Bosch Rexroth BS 2/C Series User manual

Assembly instructions
3 842 358 724/2013-04
Replaces: –
English
BS 2/C-100
BS 2/C-H
BS 2/R-700
BS 4/R-700
BS 2/R-300
BS 4/R-300
BS 2/R-H
BS 2/R-V-1200
BS 2/C-250
BS 2/C-…, BS 2/R-…
Belt sections
Applies to the following types:
3 842 998 096 , BS 2/R-700
3 842 998 097 , BS 4/R-300
3 842 998 238 , BS 2/R-H
3 842 998 239 , BS 2/C-H
3 842 998 492 , BS 2/R-V-1200
3 842 999 901 , BS 4/R-700
3 842 999 904 , BS 2/R-300
3 842 999 917 , BS 2/C-100
3 842 999 985 , BS 2/C-250
ENGLISH
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The data specified only serve to describe the product. The information provided in the instructions
on how to use the supplied product should only be considered application examples and
suggestions. Catalog information is not binding. The information given does not release the user
from the obligation of own judgment and verification. Our products are subject to a natural process
of wear and aging.
© This document, as well as the data, specifications and other information set forth in it, are the
exclusive property of Bosch Rexroth AG. It may not be reproduced or given to third parties without
its consent.
An example configuration is shown on the title page. The delivered product may thus vary from the
illustration.
The original assembly instructions were generated in German.
DE Die vorliegende Montageanleitung ist in den hier angebenen Sprachen verfügbar. Als gedruckte Version (print) oder als PDF-
Datei (media) zum Download aus dem Medienverzeichnis: www.boschrexroth.com/medienverzeichnis
1. Geben Sie in die Suchmaske (oben rechts, unter „Suche“) 3 842 358 723 ein. 2. Klicken Sie auf „Suche“.
EN These assembly instructions are available in the languages indicated here. They come in a hard copy (print) or a PDF file (media)
that can be downloaded at: www.boschrexroth.com/mediadirectory
1. Enter 3 842 358 724 in the search mask (at the top right, under “Search”). 2. Click “Search”.
FR Les présentes instructions de montage sont disponibles dans les langues mentionnées ici. Disponible au téléchargement en
version imprimée (print) ou en fichier PDF (media) à partir du répertoire médias : www.boschrexroth.com/mediadirectory
1. Dans le masque de recherche (en haut à droite dans « Search »), saisissez 3 842 358 725. 2. Cliquez sur « Search ».
IT Le presenti istruzioni per il montaggio sono disponibili nelle lingue qui indicate, in versione stampata (print) o come file PDF
(media) da scaricare dalla media directory: www.boschrexroth.com/mediadirectory
1. Nella maschera di ricerca (in alto a destra, sotto “Search”) immettere 3 842 358 726. 2. Fate clic su “Search”.
ES Este manual de instrucciones está disponible en los idiomas aquí indicados como versión impresa o archivo PDF para descarga
desde el directorio de medios: www.boschrexroth.com/mediadirectory
1. Indique en el cuadro de búsqueda (parte superior derecha, “Search”) 3 842 358 727. 2. Haga clic en “Search”.
PT O presente manual de montagem está disponível nos idiomas aqui indicados. Como versão impressa (print) ou como arquivo
PDF(media) para ser descarregado do diretório de mídias: www.boschrexroth.com/mediadirectory
1. Introduza no motor de busca (em cima à direita, em “Search”) 3 842 358 728. 2. Clique em “Search”.
ZH 本安装说明书有这里给出的语言版本。有印刷版本 (print) 或者电子版 PDF 文件 (media) 供使用，电子版文件可在下列的公司网站媒体网
页上下载: www.boschrexroth.com/mediadirectory
1. 在搜索窗口 (右上角，“Search”窗口) 内输入编号 3 842 358 729。2. 点击“Search”。
CS Tento návod k montáži je k dispozici ve zde uvedených jazycích. Jako tištěná verze (print) nebo jako soubor PDF (media) je ke
