IEF Werner 115/42 Translation Of The Original Instructions Download Page 23

Page: 23 / 47

June 2018

Translation of the original instructions

Troubleshooting

MAN_EN_1057398_Module115-42(B)_R3b.doc

Module 115/42 (B)

Page 23 of 47

5 Troubleshooting

Interference

Reason

Correction

Increased
running noise

Nominal service life of guide
carriage exceeded

Replace all guide carriages

Guide carriage worn due to
overload

(too high torque, etc.)

Replace all guide carriages,
reduce load

Guide carriage worn from
strong contamination

Replace all guide carriages, if possible use
toothed belts with optional belt coverage

Guide rails worn

Replace guide rails, replace all guide carriages,
check load, protect linear module from strong
contamination (belt coverage)

Guide rails corroded

Replace all guide rails, replace guide carriages if
required

Deflection unit worn

Replace deflection unit

Drive unit worn

Replace drive unit

Toothed belt runs dry

Slightly lubricate toothed belt on the toothed
inner side

Toothed belt tension too high

Re-set toothed belt tension at the carriage part

Toothed belt runs diagonally

Align toothed belt with belt fastener
(pressure piece and tooth segment), tighten
cylindrical screws M6 evenly!

Toothed belt strongly
contaminated on the toothed
inner side

Replace toothed belt, protect linear module from
strong contamination (use optional belt coverage)

Toothed belt defective

Replace toothed belt

Motor (motor bearing) defective Replace motor

For motor with brake: Brake
does not disengage

Apply current to the brake, if the brake still does
not open, replace motor

Linear drive unit
does not move

Limit switch cable not
connected.

Connect the cable

Limit switch defective

Replace limit switch

Limit switch cable defective

Check limit switch cable

Solder connection on socket
has come loose

Solder on wires/strands

Motor connected incorrectly

Check and change connector assignment,
if required

Motor defective

Replace motor

Summary of Contents for 115/42

Page 1: ...odule115 42 B _R3b doc Module 115 42 B Page1 of 47 IEF Werner GmbH Wendelhofstraße 6 78120 Furtwangen Germany Phone 49 7723 925 0 Fax 49 7723 925 100 www IEF Werner de info IEF Werner de Translation of the original instructions Module 115 42 B Issue June 2018 Article no 1057398 ...

Page 2: ...chanical reproduction including in extracts We are always grateful for suggestions for improvements and information about errors June 2018 IEF Werner GmbH Document Code Date Revision MAN_EN_1057398_Modul115 42_R1a doc 26 01 2007 New release of the English document according to the original German instruction MAN_DE_1057397_Modul115_42_R1b doc MAN_EN_1057398_Modul115 42_R1b doc 19 04 2010 New artic...

Page 3: ... 4 Wiring 14 3 4 1 Motors 14 3 4 2 Initiators 14 3 4 2 1 Technical data of initiators 15 3 4 2 2 Plug for end position switch 16 3 4 3 Cable routing 16 3 5 Technical data 17 3 5 1 Tightening torques for screw connections general 17 3 5 2 Technical data of the linear module 115 42 or 115 42 B 17 3 5 3 Type label 18 3 5 4 Technical data when using a planetary gear 18 3 5 5 Axis distances and tooth n...

Page 4: ...odule 115 42 L 195 34 7 4 Slide Module 115 42 L 300 36 7 5 Slide Module 115 42 B L 195 38 7 6 Slide Module 115 42 B L 300 40 7 7 Belt Gearbox module 80 15 42 7 8 Flange 44 7 9 Design specific assemblies components 45 7 9 1 Installation flange gearbox e g planetary gear type PLFE64 45 7 9 2 Overview clamping elements 46 8 Declaration of incorporation 47 ...

Page 5: ...lists who received safety technical instruction and are able to assess potential dangers Furthermore all chapters of these operating instructions must have been read and understood completely WARNING The system must be powered down for all assembly disassembly or repair work There is a high danger of injury WARNING OF HOT SURFACE During operation heating of the motor in particular of stepper motor...

