JUNG ANTRIEBSTECHNIK U. AUTOMATION GMBH HighDynamic HA02-37 User manual

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JUNG ANTRIEBSTECHNIK U. AUTOMATION GMBH ♦Felsweg 18 ♦35435 Wettenberg ♦Germany
Tel.: [phone] ♦Fax: [phone] ♦eMail: [e-mail] ♦www.ja2-gmbh.de
eg_montageanleitung_einbauerklaerung_ha02_en.doc
Rev.: 12.06.2021
Subject to change!
Installation Guide
for partly completed maschines
according to maschinery directive 2006/42/EG app. VI
Maintenance Instructions
Declaration of Conformity
and CE-marking
according to maschinery directive 2006/42/EG app. II 1. B.
Linear Motor Guides
HA02-37

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JUNG ANTRIEBSTECHNIK U. AUTOMATION GMBH ♦Felsweg 18 ♦35435 Wettenberg ♦Germany
Tel.: [phone] ♦Fax: [phone] ♦eMail: [e-mail] ♦www.ja2-gmbh.de
Content
1. General Information....................................................................................................3
1.1 Introduction ...............................................................................................................3
1.2 Explanation of Signs .................................................................................................3
1.3 Warranty & Liability ...................................................................................................4
1.4 Copyright & Trademark Protection............................................................................4
2. Intended Use ...............................................................................................................5
2.1 Use of Linear Motor Guides ......................................................................................5
2.2 Assembly of Partly Completed Machines into Machines...........................................5
2.3 Operating Conditions ................................................................................................5
3. Safety Instructions .....................................................................................................6
3.1 Warnings for Unpacking, Handling, Assembly, processing & Storage ......................6
3.2 Warnings for Intended Use .......................................................................................8
4. Maintenance, Dismantling & Assembly ....................................................................9
4.1 Maintenance of Linear Motors...................................................................................9
4.2 Maintenance of Linear Guides ................................................................................10
4.3 Dismantling & Assembly of Linear Motor Guides ....................................................11
5. Declaration of Conformity & CE-Marking ...............................................................12

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JUNG ANTRIEBSTECHNIK U. AUTOMATION GMBH ♦Felsweg 18 ♦35435 Wettenberg ♦Germany
Tel.: [phone] ♦Fax: [phone] ♦eMail: [e-mail] ♦www.ja2-gmbh.de
1. General Information
1.1 Introduction
This manual includes instructions for the assembly, use, installation, risks of
danger, maintenance, transport, and storage of linear motor guides.
The document is intended for electricians, mechanics, service technicians
and warehouse staff. Please comply with the safety instructions at all times.
Keep this guide accessible and make it available for the assigned staff.
1.2 Explanation of Signs
Round command signs indicate what to do.
Triangular warning signs indicate danger.
JUNG ANTRIEBSTECHNIK U. AUTOMATION GMBH
the company will be refered to as JA² GmbH in the following text.

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JUNG ANTRIEBSTECHNIK U. AUTOMATION GMBH ♦Felsweg 18 ♦35435 Wettenberg ♦Germany
Tel.: [phone] ♦Fax: [phone] ♦eMail: [e-mail] ♦www.ja2-gmbh.de
1.3 Warranty & Liability
As manufacturer of linear motor systems, JA² GmbH does not accept
responsibility for the improper use, application or handling of products and
declines any liability. Warranty may not be claimed after use or combination
with third party products, like cables and power supplies. With purchase
every customer confirms to have read and understood the in the installation
and maintenance guide listed warnings. This guide is included in every
delivery and available online. Please always include this guide in your
deliveries, should you resell our linear motor systems as components or
install them into machines. We also refer to our general terms and
conditions.
1.4 Copyright & Trademark Protection
This work is protected by copyright.
All rights reserved!
Product names, as well as word and figurative marks are registered
trademarks.
We hereby give permission to reproduce and distribute this work for machine
documentation purposes or under the use of electronic systems. However,
we expressly point out, that this document is not subject to our updating
service. Technical changes reserved.