stažení z adresáře médií: www.boschrexroth.com/mediadirectory
1. Zadejte do vyhledávací obrazovky (nahoře vpravo, pod „Search“) MTCS 358 723. 2. Klikněte na „Search“.
PL Dana instrukcja montażu jest dostpna w podanych tutaj językach. W postaci wydrukowanej lub w wersji pdf (media) do
pobrania ze strony: www.boschrexroth.com/mediadirectory
1. Do wyszukiwarki wpisać (w prawym górnym rogu „Search“) MTPL 358 723 . 2. KKliknać „Search“
3 842 358 723 print media Bandstrecke BS 2/C-… + BS 2/R-… DE Deutsch
3 842 358 724 print media Belt sections BS 2/C-… + BS 2/R-… EN English
3 842 358 725 print media Section à bande BS 2/C-… + BS 2/R-… FR Français
3 842 358 726 print media Tratto a nastro BS 2/C-… + BS 2/R-… IT Italiano
3 842 358 727 print media Tramo de cinta BS 2/C-… + BS 2/R-… ES Español
3 842 358 728 print media Via de esteira BS 2/C-… + BS 2/R-… PT Português
3 842 358 729 print media 皮带输送段 BS 2/C-… + BS 2/R-… ZH 中文
MTCS 358 723 media Dopravníková trať BS 2/C-… + BS 2/R-… CS Česky
MTPL 358 723 media Przenośnik BS 2/C-… + BS 2/R-… PL Polski
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3/76Contents
1 About This Documentation 6
1.1 Scope of documentation 6
1.2 Required and supplementary documentation 6
1.3 Presentation of information 6
1.3.1 Safety instructions 6
1.3.2 Symbols 7
1.3.3 Designations 8
1.3.4 Abbreviations 8
2 Notes on Safety 8
2.1 About this chapter 8
2.2 Intended use 8
2.3 Improper use 9
2.4 Personnel qualifications 9
2.5 General safety instructions 10
2.6 Product-specific safety instructions 10
2.7 Personal protective equipment 11
2.8 Obligations of the system owner 11
3 General Notes on Equipment and Product Damage 12
4 Scope of Delivery 13
4.1 Condition on delivery 13
5 About This Product 13
5.1 Performance description 13
5.1.1 BS 2 belt section application... 13
5.1.2 BS 2 belt section version... 13
5.2 Product description 14
5.3 Product identification 15
6 Transport and Storage 15
6.1 Transporting the product 15
6.2 Storing the product 15
7 Assembly 16
7.1 Unpacking 16
7.2 Installation requirements 16
7.2.1 Mounting orientation 16
7.2.2 Mounting with T-bolts 16
7.3 Required tools 16
7.4 Required accessories 17
7.5 Symbols used 18
7.6 Assembling the product 19
7.6.1 Assembling the belt section on leg sets 19
7.6.2 Changing the mounting position of the motor/gear combination
or the gear motor 21
7.6.3 BS 2/C-100, -250, BS 2/R-300, -700, BS 4/R-300, -700:
Assembling the belt section between two sections 22
7.6.4 BS 2/C-H, BS 2/R-H, BS 4/R-V-1200:
Assembling the belt section between two sections 23
Contents
ENGLISH
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7.6.5 BS 2/R-H, reversible:
Assembling the belt section between two sections 24
7.6.6 BS 2/C-100, -250, BS 2/R-300, -700, BS 4/R-300, -700:
Assembling two belt sections, drive head to return unit 25
7.6.7 BS 2/C-H, BS 2/R-H, BS 4/R-V-1200:
Assembling two belt sections, drive head to return unit 26
7.6.8 Checking the chain elongation
BS 2/C-100, -250, BS 2/R-300, -700, BS 4/R-300, -700 27
7.6.9 Checking the chain elongation
BS 2/C-H, BS 2/R-H, BS 4/R-V-1200 28
7.6.10 BS 2/R-300, -700, BS 4/R-300, -700:
Assembling the accelerating element (only if lWT = 160/240) 29
7.6.11 Electrically connecting the product 31
8 Commissioning 33
8.1 Commissioning for the first time 33
8.2 Residual hazards 34
8.3 Recommissioning after shutdowns 34
9 Operation 35
9.1 Notes on operation 35
9.1.1 Wear 35
9.1.2 Measures to reduce wear 35
9.1.3 Loading the workpiece pallet 36
9.1.4 Ambient influences 36
10 Maintenance and Repair 37
