DE-STA-CO MDE Series Installation Manual Download

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INSTALLATION MANUAL

MDE-SERIES INDEX DRIVES MODELS

MDE600M
MDE700M
MDE900M

Summary of Contents for MDE Series

Page 1: ...INSTALLATION MANUAL MDE SERIES INDEX DRIVES MODELS MDE600M MDE700M MDE900M ...

Page 2: ...AND MONITORING INSTALLATIONS 20 4 9 WARNING DEVICES 20 4 10 TECHNICAL DATA 20 Recommended Oil and Quantity 21 Grease 22 5 TRANSPORT 22 5 1 TRANSPORTING MACHINE AND MACHINE PARTS 22 5 2 UNPACKING 23 5 3 HANDLING 23 Markings and Weight 24 Approved Transportation Equipment Procedures 24 Transportation Inside of Packaging 24 Table 2 Approximate weights of MDE models with reducer 24 Transportation Outs...

Page 3: ...nd erratic 43 8 5 SPARE AND WEAR PARTS 44 Spare Parts list 44 Input Oil Seal Replacement Consideration 44 Cam Follower Replacement Consideration 44 Input Shaft and or Cam Replacement Consideration 44 Follower Wheel and or Output Bearing Replacement Consideration 44 8 6 DISASSEMBLY 46 8 7 INSPECTION 46 8 8 OIL SEAL REPLACEMENT 47 Oil seal removal 47 Oil seal installation 47 8 9 CAM FOLLOWER REPLACE...

Page 4: ...nternet http www destaco com After Sales Service address camco destaco com europe destaco com Machine designation INDEX DRIVE MODEL Type designation MDE SERIES Serial No SEE NAME PLATE Year of construction 2015 Product No SEE NAME PLATE P O No Order No Sales DE STA CO Europe GmbH Hiroshimastraße 2 61440 Oberursel Germany Manufacturer DE STA CO Camco Products Industrial Motion Control LLC 1444 Sout...

Page 5: ... Automation division are divided into the following classes Index drive models In accordance with the Machinery Directive 2006 42 EC the above mentioned products are classified as incomplete machines according to Article 2g This results in the necessity to produce the technical documentation in accordance with Annex VII B and the declaration of incorporation in accordance with Annex II B Justifica...

Page 6: ...5 There are no elementary protection devices at the man machine interface ...

Page 7: ...e Define clear responsibilities and authorities for the operating and maintenance personnel Supplement the operating manual with rules derived from the national occupational health and safety and environmental protection regulations e g work organisation Instruct the personnel to observe the operating manual and its additions and check compliance from time to time Have one copy of the operating ma...

Page 8: ...hnical training know how and experience is able to assess the assigned duties and to recognise potential hazards Furthermore this person has know how of the applicable regulations Only qualified specialists or such persons considered by the owner to be capable are to be employed d Trained instructed persons are persons who have been instructed and possibly trained in the assigned duty and in the p...

Page 9: ...ged translation agency This operating manual was compiled with the greatest care Should you discover any gaps and or errors however please inform us accordingly in writing Your suggestions for improvements will help us in producing a user friendly operating manual Reorders and copyright Reorders and copyright Further copies of this operating manual can be ordered from the address shown under Ident...

Page 10: ... must be informed immediately Technically safe condition a Keep all safety and hazard signs on and around the machine complete and in a legible condition b Do not make any modifications attachments or alternations to the machine that could impair safety without consultation agreement with the manufacturer supplier This applies also to the installation and setting of safety devices and valves and f...

Page 11: ...equipment of the machine may only be carried out by an electrician or by trained persons under the instruction and supervision of an electrician For safety reasons the rules of electrical engineering must be observed f Work on gas and heating installations may only be carried out by appropriately qualified personnel g Only experienced and qualified personnel may be allowed to work on hydraulic and...