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JUNG ANTRIEBSTECHNIK U. AUTOMATION GMBH ♦Felsweg 18 ♦35435 Wettenberg ♦Germany
Tel.: [phone] ♦Fax: [phone] ♦eMail: [e-mail] ♦www.ja2-gmbh.de
2. Intended Use
2.1 Use of Linear Motor Guides
The linear motor guides are high-dynamic actuators. According to
European law 2006/42/EG the actuators are partly completed machines,
which are further installed into machines. They are used in machines for
industrial automation, handling and assembly technologies, packaging, as
well as testing technologies.
2.2 Assembly of Partly Completed Machines into Machines
In order to assemble the partly completed machines properly and without
compromising the safety and health of people, the following conditions must
be met:
- The installation of machines may only be carried out by qualified personnel.
- This document must be read and understood completely before installation.
- All warnings in this document must be observed.
A risk assessment for the complete machine must be carried out!
2.3 Operating Conditions
Conditions
- environmental temperature with nat. cooling 0°C to 40°C
- motor temperature -10°C to +80°C for std. linear motors
- motor temperature -10°C to +110°C for HP linear motors
(marked with HP).
- triggering of winding temperature control > 90°C for std. linear motors
- triggering of winding temperature control > 120°C for HP linear motors
- relative humidity ≤60 % not condensing
- storage temperature -15°C to +70°C
The storage room must be dry, free of dust and frost and must be protected
from shock. The linear guide must be protected from extreme weather
conditions. The storage room air may not contain any aggressive gases. The
maximum installation height is 4.000 m above sea level (MASL). When
installing above 1.000 m MASL, with identical motor power, a derating of
1 °C per 100 m is to be expected for air cooling.
The operating voltage of the linear motor stators ≤72 VDC.

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JUNG ANTRIEBSTECHNIK U. AUTOMATION GMBH ♦Felsweg 18 ♦35435 Wettenberg ♦Germany
Tel.: [phone] ♦Fax: [phone] ♦eMail: [e-mail] ♦www.ja2-gmbh.de
3. Safety Instructions
3.1 Warnings for Unpacking, Handling, Assembly, processing & Storage
Contusions
The sliders of linear motors contain neodynium magnets and have a very
strong magnetic force.
Careless handling could cause fingers or skin to become caught between
sliders and iron parts. This may lead to contusions, bruises, and bone
fractures. Protective gloves should be worn, when handling sliders.
Pacemakers / Defibrillators
When approaching strong magnetic fields, pacemakers or other devices,
may switch into test mode and will not function properly. As a wearer of such
a device, you should always keep the following minimum distances between
the devices and the sliders:
- 250 mm (10'') for slider diameters 27 mm and 28 mm (PL01-27 / 28)
- 150 mm (6'') for slider diameters 19 mm and 20 mm (PL01-19 / 20)
- 100 mm (4'') for slider diameter 12 mm (PL01-12)
Warn other persons, who wear these devices, to avoid getting too close to
sliders.
Magnetic Fields
Magnets integrated into the linear motor sliders produce a strong magnetic
field. They could damage TV's, laptops, computer hard drives, credit and
ATM cards, data storage media, mechanical watches, hearing aids, and
speakers.
Keep magnets away from devices and objects that could be damaged by
strong magnetic fields.
Please keep a minimum distance of 250 mm (10'') from the above mentioned
objects.
Flammability
The drilling dust can easily ignite while processing the magnets. Processing
the slider and the contained magnets is not permitted.

