Parker HTR Series User manual

HTR
We reserve the right to make technical changes. The data correspond to the technical state at the time of printing. 05/08 Art. Nr.: 192-530813N4
HTR - Product manual
Project planning, assembly, commissioning, maintenance, repairs
DIN EN ISO 9001
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Reg. Nr. 36 38 - 01
Parker Hannifin GmbH & Co. KG
Electromechanical Automation
Robert-Bosch-Straße 22
D-77656 Offenburg, Germany
Phone +49 (0)781 / 509-0
Fax +49 (0)781 / 509-98176
[email protected]
www.parker-automation.com

Table of Contents
1 Product description.......................................1-1
2 Technical data................................................2-1
2.1 Permissible loading of the rollers for
vertical axle construction.............................. 2-1
2.1.1 Roller load based on static side load (Fv; Fw)........2-2
2.1.2 Roller load based on existing torque (Mu; Mv;
Mw).......................................................................2-2
2.1.3 Roller load based on dynamic side load (Fa) ........2-3
2.2 Permissible toothed belt load........................ 2-3
2.3 Construction dimensions HTR80 (HTR50).... 2-4
2.4 Application examples for the diagrams........ 2-5
2.4.1 Application example 1. Working load centred
below the HTR80.................................................2-5
2.4.1.1 Determine roller loading: ................................2-5
2.4.1.2 Determine toothed belt load: ..........................2-6
2.4.2 Application example 2. Working load eccentric
below the HTR80.................................................2-8
2.4.2.1 Determine roller loading: ................................2-8
2.4.2.2 Determine toothed belt load: ........................2-10
3 Safety..............................................................3-1
3.1 Correct use ...................................................... 3-1
3.2 Identification of other dangers and danger
areas................................................................ 3-1
3.3 General dangers in the event of non-
observance of the safety notices.................. 3-2
3.4 Safe working practices................................... 3-2
3.4.1 Observe the notes.................................................3-2
3.4.2 Operating personnel..............................................3-2
3.5 Safety instructions for the user company..... 3-2
3.6 Safety instructions for the operating
personnel ........................................................ 3-2
3.7 Note regarding special dangers..................... 3-3
3.8 Unauthorised conversions or
modifications are forbidden.......................... 3-3
3.9 Transport ......................................................... 3-3
4 Assembly........................................................4-1
4.1 General remarks.............................................. 4-1
4.2 Assembly on the flange plate......................... 4-1
4.2.1 Removal of the rotor station, lower central
section.................................................................4-1
4.2.2 Removal of the rotor station, lower outer section...4-2
4.2.3 Installation of the HTR in the flange plate..............4-2
4.2.4 Installation of the rotor station, lower outer
section.................................................................4-2
4.2.5 Intallation of the rotor station, lower central
section.................................................................4-3
5 Commissioning..............................................5-1
5.1 General remarks.............................................. 5-1
5.2 Setting limit stops........................................... 5-1
6 Maintenance ...................................................6-1
7 Repairs............................................................7-1
7.1 Safety instructions ..........................................7-1
7.2 General remarks..............................................7-1
7.3 Toothed belts...................................................7-1
7.3.1 General remarks regarding toothed belts.............. 7-1
7.3.2 Tensioning toothed belts, guidelines..................... 7-2
7.3.2.1 Toothed belt tension, measurement............... 7-3
7.3.3 Replacing, tensioning and aligning the main
drive toothed belt.................................................7-4
7.3.3.1 Determine axle stroke.................................... 7-4
7.3.3.2 Replace main drive toothed belts...................7-4
7.3.3.3 Tension main drive toothed belt.....................7-7
7.3.3.4 Aligning main drive toothed belts ................... 7-7
7.3.4 Replacing, tensioning and aligning the
transmission drive toothed belt............................7-8
7.3.4.1 Replace transmission drive toothed belt ........7-8
7.3.4.2 Tensioning toothed belts of the
transmission drive.......................................7-12
7.3.4.3 Aligning the transmission drive toothed
belts............................................................7-12
7.4 Setting and aligning rollers. .........................7-13
7.4.1 Adjusting rollers of the rotor station lower outer
section...............................................................7-13
7.4.2 Adjusting rollers of the rotor station upper outer
section...............................................................7-14
7.4.3 Adjusting rollers of the rotor station lower outer
section...............................................................7-18
7.4.4 Adjusting rollers of the rotor station upper inner
section...............................................................7-19
7.5 Replace rollers...............................................7-23
7.5.1 General remarks................................................. 7-23
7.5.2 Replace fixed rollers........................................... 7-24
7.5.3 Replace eccentric rollers ....................................7-24
7.6 Replace belt tensioner..................................7-26
7.6.1 Replace main drive belt tensioner....................... 7-26
7.6.2 Replace transmission drive belt tensioner .......... 7-27
7.7 Replace gears................................................7-30
7.8 Change motor................................................7-31
8 HTR wearing parts, replacement parts and
parts lists.......................................................8-1
8.1 HTR80...............................................................8-1
8.1.1 HTR80 wearing parts............................................ 8-1
8.1.2 HTR80 replacement parts.....................................8-1
8.1.3 Component overview with position numbers.........8-2
8.1.4 Component diagrams with position numbers for
HTR80.................................................................8-3
8.2 HTR50.............................................................8-12
8.2.1 HTR50 wearing parts.......................................... 8-12
8.2.2 HTR50 replacement parts................................... 8-12
8.2.3 Component overview with HTR50 position
numbers............................................................8-13
8.2.4 Component diagrams with HTR50 position
numbers............................................................8-14

