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Service documentation

Exchange of rollers from the XTS-Mover

for AT9012-0050-0550 and AT9011-00x0-0550

1.020.10.2017

Version:Date:

Table of contents

Exchange of rollers from the XTS-Mover 3Version: 1.0

Table of contents1 Foreword .................................................................................................................................................... 5

1.1 Notes on the documentation........................................................................................................... 51.2 Documentation issue status............................................................................................................ 6

1.2.1 Scope of the documentation .............................................................................................. 61.3 Documented components............................................................................................................... 6

2 Guidelines and Standards ........................................................................................................................ 7

3 For your safety........................................................................................................................................... 83.1 Staff qualification ............................................................................................................................ 83.2 Description of symbols.................................................................................................................... 9

4 General Information ................................................................................................................................ 10

5 Roller replacement for AT9012-0050-0550 ............................................................................................ 115.1 Scope of supply ............................................................................................................................ 125.2 Disassembly ................................................................................................................................. 135.3 Mounting ...................................................................................................................................... 14



8 Support and Service................................................................................................................................ 26

Table of contents

Exchange of rollers from the XTS-Mover4 Version: 1.0

Foreword


1 Foreword

1.1 Notes on the documentationThis description is only intended for the use of trained specialists in control and automation engineering whoare familiar with the applicable national standards.It is essential that the documentation and the following notes and explanations are followed when installingand commissioning the components. It is the duty of the technical personnel to use the documentation published at the respective time of eachinstallation and commissioning.

The responsible staff must ensure that the application or use of the products described satisfy all therequirements for safety, including all the relevant laws, regulations, guidelines and standards.

Disclaimer

The documentation has been prepared with care. The products described are, however, constantly underdevelopment.We reserve the right to revise and change the documentation at any time and without prior announcement.No claims for the modification of products that have already been supplied may be made on the basis of thedata, diagrams and descriptions in this documentation.

Trademarks

Beckhoff®, TwinCAT®, EtherCAT®, Safety over EtherCAT®, TwinSAFE®, XFC® and XTS® are registeredtrademarks of and licensed by Beckhoff Automation GmbH.Other designations used in this publication may be trademarks whose use by third parties for their ownpurposes could violate the rights of the owners.

Patent Pending

The EtherCAT Technology is covered, including but not limited to the following patent applications andpatents:EP1590927, EP1789857, DE102004044764, DE102007017835with corresponding applications or registrations in various other countries.

The TwinCAT Technology is covered, including but not limited to the following patent applications andpatents:EP0851348, US6167425 with corresponding applications or registrations in various other countries.

EtherCAT® is registered trademark and patented technology, licensed by Beckhoff Automation GmbH,Germany

Copyright

© Beckhoff Automation GmbH & Co. KG, Germany.The reproduction, distribution and utilization of this document as well as the communication of its contents toothers without express authorization are prohibited.Offenders will be held liable for the payment of damages. All rights reserved in the event of the grant of apatent, utility model or design.

Foreword


1.2 Documentation issue statusVersion Comment1.0 First release0.0.1 – 0.0.5 Internal versions

1.2.1 Scope of the documentationThe documentation package for the eXtended Transport System (XTS) comprises the following manuals:

XTS - DefinitionService documentation for roller replacement on theXTS movers (this document)

Documentation regarding the replacement of rollersfor AT9012-0050-0550 and AT9011-00x0-0550.

Startup Documentation regarding the installation andcommissioning of the eXtended Transport System,including mechanical and electrical parameters.

Servicing and maintenance concept(current only available in English)

Documentation regarding the configuration of theeXtended Transport System, including maintenanceinstructions for all available components.

Application manual(current only available in English)

Documentation regarding the EtherCAT & real-timeconfiguration of the eXtended Transport System.

Configuration and parameterization(current only available in English)

Extension for XTS Startup. Description of theconfiguration and parameterization of the eXtendedTransport System in the TwinCAT system.

Soft Drive – functional description (current only available in English)

Extension for XTS Startup. Description of the Soft Drive function in the TwinCAT system.

