Systec DriveSets User manual

DriveSets
Maintenance for DriveSets
Notes for preventive maintenance of kinematics and Xemo controllers
Elektronik und Software GmbH

Maintenance for DriveSets
- 2 -
699-41-20.1
Systec Elektronik und Software GmbH
Nottulner Landweg 90
48161 Münster-Roxel
Germany
Telefon: +49 / 25 34 / 80 01-70
Telefon: +49-700-SYSTEC-DE
Telefax: +49 / 25 34 / 80 01-77
internet: www.systec.de
eMail: [email protected]
Maintenance for DriveSets
Docu-No.: 699-41-20.1
Latest revision date: 05 2017
Translation of the original manual
Copyright and all other rights to this document remain with Systec
GmbH. Systec does not take any responsibility for the correctness and/or
completeness of the contents. We reserve the right to make technical
changes.
You can download this document from the Systec website free of charge.
For this document, Systec GmbH grants you the simple charge-free right,
unlimited in space and time, for all known and not yet known types of
use. All rights with respect to patent grants or industrial design registration
and further rights remain unaffected.
You may duplicate this document. Distribution is only allowed with the
clear indication of the copyright held by Systec GmbH. You may not pro-
cess, modify or change this document in any other way. In order to dis-
tribute this document for commercial reasons and to make it available,
you will require prior written authorization from Systec GmbH.
© Copyright 2017: all rights reserved

Maintenance for DriveSets
699-41-20.1
- 3 -
Content
1Understanding the system set-up and functionality.............................5
1.1 System philosophy ..................................................................................5
1.2 Linear axes, rotary modules ....................................................................5
1.3 Motors ....................................................................................................5
1.3.1 Motors on Xemo R/S Compact Controllers..............................................5
1.3.2 Motors on Xemo P Controllers ................................................................6
1.4 Wiring.....................................................................................................6
1.4.1 Wiring on Xemo Compact Controllers ....................................................6
1.4.2 Wiring on Xemo P Controllers.................................................................6
1.5 Xemo controllers.....................................................................................6
1.5.1 Xemo R/S Compact Controllers...............................................................6
1.5.2 Xemo P Controllers .................................................................................7
2General notes on maintenance and service..........................................8
2.1 Important symbols in this manual ...........................................................8
2.2 Warning and safety information..............................................................9
3Life expectancy ....................................................................................10
3.1 Kinematics ............................................................................................10
3.2 Motors ..................................................................................................10
3.3 Hybrid cables........................................................................................10
3.4 Xemo controllers...................................................................................10
4Regular checks.....................................................................................11
4.1 Wiring...................................................................................................11
4.2 Dust deposits ........................................................................................11
5Preventive maintenance ......................................................................12
5.1 Linear axes............................................................................................12
5.2 Guide shafts..........................................................................................12
5.3 Castors..................................................................................................12
5.4 Spindles ................................................................................................12
5.5 Motors ..................................................................................................12
5.6 Xemo controllers...................................................................................12
5.6.1 General comments................................................................................12
5.6.2 Xemo R/S Compact Controllers.............................................................13
5.6.3 Xemo P Controllers ...............................................................................13
6Maintenance of linear axes .................................................................14
6.1 Cleaning axis type DuoLine ..................................................................14
6.2 Exchanging cover bands EL_ 100, 125 ..................................................14
6.3 Belt exchange .......................................................................................15
6.3.1 Axis type ELZ ........................................................................................15
6.4 Checking and adjusting belt tension......................................................17
6.4.1 Belt tension ELZ....................................................................................17
6.4.2 Tooth belt tension axis type DuoLine Z ................................................18
6.5 Adjusting roller castor ...........................................................................20
6.5.1 Adjusting roller castor axis type LLZ60 ..................................................20

