Operating Manual - reiter

Operating Manual
Electrical Reciprocator LH93
Product No.: S-LH93GB (Translation)
Issue:
07/13 - 2
REITER GmbH + Co. KG
Oberflächentechnik
Berglenstraße 23 - 25
D-71364 Winnenden
Telephone: +49 (0) 71 95 / 185 - 0
Telefax:
+49 (0) 71 95 / 185 - 30
Internet:
www.reiter-oft.de
Contents of the Operating Manual
Chapter 1
General
Chapter 2
Safety Regulations
Chapter 3
Technical Data
Chapter 4
Transport
Chapter 5
Function Description
Chapter 6
Installation
Chapter 7
Commissioning and Operation
Chapter 8
Maintenance
Chapter 9
Spare Parts
Chapter 10
Appendix (not assigned)
S-LH93gbDB
07/13 - 2
1General
Table of Contents
1.1Introduction......................................................................................................................... 1
1.2 Operating Area.................................................................................................................... 1
1.3Guarantee........................................................................................................................... 2
1.4Copyright............................................................................................................................ 2
1.1Introduction
This operating manual is intended to be read, understood and observed in all points by those responsible for the installation. The same is valid for any personnel working at the installation.
This operating manual is intended to ensure trouble-free operation of the installation.
Should there be any problems please contact our service department or your local dealer which will
be pleased to assist you (see chapter 9 “Spare parts“).
The operator is responsible for the correct installation, operation and maintenance of the equipment.
Should you intend to use the equipment in a manner different to the intended one please apply for
our approval.
The instruction manual must be completed with any local valid safety rules and environmental protection laws.
The operating manual on hand only refers to the “Electrical Reciprocator LH 93“.
We reserve the right to alterations in drawings and specifications necessary for the technical improvement of the machine.
1.2 Operating Area
The reciprocators Model LH93 are designed to be used within automatic paints installations. The
reciprocator is part of the entire paint installation system which has to be designed to fulfil all safety
regulations and paint process regulations according to the local official laws.
If subassemblies are applied to the reciprocator we want to point out the design of this subassemblies has to fulfil all local safety regulations.
Reiter can not be held responsible if applied subassemblies are against a.m. regulations.
The operating area is definitely restricted to the specified datas on the technical data sheet.
In case of doubts we recommend to contact REITER GmbH + Co. KG Oberflächentechnik.
S-LH93gb01
07/13 - 2
Page 1 of 2
1General
1.3Guarantee
Therefore, it is recommended to read this operating manual carefully before start-up, as we cannot be held liable for damage or malfunctions resulting from the non-observance of this operating
manual.
During the guarantee period repair work and changes only may be carried out by our assemblers
or with our consent.
The system is designed only for the use according to the operating area described in chapter 1.2
„Operating Area“.
Any other use is considered improper and REITER can not be held liable for any possible damage.
1.4
Copyright
The copyright for this operating manual is retained by REITER GmbH + Co. KG Oberflächentechnik. This operating manual is intended for personnel involved in installation, operation and supervision. The operating manual include regulations and technical drawings which may not be copied,
distributed, used for commercial purpose or given to others, either in full or in part.
REITER GmbH + Co. KG
Oberflächentechnik
Berglenstraße 23 - 25
D-71364 Winnenden
S-LH93gb01
Telephone: +49 (0) 71 95 / 185 - 0
Telefax:
+49 (0) 71 95 / 185 - 30
Email:
[email protected]
07/13 - 2
Page 2 of 2
2
Safety Regulations
Table of Contents
2.1
2.1.1
2.1.2
2.2
Explanation of symbols and special directions................................................................... 1
Symbol of working safety.................................................................................................... 1
Directions for “Attention“..................................................................................................... 1
Direction for working safety................................................................................................ 1
2.1
Explanation of symbols and special directions
2.1.1
Symbol of working safety
!
2.1.2
Directions for “Attention“
Attention!
2.2
This symbol accompanies all special directions for working safety
given in this operating manual, the non-observance of which may endanger life and limb. Observe these directions and take special care in
these cases. Ensure all other operators are informed of these special
directions. In addition to the special directions given in this operating
manual, the generally valid regulations for safety and prevention of accidents are also to be observed.