1.3 Documented componentsThis service documentation describes the following components of the eXtended Transport System (XTS):

12 - roller mover:AT9012-0050-0550

6 - roller mover:AT9011-0070-0550

6 - roller mover:AT9011-0050-0550

Guidelines and Standards


2 Guidelines and Standards

CAUTION

Personal injuries!The XTS movers with part numbers AT9012-0050-0550 and AT9011-00x0-0550 are notproducts within the meaning of EU Machinery Directive. The intended use of the movertypes mentioned above in machines or systems is prohibited until the machine or systemmanufacturer has provided proof of the CE conformity of the entire machine or system.

For your safety


3 For your safetyRead the section on safety and heed the notices to protect yourself against personal injury and materialdamages.

Liability limitations

All components of the eXtended Transport System (XTS) are supplied in certain hardware and softwareconfigurations, depending on the application requirements. Unauthorized modifications to the hardware and/or software configurations other than those described in the documentation are not permitted, and nullify theliability of Beckhoff Automation GmbH & Co. KG.

In addition, the following actions are excluded from the liability of Beckhoff Automation GmbH & Co.KG:

• Failure to comply with this documentation• Untrained personnel• Use of unauthorized spare parts

3.1 Staff qualificationAll the tasks relating to Beckhoff software and hardware described in the documentation, particularly relatingto the movers AT9012-0050-0550 and AT9011-00x0-0550, may only be carried out by qualified personnelwith appropriate knowledge of control and automation technology.

The technical personnel must have knowledge of drive technology and electrical systems and must alsoknow how to work safely on electrical equipment and machines.

This also includes:• work preparation and• securing of the working environment (e.g. securing the control cabinet against being switched on

again).

The technical personnel must be familiar with the current and necessary standards and directives for theautomation and drive environment.

For your safety


3.2 Description of symbolsIn this documentation the following symbols are used with an accompanying safety instruction or note. Thesafety instructions must be read carefully and followed without fail!

Symbols that warn of personal injury:

DANGER

Serious risk of injury!This is an extremely dangerous situation. Disregarding the safety notice will lead to seriouspermanent injuries or even death.

WARNING

Risk of injury!This is a dangerous situation. Disregarding the safety notice may lead to serious injuries.

CAUTION

Personal injuries!This is a dangerous situation. Disregarding the safety notice may lead to minor injuries.

Symbols that warn of damage to property or equipment:

Attention

Warning of damage to property or the environment!This notice indicates disturbances in the operational procedure that could damage theproduct or the environment.

Symbols indicating further information or tips:

Note

Tip or pointer!This notice provides important information that will be of assistance in dealing with theproduct or software. There is no immediate danger to product, people or environment.

UL note!This symbol indicates important information regarding UL certification.

General Information


4 General InformationBeckhoff Automation GmbH & Co. KG offers pre-assembled roller sets for servicing the XTS movers. A rollerset contains all the components required for replacement.The following order numbers have been generated for the roller sets:

Order number DescriptionZX9011-0050 Roller set for 6-roller movers with 50 mm lengthZX9011-0070 Roller set for 6-roller movers with 70 mm lengthZX9012-0050 Roller set for 12-roller movers with 50 mm length

Please note that the roller material and the mover are adapted to each other. Before replacing a roller,please check the version. The version can be unambiguously identified by means of the order number of themover body.On the underside of the mover there are two numbers, which are structured as follows:

• 5-digit internal product code and• 6-digit order number of the mover housing

The 6-digit order number (circled in red on the mover) indicates whether a roller set can be used forreplacing the mover rollers or whether the complete mover has to replaced or sent in.

Note

Order numbers on the mover bodyIf the part can be serviced by the customer, the rollers can be replaced with the corre-sponding roller set. If the part can only be serviced in the factory, the complete mover hasto be returned to Beckhoff Automation GmbH & Co. KG. A list of the serviceable parts canbe found below this warning. If there is no order number on the underside of the mover, the mover has to be returned toBeckhoff Automation GmbH & Co. KG! In this case, it is not possible to replace the rollers with a roller set! If such a case occurs, please send the mover to:Beckhoff Automation GmbH & Co. KGService-CenterStahlstraße 3133415 VerlGermany

List of order numbers

Mover type Description Order number(can be serviced bycustomer)

Order number(can only be serviced inthe factory)

Service number

AT9011-0050-0550 6-roller mover, 50 mm length 138279 112540 or none ZX9999-0000AT9012-0050-0550 12-roller mover, 50 mm length 138746 128550 or none ZX9999-0001*

The rollers of the mover with the part number AT9011-0070-0550 can be replaced with the correspondingroller set. The order number is 141005.*For service number ZX9999-0001 please consult with the Beckhoff XTS product management to checkwhether the curved rail has to be replaced together with the mover.

