SCHUNK LDL-US-0100 Installation and operating instructions

Translation of the Original Manual
Assembly and Operation Manual
LDL
Linear motor shaft

Imprint
62 06.00 | LDL | Assembly and Operation Manual | en | GAS341441
Imprint
Copyright:
This manual is protected by copyright. The author is SCHUNK GmbH & Co. KG. All rights
reserved. Any reproduction, processing, distribution (making available to third parties),
translation or other usage - even excerpts - of the manual is especially prohibited and
requires our written approval.
Technical changes:
We reserve the right to make alterations for the purpose of technical improvement.
Document number: GAS341441
Version: 06.00|29/09/2020|en
© SCHUNK Electronic Solutions GmbH
All rights reserved.
Dear Customer,
thank you for trusting our products and our family-owned company, the leading
technology supplier of robots and production machines.
Our team is always available to answer any questions on this product and other solutions.
Ask us questions and challenge us. We will find a solution!
Best regards,
Your SCHUNK team
SCHUNK Electronic Solutions GmbH
Am Tannwald 17
D-78112 St. Georgen
Tel. [phone]
Fax [phone]
[email protected]
schunk.com

Table of Contents
Table of Contents
1 General...................................................................................................................65
1.1 About this manual .............................................................................................. 65
1.1.1 Presentation of Warning Labels .............................................................65
1.1.2 Applicable documents ............................................................................66
1.2 Warranty ............................................................................................................ 66
1.3 Scope of delivery ................................................................................................ 66
1.4 Accessories ......................................................................................................... 66
1.4.1 Optional accessories...............................................................................66
2 Basic safety notes ..................................................................................................67
2.1 Intended use....................................................................................................... 67
2.2 Reasonably foreseeable misuse .........................................................................67
2.3 Constructional changes ...................................................................................... 67
2.4 Spare parts ......................................................................................................... 67
2.5 Ambient conditions and operating conditions ................................................... 68
2.6 Personnel qualification....................................................................................... 68
2.7 Personal protective equipment.......................................................................... 69
2.8 Notes on safe operation.....................................................................................69
2.9 Transport ............................................................................................................ 69
2.10 Malfunctions....................................................................................................... 70
2.11 Disposal .............................................................................................................. 70
2.12 Warnings on the drive ........................................................................................ 70
2.13 Fundamental dangers......................................................................................... 71
2.13.1 Protection during handling and assembly ..............................................71
2.13.2 Protection during commissioning and operation ...................................71
2.13.3 Protection against dangerous movements.............................................72
2.13.4 Protection against electric shock............................................................73
2.14 Notes on particular risks..................................................................................... 74
3 Technical Data ........................................................................................................76
3.1 Overview of types............................................................................................... 77
3.2 Type code ........................................................................................................... 78
3.3 Permissible static load........................................................................................ 79
4 Description of the options ......................................................................................80
4.1 Optional holding break....................................................................................... 80
4.2 Optional switching valve .................................................................................... 81
4.3 Optional shock absorbers................................................................................... 81
4.4 Optional limit and reference switches ............................................................... 81
5 Transport and storage.............................................................................................82
5.1 Transport ............................................................................................................ 82
5.2 Storage ............................................................................................................... 82
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Table of Contents
6 Assembly ................................................................................................................83
6.1 Mechanical connection of the module...............................................................83
6.1.1 dimensions .............................................................................................85
6.2 Electrical connection ..........................................................................................86
6.2.1 PE ground ...............................................................................................87
