Operating instructions BA M1101_EN Rotating module – horizontal
Contents
1. ROEMHELD at Operating instructions BA M1101_ EN Issue 09 12 Rotating module horizontal axis DMH 200 Max load 2 000 N manual operation Table of contents 1 O Oo N O Oo A WO ND ee ee Se Cr a Ff Ww N OO Description Validity of the documentation Target group of this document Symbols and signal words Safety instructions Application Installation Start up Operation Maintenance Trouble shooting Technical characteristics Accessory Disposal Declaration of manufacture O O O OQO Ww NY N N N ee Se Ce _ O O O O 1 Description 1 1 General description The rotating module horizontal axis DMH is a double sup ported rotation axis that can compensate high axial and radial forces The angle of rotation in both directions is 360 Due to special bearings it is insensitive to shocks and thrusts The design of the rotating module allows its integration in appli cations with light as well as with heavy loads When using the rotating module in assembly processes work pieces can be rotated rationally quickly and safely and can be assembled ergonomically from all sides Except in its basic version the rotating module is equipped with an indexing The indexing angle is 8 x 45 6 x 60 4 x 90 3 x 120 1 2 Version without indexing The rotating module does not have an indexing in its basic version The rotating operation is effected manually at the workpiece or at th2. Actively operated indexing 6508 02 XX OI Indexing with foot pedal Weight dead weight Type OOO kg 650502360 Without indexing 65050136M Automatic indexing 65050236M Actively operated indexing 6508 02 XXO1 Indexing with foot pedal gt Note For further technical data see data sheet 13 Accessory gt Note See data sheet 14 Disposal Hazardous to the environment Due to possible environmental pollution the indi vidual components must be disposed only by an authorised expert company The individual materials have to be disposed as per the existing regulations and directives as well as the environmental condi tions Special attention has to be drawn to the disposal of compo nents with residual portions of hydraulic fluids The instructions for the disposal at the material safety data sheet have to be considered For the disposal of electrical and electronic components e g stroke measuring systems proximity switches etc country specific legal regulations and specifications have to be kept 10 11 y ROEMHELD at 15 Declaration of manufacture Manufacturer Romheld GmbH Friedrichshttte RomheldstraBe 1 5 35321 Laubach Germany Tel 49 0 64 05 89 0 Fax 49 0 64 05 89 211 E mail info roemheld de www roemheld com 15 1 Validity of the documentation This document applies to the following products Rotating modules horizontal axis of data sheet M 1 101 The followi
3. Not suitable to fix add ons Threads 4 x M10 to fix the rotating module vertically on the fixture W224 a SS ae i h TA ae Figure 5 Possible principles of fixation 1 Fixation for vertical 3 Wall mounting screwed mounting screwed through rotary module gt Note through customer s fixture Angle bracket provided by if required through flange the customer at the flange Pressure generators hoses and hydraulic indexing must not be opened Penetrating air can lead to malfunction plate see accessories plate of pressure generator 4 Not admissible transmitter unit 7 6 Fixing of the product B gt Note In case of vertical mounting of the rotating module it has to be considered that the hand lever can only be rotated Injury due to overturning product a elle by 270 Overturning product due to missing or incorrect fixing B gt Note Fasten bottom plate on the floor a l When introducing torques within the load limit see To reach the third MEEKI POSUTA SWING ANEO 230 is required technical characteristics we recommend to use an additional base plate accessory and to secure this plate correctly Note The mounting types depend on the design of the rotating module Damage of components Foot pedal is pressed down below the lower edge of the base plate The customer has to make sure that this will be prevented by the concrete floor or a corresponding base plate connectin
4. uses Damage of components Side loads and forced conditions on the product lead e Max forces and or torques only with the values indicated below technical characteristics e Max torques at the hand lever only with the values indi cated below technical characteristics e Use only within closed low dust rooms e Use within the capacity indicated in the technical character istics See data sheet e Use as per operating instructions e Compliance with service intervals e Qualified and trained personnel for the corresponding activi ties e Mounting of spare parts only with the same specifications as the original part to the premature failure Avoid forced conditions overdetermination of the product Max forces and torques see technical characteris tics 3 11 O ting instructi 2 ROEMHELD a rca Damage of components Damage of components The maximum operating torque at the operating Foot pedal is pressed down below the lower edge of shaft must not be exceeded the base plate This can be achieved e g by limiting the operating The customer has to make sure that this will be stroke of the customer s operating element hand prevented by the concrete floor or a corresponding lever or pedal by the floor base plate connecting construction 7 2 Version without indexing 7 5 Version with hydraulic indexing The rotating module does not have an indexing in its basic version The rotating operatio
