DE-STA-CO MDE Series User manual

INSTALLATION MANUAL

MDE-SERIES INDEXDRIVES

MODELS

MDE600M

MDE700M

MDE900M

Contents

1IDENTIFICATION .............................................................................................................................................................. 3

2INSTRUCTIONS FOR USE .................................................................................................................................................. 6

3PRODUCT SAFETY ............................................................................................................................................................ 9

3.1 TRAINING OF THE PERSONNEL .............................................................................................................................................. 10

3.2 PRESENTATION OF SAFETY PRECAUTIONS................................................................................................................................ 10

3.3 SYMBOLS ON THE MACHINE ................................................................................................................................................. 11

3.4PERSONAL PROTECTIVE EQUIPMENT (PPE) ............................................................................................................................. 11

4MACHINE DESCRIPTION ................................................................................................................................................ 12

4.1 PRESENTATION AND IDENTIFICATION ..................................................................................................................................... 12

Figure 1 Unit.......................................................................................................................................................................... 12

Figure 2 Access ...................................................................................................................................................................... 12

4.2 INTENDED USE .................................................................................................................................................................. 13

4.3 FORESEEABLE IMPROPER USE ............................................................................................................................................... 14

4.4 DESIGN AND COMPONENTS OF THE MACHINE.......................................................................................................................... 15

Front and Top View ............................................................................................................................................................... 15

Section and Side View ........................................................................................................................................................... 16

Bill Of Materials .................................................................................................................................................................... 17

4.5 DESCRIPTION OF FUNCTION ................................................................................................................................................. 17

4.6 PLACES OF WORK OF THE OPERATING PERSONNEL .................................................................................................................... 17

4.7 HAZARD ZONES ................................................................................................................................................................. 18

4.8 SAFETY AND MONITORING INSTALLATIONS ............................................................................................................................. 20

4.9 WARNING DEVICES............................................................................................................................................................ 20

4.10 TECHNICAL DATA .............................................................................................................................................................. 20

Recommended Oil and Quantity ........................................................................................................................................... 21

Grease ................................................................................................................................................................................... 22

5TRANSPORT .................................................................................................................................................................. 22

5.1 TRANSPORTING MACHINE AND MACHINE PARTS..................................................................................................................... 22

5.2 UNPACKING ..................................................................................................................................................................... 23

5.3 HANDLING ....................................................................................................................................................................... 23

Markings and Weight............................................................................................................................................................ 24

Approved Transportation Equipment & Procedures ............................................................................................................. 24

Transportation Inside of Packaging ...................................................................................................................................... 24

Table 2 Approximate weights of MDE models with reducer ................................................................................................. 24

Transportation Outside of Packaging ................................................................................................................................... 25

Transportation Damage ........................................................................................................................................................ 25

Intermediate Storage ............................................................................................................................................................ 25

6INSTALLING AND COMMISSIONING .............................................................................................................................. 26

6.1 INSTALLATION AND CONNECTION.......................................................................................................................................... 26

Installation Safety Protocol ................................................................................................................................................... 26

Installation Prerequisites....................................................................................................................................................... 27

Installation of Unit ................................................................................................................................................................ 28

Installation ............................................................................................................................................................................ 28

Installing the Base Plate or Frame ........................................................................................................................................ 28

Attach Unit to Base-Plate...................................................................................................................................................... 29

Manual Adjustment of Unit................................................................................................................................................... 29

Installation of Additional Components.................................................................................................................................. 30

6.2 COMMISSIONING .............................................................................................................................................................. 31

6.3 SET-UP AND TOOLING......................................................................................................................................................... 31

Packaging Disposal ............................................................................................................................................................... 32

Recommissioning .................................................................................................................................................................. 35

7OPERATION ................................................................................................................................................................... 35

7.1 OPERATING AND DISPLAY ELEMENTS...................................................................................................................................... 35

7.2 OPERATION OF THE MACHINE .............................................................................................................................................. 36

8SERVICE AND MAINTENANCE ........................................................................................................................................ 37

8.1 CLEANING THE MACHINE..................................................................................................................................................... 38

8.2 PROCESS MEDIA ................................................................................................................... ERROR!BOOKMARK NOT DEFINED.

