Related Manuals for Schneeberger MONORAIL Series
Summary of Contents for Schneeberger MONORAIL Series
- Page 1 MONORAIL and AMS Profiled linear guideways and integrated measuring systems Mounting instructions 2019...
- Page 2 MONORAIL and AMS product catalog • MONORAIL and AMS application catalog This documentation and further information are available in digital form in our download area at www.schneeberger.com. These MONORAIL and AMS mounting instructions are valid together with the additional literature. Disclaimer This publication has been compiled with great care and all information has been checked for accuracy.
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Page 3: Table Of Contents
Table of contents Page number About these installation instructions Function and applications Target audience Symbols used For your safety Authorised personnel Intended use General safety and protective measures Environmentally responsible conduct Product information Product variants Components Labelling of guide rails and carriages Product identification - measuring system Storage and transportation Preparing for Installation Required tools and equipment... -
Page 4: Installation Option
Table of contents Page number Completing installation Checking parallelism and running accuracy Installing the screw cover 7.2.1 MRK/BRK plastic plugs 7.2.2 MRS/BRS brass plugs 7.2.3 MRZ steel plugs 7.2.4 MAC/BAC cover strips Removing the protective installation film for additional wipers (optional) Lubrication Laying the electronics housing and cables Installing a FBM/FBB bellows - optional... -
Page 5: About These Installation Instructions
About these installation instructions Function and applications The MONORAIL and AMS installation instructions describe how to install the MONORAIL MR and MONORAIL BM profiled linear guideway systems and the integrated AMS distance measuring system. Target audience These installation instructions are intended for installers, service technicians, and all personnel who install, operate, replace, handle, or transport MONORAIL profiled linear guideways and AMS distance measuring systems and who have read and understood these instructions. -
Page 6: For Your Safety
When installing the MONORAIL and AMS systems, the general safety instructions, warning notes, and installation notes in these instructions should be followed as precisely as possible. Please do not hesitate to contact SCHNEEBERGER should you require any further information. Authorised personnel The MONORAIL and AMS systems should be installed by appropriately qualified or trained specialists, e.g. -
Page 7: Environmentally Responsible Conduct
For your safety • To ensure the proper functioning of the products, also observe the instructions on profile and position tolerances, dynamic limits, load, lubrication, and environ- mental conditions. Environmentally responsible conduct Do not allow lubricants and electronic components to be released into the environment, and ensure that these are disposed of in accordance with country-specific regulations. -
Page 8: Product Information
Product information MONORAIL is a profiled linear guideway system. It consists of a single guide rail with accompanying carriages (MONORAIL guideway) or multiple associated MONORAIL guideways (MONORAIL system). In the case of MONORAIL AMS with integrated distance measuring system, the guide rail is equipped with a magnetic measuring scale and one or more carriages on the guide rail is equipped with a housing with a read head. -
Page 9: Components
Product information Components The following figures show the components of a MONORAIL guideway system with AMS based on the example of MONORAIL AMSA 3B. Sensor unit Fig.1 Read head Connector (various options available) Sensor slider Mounting base (various options available) Sensor cable Read head cable Electronics housing... -
Page 10: Labelling Of Guide Rails And Carriages
Sensor unit Labelling of guide rails and carriages SCHNEEBERGER labels guide rails and carriages distinctly so that products can be identified and tracked at any time. The labelling includes a precise type designation, the date of manufacture and, in the case of guide rails, a serial number. - Page 11 Product information Guide rails Guide rails are labelled at the profile base opposite the locating side. The label consists of the following information: SCHNEEBERGER company logo Type description (for order codes, see MONORAIL product catalogue) Consecutive serial number Fig.5 AMS guide rails with magnetic measuring scale...
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Page 12: Product Identification - Measuring System
Fig.12 Fig.11 Fig.13 Type designation SCHNEEBERGER GmbH company logo Address of SCHNEEBERGER GmbH (Höfen) Input voltage specification CE marking An exception is the AMSA 3L measuring system. In this case the identifying label is located directly on the read head. -
Page 13: Storage And Transportation
Storage and transportation MONORAIL guideways and the AMS distance measuring system are high-precision components which must be handled with appropriate care. The following instructions should be followed to prevent damage during storage and transportation: • Internal transportation should only be carried out by trained personnel. •... - Page 14 Storage and transportation Guide rails WARNING! Risk of injury posed by improper transportation! Rails may fall during transportation and cause injury to persons nearby. • Suspend long rails at several points with a crane during transportation. • The slewing range of long rails must be taken into consideration. WARNING! Risk of injury posed by escaping carriages! Carriages may become detached from the guide rail during transportation.