Roller replacement for AT9012-0050-0550


5 Roller replacement for AT9012-0050-0550The mover with order number AT9012-0050-0550 has 12 rollers. Defective or worn rollers affect theperformance and running characteristics of the mover. In addition, they can result in damage to theeXtended Transport System. It is therefore imperative to replace faulty or worn rollers. Replacement isnecessary when wear is visible or diagnosed.

Arrangement of the rollers on the mover

Diagram showing the arrangement of therollers

Item no. Explanation

1

1

2

2

22

2

3

3

4

43

3

1 Cylindrical rollers for straight guide rails.Arrangement: centrally in the upper part of themover housing (2 units)

2 Conical rollers for curved guide rails.Arrangement: left and right in the upper part ofthe mover housing (4 units)Please note the installation position of the rolleron the shoulder bolt!

3 Cylindrical rollers for straight guide rails.Arrangement: left and right in the upper part ofthe mover housing (4 units)

4 Conical rollers for curved guide rails.Arrangement: centrally in the lower part of themover housing (2 units)Please note the installation position of the rolleron the shoulder bolt!

Special features

The 12-roller mover with order number AT9012-0050-0550 has four different roller types. The rollers containtwo ball bearings (including adjusting washers) and are attached to the mover with a M3 x 18 shoulder bolt.The following table provides an overview of the individual components and their arrangement:

Cylindrical roller Conical roller Cylindrical roller Conical roller

1 adjusting washer [item1]: 4 x 8 x 1 (in mm)

Attention: In this installation position,the notch on the roller mustpoint to the thread of theshoulder bolt [item 1]!2 adjusting washers [item2]: 4 x 8 x 1 (in mm)

1 spacer ring [item 1]: 4 x 8 x 3 (in mm)

Attention: In this installation position,the notch on the rollermust point to the head ofthe shoulder bolt [item 1]!1 adjusting washer [item2]: 4 x 8 x 1 (in mm)

11

21

12



5.1 Scope of supplyTo replace the rollers of the mover with order number AT9012-0050-0550, you need a roller set with ordernumber ZX9012-0050.

Note

Selecting the roller set for the mover with order number AT9012-0050-0550:Further information can be found in chapter: “General information [} 10]” in this documentation.

Before installing the roller set, please check whether all components listed below are available and check thecomponents for damage. Any missing or faulty components should immediately be reported to the carrierand documented.

The following components are included:

Spare parts diagrams showing quantities6 x cylindrical roller 6 x conical roller

12 x adjusting washer 4x8x1 A2 DIN-988 4 x spacer ring 4x8x3 A2

12 x shoulder bolt M3x18 12 x nut M3 A2 DIN-6923

Composition of the rollers included in the scope of supply

The rollers consist of two ball bearings [item 1], an A2 DIN-988 adjusting washer 4x8x1 [item 2] and a rollerlining [item 3]. The rollers are pre-assembled in roller set AT9012-0050-0550.

Note regarding attaching the roller to the shoulder bolt:If it is not possible to move the shoulder bolt freely throughthe roller during installation, it is likely that the adjustingwasher [item 2] within the roller has slipped.Proceed as follows:

• Push the adjusting washer [item 2] into the correctposition using a slotted screwdriver (centrally between the two ball bearings [item 1]).

• Reinsert the shoulder bolt in the roller.Finally, check that all components are firmly seated.



