Atlanta MPZ 001e Instruction Manual

MPZ 001e
Handling, Installation, Operation &
Maintenance Instructions 4100-001-06.05
Department TB Page 1 24
Rev. Index B Name 01.06.05 Schell
Date 01.01.09 Rack & Pinion Drives Released 01.06.05 Lorch
Drive Systems
Rack and Pinion Drives
Operating Manual
© 2009 Atlanta Drive Systems Inc.
www.tekmatic.com 815.282.1775 [email protected]

MPZ 001e
Handling, Installation, Operation &
Maintenance Instructions 4100-001-06.05
Department TB Page 2 24
Rev. Index B Name 01.06.05 Schell
Date 01.01.09 Rack & Pinion Drives Released 01.06.05 Lorch
Table of Contents
Company Address ……………......…………………………………………………………. 3
General ………………...........................……………………………………………….……. 3
Safety Instructions, Signs & Symbols ...............……………………………………. 3
Exclusion of Liability ...................……………………………………………….……. 4
General Safety Instructions ……….………………………….……………………………. 4
Intended Use …………………………….…………..……………………………………….. 5
Improper Use …………………………..….……………………...………………………….. 6
Qualified Personnel …………………….….………….………...………………………….. 6
Rack Handling Safety ………………………………………….……………………………. 7
Transport and Handling …….……………………..………………….….………………… 8
Short Description …………….……………………………………………………..……….. 9
Rack Item Number …………...……..……………………………………………………….. 9
Storage …………………………………………………….…….……….………………….. 10
Installation Preparation ………………….…………………………………..……………. 10
Mounting Instructions ..………….….……………………………..….………….……….. 11
Rack Mounting to Contact Surface Only ….......……………….……………........ 11
Rack Mounting to Contact and Supporting Surfaces ………...........……………. 15
Mounting the Reducer …………………………………………….………………………. 17
Engaging the Reducer to the Rack ……………………………..………………………. 18
Final Inspection …………………………………………………………………………….. 19
Operating Conditions of Rack & Pinion …………………………….………………….. 19
Starting Automatic Lubrication System …..…………………...………...…………….. 20
Maintenance ……………………………………………………………………………….... 21
Taking Out of Operation, Preparation ………...…..……………………………..... 21
Inspection of Automatic Lubrication System …………….……………………...... 21
Restarting Operation After Maintenance ……...……………………………………….. 22
Troubleshooting ……………………..……………………………………………………... 22
Disassembly …………………………………………………………………...……………. 23
Preparation ……………………………………………………………..…………….. 23
Disassembling the Rack ……….….....………………………………………….….. 23
Lubricants ………………………………………………………………………..………….. 23
Lubrication of Rack and Pinion Drives …………………………………....……….. 23
Disposal …………………………………………………………………………..………….. 24
CAUTION! This operating manual is meant for all persons involved in the
installation, operation and maintenance of ATLANTA Rack & Pinion Drives. To
prevent damages and injuries, all instructions in this manual must be read and
understood before any work is performed.This manual should be made
accessible to all applicable personnel in a conspicuous fashion. Resellers &
Buyers agree to also include this entire document to instruct Users on the safe
and proper usage of the product.
Observe any National / Regional regulations concerning safety and accident
prevention.
www.tekmatic.com 815.282.1775 [email protected]

MPZ 001e
Handling, Installation, Operation &
Maintenance Instructions 4100-001-06.05
Department TB Page 3 24
Rev. Index B Name 01.06.05 Schell
Date 01.01.09 Rack & Pinion Drives Released 01.06.05 Lorch
Company Address:
This document is based on information available at the time of its publication. While
efforts have been made to be accurate, the information contained herein does not
purport to cover all details or variations, nor to provide for every possible contingency in
connection with handling, installation, operation, or maintenance.
Who Should Study These Instructions?
These instructions are addressed to all persons handling, installing, operating or
maintaining the ATLANTA Rack & Pinion Drives. You must not use these drives
before having read and understood all of these instructions. These instructions
should be given to all applicable personnel and kept for future reference.
Safety Instructions:
The following safety symbols and words are used throughout the instructions to warn and
inform of a hazard:
Warns you about high injury hazards
Warns you about possible injury hazards
Warns you about minor injury and/or damage hazards
Transport: Warns you of injury hazards when transporting and handling of heavy
and bulky objects.
Environmental Hazard: Warns you of a pollution hazard for the environment.
Other Signs and Symbols Used in the Instructions:
☞A “handling instruction“ in which you are asked to do something.
☺A“suggestion“ shows you a possible simplification or improvement.
Maintenance: Suggests optimal operation.
Identification: Shows the description of the rack.
Storage: Informs about the correct storage of the racks.
Tek-Matic
7316 N. Alpine Rd
Loves Park, IL 61111
815.282.1775
www.tekmatic.com [email protected]
www.tekmatic.com 815.282.1775 [email protected]