6.2.2 Electrical connections at the slide ..........................................................87
6.2.3 LE100 M12 incremental measuring system............................................88
6.2.4 LE100 incremental measuring system ...................................................89
6.2.5 MSA111C-DQ absolute measuring system .............................................90
6.2.6 Absolute measuring system TTK70/TTK70S..........................................91
6.2.7 MSA111C absolute measuring system ...................................................92
6.2.8 Motor .....................................................................................................93
6.3 Pneumatic connection (only for the holding brake)...........................................94
7 Maintenance and repair work.................................................................................96
7.1 Maintenance intervals........................................................................................ 98
7.2 Overview............................................................................................................. 99
7.3 Changing the motor housing ............................................................................ 100
7.3.1 Uninstalling the motor housing ............................................................101
7.3.2 Installing the motor housing.................................................................101
7.4 Changing the recirculating ball bearing............................................................102
7.5 Changing the stroke measuring system............................................................ 104
7.6 Changing the magnetic strip............................................................................. 104
7.7 Replacing the holding brake ............................................................................. 106
7.8 Limit switches and reference switches.............................................................108
8 Troubleshooting ...................................................................................................109
8.1 Product does not move .................................................................................... 109
8.2 Product does not achieve the cycle times........................................................ 109
8.3 Product gets too hot......................................................................................... 109
9 Spare parts ...........................................................................................................110
9.1 Note regarding spare part orders..................................................................... 110
9.2 Wearing parts ................................................................................................... 110
9.3 Axes .................................................................................................................. 111
9.4 Measuring system ............................................................................................ 112
9.5 Holding brake ................................................................................................... 113
9.6 Accessories ....................................................................................................... 114
9.7 Aids................................................................................................................... 114
10 Translation of original declaration of incorporation ..............................................115
10.1 Annex to Declaration of Incorporation............................................................. 116
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General
1 General
1.1 About this manual
This manual contains important information for a safe and
appropriate use of the product.
This manual is an integral part of the product and must be kept
accessible for the personnel at all times.
Before starting work, the personnel must have read and
understood this operating manual. Prerequisite for safe working is
the observance of all safety instructions in this manual.
Illustrations in this manual are provided for basic understanding
and may differ from the actual product design.
In addition to these instructions, the documents listed under
Applicable documents [}66] are applicable.
1.1.1 Presentation of Warning Labels
To make risks clear, the following signal words and symbols are
used for safety notes.
DANGER
Danger for persons!
Non-observance will inevitably cause irreversible injury or death.
WARNING
Dangers for persons!
Non-observance can lead to irreversible injury and even death.
CAUTION
Dangers for persons!
Non-observance can cause minor injuries.
CAUTION
Material damage!
Information about avoiding material damage.
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General
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1.1.2 Applicable documents
• General terms of business
• Start-up instructions
• Technical data for the module given on motor data sheet and
program overview
• Documentation for the used drive regulator
• Assembly instructions for the automated system in which the
module is to be used
• Machinery Directive 2006/42/EC
• Minimum safety and health requirements for the use of work
equipment by workers at work 2009/104/EC
• Accident prevention regulations and safety rules
• Other relevant safety rules
1.2 Warranty
If the product is used as intended, the warranty is valid for 24
months from the ex-works delivery date under the following
conditions:
• Observe the applicable documents,
Applicable documents [}66]
• Observe the ambient conditions and operating conditions,
Ambient conditions and operating conditions [}68]
• Observe the maximum service life. Technical Data [}76]
• Compliance with the specified maintenance and repair tasks
Maintenance and repair work [}96]
Parts touching the workpiece and wear parts are not included in
the warranty.
1.3 Scope of delivery
The scope of delivery includes
• Linear motor shaft LDL in the version ordered
• Documentation including basic parameter record on data carrier
• Enclosed pack with centering sleeves
1.4 Accessories
The following accessories, which must be ordered separately, are
required for the product:
• Drive controller
• Cable set
1.4.1 Optional accessories
For information regarding which accessory articles can be used
with the corresponding product variants, see catalog data sheet.

