INSTALLATION MANUAL HDE-SERIES INDEX DRIVES MODELS HDE1200M . - Comoso
INSTALLATION MANUAL HDE-SERIES INDEX DRIVES MODELS HDE1200M INDEXER HDE1200S SERVO www.comoso.com
Contents 1 IDENTIFICATION . 3 2 INSTRUCTIONS FOR USE . 5 3 PRODUCT SAFETY . 7 3.1 3.2 3.3 3.4 4 TRAINING OF THE PERSONNEL . 8 PRESENTATION OF SAFETY PRECAUTIONS . 9 SYMBOLS ON THE MACHINE . 9 PERSONAL PROTECTIVE EQUIPMENT (PPE) . 9 MACHINE DESCRIPTION . 10 4.1 PRESENTATION AND IDENTIFICATION . 10 . 11 Figure 1 Unit . 11 Figure 2 Access . 11 4.2 INTENDED USE . 12 4.3 FORESEEABLE IMPROPER USE . 13 4.4 DESIGN AND COMPONENTS OF THE MACHINE . 14 HDE Mechanical . 14 4.5 DESCRIPTION OF FUNCTION . 15 4.6 PLACES OF WORK OF THE OPERATING PERSONNEL . 15 4.7 HAZARD ZONES . 16 4.8 TECHNICAL DATA . 18 Recommended Oil and Quantity . 19 Grease . 19 5 TRANSPORT . 20 5.1 TRANSPORTING MACHINE AND MACHINE PARTS. 20 5.2 UNPACKING . 21 5.3 HANDLING . 22 Markings and Weight. 22 Approved Transportation Equipment & Procedures . 22 Transportation Inside of Packaging . 22 Table 2 Approximate weights of HDE models with reducer . 23 Transportation Outside of Packaging . 23 Transportation Damage . 23 Intermediate Storage . 24 6 INSTALLING AND COMMISSIONING . 24 6.1 INSTALLATION AND CONNECTION . 25 Installation Safety Protocol . 25 Installation Prerequisites . 26 Installation of Unit . 27 Installation . 27 Installation of Additional Components . 29 6.2 COMMISSIONING . 30 6.3 SET-UP AND TOOLING. 30 Packaging Disposal . 30 Recommissioning . 33 7 OPERATION . 33 7.1 OPERATING AND DISPLAY ELEMENTS. 33 1 www.comoso.com
7.2 8 OPERATION OF THE MACHINE . 34 SERVICE AND MAINTENANCE . 35 8.1 CLEANING THE MACHINE . 35 8.2 MAINTENANCE SCHEDULE . 36 Gearmotor Check . 39 HDE Lubrication. 39 Oil Change Intervals . 39 Recommended Oil and Quantity . 39 Grease . 40 8.3 MALFUNCTIONS . 40 Symptom: Indexer appears inaccurate. 40 Symptom: Looseness in one dwell only . 40 Symptom: Looseness in all dwells . 40 Symptom: Indexer is noisy . 40 Symptom: Premature wear of cam followers. 41 Symptom: Output movement is noisy and erratic . 41 8.4 SPARE AND WEAR PARTS . 41 Input Oil Seal Replacement Consideration . 41 Cam Follower Replacement Consideration . 41 Input Shaft and/or Cam Replacement Consideration . 41 Follower Wheel and/or Output Bearing Replacement Consideration . 41 8.5 DISASSEMBLY . 42 8.6 INSPECTION . 43 8.7 OIL SEAL REPLACEMENT . 44 Oil seal removal . 44 Oil seal installation . 44 8.8 CAM FOLLOWER REPLACEMENT . 45 Cam follower removal . 45 Cam follower insertion . 46 9 SHUTDOWN, STORAGE AND DISPOSAL . 48 9.1 9.2 9.3 SHUTDOWN . 48 STORAGE CONDITIONS . 48 DISPOSAL. 49 10. ANNEX . 50 Declaration of Incorporation . 50 NORD DRIVESYSTEMS . 51 SEW-EURODRIVE . 53 11. DECLARATION OF INCORPORTATION . 54 2 www.comoso.com
1 Identification Product identification Product identification Manufacturer: DE-STA-CO CAMCO PRODUCTS Street: 1444 SOUTH WOLF ROAD City: WHEELING, ILLINOIS 60090 USA Tel.: 1-847-459-5200 Fax: 1-847-459-3064 E-mail: marketing@destaco.com; Internet: http://www.destaco.com After-Sales Service address: camco@destaco.com Machine designation: INDEX DRIVE MODEL Type designation: HDE-SERIES Serial No.: SEE NAME PLATE Year of construction: 2015 Product No.: SEE NAME PLATE / europe@destaco.com P.O. No.: Order No.: DE-STA-CO Europe GmbH Sales: Hiroshimastraße 2 61440 Oberursel Germany DE-STA-CO Camco Products Manufacturer: Industrial Motion Control, LLC 1444 South Wolf Road Wheeling, IL 60090 USA 3 www.comoso.com
Document identification Document identification Version: 1.0 Creation date: IV 2015 Last revision: NA Product Identification Product: HDE1200M HDE1200S Model No.: Serial No.: 2015 Year of construction: DE-STA-CO Europe GmbH Hiroshimastraße 2 Sales: 61440 Oberursel Germany DE-STA-CO Camco Products Industrial Motion Control, LLC Manufacturer: 1444 South Wolf Road Wheeling, IL 60090 USA 2.1 Justification for classification in accordance with the Machinery Directive The products from the Automation division are divided into the following classes: Index drive models. In accordance with the Machinery Directive 2006/42/EC, the above-mentioned products are classified as incomplete machines according to Article 2g). This results in the necessity to produce the technical documentation in accordance with Annex VII B and the declaration of incorporation in accordance with Annex II B. Justification for classification as an incomplete machine: The machine as such does not fulfil a particular function. The pneumatic/hydraulic/electric control system is not included in the scope of supply. The machine is intended for incorporation into other machines or to be assembled with them. There are no elementary protection devices at the man-machine interface 4 www.comoso.com
