WEISS ST Series User guide

ASSEMBLY AND INSTRUCTIONS MANUAL
HIGH TORQUE ROTARY UNIT
Mechanical system documentation
980-209018000 / EN 04-2014
ST
High Torque Rotary Units ST0055 - ST0075 - ST0140

Document: Assembly and instruction manual
Document version: Mechanical system documentation
Valid for: High Torque Rotary Unit
Type: ST0055 - ST0140
Revision R04-2014
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 WEISS GmbH. This document may not be copied or reproduced,
in whole or in part, without the written permission of WEISS GmbH. Thisdocument is only intendedfor 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
15.04.2014 R04 -2014 3 Supplement

High Torque Rotary Unit • ST0055 - ST0140 • R04-2014 3/42
Table of contents
1. Introduction ........................................................................................................... 5
1.1. Definition ..................................................................................................... 5
1.2. Intended use ................................................................................................ 5
1.3. Non-intended use ........................................................................................ 5
1.4. Laws / EC Directives / Standards .............................................................. 5
1.5. Assembly and instructions manual .......................................................... 6
1.5.1. Explanation of safety instructions in this manual .......................................... 6
1.5.2. Legend .......................................................................................................... 7
1.5.3. Figures .......................................................................................................... 7
1.5.4. Directory of valid pages ................................................................................ 7
1.6. Further applicable documents ................................................................... 7
1.7. Warranty and liability .................................................................................. 7
2. Safety ..................................................................................................................... 8
2.1. Fundamental safety instructions ............................................................... 8
2.1.1. Operator‘s obligation to exercise diligence ................................................... 8
2.1.2. Requirements to be met by personnel .......................................................... 9
2.2. Safety equipment for the machine ............................................................ 9
2.3. Residual hazards ...................................................................................... 10
3. Product description ............................................................................................ 11
3.1. Structure .................................................................................................... 11
3.2. Function ..................................................................................................... 12
3.3. Technical data ........................................................................................... 12
3.3.1. Scope of delivery ........................................................................................ 13
3.3.2. Sound level ................................................................................................. 13
3.3.3. Type plate ................................................................................................... 13
3.3.4. Ambient conditions ...................................................................................... 13
3.3.5. Installation positions .................................................................................... 14
3.3.6. Dimensions ................................................................................................. 15
3.4. Electrical connections .............................................................................. 18
3.4.1. Plug-in connections ..................................................................................... 18
3.4.2. Connector pin assignment .......................................................................... 19
4. Transport ............................................................................................................. 25
4.1. Transport damage ..................................................................................... 25
4.2. Intermediate storage ................................................................................. 25
5. Installation ........................................................................................................... 26
5.1. Safety during installation ......................................................................... 26
5.2. Installation prerequisites ......................................................................... 26
5.2.1. Installation preparation ................................................................................ 26
5.2.2. Operating media / Auxiliary media / Tools .................................................. 26
5.3. Assemble machine ................................................................................... 27
5.3.1. Installation of additional components .......................................................... 27
5.4. Installing the safety equipment ............................................................... 27
5.5. Instructions on disposal of packaging material .................................... 27

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6. Commissioning ................................................................................................... 28
6.1. Safety during commissioning .................................................................. 28
6.2. Initial commissioning ............................................................................... 29
6.3. Recommissioning ..................................................................................... 29
7. Operation ............................................................................................................. 30
7.1. Safety during operation ............................................................................ 30
7.2. Operating the machine ............................................................................. 30
7.3. Operating personnel workstations .......................................................... 30
8. Malfunctions ........................................................................................................ 31
8.1. Safety when remedying malfunctions .................................................... 31
8.2. Errors / Cause / Remedy .......................................................................... 31
8.3. Customer Service ..................................................................................... 31
9. Maintenance ........................................................................................................ 32
9.1. Safety during maintenance ...................................................................... 32
9.2. Maintenance work ..................................................................................... 33
9.3. Inspections ................................................................................................ 33
9.3.1. Conducting a six-monthly visual inspection ................................................ 33
9.4. Maintenance .............................................................................................. 33
9.5. Repair ......................................................................................................... 33
10. Decommissioning / Dismantling / Disposal ...................................................... 34
10.1. Safety during decommissioning and dismantling ................................. 34
10.2. Decommissioning ..................................................................................... 34
10.2.1.Temporary decommissioning ..................................................................... 34
10.2.2.Ultimate decommissioning ......................................................................... 34
10.3. Dismantling and disposal ........................................................................ 35
10.3.1.Disposal of components ............................................................................. 35
11. Service and spare parts ...................................................................................... 36
11.1. Ordering spare parts ................................................................................ 36
12. Appendix .............................................................................................................. 37
12.1. Illustration index ....................................................................................... 37
12.2. Index ........................................................................................................... 38
12.3. Personal notes .......................................................................................... 40

