Schneeberger MONORAIL Series User manual

www.schneeberger.com
SCHNEEBERGER AG
Lineartechnik
St. Urbanstrasse 12
4914 Roggwil/BE
SCHNEEBERGER GmbH
Gräfenau
75339 Höfen/Enz
SCHNEEBERGER S.r.l.
Via Soldani 10
21021 Angera (VA)
SCHNEEBERGER Inc.
44 Sixth Road,
Woburn, MA 01801-1759
SCHNEEBERGER India Pvt. Ltd.
406, Satra Plaza,
Palm Beach Road, Sector 19D
Vashi,
400 703 New Mumbai
[phone]
[phone] [phone] [phone] [phone] [phone] [phone] [phone] [phone]
[e-mail] [e-mail] [e-mail] [e-mail] [e-mail]
Nippon SCHNEEBERGER K.K.
Crane Toranomon Bldg 7F
3-20-5 Toranomon, Minato-ku
Tokyo 105-0001
日本シュネーベルガー株式会社
〒105-0001
東京都港区虎ノ門3-20-5
クレイン虎ノ門ビル7階
SCHNEEBERGER
(Shanghai) Co., Ltd.
Rm 606, Shang Gao International
Building
No. 137 XianXia Road
200051 Shanghai
施耐博格（上海）传动技术有限公司
上海市长宁区
仙霞路137号盛高国
际大厦606室，上海 200051
SCHNEEBERGER Korea Ltd.
Garden5 Tool
10, Chungmin-ro,
Songpa-gu, Seoul,
Korea 05840
슈니베거코리아 유한회사
05840 서울시 송파구 충민로 10
가든파이브 툴관 10층
SCHNEEBERGER Linear
Technology Pte. Ltd.
38 Ang Mo Kio Industrial Park 2
#01-04, Singapur 569511
[phone]
[phone] [phone] [phone] [phone] [phone] + 65 6841 2385 + 65 6841 3408
[e-mail] [e-mail] [e-mail] [e-mail]
SCHNEEBERGER
Mineralgusstechnik s.r.o
Prumyslový park 32/20
350 02 Cheb – Dolní Dvory
SCHNEEBERGER Changzhou
Precision Systems Co. Ltd.
137 Hanjiang Road
Changzhou New district
213000 Changzhou, Jiangsu
施耐博格（常州）测试系统有限公司
汉江路137，常州新区，常州213022
A.MANNESMANN
MASCHINENFABRIK GmbH
Bliedinghauser Str. 27
42859 Remscheid
[phone]
[phone] [phone] [phone] [phone] [phone]
[e-mail] [e-mail] [email protected]
[phone] [phone] [phone] [phone] (West)
[phone] (Ost) [phone]
[e-mail] [e-mail] [e-mail] [e-mail] [e-mail]
[phone] [phone] [phone]
[phone]
[phone]
[phone] + 90 545 320 83 55
[e-mail] [e-mail] [e-mail] [e-mail] [e-mail]
PROSPECTUSES
• COMPANY BROCHURE
• CUSTOMIZED BEARINGS
• GEAR RACKS
• LINEAR BEARINGS AND RECIRCULATING UNITS
• MINERAL CASTING SCHNEEBERGER
• MINISLIDE MSQSCALE
• MINI-X MINIRAIL / MINISCALE PLUS / MINISLIDE
• MONORAIL AND AMS PROFILED LINEAR GUIDEWAYS
WITH INTEGRATED MEASURING SYSTEM
• MONORAIL AND AMS APPLICATION CATALOG
• POSITIONING SYSTEMS
• SLIDES
MINERALGUSSTECHNIK
50.5020/05/0819/e/0.0/SRO/CM/Printed in Germany. Subject to technical changes.
A.MANNESMANN
A member of
SCHNEEBERGER
linear technology
SCHNEEBERGER COMPANIES
SWITZERLAND GERMANY ITALY USA INDIA
JAPAN CHINA KOREA SINGAPORE
SCHNEEBERGER MINERAL CASTING A.MANNESMANN A MEMBER OF
SCHNEEBERGER LINEAR TECHNOLOGY
CZECH REPUBLIC CHINA GERMANY
SCHNEEBERGER SALES DEPARTMENTS
AUSTRIA AND
SOUTH EAST EUROPE
BENELUX DENMARK, SWEDEN FRANCE GREAT BRITAIN
ISRAEL POLAND, SLOVAKIA,
CZECH REPUBLIC
RUSSIA, BELARUS,
UKRAINE
SPAIN, PORTUGAL,
ANDORRA
TURKEY
MONORAIL and AMS
Proled linear guideways and integrated
measuring systems
Mounting instructions 2019