This warning is given in this operating manual at points which are to
be given special attention in order that guidelines, regulations, special
directions and proper work procedures are observed, and to prevent
damage or destruction of the machine and/or other parts of the plant.
Direction for working safety
This machine can be hazardous if not used as described in the instruction manual.
We recommend to install a warning sign listing the important operating and safety rules. The sign
should be in an understandable language for the operators and installed visible in the vicinity of the
spray booth.
The following directions for working safety are to be given particular attention:
This machine has been constructed according to advanced technological standards and is operationally reliable. Danger may, however, result from the machine if operated incorrectly by untrained
persons or used for purposes other than those for which it was constructed.
S-LH93gb02
07/13 - 2
Page 1 of 2
2
Safety Regulations
•
It is necessary that all persons assigned with the installation, dismantling and re-installation
(inspection, maintenance, repairs) of the machine at the user’s plant, read and understand the
entire operating instructions, and the chapter 2 „Safety Regulations“ in particular. The user is
recommended to have this confirmed in each case in writing.
•
The machine is designed only for the application specified in Chapter 1.2 „Operation Area“.
Any usage not covered in these specifications is considered contrary to regulations. •
The manufacturer is not liable for damage resulting from improper use; the user carries the risk
for this alone.
•
Proper use also includes the observance of prescribed conditions for installation, dismantling
and re-installation, start-up procedures, operation and maintenance.
•
The machine is to be serviced and repaired by authorised, trained and instructed personnel
only. This personnel must have been specially instructed regarding occurring risks.
•
Responsibility for installation, dismantling and re-installation, start-up procedures, operation
and maintenance must be clearly defined and observed in order to prevent responsibilities
concerning safety aspects from becoming unclear.
•
The switch-off procedures provided in the operating instructions are to be observed for all
procedures having to do with installation, dismantling and re-installation, start-up procedures,
modification, adaptation and maintenance.
•
Any manner of working which impairs the operating safety of the machine is to be stopped.
•
The operator is also to ensure that no unauthorized persons operate the machine.
•
Unauthorized modifications or changes which impair the operating safety of the machine are
not permitted.
•
All maintenance work or repairs on the machine are to be carried out only when the machine is
not in operation.
•
Before maintenance work or repairs are carried out on the machine, the drives and accessory
parts of the machine are to be ensured against being switched on unintentionally.
•
Before starting up after repairs, ensure that all protection devices are mounted. Protection devices are to be removed only when the machine is not in operation.
•
All safety precautions used are to be tested after corresponding electrical installations or repairs (e.g. earthing resistance).
•
The locally valid regulations for safety and prevention of accidents are valid for the operation of
the machine under all circumstances.
•
International, national and company safety regulations are to be observed for the installation
and operation of the machine, as well as the procedures involved in maintenance, repairs and
cleaning.
S-LH93gb02
07/13 - 2
Page 2 of 2
3
Technical Data
Table of Contents
3.1
3.1
Technical Data.................................................................................................................... 1
Technical Data
Initiator
control
IP54
Initiator
control
EEx
9 - 48
9 - 48
9 - 48
9 - 48
9 - 48
Ultimate load
on carriage (kg)
15
15
15
15
15
Drive output (kV)
0,75
0,75
0,75
0,75
0,75
EEx
EEx
Stroke lenght
Stroke speed
Drive
Potentiome- Programmed
ter control
control
EEx
EEX
1000 - 2500 mm
Power supply
Electrical
protection
Potentiometer control
IP54
230/400 V, NE/PE, 50 Hz
IP54
EEx
IP54
Three-phase current gear motor, frequency regulated
Clamping device
for bracing tube
Standard: 30 mm diameter
Control 1 unit,
product no.:
14 0056 0
14 0061 0
14 00058 0
14 00063 0
Control 2 units,
product no.:
14 0057 0
14 0062 0
14 00041 0
14 00064 0
S-LH93gb03
07/13 - 2
Page 1 of 1
4Transport
Table of Contents
4.1Packing............................................................................................................................... 1
4.2
Intermediate storage........................................................................................................... 1
4.3
Damage during transport.................................................................................................... 1
4.1Packing
Type of packing depends in part on the distance the machine is to be shipped. The machine is
transported on square strips of timber without crate if not agreed otherwise. The designations and
graphical symbols affixed to the machine are to be observed!
