Bosch Rexroth HQ 5/H Assembly Instructions Manual Download Page 1

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Assembly instructions

3 842 558 544/2017-07

Replaces: –

ENGLISH

HQ 5/H, HQ 5/XH

Lift transverse unit

3 842 998 854

3 842 998 855

GLISH

Summary of Contents for Rexroth HQ 5/H

Page 1: ...Assembly instructions 3 842 558 544 2017 07 Replaces ENGLISH HQ 5 H HQ 5 XH Lift transverse unit 3 842 998 854 3 842 998 855 ENGLISH ...

Page 2: ...Search 窗口内输入编号 3 842 558 549 2 点击 Search CS Tento návod k montáži je k dispozici ve zde uvedených jazycích Jako tištěná verze print nebo jako soubor PDF media je ke stažení z adresáře médií www boschrexroth com mediadirectory 1 Zadejte do vyhledávací obrazovky nahoře vpravo pod Search MTCS 557 617 2 Klikněte na Search PL Dana instrukcja montażu jest dostpna w podanych tutaj językach W postaci wyd...

Page 3: ... 1 1 Utilization of the HQ 5 H and HQ 5 XH lift transverse unit 11 5 1 2 HQ 5 H and HQ 5 XH lift transverse unit features 12 5 2 Product description 13 5 3 Identiﬁcation of the product 15 6 Transport and storage 15 6 1 Transporting the product 15 6 2 Storing the product 15 7 Assembly 16 7 1 Unpacking 16 7 2 Installation requirements 16 7 2 1 Installation position 16 7 2 2 Fastening with T bolts 16...

Page 4: ... 10 3 Maintenance 41 10 3 1 Toothed belt 41 10 4 Replacement of wear parts 42 10 4 1 Replacing the toothed belt 43 10 4 2 Adjusting the belt tensioner with a frequency meter 44 10 4 3 Replacing a standard motor 45 10 4 4 Replacing the SEW gear motor 46 10 4 5 Replacing the gear on a standard motor 47 10 4 6 Removing the split rollers 48 10 4 7 Spare parts 51 11 Decommissioning 51 12 Disassembly an...

Page 5: ...quired and supplementary documentation Only start up the product if the documentation marked with the book symbol is available and you have understood and followed it Table 1 Required and supplementary documentation Title Document number Document type Employee Safety Training 3 842 527 147 MTparts 3 842 529 770 Spare parts list on CD 1 3 Presentation of information Standardized safety instructions...

Page 6: ... 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 get damaged 1 3 2 Symbols The following ...

Page 7: ...ion in a location where it is accessible to all users at all times Always include it when giving the product to a third party 2 2 Intended use The product is an incomplete machine It may be used as follows For use installation in a Rexroth TS 5 transfer system For the maximum load section load see the Technical Data on page 53 For the environmental conditions see page 53 The product is only intend...

Page 8: ...must comply with the relevant technical regulations 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 the applicable regulations for accident prevention and environmental protection Observe the safety rules and regulat...

Page 9: ...ty equipment belonging to 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 within the scope of the product s intended use starting or operating the system or intervening in its normal func...

Page 10: ...sed All components of the personal protective equipment must be intact 2 8 Operator s obligations Before the initial start up or re commissioning of a conveyor system run a risk assessment in accordance with DIN EN ISO 12100 Please also refer to the residual risks of the individual components see the section 8 2 Residual risks on page 35 Before the initial start up make sure there are no protrudin...

Page 11: ... H HQ 5 XH lift transverse unit 4 1 Condition on delivery HQ 5 lift transverse unit installed in an ST 5 conveyor unit 5 About this product 5 1 Speciﬁcations Fig 1 557 671 01 Q b b L Speciﬁcations for the HQ 5 H and HQ 5 XH lift transverse unit 5 1 1 Utilization of the HQ 5 H and HQ 5 XH lift transverse unit HQ 5 H For use installation in the ST 5 H conveyor units HQ 5 XH For use installation in t...

Page 12: ...H and HQ 5 XH lift transverse unit features Extremely compact construction Suitable for tight installation conditions Pneumatic drive lifting electric drive transverse conveying Conveyor medium Toothed belt roller section Suitable for reverse operation Cable plug or terminal box motor connection ...

Page 13: ...tion C Transverse conveyor module protective covers preassembled D Mounting bracket 4x E Protective casing fully assembled F Position monitoring kit 3 842 554 942 Please note The mounting position of the position monitoring kit is derived from the dimensions C1 and C2 position of the proximity switch for querying the WT in the dimensions table on Page 27 The preassembled protective covers of the t...