MPZ 001e
Handling, Installation, Operation &
Maintenance Instructions 4100-001-06.05
Department TB Page 4 24
Rev. Index B Name 01.06.05 Schell
Date 01.01.09 Rack & Pinion Drives Released 01.06.05 Lorch
General Safety Instructions:
The Rack & Pinion Drives incorporate the latest technological development at the
time of delivery and can be principally regarded as safe to operate, but below
instructions should be observed.
Improper performance of the work may cause personal injury
and material damage.
☞Installation, maintenance and disassembly of rack and pinion drive must only be carried
out by skilled personnel with the necessary knowhow and experience.
Contact with sharp edges may cause serious personal injury!
☞Always wear safety helmet, goggles, protective gloves and safety shoes when handling
this product.
Flying debris can cause grave personal injury and damages!
☞Before starting the drive system, make sure there is no debris or tools nearby.
Contact with hot surfaces may cause burns!
☞Never touch surfaces which have high operating temperatures. Use extreme
care and suitable protective equipment (e.g. gloves)
Loose or incorrectly tightened screws can cause damage.
☞Check that all screw connections are tightened to the recommended torque using a
calibrated torque wrench.
Moving and rotating machinery may cause personal injury
by being caught or pulled into a machine!
☞Do not wear loose or hanging clothing
☞Keep a sufficient distance away from moving and rotating machinery.
☞For safety, Buyer or User should provide protective safety guards for all moving
machinery. The User is responsible for checking all applicable local safety codes and
providing suitable guards. Failure to do so may result in bodily injury and/or damage.
Unintentional machine starting during work can lead to serious
injury! Insure lock-out/tag-out procedures are in place.
☞Make sure that all safety devices are active and operational, and no one can start the
machine while people are working on it.
Never install or operate defective products.
www.tekmatic.com 815.282.1775 [email protected]

MPZ 001e
Handling, Installation, Operation &
Maintenance Instructions 4100-001-06.05
Department TB Page 5 24
Rev. Index B Name 01.06.05 Schell
Date 01.01.09 Rack & Pinion Drives Released 01.06.05 Lorch
☞In case of defects seen in products, please contact ATLANTA immediately.
Lubricants are hazardous substances that can contaminate soil and water.
☞Dispose of the lubricants as required by national regulations.
Exclusion of Liability:
ATLANTA will not assume any liability for damage or injuries resulting from improper
use or handling of the Rack & Pinion Drives. Buyer assumes all risk and liability for
loss, damage or injury to persons or property of buyer or others arising out of use or
possession of any product sold hereunder. Any improper use or handling not in
accordance with these instructions may impair the quality of the product and will void
any warranties contained herein.
Modifications & Conversions:
Modifications and/or conversions of the Rack & Pinion Drives are not permissible unless
expressly approved by ATLANTA in writing.
EC Machinery Directive:
As defined by the EC Machinery Directive 98/37 EG, the Rack & Pinion Drives are not
considered an autonomous machine but a component to be installed in machines. Within
the purview of the EC directive, the Rack & Pinion Drives must not be operated unless the
machine into which this product is installed fulfills the requirements of the directive.
Technical Changes:
ATLANTA Drive Systems Inc. reserves the right to make technical changes to improve the
product without notice.
Intended Use:
Rack & Pinion Drives must be used exclusively for converting rotary
motion with torque into power-transmitting linear motion in machine
and plant construction applications under atmospheric conditions.
☞The allowable load capacities are listed in our servo catalog or on our website:
www.atlantadrives.com
The Buyer shall be solely responsible for determining the adequacy
of the Rack & Pinion Drives for any and all uses to which Buyer
shall apply the product.
The drive train containing the Rack & Pinion Drives must be free
www.tekmatic.com 815.282.1775 [email protected]

