SCHUNK RPE 100 User instructions

01-A/RPE/en/2011-08-04/SK-CW Document last updated: 2011-02-15
Three-dimensional gantry electric
RPE 100
RPE 200
Assembly- and Operating manual

201-A/RPE/en/2011-08-04/SK-CW
Translation of the original manual
Dear Customer,
Congratulations on choosing a SCHUNK product. By choosing SCHUNK, you have opted for
the highest precision, top quality and best service.
You are going to increase the process reliability of your production and achieve best
machining results –to the customer’s complete satisfaction.
SCHUNK products are inspiring.
Our detailed assembly and operation manual will support you.
Do you have further questions? You may contact us at any time –even after purchase. You
can reach us directly at the mentioned addresses in the last chapter of these instructions.
Kindest Regards,
Your SCHUNK GmbH & Co. KG
Precision Workholding Systems
Bahnhofstr. 106 –134
D-74348 Lauffen/Neckar
Tel. [phone]
Fax [phone]
[email protected]k.com
www.schunk.com

Table of contents
01/RPE/en/2011-08-04/SK-CW 3
Table of contents
1 About this manual.................................................................................................5
1.1 Purpose/validity..........................................................................................5
1.2 Target groups.............................................................................................5
1.3 Applicable documents................................................................................5
1.4 Symbols in this manual ..............................................................................6
1.5 Copyright....................................................................................................6
1.6 Technical changes.....................................................................................6
2 Basic safety notes ................................................................................................7
2.1 Intended use ..............................................................................................7
2.2 Controlled production.................................................................................8
2.2.1 Protective equipment.....................................................................8
2.2.2 Constructional changes, attachments, or modifications.................8
2.2.3 Spare parts....................................................................................9
2.3 Obligations of the manufacturer/operator...................................................9
2.3.1 Choice of personnel and personnel qualifications .........................9
2.3.2 Organizational measures.............................................................10
2.3.3 Disposal.......................................................................................10
2.4 Personnel responsibilities.........................................................................11
2.4.1 Safety-conscious working............................................................11
2.4.2 Safety measures during transport................................................11
2.4.3 Safety measures during operation...............................................11
2.4.4 Behaviour in the event of faults and/or emergencies...................11
2.4.5 Testing/inspections......................................................................11
2.5 Notes on particular risks...........................................................................12
3 Warranty..............................................................................................................13
4 Technical Data ....................................................................................................13
5 Configuration ......................................................................................................14
6 Assembly and initial operation..........................................................................16
6.1 Mechanical connection.............................................................................16
6.2 Connection of the motors.........................................................................17
6.3 Connection of Sensors.............................................................................17

Appendix (on CD-ROM)
401/RPE/en/2011-08-04/SK-CW
6.4 Assembly of handling modules.................................................................18
7 Maintenance and repair......................................................................................19
8 Troubleshooting..................................................................................................20
9 Component documentation ...............................................................................20
10 Translation of original EC declaration of incorporation..................................21
11 Contacts ..............................................................................................................22
Appendix (on CD-ROM)
Documentation Linear axis Beta.................................................................Appendix 1
Documentation Drive MSK ..........................................................................Appendix 2

About this manual
01/RPE/en/2011-08-04/SK-CW 5
1 About this manual
1.1 Purpose/validity
This manual is part of the module and describes the safe and
proper assembling.
This manual is valid only for the module specified on the front
page.
1.2 Target groups
Target group
Task
Manufacturer, operator
Keep this manual available for the personnel at all times.
Require personnel to read and observe this manual and the
applicable documents, especially the safety notes and warnings.
Skilled personnel, fitter
Read, observe and follow this manual and the applicable
documents, especially the safety notes and warnings.
Tab. 1
1.3 Applicable documents
Detailed device documentation is included in the unit's scope of
delivery:
Document
Purpose
See
Component documentation
Technical data or application parameters of indi-
vidual components and information about mainte-
nance and repair and troubleshooting
Chapter 9, page 20
Tab. 2

About this manual
601/RPE/en/2011-08-04/SK-CW
1.4 Symbols in this manual
To give you quick access to information, the following symbols
will be used in this guide:
Symbol
Meaning
DANGER
Dangers for persons.
Nonobservance causes death or serious injuries.
WARNING
Dangers for persons.
Nonobservance causes death or serious injuries.
CAUTION
Dangers for persons.
Nonobservance can cause slight injuries.
NOTICE
Information on avoiding material damage.

Handling instruction, also measures in a warning or note.
Tab. 3
1.5 Copyright
This manual remains the copyrighted property of SCHUNK
GmbH & Co. KG. It is solely supplied to our customers and op-
erators of our products and forms part of the unit.
This documentation may not be duplicated or made accessible to
third parties, in particular competitive companies, without our
prior permission.
1.6 Technical changes
We reserve the right to make alterations for the purpose of tech-
nical improvement.