5.2 DisassemblyThe following tools are required to disassemble the rollers:

• Angled screwdriver T20 (Torx)• Socket wrench, size 5.5• Commercial cleaning material (e.g. isopropanol as cleaning agent)

Attention

Aggressive substances may damage the rollers!The rollers of the mover with article number AT9012-0050-0550 may be damaged if ag-gressive substances are used. Only use commercially available cleaning materials (e.g.isopropanol) for servicing the movers and components. Other materials can damage thecomponents and thus significantly reduce the service life of the rollers.

Removing the rollers

Note

Dismantling sequence for the rollersAlways dismantle the rollers from outside to inside:

- Start with the rollers [item 3] [} 11] and [item 2] [} 11] on the outside of the mover.

- Continue with the rollers [item 1] [} 11] and [item 4] [} 11] on the inside of the mover.It is essential to follow the roller disassembly instructions below.The specified steps ensure avoidance of:- damage to the mover- wasted time as a result of incorrect disassemblyShould you have any questions regarding one of the steps listed below, please stop work-ing on the mover and contact the Beckhoff applications department!

Infographic Disassembly instructions for the rollersPreparation

• Use the angled screwdriver T20 (Torx) to holdthe shoulder bolt [1] of the roller [2], which is tobe removed.

Releasing the bolted connection• Release the nut [3] of the shoulder bolt [1] with

the socket wrench, size 5.5.Removing the individual components

• Pull the shoulder bolt [1] out of the moverhousing.

• Make sure you pull the shoulder bolt [1] straightto avoid jamming at the mover housing.

Clean the mover housing after disassembly!Collect the individual components (shoulderbolts, rollers, adjusting washers, nuts) anddispose of them properly after disassembly!



5.3 MountingThe following tools are required to install the rollers:

• Angled screwdriver T20 (Torx)• Torque socket wrench, size 5.5 (set to 3 Nm)

Installing the rollers

Note

Installation sequence for the rollersAlways install the rollers from inside to outside:

- Start with the rollers [item 1] [} 11] and [item 4] [} 11] on the inside of the mover.

- Continue with the rollers [item 3] [} 11] and [item 2] [} 11] on the outside of the mover.Please refer to the diagram below this box.It is essential to follow the roller installation instructions below.The specified steps ensure avoidance of:- damage to the mover- wasted time as a result of incorrect assembly- consequential damage during operationShould you have any questions regarding one of the steps listed below, please stop work-ing on the mover and contact the Beckhoff applications department!

Diagram illustrating the assembly sequence

Step 1: Install the rollers on the inside of themover [items 1 and 4]*

Step 2: Install the rollers on the outside of the mover [items 3 and 2]

*to simplify the display of the inner rollers, the diagram shows a section view of the mover.



Infographic Installation instructions for the rollersPreparation

• First, push the roller [2] and then thecorresponding adjusting washers [4] onto theshoulder bolt [1].

Inserting the shoulder bolt• Insert the prepared shoulder bolt [1] into the

mover housing from inside.• Secure the shoulder bolt against falling out.

Fastening the shoulder bolt• Screw the nut [3] onto the shoulder bolt [1]• Hold the shoulder bolt [1] with the angled

screwdriver T20 (Torx).• Tighten the nut with the torque socket wrench,

size 5.5, and a torque of 3 Nm.Clean the mover housing after assembly!







1

2

2

2

2

1

1 Cylindrical rollers, 26 mm dia.Arrangement: centrally in the lower part ofthe mover housing (2 units)

2 Cylindrical rollers, 22 mm dia.Arrangement: left and right in the upper partof the mover housing (4 units)

Special features

The 6-roller mover with article number AT9011-0070-0550 has two different roller types. Each roller containstwo ball bearings. They are attached to the mover with two different shoulder bolts (M4 x 20 and M4 x 25).The following table provides an overview of the individual components and their arrangement:

Cylindrical roller, 26 mm dia. Cylindrical roller, 22 mm dia.

1 adjusting washer [item 1]:5 x 10 x 1 (in mm)1 shoulder bolt:M4 x 25





Note




Spare parts diagrams showing quantities4 x cylindrical roller (22 mm) 2 x cylindrical roller (26 mm)

6 x adjusting washer 5x10x1 A2 DIN-988 8 x plug D12 T4

6 x shoulder bolt 6 x nut M4 A2 DIN-69234 x M4x20 2 x M4x25


The rollers consist of two ball bearings [item 1] and a roller lining [item 2]. The rollers are pre-assembled inroller set AT9011-0070-0550.