User guidelines
DIN 637 should always be observed when operating and dimensioning MONORAIL
guideways. DIN 637 is always valid even if this document contains statements that
are contradictory to DIN 637.
Additional literature
• MONORAIL and AMS product catalog
• MONORAIL and AMS application catalog
This documentation and further information are available in digital form in our download
area at www.schneeberger.com.
These MONORAIL and AMS mounting instructions are valid together with the
additional literature.
Disclaimer
This publication has been compiled with great care and all information has been
checked for accuracy. However, we can assume no liability for incorrect or incomplete
information. We reserve the right to make changes to the information and technical
data as a result of enhancements to our products. Reprinting or reproducing, even
in part, is not permitted without our written consent.
SCHNEEBERGER AGENCIES
EUROPE
AUSTRIA
Haberkorn GmbH
6961 Wolfurt
Phone: [phone]
Fax: [phone]
[email protected]
BULGARIA / MACEDONIA
Atlas Technik EOOD
Hippodroma, Bl. 139B, Eing. A, App. 6
1612 Sofia, PB 51
Bulgarien
Phone [phone]
Fax [phone]
Mobile [phone]
E-Mail: [email protected]
CROATIA
Haberkorn CRO d.o.o.
10431 Sveta Nedelja
Phone [phone]
Fax. [phone]
E-Mail: [email protected]
CZECH REPUBLIC
INOMECH s.r.o. .
Martina Koláře 2118
390 02 Tábor
Phone [phone]
E-Mail: [email protected]
DENMARK
HERSTAD + PIPER A/S
Jernholmen 48c
2650 Hvidovre
Phone [phone]
Fax [phone]
E-Mail: [email protected]
FINLAND
EIE Maskin OY
PL, 80 Asematie 1
10601 Tammisaari
Phone [phone]
Fax [phone]
E-Mail: [email protected]
FRANCE
Region Rhône-Alpes
Groupe BARET
6 avenue du 11 novembre 1918
69200 Venissieux
Phone [phone]
Fax [phone]
E-Mail: [email protected]
Regions Ile de France,
Normandie, Bretagne
Groupe LECHEVALIER
56 rue Jean Mermoz
Parc d›activités de la Bretèque
76230 Bois-Guillaume Cedex
Phone [phone]
Fax [phone]
E-Mail: [email protected]
Region Nord Pas de Calais
LEFRANC LTL «Le Panetier»
35, rue Pierre Martin
Parc d›Activités de l›Inquétrie
62280 Saint Martin Boulogne
Phone [phone]
Fax [phone]
E-Mail: [email protected]
GERMANY
BGP-Blazevic Geradlinige Präzisionstechnik
Stipo Blazevic
Auerbacher Straße 8
93057 Regensburg
Phone [phone]
Fax [phone]
Mobile [phone]
E-Mail: [email protected]
EUROPE
HUNGARY
Haberkorn Kft.
Asztalos Sándor u.12
Budapest, 1087
Phone [phone]
Fax [phone]
E-Mail: [email protected]
ITALY
Gruppo Rinaldi
Via Campana, 233G
80078 Pozzuoli (NA)
Phone [phone]
Fax [phone]
E-Mail: [email protected]
Nadella S.r.I.
Via Melette, 16
20128 Milano
Phone [phone]
Fax [phone]
E-Mail: [email protected]
NORWAY
EIE Maskin AS
Tvetenveien 164
0671 Oslo
Phone [phone]
Fax [phone]
E-Mail: [email protected]
POLAND
TECHNIKA LINIOWA
Rollico Rolling Components
UI. Cegielniana 21
42-700 Lubliniec
Phone [phone]
Fax [phone]
E-Mail: [email protected]
ROMANIA
Meximpex SRL
4, Burebista Blvd.,
bl. D13 sc. A et 2 ap. 9-10
031108 Bucharest
Phone [phone]
Fax [phone]
E-Mail: [email protected]
RUSSIA
Bearing Alliance, TD
121069 Moscow
Phone [phone] add 114,
8 800 100 42 92
Fax. [phone]
E-Mail: [email protected]
SERBIA/MONTENEGRO
Haberkorn d.o.o.
Kralja Petra I, 59
21203 Veternik,
Phone [phone]
Fax [phone]
E-Mail: [email protected]
SLOVAKIA
KBM, s.r.o.
Juraj Hajovsky
Zitná 13
010 04 Zilina
Phone [phone]
Fax [phone]
Mobile [phone]
E-Mail: [email protected]
SLOVENIA / BOSNIA HERZEGOVINA
Haberkorn d.o.o.
Vodovodna ul. 7
2000 Maribor
Phone [phone]
Fax [phone]
E-Mail: [email protected]
EUROPE
SPAIN / PORTUGAL
TECNOMECA-KIDELAN-DEXIS
Pol lndustrial ltziar
20829 DEBA (Gipuzkoa)
Phone [phone]
Phone [phone]
E-Mail: [email protected]
SWEDEN
EIE Maskin AB
Box 7
12421 Bandhagen
Phone [phone]
Fax [phone]
E-Mail: [email protected]
TURKEY
Birlik Rulman (Paz.ltd.sti.)
Mumhane Cad. No: 16
80030 Karakoy-Istanbul
Phone [phone]
Fax [phone]
E-Mail: [email protected]
Mustafa Kozanlı Mühendislik Ltd. Şti.
Çalı Kavşağı Alaaddinbey Cad. No: 7
16130 Nilüfer / BURSA
Phone [phone]
Fax [phone]
E-Mail: [email protected]
ASIA
TAIWAN / REPUBLIC OF CHINA
Ever Bright Systems Co., Ltd.
1F., No. 52, Lane 10, Chi-Hu Road
11492, Taipei
Phone [phone]
Fax [phone]
E-Mail: [email protected]
INDIA
Jagat Enterprise
83, Narayan dhuru street, 3rd floor, Mazjid Bunder
Mumbai - 400 003
Phone [phone]
Fax [phone]
E-Mail: [email protected]
M.R. Bearing Company
MR Complex, 224 Linghi Chetty Street Parrys,
Chennai - 600001
Phone [phone]
Fax [phone]
E-Mail: [email protected]
AUSTRALIA / NEW ZEALAND
Benson Machines
118 Carnarvon Street
NSW 2128 Silverwater
Australia
Phone [phone]
Fax [phone]
E-Mail: [email protected]
SOUTH AFRICA
Fischli & Fuhrmann Ltd.
P.O Box 253
1600 Isando Gauteng
Phone [phone]
Fax [phone]
E-Mail: [email protected]
SOUTH AMERICA
Ibatech Tecnologia Ltda.
Estrada da Arrozeira, 90 – Residencial Eldorado
92990-000 Eldorado do Sul
Brazil
Phone [phone] (RS)
Phone [phone] (SP)
E-Mail: [email protected]
C100493

