GUDEL ZP 3-5 V4 User manual

OPERATING MANUAL
ZP 3-5 V4
Project / Order:
Bill of materials:
Serial number:
Year of manufacture:
BETRIEBSANLEITUNG ZP 3-5 V472057594174110603_V5.0_EN-US
B1M.10xxxxxxx-xxxx
10xxxxxxx
99xxxxxxx
2018

© GÜDEL
Translation of the original instructions
This manual contains standard illustrations that may deviate from the original.
In the case of special models, options, or technical changes, the scope of deliv-
ery may differ from the descriptions here. Reprinting the instructions, in whole
or in part, requires our permission. Subject to change due to technical im-
provements.
72057594174110603_v5.0_EN-US

Revision history
Version Date Description
5.0 02.05.2018 Valid as of product version ZP-3V4.11;
ZP-4V4.21; ZP-5V4.01
New
• Maintenance tasks after downtimes <4
weeks ÜChapter9.3.4,2156
• Maintenance tasks after downtimes >4
weeks ÜChapter9.3.5,2156
Modified:
• Maintenance schedules
ÜChapter9.4,2224
Updated:
• Position the base plates Ü256
• Anchor the base plates Ü258
• General inspection Ü2161
• Mount motor Ü294
4.0 15.02.2018 New:
• Feedback on instructions
ÜChapter9.7,2243
• Intervention report
• Malfunctions / Troubleshooting
ÜChapter10.4,2272
Modified:
• New gearbox unit with elastomer cou-
pling
Added:
• Double rollers Ü2197
Updated:
• Module of ZP-5 rack module Ü2220
• Setting the gear backlash Ü2265
3.0 16.02.2017 Updated:
• Entire manual updated
Revision historyOPERATING MANUAL ZP 3-5 V4
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3

Version Date Description
2.0 29.11.2016 Updated:
• New signatures on declaration of incor-
poration ÜChapter1,217
• Entire manual updated
1.0 21.04.2016 Basic version
Table-1 Revision history
Revision history OPERATING MANUAL ZP 3-5 V4
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Table of contents
1 Declaration of incorporation 17
2 General 19
2.1 Further applicable documentation................ .................19
2.2 Purpose of the document..................... ......................19
2.3 Explanation of symbols/abbreviations.............................. 20
3 Safety 21
3.1 General ...............................................................21
3.1.1 Product safety .........................................................21
3.1.2 Personnel qualifications..................................................22
3.1.2.1 Operating companies....................................................23
3.1.2.2 Transport specialists....................................................23
3.1.2.3 Fitters ................................ .................................23
3.1.2.4 Commissioning technicians ...................... .......................24
3.1.2.5 Operators .............................. ...............................24
3.1.2.6 Manufacturer's technicians.............................................. 24
3.1.2.7 Maintenance technicians.................................................25
3.1.2.8 Service technicians .......................... ...........................25
3.1.2.9 Disposal specialists.......................... ...........................25
3.1.3 Disregarding safety regulations.......................................... 26
3.1.4 Installation instructions..................................................26
3.2 Hazard symbols in the manual .....................................27
3.2.1 Hazard warnings .......................................................27
3.2.2 Explanation of warning symbol.......................................... 28
3.3 Hazard symbols on the product.................................... 29
3.3.1 Danger label "danger sign"...............................................29
3.3.2 Danger label "Transport information"................. ..................30
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3.4 Fundamentals of safety..............................................30
3.4.1 Separating protective equipment, monitoring equipment........ .........30
3.4.2 Product-specific hazards.................................................31
3.4.3 Material safety data sheets (MSDS)...................................... 32
4 Product description 33
4.1 Use ................................. ..................................33
4.1.1 Intended use............................. ..............................33
4.1.2 Non-intended use.......................................................33
4.2 Product designation........................ .........................34
4.2.1 Type plate .............................. ...............................34
4.2.2 Position of the type plate................................................35
4.3 Technical data........................... ............................35
4.4 Options .............................. ................................36
5 Design, function 37
5.1 Design................................................................ 37
5.2 Function .............................................................38
6 Transport 39
6.1 Packaging symbols....................................................40
6.2 Industrial trucks .......................... ...........................41
6.3 Slings................................ .................................41
6.3.1 Attaching the slings: Güdel uprights.................. ...................42
6.3.2 Attaching the slings: Beam...............................................44
6.3.3 Attaching the slings: Z-axis, sizes 2-5.................................... 45
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7 Commissioning 47
7.1 Introduction .........................................................47
7.1.1 Safety.................................................................. 47
7.1.2 Personnel qualifications..................................................48
7.2 Intermediate storage................................................48
7.3 Downtimes ............................ ..............................49
7.4 Setup, fastening .....................................................50
7.4.1 General................................................................ 50
7.4.2 Prerequisites............................................................50
7.4.3 Unpacking .............................................................51
7.4.4 Attaching the slings: Beam...............................................52
7.4.5 Setup process.......................................................... 53
7.4.5.1 Special tools, testing and measuring instruments..........................53
7.4.5.2 Positioning the base plates.............................................. 56
7.4.5.3 Anchoring the base plates ...............................................58