Page 14: ...d workpiece pallets Lift transverse unit Usable conveyor units Usable workpiece pallets HQ 5 H 3 842 998 854 ST 5 H 45x90 Load up to 300 kg ST 5 H WT 5 HQ 5 XH 3 842 998 855 ST 5 XH 45x180 Load up to 300 kg ST 5 XH WT 5 Observe the conveyor section s permissible section load see section 16 Technical data on page 53 ...

Page 15: ...ngs with a sufﬁciently high bearing load see delivery documents for the product weight Make sure the lifting straps are correctly fastened before lifting the product Secure the product against tipping during lifting Make sure that no one but the operator is in the danger zone during lifting and lowering 6 2 Storing the product Only set the product down on a ﬂat surface Protect the product from mec...

Page 16: ...sition Install the product level and plumb at right angles and axially parallel This ensures proper functioning and prevents premature wear 7 2 2 Fastening with T bolts Fasten the TS 1 TS 2plus TS 2pv TS 4plus and TS 5 transfer systems and the VarioFlow and VarioFlow S chain conveyor systems with T bolts and ﬂange nuts Make sure the T bolt is in the correct position when inserting into the slot an...

Page 17: ...ed tightening torque Nm PH3 PZ2 Screwdrivers for cross head screws PZ Pozidriv cross recess size PH Phillips cross recess size gleitmo 585 K Lubricate with speciﬁc grease lubricant Fuchs Lubritech gleitmo 585 K www fuchs lubritech com The marked parts are not required for the described assembly Dispose of the parts or use them for other purposes 2 1 3 Graphical depiction of the installation steps ...

Page 18: ...erter and the JU 5 junction See the assembly instructions for these components See page 21 for installing the VE 5 stop gates See page 24 for installing the DA 5 damper Please note Depending on the length of the workpiece pallet lWT and the roller pattern p the HQ 5 lift transverse unit is installed at a predeﬁned distance from a roller axle This gives rise to the mounting dimensions for the VE 5 ...

Page 19: ...75 5 110 215 150 77 5 507 5 195 26 25 26 25 202 5 46 5 49 5 43 77 5 247 5 117 5 45 540 845 130 6 25 6 25 462 5 46 5 49 5 43 77 5 345 117 5 45 735 195 260 1040 130 6 25 6 25 592 5 79 82 75 5 110 410 150 77 5 897 5 195 26 5 26 25 592 5 46 5 49 5 43 77 5 442 5 117 5 45 930 260 46 25 6 25 592 5 79 82 75 5 110 410 150 77 5 897 5 325 26 5 26 5 592 5 46 5 49 5 43 77 5 442 5 117 5 45 930 For an explanatio...

Page 20: ... 3 842 549 814 2 x switch brackets 3 842 537 289 Please note The mounting position of the position monitoring kit F is derived from the dimensions C1 and C2 position of the proximity switch A for querying the WT in the dimensions table on Page 27 1 Install the switching ﬂag on the lift frame of the lift transverse unit 2 Assemble the position monitoring kit including switch bracket 3 Install the p...

Page 21: ...5 stop gate on the HQ 5 Required accessories VE 5 D 300 stop gate 3 842 998 517 VE 5 D 1000 stop gate 3 842 998 805 Install the VE 5 stop gate for the mounting dimensions See page 18 Please note When using stop gates before and after the HQ the lower horizontal guard plate needs to be notched The guard plates are perforated to make them easier to remove Protect the cut surface against corrosion Re...

Page 22: ...rse sections are mounted directly on the longitudinal sections For parallel transverse sections with lift transverse units and curves diverters use the connection bridges 3 842 998 604 or 3 842 998 605 to offset the length 1 Close off open section ends with end plates and end caps 2 Mount the transverse section or connection bridge for the mounting dimensions See page 18 Assembly tip Insert a bolt...

Page 23: ...ansverse sections are mounted directly on the longitudinal sections For parallel transverse sections with lift transverse units and curves diverters use the connection bridges 3 842 998 604 or 3 842 998 605 to offset the length 1 Close off open section ends with end plates and end caps 2 Mount the transverse section or connection bridge for the mounting dimensions See page 18 Assembly tip Insert a...

Page 24: ... 545 128 DA 5 D1000 damper 3 842 545 130 Installing the DA 5 damper and stop for the mounting dimensions See page 18 Use a WT 5 workpiece pallet as a positioning aid Align the DA 5 damper with the center of the workpiece pallet Align the stop with the guide rollers of the workpiece pallet If necessary install the lateral guide cover A See page 29 Please note The stop B is no longer required when t...