2 Instructions for Use Purpose of the document Purpose of the document The operating manual is intended to help the user familiarise himself with the machine and its intended application possibilities. The operating manual contains important information on the safe, proper and profitable operation of the machine. Observation of this information will help avoid hazards, reduce repair costs and standstill times and increase the reliability and service life of the machine. Notes on precautionary measures to be taken by the machine owner: Employ only personnel with the necessary qualification for the work in hand to operate the machine. Define clear responsibilities and authorities for the operating and maintenance personnel. Supplement the operating manual with rules derived from the national occupational health and safety and environmental protection regulations (e.g. work organisation). Instruct the personnel to observe the operating manual and its additions, and check compliance from time to time. Have one copy of the operating manual available at the place of operation of the machine at all times! Operate the machine only when it is in a technically safe condition, and take measures to maintain this safety. In addition to the operating manual, the binding accident prevention regulations applicable in the country of operation and at the place of work must also be observed. In addition, the acknowledged engineering rules for safe and proper working must be observed. 5 www.comoso.com
Target groups Target groups a) The owner as superordinate legal entity is responsible for the intended use of the machine and for the training and employment of the authorised persons. He lays down the binding competencies and authorities of the authorised persons for his company. b) According to the latest Machinery Directive, the operating personnel are the persons responsible for installation, operation, set-up, maintenance, cleaning, repair or transport of machines. c) A specialist is a person who thanks to his technical training, know-how and experience is able to assess the assigned duties and to recognise potential hazards. Furthermore, this person has know-how of the applicable regulations. Only qualified specialists or such persons considered by the owner to be capable are to be employed. d) Trained/instructed persons are persons who have been instructed and possibly trained in the assigned duty and in the potential dangers associated with improper behaviour. The person has also been instructed about the necessary protective devices and safety measures. Persons undergoing training, instruction or familiarisation and persons undergoing general training may only work under the constant supervision of an experienced person. Liability and warranty Liability and warranty All information and tips given in this operating manual are given to the best of our knowledge and belief and on the basis of our experience and findings to date. The original version of this operating manual was drawn up in English and was examined technically by us. The translation in the respective national/contract language was produced by an acknowledged translation agency. This operating manual was compiled with the greatest care. Should you discover any gaps and/or errors, however, please inform us accordingly in writing. Your suggestions for improvements will help us in producing a user-friendly operating manual. 6 www.comoso.com
Target groups Reorders and copyright Reorders and copyright Further copies of this operating manual can be ordered from the address shown under "Identification" in chapter 1. Please note that further copies are subject to payment. All rights are expressly reserved. Duplication or notification to third parties in whatever form is not permitted without our written approval. 