- Page 15 Following successful system installation, the aluminium profile is disassembled and can be disposed of. It is possible to arrange a return consignment for recycling with Schneeberger GmbH on a case by case basis which may contain all installation components where applicable.
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Page 16: Preparing For Installation
Preparing for Installation Required tools and equipment Installing MONORAIL MR/BM/BZ • MRM assembly rails for MONORAIL MR or MBM for MONORAIL BM • Oil stone and polishing pad • Suitable solvent (e.g. white spirit) • Lubricating oil or lubricating grease • Grease containing MoS2 for the fastening screws, in order to ensure consistent and therefore optimal screwing forces •... -
Page 17: Corrosion Protection
Preparing for Installation Individual carriages are delivered on a transport rail to protect the rolling elements. AMS measuring systems are installed ready to plug-in, and electrical accessories and cables are packaged together with the mechanism. In its delivered condition the read head can be either installed in its housing or separately packaged as an individual component. -
Page 18: Preparing The Locating Surfaces
Read installation notes and accompanying product documentation carefully before installation. Preparing the locating surfaces The locating surface of the rails can be found on the side facing away from the SCHNEEBERGER and type number labels. Mounting plate locating surface Carriage locating surface Machine bed locating surface... - Page 19 Preparing for Installation Fig.17 Activation strip Magnet...
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Page 20: Installation
Press the rail into the desired position. Introduce guide rail fastening screws into the guide rail from above via the central Fig.18 fixing hole and tighten. The installation carriage is available from SCHNEEBERGER as an accessory. Handling carriages Danger! Risk to life posed by falling machine elements! Possible consequences include death and serious injury. -
Page 21: Handling Guide Rails
Always brace the locating surface of the guide rails against the locating surface of the machine bed. The locating surface of the guide rails is the surface on the op- posite side of the Schneeberger logo and part numbering. For optimal screwing force, proceed as follows: Lubricate the screw head rests and threads of the fastening screws with grease containing MoS2. -
Page 22: Handling Multi-Part Guide Rails
Installation Handling multi-part guide rails Multi-part guide rails are marked with a number at their joints. In the case of a matched design, the guide rails are also marked with a set number at the start of the rail. The guide rail with the set number index 1, or with the butt joint number 1 is designated as the reference rail. -
Page 23: Handling Measuring Systems
Installation Handling measuring systems 6.5.1 Handling magnetic fields Failure to observe the points specified in this section may result in material damage. ATTENTION! Risk of material damage posed by magnetic fields! Incorrect handling of AMS rails in relation to magnetic fields may result in material damage. •... - Page 24 Installation Avoid direct contact between tools and the magnetic measuring scale (Fig. 28). Fig.28 Disassemble the AMS read head (1) before mounting or dismounting the MONORAIL carriage onto or from the guideway (2) (Fig. 29). Fig.29...
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Page 25: Installing And Connecting The Read Head
Installation 6.5.2 Installing and connecting the read head ATTENTION Risk of material damage posed by incorrect insertion of read head! May result in damage to sliding parts. • Do not allow any particulates to become caught between the sensor slider and the scale. • Do not allow sliding parts to come into contact with the read head. •... -
Page 26: Installing Product Versions Ams 3B, Ams 4B, And Amsa 3L
Installation 6.5.3 Installing product versions AMS 3B, AMS 4B, and AMSA 3L Where necessary, remove the cover plate from the housing. Carefully insert the read head into the lateral recess of the housing. Insert and tighten the fastening screws. No additional adjustment is necessary. The tightening sequence is irrelevant in this case. Fig.31 6.5.4 Installing product version AMSABS Where necessary, remove the cover plate from the housing. -
Page 27: Installation Options
Installation Installation options 6.6.1 Installation option 1 Installation option 1 is applicable in cases in which locating surfaces are present for one guide rail and for one carriage. Fig.34 Brace the reference rail (1) against the locating surface of the machine bed and fasten with screws (see „6.3 Handling guide rails“... -
Page 28: Installation Option
Installation Fasten one carriage on the pre-fastened guide rail to the mounting plate (3) with screws. If carriages with additional wipers are protected by an installation protection film: prevent the protective film from slipping (see „7.3 Removing the protective instal- lation film for additional wipers (optional)“... - Page 29 Installation 6.6.3 Installation option 3 Installation option 3 is applicable in cases in which locating surfaces are present for one guide rail and for both carriages. Fig.40 Brace the reference rail (1) against the locating surface and fasten with screws (see „6.3 Handling guide rails“ on page 19). Adjust the opposite guide rail (2) so that it is parallel and pre-fasten it.
