ITEM KRF 8 80x40 ZR Operating instructions

Linear Unit KRF 8 80x40 ZR
Notes on Use and Installation

2
Symbols, safety
Important, safety information, recommendation Maintenance
Contents
General safety information
The details and information in the installation guide are provided for the purposes of
describing the product and its assembly only. The information does not discharge
the user from the obligation to carry out his own assessments and checks. It is
important to bear in mind that our products are subject to a natural process of wear
and ageing. These notes contain 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 installation guide.
When installing, operating and maintaining Linear Unit KRF 8 80x40 ZR, it is
important to ensure that all moving elements are secured so that they cannot
be switched on and moved unintentionally. Rotating and moving parts can
cause serious injury! You must therefore read and follow the safety instructions
set out below.
All work on and with Linear Unit KRF 8 80x40 ZR must be performed with
“safety first” in mind.
Always switch off the drive assembly before you start working on Linear Unit
KRF 8 80x40 ZR
Ensure the drive unit cannot be switched on unintentionally, e.g. by affixing warn-
ing notices at the activation point or by removing the fuse from the power supply.
Do not place your hand within the operating range of moving parts in Linear
Unit KRF 8 80x40 ZR when the unit is still switched on.
Fit guards and covers so that the moving parts of Linear Unit KRF 8 80x40 ZR
cannot be touched unintentionally.
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 that 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.
Accessories 9
Correct use 3
General safety information 2
Improper use 3
Installation 5
Maintenance 11
Operating parameters 4
Symbols, safety 2

3
Linear Unit KRF 8 80x40 ZR
Correct use
Improper use
Linear Unit KRF 8 80x40 ZR is a partly completed machine as defined in the
Machinery Directive (2006/42/EC). Linear Unit KRF 8 80x40 ZR must only be
used in accordance with the technical data and safety requirements set out in
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 modifications to Linear Unit KRF 8 80x40 ZR yourself. We
will assume no liability for any resulting damage or injury. You may only install,
operate and maintain Linear Unit KRF 8 80x40 ZR if:
Linear Unit KRF 8 80x40 ZR has been integrated properly and safely into the
completed machine,
You have carefully read and understood the installation guide,
You are appropriately qualified,
You are authorised to do so by your company,
You are using only original equipment from the manufacturer.
Unsafe or inappropriate use of Linear Unit KRF 8 80x40 ZR runs a risk of serious
injury through crushing and cuts.
Improper use is defined as any use of the product for purposes other than those
authorised in the installation guide and under the definition of correct use. We
will assume no liability for any resulting damage or injury.
Linear Unit KRF 8 80x40 ZR, as described here, corresponds to the state of
the art and takes into account the general principles of safety applicable at the
time this installation guide was published. Nevertheless, failure to observe the
safety instructions and warning notices in this installation 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 technical changes that represent technical advances. Keep these
installation notes in a place where they can be easily accessed by all users.
Observe the directions contained in the main user guide for the completed
machine.
The general safety information applies to the entire lifecycle of the partly
completed machine.
1. During transportation
Observe the handling instructions on the packaging. Until it is installed, the
product must be stored in its original packaging, protected from moisture and
damage. Ensure that moving parts are secured when in transit and cannot
cause any damage.
2. During installation
Always deactivate the power to the relevant system part and ensure it is not live
before installing the product and/or plugging it in or unplugging it. Ensure the
system cannot be switched back on. Lay cables and lines in such a way that
they cannot be damaged and do not represent a trip hazard. Avoid areas that
pose slip, trip and fall hazards.
3. During start-up
Allow the product to acclimatise for a few hours before starting it up. Ensure
that the partly completed machine is securely and safely integrated into the
completed machine. Only start up a product that has been installed in full.
4. During operation
Ensure that only persons who have been authorised by the operator have ac-
cess to the immediate operating environment of the system. This also applies
when the system is not in operation. It must not be possible to actuate moving
parts unintentionally. During emergencies, malfunctions or other irregularities,
deactivate the system and ensure that it cannot be switched back on. Prevent
the possibility of persons becoming trapped in the system’s hazard zone.
5. During cleaning
Close all openings with suitable protective equipment to ensure that cleaning
agents cannot penetrate the system. Do not use aggressive cleaning sub-
stances. Do not use a high-pressure cleaner when cleaning the system.
6. During maintenance and servicing work
Carry out the prescribed maintenance work at the intervals stipulated in the
user guide. Ensure that no line links, connections or components are removed
while the system is live and under pressure. Ensure the system cannot be
switched back on.
7. During disposal
Dispose of the product in accordance with the national and international regula-
tions that apply in your country.