5. as to check all hydraulic hoses at least once a year if they are still work proof Assessed damages have to be repaired immediately e The hydraulic hoses of the device have to be exchanged as per BGR 237 at least after 6 years by new ones 10 5 Repair gt Note Repair works as e g the change of the interior lifting jack may only be effected by the ROEMHELD service technicians 10 6 Maintenance of the hydraulic indexing The rotating module with hydraulic indexing is a compact and functional unit It consists of a basic module with integrated indexing mecha nism and an operating unit with foot pedal connected by a 2 m long hydraulic hose This flexible connection allows the individual placement of the operating unit at the most favourable ergonomic position The rotating operation is manually effected at the workpiece or at the assembly fixture The design of the indexing is a closed system When opening the system the preloaded effect will get lost To guarantee a system free from air the transmitter unit the high pressure hose and the receiver unit must be flushed 8 11 2 ROEMHELD crete areng Procedure a Note Align the transmitter unit as shown in the figure Oil must be in the connecting port up to the upper edge of the connecting thread Refill oil if required Put the plug slightly tilted onto the surface of the oil and screw in 5 Vent the receiver unit Injury due to the spring in the su
6. bassembly The component can slip and the the piston extends Provide a holding device gt Direction of flushing Pressure generator for 1 Transmitter unit flushing with return line to the reservoir Flushing line Reservoir line 2 Receiver unit 3 High pressure hose 2 m 1 Connection of hose lines see fig of the sketch gt Note The ports have to be aligned towards the top 2 Connect to a pressure generator preferably to a small power unit 3 Flush the system several minutes Actuate the pedal several times to loosen trapped air bub bles Figure 11 Alignment for bubble free mounting of the fittings 3 High pressure hose 2 m F Force required 6 Reservoir line S Stroke approx 13 5 mm 8 Vice or clamp Receiver unit in shown alignment in the vice preload and remove reservoir line a Note Align the receiver unit as shown in the figure Oil must be in the connecting port up to the upper edge of the connecting thread Refill oil if required l l Put the plug slightly tilted onto the surface of the oil and Figure 10 Alignment for bubble free mounting of the fittings screw in T Pay attention to the oil 7 Plug 6 Loosen the preload of the receiver unit level 7 Check function 4 Align the transmitter unit as shown and remove the flushing line 9 11 ROEMHELD at 11 Trouble shooting Damage of components All works only to be effected by ROEMHELD ser
7. e assembly fixture 1 3 Automatic indexing The rotating module with automatic indexing is a compact and functional unit Rotating as well as indexing are ergonomically operated by one hand lever only 1 4 Actively operated indexing The rotating module horizontal axis DMH 200 with actively operated indexing is a compact and functional unit Rotating as well as indexing are ergonomically operated by one hand lever only The rotating module with hydraulic indexing is a compact and functional unit It consists of a basic module with integrated indexing mecha nism and an operating unit with foot pedal connected by a2 m long hydraulic hose This flexible connection allows the individual placement of the operating unit at the most favourable ergonomic position The rotating operation is manually effected at the workpiece or at the assembly fixture Romheld GmbH Postfach 1253 35317 Laubach Germany Tel 49 0 6405 89 0 Fax 49 0 6405 89 211 www roemheld de Subject to change without notice Translation of the original German document 1 11 y ROEMHELD at 2 Validity of the documentation This document applies to the following products Rotating modules horizontal axis of data sheet M 1 101 The following types or part numbers are concerned e Version without indexing 6505 02 36 O e Automatic indexing 6505 01 36 M e Actively operated indexing 6505 02 36 M e Indexing with foot pedal 6508 02 45 O
8. g construction 1 Install the product so that for the required cleaning and maintenance works there is all around a clearance zone of at least 700 mm 2 The product has to be mounted horizontally on a plane and solid concrete floor concrete strength grade B 25 ora rigid connecting construction of the customer flatness 0 20 mm 3 Fasten the bottom plate of the product with hexagon socket head cap screws ISO 4762 M10 onto the concrete floor or the connecting construction of the customer 5 11 y ROEMHELD at 7 7 Mounting of the customer s connecting construc tion Injury due to overturning product Overturning product due to eccentric load provided by the user The centre of gravity of the user s load must be within the 4 fixing screws of the bottom plate When introducing torques within the load limit see technical characteristics we recommend to use an additional base plate accessory and to secure this plate correctly 1 For fixing of the customer s connecting construction there are 4 bore holes for M10 10 5 mm at the top plate All provided bore holes have to be used 2 Fasten the connecting construction at the top plate a Note Dangers due to the connecting construction of the cus tomer as e g Squeezing points have to be excluded by the customer s design In the case of eccentric loads it is recommended to compen sate these by counterweights This prevents unregulated swin
