Bosch Rexroth VarioFlow plus Assembly Instructions Manual
  1. Manuals
  2. Brands
  3. Bosch Manuals
  4. Accessories
  5. Rexroth VarioFlow plus
  6. Assembly instructions manual

Bosch Rexroth VarioFlow plus Assembly Instructions Manual

Chain conveyor system
Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
Chain conveyor system
VarioFlow plus
Modules
Valid for the following types:
3 842 998 291 + ...742
3 842 998 776
3 842 546 120 – ...125
3 842 547 380 + ...381
3 842 547 516 – ...531
3 842 547 712 + ...713
3 842 549 023 – ...026
3 842 552 940 – ...942
3 842 552 984 + ...985
3 842 553 914 + ...915
Assembly instructions
3 842 549 802/2016-04
Replaces: 2014-05
ENGLISH

Advertisement

Table of Contents
loading

Related Manuals for Bosch Rexroth VarioFlow plus

Summary of Contents for Bosch Rexroth VarioFlow plus

  • Page 1 Chain conveyor system VarioFlow plus Modules Valid for the following types: 3 842 998 291 + …742 3 842 547 712 + …713 3 842 998 776 3 842 549 023 – …026 3 842 546 120 – …125 3 842 552 940 – …942 3 842 547 380 + …381 3 842 552 984 + …985 Assembly instructions...
  • Page 2 Our products are subject to a natural process of wear and aging. © All rights reserved by Bosch Rexroth AG, including for the registration of industrial property rights. This document may not be reproduced or distributed to third parties without our consent.

  • Page 3: Table Of Contents

    Horizontal roller curve in base unit / return unit Vertical sliding curve, VF 65 / VF 90 / VF 120 Vertical sliding curve, VF 160 / VF 240 / VF 320 3 842 549 802/2016-04, MIT: VarioFlow plus, Bosch Rexroth AG...
  • Page 4 Opening (shortening) conveyor chain, VF 160 / VF 240 / VF 320 7.5.6 Connection kit Passive connection kit Active connection kit Active connection kit, machine connection 7.5.7 Lateral guide Installing lateral guide Lateral guide accessories Bosch Rexroth AG, MIT: VarioFlow plus, 3 842 549 802/2016-04...
  • Page 5 Slide rails Drive gears 10.5 Spare parts Decommissioning Disassembly and replacement 12.1 Preparing the product for storage/later use Disposal Upgrading and modifi cation Troubleshooting and repair Technical data 16.1 Ambient conditions 3 842 549 802/2016-04, MIT: VarioFlow plus, Bosch Rexroth AG...

  • Page 6: About This Documentation

    Section 3 “General Information on Property and Product Damage”, as well as before any sequence of actions or any required action which involves a risk of personal injury or property damage. Be sure to observe all safety precautions. Bosch Rexroth AG, MIT: VarioFlow plus, 3 842 549 802/2016-04...

  • Page 7: Symbols

    If this information is not heeded, the product cannot be used and/ or operated as designed.  Single, isolated step Numbered steps: The numbers indicate that the steps must be performed in sequence. 3 842 549 802/2016-04, MIT: VarioFlow plus, Bosch Rexroth AG...

  • Page 8: Safety Instructions

    Any use other than that described as intended use is considered to be improper, and therefore not permitted. Bosch Rexroth AG is not liable for any loss or damage resulting from improper use. The user alone bears any risks associated with improper use.

  • Page 9: General Safety Information

    • in particular, fully understanding the interrelationships between the safety equipment, and • having a knowledge of the function and design of pneumatic components. Bosch Rexroth offers measures to support training in specifi c areas. You can fi nd an overview of the training content online at: http://www.boschrexroth.de/didactic 2.5 General safety information...
  • Page 10 Secure the system against being switched back on. • Dispose of the product in accordance with the applicable national regulations in During disposal your country. Bosch Rexroth AG, MIT: VarioFlow plus, 3 842 549 802/2016-04...

  • Page 11: Personal Protective Equipment

    • Various VarioFlow plus modules in accordance with your order. Please use the shipping documents to check that the consignment is complete. • 1 assembly instructions “VarioFlow plus modules” 4.1 Condition on delivery • Modules fully or partially assembled 3 842 549 802/2016-04, MIT: VarioFlow plus, Bosch Rexroth AG...

  • Page 12: About This Product

    M (N) Roller curve vertical sliding curve Assembly module Return unit Base unit Conveyor chain Lateral guide W: Drive kit ) Size shown 549 801-01 VarioFlow plus modules Fig. 1: Bosch Rexroth AG, MIT: VarioFlow plus, 3 842 549 802/2016-04...

  • Page 13: Identifi Cation Of The Product

    • Protect the product from environmental infl uences such as dirt and humidity. • Ensure the correct ambient conditions, see page 119. • Support the product so that there is no load on motors that are installed in a suspended position. 3 842 549 802/2016-04, MIT: VarioFlow plus, Bosch Rexroth AG...