80
100
L=2xS+H+360
200
80
80
40
100
S
H
S
x
y
z
Fz
Fy
Fx
Mz
Mx
My
4
Operating parameters
Load Specifications
KRF Mx max
[Nm]
My max
[Nm]
Mz max
[Nm]
Fy max
[N]
Fz max
[N]
50 175 175 2,500 2,500
|Mx|
____
Mx max
+
|My|
____
My max
+ |Mz|
____
Mz max
+
|Fy|
___
Fy max
+ |Fz|
___
Fz max
≤1
Eight rollers, arranged play-free in a criss-cross pattern, ensure maximum load-carrying capacity with compact size.
Simplified method for determining the maximum permis-
sible load for the Roller Guides of a KRF:
Transmissible drive torque: MAmax = 23 Nm
Operating load: Fmax = 1000 N
Max. speed: vmax = 10 m/s
Max. acceleration: amax = 10 m/s²
System-related frictional moment: Mfrictional = 2 Nm
Effective radius of pulley rW= 23.1 mm
Tightening torque for the screws used:
M3 - 1.5 Nm
M5 - 6 Nm
M6 - 10 Nm
M8 - 25 Nm
The special Timing Belt:
Gearing type: AT profile, 5 mm pitch
Belt width: 25 mm +0/-0.5 mm
Special belt with 0.9 mm steel wires for high positioning accuracy
Wire strength: 4000 N
Specific spring rate: 0.998 x 10^6 N
Polyamide coating on teeth side, colour: grey/anthracite
Max. load capacity of Timing Belt: 1000 N limited by the tooth stability of the Timing Belt
Caution! Timing Belt pretensioning: max. 1‰ of the Timing Belt length
Linear Unit KRF 8 80 x40 ZR
0.0.641.21
Lmin 400 mm
Smin 20 mm
Hmax 5,760 mm
m1 (basic unit) 6 kg
m2
( per add. mm travel )
4.4 g/mm

10
10
f
max
F
40
80
5
Installation
Linear Unit KRF 8 80x40 ZR
Z
Y
Linear Unit KRF 8
Iy 95.66 cm4
Iz22.05 cm4
lt20.06 cm4
Wy23.80 cm3
Wz11.02 cm3
The maximum deflection, fmax of the system is governed by the
dimension of the profile cross-section, the free profile length
and the force applied. It should not exceed 1 mm/m. The KRF
profile must be given appropriate support if the linearity of
movement has to be very precise.
Deflection
The mass moments of inertia of the profile provide the basis
for calculating the deflection:
The compact Roller Guide with the best load-to-size ratio of all item drive elements.
Light, quiet-running rollers arranged in a criss-cross pattern for high speed
Innovative track technology – hardened steel tracks (50 m steel strip supplied as roll) rigidly connected to the aluminium guide profile
Solid, machined, rigid sliding carriage with a broad range of attachment options and integrated Timing-Belt clamping mechanism
Fully usable Profile 8 grooves on three sides of the KRF guide profile ensure unbeatable flexibility for attachment geometries
Axes sized to requirements, guide length up to max. 6000 mm recommended
Motors can be adapted using the universal coupling elements in the Drive Set
Linear Unit KRF is augmented by a range of useful accessories that make it easy to attach carriage constructions and drive modules

6
Use the roller assembly tool to bead the aluminium ribs and fix
the steel strips in place. Start at the top of the profile then turn
the profile and repeat at the bottom.
Insert the steel strips into their intended
positions.
Fastening screws
Maintenance openings
Adjusting screws
1. Preparation – Profile 8 80x40 KRF and steel strip:
Cut four M8x20 threads into the core bores at both ends of the Profile 8
80x40 KRF.
Next, insert the steel strips between the mounting ribs provided.
The steel strips should be approximately 5 mm shorter than the support
profile.
A roller assembly tool is used to secure the steel strips in place.
Steel strip, hardened, in a 50 m roll: Lsteel strip = Lprofile - 5mm
2. The carriage:
Solid, rigid sliding carriage made from high-quality aluminium alloy with rollers
arranged in a criss-cross pattern to absorb loads in the form of radial forces.
The carriage is supplied as a preassembled construction kit with one side
that is screwed firmly in place while the opposite side is a floating bearing
end.
The floating bearing end incorporates two adjusting screws with anti-clock-
wise fine threads for moving and adjusting the floating bearing end.
Consequently, the floating bearing is secured by turning clockwise, as usual
(turn towards the track on the profile). Turn anti-clockwise to loosen.
Slot the carriage onto the ready-prepared profile, pushing in the spring-
mounted felt pieces a little to stop them getting damaged.
Tighten the adjustable side (floating bearing end) of the carriage alternately
until the carriage is play free.
Careful adjustment is required to eliminate play when assembling the bearing.
Next, move the carriage along the entire length of the axis and check that it
is free from play.
Once the carriage is free from play, use the fastening screws to tighten the
adjustable carriage side (tightening torque, M8: 25 Nm).
Retrospective adjustments can be made at any time, as long as the screws
are accessible.