Maintenance for DriveSets
- 4 -
699-41-20.1
6.5.2 Adjusting roller castor axis type QL_ 60, 80, 100..................................21
6.6 Lubrication amounts............................................................................. 21
6.7 Lubrication of axes with castors ............................................................22
6.7.1 Trapeze spindle scale EL 30, 40............................................................22
6.7.2 Ball screw spindle scale EL 30, 40.........................................................22
6.7.3 Spindle scale EL 60, 80 100, 125 ......................................................... 23
6.7.4 Castors scale EL 100, 125 ..................................................................... 24
6.7.5 Lubrication roller castors axis type LLZ 60 ............................................24
6.7.6 Guide shaft EL ......................................................................................25
6.7.7 Lubrication guiding rods axis type DL_ und QL_ ..................................26
6.7.8 Lubrication leading nut axis type DLT und DLK....................................27
6.7.9 Lubrication Axis type MZK.................................................................... 28
6.7.10 Lubrication axis type DuoLine .............................................................. 29
6.7.11 Lubrication Axis type PLS-II .................................................................. 30
6.8 Maintenance of axes with carriages ...................................................... 33
6.8.1 Lubrication leading-nut axis type DSK and DST, QS_ ........................... 33
6.8.2 Lubrication runner blocks axis type DS_ und QS_ ................................36
6.8.3 Lubrication carriage axis type LS_ ......................................................... 37
6.8.4 Lubrication Axis type KR....................................................................... 37
6.8.5 Lubrication axis type DuoLine .............................................................. 38
6.9 Maintenance of axes with bush bearings...............................................39
6.9.1 Linear axis ZLW.................................................................................... 39
6.10 Maintenance of rotary modules ............................................................ 39
6.10.1 Rotary modules with worm gears..........................................................39
6.10.2 Rotary modules with toothed belt gearbox ........................................... 40
7Index.................................................................................................... 42

Maintenance for DriveSets
699-41-20.1
- 5 -
1Understanding the system set-up and functionality
1.1 System philosophy
DriveSets are systems with kinematics (with linear axes and rotary mod-
ules) and complete controller electronics.
They can be operated either autonomously or as intelligent subsystems
together with a master computer.
The systems have been constructed according to the newest state of the
art, with strong emphasis on high reliability and low maintenance.
The systems and components are subjected to extensive and strict single
tests, so they require only minimum maintenance when properly in-
stalled and operated within the warranted parameters
DriveSets are divided into four parts:
linear axes or rotary modules
motors
wiring
a Xemo controller
1.2 Linear axes, rotary modules
The linear axes or rotary modules constitute the mechanical structure
with which corresponding motions can be carried out. The linear axes
can be driven either by a spindle or a cogged V-belt. In addition, linear
motors are also used. Rotary modules, designed as turntables, consist in
as a rule of a plate and a gearbox with motor. Inductive proximity
switches or roll-switches for trajectory limitation and reference-point de-
termination are attached to the linear axes. As a rule, two end switches
and a reference switch are located on each axis. In addition, optional
drag chains can be attached.
1.3 Motors
1.3.1 Motors on Xemo R/S Compact Controllers
On DriveSets with Xemo R/S Compact Controllers 2-phase stepping mo-
tors are deployed. These are connected to the linear axes directly by
couplers or by way of cogged V-belts or other gearboxes.
The stepping motors are distinguished by:
torque
revolutions per minute
number of terminals (50 or 100)
operating voltage (24 V/48 V)
mechanical dimensions

Maintenance for DriveSets
- 6 -
699-41-20.1
1.3.2 Motors on Xemo P Controllers
On DriveSets with Xemo P Controllers, hybrid stepping motors are de-
ployed. These are connected to the linear axes directly by couplers or by
way of cogged V-belts or other gearboxes.
The stepping motors are distinguished by:
torque
revolutions per minute
operating voltage (70 V to 325 V)
mechanical dimensions
1.4 Wiring
1.4.1 Wiring on Xemo Compact Controllers
The wiring of the motors and switches of an axis is done via adapter plugs
and special hybrid cables which meet EMF requirements. The cables are
cropped to specific lengths. At the opposite ends of the cables, 10-pole
bolt and nut clamps are attached for direct connection to the Xemo con-
trollers. These cables may be cropped by qualified technical personal,
provided that the EMF regulations are met.
1.4.2 Wiring on Xemo P Controllers
The wiring of the motors and switches of an axis is done via special hybrid
cables which meet EMF requirements. The cables are cropped to specific
lengths. The cables are attached to the motors by means of plug connect-
ors. On the switching cabinet end, the attachment varies according to
model. In most cases, the motor cables are LED directly to the power
electronics. In individual cases, an adapter plug system can be used. As
a rule, the cables of the end and reference switches are LED to terminal
blocks. From there, the internal wiring proceeds further to the digital in-
puts of the power electronics. These cables may be cropped by qualified
technical personal, provided that the EMF regulations are met.
1.5 Xemo controllers
A distinction is made between the Xemo R/S Compact Controllers and
the Xemo P Controllers which are built into a switch cabinet (comfort
version) or onto a control board (eco version).
1.5.1 Xemo R/S Compact Controllers
The Xemo controllers contain the complete electronics and operational
software for running the linear axes. They are fitted with the appropriate
drive components for the specific axis and motor types. Depending on
the Xemo S Controller model, the user must additionally provide 24 or
48 VDC.