  • Page 14: Assembly

    This ensures proper functioning and prevents premature wear. 7.3 Required tools • Hex wrench SW13 • Hex key SW3, SW4, SW5 • Phillips screwdriver PZ2 • Hammer • Spirit level Bosch Rexroth AG, MIT: VarioFlow plus, 3 842 549 802/2016-04...

  • Page 15: Symbols Used

    Detail view from a different direction, for example of the back or the bottom side of the product. Assembly videos are available for downloading at www.boschrexroth.com,  service  downloads  VarioFlow plus assembly of the system • http://dc-emea.resource.bosch.com/media/de/service_4/downloads_2/ montagetechnik_2/VFplus_Service_-_Allgemein_SD_480p.m4v • http://dc-emea.resource.bosch.com/media/de/service_4/downloads_2/ montagetechnik_2/VFplus_Service_-_Detail_SD_480p.m4v 3 842 549 802/2016-04, MIT: VarioFlow plus, Bosch Rexroth AG...

  • Page 16: Installing The Product

    Install the slide rail (see page 69 and following). Install the conveyor chain (see page 78 and following). Install the lateral guide (see page 91 and following). Install the drive unit (see page 96 and following). Bosch Rexroth AG, MIT: VarioFlow plus, 3 842 549 802/2016-04...

  • Page 17: Al System

    fl oor. L = max. 2000 SW13 M = 25 Nm Ø 8 549 801-11 Fig. 4: AL system, installing section supports 3 842 549 802/2016-04, MIT: VarioFlow plus, Bosch Rexroth AG...

  • Page 18: Open-Type Section Profi Les

    24, 27, 33. 6070 mm: 3842 546 705 3000 mm: 3842 547 904 L mm: 3842 996 028/L 549 801-18 Fig. 5: AL system, pre-assembling open-type section profi les ) Size shown Bosch Rexroth AG, MIT: VarioFlow plus, 3 842 549 802/2016-04...

  • Page 19: Section On Section Supports

    fl oor. VF 160 ) Size shown VF 240 VF 320 SW13 =22 Nm 549 801-12 Fig. 6: AL system, installing section on section supports 3 842 549 802/2016-04, MIT: VarioFlow plus, Bosch Rexroth AG...

  • Page 20: Straight Section

    • Profi le connector (J) VF 120 3842 530 277 ) Size shown =8 Nm VF 160 VF 240 VF 320 =8 Nm 549 801-17 Fig. 7: AL system, installing straight section Bosch Rexroth AG, MIT: VarioFlow plus, 3 842 549 802/2016-04...

  • Page 21: Curve Wheel

    For circuit systems without chain return in the bottom run (using a curve wheel or connection drive), use the protective cover (L) and closed profi les as a safety guard to prevent access from below. 3 842 549 802/2016-04, MIT: VarioFlow plus, Bosch Rexroth AG...

  • Page 22: Installing The Curve Wheel Drive

    23. ) Size shown ) Drilled hole for fi xing the slide rail, see page 68 and following. =8 Nm 549 801-24 Fig. 9: AL system, installing curve wheel drive Bosch Rexroth AG, MIT: VarioFlow plus, 3 842 549 802/2016-04...
  • Page 23 SW17 slide rail, see page 68 and =25 Nm =20 Nm following. SW13 =8 Nm =25 Nm SW13 =25 Nm 549 801-28 Fig. 10: AL system, installing curve wheel drive 3 842 549 802/2016-04, MIT: VarioFlow plus, Bosch Rexroth AG...

  • Page 24: Sliding Curve Horizontal

    The friction which arises in sliding curves increases the required chain tensile force. Therefore in the case of sliding curves always use the UHMWPE slide rail for the entire system. Bosch Rexroth AG, MIT: VarioFlow plus, 3 842 549 802/2016-04...

  • Page 25: Horizontal Roller Curve In Section

    DIN7981 / DIN EN ISO 7049 ISO 7380, MLF-M6x20-10.9-vz 2,9 x 9,5 =1-2 Nm DIN 9021-A6,4-vz ISO 4032-M6-8-vz 549 801-20 Fig. 12: AL system, installing horizontal roller curve in section 3 842 549 802/2016-04, MIT: VarioFlow plus, Bosch Rexroth AG...

  • Page 26: Horizontal Roller Curve In Base Unit / Return Unit

    DIN EN ISO 7049 2,9 x 9,5 =8 Nm =1-2 Nm DIN 9021-A6,4-vz ISO 4032-M6-8-vz 549 801-90 Fig. 13: AL system, installing horizontal roller curve in base unit / return unit Bosch Rexroth AG, MIT: VarioFlow plus, 3 842 549 802/2016-04...

  • Page 27: Vertical Sliding Curve, Vf 65 / Vf 90 / Vf 120

    Fig. 14: AL system, installing vertical sliding curve, VF 65 / VF 90 / VF 120 Slide rail installation, see page 68 and following. ) Size shown 3 842 549 802/2016-04, MIT: VarioFlow plus, Bosch Rexroth AG...