4.2
Intermediate storage
If the machine is not to be installed directly after delivery, it must be stored properly in a protected
place. Ensure proper covering for storage.
4.3
Damage during transport
Possible transport damage and/or missing parts are to be reported immediately in writing.
S-LH93gb04
07/13 - 2
Page 1 of 1
5
Function Description
Table of Contents
5.1Design................................................................................................................................. 1
5.2
Function (Mechanic)........................................................................................................... 1
5.1Design
The reciprocator consists of the following functional assemblies:
•
gearbox with driving wheel
•
deflection wheel - bottom
•
roller chain with chain tensioner
•
support tube with precision guide rail and carriage
•
limit switches
•
clamping unit for support tube
•
analogue encoder
•
covers
•
separate control cabinet
All assemblies are mounted on the support tube giving one reciprocator. Mandatory subassemblies
must be mounted on the corresponding holder.
5.2
Function (Mechanic)
The carriage, to which the spraying elements are fixed by corresponding holders, rolls up and down
alongside the guide rails.
The carriage is driven by a reversible gearmotor with driving wheel through a roller chain whereas
the carriage is mounted.
The lower chain wheel is used for the deflection of the chain wheel. The reversing point can be adjusted by the movement of proximity switches or by the analogue stroke control potentiometers at
the control cabinet.
The speed of the gearmotor, and thus the speed of, is continuously variable by a potentiometer in
conjunction with a frequency converter.
S-LH93gb05
07/13 - 2
Page 1 of 1
6Installation
Table of Contents
6.1General............................................................................................................................... 1
6.2
Provisions on site and special notes................................................................................... 1
6.1General
The setting up and installation of the machines should be carried out only by trained personnel.
We can not be held liable for any damage caused by a installation which not carried out according
to this manual.
6.2
Provisions on site and special notes
Set up conditions:
•
Electric power supply
•
Safety barrier
•
Air supply (if required)
Additional information
The reciprocator is built in different types which are according to the requirements of the customer
and specified for each project.
•
As a assembly unit mounted outside on a paint booth wall.
•
As standard with support tube to be fixed on the floor.
•
As moveable unit with fixable rollers.
During the installation and assembly of the machine it has to be proceeded with care to secure the
correct set up without any defects.
Mounting of the painting elements should be done after the first movement test of the reciprocator.
S-LH93gb06
07/13 - 2
Page 1 of 1
7
Commissioning and Operation
Table of Contents
7.1
Power supply and commissioning...................................................................................... 1
7.2Control................................................................................................................................ 1
7.2.1General............................................................................................................................... 1
7.2.2
Proximity switch control...................................................................................................... 2
7.2.2.1General............................................................................................................................... 2
7.2.2.2Commissioning................................................................................................................... 3
7.2.2.3Operation............................................................................................................................ 4
7.2.3
Potentiometer control ......................................................................................................... 5
7.2.3.1Commissioning/adjustment................................................................................................. 5
7.2.3.2 Preadjustments (before start of reciprocator) .................................................................... 6
7.2.3.3 Start of reciprocator ........................................................................................................... 7
7.2.3.4Operation............................................................................................................................ 7
7.2.3.5Function.............................................................................................................................. 8
7.2.3.6 Reversing procedure – Hoisting path................................................................................. 8
7.2.4
Programmed control........................................................................................................... 9
7.3
Trouble shooting ................................................................................................................ 9
7.1
Power supply and commissioning
!
The reciprocator should be connected by a specialist according to the
circuit diagram and in keeping with the pertaining electrical standards.
It is particularly essential to observe the requisite statutory to observe
the rules and remarks.
It is only allowed to switch on the reciprocator if the cover is closed
and it is ensured that moving parts are protected in a suitable way.
The reciprocator must be connected by a electrical specialist according of the circuit diagram and
in keeping with the pertaining electric standards.
Attention!