Basic safety notes
2 Basic safety notes
2.1 Intended use
The product is exclusively designed for linear movement of useful
loads into any position where the load does not react in a manner
endangering persons, property or the environment as a result of
this manipulation.
• The product may only be used within the scope of its technical
data, Technical Data [}76].
• The product is intended for installation in a machine/system.
The applicable guidelines must be observed and complied with.
• The product is intended for industrial and industry-oriented use.
• Appropriate use of the product includes compliance with all
instructions in this manual.
2.2 Reasonably foreseeable misuse
The product is not suitable for the following applications:
• Use as passenger or animal transportation
• Operation of the motor directly on the network
• Operation under water
• Operation in areas where there is a danger of explosion
2.3 Constructional changes
Implementation of structural changes
By conversions, changes, and reworking, e.g. additional threads,
holes, or safety devices can impair the functioning or safety of the
product or damage it.
• Structural changes should only be made with the written
approval of SCHUNK.
2.4 Spare parts
Use of unauthorized spare parts
Using unauthorized spare parts can endanger personnel and
damage the product or cause it to malfunction.
• Use only original spare parts or spares authorized by SCHUNK.
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Basic safety notes
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2.5 Ambient conditions and operating conditions
Make sure that the product, its mounting elements and the flange-
mounted parts are a sufficient size for the application.
Make sure that the environment is clean and the ambient
temperature corresponds to the specifications given in the catalog.
Observe the maintenance and lubrication intervals.
Make sure that the environment is free from splash water and
vapors as well as from abrasion or processing dust.
The product must be operated with drive control units. We
recommend using the control units offered by SCHUNK. Please
consult SCHUNK if you intend to use control units of other
manufacturers.
Protect the product from strong sunlight or heat.
Protect the product from chips or dust, abrasive media, vibration,
shock and moisture in order to prevent contamination.
2.6 Personnel qualification
Inadequate qualifications of the personnel
If the personnel working with the product is not sufficiently
qualified, the result may be serious injuries and significant
property damage.
• All work may only be performed by qualified personnel.
• Before working with the product, the personnel must have read
and understood the complete assembly and operating manual.
• Observe the national safety regulations and rules and general
safety instructions.
The following personal qualifications are necessary for the various
activities related to the product:
Trained electrician Due to their technical training, knowledge and experience, trained
electricians are able to work on electrical systems, recognize and
avoid possible dangers and know the relevant standards and
regulations.
Qualified personnel Due to its technical training, knowledge and experience, qualified
personnel is able to perform the delegated tasks, recognize and
avoid possible dangers and knows the relevant standards and
regulations.
Instructed person Instructed persons were instructed by the operator about the
delegated tasks and possible dangers due to improper behaviour.
Service personnel of
the manufacturer
Due to its technical training, knowledge and experience, service
personnel of the manufacturer is able to perform the delegated
tasks and to recognize and avoid possible dangers.

Basic safety notes
2.7 Personal protective equipment
Use of personal protective equipment
Personal protective equipment serves to protect staff against
danger which may interfere with their health or safety at work.
• When working on and with the product, observe the
occupational health and safety regulations and wear the
required personal protective equipment.
• Observe the valid safety and accident prevention regulations.
• Wear protective gloves to guard against sharp edges and
corners or rough surfaces.
• Wear heat-resistant protective gloves when handling hot
surfaces.
• Wear protective gloves and safety goggles when handling
hazardous substances.
• Wear close-fitting protective clothing and also wear long hair in
a hairnet when dealing with moving components.
2.8 Notes on safe operation
Incorrect handling of the personnel
Incorrect handling and assembly may impair the product's safety
and cause serious injuries and considerable material damage.
• Avoid any manner of working that may interfere with the
function and operational safety of the product.
• Use the product as intended.
• Observe the safety notes and assembly instructions.
• Do not expose the product to any corrosive media. This does
not apply to products that are designed for special
environments.
• Eliminate any malfunction immediately.
• Observe the care and maintenance instructions.
• Observe the current safety, accident prevention and
environmental protection regulations regarding the product's
application field.
2.9 Transport
Handling during transport
Incorrect handling during transport may impair the product's
safety and cause serious injuries and considerable material
damage.
• When handling heavy weights, use lifting equipment to lift the
product and transport it by appropriate means.
• Secure the product against falling during transportation and
handling.
• Stand clear of suspended loads.
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Basic safety notes
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2.10 Malfunctions
Behavior in case of malfunctions
• Immediately remove the product from operation and report the
malfunction to the responsible departments/persons.
• Order appropriately trained personnel to rectify the
malfunction.
• Do not recommission the product until the malfunction has
been rectified.
• Test the product after a malfunction to establish whether it still
functions properly and no increased risks have arisen.
2.11 Disposal
Handling of disposal
The incorrect handling of disposal may impair the product's safety
and cause serious injuries as well as considerable material and
environmental harm.
• Follow local regulations on dispatching product components for
recycling or proper disposal.
2.12 Warnings on the drive
Item Designation
1 Name plate
2 Caution - magnetic field
3 Measuring system type
4 Grounding symbol
5 Serial number
6 Mandatory sign "read manual"