3 Product Safety A basic precondition for the safe handling and trouble-free operation of this machine is thorough knowledge of the fundamental safety precautions. Organisational measures Keep the operating manual available at the place of operation of the machine and in a legible condition at all times! a) Supplement the operating manual to include provisions to cover specific company aspects (e.g. supervisory and reporting obligations, work organisation, work processes, personnel employed, and fire alarm and firefighting possibilities, operation of fire extinguishers). b) Supplement the operating manual to include binding local provisions on accident prevention and environmental protection (e.g. handling of hazardous substances, disposal of operating and/or ancillary media, provision/wearing of personal protective equipment)! c) Instruct all personnel to observe the operating manual! d) If the personnel discovers faults or hazards, the owner or his representative must be informed immediately. Technically safe condition a) Keep all safety and hazard signs on and around the machine complete and in a legible condition! 7 www.comoso.com
b) Do not make any modifications, attachments or alternations to the machine that could impair safety without consultation/agreement with the manufacturer/supplier. This applies also to the installation and setting of safety devices and valves, and for welding on load-bearing parts. c) Do not make any program changes to the software of programmed control systems! Major modifications to the machine and/or program changes may invalidate the EC Declaration of Conformity! d) Observe intervals prescribed by law or in the operating manual for recurring tests/inspections and the replacement intervals for safety-critical components! e) Spare parts must satisfy the technical requirements stipulated by the manufacturer. This is always guaranteed with OEM spare parts. f) Be sure to have appropriate workshop equipment available for carrying out independent service and maintenance work. g) In addition to this operating manual, the information and tips contained in the suppliers' documentation (see Annex) must also be observed! 3.1 Training of the personnel Training of the personnel Personnel selection and qualification a) Work on and with the machine may only be carried out by reliable personnel. Observe the statutory minimum working age! b) Employ only qualified or at least trained personnel. Give the necessary instructions and check from time to time that only authorised personnel are working on/with the machine! c) Clearly define the responsibilities and authorities of the personnel for operation, set-up, maintenance and repair! d) Allow persons undergoing training, instruction or an apprenticeship to work on the machine only under the supervision of an experienced person. e) Work on the electrical equipment of the machine may only be carried out by an electrician or by trained persons under the instruction and supervision of an electrician. For safety reasons, the rules of electrical engineering must be observed. f) Work on gas and heating installations may only be carried out by appropriately qualified personnel. g) Only experienced and qualified personnel may be allowed to work on hydraulic and pneumatic installations! 8 www.comoso.com
Training of the personnel 3.2 Presentation of safety precautions HAZARD SYMBOLS SYMBOL DEFINITION Indicates a hazardous situation which, if not avoided, will result in death or serious injury. Indicates a hazardous situation which, if not avoided, could result in death or serious injury. Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. Indicates a situation which, if not avoided, could result in damage to the unit, equipment, or environment. Adhere to subsequent SAFETY PROTOCOLS throughout this document, and observe all HAZARD SYMBOLS. 3.3 Symbols on the machine Symbols on the machine Electric shock hazard 3.4 Personal protective equipment (PPE) Personal protective equipment (PPE) The personal protective equipment (PPE) described below must be provided by the machine owner and be worn by the responsible operating personnel when working with the machine. 9 www.comoso.com
Personal protective equipment (PPE) Wear protective gloves Wear safety shoes Wear ear protectors Wear a safety helmet 4 Machine Description 4.1 Presentation and identification 10 www.comoso.com
Presentation and identification General view of the machine 02 The unit consists of the following main components 01. Housing: Machined Housing Weldment, Cover Plate 02. Output Assembly: FollowerWheel, Dial Plate, Output bearing 03. Input Assembly: Cam, CamShaft, Reducer Mounting plate, Gear motor with brake. 01 03 Figure 1 Unit Center-Bore: Allows passage of wires, robotics and various tooling through unit. 02. Allows for cam follower removal access 01. 01 02 Figure 2 Access Identification of the machine 11 www.comoso.com
