WEISS HL50 User manual

Installation- and operating manual
Mechanical system documentation
980-208018000 / EN 07/2011
Compact linear motor shafts
HL50 - HL100

Document: Installation- and operating manual
Document version: Mechanical system documentation
Valid for: Linear motor shafts
Type: HL50 - HL100
Revision R07-2011
This document has been prepared by
WEISS GmbH, Siemensstrasse 17, D-74722 Buchen
Service
Tel: [phone]
[email protected]
www.weiss-gmbh.de
© WEISS GmbH
All rights in this document are the copyright of WEISSGmbH. This document may not be copied or reproduced, in
whole or in part, without the written permission of WEISS GmbH. This document is only intended for the user of
the product described and may not be passed on to third parties, in particular competitors.
Revisions
Date Revision Chapter Reason
15.10.2010 R10-2010 All Created
15.07.2011 R07-2011 2, 4, 5, 6, 7, 10 Supplement

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List of contents
1. Introduction ........................................................................................................... 5
1.1. Definition ....................................................................................................... 5
1.2. Correct use ................................................................................................... 5
1.3. Incorrect use ................................................................................................. 5
1.4. Laws / EC Directives / Norms ....................................................................... 5
1.5. EC Declaration .............................................................................................. 6
1.6. System-dependant documentation ............................................................... 6
1.7. Operating manual ......................................................................................... 7
1.8. Guarantee and liability .................................................................................. 8
2. Safety ..................................................................................................................... 9
2.1. Fundamental safety instructions ................................................................... 9
2.2. Safety equipment for the machine .............................................................. 10
2.3. Residual hazards ........................................................................................ 12
3. Product description ............................................................................................ 13
3.1. Structure ..................................................................................................... 13
3.2. Function ...................................................................................................... 14
3.3. Technical data ............................................................................................. 14
3.4. Electrical connections ................................................................................. 22
3.5. Option with tool connector .......................................................................... 25
3.6. Lubrication .................................................................................................. 26
4. Transportation ..................................................................................................... 27
4.1. Transportation damage ............................................................................... 27
4.2. Intermediate storage ................................................................................... 28
5. Installation ........................................................................................................... 29
5.1. Safety during installation ............................................................................. 29
5.2. Installation prerequisites ............................................................................. 29
5.3. Assemble machine ...................................................................................... 30
5.4. Assembly suggestions ................................................................................ 30
5.5. Weiss Tool-Connector ................................................................................ 31
5.6. Installing the safety equipment ................................................................... 32
5.7. Instructions on disposal of packaging material ........................................... 32
6. Commissioning ................................................................................................... 33
6.1. Safety during commissioning ...................................................................... 33
6.2. Initial commissioning ................................................................................... 34
6.3. Recommissioning ........................................................................................ 34
7. Operation ............................................................................................................. 35
7.1. Safety during operation ............................................................................... 35
7.2. Operating the machine ................................................................................ 35
7.3. Operating personnel workstations .............................................................. 35
8. Malfunctions ........................................................................................................ 36
8.1. Safety when remedying malfunctions ......................................................... 36
8.2. Errors / Cause / Remedy ............................................................................ 36
8.3. Customer Service ....................................................................................... 36
9. Maintenance ........................................................................................................ 37
9.1. Safety during maintenance ......................................................................... 37
9.2. Maintenance work ....................................................................................... 38
9.3. Inspections .................................................................................................. 38
9.4. Maintenance ............................................................................................... 39
9.5. Repair ......................................................................................................... 40
10. Decommissioning / Dismantling / Disposal ...................................................... 41
10.1. Safety during decommissioning and dismantling ........................................ 41
10.2. Decommissioning ........................................................................................ 41
10.3. Dismantling and disposal ............................................................................ 42
1
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11. Service and spare parts ...................................................................................... 43
11.1. Ordering spare parts ................................................................................... 43
12. Appendix .............................................................................................................. 44
12.1. Index ........................................................................................................... 44
12.2. Personal notes ............................................................................................ 46
Illustration indexGeneral view of the linear motor shaft ........................................................................... 13
Example of a type plate ................................................................................................. 16
Installation positions ...................................................................................................... 17
Plug-in connections ....................................................................................................... 22
Tool connector ............................................................................................................... 25
Connection automatic lubrication .................................................................................. 26
Gripper front side........................................................................................................... 31
Gripper left ..................................................................................................................... 31
Gripper right ..................................................................................................................32
1
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Introduction
1.1 Definition
1
1Introduction
1.1 Definition
The linear motor shaft is a Handling system with a highly dynamic, high-performance
Linear motor.
The linear motor shaft is referred to as machine in the following text of this opera-
ting manual.
1.2 Correct use
The machine is a noncomplete machine conforming to Directive 2006/42/EC,
Article1gand2g.
The machine is designed for integration in other machines, in other incomplete machines
or equipment or for connection to these.
It may only be used within the limitations defined in the order characteristics.
Commissioning is forbidden until the conformity of the product in which the machine is
installed with Directive 2006/42/EC and all other Directives governing use has been
determined and confirmed.
Observance of the accompanying documentation and adherence to maintenance
regulations are also component parts of correct use.
1.3 Incorrect use
Any use of the machine above or beyond the directions for correct use is regarded as
incorrect and prohibited.
The machine must not be subjected to loads that exceed the maximum limits.
The machine is not suitable for use
• in wet or damp environments of any kind (water, oils, acids, steam or vapours, etc.).
• in an environment with gases or radiation.
• in potentially-explosive atmospheres.
• in environments which contain swarf.
1.4 Laws / EC Directives / Norms
The machine is designed and constructed to conform to
• applicable laws
• Directive 2006/42/EC (Machinery Directive)
• Low Voltage Directive, 2006/95/EC
• EMC Directive 2004/108/EC
• and the harmonised standards that we have cited
and meets state-of-the-art technological standards in terms of its construction.