1
Page number
Table of contents
Table of contents
1 Abouttheseinstallationinstructions 3
1.1 Function and applications 3
1.2 Target audience 3
1.3 Symbols used 3
2 Foryoursafety 4
2.1 Authorised personnel 4
2.2 Intended use 4
2.3 General safety and protective measures 4
2.4 Environmentally responsible conduct 5
3 Productinformation 6
3.1 Product variants 6
3.2 Components 7
3.3 Labelling of guide rails and carriages 8
3.4 Product identification - measuring system 10
4 Storageandtransportation 11
5 PreparingforInstallation 14
5.1 Required tools and equipment 14
5.2 Packaging material 14
5.3 Condition as received 14
5.4 Corrosion protection 15
5.5 Unpacking and checking the delivery 15
5.6 Preparing the locating surfaces 16
5.7 Preparing the measuring system for installation 16
6 Installation 18
6.1 MWM Installation carriage 18
6.2 Handling carriages 18
6.3 Handling guide rails 19
6.4 Handling multi-part guide rails 20
6.5 Handling measuring systems 21
6.5.1 Handling magnetic fields 21
6.5.2 Installing and connecting the read head 23
6.5.3 Installing product versions AMS 3B, AMS 4B, and AMSA 3L 24
6.5.4 Installing product version AMSABS 24
6.6 Installation options 25
6.6.1 Installation option 1 25
6.6.2 Installation option 2 26
6.6.3 Installation option 3 27
6.6.4 Installation option 4 28
6.7 Installing MONORAIL BZ 29

2
Table of contents
Page number
7 Completinginstallation 30
7.1 Checking parallelism and running accuracy 30
7.2 Installing the screw cover 31
7.2.1 MRK/BRK plastic plugs 31
7.2.2 MRS/BRS brass plugs 32
7.2.3 MRZ steel plugs 38
7.2.4 MAC/BAC cover strips 42
7.3 Removing the protective installation film for additional wipers (optional) 48
7.4 Lubrication 49
7.5 Laying the electronics housing and cables 52
7.6 Installing a FBM/FBB bellows - optional 54
7.7 Checking the results of the installation 55
8 Commissioning 57
8.1 Guideway check list 57
8.2 Measuring system check list 57
9 Maintenance 58
9.1 Optical inspection check list 58
9.2 Clean 58
9.3 Replacing defective components 58
9.4 Replacing the read head 59
9.5 Battery AMSABS 61
9.6 Checking and replacing accessories and wear parts 62
9.6.1 Front plates and additional wipers 62
9.7 Spare parts - availability 67
10 Disposal 68
11 TroubleshootingtheAMSmeasuringsystem 69
12 Appendix 70
12.1 Dimensions of accessories 70
12.2 Screw tightening torques 73
12.3 Amount of lubricants 75
12.4 Cable bending radii 76

