Timken ROLLON SC 100 User guide

Smart System
Use and maintenance
Actuator Line
Plus system
SC

Content
Use and maintenance
Lubrication, Drive belt replacement UM-2
Replacement of the ball re-circulation sliding blocks UM-6
Assembly of clamp/brake unit (only for SC130 and SC160) UM-7
Proximity switch adjustment, Warnings UM-8
Gearbox side replacement UM-9
Gearbox assembly UM-9
Components UM-10
Warnings and legal notes UM-11

UM-2
SC
Lubrication
Quantity of lubricant for each block
Insert the tip of the grease gun in the specific grease blocks.
For lubrication of linear units use lithium soap grease NLGI 2.
For specially stressed applications or difficult enviromental condi-
Type Unit
[cm3]
SC 100 0.7
SC 130 0.7
SC 160 1.4
Use and maintenance
Tab. 1
Fig. 1
Linear units with linear ball guides
SC Linear units are equipped with self lubricating linear ball
guides. On the front plates of the linear blocks special lu-
be-units are mounted which are continuously providing the
necessary quantity of grease to the ball rows under load.
tions, lubrication should be carried out more frequently. Apply to
Rollon for futher advice.
This system guarantees a long interval between maintenan-
ces: every 5000 km or 1 year of use, based on the value
reached first. If a longer service life is required or in case of
high dynamic or high loaded applications please contact our
offices for further verification.
Fig. 2 Fig. 3
Drive belt replacement
1) Untight the 4 screws which fix the upper belt clamp (Fig. 2).
2) Remove the cap which covers the tensioning screw, untight
the set-screw. Remove the tensioning screw (see Fig. 3).

UM-3
Smart System
Fig. 8 Fig. 9
Fig. 4
Fig. 5 Fig. 6 Fig. 7
3) Untight the 4 screws and remove the upper plate at the end
of the aluminum profile (see Fig.4).
5) Remove the screws of the lower end plate and separate
the plate from the actuator (see Fig. 8 and Fig. 9).
4) Remove the screws of the belt clamp plate and separate it
from the actuator (see Fig. 5, Fig. 6 and Fig. 7).

UM-4
SC
Fig. 10 Fig. 11 Fig. 12
Fig. 13 Fig. 14
6) Remove all the screws of the lower belt clamp plate and sepa-
rate it from the actuator (see Fig. 10, Fig. 11 and Fig. 12).
7) Untight the screws which fix the driving head plate and
remove the head from the actuator. Remove the old belt
from the driving head (see Fig. 13 and Fig. 14).

UM-5
Smart System
N
11) Re-assembly the belt clamp plate without completely fixing
the screws.
Re-assembly the upper plate at the end of the profile.
Tension the belt by acting on the tensioning screw, when
the tension is reached tight the set-screw and then tight all
the screws blocking the belt and the ones blocking the belt
tension plate.
8) Insert the new belt inside the driving head taking care about
the orientation of the teeth which must engage with the dri-
ving pulley (see Fig. 15).
9) Re-assembly the driving head plate (see Fig. 16).
10) Place the new belt on the lower belt clamp (see Fig. 17).
Re-assembly the belt clamp plate.
Re-assembly the lower plate, take care about the reference
step.
Fig. 15
Fig. 17
Fig. 16
Fig. 18

UM-6 Fig. 21
4) Before re-assembling the new sliding block be sure that
the original lubricating nipples are not assembled.
Take care about the orientation of the sliding block.
The side of the lubrication tank must be on the outer
side.
For re-assembly, reverse the operations described above.
During insertion, the new sliding block will be inserted auto-
matically in the fast disconnect of the grease block.
5) Fix the sliding block with its 4 screws.
6) Re-assembly the cover plate.
Replacement of the ball re-circulation sliding blocks
Fig. 19
1) Remove the cover plate on top or lower side of the
carriage depending where the sliding block has to
be replaced. Unscrew the two screws (see Fig.19).
2) Loosen and remove the sliding block screws.
3) Slide out the sliding block. In case the seal OR is removed
during this operation, it must be re-positioned when
re-assembling the sliding block (see Fig. 21).
Fig. 20
SC