Page 12: ...m during all life phases of the unit 3 3 Symbols on the Machine Symbols on the machine Electric shock hazard 3 4 Personal Protective Equipment PPE Personal protective equipment PPE The personal protective equipment PPE described below must be provided by the machine owner and be worn by the responsible operating personnel when working with the machine Wear protective gloves Wear safety shoes Wear ...

Page 13: ...sing Weldment Cover Plate 02 Output Assembly Follower Wheel Dial Plate Output bearing 03 Input Assembly Cam Cam Shaft Reducer Mounting plate Gear motor with brake Figure 1 Unit 04 Center Bore Allows passage of wires robotics and various tooling through unit 05 Allows for Table Top or Trunnion optional mounting with mounting holes placed on front and bottom faces of housing 01 02 01 03 02 Figure 2 ...

Page 14: ...and for impairment to the machine and other assets The machine may only be operated for its intended when it is in a technically safe condition giving consideration to safety and the potential hazards in accordance with the operating manual Have all malfunctions remedied immediately in particular those which could impair safety The machine is intended exclusively for the purpose described in chapt...

Page 15: ...olely by the owner The intended use also includes observance of the operating manual and compliance with the inspection and maintenance conditions 4 3 Foreseeable Improper Use Foreseeable improper use Any use setting application or alteration of the unit beyond the stated terms in section 4 5 is defined as improper and prohibited ...

Page 16: ...15 4 4 Design and Components of the Machine Front and Top View A ...

Page 17: ...16 Section and Side View ...

Page 18: ... of Function The Mechanical MDE Series Indexer is a pre loaded right angle indexing table designed to precisely move heavy loads at a predetermined number of stations with zero backlash This machine is exactly defined as incompleted machinery that has no specific function output until incorporated into a complete machine Description of function 4 6 Places of Work of the Operating Personnel The Mec...

Page 19: ...rk is being carried out on the electrical equipment must if prescribed be isolated and secured to prevent restarting First check that the isolated parts are no longer live then earth and short circuit and isolate adjacent live parts d The electrical equipment of the machine must be inspected and checked at regular intervals Faults such as loose connections or scorched cables must be remedied immed...

Page 20: ...of the assemblies before starting the repair work d Lay and install hydraulic and compressed air lines correctly Do not confuse connections Fittings lengths and qualities of the hoses must comply with the requirements Noise a Soundproofing installations on the machine must be functional during operation b Wear the prescribed personal protective equipment ear protectors Oils greases and other chemi...

Page 21: ... e g have a second person standing by for a fast rescue 4 8 Safety and Monitoring Installations No safety or monitoring equipment is included with this unit All safety and monitoring installations as well as their legal compliance with relevant ordinances fall under the responsibility of the end user owner 4 9 Warning Devices No warning devices are included with this unit All warning devices as we...

Page 22: ...terfaces connections Electrical equipment Rated voltage 3 x 400 V 50 Hz N PE Control voltage 24 V Rated current SEE MOTOR NAME PLATE Installed load SEE MOTOR NAME PLATE Hydraulic equipment Recommended Oil and Quantity Lubricating oil should be high quality well refined petroleum oils or synthetic lubricants with extreme pressure additives They may be subjected to high operating temperatures so the...

Page 23: ...bserved 5 Transport Transport 5 1 Transporting Machine and Machine Parts The transport may only be carried out by personnel capable of carrying out such work as a result of their own know how and experience in the field of transport The machine and larger assemblies must be carefully attached and secured to lifting equipment Use only suitable lifting equipment and slings in a technically safe cond...

Page 24: ... with the applicable local regulations The machine requires an acclimatisation period of 24 hours in order to rule out malfunctions due to condensation moisture Remove any condensate formed Check the delivery condition of the installation 5 3 Handling Fixtures and Hoists Installation Attach eyebolts not supplied to points on MDE housing Attach hook to reducer Lift with long chains included angles ...

