STEIN 300 User manual

STEIN300_Hubzentriereinrichtung_HZEV_03_GB.DOC / 02.2020 1
Lift centring device with extended stroke (HZEV)
STEIN Workpiece Transport System (STEIN 300)
Operating instructions
Attention all installation, operating and maintenance personnel -
always keep these instructions by the lift centring device.

2 STEIN300_Hubzentriereinrichtung_HZEV_03_GB.DOC_D / 02.2020
© by STEIN Automation
STEIN Automation reserves the copyright in these documents.
This documentation may not be altered, distributed, reproduced or transferred to third
parties without the prior written permission of STEIN Automation.
STEIN Automation GmbH & Co. KG
Carl-Haag-Straße 26
78054 VS-Schwenningen, Germany
Telephone: (+)49 (0)7720 / 8307 – 0
Publication date: February 2020
We reserve the right to make changes to the design and construction

STEIN300_Hubzentriereinrichtung_HZEV_03_GB.DOC / 02.2020 3
Contents
1Abbreviations and symbols ............................................................................................................................4
1.1 Explanation of safety and warning notices .......................................................................................... 4
2Introduction ......................................................................................................................................................6
2.1 Short description................................................................................................................................ 6
2.2 Initial inspection................................................................................................................................. 7
2.3 Complaints......................................................................................................................................... 7
2.4 Warranty ............................................................................................................................................ 7
3Safety information ...........................................................................................................................................8
3.1 General safety information ................................................................................................................. 8
3.2 Intended use and liability exclusions .................................................................................................. 8
3.3 Residual danger ................................................................................................................................. 9
3.4 Safety information for installation and repair work............................................................................ 10
4Technical description ................................................................................................................................... 11
4.1 Scope of delivery.............................................................................................................................. 11
4.2 Installation area ............................................................................................................................... 11
4.3 System components......................................................................................................................... 12
5Installing the lift centring device (HZEV) ................................................................................................... 13
5.1 Procedure ........................................................................................................................................ 13
5.2 Preparation ...................................................................................................................................... 14
5.3 Installing the HZEV between the two belt profiles ............................................................................. 14
5.4 Fitting the stopping devices.............................................................................................................. 16
5.5 Compressed air and power connections ........................................................................................... 16
5.6 Installing safety equipment............................................................................................................... 17
6Initial operation ............................................................................................................................................. 18
7Operating the HZEV ...................................................................................................................................... 19
8Faults.............................................................................................................................................................. 20
8.1 Troubleshooting problems ................................................................................................................ 20
9Cleaning, inspection, maintenance............................................................................................................. 21
9.1 Cleaning........................................................................................................................................... 21
9.2 Inspection ........................................................................................................................................ 22
9.3 Maintenance .................................................................................................................................... 22
10 Spare parts..................................................................................................................................................... 23
11 Appendix......................................................................................................................................................... 27
11.1 Technical data.................................................................................................................................. 27

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1Abbreviations and symbols
Action symbol
1 symbol for actions which must be carried out in a specified sequence.
⇒Consequence or result of an action
•List
HZEV Lift centring device with extended stroke
WT Workpiece carrier
OI Operating instructions
Fig. Figure
i This sign indicates information that will allow the lift centring device to be used more
effectively and more economically.
The symbols used in the operating instructions for safety and hazard warnings are de-
scribed in detail in chapter 3.
1.1 Explanation of safety and warning notices
The following safety notices indicate all actions where there is danger to life and limb for
system operators or their colleagues.
Strictly comply with these instructions and act with particular care in these cases. Pass
the safety notices on to all other users.
DANGER
The sign indicating DANGER means immediate danger!
The hazard will result in serious injury to personnel or death.
WARNING
The sign indicating WARNING means potential danger!
The hazard may result in serious injury to personnel or death.
CAUTION
The notice indicating CAUTION means a potentially dangerous situation!
The hazard may result in injury to personnel.

STEIN300_Hubzentriereinrichtung_HZEV_03_GB.DOC / 02.2020 5
In the text, the safety notice frequently appears with a picture to explain the source of
the hazard.
CRUSHING HAZARD!
This symbol gives warning of a location where there is a risk of being crushed.
HIGH ELECTRICAL VOLTAGE!
This symbol gives warning of electrical voltage.
It appears for all working and operating procedures that must be followed precisely, in
order to avoid injury to personnel or damage to the system through high voltage.
Other warning signs:
ATTENTION
This sign stands for instructions which, if not followed, could endanger the system.
Protective clothing must be worn!
Wear your personal safety clothing:
Safety footwear, hard hat, goggles and safety gloves.
Environmental protection
This sign indicates warnings that will help to avoid harming the environment.