9. ge of the seals ageing and incorrect mounting of the seal kit by the operator can lead to escapes of oil Incorrect connection can lead to escapes of oil at the ports For handling with hydraulic oil consider the material safety data sheet Wear protection equipment 2 11 y ROEMHELD at Injury by crushing Components of the product make a movement while they are in operation This can cause injuries Keep parts of the body and items out of the working area Damage of components Side loads and forced conditions on the product lead to the premature failure Avoid forced conditions overdetermination of the product Max forces and torques see technical characteris tics Damage of components The admissible performance data of the product see chapter Technical characteristics may not be exceeded Note qualification of the user All works may only be effected by qualified personnel familiar with the handling of hydraulic components 5 3 Personal protective equipment Cm For works at and with the product nda wear safety goggles For works at and with the product wear protective gloves For works at and with the product wear safety shoes 6 Application 6 1 Intended use Rotating modules are designed for universal use in assembly Operating instructions BA M1101_EN 6 2 Misapplication Injuries material damages or malfunctions The product must never be opened At
10. ging of the load changing swivelling In off position the indicated maximum torques may occur see Technical characteristics The required forces and torques around the axis of rotation have to be considered by the operator During the rotating motion only 50 of the maximum values are admitted The max force of 50 N rotation or holding must not be ex ceeded by the operator 8 Start up Injury by crushing Loads torques can lead to an unexpected start of the product When releasing the index counter hold the existing load Pay attention to an ergonomic working place and max physical forces Injury by crushing Due to protruding components there can be pinch points during installation Keep hands and fingers away from pinch points The following tests have to be carried out before start up 1 Check tight seat check seating torque of the fixing screws 2 Check the freedom of motion of the existing loads Rotate the rotating modules with mounted customer s fixture 4x 90 Pay attention to shearing and squeezing points Mount a protective guard if required Operating instructions BA M1101_EN Pay attention to collision free motion with regard to surrounding equipment Pay attention to ergonomic working conditions Pay attention to maximum and admissible physical forces 3 Check movement and resulting loads Carefully rotate the mounted construction and the workpiece Carr
11. l 6508 02 60 O I 6508 02 36 O l 6508 02 12 O I 3 Target group of this document e Specialists fitters and set up men of machines and installa tions with hydro mechanical expert knowledge Qualification of the personnel Expert knowledge means that the personnel must e be inthe position to read and completely understand tech nical specifications such as circuit diagrams and product specific drawing documents e have expert knowledge of function and design of the corre sponding components A specialist is somebody who has due to its professional edu cation and experiences sufficient knowledge and is familiar with the relevant regulations so that he e can judge the entrusted works e can recognize the possible dangers e can take the required measures to eliminate dangers e knows the acknowledged standards rules and guidelines of the technology e has the required knowledge for repair and mounting 4 Symbols and signal words DANGER Danger of life heavy health damages Stands for an imminent danger If it is not avoided death or very severe injuries will result Person damage Stands for a possibly dangerous situation If it is not avoided death or very severe injuries will result Easy injuries property damage Stands for a possibly dangerous situation If it is not avoided minor injuries or material dam ages will result Operating instructions BA M1101_EN Hazardous to the envir
12. maintenance Maintenance works Interval el mode an the rotating module and control of the indexing half yearly checks Check all fixing screws retighten if required Control of the indexing Check smooth running with After 50 000 ROEMHELD turer recommendation cycles service staff Repair in case of ROEMHELD damages service staff gt Note Pay attention to the qualification of the personnel little load over the entire rotating range Check smooth running with load over the entire rotating range Revision by the manufac 10 2 Cleaning The following cleaning works have to be effected daily at the mechanical components 1 Clean with cleaning clothes or cleaning rags 2 Slightly lubricate the metallic components plates guides etc Operating instructions BA M1101_EN 10 3 Monthly checks e Visual inspection e Check the unit for damages and possible running marks repair if required e Check the axial and radial clearance repair if required e Check the indexing for smooth running and clearance a Note Repair works as e g the change of the interior lifting jack may only be effected by the ROEMHELD service technicians 10 4 Yearly checks Hydraulic system hydraulic hoses An expert has to check all hydraulic components at least once a year if they are still work proof Assessed damages have to be repaired immediately The following checks and works have to be effected e An expert h
