ITEM KGT 6 60 P20 User manual

KGT 6 60 P20
Assembly guide

2
KGT 6 60 P20 – assembly guide
Contents
Symbols, safety .......................................................................................................................................................................................................2
General safety information ...................................................................................................................................................................................3
Correct use ...............................................................................................................................................................................................................3
Improper use.............................................................................................................................................................................................................4
Product description.................................................................................................................................................................................................4
Technical data .........................................................................................................................................................................................................5
Preparing for assembly ..........................................................................................................................................................................................6
Fitting the spindle support stops..........................................................................................................................................................................7
Fitting the linear guide rail.....................................................................................................................................................................................9
Fitting the magnetic strips.................................................................................................................................................................................. 10
Fitting the carriage ............................................................................................................................................................................................... 10
Number and positioning of spindle supports................................................................................................................................................. 12
Fitting the xed and oating bearings.............................................................................................................................................................. 14
Fitting the steel strip............................................................................................................................................................................................. 15
Fitting Cover Prole LE 6 .................................................................................................................................................................................... 17
Motor connection with Drive Set KGT 6 60.................................................................................................................................................... 18
Motor connection with Parallel Drive Set 6 60..............................................................................................................................................20
Precongured variants ....................................................................................................................................................................................... 21
KGT 6 60 P20 accessories ................................................................................................................................................................................22
Proximity Switch KLE 6........................................................................................................................................................................22
Cover Prole 6 LE .................................................................................................................................................................................22
Dealer conguration and spare parts list........................................................................................................................................................23
Checklist .................................................................................................................................................................................................................26
Repair and maintenance .... ...............................................................................................................................................................................26
Care and cleaning.................................................................................................................................................................................................26
Disposal .................................................................................................................................................................................................................27
Product development and documentation .................................................................................................................................................... 27
Symbols, safety
Important information
Observe directions for disposal
Observe directions for disposal
Maintenance
Note! Failure to observe this safety instruction can result in material damage
Warning! Failure to observe this safety instruction can result in material damage, serious injury or death
Caution! Failure to observe this safety instruction can result in material damage, serious injury or death
Caution! Failure to observe this safety instruction can result in material damage or injury

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KGT 6 60 P20 – assembly guide
General safety information
The details and information in this assembly guide are provided for the purposes of describing the product and its assembly
only. This information does not discharge users from the obligation to conduct their own assessments and checks. It is also
important to bear in mind that our products are subject to a natural process of wear and ageing.
This guide contains important information that will enable you to use the product safely and appropriately. When sold, rented
out or otherwise passed on to another party, this product must be handed over with the assembly guide. You must therefore
read and follow the safety instructions set out below.
▪ All work on and with the KGT 6 60 P20 must be performed with “safety rst” in mind.
▪ Switch off the power to the KGT 6 60 P20 before carrying out any work on the linear axis.
▪Observe the regulations pertaining to accident prevention and environmental protection that apply in the country and place
of work where the product is being used.
▪Use only item products that are in perfect working order.
▪Failure to use original spare parts will invalidate the product warranty!
▪Check the product for obvious defects.
▪Use the product only within the performance range described in the technical data.
▪ Ensure all the safety equipment associated with the product is present, properly installed and in full working order.
▪ Do not alter the position of safety equipment, circumvent it or render it ineffective.
The KGT 6 60 P20, as described here, corresponds to the state of the art and takes into account the general principles of
safety applicable at the time this assembly guide was published. Nevertheless, failure to observe the safety instructions and
warning notices in this assembly guide may result in personal injury and damage to property. We will assume no liability for
any resulting damage or injury. We reserve the right to make changes that represent technical advances. Keep this guide in
a place where it can be accessed by all users at any time. This general safety information applies to the entire lifecycle of the
KGT 6 60 P20.
Correct use
The KGT 6 60 P20 is a component and must only be used in accordance with the technical data and safety requirements set
out in this document. Combining linear axis KGT 6 60 P20 with a motor and controller creates a partly completed machine as
dened in Machinery Directive 2006/42/EC. The declaration of incorporation for the variants with our Motors and Controllers,
such as the item MotionKit Linear Unit KGT 6 60 P20 as an all-in-one package for automation projects, is included with this
document. Internal company requirements and the regulations that apply in the country where the product is being used must
be observed. You must not make any design modications to the KGT 6 60 P20 yourself. We will assume no liability for any
resulting damage or injury. You may only install, operate and maintain the KGT 6 60 P20 if:
▪The KGT 6 60 P20 has been integrated into its surroundings in a proper and safe manner.
▪You have carefully read and understood the assembly guide.
▪ You are appropriately qualied.
▪You are authorised to do so by your company.
▪ You are using only original equipment from the manufacturer.
The KGT 6 60 P20 is designed for indoor use.