Information for the start up and the handling of the control can be
found under chapter “control”
7.2Control
7.2.1General
The reciprocator control is built in different types which are according to the requirements of the
customer and specified for each project. All controls include the identical basic functions and features.
The basic functions are:
•
control of stroke length
•
control of stroke speed
S-LH93gb07
07/13 - 2
Page 1 of 9
7
Commissioning and Operation
For the handling we separate between:
•
proximity switch control (see 7.2.2)
•
potentiometer control (see 7.2.3)
7.2.2
Proximity switch control
7.2.2.1General
Functions:
The gun stroke can be manually adjusted by moving the proximity switches to the necessary position.
At the control cabinet the carriage speed is adjusted by a potentiometer.
!
Adjustment of proximity switches is only allowed when the machine is
not moving!
Adjusting stroke:
• Switch off reciprocator.
•
Remove cover.
•
Loose fixing screws at proximity holder.
•
Move holder with proximity switch to correct position.
•
Tighten fixing screw. Pay attention to correct position of holder (distance to signal flag approx.
4 mm must be maintained). The stroke length will be changed 1:1 to the movement of the
proximity switch.
•
Put cover into position.
•
Switch on reciprocator.
Note:
At the lower proximity switch a distance plate is mounted which ensures the minimum stroke.
Stroke speed is adjusted with a potentiometer at the control cabinet. Correct values between: approx. 20 - 100 %
The stroke speed can be varied while the reciprocator is running.
Attention!
S-LH93gb07
This system has no stroke speed compensation.
07/13 - 2
Page 2 of 9
7
Commissioning and Operation
Proximity control for 1 reciprocator
Potentiometer for
stroke speed
Double functions:
•Alarm signal for Frequency converter
•Button to move from upper end position
Reciprocator ON
Reciprocator OFF
Signal - Main
switch ON
Emergency Stop
Main switch
7.2.2.2Commissioning
First Start
Check direction of motor or carriage and test function of proximity switches and limit switches.
Action
Move upper and lower proximity switch to approx. 250 mm distance to the max. possible positions
in up and down direction.
•
Turn main switch to (Q1) ON
•
Adjust potentiometer (R1) to approx. 25 %
•
Start reciprocator for some moments
During the start check direction of carriage. After the start button has been pressed the carriage
must always move upwards. If this not happens change direction of motor by switching the phases.
S-LH93gb07
07/13 - 2
Page 3 of 9
7
Commissioning and Operation
Check function of proximity switches for reversing points
After the correct setting of the motor direction start reciprocator again and – with low speed – let
the carriage move to the upper proximity switch.
Reciprocator must reverse at this point!
If it’s not reversing check function of proximity switch.
Proceed equal for lower proximity switch.
Check function of limit switches
The limit switches interrupt after actuation the control release and stop the movement of the carriage. This function has to be checked at low speed with a tool manually.
Note
If the upper limit switch will be actuated the movement of the carriage will stop. In this situation the
carriage must be below the lower proximity switch using button H4/S3.
7.2.2.3Operation
•
If the function of the control has been checked and the reciprocator works correctly the application equipment can be mounted.
Attention!
!
Do not exceed max carriage work load.
Adjusting of stroke only permitted when reciprocator is switched off.
•
Mount covers.
•
Mount area protection units to prevent danger to working persons caused by subassemblies.
•
Start reciprocator at low speed and small stroke to ensure that no collision occurs by the moving parts.
•
Adjust stroke to maximum and increase speed slowly to 100 %. Check limit switch situation.
•
At max. speed the carriage must reverse approx. 40 - 50 mm in front of the limit switches.
•
Readjust limit of proximity switches if necessary.
S-LH93gb07
07/13 - 2
Page 4 of 9
7
Commissioning and Operation
7.2.3
Potentiometer control
7.2.3.1Commissioning/adjustment
For correct function it is inevitable that the electrical wiring has been done correctly according to
wiring diagram.
1.) Testing control to be set up correctly.
Activities
- Switch on control
- Set potentiometer for stroke speed to 30 %
- Set potentiometer for lower reversing point to 20 %
- Set potentiometer for upper reversing point to 80 %
Attention!
