Hiwin KK User manual

Assembly instructions
Linear axes KK/KF
KX-05-02-EN-2201-MA
www.hiwin.de

Assembly instructions Imprint
Linear axes KK/KF KX-05-02-EN-2201-MA Page 2of 28
Imprint
HIWIN GmbH
Brücklesbünd 1
D-77654 Offenburg, Germany
Phone [phone]
Fax [phone]
[email protected]
www.hiwin.de
All rights reserved.
Reprinting, even in part, is not permitted without our approval.
These assembly instructions are protected by copyright. Written permission is required from
HIWIN GmbH for any duplication, publication in whole or in part, alterations or abridgement.

Assembly instructions Contents
Linear axes KK/KF KX-05-02-EN-2201-MA Page 3of 28
Contents
1General ........................................................................ 4
1.1 About these assembly instructions................................................ 4
1.2 Presentation and layout conventions used in these assembly instructions ............ 5
1.3 Warranty and liability ............................................................ 6
1.4 Manufacturer information ........................................................ 6
1.5 Product monitoring .............................................................. 6
2Basic safety information......................................................... 7
2.1 Proper use...................................................................... 7
2.2 Reasonably foreseeable misuse .................................................. 7
2.3 Conversions or modifications..................................................... 7
2.4 Residual risks ................................................................... 7
2.5 Requirements for personnel ...................................................... 7
2.6 Safety equipment ............................................................... 8
2.7 Markings on the linear axis system................................................ 8
3Description of linear axis KK/KF .................................................. 9
3.1 Application ..................................................................... 9
3.2 Structure of linear axes KK/KF .................................................... 9
3.3 Functional description .......................................................... 10
4Transport and setup............................................................ 13
4.1 Delivery ....................................................................... 13
4.2 Transport to the installation location ............................................. 13
4.3 Installation location requirements................................................ 13
4.4 Storage ....................................................................... 14
4.5 Unpacking and setup ........................................................... 14
5Assembly and connection....................................................... 15
5.1 Mounting of linear axis KK/KF ................................................... 15
5.2 Mounting a moving load ........................................................ 16
5.3 Limit switch connection......................................................... 16
5.4 Mounting of aluminium cover.................................................... 17
5.5 Mounting of bellows cover ...................................................... 18
5.6 Mounting of cross table adapter ................................................. 18
6Commissioning ................................................................ 19
6.1 Switching on linear axis system.................................................. 19
7Maintenance and cleaning ...................................................... 20
7.1 Linear guideway and spindle .................................................... 20
8Disassembly................................................................... 24
9Disposal....................................................................... 25
10 Appendix 1: Order code of linear axes KK/KF ..................................... 26
11 Installation certificate .......................................................... 27

Assembly instructions General
Linear axes KK/KF KX-05-02-EN-2201-MA Page 4of 28
1General
1.1 About these assembly instructions
These assembly instructions are intended for planners, developers and operators of systems
who plan and install the named products as machine elements. It is also addressed to all
persons who carry out the following work:
Transport
Assembly
Electrical connection including connection to the higher-level control system
Integration into a safety system
Retrofitting or upgrading
Setup
Commissioning
Operation
Cleaning
Maintenance
Troubleshooting
Decommissioning, disassembly and disposal
1.1.1 Requirements
We assume that
The operating personnel have been instructed in the safe operation of linear axes KK/KF
and have read and understood these assembly instructions in full
Maintenance personnel maintain and repair the named products in such a way that they
present no danger to persons, the environment or property
1.1.2 Availability
The assembly instructions must always be available to all persons working with or on the
named products. The assembly instructions are also available at www.hiwin.de.

Assembly instructions General
Linear axes KK/KF KX-05-02-EN-2201-MA Page 5of 28
1.2 Presentation and layout conventions used in these assembly
instructions
1.2.1 Instructions for actions
Instructions for actions are provided in sequential order and identified with a triangle symbol.
The results of the actions are accompanied by an arrow.
Example:
Instruction 1
Instruction 2
Result
1.2.2 Lists
Lists are identified through the use of bullet points.
Example:
Linear axes KK/KF must not be operated:
Outdoors
In areas where there is a risk of explosion
…
1.2.3 Presentation of safety information
Safety notices are always indicated by a signal word and sometimes with a hazard-specific
symbol (see section 1.2.4 Symbols used).
The following signal words/hazard levels are used:
Danger! Immediate danger!
Failure to follow this safety instruction will result in severe or fatal injury!
Warning! Potentially dangerous situation!
Failure to follow this safety instruction could result in severe or fatal injury!
Attention! Potentially dangerous situation!
Failure to follow this safety instruction could result in moderately severe or minor injury!
Caution! Potentially dangerous situation!
Failure to follow this safety instruction could result in damage to property or the environment!