Page 6: ...itable safety devices e g safety cell protective room protective housing light curtain NOTE Observe the Declaration of Incorporation see section Declaration of incorporation page 47 1 3 Special hazard warnings In addition this Original User s Manual also contains the following special hazard warning DANGER FROM CRUSHING These places of the components pose the danger of crushing limbs in operation ...

Page 7: ...module 115 42 or module 115 42 B can be used for many applications They usage areas range from stop adjustment in the wood industry to equipment systems for SMD components joining and pressing processes in precision mechanics loading and unloading stations of tool machines to manipulators for the packaging industry 2 1 Reasonably foreseeable misuse The linear module 115 42 or 115 42 B is not to be...

Page 8: ...llation position The installation position is optional i e the linear module can be used horizontally as well as vertically CAUTION In the vertical installation position use only motors with spring operated brake to prevent the lowering of the drive in de energized condition 3 2 Overview of motor installation variants Figure 2 Installation variants module 115 42 or 115 42 B ...

Page 9: ...ing instructions Assembly instructions MAN_EN_1057398_Module115 42 B _R3b doc Module 115 42 B Page 9 of 47 3 2 1 Module 115 42 or 115 42 B installation variant 1 Figure 3 Module 115 42 or 115 42 B subassembly number 1000901 installation variant 1 ...

Page 10: ...inal operating instructions June 2018 Page 10 of 47 Module 115 42 B MAN_EN_1057398_Module115 42 B _R3b doc 3 2 2 Module 115 42 or 115 42 B installation variant 5 Figure 4 Module 115 42 or 115 42 B subassembly number 1000901 installation variant 5 ...

Page 11: ... 5 bottom The carriage moves freely The linear module should not be attached otherwise e g by additional bores in the basic unit These bores will nearly always lead to clamping of the guide basis and damage to internal parts of the module CAUTION The clamping surface should have a levelness of 0 1 mm m Figure 5 Attachment with clamping profiles clamping elements NOTE For an overview of the differe...

Page 12: ...18 Page 12 of 47 Module 115 42 B MAN_EN_1057398_Module115 42 B _R3b doc DANGER FROM CRUSHING These places of the components pose the danger of crushing limbs There is danger of crushing at the start and end of a stroke see Figure 6 below Figure 6 Possible crushing points ...

Page 13: ...ring ring to take up clamping elements Figure 8 Centring ring article no 1024021 The threaded bores M6 make different axis configurations possible on the carriage possibly using an adapter plate The recesses Ø12 serve to centre clamping elements with supply option 3 3 1 Installation of actuators Actuators to be installed on the linear module pick up modules cylinders are usually attached to the li...

Page 14: ...h see Figure 9 and Figure 10 These switches are no safety limit switches pursuant to EN60204 1 Optionally also subsequently an additional reference point switch PNP normally open contact article no 726744 can be installed in the linear module 115 42 or 115 42 B The active button is marked with a coloured circle Normally closed contacts are marked with a green normally open contacts with a red dot ...

Page 15: ...nical data of initiators Parameter Value Operating voltage incl residual ripple 10 30 VDC 15 Current load capacity Ia 200 mA Voltage drop at Ia max 2 5 V Switching frequency 1 000 Hz Own current consumption 15 mA Nominal switching distance on steel 1 5 mm 10 Switching hysteresis 3 20 Reproducibility U const 0 01 mm Operating temperature 25 C 70 C Protection class IP 65 Short circuit proof yes Prot...

Page 16: ... Reference switch grey Figure 13 Connection assignment plug end position switch 3 4 3 Cable routing For all moving cables suitable cable routing has to be used to effectively prevent cable breaks The minimum radius rmin for cable routing chains is calculated for IEF Werner cables according to the following formula rmin 10 x cable diameter When different cables are used EN 60204 must be observed In...

Page 17: ...r module 115 42 or 115 42 B Parameter Value Repeating accuracy 0 05 mm Weight without motor at stroke 0 mm 8 85 kg Weight increase per 100 mm stroke 0 95 kg Maximum movement speed 5 m s Maximum acceleration 40 m s Max transferable feed force at max movement speed 5 m s 1 278 N Max torque Mx 150 Nm Max torque My 80 Nm Max torque Mz 150 Nm Carrying capacity C1 2 000 N Carrying capacity C2 800 N Guid...