Maintenance for DriveSets
699-41-20.1
- 7 -
In addition to running the axes, the controllers can also capture and/or
issue digital and analog signals.
The controllers are equipped with a standard security concept which
provides emergency-stop functionality.
1.5.2 Xemo P Controllers
The Xemo controllers contain the complete electronics and operational
software for running the linear axes. They are fitted with the appropriate
power electronics for the specific axis and motor types.
The Xemo P Controller is offered in the variants “comfort” and “eco”. In
the “comfort” version, the controller is built into a switch cabinet. At the
cabinet’s front, operational elements are attached. As a rule, the control-
ler is ready for connection to the power supply and then ready for oper-
ation. In the “eco” version, the controller is delivered on a control board.
Likewise, there are no control elements. Depending on the order, you
must provide a 24 V DC direct current supply.

Maintenance for DriveSets
- 8 -
699-41-20.1
2General notes on maintenance and service
DriveSets and –especially –the Xemo controllers may be maintained
only by qualified or trained personnel and repaired only by qualified
technical personal.
2.1 Important symbols in this manual
indicates a hazardous situation which, if not avoided, will result in death
or serious injury.
indicates a hazardous situation which, if not avoided, could result in
death or serious injury.
indicates a hazardous situation which, if not avoided, may result in minor
or moderate injury.
indicates a property damage message.
Remark
Please read passages, which are marked with this symbol, definitely. Get
important information about dealing with these instructions and condi-
tions or limits for the use of the Maintenance for DriveSets.
Tip
Learn addition facts and practical tips in sections, which are marked with
this symbol.

Identifies an instruction.

Maintenance for DriveSets
699-41-20.1
- 9 -
2.2 Warning and safety information
Before installing and putting the DriveSets into service, please pay atten-
tion to the following warning and safety information. By doing so, you
will avoid possible defects and malfunctions resulting from improper
handling.
Danger of crushing! Shock hazard!
Depending on the specification of DriveSets in speed and load you hurt
yourself serious if an accidentally switch-on occurres during the work.
Carry out all assembly and installation work on DriveSets only when the
equipment is completely free of any electrical current.
Before starting the work, make sure that the connection plugs for the
power supply of all the power supplies to your application have been
unplugged.
Danger from flying away of parts!
Ensure that no tools or other materials are lying in the trajectory area or
on the axes.
Malfunctions or even destruction of the Xemo controller or the con-
nected components.
Do not plug or unplug cable connections within the DriveSets when the
attached supply voltage is connected or turned on.
When re-plugging cables, ensure that they are re-plugged according to
the proper allocation of the cables on the device’s connector assembly.
Endangering of the high dimensional stability of the axis!
Do not apply higher forces during mechanical work.
In case damages result from incorrect installation, no claims to free-of-
charge repairs exist, even if the warranty period is still in effect.