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Tel.: [phone] ♦Fax: [phone] ♦eMail: [e-mail] ♦www.ja2-gmbh.de
Mechanical Handling
Neodymium magnets are brittle, heat-sensitive and oxidize easily. If two
magnets attract and collide, they can crack causing sharp splinters to be
catapulted for several meters, which can lead to eye injuries. The magnet
could also crack when drilling or sawing with improper tools. The arising heat
may cause the magnet to demagnetize, which in turn will cause the magnet
to disintegrate due to the damaged coating. Processing the sliders and the
therein contained magnets is not permitted.
Linear Motor Sliders
The sliders consist of highly precise, thin-walled stainless steel tubes, which
contain the magnets and are to be handled with extreme care. Prevent
contact to other sliders or iron parts, since this can cause damage to the
surface of the slider. Sliders with a damaged surface (scratches,
deformation, etc.) should not be used, due to the fact that they can cause
damage to the stator.
Effects on People
Based on current scientific knowledge, magnetic fields of permanent
magnets do not have a measurable positive or negative effects on people. It
is unlikely that permanent magnets constitute a health risk, but it cannot be
entirely ruled out. For your own safety, avoid constant contact with magnets
and store large magnets at least one meter away from your body.
Temperature Resistance
Keep sliders away from unshielded flames or heat.
Temperatures above 120°C will cause demagnetization.

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JUNG ANTRIEBSTECHNIK U. AUTOMATION GMBH ♦Felsweg 18 ♦35435 Wettenberg ♦Germany
Tel.: [phone] ♦Fax: [phone] ♦eMail: [e-mail] ♦www.ja2-gmbh.de
3.2 Warnings for Intended Use
Fast moving Machine Parts
Our linear motor systems are high-dynamic machine elements. Necessary
precautions must be taken to prevent contact with moving parts during
operations. This can be done by installing covers, enclosures, light curtains,
safety mats, etc..
Operations, without appropriate safety measures are forbidden. Operations
may only be carried out by qualified personnel. During assembly the
machine is to be turned off!
Burn Hazards
The sliders of linear motors can reach temperatures of 80 °C during
operations, which may cause burns upon contact.
Bruises & Sprains
Our linear motor systems can apply very high accelerations, high top speeds
and forces over 1.000 N. Depending on the application and the duration of
exposure apropriate protective devices must be used!
Severing of Limbs
Our linear motor systems can apply very high accelerations, high top speeds
and forces over 1.000 N. Depending on the application and the duration of
exposure apropriate protective devices must be used!
Risk Assessment & Performance Level (PL) of Protective Measures
Since the risk depends on the type of machine, the assembly conditions and
the implemented protective measures, a general specification to minimize
risks during assembly cannot be given by us. We recommend the software
assistant SISTEMA for risk assessment and evaluation of the PL according
to DIN EN ISO 13849.

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JUNG ANTRIEBSTECHNIK U. AUTOMATION GMBH ♦Felsweg 18 ♦35435 Wettenberg ♦Germany
Tel.: [phone] ♦Fax: [phone] ♦eMail: [e-mail] ♦www.ja2-gmbh.de
4. Maintenance, Dismantling & Assembly
4.1 Maintenance of Linear Motors
The stators and sliders will be shipped with an initial lubrication and are ready for use.
Maintenance of Linear Motors
- Under industrial conditions (assembling and mounting applications, 5
days, 8 h / day) a quarterly inspection and maintenance is sufficient.
- The inspection and maintenance cycle must be reduced, if the motors
- run under 'dry' conditions (caused by heat influence or permanent
overload conditions)
- run under dust environments caused by production conditions
- Dispite the use of PA01 wipers a regular inspection and maintenance of
the linear motors is necessary, because the wipers are subject to
natural wear.
We are not able to specify a reduced inspection and maintenance intervall
for all applications. Application specific tests are necessary.
Inspection of Linear Motors
With inspections of linear motors the following points need to be checked:
- Is the the slider coated in lubricant?
- Is the lubricant not decomposed?
- Is the slider free of scratches or dents and does it move easily
A black 'Zebra'-pattern of lubricant is absolutely normal after short use.
Lubrication of Linear Motors
The lubrication improves the sliding characteristics between the steel surface
of the slider and the polymer bearing of the stator. The lubricant prevents
corrosion on the slider surface. Only the specified lubricant may be used.
Before lubrication the slider and stator should be clean, as far as possible.
Do not use harsh brushes, sandpaper, or similar things for cleaning.
Cleaning solutions with solvent additives should not be used neither.
To lubricate, dismantle die slider and carefully pull it out of the stator. Use
small amounts of methylated spirit or alcohol and a soft tissue to gently clean
the stator and slider. Coat the slider with a thin coat of fresh lubricant and
gently put it back into the stator. Make sure to install the slider in the correct
direction. If the slider cannot be dismantled, then cleaning and lubrication is
to be done on the extruding ends of the slider.