13. n is effected manually at the workpiece or at the assembly fixture 7 3 Version with automatic indexing Figure 1 Components a Basic unit Threads 4 x M10 to fix b Flange plate further components verti c1 Threads 4 x M10 to fix cally on the fixture further components Hand lever c2 Counterbores for 4 x Button for unlocking M10 to fix the rotary module at the fixture Figure 3 Components 7 4 Version with actively operated indexing Damage of components Foot pedal is pressed down below the lower edge of the base plate The customer has to make sure that this will be prevented by the concrete floor or a corresponding base plate connecting construction Figure 2 Components a Basic unit c4 Threads 4 x M10 to fix b Flange plate further components verti c1 Threads 4 x M10 to fix cally on the fixture further components Hand lever c2 Counterbores for 4 x M10 to fix the rotary module at the fixture 4 11 O ting instructi 2 ROEMHELD ii 4 For this purpose professionally insert into the concrete floor heavy duty dowels e g Fischer part no SL M 10 N J m i Bzz Basic unit Hydraulic indexing re Flange plate ceiver unit Threads 4 x M10 to fix Foot pedal further components Pressure generator Counterbores for 4 x M10 transmitter unit to fix the rotary module at Bore holes 4 x M8 to fix the fixture the pressure generator Threads 4 x M10 to fix the External stop index
14. ng types or part numbers are concerned e Version without indexing 6505 02 36 O e Automatic indexing 6505 01 36 M e Actively operated indexing 6505 02 36 M e Indexing with foot pedal 6508 02 45 O l 6508 02 60 O I 6508 02 36 O l 6508 02 12 O l 15 2 List of the applied standards 2001 95 EC General product safety 92 58 EEC Minimum requirements for the provision of safety and or health signs at work 89 391 EEC Introduction of measures to encourage improve ments in the safety and health of workers at work 89 655 EEC Minimum safety and health requirements for the use by workers of personal protective equipment at the work place Operating safety regulations BetrSichV for the transposal of the directive on the introduction of measures to encour age improvements in the safety and health of workers at work German implementation of the Work Equipment Di rective 89 655 EEC Product Safety Act PSG November 2011 DIN EN ISO 12100 2011 03 Safety of machinery Basic con cepts General principles for design replacement for part 1 and 2 DIN EN ISO 13857 2008 06 Safety of machinery Safety distances to prevent hazard zones being reached by upper and lower limbs replaces DIN EN 294 DIN EN 349 2008 09 Safety of machinery Minimum gaps to avoid crushing of parts of the human body DIN EN 614 1 a 2 2009 06 Safety of machinery Ergonomic design principles DIN EN 1494 2009 05 Mobile or movable jacks and ass
15. oci ated lifting equipment DIN EN 626 1 2008 09 Safety of machinery Reduction of risks to health from hazardous substances emitted by ma chinery DIN EN ISO 4413 2011 04 Hydraulic fluid power General rules and safety requirements for systems and their compo nents Operating instructions BA M1101_EN DIN EN 1037 2008 11 safety of machinery prevention of unexpected start up DIN EN 81714 2 2007 08 Design of graphical symbols for use in the technical documentation of products Responsible person for the documentation Dipl Ing FH Jurgen Niesner Tel 49 0 6405 89 0 Romheld GmbH Friedrichshutte Laubach 10 09 2012 11 11
16. off position of the hand lever can be engaged in steps of 90 so that for every rotation the desired off position can be adjusted With engaged indexing the button for unlocking 2 can be pushed and the lever freely swivelled To engage the indexing release the button Operating instructions BA M1101_EN 9 3 Version with actively operated indexing Figure 7 Operation Actively operated indexing 1 Unlocking of the load 2 Operation of the hand lever To unlock the indexing position the hand lever has to be tilted in axial direction by approx 10 1 to get connected by form fit with the rotating module The workpiece can now be rotated in any direction 2 by means of the hand lever Only after safe locking in the desired position by tilting back the lever the hand lever is free again and the workpiece locked with the housing by form fit The off position of the hand lever can be engaged in steps of 90 so that for every rotation the desired off position can be adjusted 7 11 y ROEMHELD at 9 4 Hydraulic indexing Figure 8 Operation Indexing operated by a foot pedal By operating the foot pedal by 35 the index is released and the workpiece or the fixture can be rotated If the foot pedal is not operated the index bolt engages auto matically into the next indexing position The operation with a foot pedal guarantees that the operator always has both hands free 10 Maintenance 10 1 Plan for