Product description
1 - 1
1 Product description
7
3
4
1
5
6
2
8
Great lifting power with small construction
height
Specially desi
g
ned for applications that require a
lar
g
e vertical liftin
g
path in limited space, the
telescopic axle has been developed by HAUSER.
With the wear-proof, hi
g
h stren
g
th toothed belt,
the main drive (1) and transmission drive (2) pro-
vide optimal power transfer to the load attach-
ment
(8).
Maintenance free, plastic rollers mounted on
roller bearin
g
s combined with surface treated
aluminium extruded sections guarantees mini-
mum wear with optimal running smoothness.
A newly developed
g
uidin
g
principle, consistin
g
of
the 3 guide profiles and the relevant rotor sta-
tions
(3), (4), (5) and (6), provides self-stabilising
properties.
The hollow shafts and flan
g
e desi
g
n of the drive
station (7) are identical to the flange dimensions
of HAUSER servo drives, offering optimal combi-
nations with HAUSER drive technology.
HTR connection possibilities are compatible with
the HAUSER modular system so that modular
application specific handlin
g
technolo
g
y can be
provided in combination with linear units.
These proven HAUSER construction principles
g
ive the user many advanta
g
es which are also
applicable to the telescopic axle.
1 Main drive 7 Drive station
2 Transmission drive 8 Connection for outer load (e.g. Gripper)
3 Rotor station, upper central section
4 Rotor station, upper inner section
5 Rotor station, lower outer section
6 Rotor station, lower central section

Product description

Technical data / Project planning
2- 1
2 Technical data
HTR Units HTR50 HTR80
Cross-section outer profile mm x mm x mm 125 x 125 x 6 180 x 180 x 10
Cross-section central profile mm x mm x mm 80 x 80 x 6 125 x 125 x 6
Cross-section inner profile mm x mm x mm 50 x 50 x 5 80 x 80 x 6
Moment of inertia about the outer profile cm4674 3261
Moment of inertia about the central profile cm4163 674
Moment of inertia about the inner profile cm431 163
Travel speed, maximum m/s 5.0 5.0
Travel path, maximum mm 2500 2500
Maximum permissible acceleration m/s255
Path travelled per rotation 1) mm/U 340 480
Tooth lock washer diameter 1) mm 108.2 152.8
Driving torque, maximum Nm 40 108
Belt tensile force, maximum at retract speed N
Æ Diagram 2-4 Æ Diagram 2-4
Roller load, maximum N
Æ Table 2- 2 Æ Table 2- 2
Pos. repeat accuracy in one direction (DIN EN 29283) mm ±0.2 ±0.2
Mass base unit, no lifting kg 12.8 35.3
Mass additional length kg/m 8.6 16.2
Moving mass, without lifting kg 2.8 7.4
Moving mass, additional length kg/m 2.4 4.5
Basic mass moment of inertia, based on the drive
shaft, without lifting kgcm252.4 302.8
Additional mass moment of inertia, based on the drive
shaft kgcm2
m49.2 202.3
Table 2-1: Technical data of HTR axle
2.1 Permissible loading of the rollers for vertical axle construction
Approach/retract speed (Vu) [m/s] 0 - 2 2-3 3-4 4-5
Maximum permissible roller load [N]
HTR50 210 170 145 125
HTR80 388 316 268 232
Table 2- 2: Maximum permissible roller load in relation to HTR speed
An additional safety factor of 1.5 must be taken into account with the given val-
ues! If it is unavoidable that this safety factor may be undershot, please contact
HAUSER.
Technical data, as of 10/98, safety based on S=1, different technical data on request. The data
applies for a temperature range from -10°C to + 40°C.
1)calculated value, take into account telescope ratio 1:2