  • Page 28: Vertical Sliding Curve, Vf 160 / Vf 240 / Vf 320

    ) Direction of movement of the ~45° returning chain on the bottom side of the profi le. 549 801-19 Fig. 15: AL system, vertical sliding curve, rising: installing slide rail for chain return Bosch Rexroth AG, MIT: VarioFlow plus, 3 842 549 802/2016-04...
  • Page 29 ~45° DIN EN ISO 7049 2,9 x 9,5 ~10° =1-2 Nm ~45° ~45° ~45° 549 801-26 Fig. 16: AL system, vertical sliding curve, falling: installing slide rail for chain return 3 842 549 802/2016-04, MIT: VarioFlow plus, Bosch Rexroth AG...
  • Page 30 Slide rail installation, see page 68 and following. ) Size shown =8 Nm 549 801-27 Fig. 17: AL system, installing vertical sliding curve, VF 160 / VF 240 / VF 320 Bosch Rexroth AG, MIT: VarioFlow plus, 3 842 549 802/2016-04...

  • Page 31: Vertical Sliding Curve In Base Unit / Return Unit

    Slide rail installation, see page 68 and following. ) Size shown =8 Nm 549 801-92 Fig. 18: AL system, installing vertical sliding curve in base unit / return unit 3 842 549 802/2016-04, MIT: VarioFlow plus, Bosch Rexroth AG...

  • Page 32: Assembly Module

     (see )) must be towards the front in the direction of conveying. ) Size shown =8 Nm 549 801-16 Fig. 19: AL system, installing assembly module Bosch Rexroth AG, MIT: VarioFlow plus, 3 842 549 802/2016-04...

  • Page 33: Return Unit

    ) Use the drilling jig 3842 553 518 8 , 5 Ø 3 ISO 7380, MLF-M6x20-10.9-vz =8 Nm =8 Nm DIN 9021-A6,4-vz ISO 4032-M6-8-vz 549 801-21 Fig. 20: AL system, installing return unit 3 842 549 802/2016-04, MIT: VarioFlow plus, Bosch Rexroth AG...

  • Page 34: Base Unit

    =8 Nm covers is fulfi lled if this locking washer (x) is fi tted. 549 801-22 Fig. 21: AL system, installing base unit, VF 65 / VF 90 / VF 120 Bosch Rexroth AG, MIT: VarioFlow plus, 3 842 549 802/2016-04...
  • Page 35 (x) is fi tted. DIN 9021-A6,4-vz ISO 4032-M6-8-vz 549 801-25 Fig. 22: AL system, installing base unit, VF 160 / VF 240 / VF 320 3 842 549 802/2016-04, MIT: VarioFlow plus, Bosch Rexroth AG...

  • Page 36: Connection Drive

    fl oor. ) Size shown ) Drilled hole for fi xing the slide rail, see page 68 and following. 549 801-151 Fig. 23: AL system, installing connection drive (1/6) Bosch Rexroth AG, MIT: VarioFlow plus, 3 842 549 802/2016-04...
  • Page 37 Clip the roller element (b) into the side plates. ) Size shown „click“ 549 801-153 Fig. 24: AL system, installing connection drive (2/6) 3 842 549 802/2016-04, MIT: VarioFlow plus, Bosch Rexroth AG...
  • Page 38 VF 65 both sides of the roller VF 90 element). ) Size shown SW10 =9 Nm 549 801-154 Fig. 25: AL system, installing connection drive (3/6) Bosch Rexroth AG, MIT: VarioFlow plus, 3 842 549 802/2016-04...
  • Page 39 Install the slide rail and conveyor chain before installing the drive of the connection kit. ) Size shown 2006/42/EG = Nm = Nm 549 801-155 Fig. 26: AL system, installing connection drive (4/6) 3 842 549 802/2016-04, MIT: VarioFlow plus, Bosch Rexroth AG...
  • Page 40 ø 1 =2,5 Nm VF 65 VF 90 549 801-158 Fig. 27: Drive position SW10 =9 Nm ) Size shown SW17 549 801-156 Fig. 28: AL system, installing connection drive (5/6) Bosch Rexroth AG, MIT: VarioFlow plus, 3 842 549 802/2016-04...
  • Page 41 VF 90 cover (J). Install the cover sheet (K). ) Size shown =1,5 Nm VF 65 VF 90 0,5 Nm! 549 801-157 Fig. 29: AL system, installing connection drive (6/6) 3 842 549 802/2016-04, MIT: VarioFlow plus, Bosch Rexroth AG...

  • Page 42: Center Drive

    ) Size shown ) Drilled hole for fi xing the slide rail, see page 68 and following. SW13 =22 Nm 549 801-168 Fig. 30: AL system, installing center drive Bosch Rexroth AG, MIT: VarioFlow plus, 3 842 549 802/2016-04...

  • Page 43: Sts System

    fl oor. ) Size shown L = max. 2000 L = max. 2000 549 801-111 Fig. 31: STS system, installing section supports 3 842 549 802/2016-04, MIT: VarioFlow plus, Bosch Rexroth AG...

  • Page 44: Preassembling Section Profi Les

    3024 mm: 3842 546 700 3024 mm: 3842 547 906 L mm: 3842 996 029/L SW13 =22 Nm ) Size shown 549 801-118 Fig. 32: STS system, pre-assembling section profi les Bosch Rexroth AG, MIT: VarioFlow plus, 3 842 549 802/2016-04...