10.1 Cleaning and care 38
10.2 Inspection 38
10.2.1 Conveyor chain (flat top chain/accumulation roller chain) 38
10.3 Maintenance 38
10.3.1 Bearings 38
10.3.2 Gears 38
10.3.3 Motor 38
10.3.4 Conveyor chain (flat top chain/accumulation roller chain) 39
10.3.5 Options to lubricate the conveyor chain manually 40
10.3.6 LU 2 automatic lubrication unit 41
10.4 Replacing wear parts 42
10.4.1 Designations 42
10.4.2 Required tools 42
10.4.3 Required accessories 42
10.4.4 Notes for mounting: Finding the master link on a functional chain 43
10.4.5 Notes for mounting: securing the chain tensioner for
BS 2/C-100, BS 2/C-250, BS 2/R-300,
BS 4/R-300, BS 2/R-700, BS 4/R-700 44
10.4.6 Notes for mounting: Securing the chain tensioner for
BS 2/C-H, BS 2/R-H, BS 2/R-V-1200 44
10.4.7 Checking the chain elongation for
BS 2/C-100, BS 2/C-250, BS 2/R-300,
BS 4/R-300, BS 2/R-700, BS 4/R-700 45
10.4.8 Checking the chain elongation for
BS 2/C-H, BS 2/R-H, BS 2/R-V-1200 45
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10.4.9 Shortening the conveyor chain:
BS 2/C-100, BS 2/R-300, BS 4/R-300, BS 2/C-250, BS 2/R-700,
BS 4/R-700, motor mounting (MA) = R/L 46
10.4.10 Shorten conveyor chain:
BS 2/C-100, BS 2/R-300, BS 4/R-300, motor mounting (MA) = M 48
10.4.11 Shortening the conveyor chain:
BS 2/C-H, BS 2/R-H, BS 2/R-V-1200, motor mounting (MA) = R/L 50
10.4.12 Shortening the conveyor chain:
BS 2/R-H, reversible, BS 2/R-V, reversible, motor mounting (MA) = R/L 52
10.4.13 Notes for mounting: Exchanging the chain and wear parts 54
10.4.14 Notes for mounting: Direction of movement of the chain 56
10.4.15 Notes for mounting: Lubrication points 56
10.4.16 Exchanging the conveyor chain:
BS 2/C-100, BS 2/R-300, BS 4/R-300
BS 2/C-250, BS 2/R-700, BS 4/R-700, motor mounting (MA) = R/L 57
10.4.17 Exchanging the conveyor chain:
BS 2/C-100, BS 2/R-300, BS 4/R-300 motor mounting (MA) = M 59
10.4.18 Exchanging the conveyor chain:
BS 2/C-H, BS 2/R-H, BS 2/R-V-1200, motor mounting (MA) = R/L 62
10.4.19 Exchanging the conveyor chain:
BS 2/R-H, reversible, BS 2/R-V, reversible, motor mounting (MA) = R/L 65
10.4.20 Exchanging the relief roller/connection roller toothed belt:
BS 2/C-H, BS 2/R-H, BS 2/R-V-1200, motor mounting (MA) = R/L 67
10.4.21 Exchanging the motor and/or gear:
BS 2/C-100, BS 2/R-300, BS 4/R-300, motor mounting (MA) = R/L 68
10.4.22 Exchanging the motor and/or gear:
BS 2/C-100, BS 2/R-300, BS 4/R-300, motor mounting (MA) = M 69
10.4.23 Exchanging the gear motor:
BS 2/C-H, BS 2/R-H, BS 2/R-V-1200, motor mounting (MA) = R/L 70
10.4.24 Exchanging the gear motor:
BS 2/C-H, BS 2/R-H, BS 2/R-V-1200, motor mounting (MA) = M 71
10.4.25 Exchanging the glide profiles:
BS 2/C-100, BS 2/C-250, BS 2/C-H 72
10.5 Spare parts 73
11 Decommissioning 73
12 Disassembly and Exchange 73
12.1 Preparing the product for storage/further use 73
13 Disposal 74
14 Extension and Conversion 74
15 Troubleshooting and Resolution 74
16 Technical Data 75
16.1 Ambient conditions 75
ENGLISH
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6/76 About This Documentation
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1 About This Documentation
1.1 Scope of documentation
This documentation applies to the following products:
• 3 842 998 096, BS 4/R-700
• 3 842 998 097, BS 4/R-300
• 3 842 998 238, BS 2/R-H
• 3 842 998 239, BS 2/C-H
• 3 842 998 492, BS 2/R-V
• 3 842 999 901, BS 2/R-700
• 3 842 999 904, BS 2/R-300
• 3 842 999 917, BS 2/C-100
• 3 842 999 985, BS 2/C-250
This documentation is intended for installers, operators, service technicians, and
system owners.