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Introduction
1.1 Definition
1
1Introduction
1.1 Definition
The High Torque Rotary Units ST0055, ST0075 and ST0140 are modules with a direct
engine (ST0055 with gear) and absolute rotary encoder for fast, precise and highly dyna-
mic rotary, pivot and gripping movements.
The High Torque Rotary Unit is referred to as machine in the following text of this
operating manual.
1.2 Intended use
The machine is an incomplete machine in terms of Directive 2006/42/EC,
Article1gand2g.
The machine is designed for integration into other machines, into other incomplete
machines or equipment or for connection to them.
It may only be used within the limitations defined in the order characteristics.
Commissioning is prohibited until it has been established that the machine into which the
aforementioned product should be installed is conform with Directive 2006/42/EC and all
other applicable directives governing its use.
Intended use also requires the observance of the included documention and compliance
with the maintenance provisions.
1.3 Non-intended use
Any use of the machine other than intended is considered non-intended use and is not
permitted.
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 that contain swarf.
1.4 Laws / EC Directives / Standards
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 Assembly and instructions manual
1
1.5 Assembly and instructions manual
In the following text of the document, the Assembly and instruction manual will be
referred to as manual.
We reserve the right to undertake modifications because of technical developments to
the data and illustrations contained in these instructions.
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 observed.
This manual describes handling of the assembly and contains important instructions and
information to assist you in using the assembly.
This manual is intended for trained technical personnel or persons who have been
instructed.
Safety instructions in individual chapters should be observed.
1.5.1 Explanation of safety instructions in this manual
This manual contains instructions that 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 which may result from failure to observe 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:
DANGER
A warning triangle with the signal word DANGER
indicates an immediate hazardous situation, which, if
not avoided, will lead to fatalities or severe injuries.
WARNING
A warning triangle with the signal word WARNING
indicates a potential hazardous situation, which, if not
avoided, can lead to fatalities or severe injuries.
CAUTION
A warning triangle with the signal word CAUTION
indicates a potential hazardous situation, which, if not
avoided, can lead to light or medium injuries.
NOTICE
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
1.6 Further applicable documents
1
1.5.2 Legend
Symbols and abbreviations with the following meaning are used in this manual to make
its content more clear:
1. Indicates a numbered list.
a) Indicates the second level of a numbered list.
•Indicates a list.
`Indicates the second level of a list.
The book symbol before a section of text indicates further applicable documents.
LThe information symbol before a section of text indicates an additional note or an
important tip for use.
1.5.3 Figures
The figures shown are examples. There may be differences between the illustrations and
the actual delivery.
1.5.4 Directory of valid pages
Pages of this manual including the title page: 42
1.6 Further applicable documents
In addition to this manual, further documents are required to ensure safe operation of this
machine. The specifications stated in these documents must to be observed.
For control system by WEISS-GmbH:
•Operating manual WAS.indexer Control ST0055 - ST0140
•Operating manual WAS.handling Windows programme
1.7 Warranty and liability
The machine is covered by a guarantee of 24 months from the date of delivery without
shift limitations.

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Safety
2.1 Fundamental safety instructions
2
2 Safety
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 documentation is maintained at all times
in legible condition and is accessible at the implementation site of the machine.
Ensure that all personnel who has to 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.
The 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:
•Transport
•Installation
•Commissioning
•Maintenance
2.2 Safety equipment for the machine
The operating company is responsible for ensuring that a suitable safety concept is
developed and applied for the safe operation of the machine.
The operating company 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 signs

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Safety
2.3 Residual hazards
2
2.3 Residual hazards
WARNING
Missing safety equipment
Operation without safety installations is dangerous. The operator is responsible for the
realisation of a suitable 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 squee-
zing or pulling in.
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 explosive atmosphere. 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 drive 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
onlybeloosenedorpluggedinwhenthe powersupplyisdeactivatedandsecuredagainst
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 rotary disc of the machine turns 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 optionally programmable, highly dynamic High Torque Rotary Unit consists of a solid
base body made of aluminium with the electrical connections and the rotary disc.
The machine can be certified for sterile room usage.
Every machine can be delivered in different sizes and lengths.
The existing holes in the base body allow versatile options of fixing.
Operator installations can be fixed on the rotary disc.
The electric connections are made via plug-in connections.
A absolute measuring system is used as a measuring system. The measuring system
used depends on the order.
The following parameters of the machine are variable:
•size
•length
•rotary encoder
•holding brake
Fig. 1: General view of the rotary unit
ST0075 ST0140ST0055