Signal lamp for overlap should not be on !!
- Start reciprocator
After the start button has been pressed the carriage must always move upwards. If this not
happens change direction of motor by switching the phases.
If the set up has been correct the carriage of the reciprocator will move at the set speed of 30
% slowly up and down.
2.) Set value potentiometer – check function!
a) Stroke speed
The function is correct if by turning the potentiometer to the right the speed will increase
and moving the potentiometer to the left the speed will reduce.
b) Upper reversing point and lower reversing point
The function is correct if the setting works like:
- turning left = reversing point lower
- turning right = reversing point upper
Note
At this test the setting of 20 % for the lower reversing point and 80 % for the upper reversing point
should not be exceeded. Also ensure that a minimum lift is maintained in order to prevent overlap
function.
S-LH93gb07
07/13 - 2
Page 5 of 9
7
Commissioning and Operation
3.) Check overlap function (see chapter “function”)
Activities
- Switch on control
- Potentiometer for lower reversing point is set to 20 %
- Potentiometer for upper reversing point is set t. 80 %
a.) Turn potentiometer for lower reversing point slowly right until signal lamp overlap is activated.
Turn back potentiometer.
Signal lamp will turn off.
b.) Turn potentiometer for upper reversing point slowly left until signal lamp overlap is activated.
Turn back potentiometer.
Signal lamp will turn off.
c.)Adjusting reversing points and speed compensation see chapter “function”.
Above mentioned adjustments are necessary after or at:
- initial start up of the system
- exchange of control board
- exchange of analogue encoder
- changing of roller chain by maintenance or repair work
- changing of work load at carriage
7.2.3.2 Preadjustments (before start of reciprocator)
•
set value of lower reversing point 20 %
•
set value of upper reversing point 80 %
•
set value of stroke speed 50 %
•
trimmer-adjustment at the control board:
Overrun compensation
vmax
vmin
Reversing points
below
above
Poti
S-LH93gb07
07/13 - 2
Page 6 of 9
7
Commissioning and Operation
•
trimmer 1 at the left stop
•
trimmer 2 at the left stop
•
trimmer 3 at “10.00 o clock” position
•
trimmer 4 at “14.00 o clock” position
7.2.3.3 Start of reciprocator
Activities
a.) Mark reversing points at reciprocator (both approx. 50 - 60 mm before stroke limit).
b.) Start reciprocator: At this situation the reversing points must be significantly before the marks.
c.) Increase stroke speed slowly to: 60 - 70 - 80 - 90 - 100 %.
The stroke will increase simultaneously with the speed in upper and lower direction. At max.
speed the stroke limit marks should not be reached.
d.) Set value potentiometer for lower reversing point (LRP) and upper reversing point (URP) slowly to maximum value.
LRP - to 0 %; URP - to 100 %
With this setting the marked reversing points should not be overrunned.
e.) Set up compensation.
- Reduce set value for carriage speed to 40 % (stroke will become shorter).
- Mark additionally the reversing points of shortened stroke.!
- Return set value for carriage speed to 100 % (stroke will become longer).
- Turn Trimmer 1 slowly into right direction (stroke will become shorter) until stroke length will
be identical with the last marked reversing points.
f.) Set up max. possible stroke length (30 - 40 mm in front of the limit switch).
Turn slowly trimmer 3 to the right (for LRP) and trimmer 4 (for URP). The adjustment of reversing points will be completed.
Note
Turn trimmers only in small steps as the control will be very sensitive at the final area of the stroke.
7.2.3.4Operation
•
If the function of the control has been checked and the reciprocator works correctly the application equipment can be mounted.
Attention!
Do not exceed max carriage work load.
•
Mount covers.
•
Mount area protection units to prevent danger to working persons caused by subassemblies.
•
Start reciprocator at low speed and small stroke to ensure that no collision occurs by the moving parts.
S-LH93gb07
07/13 - 2
Page 7 of 9
7
Commissioning and Operation
7.2.3.5Function
The lower and upper reversing point, as well as the hosting speed, are adjusted with the set-point
potentiometers at the control cabinet.
The reversing point adjustment as well as the adjustment of the stroke speed can be carried out
during operation.