Page 25: ...650 195 6x 3 842 545 609 1x 3 842 545 966 650 650 130 9x 3 842 545 405 1x 3 842 545 966 650 650 195 6x 3 842 545 360 1x 3 842 545 966 650 845 130 11x 3 842 545 405 1x 3 842 545 966 650 845 195 7x 3 842 545 360 1x 3 842 545 966 650 845 260 5x 3 842 545 612 1x 3 842 545 966 845 845 130 11x 3 842 545 361 1x 3 842 545 966 845 845 195 7x 3 842 545 362 1x 3 842 545 966 845 845 260 5x 3 842 545 363 1x 3 ...

Page 26: ... 845 195 43 845 845 260 43 845 1040 130 75 5 845 1040 195 43 845 1040 260 53 5 845 1040 325 43 7 5 8 Protective cover cutouts for an HQ 5 Fig 11 12 5 10 A1 16 16 81 5 24 1 105 6 12 5 10 B1 16 16 81 5 R6 6x 24 1 105 6 557 617 11 R6 6x Protective cover cutouts for an HQ 5 1 2 Please note Illustration shown from above Cutouts are made from the bottom side If the cutout intersects a joint ﬁrst cut thr...

Page 27: ...oint ﬁrst cut through the bar on the bottom side near the cutout bWT lWT p C1 C2 D1 D2 mm mm mm mm mm mm mm 455 455 130 166 15 66 7 43 8 455 650 130 166 15 98 7 75 5 40 5 455 650 195 166 15 66 7 43 8 650 650 130 230 98 7 75 5 40 5 650 650 195 230 66 7 43 8 650 845 130 230 66 7 43 8 650 845 195 230 49 7 43 8 650 845 260 43 8 845 845 130 230 66 7 43 8 845 845 195 230 49 7 43 8 845 845 260 43 8 845 1...

Page 28: ...ith protective covers in accordance with DIN EN 619 The user must make openings with a circumferential gap of 5 mm in the protective covers for the stop gates switch brackets and identiﬁcation system Dimensioned illustrations of the openings suitable for the installation of stop gates switch brackets and identiﬁcation systems positioning units can be found in the corresponding sections 1 Close off...

Page 29: ... HQ 5 XH Bosch Rexroth AG 7 5 10 HQ 5 lateral guide cover Fig 14 557 617 14 2 1 SW13 4x MD 25 Nm SW13 3x MD 25 Nm B A HQ 5 lateral guide cover Install the cover on the lateral guide Cover A with a slot for DA 5 dampers Cover B without a slot ENGLISH ...

Page 30: ...onnecting the product to the pneumatic system Secure the system against being unintentionally switched on again For the compressed air and operating pressure speciﬁcations see page 53 Fig 15 557 617 15 X Y Pneumatic connection example shown here on HQ 5 XH Please note Connect the pneumatics at X and Y This charges the system more quickly and evenly better synchronization The pneumatic hoses at all...

Page 31: ...Assembly 31 60 3 842 558 544 2017 07 MIT HQ 5 H HQ 5 XH Bosch Rexroth AG Fig 16 557 617 16 1 3 5 2 4 D8 D8 D8 D8 1 Pneumatic connection diagram 1 Not included in the scope of delivery ENGLISH ...

Page 32: ... the motor nameplate see Fig 17 on page 33 Connect up the motor in either a wye or a delta conﬁguration in accordance with the connection diagrams see Fig 18 on page 33 and the connection diagram in the terminal box The motor is ﬁtted with a bimetal temperature monitoring switch potential free thermal contact 230 V AC 300 mA Connect the motor so that it is de energized when the switch is triggered...

Page 33: ...allation_A Motor nameplate example Fig 18 TW1 TW2 PE T1 T2 1U2 1V2 1W2 1U2 1V2 1W2 1U1 1V1 1W1 1U1 1V1 1W1 2U1 2V1 2W1 2U1 2V1 2W1 PE U1 V1 W1 TW1 TW2 PE T1 T2 PE U1 V1 W1 Installation_DY Delta wye connection diagrams Fig 19 Installation_IEC Optional motor connection with plug ENGLISH ...

Page 34: ... 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 electrical and pneuma...

Page 35: ...orkpiece pallet and stop gate latch during approach Body parts can become trapped Crushing Pre separate before work areas Do not reach into the running system Danger zone is to be marked 5 When lowering between workpiece pallet and stop gate Body parts can become trapped Crushing Do not reach into the running system Danger zone is to be marked 6 When lowering between workpiece pallet and stop gate...

Page 36: ...ot reach into the running system Safety measure required e g use protective covers See page 25 10 Between loading workpiece pallet and damper stops Body parts can become trapped Crushing Do not reach into the running system Danger zone is to be marked 11 Motor Touching hot surfaces above 65 C Burning Install appropriate safety guards Let the unit cool down at least 30 minutes before performing mai...