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Product description
3.2 Function
3
3.2 Function
The engine is controlled via a servo drive and turns, accelerates or delays the rotary disc
of the machine. The rotary disc can be operated left-running, right-running or oscillating.
A high level of positional accuracy and repeat accuracy are achieved through the integra-
ted measuring system.
In stillstand, the rotary disc can be held in its position with the optional holding brake. The
brake force is created with springs. The brake is lifted by electromagnetic control and clo-
ses automatically if the voltage is turned off or in case of power outage.
The High Torque ST0055 rotary unit does not have a brake. No optional brake is
available.
The High Torque ST0075 and ST0140 rotary units can optionally be supplied with an
electric holding brake.
The High Torque ST0055 rotary unit is equipped with a gearbox.
The High Torque ST0075 and ST0140 rotary units are equipped with a direct drive.
3.3 Technical data
High Torque Rotary Unit ST055 ST075-1 ST075-2 ST075-3 ST140-1 ST140-2
Gear reduction ratio i = 63 -- -- -- -- --
Nominal torque 18 Nm 0,5 Nm 1,0 Nm 1,4 Nm 7,5 Nm 15 Nm
max. Torque 36 Nm 1,4 Nm 2,8 Nm 4,2 Nm 18 Nm 36 Nm
max. speed 5000/min 1000/min 600/min 600/min 600/min 600/min
Nominal voltage 200 VAC 230 VAC 230 VAC 230 VAC 230 VAC 230 VAC
Nominal current 0,68 A 0,5 A 0,6 A 0,7 A 1,9 A 3,1 A
Peak current 0,7 A 1,6 A 1,9 A 2,2 A 5,6 A 7,5 A
Holding torque of the
brake -- Nm 0,5 Nm 0,5 Nm 0,5 Nm 15 Nm 15 Nm
Temperature monitoring PTC*
* ST0055 with PTC single, 60 Ohm cold, > 1kOhm at 120 °C
* ST0075 and ST0140 with PTC triple, 180 Ohm cold, > 1kOhm at 120 °C
Heat class F
Heat class of the isolation system according to EN600341
Concentricity 0,04 mm 0,01 mm 0,01 mm 0,01 mm 0,01 mm 0,01 mm
Axial run-out 0,02 mm 0,01 mm 0,01 mm 0,01 mm 0,01 mm 0,01 mm
Weight 1,06 kg 1,6 kg 2,1 kg 2,6 kg 6,9 kg 8,6 kg
Weight with standard encoder and without brake
Measuring system Interface Sick-Stegmann Hyperface
Type SEL37 SEK52
SKM36 SEK90
Precision ± 270" ± 280"
± 120"; SIL 2 ± 130"
Measuring system Interface Heidenhain EnDat
Type -- ECN413
ECN413 ECN113 ECN225
Precision -- ± 60"; 512 lines
± 20"; 2048 lines ± 20" ± 10"

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Product description
3.3 Technical data
3
3.3.1 Scope of delivery
The scope of delivery of the machine depends on the order involved. Please refer to the
order information or order specifications for individual components.
3.3.2 Sound level
The A-weighted emission sound pressure level does not exeed the allowable peak.
3.3.3 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 only an example of amachine and is not
identical to the actual type plate of the described product.
A second type plate is included in the scope of delivery. The 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
3.3.4 Ambient conditions
Additional barcode serial number
Type
Serial Number
Motor speed
Nominal torque
Rotary encoder
Year of construction
Weight
www.weiss-gmbh.de
WEISS
type
motor
serial
weight
motor
year
STXXXXXX - X
STXXXXXX
XXXXXXX
XX kg
XXXX
encoder
XXX UPM
X,X Nm
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
3.3.5 Installation positions
Permissible installation positions for the machine are:
•horizontal and vertical at any angles.
Fig. 3: Installation positions

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Product description
3.3 Technical data
3
3.3.6 Dimensions
3.3.6.1 High Torque Rotary Unit ST55
Measurement table: Dimensions in mm
ST A Sick Stegmann
SEL37
55 109