Basic safety notes
2.13 Fundamental dangers
General
• Observe safety distances.
• Never deactivate safety devices.
• Before commissioning the product, take appropriate protective
measures to secure the danger zone.
• Disconnect power sources before installation, modification,
maintenance, or calibration. Ensure that no residual energy
remains in the system.
• If the energy supply is connected, do not move any parts by
hand.
• Do not reach into the open mechanism or movement area of
the product during operation.
2.13.1 Protection during handling and assembly
Incorrect handling and assembly
Incorrect handling and assembly may impair the product's safety
and cause serious injuries and considerable material damage.
• Have all work carried out by appropriately qualified personnel.
• For all work, secure the product against accidental operation.
• Observe the relevant accident prevention rules.
• Use suitable assembly and transport equipment and take
precautions to prevent jamming and crushing.
Incorrect lifting of loads
Falling loads may cause serious injuries and even death.
• Stand clear of suspended loads and do not step into their
swiveling range.
• Never move loads without supervision.
• Do not leave suspended loads unattended.
2.13.2 Protection during commissioning and operation
Falling or violently ejected components
Falling and violently ejected components can cause serious injuries
and even death.
• Take appropriate protective measures to secure the danger
zone.
• Never step into the danger zone during operation.
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Basic safety notes
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2.13.3 Protection against dangerous movements
Unexpected movements
Residual energy in the system may cause serious injuries while
working with the product.
• Switch off the energy supply, ensure that no residual energy
remains and secure against inadvertent reactivation.
• The faulty actuation of conected drives may cause dangerous
movements.
• Operating mistakes, faulty parameterization during
commissioning or software errors may trigger dangerous
movements.
• Never rely solely on the response of the monitoring function to
avert danger. Until the installed monitors become effective, it
must be assumed that the drive movement is faulty, with its
action being dependent on the control unit and the current
operating condition of the drive. Perform maintenance work,
modifications, and attachments outside the danger zone
defined by the movement range.
• To avoid accidents and/or material damage, human access to
the movement range of the machine must be restricted. Limit/
prevent accidental access for people in this area due through
technical safety measures. The protective cover and protective
fence must be rigid enough to withstand the maximum possible
movement energy. EMERGENCY STOP switches must be easily
and quickly accessible. Before starting up the machine or
automated system, check that the EMERGENCY STOP system is
working. Prevent operation of the machine if this protective
equipment does not function correctly.

Basic safety notes
2.13.4 Protection against electric shock
Work on electrical equipment
Touching live parts may result in death.
• Work on the electrical equipment may only be carried out by
qualified electricians in accordance with the electrical
engineering regulations.
• Lay electrical cables properly, e. g. in a cable duct or a cable
bridge. Observe standards.
• Before connecting or disconnecting electrical cables, switch off
the power supply and check that the cables are free of voltage.
Secure the power supply against being switched on again.
• Before switching on the product, check that the protective
earth conductor is correctly attached to all electrical
components according to the wiring diagram.
• Check whether covers and protective devices are fitted to
prevent contact with live components.
• Do not touch the product's terminals when the power supply is
switched on.
Possible electrostatic energy
Components or assembly groups may become electrostatically
charged. When the electrostatic charge is touched, the discharge
may trigger a shock reaction leading to injuries.
• The operator must ensure that all components and assembly
groups are included in the local potential equalisation in
accordance with the applicable regulations.
• While paying attention to the actual conditions of the working
environment, the potential equalisation must be implemented
by a specialist electrician according to the applicable
regulations.
• The effectiveness of the potential equalisation must be verified
by executing regular safety measurements.
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Basic safety notes
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2.14 Notes on particular risks
DANGER
Risk of injury due to magnetic fields
The integrated high performance permanent magnets can
represent a risk to persons with an active or passive implant.
•Persons with heart pace-makers, active or passive implants are
prohibited from entering the area of the magnetic field.
DANGER
Danger from voltage!
Touching live parts can be deadly.
•Switch off the power supply before any assembly, adjustment
or maintenance work and secure against being switched back
on again.
•Only qualified electricians my carry out electrical installation
work.
•Disconnect the converters from the power supply.
•The intermediate circuit capacitors must be discharged.
•Note the correct sequence for connecting cables (first the
grounding cable, then conductors).
DANGER
Danger from electric voltage!
Even if the voltage supply is not switched on, potentially lethal
voltage may occur on the module as a result of movement.
•Never touch the electric contacts.
•Place protective caps onto the electric contacts.
WARNING
Risk of injury due to unexpected movements of the machine/
system!
Moving the axes may cause serious injuries.
•Before performing assembly and adjustment works, switch off
the energy supply.
•Make sure there is no residual energy in the system.