7.4.5.4 Setting up an upright ...................................................59
7.4.5.5 Leveling uprights ........................... ............................62
Measuring height of upright.......................................... 62
Determining average upright height ..................................63
Correcting the upright height........................................ 63
7.4.5.6 Securing uprights against falling over .....................................64
7.4.5.7 Installing a beam: Standard.............................................. 64
7.4.5.8 Installing a beam: Beam leveling kit.......................................66
7.4.5.9 Connecting the beams.................................................. 67
7.4.5.10 Straightening beams.....................................................68
Aligning upright and beam............................................ 70
Aligning the beam horizontally....................................... 71
7.4.5.11 Assembling the bumper unit.............................................72
Bumper unit with shearing sleeves.................................... 74
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7.4.6 Anchoring the product ........................ .........................75
7.4.6.1 Base mounting with adhesive anchor.....................................75
7.4.6.2 Fixing base with welded joint ..................... ......................78
HST3............................................................... 79
HAS-TZ / HVU-TZ.................................................. 80
HIT-Z / HIT-HY-200-A.............................................. 82
7.5 Installing .............................................................84
7.5.1 Using the mounting aid: Installing the rack................................84
7.5.2 Installing the guideway.................................................. 85
7.5.3 Check rack transition....................................................87
7.5.4 Installing the Z-axis......................................................89
7.5.4.1 Attaching the slings: Z-axis, sizes 2-5.................................... 89
7.5.4.2 Preparations ............................. ..............................90
7.5.4.3 Inserting the Z-axis......................................................90
7.5.4.4 Assembling the bumper unit.............................................91
Bumper unit with limit stops......................................... 93
7.5.5 Installing the motor .....................................................94
7.5.5.1 Information on initial assembly.......................................... 94
7.5.5.2 Prerequisites............................................................94
7.5.5.3 Aligning the gearbox flange .............................................95
7.5.5.4 Aligning the input shaft to the gearbox flange............................ 97
7.5.5.5 Positioning the coupling on the motor shaft.............. ...............99
7.5.5.6 Installing the motor and coupling........................................102
7.5.6 Check leveling of the guide chute.......................................105
7.5.7 Connecting the side panels .............................................106
7.6 Assembling the energy chain ...................................... 108
7.6.1 Laying the cables and lines...................... .......................108
7.6.2 Installing the energy chain..............................................111
7.6.3 Installing the slide bars..................................................112
7.6.4 Relieving the cables and lines of strain.................................. 114
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7.7 Connection .........................................................117
7.7.1 Attaching optional components........................................ 117
7.7.2 Attaching the load .....................................................117
7.7.3 Integrating the product................................................ 117
7.8 Transport securing devices ................... .................... 118
7.8.1 Removing the transport securing device................................ 120
7.8.2 Installing transport securing device.................. ...................122
7.9 Fine adjustment of the Z-axis......................................127
7.9.1 X-direction: Standard..................................................127
7.9.2 X-direction: Beam leveling kit.......................................... 129
7.9.3 Y-direction: Standard.................................................. 132
7.9.4 Y-direction: Safety brake system................... ....................133
7.10 Initial lubrication ...................................................136
7.10.1 Clean guideways and racks..............................................136
7.10.2 Pre-lubricate guideways and racks...................................... 137
7.10.3 Carrying out a lubrication check.......................................138
7.11 Functional check....................................................139
8 Operation 141
8.1 General .............................................................141
8.2 Personnel ...........................................................141
9 Maintenance 143
9.1 Introduction ........................... ............................ 143
9.1.1 Safety................................ .................................143
9.1.2 Personnel qualifications................................................ 144
9.2 Consumables and auxiliary agents................ ................ 145
9.2.1 Cleaning agents .......................................................145
9.2.1.1 Table of cleaning agents ...............................................145
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9.2.2 Lubricants .............................................................146
9.2.2.1 Lubrication ...........................................................146
Manual lubrication..................................................147
Automatic lubrication system.......................................149
9.2.2.2 Lubricant table........................................................ 151
9.3 Maintenance tasks..................................................152
9.3.1 General prerequisites..................................................152
9.3.2 Maintenance intervals..................................................152
9.3.3 Special tools, testing and measuring instruments........................ 154
9.3.4 Maintenance tasks after downtimes <4 weeks...........................156
9.3.5 Maintenance tasks after downtimes >4 weeks...........................156
9.3.6 Maintenance tasks 100 hours after commissioning.......................157