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2Introduction
The safety of all persons who come into contact with the HZEV depends fundamentally
on knowing how the HZEV functions. Therefore:
Read these operating instructions before using the equipment for the first time.
These operating instructions contain important information which will ensure the correct,
economical and safe operation of your HZEV.
2.1 Short description
Lift centring devices are installed in the STEIN 300 Workpiece Transport System.
In conjunction with the workpiece carrier transport system, the HZEV enables the follo-
wing:
•exact positioning of workpiece carriers (and therefore of the workpieces located on
them),
•a further lift of the WT in the Z axis
•workpiece carrier elevation and support while power transfer operations are carried
out on workpieces.
Fig. 2-1:
Lift centring device
- Components
Other advantages of these devices are that
•the belt element is not under tension while the workpiece is being processed and
•belt wear is reduced.
i Please note:
From a stroke of 250mm, the WT must additionally be centred from above in the end
position by means of suitable centring pins, as otherwise the specified centring
accuracy is not given. These centring pins are not included in the scope of delivery.
Pre-stopper
Reading head
(optional)
Stopping de-
vice
HZEV
Surface
switch

STEIN300_Hubzentriereinrichtung_HZEV_03_GB.DOC / 02.2020 7
2.2 Initial inspection
The lift centring device with extended stroke is bubble-wrapped and securely transported
in a solid box.
Unpack all the components supplied.
Environmental protection!
Dispose of all packaging material in an environmentally responsible way.
Then carry out an initial inspection.
Check that:
the delivery is complete in accordance with the enclosed delivery note
components have not been damaged or lost in transit
2.3 Complaints
In order for claims for damages caused in transit to be accepted, follow this procedure:
Inform the freight company.
Draw up a damage report giving the following details
•Name and address of recipient
•Item or order number
•A description of the damage
Send components, if possible in their original packaging, with the damage report,
back to the manufacturer.
2.4 Warranty
For the lift centring devices with extended stroke as well as for the spare parts of the
equipment we grant the warranty period prescribed by law or specified in the supply ag-
reement, commencing on the date of delivery.
Within this warranty period, we will replace all spare parts with manufacturing or material
defects free of charge.
STEIN Automation's general warranty conditions apply.

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3Safety information
3.1 General safety information
•The lift centring devices with extended stroke from STEIN Automation are high quali-
ty products, manufactured to recognised technical rules.
The technical safety features of lift centring devices leave our factory in perfect con-
dition.
•All versions of our open lift centring devices comply with the requirements of UVV,
the German accident prevention regulations.
•To maintain this condition, installation staff, users and service technicians must ob-
serve the notices and warnings contained in these operating instructions.
•Lift centring devices with extended stroke must only be installed and repaired by au-
thorised personnel who have been trained by STEIN Automation.
•Only genuine components from STEIN Automation may be used when carrying out
repairs on the open lift centring devices.
3.2 Intended use and liability exclusions
The lift/centering devices with extended stroke may only be
•installed in automatic workplaces with fully enclosed workstations,
•used to hold and lift Stein workpiece carriers, and
•operated in conjunction with stopping devices.
Fig. 3-1:
Lift centring device
- loads

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Permitted WT loads are:
•in the X axis: 0 N
•in the Y axis: 0 N
•in the Z axis: 400 N if the load is centred and under an operating pressure of 6 bar
260 N if the load is centred and under a STEIN operating pressure of 4 bar and
•M=10 Nm if the load is not centred
•No transverse forces are permitted
i Unauthorised interventions, alterations or repairs carried out on the lift centring device
invalidate the warranty.
STEIN
Automation accepts no liability for any damage caused by unauthorised
interventions, modifications or repairs.
3.3 Residual danger
The lift centring device with extended stroke is manufactured using state-of-the-art tech-
nology and to recognised safety standards. Nevertheless their use can lead to dangerous
situations for users or third parties or to impairments of the system and other material
assets.
If used improperly, the following injuries can result:
•Crushing may occur due to dimensions not being observed and specified pressures
being changed.
Fig. 3-2:
Crushing points

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3.4 Safety information for installation and repair work
DANGER
Due to the Workpiece Transport System starting unexpectedly.
DANGER
HIGH ELECTRICAL VOLTAGE!
Electric shock hazard!
1 Before carrying out any installation or repair work, disconnect the relevant
Workpiece Transport System from its electrical power supply.
2 Disconnect the workpiece transport system from its compressed air supply.
3 Put up warning signs to prevent the system from being started up while installation
and repair work is being done.
4 Remove all workpiece carriers from the affected belt element!
5 Carry out the work
•in accordance with the descriptions in this documentation,
•complying with relevant safety and accident prevention regulations and
•in a technically correct manner and with the greatest possible accuracy.
6 After completing installation or repair work, carry out a test run of the entire
system and check that all the safety equipment is functioning correctly.
DANGER
Never operate the Workpiece Transport System using
•faulty safety equipment and / or
•damaged components / parts!

