Line Tech DM2.ZR User manual

Translation of the original installation and maintenance
instructions
DM.ZS-EN_23-09
DYNAMIC MODULES WITH RACK AND PINION DRIVES
Read the installation and maintenance instructions before carrying out any work!
LINE TECH AG | Europastrasse 19 | CH-8152 Glattbrugg
Tel [phone] | [email protected] | www.linetech.ch

Table of contents DYNAMIC MODULES WITH RACK AND PINION DRIVES
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Table of contents
1 General information............................................................................................ 4
1.1 Information about these assembly instructions........................................................... 4
1.2 Notes on use............................................................................................................... 5
1.3 Structure of the warnings............................................................................................ 6
1.4 Symbols used ............................................................................................................. 8
1.5 Disclaimer ................................................................................................................... 9
1.6 Spare parts ................................................................................................................. 11
1.7 Warranty conditions .................................................................................................... 11
1.8 Customer service and product monitoring .................................................................. 12
1.9 Other applicable documents ....................................................................................... 12
2 Safety ................................................................................................................... 13
2.1 Introduction ................................................................................................................. 13
2.2 Intended use ............................................................................................................... 13
2.3 Foreseeable misuse.................................................................................................... 13
2.4 Responsibilities of the operating company ................................................................. 14
2.5 Personnel requirements.............................................................................................. 15
2.5.1 General personnel requirements .................................................................. 15
2.5.2 Qualifications ................................................................................................ 15
2.5.3 Unauthorized personnel................................................................................ 15
2.6 Personal protective equipment ................................................................................... 15
2.7 Residual risks.............................................................................................................. 17
2.7.1 Note .............................................................................................................. 17
2.7.2 Mechanical hazards...................................................................................... 17
2.7.3 Hazards at the operating site........................................................................ 17
2.7.4 Hazards due to noise.................................................................................... 18
2.8 Environmental protection ............................................................................................ 18
3 Structure and function ....................................................................................... 19
3.1 Product overview ........................................................................................................ 19
3.2 Product description ..................................................................................................... 20
3.3 Product description ..................................................................................................... 21
3.4 Type plate ................................................................................................................... 22
4 Transport ............................................................................................................. 23
4.1 Safety.......................................................................................................................... 23
4.2 Transportation with a forklift truck............................................................................... 24
4.3 Transport with the crane ............................................................................................. 24
4.4 Transport inspection and scope of delivery ................................................................ 24
4.5 Storage ....................................................................................................................... 25
5 Assembly............................................................................................................. 26
5.1 Safety.......................................................................................................................... 26

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5.2 Assembly types........................................................................................................... 27
5.3 Condition on delivery .................................................................................................. 28
5.4 Gearbox selection....................................................................................................... 29
5.5 Fastening the dynamic module................................................................................... 30
5.5.1 General information ...................................................................................... 30
5.5.2 Fastening the dynamic module with clamps ................................................. 30
5.5.3 Fastening the dynamic module with sliding blocks ....................................... 32
5.6 Installing the motor and gearbox ................................................................................ 33
5.6.1 General information ...................................................................................... 33
6 Operation............................................................................................................. 34
6.1 Safety.......................................................................................................................... 34
6.2 Operating conditions................................................................................................... 35
7 Maintenance ........................................................................................................ 36
7.1 Safety.......................................................................................................................... 36
7.2 Repairs........................................................................................................................ 37
7.3 Maintenance intervals................................................................................................. 37
7.3.1 Notes ............................................................................................................ 37
7.3.2 Maintenance plan ......................................................................................... 38
7.4 Maintenance work....................................................................................................... 38
7.4.1 Check the dynamic module for externally visible damage............................ 38
7.4.2 Lubricating the dynamic module ................................................................... 39
7.4.3 Setting the toothed rack play ........................................................................ 45
7.5 Measures after completing the maintenance work ..................................................... 46
8 Disassembly and disposal................................................................................. 47
8.1 Safety.......................................................................................................................... 47
8.2 Decommissioning and disassembly............................................................................ 47
8.3 Disposal ...................................................................................................................... 48
9 Technical data..................................................................................................... 49
9.1 Exploded drawing and parts list.................................................................................. 49
9.2 General technical data................................................................................................ 50
9.3 Dimensions ................................................................................................................. 51
9.4 Torques and load ratings ............................................................................................ 57
9.5 Permissible speeds..................................................................................................... 58
9.6 Tightening torques for screws..................................................................................... 61
10 Links .................................................................................................................... 62
11 Declaration of Incorporation.............................................................................. 63
Index .................................................................................................................... 66