  • Page 45: Section On Section Supports

    fl oor. ) Size shown VF 160 VF 240 VF 320 SW13 =22 Nm SW13 =22 Nm 549 801-112 Fig. 33: STS system, installing section on section supports 3 842 549 802/2016-04, MIT: VarioFlow plus, Bosch Rexroth AG...

  • Page 46: Straight Section

    • Profi le connector (J) VF 120 3842 547 895 ) Size shown SW13 =22 Nm VF 160 VF 240 VF 320 SW13 =22 Nm 549 801-117 Fig. 34: STS system, installing straight section Bosch Rexroth AG, MIT: VarioFlow plus, 3 842 549 802/2016-04...

  • Page 47: Curve Wheel

    (bottom side = chain return), see page 68 and following. ) Use the drilling jig 3842 553 518 SW13 =22 Nm 549 801-115 Fig. 35: STS system, installing curve wheel 3 842 549 802/2016-04, MIT: VarioFlow plus, Bosch Rexroth AG...

  • Page 48: Horizontal Roller Curve In Section

    ISO 4017, M6x14-A2-70 DIN7981 / DIN EN ISO 7049 2,9 x 9,5 =1-2 Nm DIN 9021-A6,4-vz ISO 4032-M6-8-vz 549 801-114 Fig. 36: STS system, installing horizontal roller curve in section Bosch Rexroth AG, MIT: VarioFlow plus, 3 842 549 802/2016-04...

  • Page 49: Horizontal Roller Curve In Base Unit / Return Unit

    DIN EN ISO 7049 2,9 x 9,5 =1-2 Nm =8 Nm DIN 9021-A6,4-vz ISO 4032-M6-8-vz 549 801-91 Fig. 37: STS system, installing horizontal roller curve in base unit / return unit 3 842 549 802/2016-04, MIT: VarioFlow plus, Bosch Rexroth AG...

  • Page 50: Vertical Sliding Curve, Vf 65 / Vf 90 / Vf 120

    Slide rail installation, see page 68 and following. 549 801-113 Fig. 38: STS system, installing vertical sliding curve, VF 65 / VF 90 / VF 120 ) Size shown Bosch Rexroth AG, MIT: VarioFlow plus, 3 842 549 802/2016-04...
  • Page 51 ) Direction of movement of the returning chain on the bottom ~45° side of the profi le. 549 801-119 Fig. 39: STS system, vertical sliding curve, rising: installing slide rail for chain return 3 842 549 802/2016-04, MIT: VarioFlow plus, Bosch Rexroth AG...
  • Page 52 ~10° DIN7981/ DIN EN ISO 7049 2,9 x 9,5 ~45° =1-2 Nm ~45° ~45° 549 801-126 Fig. 40: STS system, vertical sliding curve, falling: installing slide rail for chain return Bosch Rexroth AG, MIT: VarioFlow plus, 3 842 549 802/2016-04...
  • Page 53 Slide rail installation, see page 68 and following. ) Size shown SW13 =22 Nm 549 801-127 Fig. 41: STS system, installing vertical sliding curve, VF 160 / VF 240 / VF 320 3 842 549 802/2016-04, MIT: VarioFlow plus, Bosch Rexroth AG...

  • Page 54: Vertical Sliding Curve In Base Unit / Return Unit

    Slide rail installation, see page 68 and following. ) Size shown SW13 =22 Nm 549 801-93 Fig. 42: STS system, installing vertical sliding curve in base unit / return unit Bosch Rexroth AG, MIT: VarioFlow plus, 3 842 549 802/2016-04...

  • Page 55: Assembly Module

    ) Size shown ) Use the drilling jig 3842 553 518 SW13 =22 Nm 549 801-116 Fig. 43: STS system, installing assembly module 3 842 549 802/2016-04, MIT: VarioFlow plus, Bosch Rexroth AG...

  • Page 56: Return Unit

    3842 553 518 8 , 5 Ø 3 ISO 4017, M6x20-A2-70 SW13 =22 Nm SW10 =8 Nm DIN 9021-A6,4-vz ISO 4032-M6-8-vz 549 801-31 Fig. 44: STS system, installing return unit Bosch Rexroth AG, MIT: VarioFlow plus, 3 842 549 802/2016-04...

  • Page 57: Base Unit

    (x) is fi tted. 549 801-32 Fig. 45: STS system, installing base unit, VF 65 / VF 90 / VF 120 3 842 549 802/2016-04, MIT: VarioFlow plus, Bosch Rexroth AG...
  • Page 58 ) Use the drilling jig 3842 553 518 SW10 =8 Nm DIN 9021-A6,4-vz ISO 4032-M6-8-vz 549 801-35 Fig. 46: STS system, installing base unit, VF 160 / VF 240 / VF 320 Bosch Rexroth AG, MIT: VarioFlow plus, 3 842 549 802/2016-04...