9.3.6.1 Carrying out a lubrication check.......................................158
9.3.7 Maintenance tasks after 150 hours.................. ...................159
9.3.7.1 Lubricating guideways, racks and pinions ...............................159
9.3.8 Maintenance tasks after 2,250 hours ...................................161
9.3.8.1 General inspection.....................................................161
9.3.8.2 Replacing the battery.................................................. 164
9.3.8.3 Replacing the cartridge.................................................164
9.3.8.4 Carrying out a lubrication check.......................................165
9.3.9 Maintenance tasks after 6,750 hours ...................................166
9.3.9.1 Replacing the lubricating pinion.........................................166
9.3.9.2 Replacing the wiper and lubrication unit................................ 168
9.3.10 Maintenance tasks after 11,250 hours...................................170
9.3.10.1 Checking automatic lubrication system................ .................170
9.3.11 Maintenance tasks after 22,500 hours...................................171
9.3.11.1 Replacing the automatic lubrication pump...............................171
9.3.11.2 Replacing the energy chain..............................................171
Removing the energy chain .........................................171
Laying the cables and lines..........................................171
Installing the energy chain...........................................174
Final tasks..........................................................176
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9.3.11.3 Replacing the slide bars................................................ 176
Replacing and pre-assembling the slide bars..........................176
Installing the slide bars..............................................177
9.3.11.4 Replacing the gearbox unit..............................................178
Attaching the slings: Motor .........................................178
Attaching the slings: Güdel gearbox unit.............................180
Removing the motor and coupling...................................181
Removing the gearbox unit .........................................183
Replacing the gearbox unit..........................................183
Installing the gearbox unit...........................................184
Installing the motor ................................................185
Final tasks..........................................................196
9.3.11.5 Replacing the roller....................................................197
Roller positions ....................................................197
Using the mounting aid: Relieving the roller..........................198
Replacing the roller ................................................200
Replacing the double roller .........................................201
Y-axis..............................................................205
Z-axis..............................................................209
Final tasks..........................................................210
9.3.11.6 Replacing the guideway................................................ 211
Disassembling the guideway.........................................211
Using the mounting aid: Installing the rack...........................211
Installing the guideway..............................................212
Check rack transition ..............................................214
Final tasks..........................................................215
9.3.11.7 Replacing switches, sensors............................................ 216
9.3.12 Setting the tooth flank backlash........................................ 216
9.3.12.1 Eccentric marking.......................... ...........................217
9.3.12.2 Blocking, unblocking the eccentric ring................ .................217
9.3.12.3 Eccentric .............................................................218
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9.3.12.4 Check the tooth flank backlash .........................................219
Blocking the drive pinions...........................................219
Rack quality and module............................................220
Exact measuring method............................................220
Inexact measuring method..........................................222
9.4 Maintenance schedules...................... ...................... 224
9.4.1 Maintenance schedule ZP.............................................. 225
9.4.2 Güdel gearbox unit maintenance schedule.............................. 227
9.4.3 Maintenance schedule for automatic lubrication system........ .........229
9.5 Maintenance table..................................................231
9.6 Intervention report: Maintenance................ .................233
9.7 Feedback on the instructions...................................... 243
10 Repairs 244
10.1 Introduction ........................... ............................ 244
10.1.1 Safety................................ .................................244
10.1.2 Personnel qualifications................................................ 245
10.2 Repairs .............................................................. 245
10.2.1 General prerequisites..................................................245
10.2.2 Replacing lubricant .....................................................246
10.2.2.1 Attaching the slings: Motor.............................................246
10.2.2.2 Attaching the slings: Güdel gearbox unit................................247
10.2.2.3 Remove the motor.................................................... 248
10.2.2.4 Removing the gearbox unit.............................................250
10.2.2.5 Replacing lubricant .....................................................251
10.2.2.6 Installing the gearbox unit .............................................254
10.2.2.7 Installing the motor ...................................................255
10.2.2.8 Final tasks .............................................................256
10.2.3 Replacing the motor....................................................257
10.2.4 Replacing the motor flange and gearbox flange..........................260
10.2.5 Replacing pinion, bearing, and clamping set .............................262
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10.2.6 Setting the gear backlash................................................265
10.2.7 Replacing the elastomer gear rim .......................................267