This documentation contains important information on the safe and appropriate
assembly, transportation, commissioning, operation, use, maintenance, disassembly,
and simple troubleshooting of the product.
Read this documentation completely, especially chapter 2 “Notes on Safety”and
chapter 3 “General Notes on Equipment and Product Damage”, before working
with the belt section.
1.2 Required and supplementary documentation
Only commission the product once you have obtained the system documentation
that is marked with a book symbol and understood and complied with its
contents.
Table 1: Required and supplementary documentation
Title Document number Document type
Instructions for Employees on Safety 3 842 527 147
MTparts 3 842 529 770 Spare parts list on CD
1.3 Presentation of information
Uniform safety instructions, symbols, terms, and abbreviations have been used in
this documentation in order to ensure that you can get to work quickly and safely
with your product. They are discussed in more detail in the following sections.
1.3.1 Safety instructions
This documentation contains safety instructions in section 2.6 “Product-specific
safety instructions”and chapter 3 “General Notes on Equipment and Product
Damage” and before any actions or steps whenever there is a danger of personal
injury or damage to the equipment. The measures described to avoid these hazards
must be observed.
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Safety instructions are set out as follows:
SIGNAL WORD
Hazard type and source
Consequences
Precautions:
…
•Safety sign: draws attention to the risk
•Signal word: identifies the degree of hazard
•Type and source of the risk: identifies the type and source of the hazard
•Consequences: describes what occurs when the safety instructions are not
complied with
•Precautions: states how the hazard can be avoided
Table 2: Hazard classes acc. to ANSI Z535.6-2006
Safety sign, signal word Meaning
DANGER Indicates an imminently hazardous situation which, if not
avoided, will certainly result in death or serious injury.
WARNING Indicates a potentially hazardous situation which, if not
avoided, could result in death or serious injury.
CAUTION Indicates a potentially hazardous situation which, if not
avoided, could result in minor or moderate injury.
NOTICE Damage to equipment: The product or surrounding
equipment may be damaged.
1.3.2 Symbols
The following symbols identify information that is not relevant for safety, but which
increases the comprehensibility of the documentation.
Table 3: Meaning of the symbols
Symbol Meaning
If this information is disregarded, the operating procedure may be
impaired.
Individual, independent action
1.
2.
3.
Numbered steps:
The numbers indicate the order for the steps.
ENGLISH
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1.3.3 Designations
This documentation uses the following designations:
Table 4: Designations
Designation Meaning
BS 2/C-100
BS 2/C-250
BS 2/C-H
BS 2: Belt section from the Rexroth TS 2plus transfer system
/C: Conveyor medium: flat top chain
-100: Permissible load, cumulative load [kg]
-250: Permissible load, cumulative load [kg]
-H: Heavy load version, permissible load, cumulative load 400 kg
BS 2/R-300
BS 2/R-700
BS 2/R-H
BS 2/R-V-1200
BS 2: Belt section from the Rexroth TS 2plus transfer system
/R: Conveyor medium: accumulation roller chain
-300: Permissible load, cumulative load [kg]
-700: Permissible load, cumulative load [kg]
-H: Heavy load version, permissible load, cumulative load 1200 kg
-V: Conveyor medium accumulation roller chain Vplus,
permissible load, cumulative load 1200 kg
1.3.4 Abbreviations
This documentation uses the following abbreviations:
Table 5: Abbreviations
Abbreviation Meaning
Chain Conveyor chain with conveyor medium:
• Flat top chain (…/C-…)
• Accumulation roller chain (…/R-…)
• Accumulation roller chain Vplus (…/R-V-…)
2 Notes on Safety
2.1 About this chapter
The product has been manufactured according to the accepted rules of current
technology. Even so, there is a risk of injury or damage if this chapter and the safety
information in these instructions are not observed.
Read these instructions completely and thoroughly before working with the
product.
Keep this documentation in a location where it is accessible to all users at all
times.
Always include the operating instructions when you pass the product on to third
parties.
2.2 Intended use
This product is an incomplete machine.
The product may be used as follows:
• For installation in a Rexroth TS 2plus transfer system
• For transporting Rexroth WT 2 workpiece pallets.
• Maximum load/section load: see Technical data on page 75.
• For ambient conditions, see page 75.
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The product is intended exclusively for professional applications and not designed
for private use.
Intended use includes having read and understood these instructions, especially
chapter 2 “Notes on Safety”.