  • Page 59: Connection Drive

    fl oor. ) Size shown ) Drilled hole for fi xing the slide rail, see page 68 and following. 549 801-152 Fig. 47: STS system, installing connection drive (1/6) 3 842 549 802/2016-04, MIT: VarioFlow plus, Bosch Rexroth AG...
  • Page 60 Clip the roller element (b) into the side plates. ) Size shown „click“ 549 801-159 Fig. 48: STS system, installing connection drive (2/6) Bosch Rexroth AG, MIT: VarioFlow plus, 3 842 549 802/2016-04...
  • Page 61 VF 65 chain on both sides of the VF 90 roller element). ) Size shown SW10 =9 Nm 549 801-160 Fig. 49: STS system, installing connection drive (3/6) 3 842 549 802/2016-04, MIT: VarioFlow plus, Bosch Rexroth AG...
  • Page 62 Install the slide rail and conveyor chain before installing the drive of the connection kit. ) Size shown 2006/42/EG = Nm = Nm 549 801-161 Fig. 50: STS system, installing connection drive (4/6) Bosch Rexroth AG, MIT: VarioFlow plus, 3 842 549 802/2016-04...
  • Page 63 ø 1 =2,5 Nm VF 65 VF 90 549 801-158 Fig. 51: Drive position SW10 =9 Nm ) Size shown SW17 549 801-162 Fig. 52: STS system, installing connection drive (5/6) 3 842 549 802/2016-04, MIT: VarioFlow plus, Bosch Rexroth AG...
  • Page 64 VF 90 cover (j). Install the cover sheet (k). ) Size shown =1,5 Nm VF 65 VF 90 0,5 Nm! 549 801-157 Fig. 53: STS system, installing connection drive (6/6) Bosch Rexroth AG, MIT: VarioFlow plus, 3 842 549 802/2016-04...

  • Page 65: Center Drive

    ) Size shown ) Drilled hole for fi xing the slide rail, see page 68 and following. SW13 =22 Nm 549 801-169 Fig. 54: STS system, installing center drive 3 842 549 802/2016-04, MIT: VarioFlow plus, Bosch Rexroth AG...

  • Page 66: Alpine Conveyor

    fl oor. ) Size shown =8 Nm SW13 SW13 =22 Nm =22 Nm 549 801-175 Fig. 55: Example of installation of alpine conveyor with connection drive, 90° return unit Bosch Rexroth AG, MIT: VarioFlow plus, 3 842 549 802/2016-04...

  • Page 67: Alpine Conveyor Connection Kit

    fl oor. ) Size shown =8 Nm GM = 1 AC = 1 549 801-174 Fig. 56: Example of installation of alpine conveyor with curve wheel drive, connection kit 3 842 549 802/2016-04, MIT: VarioFlow plus, Bosch Rexroth AG...

  • Page 68: Slide Rail

    – after a curve wheel (inside of the section profi le) – after a roller curve (inside of the support profi le) Chain return: – after the base unit – after a curve wheel (inside of the section profi le) Bosch Rexroth AG, MIT: VarioFlow plus, 3 842 549 802/2016-04...

  • Page 69: Slide Rail, (Section Profi Le)

    DIN EN ISO 7049 2,9 x 9,5 =1-2 Nm , STS DIN7982/ DIN EN ISO 7050 2,9 x 9,5 =1-2 Nm , AL 549 801-41 Fig. 58: Installing slide rail (section profi le) 3 842 549 802/2016-04, MIT: VarioFlow plus, Bosch Rexroth AG...

  • Page 70: Slide Rail (Section Profi Le, Chain Return)

    2,9 x 9,5 =1-2 Nm , AL , STS DIN7981/ DIN EN ISO 7049 2,9 x 9,5 =1-2 Nm 549 801-42 Fig. 59: Installing slide rail (section profi le, chain return) Bosch Rexroth AG, MIT: VarioFlow plus, 3 842 549 802/2016-04...

  • Page 71: Slide Rail (Support Profi Le), Only For Vf 160 / Vf 240 / Vf

    (AL / STS: oval- head screw). ) Size shown DIN7981/ DIN EN ISO 7049 2,9 x 9,5 , STS =1-2 Nm 549 801-43 Fig. 60: Installing slide rail (support profi le) 3 842 549 802/2016-04, MIT: VarioFlow plus, Bosch Rexroth AG...

  • Page 72: Slide Rail (End-To-End Joint For Connecting Slide Rails)

    (AL: countersunk screw, STS: oval-head ~45° screw). ) Size shown ~45° 5 – 10 ~10° 549 801-47 Fig. 61: Assembling slide rail (end-to-end joint for connecting slide rails) Bosch Rexroth AG, MIT: VarioFlow plus, 3 842 549 802/2016-04...

  • Page 73: Slide Rail, Al System Assembly Module, Only For Vf 65 / Vf 90 / Vf 120

    ) Size shown DIN7982 / DIN EN ISO 7050 2,9 x 9,5 =1-2 Nm 549 801-44 Fig. 62: Installing slide rail, AL system assembly module 3 842 549 802/2016-04, MIT: VarioFlow plus, Bosch Rexroth AG...