L
R
7
Linear Unit KRF 8 80x40 ZR
Fastening bores
Timing Belt clamping device
Timing-Belt Drive KRF 8 40
Drive Side
R : Right, 0.0.646.92
L : Left, 0.0.638.97
The Timing Belt running through
the profile
Reverse Unit cover
3. The Reverse Units:
The Reverse Unit housings are made from a high-strength aluminium alloy.
The Reverse Units are supplied as preassembled construction kits.
Before you can fasten the Reverse Units to the threads that you cut into the
core bores of the profile, you will need to remove the covers from the Reverse
Units.
Do not disassemble the Reverse Units any further – fix them to the profile us-
ing the built-in fastening screws, which are accessed via an upper bore hole
located in each axle and the lower assembly keyholes.
In the Reverse Unit with integrated Timing Belt tensioning device, the lower
fastening screw is accessed through the keyhole in the tensioning screw.
Fastening screws M8, tightening torque: 25 Nm.
5 A/F Allan key.
The tensioning axle in the Reverse Unit has an adjustment range of 18 mm
(= 36 mm elongation in the Timing Belt)
The current setting of the Reverse Unit is indicated via a gauge on the side
of the unit.
Caution! Ensure the Reverse Units are positioned correctly.
There is one Reverse Unit for tensioning the Timing Belt.
There are
two Reverse Units for driving the axis.
The position of the drive shaft is different on each of these Reverse Units
and must be specified during project engineering.
4. The Timing Belt:
Timing Belt length: LZ= 2 x LProfile + 190
Timing Belt pretension: max 1‰
Special Timing Belt:
•Toenablehigherspeeds
•Quietandsmoothrunning
•Tominimiseanypolygoneffect
The clamping mechanism for the Timing Belt is integrated into the carriage
plate – clamping plates hold the ends of the Timing Belt in the positive locking
toothing of the carriage.
Fit one end of the Timing Belt in place on one side of the carriage, ensuring
that all the teeth are engaged.
Next, screw the Timing Belt clamping device into place (tightening torque,
M6: 10 Nm).
Now feed the other end of the Timing Belt through the Reverse Units and the
profile to the opposite end of the carriage.
The profile does not need to be machined to accommodate the Timing Belt,
since a generous amount of space has already been provided.
To make it easier to feed the Timing Belt through the Reverse Units, first
remove the covers on the Reverse Units.
All the teeth on the Timing Belt should also be engaged in the clamping
mechanism at the other end of the carriage. You may need to shorten the
Timing Belt.
Next, screw the second Timing Belt clamping device into place (tightening
torque, M6: 10 Nm).

8
200
40
M8
40
Ø7
8
200
40
Ø7
40
M8
8
5. Tightening the Timing Belt:
A particularly “stiff” Timing Belt will result in low elongation in operation –
and therefore high positioning accuracy for Linear Units driven by a Timing
Belt.
The pulley/Timing Belt combination is virtually play free.
Belt tension is easily adjusted, all adjustment elements are accessible from
outside.
An M10 tensioning screw with a fine thread is located under the cover of the
Reverse Unit that incorporates the tensioning device.
The tensioning mechanics are designed so that turning clockwise tightens
the belt. Slotted link mechanics.
An adjustment range of 18 mm in the tensioning axle corresponds to an
elongation of 36 mm in the Timing Belt (1 mm tensioning adjustment equals
2 mm elongation in the Timing Belt).
Maximum elongation in the Timing Belt = 36 mm (this yields a maximum
theoretical Timing Belt length of 36 metres with max. 1‰ elongation).
Recommended tensioning method:
Make two marks on the Timing Belt (e.g. 1000 mm apart)
Tension the Timing Belt, 1‰ lengths (maximum elongation!)
Check distance (markings) until they are 1001 mm apart.
6. Extending the carriage with Line 8 Profiles
The preassembled carriage allows you to use the groove of a Line 8 Profile to
design a customised superstructure for the carriage.
For this purpose, two centring sleeves are included with the carriage, which
bring the profile groove into alignment, secure it in place and position the
profile in the desired orientation.
Six individually selectable M8 screws can be used to fasten the profile or a
purpose-made panel to the carriage.
Threads in the carriage: M8x18.

