Timken ROLLON CTU130-1I User manual

Smart System
User manual for the Partly Completed Machinery
Actuator System Line
Cobot Transfer Unit
Cobot Transfer Unit
for UR cobots

Content
1 Warnings and legal notes UM-3
Residual risks, Iso 9001:2015, Warranty conditions UM-4
Environmental indications, Safety warnings for handling and transport UM-5
Packaging, Transport UM-6
Handling and lifting, Check axis integrity after shipment, Installation UM-7
2 CTU - basic components
What’s included UM-8
Robot compatibility UM-8
3 Specific system references UM-9
4 Installation instructions
Handling CTU, Sensors UM-11
Installing CTU UM-12
Mounting the robot on CTU UM-13
Connecting CTU UM-14
Connecting the robot UM-16
Air connection, Carriage blocking element (optional) UM-17
Notes on lubrication UM-18
5 Rollon URCap manual (e-Serie)
Rollon URCap Installation UM-19
Drive configuration UM-21
IP connection UM-22
Manual positioning of the axis UM-23
Polyscope programming UM-24
Errors UM-27
Support UM-29
6 Rollon URCap manual (CB-Serie)
Rollon URCap Installation UM-30
Drive configuration UM-32
IP connection UM-33
Manual positioning of the axis UM-34
Polyscope programming UM-35
Errors UM-39
Support UM-41
Annexes:
• Manual of the motor
• Manual of Rollon electrical cabinet

UM-2
1 Warnings and legal notes
The Partly Completed Machinery shown in this manual is to be considered a mere supply of simple Cartesian
axes and their accessories agreed when the contract is stipulated with the client.
The following 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 to Rollon.
Rollon supplies Partly Completed Machinery. The client (direct or final) is responsible for testing and verifying that
the equipment is safe, which by definition cannot be theoretically verified or tested at our premises. The partly
completed machine must not be commissioned until the final machine, in which it is to be incorporated, has been
declared compliant, if necessary, with the instructions in Machinery Directive 2006/42/CE.
This 7th axis is not a “collaborative” equipment.
Warnings and legal notes

UM-3
Cobot Transfer Unit
It is mandatory to carefully consult this manual
prior to incorporating the Partly Completed Ma-
chinery. The information contained in the follow-
ing manual is for highly qualified and certified
personnel, possessing adequate competence in
incorporating the partly completed machinery.
Precaution in installation and handling opera-
tions. Significantly heavy equipment.
When handling the actuator, always make sure
that the support or anchoring surfaces do not
leave room for bending.
Before handling, stabilize the axis by securely
blocking its mobile parts. When handling axes
with vertical translation, it is mandatory to make
sure the carriage is at the corresponding lower
limit switch. Consult the image below and the
pertinent chapter.
Do not overload. Do not subject to bending forces.
Do not leave exposed to weather.
The system was designed following the agree-
ments and the instructions provided by the
client. The manufacturer cannot be considered
responsible for any consequences derived from
improper use or any use other than the purpose
the system 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.
To avoid damage, do not work on this machinery
with unsuitable tools.
Warning: moving parts. Do not leave objects on
the axis.
Make sure that the system is installed on a level
floor surface.
During use, carefully comply with the specific
performance values stated in the catalog
Make sure all electrical parts remain dry. In case
of contact with water, switch the power off im-
mediately.
Prevent dust from entering the electrical cabinet.
The images in this manual are to be considered
merely an indication and not binding; therefore,
the supply received could be different from the im-
ages 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. are not
designed/envisaged to operate in ATEX envi-
ronments.
Hazardous voltage.
Turn power off before commissioning or ser-
vicing.
Motor and gearbox generate heat during operation.
Do not touch the motor/gearbox while in operation
or immediately after operation, as prolonged con-
tact can cause discomfort. Cool the motor/gearbox
by powering off the system and wait.