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Introduction
1.5 EC Declaration
1
1.5 EC Declaration
An EC Declaration as specified by Directive 2006/42/EC (Machinery Directive) is
included with each machine at delivery.
The text of this EC Declaration is as follows:
WEISS GmbH Sondermaschinentechnik
Siemensstrasse 17
D-74722 Buchen, Germany
Declaration of incorporation of partly completed machinery
in accordance with EC Machinery Directive 2006/42/EC, Annex II B
Prohibition of commissioning
We hereby declare that the machine called Linear motor shafts HL50 - HL100 is intended
for the installation into another machine or is to be assembled with other machines to a
machine in terms of the directive 2006/42/EC.
Commissioning is prohibited until it has been established that the machine into which the
aforementioned product should be installed satisfies the provisions of the EC Machinery
Directive, and that a Declaration of Conformity in accordance with EC Machinery Direc-
tive 2006/42/EC, Annex II A has been issued.
1.6 System-dependant documentation
In addition to this manual, further documents are required to ensure safe operation of this
machine. The specifications stated in these documents are to be observed.
For control system by WEISS-GmbH:
• Betriebsanleitung WAS.handling Steuerung HL50 - HL100
• Operating manual WAS.handling Windows programme
• Operating manual Hand-held grease gun (for the model with lubricating nipples)
• Operating manual automatic lubrication pump (for model with automatic lubrication)