3
1Abouttheseinstallationinstructions
1.1 Functionandapplications
The MONORAIL and AMS installation instructions describe how to install the
MONORAIL
MR and MONORAIL BM profiled linear guideway systems and the
integrated AMS distance measuring system.
1.2 Targetaudience
These installation instructions are intended for installers, service technicians, and all
personnel who install, operate, replace, handle, or transport MONORAIL profiled linear
guideways and AMS distance measuring systems and who have read and understood
these instructions.
1.3 Symbolsused
Action prompts
1. This is the first step of a multi-part action prompt.
2. This is the second step of a multi-part action prompt.
ȘThis is a result.
• This is a bullet point.
NOTE
Notes and recommendations are set out here.
Warning note
Warning notes are placed before working steps that give rise to a potential danger.
Warning notes are classified as follows, in accordance with the keyword, the type and
source of the danger, the possible consequences should the danger be realised and/or
the warning note be disregarded, and the measures to be taken to avoid the danger;
DANGER
A danger is present that involves a high degree of risk.
Disregarding this note will result in death or serious injury.
WARNING
A danger is present that involves a medium degree of risk.
Disregarding this note may result in death or serious injury.
CAUTION
A danger is present that involves a low degree of risk.
Disregarding this note may result in minor or moderate injury.
ATTENTION
A possibly harmful situation is present that could result in damage
to the product or an item in its vicinity.
1.1/1.2/1.3Abouttheseinstallationinstructions

4
2Foryoursafety
These installation instructions should be read carefully prior to installation in order to
avoid potential danger and/or damage.
When installing the MONORAIL and AMS systems, the general safety instructions,
warning notes, and installation notes in these instructions should be followed as
precisely as possible.
Please do not hesitate to contact SCHNEEBERGER should you require any further
information.
2.1 Authorisedpersonnel
The MONORAIL and AMS systems should be installed by appropriately qualified or
trained specialists, e.g. by installers who have read and understood these instructions.
2.2 Intendeduse
MONORAIL and AMS are components for precise linear movement and distance
measurement.
MONORAIL and AMS must only be operated within the intended temperature ranges
(MONORAIL -40°C to +80°C, AMS 0°C to +70°C).
SCHNEEBERGER profiled linear guideways must not be used as safety components.
2.3 Generalsafetyandprotectivemeasures
SCHNEEBERGER assumes no liability for damage arising from the following:
• Improper handling, installation, and/or maintenance
• Improper use of the guideways and/or distance measuring system
• Arbitrary modifications to MONORAIL and AMS
In extreme cases – for example, in the event of the loss of rolling elements – carriages
may become separated from the rail. It should be checked prior to each use whether
a risk of personal injury exists in this case and any such risk excluded using suitable
design measures.
DANGER!
Danger to life posed by falling carriages!
Carriages may become separated from the guide rail and fall in the
event of overloading or the loss or rolling elements.
• All maintenance and conversion procedures on parts subject
to wear must be carried out in a load-free state.
• Additional fall protection must be applied.
• Design measures must be implemented to prevent individuals from
accessing the movement zones of the axis slides.
• MONORAIL and AMS are used in conjunction with heavy loads that may only
be lifted, installed and transported using a suitable lifting device together with an
adequate number of personnel.
• MONORAIL and AMS must be stored in their original packaging prior to installation
and protected from moisture and damage.
• MONORAIL AMS must be protected from magnetic fields. These could destroy
the magnetic measuring scale in the event of direct contact.
• Disconnect the power supply prior to any work on electrical equipment.
• Only use original SCHNEEBERGER parts for repair work.
• Comply with all country-specific regulations, standards, and guidelines for accident
prevention.

5
2
• To ensure the proper functioning of the products, also observe the instructions
on profile and position tolerances, dynamic limits, load, lubrication, and environ-
mental conditions.
2.4 Environmentallyresponsibleconduct
Do not allow lubricants and electronic components to be released into the environment,
and ensure that these are disposed of in accordance with country-specific regulations.
Productinformation
Foryoursafety
2.1/2.2/2.3/2.4Abouttheseinstallationinstructions