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4Technical description
4.1 Scope of delivery
The HZEV is either installed in the belt profile or it is delivered as a complete assembly
without any form of cover.
CAUTION
CAUTION! Crushing hazard!
It is the duty of the special-purpose machine manufacturer or the operator
to operate the HZEV only as part of a fully enclosed system.
Doors and openings in this fully enclosed system must be secured against
being opened during operation using safety locks or switches.
The belts feeding and releasing materials must be fitted with safety tunnel
covers of an adequate length (at least 850 mm.)
i The following accessories do not form part of the scope of delivery:
•Full enclosure (supplied and installed by the customer)
•Full enclosure Cylinder (STEIN Automation option)
•Control system (STEIN
Automation option)
•Stopping device (STEIN Automation option)
4.2 Installation area
Installing an HZEV will be required in automatic workplaces if
•workpiece carriers have to be very accurately positioned,
•workpiece carriers must be lifted very high,
•workpiece carriers are placed under load along their Z axis during processing
i Please note:
From a stroke of 250 mm, the workpiece carrier must additionally be centred from
above in the end position by means of suitable centring pins, as otherwise the specified
centring accuracy is not given. These centring pins are not included in the scope of
delivery.

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4.3 System components
Fig. 4-1:
Lift centring device with
extended stroke - over-
view
Procedure:
Workpiece carriers are transported by the two transport belts until they reach the work-
station stopping device (STEIN Automation\ option). The position query triggers the mo-
vement of the lifting unit and raises the workpiece carrier. After processing in this raised
position, the elevating platform is lowered and the workpiece carrier is transferred onto
the belt elements' transport belts.
Elevating platform
Workpiece carrier

STEIN300_Hubzentriereinrichtung_HZEV_03_GB.DOC / 02.2020 13
5Installing the lift centring device (HZEV)
Fig. 5-1:
Lift centring device with
extended stroke
- installation location
The HZEV can be installed in lengthwise or transverse sections from below, between the
edges of the two belt profiles.
ATTENTION!
An HZEV cannot be installed in the vicinity of the belt elements’ drive fitting.
5.1 Procedure
The installation procedure is divided into 6 phases:
•Preparation,
•Installing the HZEV between the edges of the two belt profiles,
•Fitting the stopping devices
•Assembling the pneumatic components
•Connecting up the power and compressed air supply, and
•Fitting the safety equipment.
ATTENTION!
On operating stations which generate shavings (for example drilling or thread-cutting
machinery), covers should be installed to avoid shavings or cooling fluid coming into
contact with the belt elements or the centring device.
i Further information is available from STEIN Automation.
Belt profile
Lift/centring device

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5.2 Preparation
DANGER
Due to the Workpiece Transport System starting unexpectedly.
DANGER
HIGH ELECTRICAL VOLTAGE!
Electric shock hazard!
1 Before carrying out any installation or repair work, disconnect the relevant
Workpiece Transport System from its electrical power supply.
2 Disconnect the workpiece transport system from its compressed air supply.
3 Put up warning signs to prevent the system from being started up while installation
and repair work is being done.
4 Remove any workpiece carriers located on the affected belt element.
5.3 Installing the HZEV between the two belt profiles
Protective clothing must be worn!
Wear your personal safety clothing:
Safety footwear and safety gloves.
ATTENTION!
If larger than 320 mm then two people will be required to install the HZEV.
i Observe the installation dimensions in fig. 5-4.
Fig. 5-2:
Inserting the HZEV
Nutenstein
Schraube
Profil

STEIN300_Hubzentriereinrichtung_HZEV_03_GB.DOC / 02.2020 15
1 Push the HZEV from below between the edges of the two belt profiles.
2 Turn the four sliding blocks by approx. 90° so that the HZEV can be hooked
into the profile with the sliding blocks.
ATTENTION!
Ensure that the HZEV T-Slot Nuts can be guided into the profile when hanging.
Fig. 5-3:
HZEO – viewed from
below
⇒The HZEV has been inserted.
3 Straighten the HZEV.
4 Turn the screws with sliding blocks 90° again so that the HZEV hangs in the
profile, tighten the screws.
Fig. 5-4:
Installation measurements
Adjustment range for cylinder strokes - 15 mm
Available cylinder strokes 100, 125, 160, 200, 250,
350
PB = Pallet width
UB = Transfer width
A Cylinder stroke – 13
B Cylinder stroke + 260
C Cylinder stroke + 224
D Pallet width + 4
E The stroke can be adjusted to 0 by moving the guide bridge.
T-slotted screw
Lifted workpiece carri-
Turn the slot nut to
hang the HZEV in
the profile!