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Introduction
1.7 Operating manual
1
1.7 Operating manual
This operating manual is a translation of the original operating manual and is part
of the scope of delivery.
We reserve the right to undertake modifications resulting from further technological
development which diverge from the data and illustrations contained in this operating
manual.
The operating manual and the associated valid documentation are not subject to an auto-
matic revision service.
Information on the respective current edition can be obtained from the manufacturer.
Local regulations must be heeded.
This operating manual describes handling of the machine and contains important instruc-
tions and information to assist you in correct use of the machine.
The operating manual is designed for trained technical personnel and instructed persons.
It should be kept at the location of use of the machine at all times and read, understood
and applied by all persons entrusted with work on or with the machine.
Safety instructions in individual chapters should be observed.
1.7.1 Explanation of safety instructions in this manual
This manual contains instructions which you should observe for your personal safety and
to avoid material damage.
Safety instructions for yourpersonal safety are highlighted by a sign containing a warning
triangle and signal word. The associated text describes the hazard involved, avoidance
options and the consequences of a failure to heed the safety instruction.
General instructions or instructions relating to possible material damage are highlighted
by a sign without a warning triangle.
They are, depending on the degree of risk involved, illustrated as follows:
A warning triangle with the signal word DANGER
indicates an immediate hazardous situation which, if
not avoided, will lead to fatalities or grievous injuries.
A warning triangle with the signal word WARNING
indicates an potential hazardous situation which, if
not avoided, can lead to fatalities or grievous injuries.
A warning triangle with the signal word CAUTION
indicates an potential hazardous situation which, if
not avoided, can lead to light or medium injuries.
A sign with the signal word NOTICE indicates
potential material damage or provides additional
information which should be observed when
operating the machine.

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Introduction
1.8 Guarantee and liability
1
1.7.2 Legend
In these manual images, symbols and abbreviations with the following meaning are used
for clarity:
1. Marks a numbered list.
a) Marks the second level of a numbered list.
• Marks a list.
`Marks the second level of a list.
The book symbol before a section of text indicates additional applicable docu-
ments.
L The information symbol before a section of text marks an additional note or an
important tip for use.
1.7.3 Figures
The figures used are examples. There may be differences between the illustrations and
the actual delivery.
1.7.4 Index of valid pages
Pages of this operating manual including the title page: 48
1.8 Guarantee and liability
The machine is covered by a guarantee of 24 months without shift limitations.

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Safety
2.1 Fundamental safety instructions
2
2Safety
2.1 Fundamental safety instructions
2.1.1 Operator‘s obligation to exercise diligence
This machine conforms to state-of-the-art technological standards and ensures a maxi-
mum level of safety.
However, this level of safety can only be attained under operating conditions if all measu-
res necessary for this have been taken. The operator‘s obligation to exercise diligence
includes planning of these measures and the inspection of their realisation.
The operator must ensure that
• the machine is only used as intended.
• the machine is only operated in faultless, functional condition and mechanical and
electrical safety devices are present.
• required personal protective clothing is provided for and used by operating, mainte-
nance and repair personnel.
• the operating manual and all other applicable documentationis maintained at all times
in legible condition and is accessible at the implementation site of the machine.
Ensure that all personnel who must execute activities tasks on the machine can
access the operating manual at all times.
• only adequately qualified and authorised personnel maintain and repair the machine.
• such personnel are instructed regularly in all questions concerning occupational
safety and environmental protection, including the operating manual and safety
instructions contained therein.
• all safety instructions and warnings affixed to the product are not removed and must
remain legible.
• national accident prevention guidelines and company-internal guidelines are complied
with.
• VDE regulations are complied with.
• the EMC legislation is complied with during installation.

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Safety
2.2 Safety equipment for the machine
2
2.1.2 Requirements to be met by personnel
It is imperative that the following safety instructions be observed during all operations
involving the machine. This ensures avoidance of life-threatening injuries, machine
damage, other material damage and environmental damage.
Personnel must ensure that
• trainees are initially permitted to only work on the machine under the supervision of an
experienced person.
• all personnel who maintain the machine read the operating manual and confirm with
their signature that they have understood the operating manual.
• unauthorised persons are not in the vicinity of the machine when tasks are being per-
formed.
• supplemental to the operating manual the operating instructions as specified in labour
protection legislation and work equipment use legislation are complied with.
• the operator or supervisory personnel are informed in the event of malfunction.
• required personal protective clothing is used.
The following work described in this operating manual should only be realised by quali-
fied personnel:
• Installation
• Commissioning
• Operating
• Maintenance
2.2 Safety equipment for the machine
There are danger signs attached to the machine. Danger signs provide information about
possible hazards, which could be caused by the machine.
Danger sign Meaning
Beware of magnetic field
ASR A1.3 Annex 1; DIN 4844-2: 2001-02 and DIN 4844-2/A1:2004-05;
92/58/EEC directive regarding safety signs
Beware of hot surface
ASR A1.3 Annex 1; DIN 4844-2: 2001-02 and DIN 4844-2/A1:2004-05