6
3Productinformation
MONORAIL is a profiled linear guideway system. It consists of a single guide rail with
accompanying carriages (MONORAIL guideway) or multiple associated MONORAIL
guideways (MONORAIL system).
In the case of MONORAIL AMS with integrated distance measuring system, the guide
rail is equipped with a magnetic measuring scale and one or more carriages on
the guide rail is equipped with a housing with a read head.
3.1 Productvariants
MONORAIL is available in the following product versions:
Roller-MONORAIL MR
Profiled linear guideway with rollers as rolling elements
Ball-MONORAIL BM
Profiled linear guideway with balls as rolling elements
Ball-MONORAIL BM WR / BM SR
Profiled linear guideway in a stainless steel design with balls as rolling elements
MONORAIL BZ
Ball-profiled linear guideway with integrated tooth rack
MONORAIL AMSA 3B
Roller-profiled linear guideway with distance measuring system with incremental analogue
interface
MONORAIL AMSD 3B
Roller-profiled linear guideway with distance measuring system with incremental digital
interface
MONORAIL AMSA 4B
Ball-profiled linear guideway with distance measuring system with incremental analogue
interface
MONORAIL AMSD 4B
Ball-profiled linear guideway with distance measuring system with incremental digital
interface
MONORAIL AMSABS 3B
Roller-profiled linear guideway with distance measuring system with absolute interface
MONORAIL AMSABS 4B
Ball-profiled linear guideway with distance measuring system with absolute interface
MONORAIL AMSABS DC 3B
Roller-profiled linear guideway with distance measuring system with absolute
DRIVE-CLiQ interface
MONORAIL AMSABS DC 4B
Ball-profiled linear guideway with distance measuring system with absolute
DRIVE-CLiQ interface
MONORAIL AMSA 3L
Ball-profiled linear guideway with distance measuring system for multi-part rails with
incremental analogue interface
DRIVE-CLiQ is a registered trademark of Siemens AG

7
3
Fig.1
Fig.2
3.2 Components
The following figures show the components of a MONORAIL guideway system with
AMS based on the example of MONORAIL AMSA 3B.
Sensor unit
MONORAIL system
The mounting plate (7) and the machine bed (10) are not included in delivery.
1 Read head 5 Connector (various options available)
2 Sensor slider 6 Mounting base (various options available)
3 Sensor cable 7 Read head cable
4 Electronics housing
(7) Mounting plate 11 Guide rail with magnetic
measuring scale
8 Carriage 12 AMS carriage
9 Guide rail without magnetic
measuring scale
13 Sensor unit (installed)
(10) Machine bed
Productinformation
3.1/3.2Productinformation

8
3.3 Labellingofguiderailsandcarriages
SCHNEEBERGER labels guide rails and carriages distinctly so that products can be
identified and tracked at any time. The labelling includes a precise type designation,
the date of manufacture and, in the case of guide rails, a serial number.
In the case of multi-part guide rails and cover strips, the individual segments and joints
are also labelled to enable installation of the individual components in the correct order.
Carriage
Carriages are labelled on their upper side between the polished mounting surfaces.
The label consists of the following information:
1 Type description (for codes, see MONORAIL and AMS product catalogue)
2 Production order No.
3 Calendar week of production
4 Production year
5 Optional: Designation of carriage differing from standard version
3
Fig.3
13 Guide rail with magnetic measuring scale 15 AMS carriage
14 Additional wipers 16 Sensor unit
Productinformation
Measuring system
Fig.4

9
3
Fig.5
Fig.6
1 SCHNEEBERGER company logo
2 Type description (for order codes, see MONORAIL product catalogue)
3 Consecutive serial number
Guide rails
Guide rails are labelled at the profile base opposite the locating side. The label consists
of the following information:
AMS guide rails with magnetic measuring scale
Guide rails with magnetic measuring scale are labelled at the profile base opposite the
measuring scale, and are also marked on the upper surface of the rail with the serial
number and a label for reference mark type.
The label is located on the same side as the measuring scale.
The following reference mark types are available:
Sign on rail Meaning AMS design Order code
DC Spacing code AMSA 3B/4B
AMSD 3B, 4B
TD 50, TD 20
TD 50, TD 20
Equidistant
reference mark
spacings
AMSA 3B/4B
AMSD 3B/4B
AMSA 3L 25
AMSA 3L 35
AMSA 3L 45
AMSA 3L 55
AMSA 3L 65
TR 50
TR 50
TR 30
TR 40
TR 60
TR 105
TR 75
ABS Absolute AMSABS 3B, 4B TA1
Matched and multi-part guide rails
Matched guide rails are marked with a consecutive serial number on the rail upper
surface. Multi-part guide rails are also marked at each butt joint using a joint numbering
system. The numbering consists of:
1 Sign for reference mark pattern (for codes, see following table)
2 Serial number
1 Set number (consecutive)
2 Rail line number (consecutive for each rail set)
3 Joint indicator serial number (consecutive for each line)
Fig.7
Productinformation
3.2/3.3Productinformation