UM-7
Smart System
Fig. 22 Fig. 23
Fig. 24 Fig. 25
Assembly of clamp/brake unit (only for SC130 and SC160)
1) Remove the screws and the plates on both sides of the car-
riage (see Fig. 22).
2) Assembly the clamp/brake on the plate taking care about the
right orientation as shown in the picture. Before tightening
completely the screws push the clamp/brake against the
reference sides on the plate. Assembly the air plug on the
clamp/brake as shown in the picture (see Fig. 23).
3) Connect the air tube to the plug.
Give pressure in order to unlock the clamp/brake.
4) While assembling the plate with the clamp/brake mounted on
it take care to put the reference of the plate in contact with
the carriage (see Fig. 24).
5) Re-assembly the plate to the actuator without firmly tighte-
ning the screws.
6) Cut air pressure, the clamp/brake is now clamping on the rail.
7) Tight all the screws of the plate.
8) Give air pressure so that the brake is released and check that
the actuator is free to move.

UM-8
Fig. 26
Fig. 27 Fig.28
Fig. 29
Proximity switch adjustment
Warnings
1) Identifiy the position along the actuator where the limit
switch must work, there the sensor dog must be fixed.
2) Insert the fixing nuts in the profile slot accessing through
the upper plate. Repeat the operation also for the sensor
dog to be installed in the lower side of the profile (Fig.26).
3) Fasten the sensor dog in place (Fig.27).
4) Insert the proximity switch on the carriage plate, and
tighten it until it gets in contact with the sensor dog.
Then losen it for 1/2 turn to bring it to the correct
distance (Fig. 28).
5) Tighten the proximity switch in position by tightening the
lock nut (Fig. 28).
WARNING: the safety block must NEVER be used as an ope-
rational end stop of the stroke.
SC

UM-9
Smart System
Gearbox assembly
Screw
8.8
Tightening torque
[Nm]
M2 0.4
M2.5 0.7
M3 1.3
M4 2.8
M5 5.6
M6 9.6
M8 23
M10 46
Gearbox
Flange 1
Screws 5
Screws 2
Spacer 3
Shrink disk 4
Fig. 30
Tab. 2
■Place the axis as shown in the figure with the gear assem-
bly component facing upwards.
■Assemble the flange (1) on the gear and tighten the screws
(2) until the torques shown in Table 2 are reached.
■Place the gearbox complete with flange on the unit without
locking it.
■Insert the spacer (3) from below and then insert the Shrink
disk (4) without locking it.
■Tighten the flange fixing screws (5).
■Tightening sequence of the shrink disc screws until a tor-
que value is obtained as in Tab. 3:
■Tighten all the screws to 50% of the value of the tighte-
ning torque indicated in Tab. 3 in a crossed sequence.
■Repeat the same operation at 100% of the tightening
torque indicated in Tab. 3.
■Check, in continuous sequence, that the tightening tor-
que has been reached.
■Loosen and then tighten the gear fixing screws (5) until
the torques shown in Table 2 are reached.
Tab. 3
Code* Hollow shaft
[mm] Shrink disc dxD [mm] Screw Tightening torque
[Nm]
6005737
34
14x34 M4 3.1
6005738 16x34 M4 3.1
6005739 19x34 M4 3.1
6005733
41
16x41 M4 4.3
6005734 19x41 M4 4.3
6005735 22x41 M4 4.3
6005736 25x41 M4 4.3
6005730
50
22x50 M5 8.5
6005731 25x50 M5 8.5
6005732 32x50 M5 8.5
* The code refers to the purchasing of the single shrink disk. In case of purchasing a gearbox assembly KIT (flange, shrink disc and screws), please refer to the dxD dimensions to identify the shrink disc.