- Page 30 Installation 6.6.4 Installation option 4 Installation option 4 is applicable in cases in which locating surfaces are present for one guide rail and for both carriages. In this option, the mounting plate is fastened with screws from underneath through the carriages. Fig.43 Remove the read head from the delivered system (see „9.4 Replacing the read head“...
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Page 31: Installing Monorail Bz
Installation Installing MONORAIL BZ Install the system in accordance with the following steps: Remove loosely packed parts and uninstalled cover strips from the transport crate. Lift the BZ out of the transport crate by hand or using a suitable lifting device supplied by the customer. Lift the BZ horizontally. -
Page 32: Completing Installation
Completing installation Checking parallelism and running accuracy Following installation, check the functioning and accuracy of the guideway as follows: Parallelism Check compliance with parallelism tolerances using a dial gauge and two coupled carriages. Use the vertical lateral locating surface on the parallel rail as a reference surface. Special adapter plates are available for checking AMS guideways. -
Page 33: Installing The Screw Cover
Completing installation Installing the screw cover CAUTION! Risk of personal injury posed by sharp edges! Could result in cutting injuries. • Wear gloves. • Protect wipers with an assembly protection strip when passing the carriage over unsealed rail fixing holes. The following screw covers are available: •... -
Page 34: Mrs/Brs Brass Plugs
Completing installation 7.2.2 MRS/BRS brass plugs CAUTION! Risk of personal injury posed by sharp-edged rail fixing holes and sheared-off or airborne brass swarf! Could result in cutting injuries. • Wear gloves. • Wear protective goggles when working with compressed air. CAUTION! Risk of personal injury posed by non-compliance with manufacturer's guidelines! Hydraulic components can become damaged and malfunction, resulting in injury. - Page 35 The pressing stamp must therefore be checked at regular intervals and replaced if necessary. The stamp can be obtained from SCHNEEBERGER as a replacement part. In the case of the MZH hydraulic cylinder, the maintenance regulations set out in the manufacturer's operating instructions should be followed.
- Page 36 Completing installation Insert MRS brass plugs (conical) with the smaller-diameter side facing down. Insert BRS brass plugs with the recess side facing down. Fig.58 Ensure that the plugs sit parallel to top surface in the fixing holes. Fig.59 Slide the assembly tool over the plugs and position it centrally. Slide the assembly tool until both external control holes or recesses are posi- tioned exactly over a rail fixing hole.
- Page 37 Completing installation Switch on the hydraulic unit and set the desired pressure using the pressure control valve. Recommended pressure: • MRS: 80 to 120 bar • BRS: 80 to 120 bar NOTE: The stamping pressure required is dependent on the size and manufacturing tolerances.
- Page 38 Completing installation 11. Blast the gap between the gliding shoe and the upper surface of the rail with compressed air to remove any swarf adhering to the pressing stamp. 12. Slide the assembly tool once again over the plug undergoing pressing and position it.
- Page 39 Completing installation Use a thread cutter to cut a thread into the plug. Remove any swarf from the thread. Fig.67 Screw the Allen screw into the plug by hand until the tip of the screw comes into contact with the head of the guide rail fastening screw. Fig.68 Tighten the screw using a suitable Allen wrench.