Technical data / Project planning
2 - 2
Fw
Mw
Fu Mu
Fv
Mv
The total load on a single roller is calculated using the superposition principle
from the sum of all resultant forces (FRoller,
Æ see Diagrams 2-1 to 2-3). I.e. the
sum of all resultant forces (FTotalRoller) must be smaller that the maximum per-
missible roller load ( Æ Table 2- 2). Meaning:
FTotalRoller = FRoller (Fav) + FRoller (Fv) + FRoller (Mw) + FRoller (Mu)
Equation 2-1a: Composition of the total roller load (direction 1)
FTotalRoller = FRoller (Faw) + FRoller (Fw) + FRoller (Mv) + FRoller (Mu)
Equation 2-1b: Composition of the total roller load (direction 2)
Dimensioning is based on the higher value from equation 2-1a or 2-1b!
2.1.1 Roller load based on static side load (Fv; Fw)
10 20 30 40 50 100 200 300 400 500 1000
Fv, Fw
N
FRoller
N
10
20
30
40
50
100
200
300
400
500
1000 1500 20003000
retracted, optional stroke
HTR50
10 20 30 40 50 100 200 300 400 500 1000
Fv, Fw
N
FRoller
N
10
20
30
40
50
100
200
300
400
500
1000
1500
2000
3000
4000
retracted, optional stroke
HTR80
Dia. 2-1: Resultant force FRoller based on Fvor Fw. Vertical installation position. Each of the curves 500 - 4000
denotes a telescope with that stroke [mm], fully extended. Safety taken into consideration S=1.
2.1.2 Roller load based on existing torque (Mu; Mv; Mw)
123451020304050100
M
Nm
FRoller
N
10
20
30
40
50
100
200
300
400
Mv, Mw
Mu
HTR50
10 20 30 40 50 100 200 300 400 500 1000
M
Nm
FRoller
N
10
20
30
40
50
100
200
300
400
Mv, Mw
Mu
HTR80
Dia. 2-2: Resultant force FRoller based on Muor Mvor Mw. Vertical installation position. Safety-factor taken into
consideration S=1.

Technical data / Project planning
2- 3
2.1.3 Roller load based on dynamic side load (Fa)
mN
a
Fa
FaT
mT
10
20
30
40
50
100
200
300
400
FRoller
N
10 20 30 40 50 100 200 300 400 500
Fa
N
500
1000
1500
2000
3000
retracted, optional stroke
HTR50
Diagram applies
for acceleration
< 5m/s2
10
20
30
40
50
100
200
300
400
FRoller
N
10 20 30 40 50 100 200 300 400 500 1000
Fa
N
500
1000
1500
2000
3000
4000
retracted, optional stroke
HTR80
Diagram applies
for acceleration
< 10m/s2
Dia. 2-3: Resultant force FRoller based on dynamic side loads. The diagram already takes into account the own
mass of the moving telescope sections (mT). Each of the curves 500 - 4000 is based on a telescope
with this stroke [mm], fully extended. Safety taken into consideration S=1.
Fa= mN• a (mN = Mass of the working load moved in kg; a = Horizontal acceleration of the HTR with
working load in m/s2)
2.2 Permissible toothed belt load
HTR80
HTR50
0,1 0,2 0,3 0,4 0,5 1 2 3 4
5
vu
m/s
100
200
300
400
500
1000
FZR_zul.
N
Dia. 2-4: Maximum permissible belt tensile force dependent on the traversing speed of the HTR. Installation
position vertical, stroke as required between 0 - 4000 mm, acceleration < 5 m/s2.