UM-4
1 Warnings and legal notes
Residual risks Warranty conditions
The linear axis has the following residual risks:
• Mechanical risks due to the presence of moving el-
ements;
• Risk of fire resulting from the flammability of the belts
used on the axes, for temperatures more than 250
°C in contact with the flame;
• The risk of the vertical axis dropping during handling
and installation operations on the partly completed
machinery, before commissioning;
• Risk of the vertical axis dropping during maintenance
operations in the case of a drop in the electrical pow-
er supply voltage;
• Crushing hazard near moving parts with divergent
and convergent motion;
• Cutting and abrasion hazards.
ISO 9001:2015
Rollon S.p.A. is certified ISO 9001:2015.
Starting in 1995, Rollon has defined and built its own quality
management system to ensure that Client expectations and
needs are satisfied, conformity with standards and contrac-
tual specifications are guaranteed, and efficient management
of its corporate activities is achieved.
Within this scope, the as in this sense, Rollon has identified
its management and production processes, and designed the
sequences and interactions, criteria and control methods to
include and implement, analyses and measurements to re-
cord, and the actions that may be necessary to obtain the
expected results.
Rollon S.p.A. provides the following warranty pursuant to
art. 1512 of the Italian Civil Code: the proper function of its
products for the period of one year from their delivery, when
their concrete application is suggested by the Technical or
Commercial Office of our company and as long as any re-
ports of malfunction are submitted in writing within eight days
from their discovery. This warranty does not cover damage
or defects due to external agents, insufficient maintenance,
overloading, use of improper lubricant, natural use, inexact
product choice, assembly errors or other causes attributable
to improper use and not attributable to the manufacturing of
the product.
The warranty is limited to repair and/or replacement, exclud-
ing claims for further damages.

UM-5
Cobot Transfer Unit
Material Details of the supply
Aluminum alloys Profiles, plates, various details
Steel with various compositions Screws, and rails
Plastic PA6 - Chains
PVC - Covers and sliding block scrapers
Rubber of various types Plugs, seals
Lubrication of various types Used for the lubrication of sliding rails and bearings
Rust proof protection Rust proof protection oil
Wood, polyethylene, cardboard Transport packaging
Environmental indications
Environmental protection is very important for Rollon, and
therefore its operations are done with the goal of limiting
environmental impact. The indications listed below are to
ensure correct management of our supply.
Our products are mainly composed of:
At the end of the product's life cycle, it is therefore possible
to recover the various elements, in compliance with current
regulations on waste issues.
IMPORTANT!
The machine rails are protected with a layer of rust-proof oil or specific grease. Use suitable gloves when
handling.
Safety warnings for handling and transport
■The manufacturer has paid the utmost attention to pack-
aging to minimize risks related to shipping, handling and
transport.
■Transport can be facilitated by shipping certain compo-
nents dismantled and appropriately protected and pack-
aged.
■Handling (loading and unloading) must be carried out in
compliance with information directly provided in this user
manual.
Tab. 1

UM-6
1 Warnings and legal notes
Packaging
Transport
■Packaging is done keeping in mind the bulk reduction.
■Transport can be facilitated by shipping certain com-
ponents dismantled and appropriately protected and
packaged.
■All necessary information for loading and unloading is
written on the packaging.
■Every shipment is accompanied by a document (“Packing
list”) with the list and description of the axes.
■Packaging for maritime/air transport is the “barrier
bag” type to guarantee preservation of the packaged
elements.
■Bulk components are appropriately placed along with the
axes (with or without packaging) to avoid sudden and
unexpected movements.
■The packaging material must be appropriately disposed
of in compliance with the legislation in force.
■Transport, also based on the final destination, can be
done with different vehicles.
■Perform transport with suitable devices that have ade-
quate loading capacity.
■Ensure that the quasi-machine and its components are
adequately anchored to the vehicle.
■Mobile parts of the system are blocked before handling
and transport.
Packing in a crate
■Personnel authorized to lift and handle the machine and its
components must possess acquired and acknowledged skills
and experience in the specific sector, besides having full con-
trol of the lifting devices used.
■Handling and transport must be carried out with vehicles pre-
senting adequate loading capacity, and the machines must
anchored to the established points.
■During handling and if required by the conditions, have one or
more people assist in order to ensure adequate warnings.
■If the machine has to be moved with vehicles, ensure that
they are suitable for the purpose, and perform loading and
unloading without risks for the operator and for people direct-
ly involved in the process.
■Before transferring the equipment onto the vehicle, ensure
that both the quasi-machine and its components are ade-
quately secured, and that their profile does not exceed the
maximum bulk allowed. Place the necessary warning signs, if
necessary.
■Unload the axes in the immediate vicinity of the area of instal-
lation, and store them in an environment protected against
weather.
■Failure to comply with the information provided might entail
risks for the safety and health of people, and can cause eco-
nomic loss.
■The Installation Manager must have the project to organize
and monitor all operative phases.
■The installation site must have adequate environmental con-
ditions (lighting, ventilation, etc.).
■The installation site temperature must be within the maxi-
mum and minimum range allowed.
■Ensure that the installation site is protected against weather,
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 done if the machine has been
DECLARED COMPLIANT for such use.