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Page 40: Mrz Steel Plugs
Completing installation 7.2.3 MRZ steel plugs CAUTION! Risk of personal injury posed by sharp edges! Could result in cutting injuries. • Wear gloves. • Protect wipers on carriages with an assembly protection strip when passing the carriage over unsealed rail fixing holes. CAUTION! Risk of personal injury posed by non-compliance with manufacturer's guidelines! Hydraulic components can become damaged and malfunction,... - Page 41 Completing installation Required tool MWH installation tool For a description of the MWH assembly tool and its assembly, see „7.2.2 MRS/BRS brass plugs“ on page 32. Assembly process Slide the MWH assembly tool onto the guide rail. Recommendation: Use an MRM assembly rail for this purpose.
- Page 42 Completing installation Slide the assembly tool over the plug and position it centrally. Slide the assembly tool until both external control holes or recesses in the tool (MWH 25 - 65) are positioned exactly over a guide rail fixing hole. (Depending on the size, the control holes are one or two L4 hole spacings from the installation position.) Ș...
- Page 43 Completing installation ATTENTION! Risk of material damage posed by use of incorrect screws! Cross wipers/carriages may become damaged. • Safe functionality of the steel plugs is only guaranteed with the use of DIN 912/ISO 4762 high-headed screws to fasten the guide rails. •...
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Page 44: Mac/Bac Cover Strips
Completing installation Tighten the screw using a suitable Allen wrench. Ș The plug together with the clamping ring will be forced upwards (see figure). Continue tightening the screw until the plug is fully extracted. Remove the plug by hand. Check the guide rail fixing hole and fastening screw for damage. If necessary, finish the fixing hole with a grinding tool and replace the fastening screw. - Page 45 The manual MWC assembly tool is recommended by SCHNEEBERGER for proper installation of MAC cover strips and can be obtained from SCHNEEBERGER separately. Fig.83 Installation procedure for one-piece strips Fig.84...
- Page 46 Completing installation NOTE: Do not bend the free strip end at the end of the guide rail. Only move the assembly tool up to the end of the guide rail. Do not move the pressure roller over the end of the guide rail whilst applying pressure. Turn the handle of the assembly tool in the direction of installation.
- Page 47 Completing installation Installation Multi-part strips should be installed according to the same process used in the case of one-part strips (see „Installation procedure for one-piece strips“ on page 43). Follow the numbering of the strips. As with multi-part guide rails, the individual strip components are provided with a butt joint number on their underside in the joint area.
- Page 48 Completing installation Slide end pieces into the gap between cover strip and guide rail groove at each end of the guide rail until they stop. Lightly moisten the full guideway surface with the MONORAIL guideway lubricant. Fig.92 NOTE: In the case of cover strips with a length < 600 mm, secure the strip ends with a steel bracket instead of the end pieces (see next section "Steel securing bands").
- Page 49 Completing installation Use a screwdriver to lift the cover strip a few millimetres out of the groove at one end of the guide rail. Take hold of the strip end by hand and lift it. Fig.95 Insert the screwdriver laterally between the guide rail and the cover strip. Slide the screwdriver along the length of the guide rail, lifting the cover strip.
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Page 50: Removing The Protective Installation Film For Additional Wipers (Optional)
Completing installation Removing the protective installation film for additional wipers (optional) Carriages with ZBV/ZCV additional wipers are delivered with an installation protection film if the rails are screw-fastened from above and the fixing holes covered with plugs. The installation protection film protects the sealing lips during installation and should only be removed once the guide rail fixing holes have been sealed. -
Page 51: Lubrication
Completing installation Lubrication Lubrication connections General • lube connections are plastic threads. Exercise caution when inserting lube connection pieces. • Maximum tightening torque = 0.5 Nm. • Recommended screw-in depth into front plate = 4 mm. • Lube connection pieces with conical thread: max. screw-in depth accords with thread length. - Page 52 Completing installation SPL lubrication plate ATTENTION! Risk of material damage posed by improper handling of contact elements! The oil-delivering contact elements are slightly pre-stressed and can be destroyed by improper handling. • Carefully slide the lubrication plate over the end of the guideway. •...
- Page 53 A special oil bottle offered by SCHNEEBERGER as an accessory can also be used. Refilling is carried out in this case directly into the SPL lube hole, eliminating the need for a lube nipple.