Page 37: ...ective devices in place These must be provided and installed by the customer Fig 20 557 617 21 X Y Setting the lifting speed example shown here on HQ 5 XH Please note Mount the corresponding WT workpiece pallet before conﬁguring the lifting speed operating load Try to conﬁgure the HQ to lift evenly and smoothly Throttle the supply air evenly using both throttles to adjust the speed of the lifting ...

Page 38: ...and lead to the premature breakdown of motors and gears If pneumatically activated components are overloaded it is not possible to guarantee their function 9 1 2 Measures to reduce wear The following commonsense measures will reduce wear Switch off the conveyor section during system shutdowns for example during breaks at night and on weekends Do not select a higher speed for the conveyor section t...

Page 39: ...nding area such as sand and silicates e g from construction as well as machining processes in the transfer system e g welding beads pumice powder glass shards chips waste parts etc Maintenance intervals should be signiﬁcantly reduced under these circumstances Resistance to media and contamination does not mean that functional safety is guaranteed in every case Liquids that thicken as they evaporat...

Page 40: ...s Only inspect and adjust continuous conveyors 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 switch...

Page 41: ...Bearings The bearings have lifelong lubrication and are maintenance free under normal conditions of use Gear The gear is maintenance free Motor To ensure adequate cooling of the motors remove dirt and accumulations of dust regularly from the surface of the motor from the intake openings on the fan hood from between the cooling ribs The cleaning intervals are dependent on the ambient and operating ...

Page 42: ...idth and the installation situation it may be necessary to remove the rollers See page 48 or the HQ 5 from the section for better accessibility Required tools Hex wrenches open ended spanner SW13 SW24 Hex socket wrenches SW3 SW4 SW5 SW6 Required accessories Disassembly tool to remove the covers on the king shaft and passive side 3 842 545 836 ...

Page 43: ... belt 6 Install the new toothed belt in reverse order 7 Pre setting the belt tensioner Turn the adjusting screw until the setting dimension X guide value is reached b bWT mm x mm 455 16 5 650 15 5 845 14 8 The correct belt tension then need to be set with the frequency meter See page 44 Practical tip Increase the belt tension gradually 1 rotation at a time by turning the tension bolt Check using a...

Page 44: ... the permissible frequency range see table 2 Turn on the frequency meter C and hold the sensor head B over the belt 3 Strike the toothed belt gently to read the frequency f Compare the frequency f with the table bWT x lWT mm f Hz 455 x 455 63 5 455 x 650 81 5 650 x 650 39 4 650 x 845 43 4 845 x 845 27 3 845 x 1040 27 3 If the frequency is within the speciﬁed range the belt tension is correct If th...

Page 45: ... section for better accessibility Required tools Hex wrench SW8 1 Remove the motor 2 Remove the protective cap from the shaft of the new motor 3 Lubricate the motor shaft 4 Install the new motor Please note The end faces of the motor and gear must be undamaged Do not tilt the motor and make sure it has the necessary clearance area for installation Install the motor in the proper position terminal ...

Page 46: ...rientation terminal box and connect it to the drive shaft If the gear motor is not in the proper position do NOT rotate the gear motor Disconnect the gear motor from the drive shaft and reconnect it Please note Depending on the system width and the installation situation it may be necessary to remove the rollers See page 48 or the HQ 5 from the section for better accessibility Required tools Hex w...

Page 47: ...ystem width and the installation situation it may be necessary to remove the rollers See page 48 or the HQ 5 from the section for better accessibility Required tools Hex wrench SW8 1 Remove the motor See page 45 2 Remove the snap ring on the drive shaft 3 Pull the drive shaft off the gear with the aid of an M8 screw 4 Remove the adapter piece and the protective sleeve 5 Remove the gear Assembly is...

Page 48: ...842 545 836 Y Y 557 617 26 1 2 X Removing the split rollers 1 3 Required tools Disassembly tool 3 842 545 836 Please note The cover of the king shaft on the drive unit AS 5 is connected to the covers of the adjoining modular units X 1 Remove the covers from the passive side 2 Remove the cover of the king shaft The covers are assembled as shown in detail Y ...

Page 49: ... 27 3 MD 8Nm SW4 4 557 617 27 5 MD 2Nm SW4 6 Removing the split rollers 2 3 3 Loosen the proﬁle connector of the lateral guide 2 rotations 4 Move the proﬁle connectors into the adjacent module 5 Loosen the headless setscrews of the lateral guide 2 rotations 6 Remove the lateral guide ENGLISH ...