Basic safety notes
01/RPE/en/2011-08-04/SK-CW 7
2 Basic safety notes
2.1 Intended use
The unit is to be used only for the application contractually
agreed between the manufacturer/supplier and user.
The unit is intended for installation in a machine/system. The re-
quirements of the applicable guidelines must be observed and
complied with.
The unit may be used only in the context of its defined application
parameters.
To use this unit as intended, it is also essential to observe the
technical data and installation and operation notes in this manual
and to comply with the maintenance intervals.
Any other use or use exceeding that specified is an infringement
of use for intended purpose. The manufacturer bears no liability
for damage resulting from such use.
Use which is not specified as an intended use is for instance
when
•the unit is used with machines/systems or workpieces that are
not designed to be used with the unit.
•the unit is operated without protective equipment in
accordance to the EC Machinery Directive.
•the statutory safety and accident-prevention regulations and
the standards and guidelines valid at the usage site are not
observed.

Basic safety notes
801/RPE/en/2011-08-04/SK-CW
2.2 Controlled production
The unit represents the state of the art and the recognized safety
rules at the time of delivery. However, it can present risks if, for
example:
•The unit is not used in accordance with its intended purpose.
•The unit is not installed or maintained properly.
•The EC Machinery Directive, the VDE directives, the safety,
accident-prevention regulations and environmental protection
regulations valid at the usage site, or the safety and
installation notes are not observed.
The unit must only be used when in technically perfect
condition and in accordance with its designated use and the
instructions set out in the operating manual, and only by
safety-conscious persons who are fully aware of the risks
involved in operating the unit.
Immediately remedy faults that could impair safety.
In addition to this manual, statutory and other safety and
accident-prevention regulations and the standards and
guidelines valid at the usage site must be complied with.
2.2.1 Protective equipment
When the unit is in use, when in rotation and when it is stationary,
protective equipment must be used to catch flying parts should
the unit or part of the unit fail.
The protective equipment must comply with EC Machinery Direc-
tive requirements.
The machine/system manufacturer must ensure that the wall
thickness in the machine’s paneling is adequate and must not
use polycarbonate glass for protective windows, because this
may cause a threat to the life and limb of the operator if the com-
ponent should break.
2.2.2 Constructional changes, attachments, or modifications
Modifications, additions and conversions which could impair safety
may not be made to the unit without SCHUNK's permission.
Non-authorized modifications results in the exclusion from prod-
uct liability.

Basic safety notes
01/RPE/en/2011-08-04/SK-CW 9
2.2.3 Spare parts
Spare parts must meet the requirements of the manufacturer
and/or the supplier. This can always be guaranteed with original
spare parts.
Improper repair as well as use of non-original spare parts results
in the exclusion from product liability.
2.3 Obligations of the manufacturer/operator
2.3.1 Choice of personnel and personnel qualifications
Work on the unit may only be carried out by reliable personnel.
The legal minimum age must be observed.
The assembly, commissioning, maintenance, and repair of the
unit may be performed only by trained specialist personnel who
have been shown how to perform the said work activities.
The manufacturer/operator must ensure that the personnel are
adequately and appropriately trained to perform the work on the
unit allocated to them.
Every person called upon by the operator to work on the unit
must have read and understood the complete Assembly and Op-
erating Manual, especially chapter 2 "Basic safety notes". This
applies particularly to occasional personnel such as maintenance
personnel.
We recommend that the manufacturer/operator require employ-
ees to sign that they have read and understood the Assembly
and Operating Manual.
Furthermore we recommend that the manufacturer/operator re-
quire employees to sign that they have participated in training
courses.
In addition to this manual, the statutory and other safety and ac-
cident-prevention regulations and the standards and guidelines
valid at the usage site must be complied with.
We recommend that the manufacturer/operator issue in-house
operating instructions which take into account the known qualifi-
cations of the operating personnel.

Basic safety notes
10 01/RPE/en/2011-08-04/SK-CW
Only employ trained personnel who have been shown how to
perform the work activities. If necessary, make use of the
manufacturer’s training programmes.
Personnel requiring training and instruction or those who are
already receiving training and instruction must be supervised
on the unit by skilled personnel.
Define areas of responsibility of the personnel. Enable
personnel to refuse instructions issued by third parties which
breach safety regulations.
2.3.2 Organizational measures
Ensure that at least one copy of this manual is kept in the
direct vicinity of the machine/system where the unit is
installed, and that it is accessible for the relevant persons.
Ensure that personnel have read and understood this manual,
especially chapter 2"Basic safety notes".
Provide instruction about and observe the safety and
accident-prevention regulations valid at the usage site.
Provide instruction about and observe the environmental
protection regulations valid at the usage site.
Ensure that the safety and hazard warning signs on the
machine/system are observed and that the signs are clearly
legible.
Provide protective equipment.
Check the personnel’s conduct regarding awareness of safety
and hazards from time to time.
2.3.3 Disposal
Send unit components for recycling or properly dispose of
them according to local regulations.