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Safety
2.2 Safety equipment for the machine
2
The operator is responsible for ensuring that a suitable safety concept is developed and
applied for the safe operation of the machine.
The operator must take all measures to protect his personnel against injury by the
machine.
These include:
• Safety housing with monitored safety door
• Emergency stop circuit
• Light barriers or switch mats
• Warning indicators
• Attach danger sign at the access point of the entire machine
L We also recommend that the danger signs shown in chapter 2.2 are attached in an
enlarged form at the access points to the protection area of the entire machine.
Danger sign Meaning
Prohibited for persons with pacemakers
ASR A1.3 Annex 1; DIN 4844-2:2001-02 and DIN 4844-2/A1:2004-05;
ISO/FDIS 7010: 2003; ISO 7010

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Safety
2.3 Residual hazards
2
2.3 Residual hazards
Strong magnetic fields
Strong magnetic fields are emitted from the permanent magnets of the secondary part.
Assembly, commissioning and maintenance only by qualified, trained and instructed
personnel.
Pacemakers and/or medical The functioning of metal implants can be compromised.
Persons with pacemakers and/or medical implants made of metal may not handle the
machine under any circumstances. Danger of severe to fatal injuries.
Objects made of magnetisable materials such as jewellery, watches or tools can be
attracted. Do not wear any magnetisable materials when handling the machine. Handle
tools carefully. Injuries caused by being pulled in.
Missing safety equipment
Operation without safety equipment is dangerous. The realisation of a suitable The
operator is responsible for the safety concept. The operator must provide for sufficient
safety measures such as protective grating, light grids, emergency stop button, covers,
warning notices, etc. Operation without safety equipment is prohibited. Injuries caused by
squeezing, impact, magnetism.
Missing danger signs
Damaged or illegible danger signs no longer fulfil their purpose. Make sure the danger
signs are complete and legible. Replace damaged danger signs.
Danger of explosion
Danger of explosion during operation in a potentially explosiveatmosphere. Operation in
a potentially explosive atmosphere is prohibited according to correct use. Only correct
use is permitted. Injuries caused by an explosion.
Incorrect spare pats / mounting of ancillary equipment
The use of incorrect spare parts orthe mounting of unauthorised ancillary equipment can
lead to subsequent damage with the risk of injury. Only use spare parts from our spare
parts list or spare parts we have approved. The mounting of ancillary equipment must be
coordinated with us. Injury of persons due to subsequent damage.
Impermissible modifications
Impermissible modifications can lead to subsequent damage with risk of injury. Modifica-
tions on the machine are prohibited. Injury of persons due to subsequent damage.
Electric shock
Power and control connections may still conduct electricity after the machine has been
deactivated and is stationary. Energised capacitors inside the servo amplifier may still be
charged, despite the power supply being deactivated. Work on electrical equipment
should only be realised by skilled electrical personnel and under observance of specifica-
tions in the electrical operating manual. Electrical connections for the machine should
onlybeloosenedorpluggedin whenthepowersupplyisdeactivatedandsecuredagainst
reactivation. The status of capacitor charging should be measured prior to working on
machine electrical equipment. The procedure for measuring charges is described in the
electrical operating manual. Touching energised components can lead to serious or even
fatal injuries.
Squeezing or pulling in
The secondary part of the machine moves at a very high speed. Extremities can be
crushed or pinched when interfering with the motion sequence. Never put hands into the
work area of the machine. Injuries caused by squeezing.