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1 General information
1.1 Information about these assembly instructions
Using the assembly instructions
These assembly instructions allow you to work safely and efficiently with the dynamic module
throughout all phases of the dynamic module's service life. All warnings and instructions in these
assembly instructions must be observed in order to ensure safe working conditions.
Mandatory reading
The operating/maintenance personnel are required to carefully read and understand these
assembly instructions before starting any work.
Storage location
The assembly instructions are an integral part of the linear module and must be kept readily
available to the relevant personnel in the immediate vicinity of the dynamic module.
Resale
If the dynamic module is resold to a third party, these assembly instructions must also be
included.
Other applicable documents, regulations and requirements
In addition to these assembly instructions, the instructions, notes and signs on the dynamic
module in the annex also apply. Attach notes on technical changes to these assembly
instructions. In addition, the local accident prevention regulations and general safety
requirements for the area where the dynamic module is used apply.
Figures in these assembly instructions
Figures contained in these assembly instructions are provided for basic understanding and may
vary from the actual version of the dynamic module.
Loss of the assembly instructions
If the assembly instructions are lost, request a replacement set immediately. Contact details
Legal notice (See reverse side) .

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1.2 Notes on use
Instructions and steps
The steps to be carried out by the operating personnel are displayed consecutively. The order of
the steps must be observed.
Example:
a) Step 1
Lists
Lists without a mandatory sequence are displayed as a list preceded by a bullet point.
Example:
– Item 1
– Item 1, subitem A
– Item 2
Lists with a mandatory sequence are displayed as a list preceded by a number.
Example:
1. First
2. Second
References to chapters/pages
References to specific chapters in which procedures and instructions are described are displayed
as active links.
Example: see chapter Information about these assembly instructions [}4].
Figures
All figures and drawings in these assembly instructions are intended for general illustration
purposes. They may vary from the actual design of the dynamic module.

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1.3 Structure of the warnings
The warnings used in these assembly instructions are introduced by signal words that indicate
the extent of the danger.
The warning symbol also indicates the type of danger.
The following warnings are used in these assembly instructions:
Danger level, danger to life
DANGER
Danger to life!
Consequences in case of non-compliance...
4Notes on prevention
A warning assigned to this danger level indicates an imminently dangerous situation.
If the dangerous situation is not avoided, it will result in death or serious injury.
Follow the instructions in this warning to avoid the risk of death or serious injury to persons.

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Danger level, risk of injury
WARNING
Risk of injury!
Consequences in case of non-compliance...
4Notes on prevention
A warning assigned to this danger level indicates a potentially dangerous situation.
If the dangerous situation is not avoided, it may result in death or serious injury.
Follow the instructions in this warning to avoid the potential risk of death or serious injury to
persons.
Danger level, personal injury
CAUTION
Personal injury due to...
Consequences in case of non-compliance...
4Notes on prevention
A warning assigned to this danger level indicates a potentially dangerous situation.
If the dangerous situation is not avoided, it may result in minor or moderate injuries.
Follow the instructions in this warning to avoid the risk of injury to persons.
Danger level, property damage
NOTICE
Property damage due to...
Consequences in case of non-compliance...
4Notes on prevention
A warning assigned to this danger level indicates possible damage to property.
If the situation is not avoided, property damage may occur.
Follow the instructions in this warning to avoid damage to property.