Technical data / Project planning
2 - 4
2.3 Construction dimensions HTR80 (HTR50)
684 (434) + 0,5 x Stroke
0,5 x Stroke
0,5 xStroke
125 x 6
80 x 6
180 x 10
10
20
30
25
8,5
175 (109)
10
170
250
Stroke
234 (162)450 (272)
28,5
(5)
57
(43)
(4,5)
(16)
(18)
(10)
(15)
(170)
(8)
180 x 10
Limit switch gear
box (accessory)
70 (49)
140
(90)
Ø100
(Ø100)
68
(68) 234 (159)
103,5
(69,5)
X - X
M 1:2
Key complying with
DIN 6885/1
Ø 110
H7
6
58
Ø130 (Ø100)
Ø 25 H7
Ø 20 H7
(47,5)
(Ø 80
H7
)
(4)
4xM8x30
(4xM6x12)
(125 x 6)
(80 x 6)
(50 x 5)
(123)
290
(190)
Mounting angle (accessory)
HTR80:
MW140/290 (Art.Nr.: 500-000524)
HTR50:
MW90/190 (Art.Nr.: 500-000513)
233 + 0,5xStroke *1
(147,5 + 0,5xStroke) *1
*1: The angle bracket can be
fixed in other positions.
Please contact HAUSER.
67,5
(48,5)
15 (0)
A - A
86
(76)
(112,5)
160
138
(88)
90
(60)
30
(20)
120
(80)
4 x Ø11
(4 x Ø9)
Dimensions in ( ): HTR50

Technical data / Project planning
2- 5
2.4 Application examples for the diagrams
2.4.1 Application example 1. Working load centred below the HTR80
This shows the moment that occurs during the greatest axle loading: HTR fully extended, accelera-
tion of working load upwards and simultaneous acceleration of the HTR in the horizontal direction.
mN
Fg +Fu
vu
aw
Faw
au
Equation symbols used:
mN= Mass of working load [kg]
vu= Approach speed of the HTR [m/s]
au= Maximum acceleration while HTR is
approaching [m/s2]
Fu= Inertia force on the HTR produced by
acceleration and mass [N]. Fu= mN
x au
Fg= Gravity based loading of the HTR [N]
aw= Maximum acceleration while HTR is
travelling [m/s2]
Faw = Inertia force on the HTR produced by
acceleration and mass [N]. Fw=
mN
x aw
g= Acceleration due to gravity (9.81 m/s2)
Required results:
Mass of working load on the HTR: mN= 36.5 kg
Maximum stroke of the HTR: Stroke = 1000 mm
Approach speed of the HTR: vu= 3 m/s
Acceleration during approach of HTR: au= 3 m/s2
Horizontal acceleration of the total system (HTR + working load): aw= 4.5 m/s2
2.4.1.1 Determine roller loading:
Step 1: Calculate resulting forces:
Faw = mN
y aw = 36.5 kg
y 4.5 m/s2= 164 N
Fv, Fav, Fw, Mu, Mv, Mw= 0
Step 2: Determine resultant forces with the help of the diagrams:
10
20
30
40
50
100
300
400
FRoller
N
200
10 20 30 40 50 100 200 300 400 500 1000
Fa
N
500
1000
1500
2000
3000
4000
retracted, optional stroke
Faw
FRoller (Faw)
= 260 N
From diagram 2-3:
FRoller (Faw) = 260N
From equation 2-1b:
FTotalRoller = FRoller (Faw) = 260N
From Table 2- 2:
FRollerPerm. (vu= 3 m/s) = 316N
Safety factor:
FRollerPerm. / FTotalRoller
= 316N / 260 N = 1.2.

Technical data / Project planning
2 - 6
Step 3: Back-calculate to permissible output value
The safety factor obtained is too low at 1.2! It should be at least 1.5. To achieve this, there are three possibili-
ties:
a) Reduce acceleration aw;
b) Reduce working load
c) First fully approach the HTR and then accelerate horizontally.
The following is calculated using possibility a) to determine how large awmaximum can be:
From FRollerPerm. / FTotalRoller = 1.5:
FTotalRoller = FRollerPerm. / 1.5 = 316 N / 1.5 = 211 N
10
20
30
40
50
100
200
300
400
FRoller
N
10 20 30 40 50 100 200 300 400 500 1000
Fa
N
500
1000
1500
2000
3000
4000
retracted, optional stroke
Faw =
130 N
FRoller (Faw)
= 211 N
From diagram 2-3:
Faw = 130N
From Faw = mN
y
aw :
aw= Faw / mN
aw= 130 N / 36.5 kg = 3.6 m/s2
2.4.1.2 Determine toothed belt load:
Step 1: Determine maximum permissible toothed belt load at the required approach speed:
0,1 0,2 0,3 0,4 0,5 1 2 3 4
5
vu
m/s
100
200
300
400
500
1000
FZR_zul.
N
FZR_zul.=
600 N
HTR80
HTR50
From diagram 2-4:
FTB_per = 600 N
The safety factor of minimum 1.5
must also be taken into account
here:
FTB_max. = FTB_per / S
FTB_max = 600N / 1.5 = 400N