Presentation and identification The following information can be found on the machine rating plate: HDE1200M-A-ND1-B-D-1-F CODE HDE 1200 M A ND1A B D 1 F NAME MODEL FAMILY MODEL DIAL SIZE MODEL TYPE MODEL MOTION MODEL GEAR-MOTOR GEAR-MOTOR RATIO GEAR-MOTOR BRAKE GEAR-MOTOR MOUNT SIDE MODEL SENSOR OPTION Company name with full address DE-STA-CO CAMCO PRODUCTS 1444 SOUTH WOLF ROAD WHEELING, ILLINOIS 60090 USA Article No.: HDE1200M, HDE1200S Year of construction: 2015 4.2 Intended use Intended use The machine has been built within the battery limits to the state-of-the-art and in accordance with the acknowledged general safety engineering rules. Nevertheless hazards can arise during its use for the life and limb of the operator or third parties and for impairment to the machine and other assets. The machine may only be operated for its intended when it is in a technically safe condition, giving consideration to safety and the potential hazards, in accordance with the operating manual! Have all malfunctions remedied immediately, in particular those which could impair safety. The machine is intended exclusively for the purpose described in chapter 4.5 "Description of function". Any other or further use constitutes an improper use. The 12 www.comoso.com
Intended use manufacturer/supplier assumes no liability for injury or damage resulting from such use. This risk must be borne solely by the owner. The intended use also includes observance of the operating manual and compliance with the inspection and maintenance conditions. 4.3 Foreseeable improper use Foreseeable improper use Any use, setting, application or alteration of the unit beyond the stated terms in section 4.5 is defined as improper and prohibited. 13 www.comoso.com
4.4 Design and components of the machine HDE Mechanical 14 www.comoso.com
HDE Bill Of Materials ITEM NO. 1 2 3 5 6 7 8 9 11 19 20 21 22 25 36 37 38 39 DESCRIPTION QTY. HDE BASE HDE OUTPUT BEARING HDE TOP PLATE CAM FOLLOWERS HDE INDEX RING HDE CAM BOX HDE COVER , CAM BOX SHAFT INP CAM OIL SEAL DRAIN PLUG SIGHT GLASS BREATHER COVER, CAM FOLLOWER REMOVAL KEY ( PROXIMITY SENSOR) SET SCREW BRACKET PROXIMITY SWITCH PROXIMITY SWITCH 1 1 1 V 1 1 1 1 1 2 1 1 1 1 1 1 1 1 Design and components of the machine 4.5 Description of function The Mechanical HDE Series Indexer is a pre-loaded-right-angle indexing table designed to precisely move heavy loads at a predetermined number of stations with zero-backlash. This machine is exactly defined as incompleted machinery that has no specific function / output until incorporated into a complete machine Description of function 4.6 Places of work of the operating personnel The Mechanical HDE Series Indexer is designed for integration into complete machines. Safe operation and control are the responsibility of the machine builder and the machine operator. 15 www.comoso.com Places of work of the operating personnel
4.7 Hazard zones Hazard zones Hazardous zones of the machine may only be entered by designated and authorised persons! If several persons are working on the machine, good cooperation and close coordination of the activities is necessary. Electrical energy a) Use only original fuses with the prescribed amperage! In the event of faults in the electric power supply, switch off the machine immediately! b) Work on electrical installations or equipment may only be carried out by an electrician or by trained persons under the instruction and supervision of an electrician. c) Parts of machines and installations on which inspection, maintenance and repair work is being carried out on the electrical equipment must – if prescribed – be isolated and secured to prevent restarting. First check that the isolated parts are no longer live, then earth and short-circuit and isolate adjacent live parts d) The electrical equipment of the machine must be inspected and checked at regular intervals. Faults such as loose connections or scorched cables must be remedied immediately. e) If work is necessary on live parts, have a second person standing by who can turn off the master switch or emergency stop switch in the event of an emergency. Cordon off
installation manual hde-series index drives models hde1200m indexer hde1200s servo www.comoso.com
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