UM-10
SC
Components
Fig. 32
ELM SP Linear unit
1 Anodised aluminium extrusion
2 Driving head
3 Driving pulley
4 Idle pulley
5 Rails
6 Driving belt
7 Lower belt clamp
8 Grease nipple
9 Belt tensioning device
10 Carriage
11 Sliding block
RIGHT POSITION OF THE ELEMENTS
In the image below are
reported the correct angle
positions of the components
that build the shrink ring to
use only in the case it was
dismounted completely.
Fig. 31
IT IS NOT
RECOMMENDED
TO ASSEMBLE THE
RINGS WITH THE
CUTS ALIGNED
IT IS FORBIDDEN
TO ASSEMBLE THE
RINGS WITH THE
THREADS ALIGNED
9
6
3
2
4
7
1
10
8
11
5

UM-11
Smart System
Warnings and legal notes
Before incorporating the partly completed machinery,
we recommend consulting this chapter carefully, in
addition to the assembly manual supplied with the
individual modules. The information contained in
this chapter and in the manuals for the individual
modules, is provided by highly qualified and certified
personnel, possessing adequate competence in in-
corporating the partly completed machinery.
Avoid damage. Do not operate with inadequate tools
Precaution in installation and handling operations.
Significantly heavy equipment.
When handling the axis or system of axes, always
make sure that the support or anchoring surfaces do
not leave room for bending.
In order to stabilize the axis or system of axes, before
handling it is mandatory to securely block the mobile
parts. When moving axes with vertical translation (Z
AXES) or combination systems (horizontal X and/or
more than one vertical Z), it is mandatory to use the
vertical movement to put all of the axes at the corre-
sponding lower limit switch.
Warning: moving parts. Do not leave objectson the axis
Do not overload. Do not subject to torsion stress.
Do not leave exposed to atmospheric agents.
Special installations: check the depth of the threads
on moving elements
Make sure that the system has been installed on a
level floor surface.
In use, accurately comply with the specific perfor-
mance values declared in the catalog or, in particular
cases, the load and dynamic performance character-
istics requested in the phase prior to design.
Before mounting the motor on the gearbox, it is ad-
visable to perform a pre-test of the motor itself, with-
out connection to the gear unit. The testing of this
component was not carried out by the manufacturer
of the machine. It will therefore be the responsibility
of the customer of Rollon to perform the testing of
the same, in order to verify its correct operation.
For modules or parts of modular systems with ver-
tical movement (Z axis), it is mandatory to mount
self-braking motors to neutralize the risk of the axis
dropping.
The images in this manual are to be considered
merely an indication and not binding; therefore, the
supply received could be different from the imag-
es contained in this manual, and Rollon S.p.A has
deemed it useful to insert only one example.
Systems supplied by Rollon S.p.A. were not de-
signed/envisaged to operate in ATEX environments.
The manufacturer cannot be considered responsible
for any consequences derived from improper use or
any use other than the purpose the axis or system
of axes was designed for, or derived from failure to
comply, during incorporation phases, with the rules
of Good Technique and with what is indicated in this
manual.