Technical data / Project planning
2- 7
Step 2: Determine maximum possible vertical acceleration:
The toothed belt load is composed of:
Fg+ Fu= mN
y
g + mN
y
au
From Fg+ Fu= FTB_max:
au= (FTB_max - mN
y
g) / mN
au= (400N - 36.5 kg
y
9.81 m/s2) / 36.5 kg
au= 1.1 m/s2
The maximum possible vertical acceleration is less than required (required: au= 3 m/s2). To increase this
value, there are two possibilities:
a) Reduce approach speed;
b) Reduce working load
The following is calculated using possibility a) to determine how large vumaximum can be:
FTB_max = mN
y
g + mN
y
au = 36.5 kg
y
9.81 m/s2+ 36.5 kg
y
3 m/s2 = 468 N
FTB_per = FTB_max
y
S = 468 N
y
1.5 = 702 N
FZR_zul.=
702 N
0,1 0,2 0,3 0,4 0,5 1 2 3 4
5
vu
m/s
100
200
300
400
500
1000
FZR_zul.
N
HTR50
HTR80
From diagram 2-4:
vu_max = 2 m/s
When vuis reduced to 2 m/s,
the permissible roller loading
increases from 316 N to 388
N (
Æ
Table 2- 2) - the original
required horizontal accelera-
tion of aw = 4.5 m/s2is then
permissible.
Total result, Example 1:
The required performance ratings are achievable if the approach speed of the telescope (vu) is reduced from
3 m/s to 2 m/s!

Technical data / Project planning
2 - 8
2.4.2 Application example 2. Working load eccentric below the HTR80
This shows the moment that occurs during the greatest axle loading: HTR fully extended,
acceleration of working load upwards and simultaneous acceleration of the HTR in the
horizontal direction.
Fg +Fu
mN
vu
aw
Faw
au
L
Mu
Mw
Equation symbols used:
mN= Mass of working load [kg]
vu= Approach speed of the HTR [m/s]
au= Maximum acceleration while HTR is
approaching [m/s2]
Fu= Inertia force on the HTR produced by
acceleration and mass [N]. Fu= mN
x
au
Fg= Gravity based loading of the HTR [N]
aw= Maximum acceleration while HTR is
travelling [m/s2]
Faw = Inertia force on the HTR produced by
acceleration and mass [N]. Fw=
mN
x
aw
g= Acceleration due to gravity (9.81 m/s2)
L= Lever arm for centre of mass of outer
load
Required results:
Mass of working load on HTR: mN= 12 kg
Maximum stroke of HTR: Stroke = 1500 mm
Approach speed of HTR: vu= 3.5 m/s
Acceleration during approach of HTR: au= 3 m/s2
Horizontal acceleration of the total system (HTR + working load): aw= 2 m/s2
Lever arm for centre of mass of outer load: L = 0.4 m
2.4.2.1 Determine roller loading:
Step 1: Calculate resulting forces:
Faw = mN
y
aw = 12 kg
y
2 m/s2= 24 N
Fg+ Fu= mN
y
g + mN
y
au= 12 kg
y
9.81 m/s2+ 12 kg
y
3 m/s2= 153.7 N
Mu= Faw
y
L = 24 N
y
0.4 m = 10 Nm
Mw= (Fg+ Fu)
y
L = 153.7 N
y
0.4 m = 61.5 Nm
Fv, Fav, Fw, Mv= 0
Step 2: Determine resultant forces with the help of the diagrams:
10
20
30
40
50
100
200
300
400
FRoller
N
10 20 40 50 100 200 300 400500 1000
Fa
N
500
1000
1500
2000
3000
4000
retracted, optional stroke
FRoller (Faw)
= 57 N
Faw=
24 N
From diagram 2-3:
FRoller (Faw) = 57N