MPZ 001e
Handling, Installation, Operation &
Maintenance Instructions 4100-001-06.05
Department TB Page 6 24
Rev. Index B Name 01.06.05 Schell
Date 01.01.09 Rack & Pinion Drives Released 01.06.05 Lorch
from critical speed, torsional, or other type vibration, regardless of how induced.
The Buyer shall be solely responsible for this analysis.
The Rack & Pinion Drives are not to be considered fail safe or self-
locking devices & may drive from the output to the input. If these
features are required, a properly sized, independent holding device should be
utilized.
Improper Use:
☞ Exceeding the permissible force and torque ratings shall be considered improper use
and is therefore prohibited.
☞ The machine design must be made strictly in accordance with our instructions. Any
deviation requires written approval by ATLANTA, otherwise this will be considered
improper use and is prohibited.
☞ Wrong alignment (see section “Final Inspection“ on page 19) of the pinion with relation
to the rack shall be considered improper use and is therefore prohibited.
☞ Improper lubrication, e.g. lack of lubricant and/or use of a wrong lubricant, or insufficient
protection against pollution shall be considered improper use and is therefore
prohibited.
☞ If several racks are mounted end-to-end, it must be assured that the pitch at the joints
lies within the permissible individual pitch error tolerances. Otherwise, this will be
considered improper use and is prohibited.
Qualified Personnel:
Only skilled and trained personnel, being aware of the possible risks, may carry out
mounting, installation, start-up, service, and maintenance work. The personnel must have
the necessary qualifications for the work to be done and must be familiar with mounting,
installation, start-up and operation of the product.
The personnel must carefully read, understand and observe the operating instructions and,
in particular, the safety instructions. They must also observe the applicable regional and
national regulations on safety and accident prevention.
The following work should only be carried out only by qualified personnel: transport,
storage, installation, connection, start-up, service, maintenance.
www.tekmatic.com 815.282.1775 [email protected]

MPZ 001e
Handling, Installation, Operation &
Maintenance Instructions 4100-001-06.05
Department TB Page 7 24
Rev. Index B Name 01.06.05 Schell
Date 01.01.09 Rack & Pinion Drives Released 01.06.05 Lorch
Rack Handling Safety:
The racks must be assembled and installed only by skilled
personnel having the necessary knowhow and experience.
☞ See section “Qualified Personnel”
Always wear suitable safety helmet, goggles, protective gloves, and
safety shoes when lifting rack out of its packing and handling it.
A second person should be called in or a crane be used, if the weight exceeds 20 lb. A
second person should also be used if the rack length exceeds 1,000 mm, in order to prevent
injury due to bad posture. The crane must always be operated by a crane driver. The rack
to be carried must be properly secured and, if necessary, the ends of the rack marked in a
clearly visible way.
☺The table below shows the weight of the individual racks. The lengths are rounded
to the nearest round length.
Mass of the Rack (in pounds)
Module 1 1.5 1.591 2 2.5 3 3.183 4 5 6 8 10
Length
(mm)
200 - - - 1.9 - 2.7 - 6 6.6 10 21 24
250 0.9 1.1 0.9 2.2 2.4 3.5 3.4 6.2 7.6 10.6 24.4 -
500 1.8 2.3 1.7 4.9 4.9 7.1 7 12.5 15 23 50 -
1,000 3.6 4.5 3.4 9.7 9.7 14 14 25 29 55 99 155
1,500 - - - 13.5 - 21 - 37 45 67 - -
2,000 - 9 - 20 20 28 28 50 57 110 197 -
3,000 - - - 30 - 43 - 75 - - - -
When pivoting with a rack in hand, mark the pivoting radius with
a warning sign and warning tape. This area must be blocked
during transport and handling so that no person may be endangered.
Before starting transport of racks, make sure that the travel path is
clean & clear, with ample room to maneuver with good footing.
Avoid twisting and bending while lifting or moving. Lift the racks
comfortably and smoothly, keeping them close to the body.
Before starting transportation of racks, it must be ascertained that
the overall dimensions of the rack permit safe handling. Never allow
the load to obstruct your view!
www.tekmatic.com 815.282.1775 [email protected]