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5.4 Fitting the stopping devices
i
Further information can be found in the technical description for the “Stopping Device”
(SE).
5.5 Compressed air and power connections
5.5.1 Connecting the HZEV to the compressed air supply
ATTENTION!
Maximum operating pressure: 6 bar.
STEIN operating pressure: 4 bar.
i Festo GRLA–1/8-QS6 throttle check valves are used as connectors.
Type PUN-S hoses with an exterior diameter of 6mm and wall thickness of 1 mm are
used, manufactured by: Festo.
Fig. 5-5:
Connecting the HZEV to
the compressed air supply
Compressed air connec-
tions
Wiring diagram
Connect the HZEV to the compressed air supply using the two screw connections.
i Connection at top (4): Cylinder goes down
Connection at bottom (2): Cylinder goes up
4
1. Pneumatic cylinder
2. Cylinder switch
3. Throttle check valve
4. ASI module (optional)
2

STEIN300_Hubzentriereinrichtung_HZEV_03_GB.DOC / 02.2020 17
5.5.2 Connecting the induction proximity switch to the power supply
DANGER
HIGH ELECTRICAL VOLTAGE!
Electric shock hazard!
ATTENTION!
Only proximity switches manufactured by FESTO may be used.
Fig. 5-6:
Inductive proximity switch
Proximity switch
Connect the inductive proximity switches to the power supply as per the wiring
diagram.
5.6 Installing safety equipment
CAUTION
Crushing hazard!
It is the duty of the special-purpose machine manufacturer to operate the
HZEV only as part of a fully enclosed system.
Doors and openings in this fully enclosed system must be secured against
being opened during operation using safety locks or switches.
The belts feeding and releasing materials must be fitted with safety tunnel
covers of an adequate length (at least 850 mm.)
Install the full safety enclosure onto the processing station with the HZEV.
ATTENTION!
The protective housing for the cylinder is not included in the scope of delivery of HZEV.
The protective housing must be fitted if:
•no protective housing for the cylinder is guaranteed by third parties,
•the HZEV is controlled by STEIN Automation.

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6Initial operation
Carry out the following checks before initial operation:
Are all the electric and pneumatic leads and hoses undamaged?
Are all the electric and pneumatic leads / hoses correctly connected?
Have all the mechanical components been tightly fastened in place?
Have all tools and other equipment been cleared from the transport area?
Has all safety equipment been installed and is it working correctly?
Are any hoses or cables in an area where they may get crushed?
Once you have carried out all these checks, you can continue with the initial operation.
Switch on the Transport System and its associated processing stations and carry out
a trial run.
Check the functions of the individual elements and processing stations as well as the
pre-programmed overall operation of the entire system.
Check that the safety equipment is functioning correctly!
WARNING
Only start the Transport System once you have carried out a successful trial run!

STEIN300_Hubzentriereinrichtung_HZEV_03_GB.DOC / 02.2020 19
7Operating the HZEV
WARNING
Only operate the HZEV in fully enclosed stations.
Fig. 7-1:
Lift centring device
- components
The customer starts up the HZEV in normal operating mode.
If the HZEV is to be controlled by the WTS control system:
•The reading head detects “WT present” – no defective component, processing can
start.
If a defective component is detected, the WT moves on unprocessed.
•WTs are stopped at the processing station by the stopper
•Further WTs are stopped at the pre-stopper.
⇒The HZEV extends and the following signal is sent to the top-level control
system: “Processing on WT can proceed”
•The workpiece is processed
•Signal to the WTS control system: “Processing completed”
⇒The HZEV moves down
•The stopper opens, the WT moves on.
Pre-stopper
Reading head
(optional)
Stopping
HZEV
Surface switch

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8Faults
WARNING
When faults, malfunctions or damage affecting safety occur, immediately push the
EMERGENCY OFF button to switch the Transport System off.
Have the cause of the malfunction identified and the problem fixed by trained personnel.
8.1 Troubleshooting problems
Problem Cause Solution
Stop handle not releasing Static load too high. Install intermediate stopper.
No power Power supply cut. Restore the power supply.
Variable power supply Uneven power supply voltage Ensure power supply voltage is
constant.
Compressed air supply fails Faulty valve. Replace valve.
Compressed air supply cut. Restore compressed air supply.
HZEV does not elevate WTS transport system control
failure.
Restore control system.
Processing station control system
failure.
Inductive proximity switch not
connected to power supply.
Connect inductive proximity switch
to power supply.
Inductive proximity switch faulty. Replace inductive proximity switch.
Poor contact between plug and
socket.
Firmly insert plug into socket.
HZEV wrongly installed. Check and, if necessary, adjust
position and screw connections.
HZEV elevates too soon / too late Position switch incorrectly set. Re-set position switch.
HZEV does not position itself exactly
right
Too much play. Guides worn. Replace guides.
Loose screw connections Re-tighten screws.
WARNING
Only start the Transport System once you have carried out a successful trial run!