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Product description
3.1 Structure
3
3 Product description
3.1 Structure
The freely programmable, compact linear motor shaft HL consists of a primary and
secondary part. The primary part is the stable base body [A] made of steel (optionally
made of aluminium) with the electric connections. The secondary part is is the movable
guide rail [B] with the permanent magnets and the adapter plates [C].
The machine can be supplied in two installation sizes each with different stroke lengths
Each stroke length can be supplied without brake, with one brake or with two brakes.
A gripper or other epqipment can be mounted at the adapter plate [C] of the secondary
part by the operator. Mounting position is left or right.
The electric connections are made via a multi-purpose plug. One connection for a lubri-
cation unit for automatic lubrication is available (see chap. 3.6 „Lubrication“ on page 26).
Multi-purpose plug and connection for a lubrication are mounted freely accessible at the
secondary part.
An incremental magnetic length-measuring system is employed.
The reference motion involves moving towards one fixed stop of the machine.
An absolute measuring system can be optionally applied for travelling distances up to
500 mm.
The following parameters of the machine are variable:
• maximum stroke
• Design with brake/brakes
• Adaption grippers
• Measuring system
• Design of the lubrication connections
Fig. 1: General view of the linear motor shaft
A
B
C
C
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Product description
3.2 Function
3
3.2 Function
The secondary part conducts linear movements across the indicated stroke length.
The motor of the machine is controlled via servo amplifier. A high level of positional accu-
racy and repeat accuracy are achieved through the integrated measuring system.
The positional accuracy describes the acceptable tolerance of the linear unit for an ope-
rating command involving movement to a specified position. It is determined by mechani-
cal tolerances and the accuracy of the measurement system. Furthermore, the positional
accuracy is influenced by external and internal temperature changes. The specified posi-
tional accuracy is attained for temperatures within a range of +/-15°C.
The repeat accuracy describes the deviation of the linear unit, which is permissible for
the repeated movement to the same position - even after repeated switch on and off. It is
influenced by external and internal temperature changes as well as the condition of the
mechanical stops for the referencing. The specified repeat accuracy only applies at a
constant temperature of +20°C and without any external strain.
3.3 Technical data
Linear motor shaft HL50 HL100
Max. driving force 180 N 360 N
Nominal force 65 N 120 N
Max. speed 4 m/s 4 m/s
Max. acceleration 40 m/s240 m/s2
Max. payload 3,5 kg 8,0 kg
Nominal voltage 230 V 230 V
Nominal current 1 A 3 A
Peak current 2,5 A 9 A
Temperature control PTC-switch
Repeat accuracy 0,01 mm 0,01 mm
The accuracy applies at a constant ambient tem-
perature of 20 °C.
Available strokes 150 - 300 mm 150 - 300 - 450 mm
Max. surface temperature 75 °C
Max. ambient temperature depending on the load
Brake
Holding power per clamp unit 200 N
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Product description
3.3 Technical data
3
3.3.1 Measuring system
3.3.2 Scope of delivery
The scope of delivery of the machine depends on the order involved. Please refer to the
ordering information or order characteristics for individual components.
3.3.3 Sound level
The A-weighted emission sound pressure level do not exeed the allowable peak.
Linear motor shaft HL50 HL100
Incremental measuring system
Type EHP 1
Voltage supply +5 V ±5 %, 35 mA