Basic safety notes
WARNING
Risk of injury from objects falling and being ejected!
Falling and ejected objects during operation can lead to serious
injury or death.
•Take appropriate protective measures to secure the danger
zone.
WARNING
Risk of burns through contact with hot surfaces!
Surfaces of components can heat up severely during operation.
Skin contact with hot surfaces causes severe burns to the skin.
•For all work in the vicinity of hot surfaces, wear safety gloves.
•Before carrying out any work, make sure that all surfaces have
cooled down to the ambient temperature.
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Technical Data
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3 Technical Data
Construction size LDL-US-0100 LDL-UL-0200
Max. hub [mm] 3800 3700
Nominal strengh [N] */** 105 180
Maximum strengh [N] 250 500
Repeatability [mm] ±0,01 ±0,01
Max. standstill current [A eff] 1.8 3.1
Maximum current [A eff] 7.5 15
Winding resistance at
25°C Z [Ohm]
7.6 38
Max. intermediate circuit
voltage [V]
750
Ambient temperature
max. [°C]
40
Ambient temperature
min. [°C]
10
Surface temperature max. [°] 70
Impermeability IP 00
Pressurising medium:
compressed air - quality
ISO 8573-1:7 4 4
Pressurising medium: com-
pressed air min/max [bar]
5-7
Noise emission [dB(A)] ≤ 70
* Above an installation altitude of 1000 metres above sea level the
technical data is reduced.
** Depending on the situation of installation (heat dissipation) and
at 20°C ambient temperature.
Guarantee
Construction size LDL-xx-xxxx
Length of guarantee [months] 24
or maximum mileage [km] 20,000
or maximum cycles [units] 50,000,000
Further technical data contain the catalogue data sheets. The most
recent version is valid.

Technical Data
3.1 Overview of types
LDL-UL-0200 and LDL-US-0100 linear motor axes
All versions of the linear motor axes are available with multiple
slides
Linear motor axes type LDL-US—2 with two slides
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Technical Data
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3.2 Type code
Example: LD L - U S- 0100 - 1 - 300 - 524 - LxBV - 111A - 0122
LD L - U S - 0100 - 1 - 300 - 524 - LxBV - 111A - 0122
Linear Motor Axis
Profile type
U = supported
S = standard slide
L = long slide
Size
number of active slides
Useful stroke
Axis length
V = brake valve
B = brake
x = placeholder
L/R = motor left/right
Limit and reference switch
Stroke measuring system
Type designation

Technical Data
3.3 Permissible static load
Permissible static load of the unit
Item LDL-US-0100 LDL-UL-0200
Mx max. [Nm] 406 406
My max. [Nm] 340 657
Mz max. [Nm] 340 657
Fy max [N] 6350 6350
Fz max [N] 6350 6350
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Description of the options
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4 Description of the options
4.1 Optional holding break
In this option the product is equipped with a pneumatic brake.
Pneumatic connection (only for the holding brake) [}94].
The following should be noted here:
• The holding brake is only released if the brake valve is driven
and the axis is supplied with compressed air.
• The holding brake holds the axis in its current position.
• The holding brake is not suitable for operation while the unit is
in motion to brake the axis.
• The holding brake must be actuated when the axis is at a
standstill.
• Forced movement when the holding brake is activated will
damage it.
• Do no move the axis without the brake having been released.
• Ensure that the pneumatic holding brake is released before
moving the axis.
• The holding brake is not for personal protection.
• The holding brake is not a safety component.
• The holding force is in new condition 150N per brake piston
WARNING
Danger of crushing! The holding brake triggers as soon as it is
driven.
Parts of the body may become crushed when the axis is
pressurized and moves unexpectedly.
•Persons must keep out of the danger zone.
CAUTION
Damage to the holding brake
Forced movement when the holding brake is activated will
damage it.
•The holding brake must be actuated when the product is at a
standstill.