Maintenance for DriveSets
- 10 -
699-41-20.1
3Life expectancy
3.1 Kinematics
DriveSets are subject to normal mechanical wear and tear. According to
axle type, i.e. spindle or cogged V-belt drive, different running times can
be reached. This applies however only when used in accordance to the
warranted characteristics as well as regularly performed maintenance. To
make sure of an even distribution of the lubrication in the linear axes,
the trajectory paths must be greater than the carriage length.
3.2 Motors
Both stepping motors and hybrid stepping motors work without collec-
tors; their life expectancy is limited mainly by bearing deterioration.
3.3 Hybrid cables
Through constant motion, the cables are subject to wear and tear, espe-
cially those in drag chains. The operating life of bending radii with a 10-
fold size of the cable diameter (8 mm) amounts to more than 2 million
cycles. Smaller bending radii (minimum 5-fold size of the cable diameter)
this amount declines. In the case of non-moving hybrid cables, bending
radii which are smaller than the 2-fold size of the cable diameter are not
permissible.
3.4 Xemo controllers
The Xemo controllers have a life expectancy of about 8 years. Once this
period is exceeded, problems can arise because of aged condensers in
the power supply and the final stages.
The electromechanical components with moving switch contacts have a
life span of more than 50,000 switching cycles. This includes on/off
switches, feelers and probes, emergency stop switches, sliding gates and
relays (operational elements vary according to the type of controller.
Membrane keyboard keys have a life span of more than 1,000,000 hits.
The hand wheel works optically and is correspondingly virtually void of
wear and tear. The override-POT can make more than 20,000 adjust-
ments without aging problems

Maintenance for DriveSets
699-41-20.1
- 11 -
4Regular checks
4.1 Wiring
All plug connectors should be clamped or screwed together. The cables
deployed from the Xemo controllers’ motors to their power stages are
compatible with drag chains and have long life spans. However, these
life spans can only be reached if the cables can move freely within the
drag chains and without being pinched by others cables, air line hoses
etc. For that reason, you should check the drag chains at regular intervals
and, if necessary, rearrange the other cables, lines, etc.
4.2 Dust deposits
At least once per year, Xemo controllers should be checked for dust de-
posits which can occur through normal convection. If there are obvious
dust deposits, these must be removed by blowing-out or vacuuming the
unit. If a pressed-air pistol is used for this purpose, the pressed-air stream
should not be directed at the system from close proximity, otherwise
some parts might be damaged. A thick layer of dust prevents heat con-
vection from integrated performance components, and in extreme cases
can lead to electrical short circuits.
Because of their forced convection, Xemo R Controllers must be checked
more frequently. In case you suspect stronger dust deposits in the inte-
rior, the device should be completely.

Maintenance for DriveSets
- 12 -
699-41-20.1
5Preventive maintenance
5.1 Linear axes
Linear axes require preventative maintenance. This depends on the kind
of linear axis and determines to a large degree the functional quality as
well as the life span of the entire DriveSet.
5.2 Guide shafts
The guide shafts inserted sideways into the aluminium profiles should be
lubricated once a month when regularly used.
5.3 Castors
The lubricating points of units with EL100 and EL125 profiles should be
lubricated with bearing lubricant every 1000 operating hours or every 6
months.
5.4 Spindles
The lubricant on linear axes with spindles must be distributed regularly.
For this purpose, the normal trajectory paths should be traversed at reg-
ular intervals in order to spread accumulations of lubricant into the tra-
jectory area. Re-lubrication of the spindles should be done every 500 to
1000 operating hours. According to axle type, this is done by way of the
lubrication points or –in the case of EL30 and EL40 axes with trapeze
spindles –by lubrication with a brush.
5.5 Motors
Stepping motors require no preventative maintenance. The motors have
ball bearings with long-term lubrication and, at normal temperatures,
have a life span of at least 40,000 hours.
5.6 Xemo controllers
5.6.1 General comments
According to ambient conditions (exposure to dust), the controllers
should be cleaned at least once every two years. Compressed air must
not be used to blow out a controller, as this can lead to the destruction
of structural components.