Page 25: ...arked and closed off Inspect package for any weak or damaged areas EXECUTION INDEXER REDUCER WEIGHT Kg MDE 600 SEWKHZ77 570 MDE 600 SEWKHZ67 570 MDE 600 NORDSK9042 655 MDE 600 NORDSK9032 605 MDE700 SEWKHZ87 770 MDE700 SEWKHZ77 730 MDE700 NORDSK9042 820 MDE700 NORDSK9032 770 MDE900 SEWKHZ97 1270 MDE900 SEWKHZ87 1130 MDE900 NORDSK9052 1270 MDE900 NORDSK9042 1180 Table 2 Approximate weights of MDE mo...

Page 26: ...n a safe pre assigned area marked appropriately Transportation Damage Inspect the following areas of the unit for any signs of damage after transportation Housing Assembly dents cracks bends leaks Output Assembly seal leaks dents looseness flatness a level should be fine in this application as a noticeable change in flatness due to damage is the measurement being observed not the function paramete...

Page 27: ...quate lighting in accordance with the ergonomic regulations 6 1 Installation and Connection Installation and connection Before the respective energy and media supplies are connected the corresponding shut off device must be closed and secured to prevent unauthorised opening Pay attention that there are no leaks after installation of the media connections Installation and adjustment instructions De...

Page 28: ... accessible Motor easily accessible Seal Integrity Ensure integrity of input and output assembly seals Lifting the unit introduces the hazard of falling crushing Ensure lifting area is clear of all but authorized personnel Lifting the unit introduces a hazard of free movement Move the unit at a slow deliberate pace Take care working with a hoist that does not have a brake as it will not lock in pl...

Page 29: ...nditions Retain enclosed space building garage doors remain closed etc as this can affect any adhesives to be set o Properly isolate protect seals from all preparation processes to prevent damage o Thoroughly clean base plate surfaces with neutral solvent Installing the Base Plate or Frame Transport base plate to installation surface slowly and deliberately with appropriate equipment Install base ...

Page 30: ... as once any adhesives set it will be much more difficult to properly align the unit 09 Use an electric pneumatic bolt gun to tighten the mounting bolts in a star pattern Do not tighten bolts in a sequential pattern as this can lead to cock eyeing 10 Use a large torque wrench with a long bar to apply finishing torques to the mounting bolts Manual Adjustment of Unit HAZARDS Unexpected Activation un...

Page 31: ...posed input shaft 07 Place lock nut followed by lock washer on proximity sensor switch 08 Screw the lock nut until halfway down the length of the proximity sensor switch 09 Place the proximity sensor switch face down in the slot of the bracket 10 Screw lock nut and lock washer on to end of proximity sensor switch protruding from the bracket 11 Adjust locknuts of proximity sensor switch until the s...

Page 32: ...rating distances Tooling presents the hazard of stabbing puncture Make sure personnel are trained and aware of safe operating distances Tooling presents the hazard of ejected objects Make all tooling is securely fastened to the unit before initiating operation Tooling presents the hazard of exposing personnel with parts live under fault by pinching pulling cables and control feeds Please make sure...

Page 33: ...sed on the machine product change A product change necessitates various retooling and or modification measures The following operations have to be performed Installation of Additional Dial Plates and Tooling It is highly recommended that additional mounting plates be installed using only the supplied fixture holes This is to ensure that concentricity and accuracy are maintained Installation of Saf...

Page 34: ...t colors or highly visible warnings are present at sharp edges and circuit boxes etc At time of activation the motor is running smoothly consistent speeds frequency noise no smell of burning Unit runs quietly relatively Gear motor input values agree with the Type Plate Configuring the Unit Zero Point A zero point marking can be applied to the unit output dial and housing if needed for reference Ho...

Page 35: ... with reversing directions is a variation of the standard mode but the output direction is reversed after each cycle This application requires two sensors to properly stop the indexer camshaft when moving in opposite directions It may be necessary to advance the mounting position of the sensor to assure the indexer stopping point See section 7 2 1 Set Proximity sensor Switch Brake Motor Use and Wi...