2.3 Improper use
Any use other than that described in section “Intended use” is considered improper
and is not permitted.
Bosch Rexroth AG is not liable for any damages resulting from improper use.
The user alone bears the risks of improper use of the product.
The following foreseeable cases of misuse are also considered improper use:
• Transport of goods other than those specified.
• Persons riding on the product or transported material.
• Persons climbing on the product
– walking on the product is not permitted.
• Operation of the product without a safety device to prevent toppling.
• Personal use of the product.
2.4 Personnel qualifications
The work described in this documentation requires basic mechanical, electrical,
and pneumatics knowledge, as well as knowledge of the appropriate technical
terms. Additional knowledge of the lifting device’s usage and of the associated lifting
equipment are necessary to transport and handle the product. In order to ensure
operating safety, these activities may therefore only be carried out by qualified
technical personnel or an instructed person under the direction and supervision
of qualified personnel.
Qualified personnel are those who can recognize possible hazards and institute
the appropriate safety measures due to their professional training, knowledge,
and experience, as well as their understanding of the relevant conditions pertaining
to the work to be done. Qualified personnel must observe the rules relevant
to the subject area and carry the necessary technical expertise.
For pneumatic products such expertise would, for example, involve:
• Being able to read and fully understand pneumatic diagrams,
• Especially understanding completely the complexity and interactions of safety
equipment, and
• Having knowledge of the function and structure of pneumatic components.
Bosch Rexroth offers training for special fields. You can find an overview
of the training contents on the Internet at http://www.boschrexroth.de/didactic
ENGLISH
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2.5 General safety instructions
• Observe the regulations for accident prevention and environmental protection.
• Observe the safety instructions and regulations applicable in the country in which
the product is used.
• Exclusively use Rexroth products in good technical order and condition.
• Follow all instructions printed on the product.
• Persons who assemble, operate, disassemble or maintain Rexroth products must
not consume any alcohol, drugs, or pharmaceuticals that may affect their ability
to respond.
• To avoid injuries due to unsuitable parts, only use original accessories and spare
parts from Rexroth.
• Comply with the technical data and ambient conditions listed in the product
documentation.
• The installation or use of unsuitable products in safety-relevant applications
can result in unanticipated operating states in the application that can lead to
personal injury or damage to equipment. The product should thus only be used in
applications relevant to safety if this use is explicitly specified and permitted in the
product documentation, for example in explosion protection areas or safety-related
control components (functional safety).
• Only commission the product after verifying that the end product (e.g. machine or
system) in which Rexroth products are installed complies with national regulations,
safety guidelines, and norms.
2.6 Product-specific safety instructions
The following safety instructions apply to chapters 6 to 14.
• Do not modify or convert the product.
• Do not expose the product to any mechanical loads under any circumstances.
Never use the product as a handle or step. Do not place any objects on
the product.
• Always secure the product to prevent toppling.
• Observe the transport instructions on the packaging.
• Check the product for visible transport damage.
• Lay cables and lines so that they cannot be damaged and no one can trip
over them.
• Make sure the relevant system component is not under pressure or voltage
before assembling the product or when connecting and disconnecting plugs.
• Protect the system component against being switched on.
• Before commissioning, make sure that all seals and caps for the screwed
connections are correctly installed and undamaged to prevent fluids and foreign
bodies from penetrating the product.
• Let the product acclimate itself for several hours before commissioning,
otherwise water may condense in the housing.
• Make sure that all electrical and pneumatic connections are either used or covered.
• Check the safety requirements in accordance with DIN EN 619.
• Commission the product only if it is installed completely.
• Make sure that all safety equipment belonging to the product is present, has been
installed properly, and is fully functional. Do not modify the position of, bypass,
or disable the safety equipment.
General
During transport
During assembly
During commissioning
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• Do not reach into moving parts.
• Check the product for malfunctions.
• Ensure that only authorized personnel do the following within the scope
of intended product use
– Start or operate the system, or intervene in its normal functioning
– Activate adjustment devices on components.
• Only allow persons who are authorized by the system owner to access
the product’s direct operating area. This also applies when the product
is standing still.
• Make sure that
– There are no obstacles preventing access to the EMERGENCY STOP
command devices.
– All delivery points, workstations and passages remain freely accessible.
• Do not use EMERGENCY STOP command devices for routine stops.
• Regularly check the proper functioning of the EMERGENCY STOP command
devices.