Assembly instructions General
Linear axes KK/KF KX-05-02-EN-2201-MA Page 6of 28
1.2.4 Symbols used
The following symbols are used in these assembly instructions and on the product:
Warning symbols
Warning of dangerous
electrical voltage!
Warning of hot surfaces!
Warning of crushing risk!
Warning of danger from
suspended loads!
Environmentally
hazardous substance!
Instruction symbols
Release prior to work!
1.2.5 Information
Note:
Provides general information and recommendations.
1.3 Warranty and liability
The manufacturer's "General Terms and Conditions of Sale and Delivery" apply.
1.4 Manufacturer information
Address HIWIN GmbH
Brücklesbünd 1
77654 Offenburg, Germany
Telephone +49 (0) 781 / 9 32 78 - 0
Technical customer service team +49 (0) 781 / 9 32 78 - 77
Fax +49 (0) 781 / 9 32 78 - 90
Technical customer service team fax +49 (0) 781 / 9 32 78 - 97
E-mail [e-mail]
Internet www.hiwin.de
1.5 Product monitoring
Please inform HIWIN, as manufacturer of the named products, about:
Accidents
Possible sources of danger on the named products
Any unclear information in these assembly instructions

Assembly instructions Basic safety information
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2Basic safety information
Warning!
This chapter is for the safety of everyone who works with, assembles, installs, operates,
maintains or disassembles linear axes KK/KF. Failure to comply with the following
information could be dangerous!
2.1 Proper use
Linear axis KK/KF is a linear drive and guide system for the exact, time-controlled positioning of
permanently mounted loads in an automated system.
Several linear axes KK/KF can be mounted on top of each other to form cross tables.
In the event of vertical mounting, a suitable clamping or braking device must be provided to be
able to prevent unintentional lowering of the load.
All linear axes KK/KF may only be used as described for the intended purpose.
The named products may only be operated within their specified performance limits
The assembly instructions and the maintenance and servicing instructions must be
complied to ensure the intended use of the products.
The products must not be used in potentially explosive atmospheres.
The products may only be used and operated indoors.
Any other use of the products is considered improper use.
The products are delivered as a system. That is why the entire documentation of the system
must be observed. Depending on the linear axis type, the accompanying documentation may
vary.
2.2 Reasonably foreseeable misuse
The named products must not be operated:
Outdoors
In areas where there is a risk of explosion
2.3 Conversions or modifications
Conversions or modifications to the named products are not permitted!
2.4 Residual risks
No residual risks emanate from the named products during normal operation. Dangers that may
arise during maintenance and servicing are specified in the respective chapters.
2.5 Requirements for personnel
Only authorised and competent persons may carry out work on the products! They must be
familiar with the safety equipment and regulations before they start work (see Table 2.1).

Assembly instructions Basic safety information
Linear axes KK/KF KX-05-02-EN-2201-MA Page 8of 28
Table 2.1: Requirements for personnel
Activity Qualifications
Normal operation Instructed personnel
Cleaning Instructed personnel
Maintenance Qualified personnel of the operator or manufacturer
Servicing Qualified personnel of the operator or manufacturer
Transport Instructed personnel
Assembly Instructed qualified personnel
Disassembly Instructed qualified personnel
2.6 Safety equipment
Table 2.2: Personal protective equipment
Operating phase Personal protective equipment
Normal operation The following personal protective equipment is required when
standing or working near the linear axes:
Safety shoes
Cleaning The following personal protective equipment is required when
cleaning the named products:
Safety shoes
Servicing and maintenance The following personal protective equipment is necessary
during maintenance and servicing:
Safety shoes
2.7 Markings on the linear axis system
2.7.1 Warning symbols
Table 2.3: Warning symbols
Pictograms Type and source of danger Protective measure
Danger due to electric shock! Disconnect linear axes KK/KF
from the power supply before
servicing or maintenance!
Danger due to hot surfaces! Let hot surfaces cool down
before touching them!
2.7.2 Type plate
Fig. 2.1: Example of a type plate

Assembly instructions Description of linear axis KK/KF
Linear axes KK/KF KX-05-02-EN-2201-MA Page 9of 28
3Description of linear axis KK/KF
3.1 Application
Linear axis KK/KF is used for traversing and moving loads firmly mounted on the traversing
carriage (linearly). It can be mounted horizontally or, with the help of clamping or braking
devices, vertically.
3.2 Structure of linear axes KK/KF
Linear axes KK/KF consist of the components shown as examples in Fig. 3.1.
Fig. 3.1: Structure of linear axis KK/KF
1 Supported bearing 8 Drive flange
2 Recirculation system 9 Bearing cover
3 Seal 10 Bearing cover
4 Block with integrated ballscrew nut 11 End seal
5 Ballscrew 12 Grease nipple
6 Fixed bearing 13 End plate
7 Locknut
Special feature of KK axis
Special feature of KF axis