Page 36: ...rational and active Once all hazards have been addressed and visual inspection passed proceed with normal commissioning procedures 7 Operation 7 1 Operating and Display Elements Operating and display elements The following hazards may be present during this Life Phase of the unit HAZARDS Interference Serious to fatal injury can result from rotating parts striking loading equipment tooling due to i...

Page 37: ...oximity sensor Switch 1 and 2 switch option The single 1 proximity sensor switch Item 41 is attached to the side opposite reducer The switch is set as shown and the indexer should stop in the center of the dwell key pointing up If the key does not point up when the indexer is stop then loosen the two screws that hold the switch bracket in place and remount the bracket into a new location There are...

Page 38: ...etting maintenance and inspection operations prescribed in the operating manual including information on the replacement of parts parts of the equipment Observe the specified intervals This work may only be carried out by specially trained and authorised specialist personnel In order that safety can be assured during work on the machine or on the technical installation all types of power supply el...

Page 39: ...chine switched off and secured to prevent restarting The machine must be kept clean at all times during operation This means also keeping the floor clean clearing away packaging materials chemicals etc and not leaving tools lying around Do not use compressed air to clean the machine This can result in increased wear and malfunctions Use only a soft brush in combination with a vacuum cleaner for cl...

Page 40: ...substances and ensure adequate ventilation There is a risk of fire and explosion The spare and wear parts indicated in the technical documentation must be replaced immediately in the event of damage Maintenance overview Various inspection and maintenance operations have to be carried out during the period of machine operation The corresponding intervals to be observed are indicated in the maintena...

Page 41: ...peration Interval Remarks Warning pictograms Inspect for damaged or missing pictograms Visual inspection P T Electrical equipment Inspect cables and leads for Secure connection damage marking Inspect the protective earth system for continuity Inspect actuators for damage marking Visual inspection P t Hydraulic equipment Oil level visible in sight glass Item 6 Visual inspection P T ...

Page 42: ... or every 5 years whichever occurs first It may be necessary to change the oil more often if enviromental conditions are severe such as rapid rise and fall in temperature of the indexer housing which is accompanied by sweating of the inside walls with a resulting formation of sludge The magnetic drain plug should be visually inspected at oil change time for metallic chips that might indicate failu...

Page 43: ...ve manufacturer or technician for repairs Symptom Indexer appears inaccurate 1 Check if unit stops in dwell See the assembly drawing for your unit for keyway position in dwell Also refer to cycle cam and limit switch function in this manual 2 Is the output shaft backlash free in dwell Be sure to disconnect all other devices from the indexer output including an overload clutch All indexers must be ...

Page 44: ...preload 9 Check if there is sufficient oil in the unit Is oil used consistent with CAMCO specifications Symptom Premature wear of cam followers 1 Actual forces on the unit could be greater than calculated due to loose input or output 2 Lack of oil or wrong oil used See Lubrication section of Index Drive Service 3 Frequent or severe overloads 4 Improper input systems where there is not a constant v...

Page 45: ...tails Input Shaft and or Cam Replacement Consideration The assistance of a CAMCO trained serviceman is recommended Follower Wheel and or Output Bearing Replacement Consideration The assistance of aCAMCO trained serviceman is recommended BEFORE STARTING CAMCO uses either Red Perma Lok HM118 or Green Perma Lok HM160 to secure most screws and set screws Exceptions are removable covers etc If you enco...

Page 46: ...NTS FOR TIGHTENING SCREWS The included table provides torque specification for Metric Socket Head Cap Screws SHCS Metric Socket Head Cap Screw Thread Size Torque Nm M6 16 M8 39 M10 76 M12 136 M14 210 M16 325 M20 640 Table 3 Required torque tightening values Table 1 lists the required torque tightening values for a Metric12 9 grade Torque values are for lubricated threads coated only with a residua...