Technical data / Project planning
2- 9
10 20 30 40 50 100 200 300 400 500 1000
M
Nm
10
20
30
40
50
Mv, Mw
Mu
FRoller
(Mu) = 95
FRoller
(Mw) = 100
Mu= 10 Mw= 61,5
300
400
200
150
From diagram 2-2:
FRoller (Mu) = 95 N
FRoller (Mw) = 100 N
From equation 2-1a: FTotalRollera = FRoller (Fav) + FRoller (Fv) + FRoller (Mw) + FRoller (Mu):
FTotalRollera = 0 N + 0 N + 100 N + 95 N = 195 N
From equation 2-1b: FTotalRollerb = FRoller (Faw) + FRoller (Fw) + FRoller (Mv) + FRoller (Mu):
FTotalRollerb = 57 N + 0 N + 0 N + 95 N = 152 N
The higher roller total load results from equation 2-1a.
From Table 2- 2:
FRollerPerm. (vu= 3.5 m/s) = 268N
Safety factor:
FRollerPerm. / FTotalRollera = 268N / 195 N = 1.37.
Step 3: Back-calculate to permissible output value
The safety factor obtained is too low at 1.37! It should be at least 1.5. To achieve this, there are four possibili-
ties:
a) Reduce acceleration awand/or acceleration au.
b) Reduce working load
c) Reduce lever arm
d) First fully approach the HTR and then accelerate horizontally.
The following is calculated using possibility a) to determine how large awmaximum can be:
From FRollerPerm. / FTotalRoller = 1.5:
FTotalRollera = FRollerPerm. / 1.5 = 268 N / 1.5 = 178.7 N
From equation 2-1a: FTotalRollera = FRoller (Fav) + FRoller (Fv) + FRoller (Mw) + FRoller (Mu):
FRoller (Mu) = FTotalRollera - FRoller (Fav) - FRoller (Fv) - FRoller (Mw)
FRoller (Mu) = 178.7 N - 0 N - 0 N - 100 N = 78.7 N

Technical data / Project planning
2 - 10
10 20 30 40 50 100 200 300 400500 1000
M
Nm
20
30
40
50
100
Mv, Mw
Mu
FRoller
(Mu) = 78,7
200
400
300
Mu= 8
From diagram 2-2:
Mu(FRoller) = 8 Nm
From Mu= Faw
y
L:
Faw = Mu/ L = 8 Nm / 0.4 m = 20 N
From Faw = mN
y
aw :
aw= Faw / mN= 20 N / 12 kg = 1.7 m/s2
2.4.2.2 Determine toothed belt load:
Step 1: Determine maximum permissible toothed belt load at the required approach speed:
FZR_zul.=
550 N
0,1 0,2 0,3 0,4 0,5 1 3
5
vu
m/s
100
200
300
400
FZR_zul.
N
vu=
3,5 m/s
HTR50
HTR80
700
2
From diagram 2-4:
FTB_per = 550 N
The safety factor of minimum 1.5
must also be taken into account
here:
FTB_max. = FTB_per / S
FTB_max = 550N / 1.5 = 367N
Step 2: Determine maximum possible vertical acceleration:
The toothed belt load is composed of:
Fg+ Fu= mN
y
g + mN
y
au
From Fg+ Fu= FTB_max:
au= (FTB_max - mN
y
g) / mN
au= (367N - 12 kg
y
9.81 m/s2) / 12 kg
au= 20.8 m/s2
The maximum possible vertical acceleration for the toothed belt is theoretically 20.8 m/s2. It must be noted
however that diagram 2-4 only applies up to an acceleration of 10 m/s2. Based on the resulting roller loading,
aumust not exceed 3 m/s2.
Total result, Example 2:
The required performance ratings are achievable if the horizontal acceleration (aw) is reduced from 2 m/s2to
1.7 m/s2!

Safety instructions
3 - 1
3 Safety
3.1 Correct use
The HTR is used for many purposes, including:
positioning, transporting, feeding, removing, palletting, loading, unloading, handling and
manipulating workpieces or tools.
As it can be used in the most widely differing areas, the responsibility for use in specific pur-
poses is handed over to the user.
The user must ensure that when mounting workpieces or tools on the load attachment of the
HTR, that personnel and/or property cannot be injured or damaged.
The HTR may only be used in areas which are not accessible by personnel during operation.
Where the HTR is used in areas accessible to personnel, it must be installed in such a way that
personnel are not endangered during operation.
The HTR must not be driven against the limit damper (Block). For prevention, our safety limit
switches or limit switch gears can be installed.
Note that for vertical installation, the rotors can fall downwards if the belt breaks.
If the HTR has been driven up to the block, the axle must not be operated. Notify our Service
Department immediately:
Parker Hannifin GmbH
Service Department
+49-(0)7 81 / 5 09-43 81
3.2 Identification of other dangers and danger areas
If other dangers still exist for personnel or property despite the structurally secure application of
the HTR, the user must indicate these other dangers by means of signs and written behaviour
regulations.
The safety instructions given in these operating instructions are summarised in Table 3.1.
STOP
Danger;
means that death, serious physical injury or damage to property may occur
unless prevented by corresponding safety measures.
!
Caution;
means that physical injury or damage to property may occur unless prevented by
corresponding safety measures.
Note;
important information which must be observed regarding the product, the opera-
tion of the product or the relevant section of the manual.
Table 3.1: Safety symbols and their significance
3.3 General dangers in the event of non-observance of the safety notices
The machine components are built according to the state of the art and is safe in use. Dangers
may, however, be generated by the machine if it is used by personnel who are not trained or at
least instructed, or is used incorrectly or for purposes other than those intended.
As a consequence, there may be a risk of:
)Danger to life and limb of the user or a third party
)Damage to the machine and the user's other property