Page 50: ...IT HQ 5 H HQ 5 XH 3 842 558 544 2017 07 Fig 28 557 617 28 8 7 Removing the split rollers 3 3 7 Remove the clamps 8 Remove the split rollers vertically upwards After mounting the PE the split rollers are correspondingly assembled in the reverse order ...

Page 51: ...ng any maintenance or repair work Secure the system against being unintentionally switched on again Suspended loads can fall Falling objects can result in serious injury or even death Only use slings with a sufﬁciently high bearing load see delivery documents for the product weight Make sure the lifting straps are correctly fastened before lifting the product Secure the product against tipping whe...

Page 52: ...art Careless disposal may lead to environmental contamination Dispose of the product in accordance with the regulations in your country 14 Upgrading and modiﬁcation Do not modify the product The Bosch Rexroth warranty only applies to the conﬁguration as delivered and to approved upgrades The manufacturer will not accept any warranty claims for systems with unapproved modiﬁcations or upgrades 15 Tr...

Page 53: ...industrial equipment producing chemical emissions Do not install or operate near sources of sand or dust Do not install or operate in areas that are regularly subjected to high energy forces caused for example 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...

Page 54: ...op gates are used to stop the workpiece pallets The position of the workpiece pallets is queried using separate proximity switches Action block Explanation S Storing NS Non storing S Set R Reset T3 T3 NS D S S Y2 1 Non storing triggering of a time function with runtime T after which a switching function is triggered General abbreviations WT Workpiece pallet VE Stop gate S Signaling device Y Valve ...

Page 55: ... S4 S2 S3 S5 1N1 1N2 1N3 1N5 NS Y1 T3 T3 NS Y2 Z2 S Y3 Z2 R Y3 Z2 S4 1N4 NS NS D Y4 Z4 Z1 2 1 1 Start pulse after end of start up Enable cyclic travel S2 WT after VE S3 WT in position on HQ S4 Enable secondary section HQ free S5 HQ down Y1 Main section VE Z1 Y2 HQ up Z2 Y3 HQ down Z2 Y4 Extend DA damper Z4 stop position Note Distance Z1 Z3 lWT 200 mm ENGLISH ...

Page 56: ...2 S2 S2 S3 S1 S1 S2 S3 1N1 1N2 1N3 1N4 NS Y1 NS F T T F T2 D NS T2 D Z1 NS Y3 Z2 S Y2 Z2 R Y2 Z2 NS Y4 Z4 2 1 1 Start pulse after end of start up Enable cyclic travel S1 WT after VE S2 WT in position on HQ S3 Enable secondary section HQ free Y1 Secondary section VE Z1 Y2 HQ up Z2 Y3 HQ down Z2 Y4 Extend DA damper Z4 Note Distance Z1 Z3 bWT 200 mm ...

Page 57: ... Z2 S Y3 Z2 R Y3 Z2 NS Y4 Z4 1N5 Start pulse after end of start up Enable cyclic travel S1 WT after VE S2 WT in position on HQ S3 Enable secondary section HQ free S4 Enable main section HQ free S5 HQ down Z2 Y1 Main section VE Z1 Y2 HQ up Z2 Y3 HQ down Z2 Y4 Extend DA damper Z4 A1 Straight ahead signal Note Central position WT 4 stop position of HQ 4 is centered by springs without pressurization D...

Page 58: ... Z2 1N6 1N7 S2 S1 S2 S5 S6 S6 S3 S4 P10 S5 1N1 1N2 1N3 1N4 1N5 S3 S4 1 NS Y1 Z1 NS Y5 Z5 S Y3 Z3 NS Y2 Z2 R Y3 Z3 NS Y4 Z3 R P10 S P10 NS T T F T3 F D NS T3 D 2 1 1 1 1 P10 S1 1 Start pulse after end of start up Enable cyclic travel S1 WT before VE 1 S2 WT after VE 1 S3 WT in position on HQ S4 WT after HQ S5 WT before VE 2 S6 WT after VE 2 Y1 Secondary section VE 1 Z1 ...

Page 59: ...Appendix 59 60 3 842 558 544 2017 07 MIT HQ 5 H HQ 5 XH Bosch Rexroth AG Y2 Secondary section VE 2 Z2 Y3 HQ up Z3 Y4 HQ down Z3 not required Y5 Extend DA damper Z4 P10 Priority ENGLISH ...

Page 60: ...Bosch Rexroth AG Postfach 30 02 07 70442 Stuttgart Germany Fax 49 711 811 7777 info boschrexroth de www boschrexroth com Subject to change 3 842 558 544 2017 07 ...

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