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Product description
3.3 Technical data
3
3.3.6.2 High Torque Rotary Unit ST75
Measurement table: Dimensions in mm
ST
A
Sick Stegmann Heidenhain
SEK52 SKM36 ECN413
with holding brake with holding brake with holding brake
75-1 111 150 123 165 143 180
75-2 131 170 143 185 163 200
75-3 151 190 163 205 183 220
X = Option with flange
Y = Trough hole only when encoder SEK52. Installation of other encoders with centred fastening screw .
7
(SEK52)
(SEK52)
40,7
40,7
4,5
4,5
10,5
10,5
5,1
5,1
10
10
H7
H7
x2,6
x2,6
M6
M6
27,8
27,8
20,7
20,7
74
74 -
0,1
0,1
0
4x M5x8
4x M5x8
8
8
H7
H7
x2,6
x2,6
50 ±0,01
50 ±0,01
25,2
25,2
±0,1
±0,1
49,20
49,20
±0,01
±0,01
73,2
73,2
±0,1
±0,1
A
4x
4x
6
H7
H7
x5
x5
8x M5x6,5
8x M5x6,5
12
12
38
38
75
75
75
75
19,3
19,3
61 ±0,01
61 ±0,01
61 ±0,01
61 ±0,01
LK
LK
30
30
±0,1
±0,1
Lk
Lk
55
55
±0,01
±0,01
4x M5x8
4x M5x8
50 ±0,01
50 ±0,01
8
8
H7
H7
x2,6
x2,6
0
25,2
25,2
±0,1
±0,1
49,20
49,20
±0,01
±0,01
73,2
73,2
±0,1
±0,1
100
100
100
100
2x
2x
5
H7
H7
13
13
60 ±0,01
60 ±0,01
80 ±0,1
80 ±0,1
80 ±0,1
80 ±0,1
90 ±0,01
90 ±0,01
10
10
-
0,05
0,05 0
11
11
6,6
6,6
6,4
6,4
21,2
21,2
X
Y

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Product description
3.3 Technical data
3
3.3.6.3 High Torque Rotary Unit ST140
Measurement table: Dimensions in mm
ST
A
Sick Stegmann Heidenhain
SEK90 ECN113 ECN225
with holding brake with holding brake with holding brake
140-1 137 196,8 168 224 168 224
140-2 164,5 224,3 195,5 251,5 195,5 251,5
8x 14
H7
x5+0,1 8x M10x18
70 ±0,01
B
0
32,50 ±0,01
92,50 ±0,01
140
-
0
0,1
70 ±0,01
0
32,50 ±0,01
92,50 ±0,01
A
140
140
2x
6
H7
x10
6x M8x10
76
25,6
120 ±0,01
120 ±0,01
50
Lk 90 ±0,01
60°
30°
28 4x 14
H7
4x M10
20
5
+
0,1 0
4x M10
15
4x 15
32,5

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Product description
3.4 Electrical connections
3
3.4 Electrical connections
The servo drive and the ready-made electric cables are included in delivery when the
machine is supplied with the electrical package.
3.4.1 Plug-in connections
The multi-purpose plug for motor cable [A] and measuring system [B] are mounted in an
easily accessible and rotatable manner on the casing of the machine on the High Torque
Rotary Units ST55 and ST75.
The plugs for motor cable [A] and measuring system [B] are mounted in an easily acces-
sible manner on the casing of the machine on the High Torque Rotary Unit ST140.
Fig. 4: Plug-in connections
ST75 ST140
A
B
A
B
ST55
A
B

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Product description
3.4 Electrical connections
3
3.4.2 Connector pin assignment
3.4.2.1 ST55: Connection motor
⇐ to the drive Pin assignment
InterContec yTec - 9-pin EEDA101MR04000001000
4
1
2
3
5
A
B
C
-
U
V
W
T -
B +
T +
B -
n.c
3
4
C
2
1
B
5A
E
A
A
B

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Product description
3.4 Electrical connections
3
3.4.2.2 ST55: Connection encoder
⇐ to the drive Pin assignment
InterContec yTec - 12-pin EEDA101MR04000001000
10
7
12
8
4
1
9
2
3
5
6
11
GND
+ 7...12V
+ SIN
+ COS
REFSIN
n.c
REFCOS
n.c
Data +
Data -
1
2
3
4
678
5
10
11
12
9
E
n.c
n.c
B
A
B