UM-12
ELM
The Partly Completed Machinery shown in this ca-
talog is to be considered a mere supply of simple
Cartesian axes and their accessories agreed when
the contract is stipulated with the client. The fol-
lowing are therefore to be considered excluded from
the contract:
1. Assembly on the client’s premises (direct or final)
2. Commissioning on the client’s premises (direct or
final)
3. Testing on the client’s premises (direct or final)
It is therefore understood that the aforementioned
operations in points 1.,2., and 3. are not chargeable
■Mechanical risks due to the presence of moving elements (X, Y
axes).
■Risk of fire resulting from the flammability of the belts used on
the axes, for temperatures in excess of 250 °C in contact with
the flame.
■The risk of the Z axis dropping during handling and installation
operations on the partly completed machinery, before com-
missioning.
Basic components
Residual risks
to Rollon. Rollon is the supplier of Partly Completed Machinery, the
(direct or final) client is responsible for testing and safely checking
all equipment which, by definition, cannot be theoretically tested or
checked at our facilities where the only movement possible is ma-
nual movement (for example: motors or reduction gears, cartesian
axes movements that are not manually operated, safety brakes,
stopper cylinders, mechanical or induction sensors, decelerators,
mechanical limit switches, pneumatic cylinders, etc.). The partly
completed machine must not be commissioned until the final ma-
chine, in which it is to be incorporated, has been declared com-
pliant, if necessary, with the instructions in Machinery Directive
2006/42/CE.
■Risk of the Z axis dropping during maintenance operations in
the case of a drop in the electrical power supply voltage.
■Crushing hazard near moving parts with divergent and
convergent motion.
■Shearing hazard near moving parts with divergent and
convergent motion.
■Cutting and abrasion hazards.
Instructions of an environmental nature
Material Details of the supply
Alluminum alloys Profiles, pleates, various details
Steel with various composition Screws, racks and pinions, and rails
Plastic
PA6 – Chains
PVC – Covers and sliding
block scrapers
Rubber of various types Plugs, seals
Lubrification of various types Used for the lubrication of sliding
rails and bearings
Rust proof protectione Rust proof protection oil
Wood, polyethylene, cardboard Transport packaging
Rollon operates with respect for the envirorment, in order to limit
environmental impact. The following is a list of some instructions
of an environmental nature for correct management of our sup-
plies. Our products are mainly composed of:
At the end of the product’s life cycle, it is therfore possible to
recover the various elements, in compliance with current regu-
lations on waste issues.

UM-13
Smart System
Note
Safety warnings for handling and transport
■The manufacturer has paid the utmost attention to packaging to
minimize risks related to shipping, handling and transport.
■Transport can be facilitated by shipping certain components
dismantled and appropriately protected and packaged.
■Handling (loading and unloading) must be carried out in complian-
ce with information directly provided on the machine, on the
packing and in the user manuals.
■Personnel authorized to lift and handle the machine and its
components shall possess acquired and acknowledged skills
and experience in the specific sector, besides having full control
of the lifting devices used.
■During transport and/or storage, temperature shall remain wi-
thin the allowed limits to avoid irreversible damage to electric
and electronic components.
■Handling and transport must be carried out with vehicles pre-
senting adequate loading capacity, and the machines shall be
anchored to the established points indicated on the axes.
■DO NOT attempt to bypass handling methods and the establi-
shed lifting points in any way.
■During handling and if required by the conditions, make use of
one or more assistants to receive adequate warnings.
■If the machine has to be moved with vehicles, ensure that they
are adequate for the purpose, and perform loading and unloading
without risks for the operator and for people directly involved in
the process.
■Before transferring the device onto the vehicle, ensure that both
the machine and its components are adequately secured, and that
their profile does not exceed the maximum bulk allowed. Place
the necessary warning signs, if necessary.
■DONOTperformhandling withaninadequatevisual field andwhen
there are obstacles along the route to the final location.
■DO NOT allow people to either transit or linger within the range of
action when lifting and handling loads.
■Download the axes just near the established location and store
them in an environment protected against atmospheric agents.
■Failure to comply with the information provided might entail
risks for the safety and health of people, and can cause econo-
mic loss.
■The Installation Manager must have the project to organize and
monitor all operative phases.
■The Installation Manager shall ensure that the lifting devices and
equipment defined during the contract phase are available.
■The Manager of the established location and the Installation
Manager shall implement a “safety plan” in compliance with the
legislation in force for the workplace.
■The “safety plan” shall take into account all surrounding work-
related activities and the perimeter spaces indicated in the project
for the established location.
■Mark and delimit the established location to prevent unauthori-
zed personnel from accessing the installation area.
■The installation site must have adequate environmental condi-
tions (lighting, ventilation, etc.).
■Installation site temperature must be within the maximum and
minimum range allowed.
■Ensure that the installation site is protected against atmospheric
agents, does not contain corrosive substances and is free of the
risk of explosion and/or fire.
■Installation in environments presenting a risk of explosion and/or
of fire must ONLY be carried out if the machine has been DE-
CLARED COMPLIANT for such use.
■Check that the established location has been correctly fitted out,
as defined during the contract phase and based on indications
in the relative project.
■The established location must be fitted out in advance to carry
out complete installation in compliance with the define methods
and schedule.
■Evaluate in advance whether the machine must interact with
other production units, and that integration can be implemented
correctly, in compliance with standards and without risks.
■The manager shall assign installation and assembly interven-
tions ONLY to authorized technicians with acknowledged
know-how.
■State of the art connections to power sources (electric, pneuma-
tic, etc.) must be ensured, in compliance with relevant regula-
tory and legislative requirements.
■“State of the art” connection, alignment and leveling are essen-
tial to avoid additional interventions and to ensure correct machine
function.
■Upon completion of the connections, run a general check to
ascertain that all interventions have been correctly carried out
and compliance with requirements.
■Failure to comply with the information provided might entail
risks for the safety and health of people, and can cause econo-
mic loss.