Page 18: ... lead to increased wear at the gear and or thermal problems The accuracy of the linear unit is influenced by the reverse play of the gears Example The gear reverse play S is 9 angle minutes How high is the reverse play at the carriage of the linear unit Feed constant of the linear unit Vk 140 mm Reverse play at the carriage Vk S 360 x 60 140 mm 9 360 x 60 0 058 mm Consider the information of the r...

Page 19: ...lanations on the table axis distances subassembly no 1000475 Comply with the following axis distances in the required standard reductions i Z1 output Z2 drive Bore diameter of Z1 Length of toothed belt AA mm Feed constant mm 1 1 42 42 max Ø 32 mm 450 mm 120 140 2 1 1 42 20 max Ø 16 mm 390 mm 116 18 66 667 2 625 1 42 16 max Ø 14 mm 390 mm 120 73 53 333 3 1 42 14 max Ø 12 mm 375 mm 115 35 46 667 ...

Page 20: ...3b doc 3 5 6 Load cases 3 5 6 1 Torques and carrying capacities Figure 17 Torques and carrying capacities Excerpt from the technical data Figure 14 page 17 Parameter Value Max torque Mx 150 Nm Max torque My 80 Nm Max torque Mz 150 Nm Carrying capacity C1 2 000 N Carrying capacity C2 800 N Figure 18 Table torques and carrying capacities ...

Page 21: ...ginal instructions Assembly instructions MAN_EN_1057398_Module115 42 B _R3b doc Module 115 42 B Page 21 of 47 3 5 6 2 Tilting of the carriage unit at lateral load Figure 19 Tilting of the carriage Figure 20 Deflection at lateral load ...

Page 22: ...n elements and a ball chain This makes it possible to achieve a running performance of 10 000 km with initial lubrication In single shift operation this corresponds to nearly 5 years at a stroke of 500 mm and 20 cycles per minute Once the indicated running output is reached the guide carriage can be re lubricated with a special grease press IEF item no 1055123 see Figure 21 below The grease gun is...

Page 23: ...oothed belt runs dry Slightly lubricate toothed belt on the toothed inner side Toothed belt tension too high Re set toothed belt tension at the carriage part Toothed belt runs diagonally Align toothed belt with belt fastener pressure piece and tooth segment tighten cylindrical screws M6 evenly Toothed belt strongly contaminated on the toothed inner side Replace toothed belt protect linear module f...

Page 24: ...ws with threadlocker For planetary gear Clutch between motor and planetary gear slips Engage clutch tightly and secure screws with threadlocker For motor with brake Brake does not disengage Apply current to the brake if the brake still does not open replace motor Play on reversal Gearbox toothed belt not tensioned Tension gear toothed belt Motor toothed disk has play key connection Replace motor t...

Page 25: ...42 B Page 25 of 47 6 Repair instructions WARNING Always power down the system before starting repairs WARNING Any repairs must only be performed by specialist personnel who have read and understood the operating instructions CAUTION Only use original replacement parts otherwise IEF Werner GmbH will not accept any warranty ...

Page 26: ... setting of the toothed belt tension The toothed belt tension of the axial toothed belt is set via adjustment screws see Figure 22 It is correctly set at delivery Figure 22 Adjustment screws for belt tension NOTE Do not remove the threadlocker from the adjustment screws The belt tension of the gear toothed belt motor installation variants 1 4 is 150 N ...

Page 27: ... 115 42 B Page 27 of 47 6 2 Replace toothed belt Proceed as follows to replace the toothed belt 1 Loosen the four attachment screws M6 x 30 see Figure 23 item 200 2 Remove the pressure pieces see Figure 23 item 30 Figure 23 Loosen attachment screws 3 Remove the covers see Figure 24 item 90 Figure 24 Remove the covers ...