MA
Fx
93
□80
Ø53
9
Linear Unit KRF 8 80x40 ZR
Connection for clamping
motor shaft to coupling KRF 8
Hole diameter D[mm] for
motor shaft 8 - 25
Transferable drive torque
MA max [Nm] 23
Permissible operating load
of Timing Belt
Fx max [N] 1,000
Effective radius of pulley
rW [mm]23.1
Clamping screw M6
Tightening torque [Nm] 14.5
Accessories
Technical data for the mounting of couplings:
The Drive Set
Drive Set KRF 8 ZR, 0.0.627.46
Use of high-strength aluminium alloy Coupling Housing with prepared centring
piece on the drive Reverse Unit
Coupling Housing with plenty of area available on the motor side for the
customer to machine as required.
New coupling made from stainless steel
A complete component and therefore entirely play-free
Nominal torque: 60 Nm (
Caution ! Timing Belt transfers only 23 Nm)
Axial deviation: 0.2 mm
Radial deviation: 0.3 mm
Angular deviation: 1.4°
Clamping screws: DIN 912 - M6
Tightening torque: 14.5 Nm
Up to 50 % deviation, full nominal torque can be transmitted.
At 100% deviation, 50% of the nominal torque can be transmitted.
Deviations in between are linear in nature.
Axial deviations do not affect torque
This coupling cannot be used with the other Reverse Units because the
attachment dimensions of the Reverse Units are far more generously toleranced
(die-cast parts). Axial and radial deviations are too great.

k
k
min
max
93
80
Ø53
22
MA
Fx
5
5
93
□80
Ø53
10
The housing of the drive Reverse Unit and the Coupling Housing of the Drive
Set fit together perfectly thanks to their design and a centring disc. Machine
the Coupling Housing of the Drive Set to suit the connection dimensions of
the motor or transmission you are using.
To connect the Drive Set to the drive Reverse Unit, remove 4 of the 6 fasten-
ing screws in the drive Reverse Unit and replace them with the longer M6x50
Hexagon Socket Head Cap Screws included with the Drive Set.
The M6x50 Hexagon Socket Head Cap Screws are driven through the drive
Reverse Unit into the Coupling Housing of the Drive Set.
Tightening torque, M6: 10 Nm
Bore out the equaliser coupling to match the diameter of the drive shaft of
the motor or transmission you are using and clamp it to the drive shaft in line
with the mounting dimensions below.
kmin = 42 mm
kmax = 62 mm
Next, insert the drive and coupling into the Coupling Housing of the Drive Set
and connect them to the drive shaft of the drive Reverse Unit through the
Coupling Housing.
Limit-Switch Holder KRF 8
The Limit-Switch Holder is prepared for fastening to the lower side grooves of
Profile 8 80x40 KRF.
Optimised for Proximity Switch 8
Proximity Switch 8 1NO, 0.3.001.30 (normally open)
Proximity Switch 8 1NC, 0.0.600.05 (normally closed)
Limit-Switch Holder KRF 8 can also be used for position detection on other
item linear slides.

11
Maintenance
Linear Unit KRF 8 80x40 ZR

Recommended oil: Track Oil for Linear Slides (Klüber Oil 4 UH1-460),
0.0.612.75
Auxiliary tool: Pressol oil can KLE-LR, 0.0.612.74
The felt pieces are supplied in ready-oiled condition.
Greases containing solid particles (e.g. graphite and MoS2 additives)
must
not be used!

The maintenance openings (page 6) are located on both sides of the
preassembled carriage.
All 4 End Cap and Lubricating Systems are re-oiled through the
maintenance openings.
Minimum stroke, full lubrication: Hmin = 100 mm.
Maintenance interval: every 6 months or every 2,500 km
Fill quantity: approx. 1 ml per End Cap and Lubricating System and
maintenance interval (1 ml is equivalent to one pump actuation of the
Pressol oil can).

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