Bosch Rexroth BS 2/C Series Bedienungsanleitung

Assembly instructions

3 842 358 724/2013-04

Replaces: –

English

BS 2/C-100

BS 2/C-H

BS 2/R-700

BS 4/R-700

BS 2/R-300

BS 4/R-300

BS 2/R-H

BS 2/R-V-1200

BS 2/C-250

BS 2/C-…, BS 2/R-…

Belt sections

Applies to the following types:

3 842 998 096 , BS 2/R-700

3 842 998 097 , BS 4/R-300

3 842 998 238 , BS 2/R-H

3 842 998 239 , BS 2/C-H

3 842 998 492 , BS 2/R-V-1200

3 842 999 901 , BS 4/R-700

3 842 999 904 , BS 2/R-300

3 842 999 917 , BS 2/C-100

3 842 999 985 , BS 2/C-250

ENGLISH

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The data speciﬁed only serve to describe the product. The information provided in the instructions

on how to use the supplied product should only be considered application examples and

suggestions. Catalog information is not binding. The information given does not release the user

from the obligation of own judgment and veriﬁcation. Our products are subject to a natural process

of wear and aging.

exclusive property of Bosch Rexroth AG. It may not be reproduced or given to third parties without

its consent.

An example conﬁguration is shown on the title page. The delivered product may thus vary from the

illustration.

The original assembly instructions were generated in German.

DE Die vorliegende Montageanleitung ist in den hier angebenen Sprachen verfügbar. Als gedruckte Version (print) oder als PDF-

Datei (media) zum Download aus dem Medienverzeichnis: www.boschrexroth.com/medienverzeichnis

1. Geben Sie in die Suchmaske (oben rechts, unter „Suche“) 3 842 358 723 ein. 2. Klicken Sie auf „Suche“.

EN These assembly instructions are available in the languages indicated here. They come in a hard copy (print) or a PDF ﬁle (media)

that can be downloaded at: www.boschrexroth.com/mediadirectory

1. Enter 3 842 358 724 in the search mask (at the top right, under “Search”). 2. Click “Search”.

FR Les présentes instructions de montage sont disponibles dans les langues mentionnées ici. Disponible au téléchargement en

version imprimée (print) ou en ﬁchier PDF (media) à partir du répertoire médias : www.boschrexroth.com/mediadirectory

1. Dans le masque de recherche (en haut à droite dans « Search »), saisissez 3 842 358 725. 2. Cliquez sur « Search ».

IT Le presenti istruzioni per il montaggio sono disponibili nelle lingue qui indicate, in versione stampata (print) o come ﬁle PDF

(media) da scaricare dalla media directory: www.boschrexroth.com/mediadirectory

1. Nella maschera di ricerca (in alto a destra, sotto “Search”) immettere 3 842 358 726. 2. Fate clic su “Search”.

ES Este manual de instrucciones está disponible en los idiomas aquí indicados como versión impresa o archivo PDF para descarga

desde el directorio de medios: www.boschrexroth.com/mediadirectory

1. Indique en el cuadro de búsqueda (parte superior derecha, “Search”) 3 842 358 727. 2. Haga clic en “Search”.

PT O presente manual de montagem está disponível nos idiomas aqui indicados. Como versão impressa (print) ou como arquivo

PDF(media) para ser descarregado do diretório de mídias: www.boschrexroth.com/mediadirectory