Basic potentiometer position at maximum lift for the lower reversing point at the left stop, and the
potentiometer for the upper reversing point at the right stop.
Basic position:
V min. left stop
V max. right stop
When short lifts are involved it is necessary to note that there must be a minimum lift of at least 400
mm in conformity with the difference of the two potentiometer setting values. Id this minimum difference no longer exists (e.g. when the setting values are identical or even exceed each other), then a
so-called state of „overlap“ is created and the control will no longer operate properly.
This condition is indicated by the red LED and the outer signal lamp. The control operates normally
again as soon as the minimum difference is reset.
When the hoists are set into operation for the first time it is necessary to adjust the hoist control
with the actual value transmitter.
Adjustment is completed when the final carriage load has been established, and after the frequency converter has been adjusted to correct hoist operation.
7.2.3.6 Reversing procedure – Hoisting path
The entire hoist path is the result of the adjusted spacing of the two reversing points, plus the
length of the low level after-run (ramp) adjusted on the controller.
Different hoisting speeds produce differing low-level after-run paths (ramp length).
Maximum hoisting speed results in the longest after-run path (ramp length) of the hoist carriage,
measured from the electric change-over point to the actual reversing point of the hoist carriage.
The integrated after-run correction minimizes the deviation.
Note
Changes of the load or of the controller setting may make readjustment necessary. This may happen when the displacement pick-up and the pc-card are exchanged.
The setting of the control is correct when, at maximum hoist path setting, hoist carriage reversal
takes place approximately 30 to 40 mm before the stop is reached.
It is impermissible to allow the hoist carriage to hit the end stops.
Controller release is interrupted after actuation of the limit switches that have been incorporated to
safeguard the end positions. The hoist will no longer move.
S-LH93gb07
07/13 - 2
Page 8 of 9
7
Commissioning and Operation
7.2.4
Programmed control
Is carried out by the company Reiter.
7.3
Trouble shooting
Possible errors, reasons and solutions
1.) Carriage is moving unsmooth at reversing points
Possible reasons:
a) chain tension not sufficient
b) set up of deceleration and acceleration time at frequency converter not correct.
c) play within guide at carriage
d) play at the connection between driving wheel at gear box and actuation shaft
Solutions:
a) tension chain (see chapter 8 “chain tensioning”)
b) change set up (see manual frequency converter)
c) replace driving wheel and actuation shaft
2.) Loud moving noise at the reciprocator
Possible reasons:
a) dry operation of chain
b) damaged ball bearings at the moving wheels; actuations shaft or at the guiding elements of
the carriage.
c) insufficient oil level at gear box.
d) touching of holders or subassembly on the cover or reciprocator tower.
Solutions:
a) lubricate chain (see chapter 8 “lubrication and maintenance of chain drives”)
b) replace defect ball bearings
c) check oil level at gear box (see chapter 8)
d) readjust subassemblies or holders
S-LH93gb07
07/13 - 2
Page 9 of 9
8Maintenance
Table of Contents
8.1
8.2
8.2.1
8.3
8.3.1
8.4
8.4.1
8.4.2
8.5
8.6
8.7
8.1
Lubrication and maintenance of chain drives..................................................................... 1
Rail guide............................................................................................................................ 3
Lubrication and maintenance.............................................................................................. 3
Lubrication points and maintenance overview – Encoder.................................................. 4
Tensioning of encoder chain............................................................................................... 5
Lubrication points and maintenance overview – Proximity switch...................................... 6
Pulse generator – Removing and Mounting....................................................................... 7
Justification of the proximity switch..................................................................................... 7
Lubrication points list.......................................................................................................... 8
Chain tension...................................................................................................................... 9
Lubrication and maintenance of the gear box................................................................... 10
Lubrication and maintenance of chain drives
It is possible to use solid lubricants for the chain drives.
Solid lubricants are:
•
Colloidal graphite
•
Fine graphite for coarse drives
•
Molybdenum sulphide (MoS2)
The use of a spray for the chains, no matter what kind, is not supported by REITER GmbH + Co.
KG Oberflächentechnik. REITER GmbH + Co. KG Oberflächentechnik must be consulted first
before using a spray.