UM-7
Cobot Transfer Unit
Packaging
Transport
Handling and lifting
■Before handling, read the instructions, especially safety
instructions, provided in the installation manual, on the
packages 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
oscillations.
■Make sure you can see properly. DO NOT move the ma-
chine with an inadequate visual field and when 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.
■Do not stack packages to avoid damaging them, and re-
duce 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.
Correctly connect the lifting devices to the established points
on the boxes and/or on the packages.
These symbols can be found on the Partly Completed Machin-
ery or on the crate.
Symbol indicating the center of
mass of the package to handle
Symbol indicating the pick up
points to use to lift the package
Check axis integrity after shipment
Installation
Every shipment is accompanied by a document (“Packing
list”) with the list and description of the axes.
■When a shipment is received, check to make sure that
the materials received correspond to specifications in the
delivery document.
■Check that packaging is perfectly intact and, check that
each axis is intact.
■In case of damage or missing parts, contact the manufac-
turer to define the relevant procedures.
■Fitting out the established location in advance makes it
possible to avoid wasting the time of installation techni-
cians.
■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 in-
terventions ONLY to authorized technicians with acknowl-
edged know-how.
■State-of-the-art connections to power sources (electric,
pneumatic, etc.) must be ensured, in compliance with rel-
evant regulatory and legislative requirements.
■State-of-the-art connections, alignment and leveling are
essential to avoid additional interventions and to ensure
correct machine function.
■Upon completion of the connections, run a general check
to ascertain that all work has been correctly carried out
and to ensure compliance with requirements.
■Failure to comply with the information provided might
entail risks for the safety and health of people, and can
cause economic loss.

UM-8
2 Integrated CTU - basic components
Axis type Robot type
CTU130-1I UR3e
CTU160-1I UR5e
CTU 220-1I UR10e - UR10CB - UR16e
Fig. 1
Tab. 2
CTU system is made up of:
• Rollon Seventh Axis [1]
• Rollon electrical cabinet [2]
• Connection cables [3]
• Fixing and leveling screws [4]
• High-flex robot power and signal cable
(The components must be assembled)
System requirements:
• Power supply: 380-480 V (power cable supplied with plug
IEC 60309 4 pins 3P + E)
• UR model: CB series robot 3.1 onwards e-Series robot with
Base Flange Connector. This is found on new e-Series
systems,with part numbers 1103xx (eg. 110305 for UR5e w.
Base Flange Connector).
• Polyscope 3.6 or higher.
3
2
CTU is available in different sizes:
CTU - basic components
What’s included Robot compatibility
1
4

UM-9
Cobot Transfer Unit
V max
[m/s] a max [m/s2]
1.5 3.0
Fig. 2
Tab. 4
Tab. 3
*Electrical cabinet weight 29 Kg not included.
** Width for vertical configuration.
CTU130-1I CTU160-1I CTU220-1I
Stroke
[mm]
Weight*
[kg]
Length
[mm]
Width
[mm]
Height
[mm]
Weight*
[kg]
Length
[mm]
Width
[mm]
Height
[mm]
Weight*
[kg]
Length
[mm]
Width
[mm]
Height
[mm]
500 46 1344
608
(662**) 211
73 1429
736
(727**) 229
99 1458
771
(788**) 231
1000 55 1844 88 1929 114 1958
1500 64 2344 103 2429 133 2458
2000 73 2844 117 2929 150 2958
2500 81 3344 130 3429 167 3458
3000 90 3844 145 3929 185 3958
3500 99 4344 159 4429 202 4458
4000 108 4844 174 4929 219 4958
4500 116 5344 188 5429 236 5458
5000 125 5844 202 5929 254 5958
5500 134 6344 216 6429 271 6458
Maximum dynamic performance
Specific system references
Robot compatibility
LENGTH
WIDTH
HEIGHT
LENGTH
WIDTH
HEIGHT

UM-10
3 Specific system references
All CTU systems have crosspieces that allow them to support
the load-bearing profile and simultaneously fasten the entire
structure together. The fixing crosspieces can also be used to
level the entire system.
Driving head
Chains
Support
chains
Motor + reduction gear
Fixing and levelling
crosspiece
Robot interface flange
Carriage
Examples of fixing and levelling
crosspieces
Fig. 3
Fig. 4
Main parts
Label
(1) Axis code.
The 3 digits after CTU indicate the size: 130, 160, 220.
(2) Stroke in millimeters
(3) Serial Number.
(4) Rollon’s traceability number.
1)
2)
3)
4)
CTU130-1I-CTU130-1I-xxxx-xxxxx-x
CTU130-CTU130-XXXXXXXX