10
3
Multi-part cover strips
Multi-part cover strips are labelled at the butt joint with a joint indicator serial number.
This is located at the end of each strip on its underside:
3.4 Productidentification-measuringsystem
The MONORAIL AMS distance measuring system is available in five versions:
• AMSA
• AMSD
• AMSABS
• AMSABS DC
• AMSA 3L
With the exception of AMSA 3L, these are available both for Ball MONORAIL BM
and for Roller MONORAIL MR. Each distance measuring system can be identified
by its electronics housing.
The labelling on each electronics housing includes the following information:
An exception is the AMSA 3L measuring system. In this case the identifying label is
located directly on the read head.
Fig.8
1 Joint indicator serial number (consecutive for each rail set)
2 Rail line 1
3 Rail line 2
Fig.9
1 Type designation
2 SCHNEEBERGER GmbH company logo
3 Address of SCHNEEBERGER GmbH (Höfen)
4 Input voltage specification
5 CE marking
Productinformation
Fig.10
Fig.11
Fig.12
Fig.13

11
3.4/4Storageandtransportation
Storageandtransportation
MONORAIL guideways and the AMS distance measuring system are high-precision
components which must be handled with appropriate care. The following instructions
should be followed to prevent damage during storage and transportation:
• Internal transportation should only be carried out by trained personnel.
• Where possible, guideways and accessories should be stored and transported in
their original packaging to protect them against corrosion.
• Do not store products outdoors and protect them from impact damage and
moisture.
• Observe the following storage temperatures:
Ș-40°C to +80°C for MONORAIL guideways and accessories
Ș-20°C to +70°C for the AMS measuring system
• Only remove the products from their original packaging at their installation location
and immediately prior to assembly.
The packaging supplied affords the products sufficient protection against damage
during proper transportation, and will protect them from corrosion resulting from
fluctuations in humidity and temperature for a period of eight weeks.
The products must be checked for damage and corrosion every eight weeks. Where
necessary, they should be cleaned and freshly packaged using a suitable corrosion
inhibitor.
Transport packaging
The MONORAIL products will be dispatched either in individual cardboard boxes, in
wooden crates, or on pallets containing several packaged items. The packaged items
may measure over 6 m in length. In the case of cardboard packages from a gross
weight of 30 kg upwards, disposable or returnable pallets are placed underneath them
to make them easier to stack. Where a package length exceeds 1.50 m, boards are also
placed beneath the cardboard boxes for reinforcement to prevent excessive sagging.
• Long packaged items must be lifted from their centre of gravity at the mid-point
of the package.
• Wooden crates may be stacked to a maximum height of three on top of one
another.
• Pallets with cardboard boxes may not be stacked.
Auxiliary tools
Any suitable lifting devices may be used to move individual carriages, rails, or
packaged items that do not pose a risk of bending the rails or causing other damage
to the products.
• The lifting device must not damage the products or their packaging.
• The lifting device must minimise the amount of deflection.
4

12
Guide rails
WARNING!
Risk of injury posed by improper transportation!
Rails may fall during transportation and cause injury to persons nearby.
• Suspend long rails at several points with a crane during transportation.
• The slewing range of long rails must be taken into consideration.
WARNING!
Risk of injury posed by escaping carriages!
Carriages may become detached from the guide rail during transportation.
• Never position guide rails with carriages at an incline during
transportation or handling.
Guide rails must be supported over their entire length during storage.
Cover strips
CAUTION!
Risk of injury posed by sharp-edged cover strips!
Cover strips may have sharp edges which can cause cutting injuries
when touched.
• Protective gloves should be worn during cover strip installation.
• Where possible, cover strips should be stored and transported rolled up in their
original packaging.
• Straight strips should be supported across their full length and not allowed to bend.
• Observe the minimum bending radius of the strips (Rmin = 0.4 m).
Carriage
To prevent the loss of rolling elements, ensure that the carriages are protected from
impact loads.
• For the protection of rolling elements, always store and transport carriages on the
guide rail or on a transport or assembly rail.
ATTENTION!
Risk of material damage posed by mounting carriages onto
the guide rail using a transport rail!
Mounting carriages onto the guide rail using a transport rail may cause
rolling elements to fall out.
• Do not use transport rails for carriage installation.
• Mount carriages onto the guide rail using an MRM or MBM
assembly rail, see also „9.3 Replacing defective components“
on page 58.
4Storageandtransportation

