Jges kgm Diagram mass moment of inertia size 2 Table 9 Mass moment of inertia size 2 Mass moment of inertia kgm2 0 1 0 5 2 0 2 93 4 0 5 0 6 0 7 0 8 0 9 0 10 0 Rotation time s 1 84 1 65 1 65 2 0 2 33 2 61 2 86 3 09 3 3 3 5 3 69 Mass moment of inertia kgm2 11 0 12 0 13 0 14 0 15 0 15 9 Rotation time s 3 87 4 05 4 21 4 37 4 52 4 66 358732_2015_01_EN indd 5...

Page 53: ...f inertia kgm2 2 8 10 0 15 84 20 0 25 0 30 0 35 0 40 0 45 0 50 0 55 0 57 6 Rotation time s 3 03 3 2 4 0 4 7 5 27 5 78 6 22 6 67 7 07 7 45 7 82 8 02 The following formulas are available for the calculation Jx m bwt lwt Jx Mass moment of inertia of the uniformly distributed load Jz Steiner s displacement law Jz m d Jges Total mass moment of inertia kgm m Mass including workpiece carrier kg Jges Jx J...

Page 54: ...s caused by presses or heavy machinery for example Resistant to many conventional substances used in the manufacturing sector such as water oil grease and detergents If you are unsure about resistance against certain chemicals such as test oil doped oils aggressive detergents solvents or brake ﬂuid we recommend that you consult with your specialized Rexroth representative Prolonged contact with hi...

Page 55: ...Technical data 55 56 3 842 358 796 2015 01 MIT HD 2 H Bosch Rexroth AG ENGLISH 358732_2015_01_EN indd 55 358732_2015_01_EN indd 55 29 05 2015 08 33 02 29 05 2015 08 33 02 ...

Page 56: ... 02 07 70442 Stuttgart Germany Fax 49 711 811 7777 info boschrexroth de www boschrexroth com Subject to modiﬁcations 3 842 358 796 2015 01 358732_2015_01_EN indd 56 358732_2015_01_EN indd 56 29 05 2015 08 33 02 29 05 2015 08 33 02 ...

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