UM-14
Warnings and legal notes
Transport
Handling and lifting
Check axis integrity after shipment
■Transport, also based on the final destination, can be done with
different vehicles.
■Perform transport with suitable devices that have adequate
loading capacity.
■Ensure that the machine and its components are adequately
anchored to the vehicle.
■Correctly connect the lifting devices to the established points
on the packages and/or on the dismantled parts.
■Before handling, read the instructions, especially safety
instructions, provided in the installation manual, on the packa-
ges and/or on the dismantled parts.
■DO NOT attempt, in any way, to bypass handling methods and
the established lifting, moving and handling points of each
package and/or dismantled part.
■Slowly lift the package to the minimum necessary height and
move it with the utmost caution to avoid dangerous oscilla-
tions.
■DO NOT perform handling with an inadequate visual field and
when there are obstacles along the route to reach the final
location.
■DO NOT allow people to either transit or linger within the range
of action when lifting and handling loads.
■Do not stack packages to avoid damaging them, and reduce
the risk of sudden and dangerous movements.
■In case of prolonged storage, regularly ensure that there are no
variations in the storage conditions of the packages.
Every shipment is accompanied by a document (“Packing list”
with the list and description of the axes.
■Upon receipt check that the material received corresponds to
specifications in the delivery note.
■Check that packaging is perfectly intact and, for shipments
without packaging, check that each axis is intact.
■In case of damages or missing parts, contact the manufacturer
to define the relevant procedures.

UM-15
Smart System

ROLLON S.A.R.L. - FRANCE
Les Jardins d’Eole 2 allée des Séquoias
69760 Limonest
Phone [phone]
[email protected]
www.rollon.fr
ROLLON LTD. - CHINA
No. 1155 Pang Jin Road,
China, Suzhou, 215200
Phone [phone]
[email protected]
www.rollon.cn.com
ROLLON S.p.A. - ITALY (Headquarters)
Via Trieste 26
20871 Vimercate (MB)
Phone [phone]
[email protected]
www.rollon.com
ROLLON GMBH - GERMANY
Bonner Straße 317-319
40589 Düsseldorf
Phone [phone]
[email protected]
www.rollon.de
ROLLON LTD. - UK (Rep. Office)
The Works 6 West Street
Olney, Buckinghamshire
United Kingdom, MK46 5 HR
Phone [phone]
[email protected]
www.rollon.uk.com
ROLLON S.P.A. - RUSSIA (Rep. Office)
117105, Moscow, Varshavskoye
shosse 17, building 1
Phone [phone]
[email protected]
www.rollon.ru
ROLLON CORP. - USA
101 Bilby Road. Suite B
Hackettstown, NJ 07840
Phone [phone]
[email protected]
www.rollon.com
ROLLON - SOUTH AMERICA
101 Bilby Road. Suite B
Hackettstown, NJ 07840
Phone [phone]
[email protected]
www.rollon.com
EUROPE
AMERICA
ASIA
ROLLON INDIA PVT. LTD. / INDIA
39-42, Electronic City, Phase-I,
Hosur Road, Bangalore-560100
www.rollonindia.in - [e-mail]
ROLLON S.P.A. - JAPAN
〒252-0131
神奈川県相模原市緑区西橋本1-21-4
橋本屋ビル
電 話 番 号：042-703-4101
www.rollon.jp - [email protected]