13
Fig.14
Fig.15
MONORAIL BZ
The MONORAIL BZ system is fitted with an aluminium L profile for improved
transportation safety and handling. The BZ is packaged in wooden crates together
with wooden inserts that protect the guide rails from tipping over and slippage.
All steel parts are treated with a corrosion inhibitor and packaged in VCI film.
Following successful system installation, the aluminium profile is disassembled
and can be disposed of. It is possible to arrange a return consignment for recycling
with Schneeberger GmbH on a case by case basis which may contain all installation
components where applicable.
Measuring system
ATTENTION
Risk of material damage posed by magnetic fields!
The magnetic scale of the AMS guide rails may be destroyed in the
event of direct contact with magnetic fields.
• Protect rails with integrated scale from magnetic fields.
• Do not use lifting magnets for transportation.
• Protect read heads from strong vibrations or impacts.
• Where possible, always transport read heads installed in their housing. Only
remove
read heads from their housing in order to mount carriages onto guide rails.
• Always disassemble the read head before mounting carriages.
• During storage: In the case of the AMSABS measuring system, do not remove
the activation strip on the power supply on the electronics housing (see „5.7
Preparing the measuring system for installation“ on page 16). Only activate the
battery during commissioning.
4
1 Assembly rail
2 Transport rail
Storageandtransportation
4Storageandtransportation

14
PreparingforInstallation
5.1 Requiredtoolsandequipment
Installing MONORAIL MR/BM/BZ
• MRM assembly rails for MONORAIL MR or MBM for MONORAIL BM
• Oil stone and polishing pad
• Suitable solvent (e.g. white spirit)
• Lubricating oil or lubricating grease
• Grease containing MoS2 for the fastening screws, in order to ensure consistent
and therefore optimal screwing forces
• Torque wrench
• MWM installation carriage for MONORAIL MR
• Fastening screws for the guide rails
• Spanner, screwdriver, and Allen wrench for the installation of lubricating accessories
and additional wipers
• Soft cloth
• Corrosion protection
Additional for installation of MRK/BRK plastic plugs
• Plastic hammer and spacer
Additional for installation of MRS/BRS brass plugs
• MWH/BWH hydraulic assembly tool and MZH hydraulic cylinder incl. hydraulic unit
• Scalpel, brass brush, and compressed air pistol for installation
• Portable drill, thread cutter, drill, centre punch, and a screw with hexagonal socket
(e.g. DIN 912/ISO 4762) for dismantling
Additional for installation of MRZ steel plugs
• MWH/BWH hydraulic assembly tool and MZH hydraulic cylinder incl. hydraulic unit
• Portable drill, thread cutter, drill, centre punch, and a screw with hexagonal socket
(e.g. DIN 912/ISO 4762) for dismantling
Additional for installation of MAC / BAC cover strip
• MWC or BWC assembly tool for installation
• Flat-tipped screwdriver and small Allen wrench for dismantling
5.2 Packagingmaterial
Cardboard packaging is used for individual guide rail deliveries and system deliveries.
Wooden crates are available for certain countries or special requirements for an
additional fee. These are IPPC (International Plant Protection Convention) treated.
The carriages are individually packaged in cardboard boxes.
Carriages and rails are wrapped in VCI film prior to delivery in all cases to protect
them against corrosion. Systems are delivered using inserts made from corrugated
cardboard (for delivery in cardboard packaging) or maritime pine slabs (for delivery
in wooden crates). Accessories and lubricating accessories are enclosed.
5.3 Conditionasreceived
Individual packaging
All guideway components are delivered unassembled in individual packaging.
Accessories are included in a separate package.
Unless otherwise specified by the customer, all standard lube connections are
opened and closed with set screws (S99/S98). Lube connections that are not
required for use are closed.
5

15
5
Individual carriages are delivered on a transport rail to protect the rolling elements.
AMS measuring systems are installed ready to plug-in, and electrical accessories
and cables are packaged together with the mechanism. In its delivered condition
the read head can be either installed in its housing or separately packaged as an
individual component.
System delivery
A system delivery means that the carriages are assembled with all of their accessories
and installed onto the guide rail. Lube connections on the carriages are prepared
according to the customer's specifications. Lubricating accessories are installed
as specified or supplied in separate packaging.
5.4 Corrosionprotection
The external surfaces of the carriages and of the rails are treated with a hardening
corrosion protection. The rolling elements are given a mineral-oil-based corrosion
protection. Grease protection can also be provided upon request. Carriages and rails
are wrapped in a VCI film. Additional precautions are taken for special requirements
such as overseas transport.
5.5 Unpackingandcheckingthedelivery
ATTENTION!
Risk of material damage posed by improper unpacking!
Incisions in the groove base of the distance measuring system can
damage the measuring scale.
• Only cut at the upper or underside of the rails.
• Never make cuts in the groove base.
ATTENTION!
Risk of material damage posed by premature unpacking!
Read heads can be damaged by premature unpacking.
• Only remove individually packaged read heads from their packaging
immediately prior to installation.
• Unpack profiled linear guideways (including with integral distance measuring
system) at the installation location directly prior to installation. Carefully cut open
the corrosion protection film using a commercially-available film cutter and
without scratching parts of the guideway.
• Special care must be taken in the case of guide rails with an integrated distance
measuring system to ensure that cuts are only made at the upper and undersides
of the rails and never in the groove base, as this is where the measuring scale
is located.
• Always support long guide rails at several points of contact during handling.
• Always keep carriages on the guide rail where possible. Always leave individually
packed carriages on the transport rail.
• Use an MRM or MBM assembly rail for mounting carriages onto and dismounting
them from the guide rail. Once dismounted, keep carriages on the assembly rail.
• Check the parts delivered for completeness and condition. Take particular care
to check that cover strips, lube connection parts, gaskets, plugs etc are not bent.
PreparingforInstallation
5.1/5.2/5.3/5.4/5.5Preparingforinstallation