Two-row version

Full-ball type

Four-row version

SynchMotionTM technology

Assembly instructions Description of linear axis KK/KF
Linear axes KK/KF KX-05-02-EN-2201-MA Page 10 of 28
3.3 Functional description
HIWIN linear axes KK/KF are compact positioning axes. The feed is generated by a ballscrew
mounted in a drive flange. The movement is guided by a special linear guideway. Due to the
recirculating ball bearing guide of the block in the steel profile and the integrated nut of the
ballscrew, linear axis KK/KF achieves very high load ratings and high rigidity with minimal
frictional or idle torque.
Depending on the application requirements, different sizes and the following optional
accessories are available:
Limit switch
Second block
Aluminium cover
Bellows cover
Motor adapter flanges
Linear axes KK/KF are delivered completely assembled. The optional accessories can be
supplied separately on customer request. To avoid damage to the linear axes, please observe
the safety instructions in chapter 4.3.
The mounting surface must be a flat surface. The required evenness is 0.03 mm over 300 mm.
Typical properties

Complete axis ready for installation

Universally applicable

Compact design

Adaptable and sturdy

High accuracy and rigidity
Advantages of KK axis
Additional advantages of KF axis

Two-row version

Standard version

Horizontal mounting position possible

Vertical mounting position possible with clamping
or braking device shown

Application with high precision

Compact design

Four-row version

Optimised synchronisation properties

Reduced running noise

Same dimensions as KK axis

SynchMotionTM technology
3.3.1 Limit/Reference switch (option)
On linear axis KK/KF, two optical or inductive PNP-switching proximity switches send a signal to
the control system when the ends of the travel distance are reached. The limit switches are
delivered wired and ready for use.
The limit switches are mounted on a sensor rail attached to linear axis KK/KF and can be
positioned freely. On delivery, the proximity switches are mounted on the sensor rail ready for
use.
Cable length 2 m/4 m
Open cable end
Optionally with Sub-D connection

Assembly instructions Description of linear axis KK/KF
Linear axes KK/KF KX-05-02-EN-2201-MA Page 11 of 28
Fig.
3.2: Linear axis KK/KF with limit/reference
switches
Fig.
3.3: Inductive proximity switch on bracket
Table 3.1: Technical data of the limit/reference switch
Inductive
Switching distance 2 mm
Correction factor V2A/brass/aluminium 1.16 /0.70 /0.67
Type of installation Flush
Switch hysteresis < 10%
Electric
Power supply 10 to 30 VDC
Current consumption (Ub = 24 V) < 8 mA
Switching frequency 930 Hz
Temperature drift < 10%
Temperature range -25 to +80 °C
Voltage drop of switching output < 1 V
Switching current 100 mA
Residual current of switching output < 100 μA
Short-circuit resistant Yes
Reverse polarity protected Yes
Overload-proof Yes
Mechanical
Housing material Plastic
Full potting
Yes
Protection class IP67
Connection type Cable
Cable length 4 m, 2 m
Protection class III

Assembly instructions Description of linear axis KK/KF
Linear axes KK/KF KX-05-02-EN-2201-MA Page 12 of 28
Fig. 3.4: Dimensioned drawing of the reference switch
1 Switch state indicator
The proximity switch is attached to the sensor rail with M3 screws. The tightening torque is 1.8
Nm.
3.3.2 Covers (option)
Aluminium sheet metal covers are optionally available for all sizes of linear axes KK. Bellows
covers are also available for sizes KK60 and KK86. The covers are delivered mounted as
standard.
3.3.3 Motor adapter flange (option)
Linear axis KK/KF is delivered with motor adapter flange F0 as standard. Depending on the size,
different adapter flanges are available. Additional adapter flanges F1, F2, F3, ... are delivered
mounted on standard motor adapter flange F0.