  • Page 74: Slide Rail, Sts System Assembly Module, Only For

    ) Size shown DIN7981 / DIN EN ISO 7049 2,9 x 9,5 =1-2 Nm 549 801-45 Fig. 63: Installing slide rail, STS system assembly module Bosch Rexroth AG, MIT: VarioFlow plus, 3 842 549 802/2016-04...

  • Page 75: Sts Slide Rail, Section Profi Le

    Fix the slide rail in position with blind rivets. ) Size shown ~30° Ø3 Ø3 ~45° 549 801-165 Fig. 64: Assembling STS slide rail, section profi le 3 842 549 802/2016-04, MIT: VarioFlow plus, Bosch Rexroth AG...

  • Page 76: Sts Slide Rail, 90° Curve Wheel

    Fix the slide rail in position with blind rivets. ) Size shown VF 65 VF 90 Ø 3 Ø3 Ø3 549 801-166 Fig. 65: Installing STS slide rail, 90° curve wheel Bosch Rexroth AG, MIT: VarioFlow plus, 3 842 549 802/2016-04...

  • Page 77: Sts Slide Rail, 180° Curve Wheel

    Fix the slide rail in ~45° position with blind rivets. ) Size shown ~30° VF 65 VF 90 Ø3 Ø3 Ø 3 549 801-167 Fig. 66: Installing STS slide rail, 180° curve wheel 3 842 549 802/2016-04, MIT: VarioFlow plus, Bosch Rexroth AG...

  • Page 78: Conveyor Chain

    (see page 82) after a break-in period of approx. 40 hours. 549 801-51 ) Size shown Fig. 67: Installing conveyor chain, VF 65 / VF 90 / VF 120 Bosch Rexroth AG, MIT: VarioFlow plus, 3 842 549 802/2016-04...

  • Page 79: Conveyor Chain, Vf 160 / Vf 240 / Vf 320

    (see page 82) after a break-in period of approx. 40 hours. ) Size shown 549 801-52 Fig. 68: Installing conveyor chain, VF 160 / VF 240 / VF 320 3 842 549 802/2016-04, MIT: VarioFlow plus, Bosch Rexroth AG...

  • Page 80: Closing (Extending) Conveyor Chain, Vf 65 / Vf 90 / Vf 120

    – only then is the chain pin positioned correctly! ) Size shown 549 801-53 Fig. 69: Closing (extending) conveyor chain, VF 65 / VF 90 / VF 120 Bosch Rexroth AG, MIT: VarioFlow plus, 3 842 549 802/2016-04...
  • Page 81 Close the conveyor chain, see page 80. Install the missing chain plates. ) Size shown 549 801-56 Fig. 70: Closing (extending) conveyor chain, VF 160 / VF 240 / VF 320 3 842 549 802/2016-04, MIT: VarioFlow plus, Bosch Rexroth AG...

  • Page 82: Opening (Shortening) Conveyor Chain, Vf 65 / Vf 90 / Vf 120

    Press the chain pin out of the chain links and onto the mounting lug (E). 549 801-54 Fig. 71: Opening (shortening) conveyor chain, VF 65 / VF 90 / VF 120 Bosch Rexroth AG, MIT: VarioFlow plus, 3 842 549 802/2016-04...
  • Page 83 Remove 2 chain plates. Open the conveyor chain, see page 82. ) Size shown 549 801-57 Fig. 72: Opening (shortening) conveyor chain, VF 160 / VF 240 / VF 320 3 842 549 802/2016-04, MIT: VarioFlow plus, Bosch Rexroth AG...

  • Page 84: Connection Kit

    Clip the roller element (b) into the side plates. ) Size shown 549 801-131 Fig. 73: Installing the passive connection kit Bosch Rexroth AG, MIT: VarioFlow plus, 3 842 549 802/2016-04...

  • Page 85: Active Connection Kit

    Align the conveyor height of the roller element (with the aid of SW10 =9 Nm two pieces of chain). ) Size shown 549 801-141 Fig. 74: Installing the active connection kit (1/3) 3 842 549 802/2016-04, MIT: VarioFlow plus, Bosch Rexroth AG...
  • Page 86 Install the toothed belt (g). VF 120 Install the tensioner VF 160 pulley (h). ) Size shown SW10 =9 Nm SW17 549 801-142 Fig. 76: Installing the active connection kit (2/3) Bosch Rexroth AG, MIT: VarioFlow plus, 3 842 549 802/2016-04...
  • Page 87 (k). ) Size shown =1,5 Nm VF 65 VF 90 VF 120 VF 160 0,5 Nm! 0,5 Nm! 549 801-143 Fig. 77: Installing the active connection kit (3/3) 3 842 549 802/2016-04, MIT: VarioFlow plus, Bosch Rexroth AG...