10.3 Tasks to perform after a crash ................. .................. 268
10.3.1 Replacing the bumper unit...................... .......................268
10.3.1.1 Bumper unit with shearing sleeves .....................................269
10.3.1.2 Bumper unit with pins........................ .........................270
10.3.1.3 Bumper unit with limit stops............................................271
10.3.2 Referencing the axes ...................................................271
10.4 Malfunctions / Troubleshooting....................................272
10.5 Intervention report: Repairs................... ....................273
10.6 Other documentation..............................................275
10.7 Service departments....................... ........................275
11 Decommissioning, storage 276
11.1 Introduction ........................... ............................ 276
11.1.1 Personnel qualifications................................................ 276
11.2 Storage conditions .................................................276
11.3 Decommissioning......................... ......................... 277
11.3.1 Shutdown.............................. ...............................277
11.3.2 Cleaning, rust-proofing.................................................277
11.3.3 Transport securing devices .............................................277
11.3.4 Identification.......................................................... 278
11.4 Recommissioning......................... ..........................278
12 Disposal 281
12.1 Introduction ........................... ............................ 281
12.1.1 Safety................................ .................................281
12.1.2 Personnel qualifications................................................ 282
12.2 Disposal .............................................................282
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12.3 Waste management compliant assemblies........... ............283
12.3.1 Disassembly ...........................................................283
12.3.2 Material groups .......................................................284
12.4 Disposal facilities, authorities......................................284
13 Spare parts supply 285
13.1 Service departments....................... ........................287
13.2 Explanations regarding the spare parts list.......................293
13.2.1 Parts list...............................................................293
13.2.2 Position drawings .....................................................293
14 Torque tables 294
14.1 Tightening torques for screws................... ................... 294
14.1.1 Zinc plated screws ......................................................295
14.1.2 Black screws ............................................................296
14.1.3 Stainless steel screws ...................................................297
14.2 Tightening torques for HV sets .....................................298
14.3 Tightening torques for clamping sets .............................. 299
14.4 Thread rolling screws ....................... ........................300
Illustrations 301
List of tables 307
Index 311
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Appendix
Hazard analysis, Risk analysis
Addition to declaration of incorporation
Technical data
Layout
Spare parts lists
Options
Third-party documentation
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1 Declaration of incorporation
The manufacturer: GÜDEL AG
Industrie Nord
CH-4900 Langenthal
hereby declares that the partly completed machine:
Product, type
Serial number
Parts list
Year of manufacture
corresponds to the fundamental requirements of the Machinery Directive
(2006/42/EC), Appendix 1.
The partly completed machine may only be commissioned after it has been
determined that the machine into which the partly completed machine is to
be incorporated complies with the stipulations of Machinery Directive
(2006/42/EC).
The special technical documentation as per Appendix VII Part B has been
compiled. This is submitted in electronic form, depending on the respective
regulations of the national bodies.
Authorized representative responsible for compiling the technical documenta-
tion:
Alain Knuchel Tel. [phone]
The partly completed machine complies with the following additional EC di-
rectives:
• Low Voltage Directive2014/35/EU
• EMC Directive2014/30/EU
The following harmonized standards have basically been applied:
EN ISO 12100:2010; EN ISO 13850:2015; EN 60204-1:2006; EN ISO
14119:2013; EN ISO 4413:2010; EN ISO 4414:2010; EN ISO 13849-1:2015
Langenthal,
Markus Ruprecht
CEO
Alain Knuchel
General Manager
Robotics
Declaration of conformity, declaration of incorporationOPERATING MANUAL ZP 3-5 V4
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ZP 3-5 V4
99xxxxxxx
10xxxxxxx
2018
xx.xx.20xx

Declaration of conformity, declaration of incorporation OPERATING MANUAL ZP 3-5 V4
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2 General
Read the entire manual before working with the product. The manual con-
tains important information for your personal safety. The manual must be
read and understood by all persons who work on the product in any of the
product life phases.
2.1 Further applicable documentation
All documents delivered with this manual are further applicable documenta-
tion. They must be observed in addition to this operating manual for the safe
handling of the product.
2.2 Purpose of the document
This manual describes all the product life phases of the product:
• Transport
• Commissioning
• Operation
• Maintenance
• Repairs
• Disposal
The manual contains the information required for using the product as in-
tended. It is an essential component of the product.
The manual must be available at the product site throughout the entire ser-
vice life of the product. If the product is sold, the manual must be transferred
to the new owner.
Assembly instruc-
tions for partly
completed ma-
chinery
This document serves as the "Assembly instructions for partly completed ma-
chines" in accordance with the Machinery Directive 2006/42/EC, and is in this
respect an "Operating Manual".
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2.3 Explanation of symbols/abbreviations
The following symbols and abbreviations are used in this manual:
Symbol/Abbrevia-
tion
Use Explanation
Ü
For cross-reference See
2
Possibly for cross-ref-
erence
Page
Fig. Designation of graphics Figure
Table Designation of tables Table
In the tip Information or tip
Table2-1 Explanation of symbols/abbreviations
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