16
• Store delivered parts prior to installation in order to achieve temperature equalisa-
tion. Read installation notes and accompanying product documentation carefully
before installation.
5.6 Preparingthelocatingsurfaces
The locating surface of the rails can be found on the side facing away from the
SCHNEEBERGER and type number labels.
The locating surfaces are prepared as follows:
1. Check the locating surfaces of the machine bed and mounting plate for shape
and positional accuracy. Rework the locating surfaces if these do not meet the
specifications.
2. Clean all locating surfaces thoroughly. Remove ridges and surface irregularities
with an oil stone.
3. Ensure prior to and during installation that the guideways and mounting base are
at the same temperature.
4. Remove the corrosion protection from guide rails and carriages using a suitable
solvent, e.g. white spirit. Do not use any solvents capable of damaging plastics.
Do not move carriages during this time, as this could result in damage.
ATTENTION!
Risk of material damage posed by movement of carriage!
This can result in material damage.
• Never move carriages during use of a corrosion protection or suitable
solvents.
5. Lightly oil the locating surfaces of the guide rails and carriages.
5.7 Preparingthemeasuringsystemforinstallation
The absolute distance measuring system has an integrated battery-assisted power
supply which ensures that the position information is retained even if the controller
is switched off.
The measuring system is prepared as follows:
1. Unpacking
2. Remove the cover plate from the housing (see „6.5.1 Handling magnetic fields“
on page 21).
3. Activate the power supply:
• Remove the activation strip together with the magnet beneath it from the
electronics housing (see figure).
ȘThe LED will briefly flash red.
4. Install the read head.
ȘThe LED will briefly light up green.
5
1 Mounting plate locating surface
2 Carriage locating surface
3 Machine bed locating surface
4 Guide rail locating surface
Fig.16
PreparingforInstallation

17
5
Fig.17
1 Activation strip
2 Magnet
3 LED
PreparingforInstallation
5.6/5.7Preparingforinstallation

18
Installation
6.1 MWMInstallationcarriage
The installation carriage can be used to carry out the following installation work:
Alignment of the butt joints in the case of multi-part guide rails
1. Position the carriage over the joint so that one of the two external fixing holes of
the guide rail is visible.
2. Position the carriage over the fixing hole of the other guide rail and insert and
tighten the screw.
Adjusting the guide rails without lateral reference
1. Pass the installation carriage gradually over the guide rail.
ȘThe lateral position is measured by laser or dial gauge.
2. Place the carriage over the central guide rail fixing hole.
3. Press the rail into the desired position.
4. Introduce guide rail fastening screws into the guide rail from above via the central
fixing hole and tighten.
The installation carriage is available from SCHNEEBERGER as an accessory.
6.2 Handlingcarriages
Danger!
Risk to life posed by falling machine elements!
Possible consequences include death and serious injury.
• Ensure that additional fall protection is provided.
• Never remove the front plate from MONORAIL BM.
• Rolling elements must under no circumstances be allowed to fall
out of the carriage.
• In order to prevent rolling element loss, always store and transport
carriages on transport/assembly rails.
• Always keep carriages on the guide rail. Mount carriages onto and dismount
them from the transport rail using an assembly rail.
• If optionally implementing paired systems, ensure that the carriages of different
guide rails are not interchanged.
• In the case of carriages with a read head, always remove the read head before
mounting the carriage onto an assembly rail.
• Protect individual carriages from dirt and the loss of rolling elements.
• Always brace the locating surfaces of the carriage against the locating surfaces
of the mounting plate. The locating surface of the carriage is the side that has
been ground.
• Arrange for reworking of front plates to alter the lube connection to be carried
out through SCHNEEBERGER.
• Before mounting carriages onto the guide rail, remove the factory-applied
protective coating. In the case of repeated movement of the carriages back and
forth on the guide rail, protect wipers from damage caused by sharp-edged rail
fixing holes.
• Always tighten fastening screws using a torque wrench (for tightening torques,
see „12.2 Screw tightening torques“ on page 73).
6
Fig.18
Fig.19