Incremental signals sin / cos 1 Vss
Signal period 1 mm
Resolution 0,244 µm (bei 4096times-Interpolation)
Accuracy measuring system 10 µm (transmitter + tape measure) at 20 °C
Reference marks none
Measuring system absolute - BISS - C mode
Type AHP 1
Voltage supply +5 V ±5 %, 80 mA max.
Absolute signals BISS - C
Measuring length (max.) 512 mm
Resolution 19 bits
Standardisation 1024/mm
Accuracy measuring system ± 5 µm (transmitter + tape measure) at 20 °C
Measuring system absolute - BISS - C mode
Type AHP 1
Voltage supply +5 V ±5 %, 80 mA max.
Absolute signals SSI
Baud rate (adjustable) 1000 kHz; 500 kHz; 125 kHz; 62,5 kHz
Measuring length (max.) 512 mm
Resolution 19 bits
Standardisation 1024/mm
Incremental signals SIN / COS 1 Vpp
Signal period 1 mm
Accuracy measuring system ± 5 µm (transmitter + tape measure) at 20 °C
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Product description
3.3 Technical data
3
3.3.4 Type plate
The type plate is fitted to the housing of the machine and contains the details described
in the illustration.The illustrated type plate is merely an example of any machine and
is not identical to the actual type plate of the described product.
A second type plate is included in the scope of delivery. This second plate can be moun-
ted at a clearly-visible location on the machine to allow viewing of performance data if the
type plate fitted by the manufacturer is concealed by any other structures.
Fig. 2: Example of a type plate
3.3.5 Ambient conditions
Additional barcode serial number
Type
Serial Number
Stroke
Measurement system*
Year of construction
Weight
* sinus / cosinus measurement system with pole pitch of 1 mm
type
horiz.
serial
weight
encoder
year
www.weiss-gmbh.de
HLXXXXT - XX
HLXXXXXX
XX mm
sin / cos, 1
XXXX
XX kg
WEISS
Humidity 5 % to 95 %, non-condensing
Allowable temperature range Storage: +5 °C to +55 °C
Operation: +15 °C to +45 °C
Environment It is not permissible to use the machine in environ-
ments that contain abrasive dusts.
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Product description
3.3 Technical data
3
3.3.6 Installation positions
Permissible installation positions for the machine are:
• horizontal and vertical at any angles.
Fig. 3: Installation positions
At all non-horizontal installation positions an appropriate brake ap-
plication has to be privided.
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Product description
3.3 Technical data
3
3.3.7 Dimensions
3.3.7.1 Linear motor shaft HL50
Tolerance of the drill holes and pinholes: ± 0.02 mm
Measurement table:
Dimensions in mm
3,3
10
H7
79,5
x 9 tief
8,7
16,7
10
3
M6
38
31
5
13
4
H7
26
4,5
5
31,8
13
4
4,5
H7
26
52
86,3
6
46
40 40
160
x10
H7
52
66 55
A
55
L
2x6
52
H7
146
6
52
3
6
65
10
M
10
H7
3x5
H7
4,5
4
H7
4
H7
4,5
Stroke L A
at numbers holding brake
012
150 Hub + 160 Hub + 209 Hub + 258 L + 110
300
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Product description
3.3 Technical data
3
Option: Holding brake
Tolerance of the drill holes and pinholes: ± 0.02 mm
Alternative: Mounting flange wide
Tolerance of the drill holes and pinholes: ± 0.02 mm
49 49
70 80
61
70
80
61
24,3
6,6
52
12
11
6,4
81
120
H7
5
146
x
160
95
112
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Product description
3.3 Technical data
3
3.3.7.2 Linear motor shaft HL100
Tolerance of the drill holes and pinholes: ± 0.02 mm
Measurement table:
Dimensions in mm
4,5
24
24 624
24
4,5
4
H7
4,5
H7
4
4
H7
4,5
6
4
H7
140
160
76 90
10
H7
10
H7
3
6
12
6M
4x5
H7
75
111
A
65,5
L
64,5
100
120 64,5
175
39,5 39,5
65,5
40,4
8,7
38
87
3
H7
10
x9tief
16,7 18
M6
4,3
Stroke L A
at numbers holding brake
012
150 Hub + 175 Hub + 215 Hub + 255 L + 129
300
450012
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