8.3 MAINTENANCE SCHEDULE................................................................................................................................................... 39

Gearmotor Check .................................................................................................................................................................. 41

MDE Lubrication.................................................................................................................................................................... 41

Oil Change Intervals .............................................................................................................................................................. 41

Recommended Oil and Quantity ........................................................................................................................................... 41

Grease ................................................................................................................................................................................... 42

8.4 TROUBLESHOOTING AND FAULT CORRECTION ......................................................................................................................... 42

Symptom: Indexer appears inaccurate.................................................................................................................................. 42

Symptom: Looseness in one dwell only ................................................................................................................................. 42

Symptom: Looseness in all dwells ......................................................................................................................................... 42

Symptom: Indexer is noisy..................................................................................................................................................... 43

Symptom: Premature wear of cam followers........................................................................................................................ 43

Symptom: Output movement is noisy and erratic................................................................................................................. 43

8.5 SPARE AND WEAR PARTS.................................................................................................................................................... 44

Spare Parts list ...................................................................................................................................................................... 44

Input Oil Seal Replacement Consideration ............................................................................................................................ 44

Cam Follower Replacement Consideration........................................................................................................................... 44

Input Shaft and/or Cam Replacement Consideration ........................................................................................................... 44

Follower Wheel and/or Output Bearing Replacement Consideration ................................................................................... 44

8.6 DISASSEMBLY ................................................................................................................................................................... 46

8.7 INSPECTION...................................................................................................................................................................... 46

8.8 OIL SEAL REPLACEMENT ...................................................................................................................................................... 47

Oil seal removal..................................................................................................................................................................... 47

Oil seal installation................................................................................................................................................................ 47

8.9 CAM FOLLOWER REPLACEMENT ............................................................................................................................................ 48

Cam follower cartridge removal ........................................................................................................................................... 48

Cam follower removal from cartridge ................................................................................................................................... 49

Cam follower installation into cartridge ............................................................................................................................... 49

Cam follower cartridge installation....................................................................................................................................... 50

9SHUTDOWN, STORAGE AND DISPOSAL ......................................................................................................................... 51

9.1 SHUTDOWN ..................................................................................................................................................................... 51

9.2 STORAGE CONDITIONS........................................................................................................................................................ 51

9.3 DISPOSAL......................................................................................................................................................................... 52

10. ANNEX ............................................................................................................................................................................. 53

Declaration of Incorporation................................................................................................................................................. 53

NORD DRIVESYSTEMS ........................................................................................................................................................... 54

SEW-EURODRIVE................................................................................................................................................................... 56

TL6615 EXTRACTION TOOL PAGE 1 OF 2 .............................................................................................................................. 57

TL6615 EXTRACTION TOOL PAGE 2 OF 2 .............................................................................................................................. 58

11. DECLARATION OF INCORPORTATION............................................................................................................................... 59

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:

[email protected];

Internet:

http://www.destaco.com

After-Sales Service

address:

[email protected] / [email protected]

Machine designation:

INDEX DRIVE MODEL

Type designation:

MDE-SERIES

Serial No.:

SEE NAME PLATE

Year of construction:

2015

Product No.:

SEE NAME PLATE

P.O. No.:

Order No.:

Sales:

DE-STA-CO Europe GmbH

Hiroshimastraße 2

61440 Oberursel

Germany

Manufacturer:

DE-STA-CO Camco Products

Industrial Motion Control, LLC

1444 South Wolf Road

Wheeling, IL 60090

USA

Document identification

Document

identification

Version:

1.0

Creation date:

IV 2015

Last revision:

Product Identification

Product:

Model No.:

MDE600M, MDE700M MDE900M

Serial No.:

Year of construction:

2015

Sales:

DE-STA-CO Europe GmbH

Hiroshimastraße 2

61440 Oberursel

Germany

Manufacturer:

DE-STA-CO Camco Products

Industrial Motion Control, LLC

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

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.

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.

Target groups

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.

Reorders and copyright

Reorders

and

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!

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.In addition to this operating manual, the information and tips contained in

the suppliers' documentation (see Annex) must also be observed!

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