Assembly instructions Transport and setup
Linear axes KK/KF KX-05-02-EN-2201-MA Page 13 of 28
4Transport and setup
4.1 Delivery
4.1.1 Delivery condition
Linear axes KK/KF are delivered fully assembled, functionally tested and ready for connection.
4.1.2 Scope of delivery
The scope of delivery may vary depending on the configuration ordered. Please refer to the
contract documentation.
4.2 Transport to the installation location
From a weight of 25 kg, suitable and appropriately dimensioned lifting gear must be used for
transport. Comply with the applicable industrial safety regulations for handling suspended
loads.
Caution! Danger of property damage!
Linear axis KK/KF can be damaged by mechanical stress.
Lift linear axis KK/KF only at the profile, not at the motor or spindle!
For longer linear axes, ensure the centre sections have additional protection!
Ensure that the linear axis does not bend, as this will permanently damage the precision!
Do not transport any additional loads on the linear axis during transport!
Secure linear axis and components against tipping before transport!
Note
Linear axes KK/KF must always be operated in conjunction with suitable safety devices
(electrosensitive protective equipment, mechanical protective equipment); these protective
devices must be designed, installed and regularly checked in accordance with the applicable
national and international laws and regulations.
4.3 Installation location requirements
4.3.1 Environmental conditions
Ambient temperature
+ 5
°C to + 40 °C
Installation site
Level, dry, vibration
-free
Atmosphere
Non
-corrosive, non-explosive
Flatness
0.03 mm to 300 mm
4.3.2 Safety equipment to be provided by the operator
Possible safety equipment/measures:
Personal protective equipment according to UVV
Electrosensitive protective equipment
Mechanical safety equipment

Assembly instructions Transport and setup
Linear axes KK/KF KX-05-02-EN-2201-MA Page 14 of 28
4.4 Storage
Store linear axes KK/KF in the transport packaging.
Store linear axes KK/KF only in dry, frost-free rooms with a corrosion-free atmosphere.
Clean and protect used linear axes KK/KF before storage.
4.5 Unpacking and setup
Note
Linear axis KK/KF may only be set up and operated indoors.
Note
Linear axes KK/KF are ideally designed for horizontal installation. These linear axes should not
exceed an angle of 1° on the X- and Y-axis when installed.
Remove protective film.
Carefully transport linear axis to the intended installation site.
Ensure that the maintenance points are freely accessible.
Dispose of packaging in an environmentally-safe manner.

Assembly instructions Assembly and connection
Linear axes KK/KF KX-05-02-EN-2201-MA Page 15 of 28
5Assembly and connection
Warning! Danger of crushing due to traversing carriage!
Risk of injury due to crushing and damage to the linear axis axis systems due to movement of
the traversing carriage due to gravity, as linear axes KK/KF do not have a brake by default.
Ensure that linear axis KK/KF has a maximum of 1° horizontal deviation on the X and Y
axes during installation!
Warning! Danger from suspended loads or falling parts!
Lifting heavy loads can cause damage to health.
Use appropriately dimensioned lifting equipment for positioning heavy loads!
Comply with the applicable industrial safety regulations for handling suspended loads.
Only lift the linear axis by the profile!
Note
Mounting surface must have an evenness of 0.03 mm on 300 mm!
Note
Assembly of linear axis KK/KF only by qualified personnel!
5.1 Mounting of linear axis KK/KF
Caution! Danger of property damage!
As standard, linear axis KK/KF does not have a brake.
When used in vertical applications, prevent unintentional lowering of the linear axis!
Linear axes KK/KF are designed for horizontal use as standard. For vertical installation, the
applicable safety guidelines must always be observed.
The linear axis is only attached from above. Holes for cap screws are available for this purpose.
The number of holes depends on the length of the support profile.
Make suitable mounting hole on the mounting surface, if not already present
Clean the mounting surface and position linear axis KK/KF on the mounting surface
Place linear axis KK/KF firmly against the reference edge (Fig. 5.1)
Screw in the mounting bolts for all mounting holes and tighten them from the inside to the
outside in a spiral sequence
Linear axis KK/KF is mounted
Note
Secure the screws against unintentional loosening!

Assembly instructions Assembly and connection
Linear axes KK/KF KX-05-02-EN-2201-MA Page 16 of 28
Table 5.1: Tightening torques of the mounting bolts
Series/Size Screw size Torque [Nm]
KK30 M3 1.8
KK40 M3 1.8
KK50 M4 4.4
KK/KF60 M5 7.2
KK/KF86 M6 10.2
KK100 M8 18.6
KK130 M8 18.6
5.2 Mounting a moving load
Warning! Danger from suspended loads or falling parts!
Lifting heavy loads can cause damage to health.
Use appropriately dimensioned lifting equipment for positioning heavy loads!
Comply with the applicable industrial safety regulations for handling suspended loads.
Clean the mounting surfaces for the load on linear axis KK/KF
Clean the mounting surface of the load
Position the load on the linear axis KK/KF
Tighten the mounting bolts in a spiral sequence
Check freedom of movement of the load over the entire travel distance
Secure screws
Load on linear axis KK/KF is mounted
Fig. 5.1: Reference edge
5.3 Limit switch connection
One to three inductive proximity switches installed in the linear axis ready for operation
Available with 2 m or 4 m connection cable

