Operating instructions BA_M3101_EN Rotating
Contents
1. functional unit It consists of a basic module with integrated indexing mecha nism and an operating unit with foot pedal connected by a2m 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 2 Validity of the documentation This document applies to the following products Rotating modules horizontal axis of data sheet M 3 101 The following types or part numbers are concerned e Version without indexing 6506 10 36 O e Indexing with foot pedal 6509 10 45 O l 6509 10 60 O l 6509 10 36 O l 6509 10 12 O l 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 in the 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 Romheld GmbH Postfach 1253 35317 Laubach Germany Te2. 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 encoura ge 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 Operating instructions BA_M3101_EN 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 associ 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 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 64
3. hydraulic oil consider the material safety data sheet Wear protection equipment Hazardous to the environment 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 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 Mandatory sign The symbol stands for important information neces sary protection equipment etc a Note This symbol stands for tips for users or especially useful information This is no signal word for a dangerous or harmful situation 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 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 wil
4. the body and items out of the working area Damage of the indexing If the indexing bolt engages in full motion the inde xing 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 9 2 Hydraulic indexing Figure 6 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 Operating instructions BA_M3101_EN 10 Maintenance 10 1 Plan for maintenance Maintenance works Interval by Cleaning visual check of the rotating module and control of the indexing Check all fixing screws retighten if required Control of the indexing Check smooth running with little load over the entire rotating range Check smooth running with load over the entire rotating range Revision by the manufactu rer recommendation Repair half yearly Expert checks yearly After 50 000 ROEMHELD cycles service staff in case of ROEMHELD damages service staff Expe
5. 05 89 0 Romheld GmbH Friedrichshutte Laubach 06 12 2012 10 10
6. 1_EN Trimming potentiometer to adjust the indexing an gle tation 3 Trimming potentiometer to adjust the speed of ro LED for the display of malfunctions Trimming potentiometer to adjust the braking cur ve The speed of rotation can be adjusted by a trimming potentio meter on the control board For this purpose open the cover of the control Carefully operate the trimming potentiometer with the screwdri ver until the desired speed of rotation is obtained Close the cover again 8 9 Adjust the indexing angle The indexing angle is factory set to an angle of 90 This means that the rotating module stops automatically when rea ching one of the 90 positions However this can be adapted afterwards to the desired requi remenis The indexing angle can be changed step by step by means of the trimming potentiometer with the marking E on the control board e Pos 0 indexing angle 90 factory setting e Pos 3 indexing angle 45 e Pos 7 indexing angle 60 e Pos 10 indexing angle 180 Screw on the cover 6 10 2v ROEMHELD a4 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
7. Angle bracket provided by the customer at the flange plate Not admissible S gt Note To reach the third indexing position a swing angle of 230 is required La Note The mounting types depend on the design of the rotating module 15 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 La 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 Operating instructions BA_M3101_EN In the case of eccentric loads it is recommended to compen sate these by counterweights This prevents unregulated swinging 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 mo
8. Operating instructions ROEMHELD ht Table of contents 1 O Oo N O Oo A WO ND ee ee ee CC O a A Q 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 EC Declaration of conformity List of the applied standards h O O N N OF CO WO N N A b d O O O BA M3101 EN Issue 09 12 Rotating module vertical axis DMV 600 1 Description 1 1 General description The rotating module horizontal axis DMV is a plain bearing 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 The rotating module is except in its basic version equipped with an indexing Indexing is the procedure to proceed to the next working proc ess The indexing angle is 8 x 45 6 x 60 4 x 90 3 x 120 1 2 Version with indexing by foot pedal The rotating module with hydraulic indexing is a compact and
9. art 6 2 Misapplication Injuries material damages or malfunctions The product must never be opened At 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 da mages 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 Operating instructions BA_M3101_EN 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 Damage of components Side loads and
10. cting cable to the power supply Connection 1 24V 2 0 V GND numbered 5 10 ROEMHELD HILMA STARK 8 3 Connect manual switch or foot switch e Connect the manual switch or foot switch to the bushing of the rotating module and fix it with the enclosed screw Tigh tening torque max 0 4 Nm Figure 4 Connection of the ports 24V output for manual switch input at the left side output position reached 24V error GND input at the right side 8 4 Switch on power supply To set up the rotating drive and the control switch on the power supply 8 5 Move to the off position zero position Push a directional key T or J of the manual switch or foot switch see accessory Turn the flange plate with mounted parts to the desired off position zero position 8 6 Save the off position zero position To save the off position push both directional keys of the ma nual switch or foot switch for three seconds The current positi on will be saved as off position zero position 8 7 Interface for higher level control Reaching of the position position reached 5 can be evalu ated by the higher level control 8 8 Adjustment of the speed of rotation Injuries due to rotating movement of the flange plate and their mounting parts Adjust the speed as per the developed safety con cept general guidelines and standards or provide safety devices if required Operating instructions BA_M310
11. ent 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 15 EC Declaration of conformity Manufacturer R mheld GmbH Friedrichsh tte R mheldstra e 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 Rotating modules horizontal axis of data sheet M 3 101 The following types or part numbers are concerned e Version without indexing 6506 10 36 O e Indexing with foot pedal 6509 10 45 O l 6509 10 60 O l 6509 10 36 O l 6509 10 12 O l 16 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
