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
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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
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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
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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