UM-11
Cobot Transfer Unit
Fig. 5
Handling CTU
Lift the system, making sure to set the lift truck forks on both
load bearing beams that make up the system. Make sure that
the lift truck forks are in points equidistant from the fixing
crosspieces that support the load-bearing beam. Place the
carriage in a central position on the axis to keep the weight
balanced. Always monitor the load during handling to make
sure that it does not tip over suddenly.
The images below will give you an idea for positioning the
lifting points. Please consider them as indications only. They
are to help explain what is written above.
The direction of the carriage -/+ for programming is shown
on the carriage sides. The direction “-” is towards the motor
driving head, the direction “+” is towards the idle head.
Pick up points for lifting
IMPORTANT!
If the mass of the individual pieces totals over
20 kg, to avoid damage or accidents to the
operator(s), it is recommended to use lifting
machines suited to the specific use and ma-
neuvered by qualified technicians.
Installation instructions
Fig. 6
Fig. 7
Sensors
Limit switch 1 Machine homing Limit switch 2

UM-12
After placing the axis in its work position, turn the leveling
screws to align it as desired and to compensate for possible
misalignments due to irregular mounting surfaces. After lev-
elling, tighten the two fixing screws with the torque indicated
in the table.
Installation:
1. Position the axis with all leveling screws in full raised po-
sition;
2. Adjust the screws to achieve the desired alignment;
3. Fasten the fixing screws alternately and progressively. Do
not fix a screw completely while having the other com-
pletely unfastened. Both should be tightened progressively
and alternately until the specified torque is reached.
If the bolt provided is not of a suitable length, it can be re-
placed with one of a different length but of the same type
and property class.
Fig. 8
Fig. 9
Anchoring the CTU
Leveling screw
Fixing screws
Fasten both fixing screws
Hexagon head bolt with
shank UNI 5737 Friction coefficient
Tightening torque [Nm]
Property class 10.9
CTU130-1I M8x40
0.15
34
CTU160-1I M10x50 67
CTU220-1I M10x50 67
Tab. 5
Power down the system while any operation
of assembly/disassembly is performed.
IMPORTANT!
All screws used for installing Rollon modules have “self-locking” washers or semi-permanent “threadlock”
fluid (blue, such as Loctite 243). We recommend that the user also employ these devices, both while setting
up the partially assembled machine described in this manual, and during the assembly or maintenance
phases: if this is not done, the manufacturer of the partially assembled machine declines all responsibility
for any accidents, breakage, damage and the consequences of said events on people, animals and property,
due to the failure of fixing elements.
4 Installation instructions

UM-13
Cobot Transfer Unit
Power down the system while any operation
of assembly/disassembly is performed.
Proceed with the installation of the robot in working position.
The axis carriage is supplied with an adaptation counter plate
for fixing the robot. This flange is custom made to be compat-
ible with the robot base, and it is in turn anchored to the axis
carriage. To anchor the robot to the interface flange, follow
the instructions shown in the robot manual.
Mounting the robot on CTU
Fig. 11
Fig. 13
Robot power supply connector
Robot power supply connector
Robot interface flange
Robot interface flange
Fig. 12
Fig. 14
Fig. 10
Plug the cable
connector that
comes out of
the chains to the
robot’s connector.
Robot interface flange
UR 10CB
UR 3e, UR 5e, UR10e
UR 10CB
UR 3e, UR 5e, UR10e
Plug the cable
connector that
comes out of
the chains to the
robot’s connector.

UM-14
Fig. 15
Connecting the CTU
White power indicator light (24 V)
Lifting eyebolts
Detail of cable connection area
Cable connection area
General knob
to power up the Rollon cabinet
Cabinet power supply
electric (BLACK cable)
Motor signal
(GREEN cable)
Safety signal
(bypass installed)
Sensors power supply
(GREY cable)
Motor power supply
(ORANGE cable)
Network cable robot connection
(WHITE cable - ethernet)
It is mandatory to perform any operation of
assembly/disassembly and cable connection/
disconnection with the power down. Ensure
the power is off and the white light is off.
The electrical cabinet is not supposed to be
opened to use the system. All connectors
are placed outside. In case of malfunction-
ing please contact Rollon.
Only use the original cables supplied with
the CTU.
Power down the system while any opera-
tion of assembly/disassembly is performed.
The UR robot operates even if the CTU con-
trol cabinet is turned off.
4 Installation instructions