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Page 54: Laying The Electronics Housing And Cables
Completing installation Laying the electronics housing and cables Electronics housing The sensor unit of the measuring system (excluding AMSA 3L) has a separate electronics housing. The electronics housing is mounted near the read head at the machine slide and has an LED display on its front for indicating various operating states. The electronics housing should be installed in accordance with the following points: •... - Page 55 Completing installation Connecting the measuring system and suitable extension cable length MONORAIL AMS is connected directly to the drive controller of the axis. Extension cables with a length of up to 50 m can be used depending on the model of sensor unit and controller used.
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Page 56: Installing A Fbm/Fbb Bellows - Optional
Completing installation Installing a FBM/FBB bellows - optional Bellows are mainly used as an additional form of protection for carriages against dust and splashes of water. Prior to installing the bellows, ensure that guide rail fixing holes are sealed with plugs and the cover strip. -
Page 57: Checking The Results Of The Installation
Completing installation Checking the results of the installation Following installation, check that the guideway and accessories have been installed are functioning correctly: Push Force Move the machine slide by hand over the full stroke, ensuring that push force remains constant and that the movement is jerk-free. Lubrication Ensure that the lubricant lines are properly connected and vented, and that the carriages are sufficiently supplied with lubricant. - Page 58 Completing installation NOTE: An absent or interrupted line of lubricant is indicative of an improperly-fitting wiper. The wiper must be exchanged if this is the case. Metal wipers The wipers must form an even gap around the guide rail profile and should not make contact with the guide rail at any point.
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Page 59: Commissioning
Commissioning Guideway check list Prior to commissioning, check the functionality of the guideway: • For proper installation of the guideway, see „6 Installation“ on page 18. • For system accuracy and push force, see „7 Completing installation“ on page 30 and „7.7 Checking the results of the installation“ on page 55. •... -
Page 60: Maintenance
Maintenance Optical inspection check list During guideway maintenance, ensure by optical inspection that none of the following are damaged and that no preventable damage to them is impending: • Check the guide rail surfaces for damage. • Check the wiper (see „7.7 Checking the results of the installation“ on page 55). •... -
Page 61: Replacing The Read Head
Maintenance • The carriage and guide rail form a single unit. In the case of matched designs, ensure that the carriages of different guide rails are not interchanged. • To prevent rolling elements from being dislodged from carriages, use an MRM/MBM assembly rail when transferring carriages to and from guide rail. - Page 62 Maintenance Dismantling AMS 3B and 4B and AMSABS 3B and 4B read heads Turn off the main switch and ensure that it cannot be turned back on. Dismount protective covers if required. Ensure the proper positioning of the out-of-service axis. Unplug the read head connecting cable.
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Page 63: Battery Amsabs
This means that in the case of typical usage where the machine is regularly in operation, the buffer battery guarantees functionality of the sensor unit for many years. Schneeberger recommends in this case that the battery is replaced proactively every 5 years. -
Page 64: Checking And Replacing Accessories And Wear Parts
Maintenance Checking and replacing accessories and wear parts 9.6.1 Front plates and additional wipers Making sure that the carriage seals function properly is a prerequisite in ensuring that the guideway provides a long service life. In general, the seals are designed to be maintenance-free if given sufficient lubrication and kept a clean environment. Certain operating conditions, such as dust or swarf on the guideway or inadequate guideway lubrication, lead to increased wear of the sealing lips. - Page 65 Maintenance Cross wipers Checking cross wipers Check cross wipers regularly for wear and replace where required. Replacing cross wipers in the case of MONORAIL MR Leave carriages on the guideway. Remove the upper and lower screws. Remove front panel and accessories (where applicable) from the front plate (can be left on the guideway).
- Page 66 Maintenance Replacing cross wipers in the case of MONORAIL BM front plates In the case of MONORAIL BM, only the cross wipers in the front plate should be replaced. The screws of the front plate must not be loosened during this process. Use an assembly rail to transfer the carriage from the guideway.
- Page 67 Maintenance Replacing ASM/ABM metal wipers Loosen the screws on the front plate. Pull the wiper over the guide rail end. Mount a new metal wiper over the guide rail end. Tighten the fastening screws until the wiper can no longer be moved by hand. Use a feeler gauge and relevant documentation to ensure an even gap between the guide rail and wiper edge.