Page 28: ...thed belt and insert a new one 5 Insert the toothed belt into the tooth segment see Figure 25 item 70 6 Screw the pressure piece tightly on both sides to block see Figure 25 item 200 Figure 25 Tooth segment 7 Install the covers again see Figure 24 page 28 item 90 NOTE The belt tension is pre set in the factors Do not remove the threadlocker from the retention screws ...

Page 29: ...side of the carriage plate marked by two unilateral alignment pins is on the same side as the reference side of the basic unit see Figure 26 Figure 26 Reference side The adapter plate is applied to the two guide carriages on the reference side In the new condition the guide carriages are harder to push After a brief run in time 1 2 days the pushing resistance reduces to its regular amount NOTE Do ...

Page 30: ... 1 Cover 100 626124 1 Countersunk screw zinc plated M4 x 10 110 1052769 1 Covering 120 626050 1 Countersunk screw zinc plated M6 x 16 28585 1 Limit switch holder 25165 1 Induction switch PNP normally closed contact 726744 1 Induction switch PNP normally open contact 190 25626 1 Retaining plate 200 725164 1 Angle coupling WKV 50 6 210 725163 1 Installation plug SFV 50 6 220 1072646 1 Fillister head...

Page 31: ...e 2018 Translation of the original instructions Parts lists and drawings MAN_EN_1057398_Module115 42 B _R3b doc Module 115 42 B Page 31 of 47 Figure 28 Module 115 42 exploded drawing parts group no 1000901 ...

Page 32: ...nc plated M4 x 10 120 1052923 1 Bearing cover module 115 42 130 626037 1 Cylindrical screw zinc plated M6x20 140 1059769 1 Cover module 115 42 150 28585 1 Limit switch holder 160 25165 1 Induction switch PNP normally open contact 170 726744 1 Induction switch PNP normally closed contact 190 25626 1 Retaining plate 1 5 x 23 x 36 200 725164 1 Angle coupling WKV 50 6 210 725163 1 Installation plug SF...

Page 33: ...une 2018 Translation of the original instructions Parts lists and drawings MAN_EN_1057398_Module115 42 B _R3b doc Module 115 42 B Page 33 of 47 Figure 29 Module 115 42 B exploded drawing part no 1305569 ...

Page 34: ...ressure piece module 115 42 60 1054179 1 Lubrication tube 61 1007437 1 O ring NBR 70 Shore A 4 1 50 X 70 1054232 1 Lubrication adapter 80 737231 1 O ring NBR 70 Shore A 12 1 50 X 90 1031602 1 O ring NBR 70 Shore A 1 8 1 80 X 100 1028704 1 Lubrication nipple T 110 626059 1 Cylinder head screw galvanized M5 x 16 120 1019272 1 Cylinder head screw galvanized M6 x 30 130 58044 1 Hex socket set screw ga...

Page 35: ...June 2018 Translation of the original instructions Parts lists and drawings MAN_EN_1057398_Module115 42 B _R3b doc Module 115 42 B Page 35 of 47 Figure 30 Slide Module 115 42 L 195 Art No 1052929 ...

Page 36: ...60 1054179 1 Lubrication tube 61 1007437 1 O ring NBR 70 Shore A 4 1 50 X 70 1081065 1 Lubrication adapter long slide 80 737231 1 O ring NBR 70 Shore A 12 1 50 X 90 1031602 1 O ring NBR 70 Shore A 1 8 1 80 X 100 1028704 1 Lubrication nipple T 110 626059 1 Cylinder head screw galvanized M5 x 16 120 1019272 1 Cylinder head screw galvanized M6 x 30 130 58044 1 Hex socket set screw galvanized M6 x 10 ...

Page 37: ...June 2018 Translation of the original instructions Parts lists and drawings MAN_EN_1057398_Module115 42 B _R3b doc Module 115 42 B Page 37 of 47 Figure 31 Slide Module 115 42 L 300 Art No 1081043 ...