Manual Lubrication
The lubricant is applied between the inner and outer plates of the chain with an oilcan or on the
inside of the chain lustrum with a brush. A chain that is lubricated periodically should be cleaned
with oil- and dirt dissolving cleaning agents first before lubrication.
A spray can is suited for manual lubrication on open chain drives. The lubrication can be done
without having to disassemble the chain. With help of a small extension straw a well-aimed and
economical application is possible. The spraying jet should be aimed between the inner and outer
plates so that the lubricant can penetrate the chain links.
When greasing the chains it is recommended to lay them in heated, liquefied grease. The chain
should stay in the grease until it has reached the same temperature as the grease and air bubbles
are no longer rising. Then the chain links are filled sufficiently with grease.
The grease has to be heated in a container which is placed in warm water. Heating grease over an
open flame will lead to overheating of the grease and the lubrication ability will be decreased.
S-LH93gb08
07/13 - 2
Page 1 of 10
8Maintenance
Lubricating intervals are dependent on the conditions of operation and vary greatly. It is therefore
difficult to specify an exact lubricating schedule.
For operation in enamelling lines or similar, the lubricant may loose its lubricity relatively quickly
due, for example, to the evaporation of solvents.
In any case, the operator must ensure that the lubricating intervals are short enough to ensure sufficient lubrication of the chain drives and to prevent dry running.
In addition to routine lubrication, the chain slack and the sprockets must be checked on a regular
basis.
Within the first 3 month after commissioning of the system the chain
slack must be checked once a week.
Attention!
The slack of the return strand should not be greater than 2 % of the length of the return strand.
Otherwise it needs to be tensioned.
To recognize when the chain needs to be replaced the chain manufacturers recommend the following method:
The wearing limit is established by compared measurements.
Therefore an control length of 34 increments (see spread sheet) is compared with the stretched
chain. If there are 33 or less increments within the control length, the chain must be replaced.
Oscillating chains must be measured at the area stressed by the reversing.
p
p x 34 increments = control lenght
33 and less increments, replace chain
Increments
S-LH93gb08
8 mm
original lenght p
(mm)
control lenght
(mm)
8
272
3/8“
9,525
323,9
1/2“
12,7
431,8
5/8“
15,875
539,8
3/4“
19,05
647,7
1“
25,4
863,6
07/13 - 2
Page 2 of 10
8Maintenance
8.2
Rail guide
8.2.1
Lubrication and maintenance
The usual regulations for roller bearings apply. Conventional roller bearing grease may be used;
however, different brands should not be mixed.
Lithium soap grease of consistency class NLGI2, DIN 51 818 may be used for roller bearing guides
subject to normal wear.
Lubricate with a grease gun until lubricant is exuded.
Lubricating intervals are dependent on the conditions of operation and vary greatly. It is therefore
difficult to specify an exact lubricating schedule.
For operation in enamelling lines or similar, the lubricant may loose its lubricity relatively quickly
due, for example, to the evaporation of solvents.
In any case, the operator must ensure that the lubricating intervals are short enough to ensure sufficient lubrication of the bearings.
Attention!
Ensure that the guide elements are kept clean and that mechanical
damage does not occur.
Compact guide unit
S-LH93gb08
07/13 - 2
Page 3 of 10
8Maintenance
8.3
Lubrication points and maintenance overview – Encoder
S-LH93gb08
07/13 - 2
Page 4 of 10
8Maintenance
8.3.1
Tensioning of encoder chain
Tools required:
2 off spanners 17 mm
•
Loosen lock nut (1)
•
Loosen fixing screws (2)
•
Turn screw (3) until chain is tensioned
Attention!
Do not overtension chain (see note chapter 8.1.1).
The tension force should not exceed 20N, this could cause damage to
the encoder !