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Note on working safely
SAFETY INSTRUCTIONS
Working safely during...!
Carry out all work in compliance with the following safety
instructions:
4Notes on working safely
This note contains important information and instructions for safe working during the following
steps.
Follow the instructions in this note to avoid accidents and injuries.
Note on useful information
NOTE
Note text…
Consequences
A note indicates additional information that is important for subsequent processing or simplifies
the described work step.
1.4 Symbols used
Warnings in these assembly instructions are also marked with warning symbols.
Warning symbols
The following warning symbols are used in these assembly instructions:
Symbol Meaning
General warning
Warning of electrical voltage

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Symbol Meaning
Warning of hand injuries
Warning of heavy loads
Warning of suspended load
Warning of environmental pollution
1.5 Disclaimer
Information in these assembly instructions
The information and warnings contained in these assembly instructions have been compiled
taking into consideration the applicable standards, guidelines and regulations, the state of the art
as well as our many years of experience. The scope of delivery or the design of the dynamic
module may vary from the descriptions and figures provided here due to optional order items, the
production of customized designs or the latest technical changes.
Obligations
In addition to the contractually agreed obligations, the manufacturer's General Terms and
Conditions of Business and Delivery apply. They are subject to the laws in force at the time the
contract is concluded.
Technical changes
The date of issue of these assembly instructions applies. We reserve the right to make technical
changes to the dynamic module within the scope of further development in order to improve its
performance features and safety.

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Disclaimer in case of non-compliance
The manufacturer is not liable for damage and accidents resulting from the following:
– Non-intended use ( Intended use [}13]) of the dynamic module
– Non-compliance with the information and instructions in these assembly instructions
– Work performed on or with the dynamic module by unqualified or unauthorized personnel
– Installation of non-original spare parts
– Unauthorized conversions without written approval from the manufacturer

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1.6 Spare parts
Spare parts can be acquired directly from the manufacturer. See the reverse side for contact
details.
CAUTION
Incorrect or faulty spare parts.
Risk of injury, risk of damage, malfunctions or total failure!
4Only use original spare parts from the manufacturer or spare parts
approved by the manufacturer.
4Always contact the manufacturer if there are any doubts.
NOTE
If non-approved spare parts are used, all warranty, service,
compensation and/or liability claims against the manufacturer or its
agents, dealers and representatives will be invalidated.
For all requests for spare parts or when ordering spare parts, always provide the complete data
on the type plate ( Type plate [}22]).
1.7 Warranty conditions
Location
The warranty conditions are included in the purchase contract and the manufacturer's General
Terms and Conditions.
Basic information
The manufacturer or sales partner will make the final decision on a warranty claim after all
defective parts have been returned or possibly after an on-site inspection. The replacement of
defective parts does not extend the warranty period for the module. In case of modifications or
significant repairs carried out by the operator or third parties without the written consent of the
manufacturer or sales partner, the warranty claim will be completely invalidated.

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1.8 Customer service and product monitoring
Customer service
For problems and questions that cannot be solved using these assembly instructions and for
technical information, please contact our customer service or sales partner; contact details (See
reverse side) .
Product monitoring
We aim to continuously improve our products and are also interested in any experience gathered
when using the linear module.
We are happy to receive information about problems with the linear module, faults during
operation and errors that occur.
Always notify the manufacturer in the event of accidents or near-accidents.
1.9 Other applicable documents
In addition to the information contained in these assembly instructions, the information contained
in the following sources of information, in particular the safety instructions, must also be taken
into consideration:
– Information on the dynamic module's type plate
– Instructions for the modules used
– Work instructions issued by the operating company
– Safety data sheets for auxiliary and operating materials
– Local accident prevention regulations and regional regulations at the operating site of the
dynamic module
– Data sheets for the installed components

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2 Safety
2.1 Introduction
This section provides an overview of all the important safety aspects for ensuring optimum
protection of personnel and for safe and smooth operation.
Failure to observe the instructions and warnings in these assembly instructions can result in
serious hazards.
Only those risks that have been determined based on a risk assessment can be considered in
these assembly instructions. Risks arising from the working conditions, the operating site and
interfaces with external components must be determined and warnings must be added
accordingly.
2.2 Intended use
The dynamic module is solely intended for use in industrial applications.
The dynamic modules are solely intended for installation in machines and are used to move,
precisely position and transport light to medium loads.
The permissible values specified in the Technical data [}49] chapter must be observed.
Any other use or use beyond this is considered improper use.
2.3 Foreseeable misuse
Any use for a purpose other than that specified in the Intended use [}13] chapter is considered
improper use.
Any use of the dynamic module that goes beyond and/or deviates from the intended use can
result in dangerous situations.
The risk of improper use or misuse is borne solely by the operating company.
Misuse occurs, for example, if
– The dynamic module is operated outside the limits specified in Technical data [}49].
– Modifications are made to the dynamic module.
– Safety devices are disabled.
– The dynamic module is used in an explosion-protected area.