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JUNG ANTRIEBSTECHNIK U. AUTOMATION GMBH ♦Felsweg 18 ♦35435 Wettenberg ♦Germany
Tel.: [phone] ♦Fax: [phone] ♦eMail: [e-mail] ♦www.ja2-gmbh.de
Lubricant for
Description
&
application
Linear motor stator / slider LU02-lubricant is
deliverable in containers of
- 8 gramm item-No. 2550039
- 45 gramm item-No. 2550007
- 1.000 gramm item-No. 2550102
This lubricant corresponds to Klübersynth UH1 14-31 from
Klüber GmbH, which is also suitable for the FDA food
processing industry.
4.2 Maintenance of Linear Guides
The linear guides will be shipped with an initial lubrication and are ready for use.
Maintenance of Linear Guides
- Under industrial conditions (assembling and mounting applications, 5
days, 8 h / day) an inspection and maintenance cycle after an
operational performance of 5.000 km or every 6 months is sufficient.
- The inspection cycle must be reduced, if the linear guides run under
dust environments caused by production conditions.
We are not able to specify a reduced inspection and maintenance intervall
for all applications. Application specific tests are necessary.
Lubrication of Linear Guides
Lubricant can be applied with grease nipples. Alternatively the old lubricant
can be washed out with the help of methylated spirits or alcohol and then the
new lubricant can be applied.
Lubricant for
Description
&
application
Carriages for general applications THK lubricant AFB
for FDA applications Klübersynth UH1 14-151 from
Klüber Lubrication GmbH

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JUNG ANTRIEBSTECHNIK U. AUTOMATION GMBH ♦Felsweg 18 ♦35435 Wettenberg ♦Germany
Tel.: [phone] ♦Fax: [phone] ♦eMail: [e-mail] ♦www.ja2-gmbh.de
4.3 Dismantling & Assembly of Linear Motor Guides
Dismantling & Assembly
We recommend any dismantling and assembly to be done in our facilities.

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JUNG ANTRIEBSTECHNIK U. AUTOMATION GMBH ♦Felsweg 18 ♦35435 Wettenberg ♦Germany
Tel.: [phone] ♦Fax: [phone] ♦eMail: [e-mail] ♦www.ja2-gmbh.de
5. Declaration of Conformity & CE-Marking
The following declarartion of conformity is generated by computer.
We declare, that this declaration has legal validity.

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JUNG ANTRIEBSTECHNIK U. AUTOMATION GMBH ♦Felsweg 18 ♦35435 Wettenberg ♦Germany
Tel.: [phone] ♦Fax: [phone] ♦eMail: [e-mail] ♦www.ja2-gmbh.de
Declaration of Conformity
&
CE-Marking
According to EC Machinery Directives 2006/42/EG, appendix II 1. B.
We hereby declare, that the below listed partly completed machine is in accordance with
safety and health requirements of the EC Machinery Directives 2006/42/EG.
Partly completed machine: HighDynamic
®
Linear Motor Guides HA02
Drawing number: 0481.000.0
The following EU guidelines are applied:
•Electromagnetic Compatibility Directive 2004/108/EG
We also declare, that the special technical documentation for this partly completed
machine was created in accordance with the appendix VII B. Also we commit to sending it
to market surveillance authorities on demand. Authorized representative for the
compilation of the technical documentation is managing director Wilhelm Jung.
The operating of the partly completed machine is forbidden until it is installed into the
complete machine and the machine is in accordance with the requirements of the EU
guidelines. The declaration of conformity according to appendix II 1. A. must exist.
Wettenberg, May 21
th
, 2019
Wilhelm Jung
Managing Director
JUNG ANTRIEBSTECHNIK U.
AUTOMATION GMBH