  • Page 88: Active Connection Kit, Machine Connection

    =9 Nm (with the aid of two pieces of chain). ) Size shown, right-hand installation position (R) 549 801-201 Fig. 78: Installing the active connection kit, machine connection (1/3) Bosch Rexroth AG, MIT: VarioFlow plus, 3 842 549 802/2016-04...
  • Page 89 =2,5 Nm ) Size shown ø 1 VF 65 VF 90 VF 120 VF 160 SW10 =9 Nm SW17 549 801-202 Fig. 79: Installing the active connection kit, machine connection (2/3) 3 842 549 802/2016-04, MIT: VarioFlow plus, Bosch Rexroth AG...
  • Page 90 (l). ) Size shown =1,5 Nm VF 65 VF 90 VF 120 VF 160 0,5 Nm! 0,5 Nm! 549 801-203 Fig. 80: Installing the active connection kit, machine connection (3/3) Bosch Rexroth AG, MIT: VarioFlow plus, 3 842 549 802/2016-04...

  • Page 91: Lateral Guide

    VF 65 VF 90 VF 120 ) Size shown VF 160 VF 240 VF 320 = 6 Nm DIN 912 M6 x 16 549 801-85 Fig. 81: Installing lateral guide 3 842 549 802/2016-04, MIT: VarioFlow plus, Bosch Rexroth AG...

  • Page 92: Lateral Guide Accessories

    =6 Nm DIN 912 =6 Nm M6 x 16 DIN 912 M6 x 55 =max. 5 Nm DIN 912 M6 x 35 549 801-81 Fig. 82: Lateral guide accessories (1/4) Bosch Rexroth AG, MIT: VarioFlow plus, 3 842 549 802/2016-04...
  • Page 93 3 842 539 500 3 842 539 613 =max. 5 Nm =max. 5 Nm 3 842 539 345 3 842 539 826 549 801-82 Fig. 83: Lateral guide accessories (2/4) 3 842 549 802/2016-04, MIT: VarioFlow plus, Bosch Rexroth AG...
  • Page 94 94/120 Assembly 3 842 539 501 =5 Nm =5 Nm 3 842 539 505 =5 Nm 549 801-83 Fig. 84: Lateral guide accessories (3/4) Bosch Rexroth AG, MIT: VarioFlow plus, 3 842 549 802/2016-04...
  • Page 95 3 842 990 720 / … 3 842 538 710 3 842 538 707 3 842 523 516 + 2x 3 842 992 888 /… 549 801-84 Fig. 85: Lateral guide accessories (4/4) 3 842 549 802/2016-04, MIT: VarioFlow plus, Bosch Rexroth AG...

  • Page 96: Gear Motor

    (with opening facing downwards). ) Base unit scope of delivery =8 Nm 549 801-61 Fig. 86: Base unit, AL system, gear motor GM = 1 installation Bosch Rexroth AG, MIT: VarioFlow plus, 3 842 549 802/2016-04...

  • Page 97: Base Unit, Al System, Gear Motor Gm = 2 Installation

    (with opening facing downwards). ) Base unit scope of delivery =21 Nm =8 Nm 549 801-62 Fig. 87: Base unit, AL system, gear motor GM = 2 installation 3 842 549 802/2016-04, MIT: VarioFlow plus, Bosch Rexroth AG...

  • Page 98: Base Unit, Sts System, Gear Motor Installation

    Install the gear motor. =8 Nm ) Size shown ) Base unit scope of delivery SW13 =21 Nm GM=2 SW10 =8 Nm 549 801-63 Fig. 88: Base unit, STS system, gear motor installation Bosch Rexroth AG, MIT: VarioFlow plus, 3 842 549 802/2016-04...

  • Page 99: Center Drive, Al/Sts System, Gear Motor Gm = 1 Installation

    (with opening facing downwards). ) Base unit scope of delivery SW10 =8 Nm SW13 =21 Nm 549 801-172 Fig. 89: Center drive, AL/STS system, gear motor GM = 1 installation 3 842 549 802/2016-04, MIT: VarioFlow plus, Bosch Rexroth AG...

  • Page 100: Transmission Drive, Al System, Gear Motor Gm = 1 Installation

    ) Size shown VF 65 VF 90 VF 120 = Nm SW13 =25 Nm Fig. 90: Transmission drive, AL system, gear motor GM = 1 installation (1/2) Bosch Rexroth AG, MIT: VarioFlow plus, 3 842 549 802/2016-04...
  • Page 101 (with opening facing downwards). ) Base unit scope of delivery = Nm 549 801-171 Fig. 91: Transmission drive, AL system, gear motor GM = 1 installation (2/2) 3 842 549 802/2016-04, MIT: VarioFlow plus, Bosch Rexroth AG...

  • Page 102: Curve Wheel Drive, Gear Motor Installation

    ) Size shown GM = 2 =8 Nm (3 842 998 742) GM = 1, v = 5m/min =8 Nm 549 801-66 Fig. 92: Curve wheel drive, gear motor installation Bosch Rexroth AG, MIT: VarioFlow plus, 3 842 549 802/2016-04...