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2.4 Responsibilities of the operating company
Basic information
The owner of the dynamic module is generally subject to the legal requirements concerning
occupational safety, since the dynamic module is intended for use in the commercial sector. In
addition to the warnings in these assembly instructions, the safety, accident prevention and
environmental protection regulations applicable to the area in which the dynamic module is used
must therefore also be observed.
Risk assessment
The operating company must keep itself informed of the applicable health and safety regulations
and carry out a risk assessment to determine any additional hazards arising from the specific
working conditions at the place where the dynamic module is used.
Instructions
The operating company must issue, implement and document instructions in accordance with the
results of the risk assessment at the workplace.
During the entire time the dynamic module is in use, the operating company is responsible for
ensuring that the instructions it issues comply with the current legal requirements.
Responsibilities
The operating company must regulate the responsibilities for work on or with the dynamic module
and designate a person responsible for the safe operation of the dynamic module and the
coordination of all activities.
Information flow
The operating company must ensure that all personnel working on or with the dynamic module
have read and understood these assembly instructions and other instructions. In addition, the
operating company must train personnel at regular intervals and inform them of the dangers.
Personal protective equipment
The operating company must provide the personnel with the necessary personal protective
equipment.
Safety requirements
If necessary, the operating company must ensure that the machine in which this dynamic module
is to be installed or of which it is a component complies with the basic safety requirements and
provisions of all relevant directives before commissioning.
Perfect working order
In order to keep the dynamic module in perfect working order at all times, the operating company
must ensure that the maintenance intervals specified in these assembly instructions are
observed.

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2.5 Personnel requirements
2.5.1 General personnel requirements
Only persons who perform their work reliably and whose ability to react is not impaired, e.g., by
drugs, alcohol or medication, are permitted to work on or with the dynamic module.
When selecting such personnel, the job-specific age requirements applicable at the location
where the dynamic module is used must be observed.
2.5.2 Qualifications
Improper handling due to inadequate qualifications may result in serious injuries.
– All activities must only be carried out by qualified personnel
– Keep unqualified personnel away from the danger zones
The following qualifications are specified in the assembly instructions for various areas of activity:
Qualified specialist personnel
Qualified specialist personnel can carry out the assigned work and independently identify and
avoid potential hazards due to their specialist training, knowledge and experience as well as
knowledge of the relevant standards and regulations.
Manufacturer (service center)
Specific work must only be carried out by the manufacturer's specialist personnel. Other
personnel are not authorized to carry out this work. Contact the manufacturer's service
department to carry out the necessary work (see the Legal notice on the reverse side).
Instructed person (operator)
The instructed person has been informed by the operating company about the tasks assigned to
them and about possible dangers in case of improper behavior.
2.5.3 Unauthorized personnel
Unauthorized personnel who do not meet the requirements described here are not aware of the
dangers in the work area.
– Keep unauthorized personnel away from the work area.
– In case of doubt, address the unauthorized personnel and direct them out of the work area.
– Stop work as long as unauthorized personnel are present in the work area.
2.6 Personal protective equipment
Personal protective equipment must be worn during certain tasks to minimize health hazards. In
addition to the personal protective equipment specified in these assembly instructions, the
instructions posted in the work area must be observed. The following personal protective
equipment must be worn depending on the work to be carried out:

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Symbols Meaning
Appropriate work clothing
is close-fitting work clothing with low tear resistance, tight sleeves and no
projecting parts. It is primarily used to protect against being caught by moving
machine parts. Do not wear rings, chains or other jewelry.
Safety shoes
are used to protect against heavy falling parts and slipping on slippery
surfaces.
Safety gloves
are used to protect the hands from friction, abrasions, punctures or deeper
injuries and from contact with hot surfaces.
Hearing protection
is used to protect hearing in the presence of harmful noise levels.
Protective goggles
are used to protect the eyes from flying small parts, dust or compressed air.
NOTE
External visitors or employees from other departments must also
wear personal protective equipment when entering the work area.