UM-15
Cobot Transfer Unit
Fig. 17
The GREY cable must be plugged into the connector. This will
activate the 3 positioning sensors.
Fig. 16
*
Procedure for connecting electrical cabinet cables:
Cables coming out of the electrical cabinet;
- ORANGE cable - motor power,
- GREEN cable - motor signals,
- BLACK cable - electrical cabinet power supplied with
plug IEC 60309 4 pins 3P + E (380-480V)
- GREY cable - sensor power;
- WHITE cable - ethernet connection cable between
the electrical cabinet of CTU and the robot.
Depending on the order the cables will be supplied in sec-
tions 3 or 5 meters in length.
*On the cabinet a connector for safety signal is installed
(e.g. laser scanner, safety mat, other safety devices, external
safety door).
An external bypass is supplied.
Fig. 18
Indications for connecting the ORANGE and GREEN cables
to the motor
Procedure for turning on the electrical cabinet:
1. Ensure that the machine is safe;
2. Turn the general knob to power up the electrical cabinet;
3. Make sure the white light (24 V) comes on;
To power up or power down the electrical cabi-
net turn the general knob.

UM-16
4 Installation instructions
Fig. 19
Fig. 20
Fig. 21
The electrical panel is supplied with the robot, not with the CTU.
Make sure that all cables are connected;
- Small BLACK cable - electrical panel power (220 V),
- BLUE cable - High-Flex robot power and signal cable
- WHITE cable - Ethernet network connection cable between
the electrical cabinets of CTU and the robot.
Depending on the order the WHITE cable will be supplied in 6
or 12 meters length.
The BLUE High-Flex robot power and signal cable is already
inserted into the cable carrier in the axis chains. It is supplied
6m or 12m long based on CTU stroke (Page UM-13 for con-
necting the robot).
BLUE cable
High-Flex robot
power and signal
cable inlet
into CTU
Connecting the robot
Power down the system while any opera-
tion of assembly/disassembly is performed.
The UR robot operates even if the CTU con-
trol cabinet is turned off.
Pressing the emergency button of the robot
stops the axis as well.

UM-17
Cobot Transfer Unit
Air connection
Fig. 23
Fig. 24
Fig. 22
EE
FF
AA
DD
BB
CC
(A-B-C-D) Air inlets to power robot accessories (fig. 23
and 24). Corresponding air outlets are on the axis carriage
(fig.22).
The cable carrier is supplied with 4 air cables.
(E-F) Air inlet for carriage clamping elements (fig. 24. Clamp-
ing elements optional if requested on order, see below chap-
ter). Corresponding air outlets are on the axis carriage (fig.
22).
Carriage clamping element (optional)
Fig. 25
If requested during the order phase, the axis comes with
clamping elements on the carriage that work on linear rails.
With this option, the carriage presents open sides like the
one shown in Fig.23. These are pneumatically activated el-
ements. Pressurized air holds the clamping element open.
The absence of pressurized air closes them and blocks the
carriage. To unblock the carriage, it is necessary to restore
pressure to the circuit. Working pressure: 5.5 bar.
Axis type Clamping force
[N]
CTU130-1I 800
CTU160-1I 1200
CTU220-1I 1500
Tab. 6
Clamping force refers to both clamps actu-
ated via E and F connections, do not activate
only one connection.
EEFF
AA
DD
BBCC

UM-18
4 Installation instructions
Notes on lubrication
CTU features rails with self-lubricating recirculating ball bear-
ings.
Carriages with recirculating ball bearings also have a retain-
ing cage that eliminates the “steel on steel” contact between
adjacent rolling bodies and prevents misalignments of theses
parts in the circuits.
Lubricant tanks are installed on the fronts of carriages with
recirculating ball bearings. These small reservoirs release the
right quantity of lubricant in the areas where the ball bearings
support the applied loads.
This system guarantees long maintenance intervals: every
5000 km or once a year, whichever quantity is reached first.
■Insert the dispensing nozzle into the specific lubricator.
■Type of lubricant: class NLGI 2 lithium soap based grease.
■More frequent lubrication is necessary for heavy duty
applications or difficult environmental conditions.
For more information, contact Rollon.
Quantity of grease necessary for re-lubricating each of the 4 blocks.
Type Quantity
[cm3]
CTU130-1I 0.7
CTU160-1I 1.4
CTU220-1I 2.4
Lithium Calcium Lithium
Calcium
Lithium
Complex
Calcium
Complex
Calcium
Complex
Sulfonate
Aluminum
Complex Polyurea Bentone Sodium
Lithium
Calcium
Lithium
Calcium
Lithium
Complex
Calcium
Complex
Calcium
Complex
Sulfonate
Aluminum
Complex
Polyurea
Bentone
Sodium
Grease compatibility
Compatible Compatible in certain
Proportions
Not compatible
Fig. 26
Tab. 7