Assembly instructions Assembly and connection
Linear axes KK/KF KX-05-02-EN-2201-MA Page 17 of 28
5.3.1 Dimensions
Fig. 5.2: Dimensions of the inductive limit switch
1 Switch state indicator
5.3.2 Circuit diagram
Fig.
5.3: Circuit diagram for normally open
Fig.
5.4: Circuit diagram for normally closed
Explanation of symbols
+
Power supply “+”
–
Supply voltage “0 V"
A/Ā
Switching output
Core colours
BN
Brown
BK
Black
BU
Blue
5.4 Mounting of aluminium cover
Screw the block adapter [1] to the block [2] with the tightening torque from Table 5.2.
Screw the aluminium cover [3] to the drive flange [4] and end plate [5].
Aluminium cover is mounted.
Fig. 5.5: KK/KF axis with aluminium cover plate

Assembly instructions Assembly and connection
Linear axes KK/KF KX-05-02-EN-2201-MA Page 18 of 28
Table 5.2: Tightening torques for mounting bolts
Thread M3 M4 M5 M6 M8 M10
Tightening torque
[Nm]
1.2 2.9 6.0 12.2 24.9 49.4
5.5 Mounting of bellows cover
Screw the block adapter [1] to the block [2] with the tightening torque from Table 5.2.
Screw bellows [3] to drive flange [4], end plate [5] and block adapter [1].
Bellows cover is fitted.
Fig. 5.6: KK/KF axis with bellows
5.6 Mounting of cross table adapter
Screw the cross table adapter [2] to the lower KK/KF axis [1] with the screws [6] as shown
in Fig. 5.7. Tighten the screws with the torque indicated in Table 5.2.
Screw the upper KK/KF axis [3] to the cross table adapter [2] as shown in Fig. 5.7, applying
the screws [4] only lightly.
To align the upper KK/KF axis [3], use the two threaded pins [5] to place the KK/KF axis
firmly against the reference edge.
Then tighten the screws [4] of the upper KK/KF axis [3].
Cross table with cross table adapter is mounted.
Fig. 5.7: Exploded view of cross table

Assembly instructions Commissioning
Linear axes KK/KF KX-05-02-EN-2201-MA Page 19 of 28
6Commissioning
6.1 Switching on linear axis system
Warning! Danger of crushing!
The travel carriage can cause bruising to limbs due to its movement at the end positions of
the machine.
Provide protective equipment to prevent reaching into the danger zone of the machine!
Warning! Risk of burns!
Motor heating can cause burns if the motor is touched.
Provide protective device and warnings on the motor!
Caution! Danger of property damage!
Uncontrolled movements of the traversing carriage in the event of a power failure can cause
property damage!
Ensure that suitable end stops are fitted to the end positions of the linear axis!
Note
Linear axes must always be operated in conjunction with suitable safety devices
(electrosensitive protective equipment, mechanical protective equipment); these protective
devices must be designed, installed and regularly checked in accordance with the applicable
national and international laws and regulations.

Assembly instructions Maintenance and cleaning
Linear axes KK/KF KX-05-02-EN-2201-MA Page 20 of 28
7Maintenance and cleaning
Warning! Danger of injury and damage to property!
Unauthorised work on the unit may cause injury and invalidate the warranty.
Assembly and maintenance of the system only by qualified personnel!
Caution! Risk of damage to health and the environment!
Contact with lubricants can cause irritation, poisoning and allergic reactions as well as
damage to the environment.
Only use suitable media that are not dangerous for humans. Observe the manufacturer’s
safety data sheets.
Dispose of substances appropriately.
For maintenance work:
Secure the linear axis system against unauthorised switch-on.
Disconnect the linear axis system from the power supply.
Secure the linear axis system against unauthorised restarting.
7.1 Linear guideway and spindle
7.1.1 Lubrication
The profile rails of the linear axes, like any rolling bearing, require a sufficient supply of
lubricant. This lubrication reduces wear, protects against dirt and deposits, prevents corrosion
and extends the service life due to its properties.
Observe the lubricant manufacturer's specifications!
Miscibility of different lubricants must be checked. Lubricants with same classification (e.g.
CL) and similar viscosity (maximum one class difference) are miscible.
Greases are miscible if their base oil and thickening type are the same. The viscosity of the
base oil must be similar and the NGLI class must not differ by more than one grade.