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2.7 Residual risks
2.7.1 Note
The following section lists residual risks that have been identified based on a risk assessment.
SAFETY INSTRUCTIONS
Note on working safely!
Failure to observe the safety instructions, warnings and instructions
in these instructions may result in serious hazards.
4Always observe the safety instructions, warnings and handling
instructions!
4Also observe the safety instructions provided in the other
applicable documents!
2.7.2 Mechanical hazards
Moving dynamic module parts
Risk of injury between moving dynamic module parts!
Parts of the body can get trapped or crushed between moving dynamic module parts.
– Do not reach into moving dynamic module parts or handle moving dynamic module parts
during operation.
– Do not open covers during operation.
– Observe the lag time: make sure that no parts are moving before opening the covers.
– Wear close-fitting clothing and tie back long hair.
2.7.3 Hazards at the operating site
Operating the dynamic modules at an unsuitable or insufficiently equipped operating site poses
various hazards!
Safety deficiencies due to work that was carried out incorrectly due to inadequate lighting:
– Make sure there is sufficient lighting at the workplace.
– Have defective lights replaced immediately.
Sharp edges, corners and materials with sharp edges can cause abrasions and cuts to the skin:
– Be careful when working near sharp edges and corners and when handling materials with
sharp edges.
– In case of doubt, wear protective gloves.
Dirt and objects lying around present sources of slipping and tripping:
– Always keep the work area clean.
– Remove objects that are no longer required.
– Mark tripping hazards with yellow and black marking tape.

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– Immediately clean up any spilled liquids.
Risk of short circuits due to an unsuitable application area:
– Only operate the dynamic module indoors.
– Protect the dynamic module from moisture.
2.7.4 Hazards due to noise
The dynamic module itself does not emit any hazardous noise emissions. However, in
combination with the connected machines, noise may be produced during operation, which may
result in tinnitus or hearing loss.
– The emissions must be measured by the operating company after the entire system has been
assembled:
– If the measured noise level is ≥80 dB(A), the operating company must provide hearing
protection.
– If the measured noise level is ≥85 dB(A), the operating company must prescribe the
use of hearing protection.
2.8 Environmental protection
Danger to the environment due to incorrect handling of environmentally hazardous substances,
in particular incorrect disposal:
– Always observe the instructions provided below.
– If environmentally hazardous substances are accidentally released into the environment, take
appropriate measures immediately. In case of doubt, notify the responsible local authority of
the damage.
– Only collect, transport and store environmentally hazardous substances in suitable
containers.
The following environmentally hazardous substances are used:
Lubricants
Lubricants, such as greases and oils contain toxic substances. They must not be released into
the environment. They must be disposed of by a specialist disposal company in accordance with
local regulations.
Machine parts
Replaced machine parts may be contaminated with grease and oil, for example, and therefore
contain toxic substances. They must not be released into the environment. They must be
disposed of by a specialist disposal company in accordance with local regulations.

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3 Structure and function
3.1 Product overview
The following drawing shows a dynamic module in its maximum configuration. The actual scope
of delivery may vary from this version.
1
2
87
5
346
1 Cover 2 Toothed rack
3 Guide rail 4 Gearbox
5 Carriage 6 Buffer
7 Base profile 8 End plate
1
2
3a
4
5
6
7
1 Base profile 2 Carriage
3a Toothed rack 4 Linear rail guide
5 Gearbox mounting plate 6 Gearbox
7 Drive and lubrication pinion

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3.2 Product description
Dynamic modules with a toothed belt drive are modular, ready-to-install linear systems with a
drive. Sealed guide elements are used in all sizes.
The base profile is made of an aluminum alloy and is manufactured via an extrusion process.
Optional integrated limit switches protect against overtravel. The respective mounting options are
prepared as standard.
Additional external sensors can be used in combination with the motor and control unit to ensure
the correct positioning of the carriage by means of a switching lug and sensor holder.
The selected design results in very high performance with highly compact dimensions.
The following load ratings are achieved:
Dynamic module Dimensions Load ratings
Type W x H
[mm]
C0
[kN]
C50
[kN]
DM2.ZR 180 x 188 162.0 116.3
DM3.ZR 220 x 231 311.5 208.8