Basic safety notes
01/RPE/en/2011-08-04/SK-CW 11
2.4 Personnel responsibilities
2.4.1 Safety-conscious working
Avoid any manner of working that may interfere with the
function and operational safety of the unit.
Observe the safety and accident-prevention regulations valid
at the usage site.
Observe the environmental protection regulations valid at the
usage site.
Wear protective equipment.
2.4.2 Safety measures during transport
Observe safety measures during the transport and handling of
very heavy units.
2.4.3 Safety measures during operation
Only operate the unit when all protective equipment has been
fitted and is in full working order.
Check the unit at least once per shift for externally visible
damage and faults.
Report any changes including changes in operational
behaviour to the responsible place/persons immediately. If
necessary immediately shut down and lock out the
machine/system.
2.4.4 Behaviour in the event of faults and/or emergencies
If faults on the unit occur which could impair safety or the opera-
tional behaviour indicates the occurrence of a fault:
Shut the machine/system down immediately, lock out and
report the fault to the responsible place/persons.
Faults may be eliminated by trained and authorized personnel
only.
Only restart the machine/system when the cause of the fault
has been eliminated.
2.4.5 Testing/inspections
Observe the stipulated periods for regular tests and
inspections.

Basic safety notes
12 01/RPE/en/2011-08-04/SK-CW
2.5 Notes on particular risks
Risk of injury when the machine/system moves
unexpectedly!
Remove the energy supplies before installation, modification,
maintenance, or adjustment work.
Make sure that there is no more residual energy in the
system.
Perform maintenance, modifications, and additions outside
the danger zone.
For all work, secure the unit against accidental operation.
Risk of injury from falling of the unit during transport and
assembly!
Secure unit during transport and assembly with adequately
sized straps.
Mount the unit, so that it will cause no harm by tilting over or
falling down.
Risk of injury due to uncontrolled movements of the unit
when malfunction of the sensors and electrical distribution
panelboard.
Observe the correct connection of the sensors and electrical
distributors.
Risk of injury due to squeezing and clamping between the
slide and the base plate during movement of the modules.
Remove the energy supplies before installation, modification,
maintenance, or adjustment work.
Make sure that there is no more residual energy in the
system.
Perform maintenance, modifications, and additions outside
the danger zone.
For all work, secure the unit against accidental operation.
The danger zone must be surrounded by a safety fence
during operation.

Warranty
01/RPE/en/2011-08-04/SK-CW 13
3 Warranty
The warranty is valid for 24 months from the delivery date to the
production facility under the following conditions:
•Observation of the maintenance and lubrication intervals
(see Component documentation)
Parts touching the workpiece and wearing parts are not part of
the warranty. Also observe our general terms of business.
The warranty does not cover:
•Damage occurring as a result of incorrect operation.
•Claims under warranty are excluded when repair or
intervention is carried out by persons not authorized to do so.
•This also applies if accessories and spare parts are used
which are not designed for our unit
4 Technical Data
Reference value
Value
noise level [dB(A)]
≤ 70
ambient temperature [C]
0° to +80°
permissible payload [kg]
Three-dimensional gantry electric RPE 100
10
Three-dimensional gantry electric RPE 200
20
dynamic values
horizontal
max. acceleration a [m/s²]
5
max. speed v [m/s]
1
vertical
max. acceleration a [m/s²]
2
max. speed v [m/s]
0,25
Tab. 4
Note
Additional technical data contain the documentations of the com-
ponents in the Appendix.

Configuration
14 01/RPE/en/2011-08-04/SK-CW
5 Configuration
The unit consists of following components:
1 3
4
9
8
6
7
1
5
2
Fig. 1

Configuration
01/RPE/en/2011-08-04/SK-CW 15
Item
Designation
See
1
Linear axis Beta 80 ZSS
with toothed beld drive - feed / rotation = 220 mm
Documentation „Linear axis Beta“, Appendix
1
2
Synchronizaztion shaft
3
Planetary gearing GTE 120-NN1-008B-NN21
4
Drive MSK-060-C-0300
Documentation „Drive MSK“, Appendix 3
5
RPE 100:
Linear axis Beta 60-SSS
with spindel drive - feed / rotation = 5 mm
RPE 200:
Linear axis Beta 80-SSS
with spindel drive - feed / rotation = 5 mm
with 2x proximity switch IN each
Documentation „Linear axis Beta“, Appendix
1
Documentation „Sensors“, Appendix 4
6
RPE 100:
Linear axis Beta 100D-ZSS
with toothed beld drive - feed / rotation = 160 mm
RPE 200:
Linear axis Beta 100D-ZSS
with toothed beld drive - feed / rotation = 220 mm
with 2x proximity switch IN each
Documentation „Linear axis Beta“, Appendix
1
Documentation „Sensors“, Appendix 4
7
Drive MSK-040-B-045
Documentation „Drive MSK“, Appendix 3
8
RPE 100:
Drive MSK-050-B-0300
RPE 200:
Drive MSK-060-C-0300
Documentation „Drive MSK“, Appendix 3
9
RPE 100:
Planetary gearing GTE 120-NN1-008B-NN20
RPE 200:
Planetary gearing GTE 120-NN1-008B-NN21
Tab. 5