• After an EMERGENCY STOP, in the case of a fault, or any other anomalies,
switch the product off and protect it against being switched on again.
• Do not reach into moving parts.
• An idle system is not a safe system, as stored energy can be released
unintentionally or through improper maintenance procedures.
• After an EMERGENCY STOP or a malfunction, only switch on the system
once the cause of the fault has been determined and the error resolved.
• Make sure that there are no obstacles blocking access to maintenance
and inspection points.
• Perform the prescribed maintenance work at the intervals specified
in section 10.3, Maintenance.
• Make sure that no lines, connectors, or components are disconnected as long
as the system is under pressure and voltage. Protect the system against being
switched on.
• Dispose of the product in accordance with the currently applicable national
regulations in your country.
2.7 Personal protective equipment
• Wear appropriate protective equipment (e.g. safety shoes, tight clothing,
hairnets for those with long hair) when working with the product.
As a plant operator, you are responsible for appropriate protective equipment
when working with the product.
All personal protective equipment must be intact.
2.8 Obligations of the system owner
• Perform a risk assessment in accordance with DIN EN ISO 12100 before initial
commissioning or recommissioning of a conveyor system.
• Instruct operating personnel on safety before initial commissioning
or recommissioning and afterwards regularly.
During operation
EMERGENCY STOPS,
malfunctions
During maintenance and
repair
During disposal
ENGLISH
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3 General Notes on Equipment and Product
Damage
The warranty only applies to the delivered configuration.
• The warranty will not apply if the product is incorrectly assembled, commissioned,
or operated, and/or if it is not handled or not used as intended.
• The following safety instructions apply to chapters 6 to 14.
• Ensure that there is sufficient lubrication on the conveyor chain, see page 39.
– Maintain a maintenance schedule.
– Keep grease-dissolving or aggressive cleaning agents away from the conveyor
chain.
• Deformations such as folds and/or the chain twisting, e.g. due to the chain coil
tipping while the chain is being mounted, cause the conveyor chain to fail and can
lead to a crash.
– Ensure that the chain is lying evenly and that it runs smoothly from the chain coil
during mounting.
– Ensure that the chain coil does not tip over during assembly.
– If the chain coil has tipped over during assembly and the chain is deformed:
Use the disassembly tool to remove all of the affected area.
• Prevent cleaning agents from entering the system.
• Never use solvents or aggressive detergents.
• Do not use a high-pressure cleaner for cleaning.
During operation
During maintenance and
repair
During cleaning
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Scope of Delivery 13/76
3 842 358 724/2013-04, MIT: BS 2/C-… + BS 2/R-…, Bosch Rexroth AG
4 Scope of Delivery
The scope of delivery includes:
• 1 BS 2/ belt section….
• 1 “Belt section BS 2/C-… + BS 2/R-…” assembly instructions.
Leg sets and fastening material for connecting to other belt sections or the floor
must be ordered separately, see the TS 2plus sales catalogue, 3 842 531 138.
4.1 Condition on delivery
• Assembled on a pallet.
5 About This Product
5.1 Performance description
5.1.1 BS 2 belt section application...
• Longitudinal conveyor for WT 2 workpiece pallets on conveyor sections
of up to 6000 mm.
• Transverse conveyor for WT 2 workpiece pallets between parallel conveyor sections
(in conjunction with two HQ 2 lift transverse units)
5.1.2 BS 2 belt section version...
• Ready-for-operation conveyor section.
• Section load: see Technical data on page 75.
• Conveyor medium:
– BS 2/C… : Polyamide flat top chain.
– BS 2/R… : Accumulation roller chain.
– BS 2/R-V-1200 : Accumulation roller chain Vplus.
• Motor mounting depending on the version, right side (MA = R), left side (MA = L)
or center (MA = M)
• Motor connection optionally with cable/plug or terminal box.
ENGLISH
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14/76 About This Product
Bosch Rexroth AG, MIT: BS 2/C-… + BS 2/R-…, 3 842 358 724/2013-04
5.2 Product description
Fig. 1:
H
547 601-01
BS 2/C-100
B
A
D
BS 2/C-250
BS 2/C-H
BS 2/R-H
BS 2/R-V-1200
BS 2/R-700
BS 4/R-700
BS 2/R-300
BS 4/R-300
D
C
C
D
C
E E
G
E, F
C
HB
A
Belt sections BS 2/C-… + BS 2/R-…
A: Gear
B:Motor
C: Gear motor
D: Flat top chains
E: Accumulation roller
chain
F:Vplus accumulation
roller chain
G: Only with: BS 2/R-H,
reversible
H: Accelerating element
for:
• BS 2/R-300, -700
• BS 4/R-300, -700
For safe bridging of
the conveyor trench
without accumulation
operation.