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KGT 6 60 P20 – assembly guide
Improper use
Improper use is dened as any use of the product for purposes other than those authorised in the assembly guide and under
the denition of correct use. We will assume no liability for any resulting damage or injury.
Product description
Compact, precise and dynamic, Linear Unit KGT 6 60 combines a ball screw drive that has a stroke of up to 2600mm with
a strong carriage, and does so in the smallest of installation spaces. In applications with a long travel distance, travelling
spindle supports keep everything running smoothly and precisely without sacricing dynamics. Mechanical coding on the
inside of the axis provides perfect support for the specially shaped spindle with any stroke length and in any carriage position.
Two Drive Sets are available that suit the performance spectrum of the mechanical axis and are fully prepared for combina-
tion with item Motors and item Controllers to produce customer-specic solutions. The universal Drive Set 6 60 D30/D12
makes it possible to connect to third-party motors.
Three precongured Linear Units complete with Motor and Controller are available for the various stroke lengths. The variants
are based on these basic mechanical components.
Linear Unit KGT 6 60 P20:
0.0.706.00
74
The distances S1and S2are built as follows:
S1: distance to the xed bearing (13mm) + safety distance (Smin = 26mm) + n x
spindle support (16mm)
S2: distance to oating bearing (11mm) + safety distance (Smin = 26mm) + n x
spindle support (16mm)
The safety distance of 26mm is in all variants the free area, in which e.g. during the
reference motion procedure is driven.
Stroke range
[mm] X [mm] S1[mm] S2[mm] Basic mass [kg]
0 - 1000 323 56 53 2.635
1001 - 1560 355 72 69 2.855
1561 - 2120 387 88 85 3.053
2121 - 2600 419 104 101 3.253
Drive Set KGT 6 60 D30/D12 SE 40: Drive Set KGT 6 60 D30/D12 SE 60: Drive Set KGT 6 60 D30/D12:
0.0.692.53 0.0.692.55 0.0.704.53

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KGT 6 60 P20 – assembly guide
Technical data
Maximum stroke: 2600mm
Safety clearance: 26mm
Mass per mm of stroke: 3592g/mm
Repeatability: 0.01mm
Maximum acceleration: 15m/s²
Maximum speed: 1m/s
Feed: 20mm/revolution
Mounting dimension: 60mm x 60mm
Spindle lead: 20mm
Maximum operating load: 1000N
Support
width Lmax
at
Fz max [mm]
Support
width Lmax
at
Fy max [mm]
Fy max [N] Fz max [N] Mx max
[Nm]
My max
[Nm]
Mz max
[Nm]
Operating
load
Fx max [N]
Linear Unit KGT
6 60 P20 600 800 2000 2000 15 120 120 1000
Ambient conditions:
Storage temperature: -20°C to +70°C
Relative humidity: 5% to 85%
Linear Unit KGT 6 60 P20 is intended as a permanent xture to be used in an area that is protected from the weather.
Do not install or use in close proximity to industrial plants that produce chemical emissions.
Do not install or use in an area that is regularly exposed to high-energy surges such as those caused by presses or heavy
machinery, for example.
In case of doubt regarding resistance to certain chemicals such as test oil, alloyed oils, aggressive cleaning substances,
solvents or brake uid, we advise that you consult your specialist representative.
Consult the manufacturer if using in very salty air.
Deection in the KGT 6 60 P20 should not exceed 1mm over an axis of 1000mm. In scenarios where high demands are
placed on the system dynamics, supports should be added every 300mm to 600mm.

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KGT 6 60 P20 – assembly guide
Nmax with support
[rpm]
Nmax without support
[rpm]
D = speed [rpm]
L = length of spindle [mm]
0
0
500
1000
1500
2000
2500
1000
3000
3500
2000 3000 350025001500500
D [1/min]
L [mm]
Maximum spindle speed with and without KGT 6 60 P20 spindle supports
The spindle supports ensure that the maximum length of the spindle that is unsupported remains more or less the same. This
means the critical speed of 3000rpm is constant over the entire possible stroke range.
Preparing for assembly
Switch off the power to the system before carrying out any installation, cleaning or maintenance work on the KGT 6 60 P20.
Preparations for assembly:
▪ Prole 6 60 LE: L = H+X-24
▪ Spindle: 15mm shorter than Prole 6 60 LE
▪ Prole, guide rail: 20mm shorter than Prole 6 60 LE
▪ Magnetic strip: Approx. 5mm longer than Prole 6 60 LE
▪ Steel strip: Approx. 12mm longer than Prole 6 60 LE
The rst step is to countersink the core bores of Support Prole 6 60 LE on both sides and give them an M5x20 thread. The
tap should have a helix to prevent it from canting in the core hole.
Anti-slip aids should be placed underneath the axis during assembly.