Assembly and initial operation
16 01/RPE/en/2011-08-04/SK-CW
6 Assembly and initial operation
6.1 Mechanical connection
WARNING
Risk of injury when the machine/system moves
unexpectedly!
Switch off power supply.
Make sure that there is no more residual energy in the
system
WARNING
Risk of injury from falling of the unit during assembly!
Secure unit during assembly with adequately sized straps.
Note the tightening torque of fixing screws.
WARNING
Risk of injury when the machine/system moves
unexpectedly, by moving of the linear axis!
Switch off power supply before assembly and maintenance.
Make sure that there is no more residual energy in the
system
The mechanical connection hast o be carried out at the linear
axis Beta 80 ZSS.
Information on mounting the linear axis Beta contains the service
manual Beta-80-100-140-ZRS-ZSS Appendix 1 -Chapter 6, from
page 20.

Assembly and initial operation
01/RPE/en/2011-08-04/SK-CW 17
6.2 Connection of the motors
GEFAHR
Danger of electrical potential!
Switch off power supply before assembly, adjustment and
maintenance, and secure against restart.
The electrical installation may be performed only by a trained
electrician.
Cover live parts.
Detect absence of voltage, ground and short-circuit.
The unit can be selected with the motors provided by SCHUNIK
and their mechanical connection or without motors, flanges and
couplings.
Information on connection of the motors contains the Project
Planning Manual MSK, Appendix 3, Chapter 8.
6.3 Connection of Sensors
WARNING
Risk of injury when the machine/system moves
unexpectedly!
Switch off power supply.
Make sure that there is no more residual energy in the
system.
WARNING
Risk of injury due to electrical energy!
Switch off power supply.
Information on connection und handling of sensors contains:
•Maintenance manual Beta 60-80-SRS-SSS (Appendix 1)
•Maintenance manual Beta 80-100-140 ZRS-ZSS (Appendix 1)

Assembly and initial operation
18 01/RPE/en/2011-08-04/SK-CW
6.4 Assembly of handling modules
WARNING
Risk of injury when the machine/system moves
unexpectedly!
Switch off power supply.
Make sure that there is no more residual energy in the
system.
Notes
•Do not contribute any excessive forces and torques during
assembly of loads.
•The evenness of the mounting surface must be less than
0.02 mm.
•Choose a proper connection, with a load that has his own
guide mechanism and align them adequately.
•Avoid contact with the linear gantry during operation.
•Select appropriate tightening torques for the assembly of the
gantry module or loads at the gantry module in accordance
with the general guidelines for screw connections.

Maintenance and repair
01/RPE/en/2011-08-04/SK-CW 19
7 Maintenance and repair
WARNING
Risk of injury when the machine/system moves
unexpectedly!
Due to movement of the axis!
Remove the energy supplies before maintenance.
Make sure that there is no more residual energy in the
system.
Perform maintenance outside the danger zone.
CAUTION
Allergic reactions due to grease in contact with skin!
Wear gloves.
Weekly examination on easily visible damages or wear, or con-
tamintion of the system.
The maintenance intervals apply to the single components ac-
cording their servicing manuals.
The component documentation contains maintenance and repair
information.
Component
See
Linear axis Beta 60 SSS
Linear axis Beta 80 SSS
Maintenance manual Beta 60-80-SRS-SSS
Appendix 1- chapter 10, from page 32
Linear axis Beta 80 ZSS
Linear axis Beta 100 D ZSS
Linear axis Beta 140 ZSS
Maintenance manual Beta 100-140 ZRS-
ZSS Appendix 1- chapter 10, from page 30
Drive MSK
Maintenance free
Sensors
Maintenance free
Pillar assembly system
Maintenance free
Tab. 6
Maintenance interval

Troubleshooting
20 01/RPE/en/2011-08-04/SK-CW
8 Troubleshooting
The component documentation contains troubleshooting informa-
tion.
9 Component documentation
The scope of delivery includes the documentation for the follow-
ing components (see CD-ROM, Appendix 1-2):
Components
Manufacturer
Appendix
Linear axis Beta
SCHUNK
1
Drive MSK
SCHUNK
2
Tab. 7