Maintenance for DriveSets
699-41-20.1
- 13 -
5.6.2 Xemo R/S Compact Controllers
The Xemo R Controllers have built-in cooling ventilators. The controllers
must be installed in such a way that the ventilators can draw in fresh air
through the slits in the floor plate and blow it out at the backside unham-
pered. At installation, however, sufficient cooling (normal convection or
forced convection through ventilators) within the control cabinet must
be assured. Never install Xemo R Controllers directly on the floor of a
control cabinet or directly over heat-emitting drawers. Otherwise the
necessary cooling is not assured. The air taken in should be dust-free.
Xemo S Controllers require no preventive maintenance.
5.6.3 Xemo P Controllers
Xemo P Controllers in the "comfort" version require no preventive
maintenance. If you are using the "eco" version, (i.e. the controller
mounted on a mounting plate,) you must be careful when installing it
into your switch cabinet that any ventilators built into the switch cabined
do not direct their air currents directly into the ventilation slits of the
controller’s components.

Maintenance for DriveSets
- 14 -
699-41-20.1
6Maintenance of linear axes
6.1 Cleaning axis type DuoLine
The cover (3) must be opened for cleaning and to remove any dirt pre-
sent. After cleaning, ensure that the cover is tightly sealed.
If a toothed belt change should be necessary, removing the cover simpli-
fies the threading in of the belt.
Fig. 1 Removing the cover
Clean outer surfaces of the linear unit with a clean, lint-free cloth.
Cleaning agents containing solvent attack the material and can dam-
age it.
Do not use cleaning agent containing solvent.
6.2 Exchanging cover bands EL_ 100, 125
Remove the cylinder screws (1) on one side of the carriage.
Shove the pull-back cap (4) to the side.
Unscrew the set screws (2), shove the carriage (5) to the side.
Loosed the set screws (3) on both bearings.
Pull the cover band (6) out.
Insert a new cover band and clamp it to the bearing (7) with a
threaded pin (3).
At the other bearing, stretch the cover band with pliers and fasten
down with the set screw (3).
Attach the carriage (5) with the set screws (2). Secure the with
locking device (medium tight).
Attach the pull-back cap (4) with cylinder-head screws (1) to the
carriage (5).

Maintenance for DriveSets
699-41-20.1
- 15 -
Fig. 2 Cover bands axis type EL_ 100, 125
Install only undamaged masking tape. Kinks, cracks, or waves in the
cover band require an exchange. The band of your linear drive unit is
defined by its length on your linear unit. A faultless functioning can only
be guaranteed by an optimal length of cover band.
6.3 Belt exchange
6.3.1 Axis type ELZ
Fig. 3 Belt exchange

Maintenance for DriveSets
- 16 -
699-41-20.1
Follow these steps for a belt exchange:
Unscrew cylindric screws (1) and dismount wiper end plates (2)
on both sides of the carriage,
Take care, that the felt wipers (2A) don`t drop out!
The belt adjusters are fixed by grub screws (3) in the carriage (10);
to reach the right belt tension measure the distance between the
edge of the carriage and the head of the grub screws. (Notice: the
distance must be the same on both sides in axial direction.)
Unscrew the grub screws (3) and dismount the belt adjusters (8-
8A).
Unscrew the grub screws (4+5) and the cylindric screws (6) and
separate the bearing-block (7) from the unit.
Pull out the toothed belt (9). In most cases it is not necessary to
separate both bearing blocks for inserting the new belt.
The reconstruction of the unit takes place in opposite order.
Shorten the new belt to the length of the old one.
Insert the toothed belt with the toothed side to the profile (11)
into the not dismounted pulley block (A); rotate the toothed pul-
ley (13) until the toothed belt (9) appears at the end of the profile
(11) and pull the belt through the dismounted pulley block (7).
Mount the pulley block (7) on the profile (12) and tighten the grub
screws (4+5) and the cylindrical screws (6).
Mount the belt adjusters (8-8A) on the ends of the toothed belt
and secure the countersunk screws by bonding!!!
Insert the belt adjusters into the carriage (10) and secure the grub
screws (3) by bonding!!!
Tension the belt as per description above and finally mount the
wiper end plates (2) on the carriage.
Tip
The easiest way for mounting the wiper end plates is to secure the wipers
with a rubberband while mounting.