Safety instructions
3 - 2
3.3 General dangers in the event of non-observance of the safety notices
The machine components are built according to the state of the art and is safe in use. Dangers
may, however, be generated by the machine if it is used by personnel who are not trained or at
least instructed, or is used incorrectly or for purposes other than those intended.
As a consequence, there may be a risk of:
) Danger to life and limb of the user or a third party
) Damage to the machine and the user's other property
When installing the HTR in a machine plant, the safety instructions given in these operating in-
structions must be sensibly integrated with those in the machine plant operating instructions.
3.4 Safe working practices
3.4.1 Observe the notes
The notes in these operating instructions and shutdown procedures must be observed in all
work relating to the installation, start-up, setting up, operation, modifications to conditions of use
and methods of operation, maintenance, inspections and repair.
3.4.2 Operating personnel
The following work should only be carried out by trained and authorised personnel.
) Assembly and calibration work on the HTR
) Installation of safety limit switches
) Installation of the drives and testing the direction of rotation
3.5 Safety instructions for the user company
Management must be familiar with the whole of Chapter "Safety" and the necessary operations
on the HTR.
Management must ensure that the Chapter "Safety" and the descriptionsof the appropriate
operations are read, understood and complied with by the assembly and operating personnel.
The HTR must only be operated when in faultless condition.
3.6 Safety instructions for the operating personnel
Refrain from any method of working which is prejudicial to the safety of the HTR.
The operating or supervisory personnel are obliged to inspect the HTR or the machine plant at
least once per shift for outerly detectable damage and defects, any changes detected (including
the operating performance) which could affect safety must be reported immediately.
Components and accessories have been specially designed for the product. Only use our origi-
nal parts when purchasing replacement parts and wearing parts. We would like to make you ex-
pressly aware that genuine parts and accessories not supplied by us have also not been
checked and released by us. The installation and/or use of such products can therefore, under
certain circumstances, have a negative effect on the constructional characteristics of the ma-
chine and thus affect active and/or passive operating safety.
We accept no liability as manufacturers for damages arising through the use of non-genuine
parts and accessories.
On no account may any safety fixtures be removed or put out of operation.
Protective fixtures may not be made ineffective or circumvented.
The relevant requirements and national accident-prevention regulations are always to be com-
plied with when installing and operating our mechanical linear units.

Safety instructions
3 - 3
3.7 Note regarding special dangers
The HTR must be fixed or supported in accordance with the indications in these operating in-
structions with the prescribed minimum distances.
Ensure that the movement of the HTR does not result in any danger.
If the HTR moves in danger areas, these areas can be secured with safety limit switches.
3.8 Unauthorised conversions or modifications are forbidden
The HTR may not be altered structurally or safety-wise without our express authorisation. Any
unauthorised alteration of this sort excludes any liability on our part.
3.9 Transport
STOP Danger When transporting components, never move under the suspended load.
This can be fatal!
Before transportation, secure axle against independent extension. Block the axle with a bolt (b).
Only use transport equipment with adequate lifting capacity. When using ropes, ensure that
these are not twisted or knotted. If several ropes are used, all should be under equal tension.
The HTR housing is fitted with eyebolts or threaded holes suitable for eyebolts for attaching
transportation ropes (HTR80: M10; HTR50: M6).
b a a
aa
Key:
a: Threaded hole transportation
eyebolts
b: Axle extension safety bolt
Fig. 3-1: Transporting the HTR