Only for lWT = 160,
lWT = 240.
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Transport and Storage 15/76
3 842 358 724/2013-04, MIT: BS 2/C-… + BS 2/R-…, Bosch Rexroth AG
5.3 Product identification
Fig. 2: Name plate
6 Transport and Storage
• Observe the transport instructions on the packaging.
• See the shipping documents for transport weight.
• Secure the product to prevent toppling!
• When storing and transporting the product, always observe the ambient
conditions, see page 75.
6.1 Transporting the product
WARNING
Lifted loads may fall!
Falling objects may result in severe injuries (or even death).
Always use lifting equipment with a sufficiently high load bearing capacity
(see the shipping documents for product weight).
Before lifting the product, make sure that the lifting equipment is correctly
fastened!
Secure the product to prevent toppling while lifting!
Make sure that no one is in the danger area when raising and lowering,
with the exception of the operator!
6.2 Storing the product
• Only store the product on a firm, flat surface.
• Protect the product against mechanical influences.
• Protect the product against environmental influences such as contamination
and humidity.
• Observe the ambient conditions, see page 75.
• Support the product so that suspended, there is no load on motors assembled.
....... ..........
....
....
.........
.................
........
A
C
B
Typschild
A: Part number
(order number)
B: Designation
C: Information about version
and dimensions
ENGLISH
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16/76 Assembly
Bosch Rexroth AG, MIT: BS 2/C-… + BS 2/R-…, 3 842 358 724/2013-04
7 Assembly
7.1 Unpacking
Lift the product out of the packaging.
Dispose of the packaging in accordance with the currently applicable national
regulations in your country.
7.2 Installation requirements
When installing the product, always observe the ambient conditions specified
in the Technical Data (see page 75).
7.2.1 Mounting orientation
The product should be aligned and level at right angles and parallel to the axis.
This ensures correct functioning and prevents premature wear.
7.2.2 Mounting with T-bolts
Mount the transfer systems TS 1, TS 2plus, TS 2pv, TS 4plus, TS 5 and chain
conveyor systems VarioFlow and VarioFlow S with T-bolts and flange nuts.
Make sure the T-bolt is in the correct position when inserting and tightening
in the slot. The notch at the end of the bolt indicates the T-bolt orientation.
1 = T-bolt insertion orientation in the slot.
2 = T-bolt clamping position in the slot.
Maximum tightening torque: 25 Nm.
7.3 Required tools
Hexagon wrenches (open-end):
WS8, WS10, WS13, WS19, WS24.
Hex socket wrench: WS4.
Water level
Combination pliers
Flat smooth file
21
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Assembly 17/76
3 842 358 724/2013-04, MIT: BS 2/C-… + BS 2/R-…, Bosch Rexroth AG
7.4 Required accessories
• Leg sets to carry the belt section.
Note: Support the belt section in the direct vicinity of the drive and return unit.
The distance between two leg sets must not exceed 2000 mm.
– For BS 2/C-100, BS 2/C-250, BS 2/R-300,
BS 4/R-300, BS 2/R-700, BS 4/R-700:
SZ 2, 3 842 999 816
SZ 2/U, 3 842 999 817
SZ 2/T, 3 842 999 818
– For BS 2/C-H, BS 2/R-H, BS 2/R-V:
SZ 2-H, 3 842 998 235
SZ 2/U-H, 3 842 9998 236
SZ 2/T-H, 3 842 998 237
• To fasten the leg sets to the floor, each connection requires:
– 1x foundation bracket, 3 842 146 815
– 1x dowel, 3 842 526 560
– 2x T-bolts, 3 842 528 718
– 2x flange nuts, 3 842 345 081
• Connection kits for the transverse conveyor when using the belt section in lateral
transverse transport (drive head to section).