- Page 68 Maintenance Cover strips MAC/BAC cover strips Cover strips must be positioned over the entire length of the guide rail cleanly and gap-free with a slight upward curve on the guide rail surface. The ends must be secured with a bracket or end pieces. Multi-part cover strips must not show any signs of a gap at the butt joint.
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Page 69: Spare Parts - Availability
SCHNEEBERGER undertakes, following the delivery of MONORAIL systems, to make compatible sub-assemblies and therefore also compatible complete systems available that can be used in sub-assembly replacement. This enables full field service capability to be maintained for all products without sacrificing improveability. -
Page 70: Disposal
Disposal NOTE: The product and packaging material, consisting of plastics, metals, batteries, electronic components, wood, and lubricants, should be disposed of or recycled by the operator in accordance with locally applicable national or regional legislation. -
Page 71: Troubleshooting The Ams Measuring System
Troubleshooting the AMS measuring system Operating state display The AMSA 3B, AMSA 4B, AMSD 3B, AMSD 4B, and AMSABS measuring system versions are fitted with a service LED in the electronics housing of the read head that displays the different measuring system operating states. AMSD Error Repair... -
Page 72: Appendix
Appendix 12.1 Dimensions of accessories Dimensions of MRK/BRK plastic plugs Size ØDT MRK 25 11.4 MRK 30/35 15.3 MRK 45 20.3 MRK 55 24.3 MRK 65 26.4 Size ØDT BRK 15 BRK 20 10.3 BRK 25 11.3 Fig.121 BRK 30/35 15.3 BRK 45 20.3 All dimensions in mm Dimensions of MRS/BRS brass plugs... - Page 73 Appendix Recommended screw sizes for dismantling MRS/BRS/MRZ Brass plugs Screw Ø core hole Sizes 15 - 35 Sizes 35 - 100 All dimensions in mm MWH/BWH assembly tool dimensions Fig.124 Size n x L4 MWH 25 MWH 30 MWH 35 135.5 MWH 45 142.5...
- Page 74 Appendix Dimensions of MAC/BAC cover strip Size MAC 25 MAC 35 MAC 45 MAC 55 28.5 MAC 65 Size BAC 15 BAC 20 Fig.125 BAC 25 BAC 30 BAC 35 BAC 45 All dimensions in mm Dimensions of steel securing bands Size BSC 15 18.2...
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Page 75: Screw Tightening Torques
Appendix 12.2 Screw tightening torques Tightening torques for guideways and carriages DANGER! Risk to life posed by falling machine elements! In the case of sufficiently high loads, the screw connections are unable to prevent guideways or carriages e.g. from lateral sliding. • Profiled linear guideways should be secured using all available mounting holes and/or threads. - Page 76 Appendix DANGER! Risk to life posed by falling machine elements! Screws for securing front plates are provided with threadlocker. The adhesive force of this is reduced by repeated screwing and unscrewing, which can lead to unwanted loosening of the screws during operation and loosening of the front plate.
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Page 77: Amount Of Lubricants
Any installation orientation NOTES • SCHNEEBERGER recommends CLP (DIN 51517) or HLP (DIN 51524) mineral oil with a viscosity range between ISO VG32 and ISO VG100 (DIN 51519). • CGLP bed track oils can be used up to ISO VG220. -
Page 78: Cable Bending Radii
BM 25 BM 30 BM 35 BM 45 10.9 NOTE: The SPL must be refilled using KLÜBER Lamora D 220 oil. Schneeberger GmbH Höfen/Enz assumes no liability for refilling using other lubricants. 12.4 Cable bending radii Cable diameter Permissible bending radius Radius... - Page 79 • MONORAIL AND AMS PROFILED LINEAR GUIDEWAYS • GEAR RACKS WITH INTEGRATED MEASURING SYSTEM • LINEAR BEARINGS AND RECIRCULATING UNITS • MONORAIL AND AMS APPLICATION CATALOG • MINERAL CASTING SCHNEEBERGER • POSITIONING SYSTEMS • MINISLIDE MSQSCALE • SLIDES www.schneeberger.com A.MANNESMANN...