Note regarding installation of the ball bearings [item 1] in theroller lining [item 2]:When transporting the roller set, the ball bearing may becomedetached from the roller lining.To install the ball bearings [item 1] in the roller linings [item 2]proceed as follows:

• Manually push the ball bearing [item 1] centrally into the rollerlining [item 2].

Finally, check that all components are firmly seated.Note: Avoid jamming the ball bearing. Jamming may lead to damageof the bandages and therefore impair the running characteristics andperformance of the mover.




• Angled screwdriver T20 (Torx)• Socket wrench, size 7• Commercial cleaning material (e.g. isopropanol as cleaning agent)

Attention



Note


- Start with the rollers [item 2] [} 16] on the outside of the mover.

- Continue with the rollers [item 1] [} 16] on the inside of the mover.It is essential to follow the roller disassembly instructions below.The specified steps ensure avoidance of:- damage to the mover- wasted time as a result of incorrect disassemblyShould you have any questions regarding one of the steps listed below, please stop work-ing on the mover and contact the Beckhoff applications department!


• Remove the plug [5]. Pierce it centrally and thenlever it out of the mover housing.

• Hold the shoulder bolt [1] to be removed with theangled screwdriver T20 (Torx).

Releasing the bolted connection• Release the nut [4] of the shoulder bolt [1] with the

socket wrench, size 7.Removing the individual components

• Pull the shoulder bolt [1] out of the mover housing.• Make sure you pull the shoulder bolt [1] straight to

avoid jamming at the mover housing.Clean the mover housing after disassembly!Collect the individual components (shoulder bolts,rollers, adjusting washers, nuts, plugs) and disposeof them properly after disassembly!




• Angled screwdriver T20 (Torx)• Torque socket wrench, size 7 (set to 5 Nm)


Note

Installation sequence for the rollersAlways install the rollers from inside to outside:- Start with the rollers [item 1] on the inside of the mover.- Continue with the rollers [item 2] on the outside of the mover.Please refer to the diagram below this box.It is essential to follow the roller installation instructions below.The specified steps ensure avoidance of:- damage to the mover- wasted time as a result of incorrect assembly- consequential damage during operationShould you have any questions regarding one of the steps listed below, please stop work-ing on the mover and contact the Beckhoff applications department!


Step 1: Install the rollers on the inside of themover [item 1]*

Step 2: Install the rollers on the outside of the mover [item 2]





• First, push the roller [2] and then thecorresponding adjusting washer [3] onto theshoulder bolt [1].


mover housing from inside.• Secure the shoulder bolt [1] against falling out.

Fastening the shoulder bolt• Screw the nut [4] onto the shoulder bolt [1]• Hold the shoulder bolt [1] with the angled

screwdriver T20 (Torx).• Tighten the nut [4] with the torque socket

wrench, size 7, and a torque of 5 Nm.• Insert the plug [5] in the mover housing.

Clean the mover housing after assembly!







2 2

2

2

1

1

1 Cylindrical rollers, 19 mm dia., with M3 x 20mm shoulder boltArrangement: centrally in the lower part ofthe mover housing (2 units)

2 Cylindrical rollers, 19 mm dia., with M3 x 16mm shoulder boltArrangement: left and right in the upper partof the mover housing (4 units)

Special features

Each roller contains two ball bearings. They are attached to the mover with two different shoulder bolts (M3 x16 and M3 x 20).The following table provides an overview of the individual components and their arrangement:

Cylindrical roller, 19 mm dia. Cylindrical roller, 19 mm dia.






Note




Spare parts diagrams showing quantities6 x cylindrical roller (19 mm) 6 x adjusting washer 4x8x1 A2 DIN-988

6 x shoulder bolt 6 x nut M3 A2 DIN-69234 x M3x16 2 x M3x20


The rollers consist of two ball bearings [item 1] and a roller lining [item 2]. The rollers are pre-assembled inroller set AT9011-0050-0550.