Page 38: ...Lubrication tube module 115 42 B 70 1021044 1 O ring NBR 70 Shore A 3 1 00 X 80 1413096 1 Lubrication adapter Module 115 42 B 90 1007437 1 O ring NBR 70 Shore A 1 8 1 80 X 1031602 1 O ring NBR 70 Shore A 1 8 1 80 X 100 1028704 1 Lubrication nipple T 110 626795 1 Cylinder head screw galvanized M5 x 14 120 1019272 1 Cylinder head screw galvanized M6 x 30 130 58044 1 Hex socket set screw galvanized M...

Page 39: ...June 2018 Translation of the original instructions Parts lists and drawings MAN_EN_1057398_Module115 42 B _R3b doc Module 115 42 B Page 39 of 47 Figure 32 Slide Module 115 42 B L 195 Art No 1305731 ...

Page 40: ... tube module 115 42 B 70 1021044 1 O ring NBR 70 Shore A 3 1 00 80 1413131 1 Lubrication adapter long carriage module 115 42 B L 300 90 1007437 1 O ring NBR 70 Shore A 4 1 50 100 1031602 1 O ring NBR 70 Shore A 1 8 1 80 110 1028704 1 T lubrication nipple type D4 120 626795 1 Cylinder head screw galvanized M5 x 14 130 1019272 1 Cylinder head screw galvanized M6 x 30 140 58044 1 Threaded pin galvani...

Page 41: ...June 2018 Translation of the original instructions Parts lists and drawings MAN_EN_1057398_Module115 42 B _R3b doc Module 115 42 B Page 41 of 47 Figure 33 Module 115 42 L 300 part no 1305752 ...

Page 42: ...70 732770 1 Clamping set 16 32 80 732294 1 Clamping set 20 38 90 734168 1 Clamping set 22 40 95 526735 1 Toothed disc AT5 20 2 incl clamping set 12 98 525983 1 Toothed disc AT5 20 2 incl clamping set 14 100 525984 1 Toothed disc AT5 20 2 incl clamping set 16 110 1005790 1 Toothed disc AT5 14 2 incl clamping set 10 120 1005756 1 Toothed disc AT5 14 2 incl clamping set 12 130 1025513 1 Belt gearbox ...

Page 43: ...une 2018 Translation of the original instructions Parts lists and drawings MAN_EN_1057398_Module115 42 B _R3b doc Module 115 42 B Page 43 of 47 Figure 34 Belt gearbox module 80 15 subassembly no 1000475 ...

Page 44: ...lastic cover 40 626037 1 Cylindrical screw DIN 912 M6x20 8 8 50 626244 1 Cylindrical screw DIN 912 M6x60 8 8 60 627215 1 Retention ring 70 1022199 1 Coupling Ø 16 75 1022203 1 Ring gear red 80 1022201 1 Coupling Ø 20 90 1022202 1 Coupling Ø 22 100 1006530 1 Sleeve 12 16 110 1007310 1 Sleeve 15 20 120 1008886 1 Sleeve 14 16 130 1022206 1 Sleeve 19 22 use depending on design Figure 35 Flange module ...

Page 45: ... of 47 7 9 Design specific assemblies components 7 9 1 Installation flange gearbox e g planetary gear type PLFE64 The following different drive sets for flange gearboxes may be used Designation Part No Drive unit 80 15 50 FLG 1059629 Figure 36 Installation flange gear example with drive set 1059629 Flanschgetriebe Drive unit Flange gears ...

Page 46: ... 9 2 Overview clamping elements Clamping element example type 105 Scaled drawing clamping element Clamping element Type L1 in mm L2 in mm Article number 16 0 16 220701 65 49 65 1062169 80 64 80 1021641 105 89 105 28674 115 99 115 1054491 140 124 140 220702 160 64 160 1039032 undrilled customer specific 1019192 Figure 37 Overview clamping elements ...

Page 47: ...014 on the harmonisation of the laws of the Member States relating to electromagnetic compatibility Directive 2014 35 EU of the European Parliament and of the Council of 26 February 2014 on the harmonisation of the laws of the Member States relating to the making available on the market of electrical equipment designed for use within certain voltage limits The technical documents were generated ac...

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