MPZ 001e
Handling, Installation, Operation &
Maintenance Instructions 4100-001-06.05
Department TB Page 8 24
Rev. Index B Name 01.06.05 Schell
Date 01.01.09 Rack & Pinion Drives Released 01.06.05 Lorch
Always wear gloves when handling racks, because racks (especially
those with helical teeth) have sharp edges.
In order to avoid injury due to bad posture, the height of the
mounting bench must be chosen in such a way that it suits the
height of the mechanic. An adjustable mounting bench would be needed if
mechanics of different height were to work at the same bench.
Suitable supports or trestles must be provided in order to prevent
hand or fingers from being squeezed and bruised when placing the
rack onto the bench or table.
It is also important to consider the center of gravity of the rack when
setting it down because it could tilt or fall, resulting in injury of
persons nearby. A suitable support should also be provided when placing the racks
to avoid excessive bending.
For tightening of the screws, a suitable working height should be
chosen for the mechanic. Furthermore it is important to choose a
suitable screwdriver to avoid wrist injury. The work surroundings must be perfectly
prepared for this process in order to avoid injury while working.
If rack contact occurs without gloves, wash your hands immediately
because the racks are oiled. Always wear protective gloves when
handling racks!
Rack Transport:
☞ Please observe the instructions in the section “Rack Handling Safety”
☞ Observe all safety regulations for transport & handling with cranes, hoists & forklifts.
☞ Make sure that the load is handled and set down slowly and carefully.
☞ Especially when transporting and handling long racks (2 meters), avoid any leverage
upon the rack. Recommended lever arm ratios are as shown below:
☞ If necessary, have one or more persons lend a hand.
www.tekmatic.com 815.282.1775 [email protected]

MPZ 001e
Handling, Installation, Operation &
Maintenance Instructions 4100-001-06.05
Department TB Page 9 24
Rev. Index B Name 01.06.05 Schell
Date 01.01.09 Rack & Pinion Drives Released 01.06.05 Lorch
Short Description:
Rack and Pinion Drives convert rotary motion and torque of a gear into the power-
transmitting linear motion of a gear rack. This takes place when the operating pitch
diameter of the gear meshes with the common pitch line of the rack without slipping. At the
point of contact, the peripheral speed of both operating pitch diameters is identical.
Racks are available in different quality levels, to be chosen by the customer to suit the
intended use.
Rack Item Number:
☺The item number A) is located on the rack.
☺Example: Racks for continuous linking.
Identification:
☞ The rack is identified by item number as well as the manufacturer’s logo and
manufacturing lot number.
Quality and
Precision Module With Mounting Holes Length of Rack
www.tekmatic.com 815.282.1775 [email protected]

MPZ 001e
Handling, Installation, Operation &
Maintenance Instructions 4100-001-06.05
Department TB Page 10 24
Rev. Index B Name 01.06.05 Schell
Date 01.01.09 Rack & Pinion Drives Released 01.06.05 Lorch
Storage:
If the rack is not going to be installed immediately after delivery, the following measures
should be taken:
☞ Store the racks in a cool and dry place and in such a way that they don’t come into
contact with any other objects.
☞Avoid any metal-to-metal contacts between the racks during storage. Put a layer of
protective foil or oil paper between them.
☞ Protect the racks against corrosion. Remove the anti-corrosive agent only immediately
before the installation. When storing for a period of more than one month, add an anti-
corrosive coating.
☞ Protect the racks against environmental influences (ozone, UV light, electric
welding, dust, dirt, moisture, temperature fluctuations (32°F to +86°F), shocks,
etc.).
☞Avoid any unfavorable leverage on the rack during storage (for lever ratios, see section
“Rack Transport”).
☞Protect the rack against dust or other pollution.
☞Take care to not damage the teeth or the supporting/contact surfaces.
☞For store keeping, we recommend a “First In - First Out” principle.
Installation Preparation:
☞ Re-read the sections “General Safety Instructions” and “Rack Handling Safety”
☞ Set your torque wrench and check its function.
☞ Wear protective gloves while assembling in order to avoid contact corrosion.
☞ Inspect the racks for external damage and cleanliness.
☞ A damaged or dirty rack must not be mounted or operated. The contact surfaces and,
if necessary, supporting surfaces, are to be carefully wiped off with a clean rag.
www.tekmatic.com 815.282.1775 [email protected]