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KGT 6 60 P20 – assembly guide
Fitting the spindle support stops
Secure the stops for the spindle supports – a screw-
washer-nut combination for subsequent positioning of
the support – in the relevant positions in the Support
Prole’s T-slot channels.
Tightening torque MT = 1.2Nm
The number of stops required depends on the stroke of the Linear Unit. Consult the drawings to determine
which of the prole channels to use and where in that channel to place the stop. The stops themselves are identical and only
their position and tightening torque are important.
Variation and number of stops
Stroke range [mm] 0 - 1000 1001 - 1560 1561 - 2120 2121 - 2600
Number of stops 1 2 3 4
Prole channel num-
ber (see drawing) 11 + 2 1 + 2 + 3 1 + 2 + 3 + 4
Position of stop 0.5 x prole length Each 0.33 x prole
length
Each 0.25 x prole
length
Each 0.2 x prole
length
Caution: It is important that the stops are positioned precisely for the KGT 6 60 PS to function correctly. Positioning the stops
incorrectly can result in damage to the linear axis and injuries for users.

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KGT 6 60 P20 – assembly guide
1. Number and position of stops in a stroke range of between 0 mm and 1000 mm:
L
1/2 L
1/2 L
4
3
4
2
1
▪ The numbers indicate the coloured prole channels in which the stops are to be installed.
▪ L is the measured length of the prole and not stroke.
The stop required for a stroke range of between 0and 1000mm must therefore be installed in channel 4, half way along the prole.
2. Number and position of stops in a stroke range of between 1001 mm and 1560 mm:
L
1/3 L
1/3 L
1/3 L
3
4
3
4
2
1
▪ The numbers indicate the coloured prole channels in which the stops are to be installed.
▪ L is the measured length of the prole and not stroke.
The stops required for a stroke range of between 1001mm and 1560mm must therefore be installed in channels 3 and 4, at
intervals of 0.33 x the prole length.
3. Number and position of stops in a stroke range of between 1561 mm and 2120 mm:
1/4 L
L
1/4 L
1/4 L
1/4 L
2
3
4
3
4
2
1
▪ The numbers indicate the coloured prole channels in which the stops are to be installed.
▪ L is the measured length of the prole and not stroke.
The stops required for a stroke range of between 1561mm and 1210mm must therefore be installed in channels 2, 3 and 4,
at intervals of 0.25 x the prole length.

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KGT 6 60 P20 – assembly guide
4. Number and position of stops in a stroke range of between 2121 mm and 2600 mm:
1/5 L 1/5 L
L
1/5 L
1/5 L
1/5 L
2
1
3
4
3
4
2
1
▪ The numbers indicate the coloured prole channels in which the stops are to be installed.
▪ L is the measured length of the prole and not stroke.
The stops required for a stroke range of between 1001mm and 1560mm must therefore be installed in channels 1, 2, 3 and
4, at intervals of 0.2 x the prole length.
Fitting the Linear Guide Rail
The next step is to t the Linear Guide Rail. Start by
checking the sawn ends of the rail are burrless and
rework them if necessary.
Fit the rail with all the necessary
Hexagon Socket Head Cap Screws and T-Slot Nuts.
Make sure the Hexagon Socket Head Cap Screws are
screwed approximately one to a maximum of two full
turns into the T-Slot Nuts. This then makes it easier to
push the rail into the Support Prole.
Push the rail, tted with the
Hexagon Socket Head Cap Screws and T-Slot Nuts, into
the Support Prole. The T-Slot Nuts must be correctly
aligned when sliding into the relevant groove.
The rail is a total of 20mm shorter than the Support
Prole and must be centred, that is to say 10mm from
each edge. Furthermore, manual pressure must be
applied to keep the rail pressed permanently against
the stop edge while the screws are being tightened.
Tightening torque MT = 1.2Nm
When tightening the screws, apply manual pressure to keep the rail permanently pressed against the stop edge.

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KGT 6 60 P20 – assembly guide
Fitting the magnetic strips
The next step is to t the magnetic strips that have been cut to size. These strips will subsequently hold the KGT’s steel strip in
place. They should be approximately 5mm longer than the Support Prole. Push the magnetic strips into the Support Prole
on the right-hand and left-hand sides.
Use an appropriate tool to remove any burrs from the prole’s insertion edge. Applying soapy water makes it easier to push in
the strips.
Once they have been tted, the magnetic
strips protrude by approximately 2.5mm at
both ends of the prole.
The ne groove in the magnetic strip should be pointing upwards when it is being tted.
Fitting the carriage
A ball screw drive (KGT) is used to move the Linear
Unit’s carriage. The xed combination of ball screw nut
and ball screw spindle makes the drive more precise.
Ball screw spindles are always tted with a ball screw
nut.
Under no circumstances should the ball screw nut be twisted off the spindle.