•
Tighten fixing screws (2)
•
Lock lock nut (1)
S-LH93gb08
07/13 - 2
Page 5 of 10
8Maintenance
8.4
Lubrication points and maintenance overview – Proximity switch
S-LH93gb08
07/13 - 2
Page 6 of 10
8Maintenance
8.4.1
Pulse generator – Removing and Mounting
Removing
•
Loosen screw (1) in coupling (2)
•
Loosen fastening cam (3)
•
Remove pulse generator (4) by hand
Mounting
•
Move pulse generator (4) at the coupling by hand (no hits at the pulse generator)
•
Screw tensioning eccentric (3) slightly
•
Fixing the coupling screws (1)
•
Adjust encoder (4) while turning
•
Fixing the fastening cam (3)
8.4.2
Justification of the proximity switch
Distance between proximity switch
and proximity flag max. 5 mm
S-LH93gb08
07/13 - 2
Page 7 of 10
8Maintenance
8.5
Lubrication points list
Position No in
No. of lubrication
Description of Symbols of
according to
points
lubrication points
lubricant
lubrication drawing
1
1
Chain drives
2 2Gear
3
1
Rail guides
Legend
Mineral oil
Synthesis fluids
Lubrication grease (mineral oil base)
S-LH93gb08
07/13 - 2
Page 8 of 10
8Maintenance
8.6
Chain tension
•
Loosen nut A (SW19).
•
Turn nut B til chain is tensioned.
•
Tighten nut A again.
The tension of the roller chain is correct when a chain strand in the centre can be moved approximately 40-50 mm when light finger pressure is exerted.
S-LH93gb08
07/13 - 2
Page 9 of 10
8Maintenance
8.7
Lubrication and maintenance of the gear box
Attention!
Check oil level and the oil-level plug according to installation position.
All worm gear units and variants as well as gear motors are filled with synthetic lubricant at the factory, unless otherwise indicated in the confirmation of order. If a gear unit is requested to be delivered dry, it should be filled with an oil quality according to the marker’s plate.
When using mineral oils, reduced performance should be taken into account. Please ask for advice
about this.
The recommended level of oil is reached when oil drips out of the oil level screw (size 100 to 315).
For lubrication amounts refer to lubrication table.
The following mineral gearing lubricants are recommended by the manufacturer:
lubricant
Oil quality acc. to
type label Viscosity in mm2/s.
(cSt) at 40°C
ARAL
BP
Esso
Klüber
Mobil
Shell
Texaco
ICI/Tribol
synthetic oils
(Polyglykole)
PG 220
BP Energol
SG-XP 220
Umlauföl
S 220
Syntheso
HT 220
Mobil
Glygoyl 30
Trivela
Oil WB
Tribol
800/220
Degol
220
We recommend using these or equivalent lubricants.
S-LH93gb08
07/13 - 2
Page 10 of 10
9
Spare Parts
Table of Contents
9.1General............................................................................................................................... 1
9.2
Spare parts order................................................................................................................ 2
9.1General
A stock of the most important spare parts and parts subject to wear at the place of installation is an
important prerequisite for the constant proper function and availability of the machine.
We provide a guarantee only for original spare parts delivered by us.
The specifications listed in the assembly drawings and parts lists provide further information.
We provide a guarantee only for original spare parts delivered by us.
We expressly point out that original spare parts and accessories not delivered by us have also not
been tested and approved by us. It is therefore possible that the installation and/or use of such
products may negatively influence characteristics of the machine which are inherent in its construction, thus impairing active and/or passive operating safety.
In case of damage resulting from the use of non-original spare parts and accessories, any liability
or guarantee provided by REITER GmbH + Co. KG Oberflächentechnik is excluded.
The stock keeping of spare parts is provision for any the validity of agreements involving system
availability, service times and guarantee or systems performance.
Please note that separate manufacturing and delivery specifications are often given for original and
non-original parts, and that we offer spare parts constructed according to the latest technological
developments and in compliance with legal regulations.
S-LH93gb09
07/13 - 2
Page 1 of 2
9
Spare Parts
9.2
Spare parts order
To the order make use of the spare parts list in the part documentation and parts lists.
The pieces marked with “E“ in the part list are spare parts.
The pieces marked with “V“ in the part list are wearing parts.
For the spare parts order the following data shall indicate:
•
Order number (see acknowledgement)
•
Part number (see part list)
•
Designation (see part list)
•
Parts lists designation
•
No. of pieces
S-LH93gb09
07/13 - 2
Page 2 of 2