Note regarding installation of the ball bearings [item 1] in theroller lining [item 2]:When transporting the roller set, the ball bearing may becomedetached from the roller lining.To install the ball bearings [item 1] in the roller linings [item 2]proceed as follows:

• Manually push the ball bearing [item 1] centrally into the rollerlining [item 2].

Finally, check that all components are firmly seated.Note: Avoid jamming the ball bearing. Jamming may lead to damageof the bandages and therefore impair the running characteristics andperformance of the mover.




• Angled Allen wrench 2 mm• Socket wrench, size 5.5• Commercial cleaning material (e.g. isopropanol as cleaning agent)

Attention



Note


- Start with the rollers [item 2] [} 21] on the outside of the mover.

- Continue with the rollers [item 1] [} 21] on the inside of the mover.It is essential to follow the roller disassembly instructions below.The specified steps ensure avoidance of:- damage to the mover- wasted time as a result of incorrect disassemblyShould you have any questions regarding one of the steps listed below, please stop work-ing on the mover and contact the Beckhoff applications department!


• Hold the shoulder bolt to be dismantled [1] with the2 mm Allen wrench.

Releasing the bolted connection• Release the nut [4] of the shoulder bolt [1] with the

socket wrench, size 5.5.Removing the individual components

• Pull the shoulder bolt [1] out of the mover housing.• Make sure you pull the shoulder bolt [1] straight to

avoid jamming at the mover housing.Clean the mover housing after disassembly!Collect the individual components (shoulder bolts,rollers, adjusting washers, nuts) and dispose ofthem properly after disassembly!




• Angled Allen wrench 2 mm• Torque socket wrench, size 5.5 (set to 3 Nm)


Note

Installation sequence for the rollersAlways install the rollers from inside to outside:- Start with the rollers [item 1] on the inside of the mover.- Continue with the rollers [item 2] on the outside of the mover.Please refer to the diagram below this box.It is essential to follow the roller installation instructions below.The specified steps ensure avoidance of:- damage to the mover- wasted time as a result of incorrect assembly- consequential damage during operationShould you have any questions regarding one of the steps listed below, please stop work-ing on the mover and contact the Beckhoff applications department!


Step 1: Install the rollers on the inside of themover [item 1]*

Step 2: Install the rollers on the outside of the mover [item 2]





• First, push the roller [2] and then thecorresponding adjusting washer [3] onto theshoulder bolt [1].


mover housing from inside.• Secure the shoulder bolt [1] against falling out.

Fastening the shoulder bolt• Screw the nut [4] onto the shoulder bolt [1]• Hold the shoulder bolt [1] with the 2 mm Allen

wrench.• Tighten the nut [4] with the torque socket

wrench, size 5.5, and a torque of 3 Nm.Clean the mover housing after assembly!

Support and Service


8 Support and ServiceBeckhoff and their partners around the world offer comprehensive support and service, making available fastand competent assistance with all questions related to Beckhoff products and system solutions.

Beckhoff's branch offices and representatives

Please contact your Beckhoff branch office or representative for local support and service on Beckhoffproducts!

The addresses of Beckhoff's branch offices and representatives round the world can be found on her internetpages:http://www.beckhoff.com

You will also find further documentation for Beckhoff components there.

Beckhoff Headquarters

Beckhoff Automation GmbH & Co. KG

Huelshorstweg 2033415 VerlGermany

Phone: +49(0)5246/963-0Fax: +49(0)5246/963-198e-mail: [email protected]

Beckhoff Support

Support offers you comprehensive technical assistance, helping you not only with the application ofindividual Beckhoff products, but also with other, wide-ranging services:

• support• design, programming and commissioning of complex automation systems• and extensive training program for Beckhoff system components

Hotline: +49(0)5246/963-157Fax: +49(0)5246/963-9157e-mail: [email protected]

Beckhoff Service

The Beckhoff Service Center supports you in all matters of after-sales service:

• on-site service• repair service• spare parts service• hotline service

Hotline: +49(0)5246/963-460Fax: +49(0)5246/963-479e-mail: [email protected]

http://www.beckhoff.de/english/support/default.htm

http://www.beckhoff.com

http://www.beckhoff.com/english/download/default.htm

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