Maintenance for DriveSets
699-41-20.1
- 17 -
6.4 Checking and adjusting belt tension
6.4.1 Belt tension ELZ
Fig. 4 Belt tension axis type ELZ
A timing-belt tensioning device is attached at the ends of the toothed
belt and is fastened in the axis carriage (5) as well. The cogged-belt ten-
sioning device is set by stud screws which are recessed into the threaded
holes (2). By screwing the stud screws in, the timing belt is stretched. By
unscrewing them, the tension is slackened. In this way, it is easy to adjust
the timing belt.
Check the belt ten-
sion
It is not necessary to disassemble the axis or the carriage to check belt
tension:
Shove the carriage (5) in front of a bearing (7) so that the maxi-
mum belt length is freed up at the other side.
Exert the prescribed force (see table) a tension spring balance in
the middle of belt.
Compare the resulting “sag” (f) with the slackened belt.
Once you have ascertained the “sag”, please compare your measured
value with the recommended value which you obtain from the diagram.
The recommended values in the diagram are displayed according to the
scale and the traverse path (hub) of the axis.
If your value diverges from the default, you must stretch or slacken the
belt. The following section describes how this is done.
Check and adjust
belt tension
Shove the carriage (5) in front of a bearing (7) so that the maxi-
mum belt length is freed up at the other side.

Maintenance for DriveSets
- 18 -
699-41-20.1
Screw out the cylinder-head screws (1) of the pull-back cap (4). If
a contact flange for inductive proximity switches is attached to the
carriage, dismantle that beforehand.
Shove the pull-back cap (4) to another bearing (7).
Exert the prescribed force (see table) a tension spring balance in
the middle of belt. - Compare the resulting “sag” (f) with the slack-
ened belt.
Compare the value with the diagram, and if necessary stretch or
slacken the belt.
Adjust the stud screws (2) with a hex. socket screw wrench.
The stud screws (2) must be bonded with the locking device.
Both screws (2) must be screwed in equally deep. Check with a
steel tape.
Screw on the pull-back cap (4) again.
Axis-scale
spring balance applied force
ELZ 30
20 N
ELZ 40
20 N
ELZ 60
30 N
ELZ 80
50 N
ELZ 100
50 N
ELZ 125
50 N
Fig. 5 Sag of belt (Durchhang) plotted against stroke (Hub)
6.4.2 Tooth belt tension axis type DuoLine Z
The toothed belt tension is set correctly ex works. A correction is unnec-
essary in normal operation.

Maintenance for DriveSets
699-41-20.1
- 19 -
All toothed belts in linear units need tension, which is required to guar-
antee safe engaging of the teeth.
The required pretensioning of the toothed belt must be checked with a
pretensioning measurement appliance.
The specific pre-tensioning values for the different types of linear unit are
dependent on environmental parameters, such as the length of the unit,
acceleration and loads to be moved and can be queried with RK
Rose+Krieger GmbH for special cases.
Tension the toothed belt with the belt tensioning kit.
Tension the toothed belt (1) by steadily tightening the tensioning screw
(2) on the front of the slide (3) clockwise.
Fig. 6 Screws to adjust the belt tension
Remark
The toothed belt of the linear unit must be replaced every 8 years irre-
spective of the amount of use and the environmental influences.
6.4.2.1 Belt tension axis type MZK
Fig. 7 Structure linear axis MZK
Set screws (1) are attached to both sides of the carriage for ten-
sioning the toothed belt (2).
Push the carriage to an end position.

Maintenance for DriveSets
- 20 -
699-41-20.1
Turn the two screws (1) in a clockwise direction. You have to turn
both screws an equal number of turns!
Check the tension of the belt (2). Tighten the belt so that you can
easily move the carriage by hand.
Maintenance interval
Annual review and if necessary adjust.
6.5 Adjusting roller castor
6.5.1 Adjusting roller castor axis type LLZ60
Fig. 8 Adjusting the roller castor for axis type LLZ60
1 Eccentric key for tightening the 2-hole counternut.
2 Hexagon socket for adjusting the eccentric.
3 Adjustable roller castors
4 Non adjustable roller castors
Loose the 2-hole counter nut with the eccentric key (1).
Try to turn the eccentric with the hexagon socket (2). The eccen-
tric must be movable.
Turn the eccentric with the hexagon socket closly and delicately
to the right, until the eccentric is playless.
Now fix the eccentric with the hexagon socket (2) and tighten the
2-hole nut by a turn to the right.