17. onment The symbol stands for important information for the proper handling with materials that are hazardous to the environment Ignoring these notes can lead to heavy damages to the environment Mandatory sign D The symbol stands for important information neces sary protection equipment etc gt Note This symbol stands for tips for users or especially useful information This is no signal word for a dangerous or harmful situation 5 Safety instructions 5 1 Basic information The operating instructions serve for information and avoidance of dangers when installing the products into the machine as well as information and references for transport storage and maintenance Only in strict compliance with these operating instructions accidents and property damages can be avoided as well as trouble free operation of the products can be guaranteed Furthermore the consideration of the operating instructions will result in e reduced down times and repair costs e increased service life of the products j gt Note These operating instructions are not a replacement for the operating instructions of the entire machine 5 2 General safety tips Injuries due to misuse incorrect operation or abuse Injuries can occur if the product is not used within the intended use and the technical performance data Before start up read the operating instructions Poisoning due to contact with hydraulic oil Wear dama
18. the product no changes must be made except the ones ex pressly mentioned in the operating instructions The use of these products is not admitted e For domestic use e On pallets or machine tool tables in primary shaping and metal forming machine tools e If due to vibrations or other physical chemical effects dam ages of the products or seals can be caused e On pallets or machine tool tables that are used to change the characteristics of the material magnetise radiation photochemical procedures etc e In areas for which special guidelines apply especially in Stallations and machines For the use on fun fairs and in leisure parks In food processing or special hygiene regulations For military purposes In mines In explosive and aggressive environments e g ATEX In medical engineering Inthe aerospace industry For passenger transport 7 Installation 7 1 Design Injury by falling parts Keep hands and other parts of the body out of the working area Wear personal protection equipment Damage of components Some product types have a considerable weight These have to be secured against working free during transport Weight specifications see chapter Technical char acteristics and handling processes in the industry They are used for industrial applications in order to rotate workpieces rationally quickly and safely Furthermore the following are possible
19. vice staff All rotating modules Indexing does not Too fast rotation elerate rotati Dec engage 2n Max admissible A Caution torques exceeded Works only to be Indexing defect effected by ROEMHELD ser vice personnel Replace the lifting jack by ROEMHELD ser vice personnel A Caution Works only to be effected by ROEMHELD ser vice personnel Top plate lowers without operation of the foot pedal Internal lifting jack defect Wear or max admissible torques exceeded Clearance in the indexing too large Only for indexing with foot pedal Indexing does not Air in the hydraulic A Caution disengage system Compo Works only to be nents were effected by opened ROEMHELD ser vice personnel 12 Technical characteristics Maximum admissible load Figure 12 Axes of the introduced forces and torques M Max torques in the axes F Max admissible forces in X YorZ the axes X Y or Z Operating instructions BA M1101_EN Max admissible forces for all versions Fx 2 000 N Fy 2 000 N Fz 1 000 N Max admissible torques Note These torques are valid for all versions with indexing in engaged mode In the case of eccentric loads it is recommended to compen sate these by counterweights In off position the indicated maximum torques may occur General characteristics 6505 02 36 O Without indexing not rele vant 65050136M Automatic indexing 65050236M
20. y out tests as listed below 2 4 Check the functions of the rotary module Pay attention to smooth running 9 Operation Injury by crushing Loads torques can lead to an unexpected start of the product When releasing the index counter hold the existing load Pay attention to an ergonomic working place and max physical forces Injury by crushing Components of the product make a movement while they are in operation This can cause injuries Keep parts of the body and items out of the working area Damage of the indexing If the indexing bolt engages in full motion the index ing will be dynamically overloaded The module must only be moved to the engaging position in a controlled manner counterhold 9 1 Version without indexing The rotating module does not have an indexing in its basic version The rotating operation is effected manually at the workpiece or at the assembly fixture 6 11 y ROEMHELD at 9 2 Automatic indexing Load swings unexpectedly This can lead to injuries or damages During swinging under load the unlocking must not be actuated Figure 6 Operation Automatic indexing 1 Operation of the hand 2 Unlocking of the hand lever lever To rotate the workpiece the hand lever is operated in any direc tion 1 Every 90 indexing of the position is made automatically En gagement and disengagement of the indexing is also effected automatically The
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