– BS 2/C-100, BS 2/C-250, BS 2/R-300,
BS 4/R-300, BS 2/R-700, BS 4/R-700 with:
ST 2/B, ST 2/B-100, ST 2/C-100, ST 2/R-100, 3 842 528 192
– BS 2/C-400, BS 2/C-700, BS 2/R-1200, BS 2/R-2200 with:
ST 2/B, ST 2/B-100, ST 2/C-100, ST 2/R-100, 3 842 518 828
– BS 2/C-H, BS 2/R-H, BS 2/R-V with:
ST 2/C-H, ST 2/R-H, ST 2/R-V, 3 842 530 868
• Connection kits for the longitudinal conveyor (drive head to return unit)
– BS 2/C-100, BS 2/C-250, BS 2/R-300,
BS 4/R-300, BS 2/R-700, BS 4/R-700 with:
BS 2/C-100, BS 2/C-250, BS 2/R-300,
BS 4/R-300, BS 2/R-700, BS 4/R-700, 3 842 529 881
– BS 2/C-400, BS 2/C-700, BS 2/R-1200, BS 2/R-2200
BS 2/C-H, BS 2/R-H, BS 2/R-V with:
BS 2/C-100, BS 2/C-250, BS 2/R-300,
BS 4/R-300, BS 2/R-700, BS 4/R-700
BS 2/C-400, BS 2/C-700, BS 2/R-1200, BS 2/R-2200
BS 2/C-H, BS 2/R-H, BS 2/R-V, 3 842 530 871
ENGLISH
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18/76 Assembly
Bosch Rexroth AG, MIT: BS 2/C-… + BS 2/R-…, 3 842 358 724/2013-04
7.5 Symbols used
Table 6: Symbols used
21 Connect with T-bolt and flange nut.
Make sure the T-bolt is in the correct position when inserting and tightening
in the slot. The notch at the end of the bolt indicates the T-bolt orientation.
1 = T-bolt insertion orientation in the slot.
2 = T-bolt clamping position in the slot.
Maximum tightening torque: 25 Nm.
M
D
SW13
= 20Nm
Wrench for hexagonal screw
SW = wrench size (WS) … mm
MD= required tightening torque … Nm
M
D
= 8Nm
SW5
Wrench for hex-socket screw
SW = wrench size (WS) … mm
MD= required tightening torque … Nm
PH3
PZ2
Screwdriver for recessed head screws
PZ … = Pozidriv recessed head, size …
PH … = Phillips recessed head, size …
Lubricate with Structovis GHD, 0 842 904 229.
gleitmo 585 K Anti-Seize
Grease/grease with specified lubricant:
• gleitmo 585 K: gleitmo 585 K, www.fuchs-lubritech.com
• Anti-Seize: Food Grade Anti-Seize/Loctite 8014, www.henkel.com
Loctite 243 Loctite 601
Secure the screws with:
• Loctite 243: medium strength adhesive (detachable), www.loctite.de
• Loctite 601: high strength adhesive (permanent), www.loctite.de
The identified parts are not required for the assembly situation described.
Use the parts in another application or dispose of them.
213 Sequence of assembly steps in the graphics.
The numbers correspond with the order of the assembly steps according
to the instructions in the accompanying text.
ABCX Designation of components in graphics.
The letters identify the components specified in the instructions.
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Assembly 19/76
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7.6 Assembling the product
7.6.1 Assembling the belt section on leg sets
Fig. 3:
SW13
M = 25 Nm
D
BS 2/...
547 601-02
SZ 2
SZ 2
Assembling the belt section on leg sets (1/2)
1. Assemble the belt
section on 2 to 4 leg
sets.
Note:
• Assemble one leg set each
in the direct vicinity of the
drive and return unit.
• Assemble the leg
sets under the cross
connectors of the belt
section.
• Maximum distance
between 2 leg sets:
2000 mm.
ENGLISH
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20/76 Assembly
Bosch Rexroth AG, MIT: BS 2/C-… + BS 2/R-…, 3 842 358 724/2013-04
Fig. 4:
SW13
Ø 8
73
M = 25 Nm
D
3 842 528 718
3 842 146 815
3 842 526 560
SZ 2
SZ 2
1
3.1
3.2
3 842 345 081
SW13
M = 25 Nm
D
SW24
M = 25 Nm
D
"A"
BS 2/...
2
547 601-03
Assembling the belt section on leg sets (2/2)
2. Align the belt section
at the same height and
level as the adjacent
components.
3. Bolt the belt section
to the floor.
The following is required
per connection:
– 1x foundation bracket,
3 842 146 815
– 1x dowel, 3 842 526 560
– 2x T-bolts,
3 842 528 718
– 2x flange nuts,
3 842 345 081
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