Page 47: ...o rotate the indexer Some safe means for running the motor at extremely low speeds is needed The motor brake if present must be released using electric power Use extreme caution when operating a live motor during inspection and repair Manually rotating the motor An alternative to using a live powered motor is to turn the motor by turning the motor fan Make sure the motor brake is electrically rele...

Page 48: ...vice Manual 6 Replace the cam if imperfections are noted This is best done by CAMCO personnel 7 Replace the follower wheel if holes are oversized This is best done by CAMCO personnel 8 7 Oil Seal Replacement CAMCO recommends replacing the input oil seals Item 12 anytime the input is disassembled regardless of whether they are damaged or not After being in service for sometime the sealing lip can b...

Page 49: ...dge face to avoidcocking the seal in the bore This also positions the seal correctly on the shaft 9 When an installation tool cannot be manufactured install the seal by tapping uniformly around the seal with a soft hammer Avoid cocking the seal and make sure the face of the seal is square to the bore 8 8 Cam Follower Replacement Cam follower cartridge removal If the machine builder has provided ac...

Page 50: ...the about one half the length of the lower portion of the hole Check the follower holes for roundness These holes should be round within 013 TIR of a mm to permit reuse of the follower wheel These holes may be worn out due to overloads Do not use a follower wheel with oversized or egg shaped cartridge holes The replacement parts will fail prematurely Cam follower removal from cartridge Clamp the u...

Page 51: ...not rush the process just proceed quickly and with sure movements 1 2 If the cam follower cartridge cannot be seated by using a twisting motion of the hand and pushing upward use a soft faced hammer to drive the cam follower cartridge into the follower wheel 1 3 If the hammer does not seat the cam follower cartridge use a hydraulic jack to push the cam follower cartridge into the follower wheel Ma...

Page 52: ...s 3 The removal of springs or parts under mechanical load should be performed with particular care so that the mechanical energy stored in these parts does not result in injuries 4 Batteries and rechargeable batteries that may be used in the installation must be disposed of separately in accordance with the local waste disposal regulations 5 Furthermore the information on outsourced parts indicate...

Page 53: ...52 Store the machine only in dry rooms 9 3 Disposal Ensure a safe and environment friendly disposal of the materials used Observe prevailing national regulations ...

Page 54: ...53 10 ANNEX Declaration of Incorporation ...

Page 55: ...54 NORD DRIVESYSTEMS ...

Page 56: ...55 ...

Page 57: ...56 SEW EURODRIVE ...

Page 58: ...57 TL6615 EXTRACTION TOOL PAGE 1 OF 2 ...

Page 59: ...58 TL6615 EXTRACTION TOOL PAGE 2 OF 2 ...

Page 60: ...this Directive are applicable and observed Annex I Articles 1 1 3 1 1 5 1 1 6 1 3 1 1 3 2 1 3 4 1 5 4 1 6 1 1 6 4 1 7 2 1 7 3 1 7 4 3 The technical documents in accordance with Annex VII B of the Machinery Directive 2006 42 EC have been drawn up for the above mentioned incomplete machine The following harmonised standards or parts thereof were applied EN ISO 12100 1 2003 A1 2009 EN ISO 14121 1 200...

Page 61: ...incorporated complies with the provisions of Directive 2006 42 EC Name and address of the person authorised to compile the technical documentation in accordance with Annex VII B Lou M Wozniak see company address above Name Address Function of the signatory Gary Labadie Product Manager Name position ...

Page 62: ...www destaco com DE STA CO Europe Germany 49 6171 705 0 europe destaco com DE STA CO Asia Thailand 66 2 326 0812 info destaco com DE STA CO South America Brazil 0800 124070 samerica destaco com This publication is for information purposes only and should not be considered a binding description of the product except is confirmed in writing by DE STA CO CAMCO Products DE STA CO 2015 All rights reserv...

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