12. 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 Figure 9 Alignment for bubble free mounting of the fittings bles 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 8 10 ROEMHELD 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 Put the plug slightly tilted onto the surface of the oil and screw in 6 Loosen the preload of the receiver unit 7 Check function 11 Trouble shooting Damage of components All works only to be effected by ROEMHELD service Staff All rotating modules Indexing does not Too fast rotation elerate rotati Dec engage on 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 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 Cleara
13. 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 maximum operating torque at the operating shaft must not be exceeded This can be achieved e g by limiting the operating stroke of the customer s operating element hand lever or pedal by the floor 7 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 the assembly fixture 3 10 YY ROEMHELD Operating instructions at BA_M3101_EN 7 3 Version with hydraulic indexing i Note Pressure generators hoses and hydraulic indexing must not be opened Penetrating air can lead to malfunction 7 4 Fixing of the product Injury due to overturning product Overturning product due to missing or incorrect fixing Fasten bottom plate on the floor 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 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 1 Components 1 Install the product so that for
14. 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 Figure 8 Alignment for bubble free mounting of the fittings at the assembly fixture Y Pay attention to the oil 7 Plug The design of the indexing is a closed system level When opening the system the preloaded effect will get lost 4 Align the transmitter unit as shown and remove the flushing To guarantee a system free from air the transmitter unit the line high pressure hose and the receiver unit must be flushed a Note Align the transmitter unit as shown in the figure Procedure 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 subassembly 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
15. l 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 10 Operating instructions g ar ae BA M3101 EN 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 Note These operating instructions are not a replacement for the operating instructions of the entire machine 4 Symbols and signal words 5 2 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 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 damage 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
16. l result in e reduced down times and repair costs e increased service life of the products 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 2 10 a ROEMHELD 5 3 Personal protective equipment oe For works at and with the product wa 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 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 uses Max forces and or torques only with the values indicated below technical characteristics Max torques at the hand lever only with the values indi cated below technical characteristics Use only within closed low dust rooms Use within the capacity indicated in the technical character istics See data sheet e Use as per operating instructions Compliance with service intervals Qualified and trained personnel for the corresponding activi ties e Mounting of spare parts only with the same specifications as the original p
17. nce in the indexing too large Only for indexing with foot pedal Indexing does not Air in the hydraulic Caution disengage system Compo Works only to be effected by ROEMHELD ser vice personnel nents were opened Operating instructions BA_M3101_EN 12 Technical characteristics Maximum admissible load Figure 10 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 Max admissible forces for all versions Fx 2 000 N Fy 2 000 N Fz 6 000 N Max admissible torques gt 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 max imum torques may occur General characteristics Type Mz IN 6506 10 36 O Without indexing not relevant 6509 10 XX OI Indexing with foot pedal Weight dead weight Type mikg 650610360 Without indexing 6509 10 XXO1I Indexing with foot pedal b gt Note For further technical data see data sheet Damage of the indexing If the indexing bolt engages in full motion the inde xing will be dynamically overloaded The module must only be moved to the engaging position in a controlled manner counterhold 9 10 2 ROEMHELD a4 13 Accessory gt Note See data sheet 14 Disposal Hazardous to the environm
18. rt a Note Pay attention to the qualification of the personnel 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 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 gt 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 has 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 7 10 Operating instructions amp A E BA_M3101_EN 10 5 Repair b 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
19. the required cleaning and maintenance works there is all around a clearance zone of at least 700 mm Damage of components 2 The product has to be mounted horizontally on a plane and Foot pedal is pressed down below the lower edge of solid concrete floor concrete strength grade B 25 ora rigid the base plate connecting construction of the customer flatness 0 20 mm The customer has to make sure that this will be 3 Fasten the bottom plate of the product with hexagon socket prevented by the concrete floor or a corresponding head cap screws ISO 4762 M10 onto the concrete floor or base plate connecting construction the connecting construction of the customer 4 For this purpose professionally insert into the concrete floor heavy duty dowels e g Fischer part no SL M 10 N Figure 2 External stop 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 Not suitable to fix add ons Threads 4 x M10 to fix the rotating module vertically on the fixture 4 10 ROEMHELD p IA NE Figure 3 Possible principles of fixation 3 Not admissible 4 of pressure generator transmitter unit Wall mounting screwed through rotary module
20. tion only 50 of the maximum values are admitted 8 Start up 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 Injury by crushing Due to protruding components there can be pinch points during installation Keep hands and fingers away from pinch points Injury burning due to contact with energized parts Before working on electric equipment the energized parts must be de energized and secured Do not open protection covers at electric parts All electrical works must only be realised by electri cians 8 1 Preparation for start up Before start up the following tests have to be made e Check if there are any transport damages at the rotating module e Check tight seating of the plug e The cables must be fixed by the user so that no bending and tensile stress will act and the cables cannot be damaged in any way e The rotating module was developed and built according to the applicable EMC standards EN 61000 6 2 and EN 61000 6 4 It has to be checked whether there are faults in or interacti ons between the components used 8 2 Connection of power supply The power supply is made via an external switching power supply See accessory Alternatively a 24 VDC switching power supply 20 A can be used that must be designed with short circuit protection e Connect the conne
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