Safety instructions

Assembly
( ): Position numbers for HTR80; [ ]: Position numbers for HTR50 4 - 1
4 Assembly
4.1 General remarks
The HTR standard axle is always fully assembled and delivered mechanically operational.
If no HAUSER drive is provided, fit your motor-gear combination according to the applicable
manufacturer's instructions.
The installation position of the HTR is always vertical, unless specially designed otherwise.
!Attention! The HTR may only be fitted / removed by specialists.
4.2 Assembly on the flange plate
1
2
3
4
5
6Key:
1. HTR
2. Assembly angle bracket
3. Flange plate
4. Robot system (for example, two HAUSER linear units)
5. Threaded holes (HTR80: M10; HTR50: M6)
6. Threaded holes (for eyebolts to „suspend" the axle HTR80:
M10; HTR50: M6)
The HTR is fixed by at least 2 assembly an
g
le brackets (2) and a
flange plate suitable for the current application purposes.
The HTR standard axle is fitted for this purpose on three sides re-
spectively with 8 (HTR50) or 10 (HTR80) threaded holes M10x10
(HTR80) or M6x6 (HTR50). Pos. 5
Fig. 4-1: Flange plate assembly
) Fix the flange plate where present in your robot system - the flange plate must be fitted so
that the axle can be inserted without having to remove the lower rotor stations!.
4.2.1 Removal of the rotor station, lower central section
(Pos-Nos. see Figure 4-2, Page 4-3)
only necessary, if the axle with rotor station attached cannot pass through flange plate
opening!
) Remove outer attachments (Gripper, etc.).
) Extend linear axle (min. 50 mm).
) Remove the cover plate (295)/[375] of the lower central section of the rotor station by re-
moving the fixing screws (296)/[376].
) Mark the position of the tensioning station (44)/[44] against the guide profile of the central
section (40)/[40].
The marking ensures that at a later date the toothed belt tension can be reset to the
correct level - if it is accidentally changed. (Adjustment, see Chapter 7.3.3)

Assembly
( ): Position numbers for HTR80; [ ]: Position numbers for HTR50
4 - 2
)
Set screws (61)/[45] must be firmly tightened so that the toothed belt tension does not
change.
)
Completely unscrew set screw (58)/[63].
)
Completely unscrew fixing screws (60)/[55].
)
Pull rotor station out of the guide profile central section (40)/[40].
4.2.2 Removal of the rotor station, lower outer section
(Pos-Nos. see Figure 4-2, Page 4-3)
only necessary, if the axle with rotor station attached cannot pass through flange plate
opening!
)
Remove the toothed belt cover (14)/[31] from the main drive by unscrewing the fixing
screws (23)/[32].
)
Remove the cover plate (215)/[295] of the lower central section of the rotor station by re-
moving the fixing screws (216)/[296].
)
Mark the position of the tensioning station (4)/[600] against the guide profile of the outer
section (1)/[1].
The marking ensures that at a later date the toothed belt tension can be reset to the cor-
rect level - if it is accidentally changed. (Adjustment, see Chapter 7.3.2)
)
Set screws (26)/[8] must be firmly tightened so that the toothed belt tension does not
change.
)
Completely unscrew set screws (27)/[10].
)
Remove fixing screws (25+21)/[4].
)
Pull rotor station out of the guide profile outer section (1)/[1].
4.2.3 Installation of the HTR in the flange plate
)
Attach the assembly angle brackets to the HTR, loosely tighten the screws so that the
brackets can still be adjusted.
)
Block the HTR rotors against independent extension using the transportation bolts (see Fig-
ure 3-1).
)
Feed the HTR from above into the flange plate and loosely screw on the assembly angle
brackets.
STOP Keep the HTR suspended until all fixing screws are firmly tightened!
)
Align the HTR at right angles to the flange plate.
)
Firmly tighten the screws between the HTR <> assembly angle brackets and assembly angle
bracket <> flange plate.
4.2.4 Installation of the rotor station, lower outer section
(Pos-Nos. see Figure 4-2, Page 4-3)
)
Carefully insert lower outer section of rotor station over the central section guide profile
(40)/[40] into the outer section guide profile (1)/[1].
Insert the rotor station so that the holes for the toothed belt tensionin
g
screws (27)/[10]
are on the side of the main drive.
)
Fix the rotor station with fixing screws (21)/[28], e.g. attach to the tension station of the
main drive at Pos. (25)/[8] inc. screw locking devices.
)
Fit the set screws (27)/[10] of the main drive.
)
Fit the cover plate (215)/[295].