  • Page 103: Safety Coupling Adjustment

    Fig. 93: Safety coupling adjustment (1/2) ) Scaling with 2 belleville spring washers (correct before delivery). ) Scaling with 1 belleville spring washer (correct after modifi cation, see page 105). 3 842 549 802/2016-04, MIT: VarioFlow plus, Bosch Rexroth AG...
  • Page 104 To do this, select a threaded hole which matches a slot. Install the adapter (Y). “+“ “–“ DIN1810-A58-62 A, B DIN1810-A58-62 549 801-71 Fig. 94: Safety coupling adjustment (2/2) Bosch Rexroth AG, MIT: VarioFlow plus, 3 842 549 802/2016-04...

  • Page 105: Safety Coupling Modifi Cation

    Adjust the release torque (see page 103). … (see page 103). … (see page 103). 549 801-173 Fig. 95: Safety coupling modifi cation 3 842 549 802/2016-04, MIT: VarioFlow plus, Bosch Rexroth AG...

  • Page 106: Making The Electrical Connection To The Product

    Please note: For motors that come with a fi tted plug, correct the direction of rotation in the control cabinet or at the socket contact (socket side). This makes replacement easier. Bosch Rexroth AG, MIT: VarioFlow plus, 3 842 549 802/2016-04...
  • Page 107 Assembly 107/120 Installation_A Fig. 96: Motor data plate (example) Installation_DY Fig. 97: Delta/wye wiring diagrams Installation_IEC Fig. 98: Connection with plug 3 842 549 802/2016-04, MIT: VarioFlow plus, Bosch Rexroth AG...

  • Page 108: Commissioning

    • Only start up the product if all safety equipment has been installed in the system and is functional. • Only start up a product which has been fully installed. 8.2 Re-commissioning after a standstill period • Follow the steps outlined for initial commissioning. Bosch Rexroth AG, MIT: VarioFlow plus, 3 842 549 802/2016-04...

  • Page 109: Operation

    • Wear can increase signifi cantly in the event of contamination – particularly with abrasive media in the environment, such as metal swarf or building dust, but also fi ne dust or sugar. Maintenance intervals should be signifi cantly reduced under these circumstances. 3 842 549 802/2016-04, MIT: VarioFlow plus, Bosch Rexroth AG...
  • Page 110 In such instances, special care must be taken when planning the system, and the maintenance intervals must be correspondingly shortened. Bosch Rexroth AG, MIT: VarioFlow plus, 3 842 549 802/2016-04...

  • Page 111: Maintenance And Servicing

    There is a risk of damage to property.  Keep degreasers or aggressive cleaning agents away from the conveyor chain!  Only clean the product with a damp cloth. 3 842 549 802/2016-04, MIT: VarioFlow plus, Bosch Rexroth AG...

  • Page 112: Inspection

    10 x 34,5 = 345 10x 34,5 ≥ 362 10 x 34,5 = 345 10x 34,5 ≥ 362 549 801-122 Fig. 100: max. permissible elongation (5%) of the conveyor chain Bosch Rexroth AG, MIT: VarioFlow plus, 3 842 549 802/2016-04...

  • Page 113: Slide Rails

    Also check for correct attachment and level of wear. 3 842 549 802/2016-04, MIT: VarioFlow plus, Bosch Rexroth AG...

  • Page 114: Wear Of Conveyor Chains

    • In the accumulation area visually check for break-in scoring of slide rails and the underside of chain plates every 500 hours. Total max. permissible wear of the slide rail and chain plate 0.7 mm. Continual system checks are recommended in accumulation operation. Bosch Rexroth AG, MIT: VarioFlow plus, 3 842 549 802/2016-04...

  • Page 115: Maintenance

    • Rubber mallet • Strainer Conveyor chain Conveyor chain replacement, see conveyor chain installation, page 78 and following Slide rails Slide rail replacement, see slide rail installation, page 69 and following 3 842 549 802/2016-04, MIT: VarioFlow plus, Bosch Rexroth AG...

  • Page 116: Drive Gears

    34 VF 120 (AL) / page 57 (STS). ) Size shown = 10 Nm VF 160 VF 240 VF 320 = 10 Nm 549 801-128 Fig. 103: Replacing drive gears Bosch Rexroth AG, MIT: VarioFlow plus, 3 842 549 802/2016-04...

  • Page 117: Spare Parts

    • Protect the product from environmental infl uences such as dirt and humidity. • Pay attention to the ambient conditions, see page 119. • For products with ready-mounted motor: Support the product so that the motor is not placed under mechanical load. 3 842 549 802/2016-04, MIT: VarioFlow plus, Bosch Rexroth AG...

  • Page 118: Disposal

    14 Upgrading and modifi cation • Do not modify the product. • The Bosch Rexroth warranty only applies to the confi guration as delivered, and to approved upgrades. The manufacturer will not accept any warranty claims for systems with unapproved modifi cations or upgrades.

  • Page 119: Technical Data

    fl uid, we recommend that you consult your specialist Rexroth representative. • Avoid prolonged contact with highly reactive acidic or alkaline materials. 3 842 549 802/2016-04, MIT: VarioFlow plus, Bosch Rexroth AG...
  • Page 120 Bosch Rexroth AG Postfach 30 02 07 70442 Stuttgart Germany Fax +49 711 811–7777 info@boschrexroth.de www.boschrexroth.com Subject to change 3 842 549 802/2016-04...

Table of Contents