1. Introduza no motor de busca (em cima à direita, em “Search”) 3 842 358 728. 2. Clique em “Search”.

ZH 本安装说明书有这里给出的语言版本。有印刷版本 (print) 或者电子版 PDF 文件 (media) 供使用，电子版文件可在下列的公司网站媒体网

页上下载: www.boschrexroth.com/mediadirectory

1. 在搜索窗口 (右上角，“Search”窗口) 内输入编号 3 842 358 729。2. 点击“Search”。

CS Tento návod k montáži je k dispozici ve zde uvedených jazycích. Jako tištěná verze (print) nebo jako soubor PDF (media) je ke

stažení z adresáře médií: www.boschrexroth.com/mediadirectory

1. Zadejte do vyhledávací obrazovky (nahoře vpravo, pod „Search“) MTCS 358 723. 2. Klikněte na „Search“.

PL Dana instrukcja montażu jest dostpna w podanych tutaj językach. W postaci wydrukowanej lub w wersji pdf (media) do

pobrania ze strony: www.boschrexroth.com/mediadirectory

1. Do wyszukiwarki wpisać (w prawym górnym rogu „Search“) MTPL 358 723 . 2. KKliknać „Search“

3 842 358 723 print media Bandstrecke BS 2/C-… + BS 2/R-… DE Deutsch

3 842 358 724 print media Belt sections BS 2/C-… + BS 2/R-… EN English

3 842 358 725 print media Section à bande BS 2/C-… + BS 2/R-… FR Français

3 842 358 726 print media Tratto a nastro BS 2/C-… + BS 2/R-… IT Italiano

3 842 358 727 print media Tramo de cinta BS 2/C-… + BS 2/R-… ES Español

3 842 358 728 print media Via de esteira BS 2/C-… + BS 2/R-… PT Português

3 842 358 729 print media 皮带输送段 BS 2/C-… + BS 2/R-… ZH 中文

MTCS 358 723 media Dopravníková trať BS 2/C-… + BS 2/R-… CS Česky

MTPL 358 723 media Przenośnik BS 2/C-… + BS 2/R-… PL Polski

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3/76Contents

1 About This Documentation 6

1.1 Scope of documentation 6

1.2 Required and supplementary documentation 6

1.3 Presentation of information 6

1.3.1 Safety instructions 6

1.3.2 Symbols 7

1.3.3 Designations 8

1.3.4 Abbreviations 8

2 Notes on Safety 8

2.1 About this chapter 8

2.2 Intended use 8

2.3 Improper use 9

2.4 Personnel qualiﬁcations 9

2.5 General safety instructions 10

2.6 Product-speciﬁc safety instructions 10

2.7 Personal protective equipment 11

2.8 Obligations of the system owner 11

3 General Notes on Equipment and Product Damage 12

4 Scope of Delivery 13

4.1 Condition on delivery 13

5 About This Product 13

5.1 Performance description 13

5.1.1 BS 2 belt section application... 13

5.1.2 BS 2 belt section version... 13

5.2 Product description 14

5.3 Product identiﬁcation 15

6 Transport and Storage 15

6.1 Transporting the product 15

6.2 Storing the product 15

7 Assembly 16

7.1 Unpacking 16

7.2 Installation requirements 16

7.2.1 Mounting orientation 16

7.2.2 Mounting with T-bolts 16

7.3 Required tools 16

7.4 Required accessories 17

7.5 Symbols used 18

7.6 Assembling the product 19

7.6.1 Assembling the belt section on leg sets 19

7.6.2 Changing the mounting position of the motor/gear combination

or the gear motor 21

7.6.3 BS 2/C-100, -250, BS 2/R-300, -700, BS 4/R-300, -700:

Assembling the belt section between two sections 22

7.6.4 BS 2/C-H, BS 2/R-H, BS 4/R-V-1200:

Assembling the belt section between two sections 23

Contents

ENGLISH

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7.6.5 BS 2/R-H, reversible:

Assembling the belt section between two sections 24

7.6.6 BS 2/C-100, -250, BS 2/R-300, -700, BS 4/R-300, -700:

Assembling two belt sections, drive head to return unit 25

7.6.7 BS 2/C-H, BS 2/R-H, BS 4/R-V-1200:

Assembling two belt sections, drive head to return unit 26

7.6.8 Checking the chain elongation

BS 2/C-100, -250, BS 2/R-300, -700, BS 4/R-300, -700 27

7.6.9 Checking the chain elongation

BS 2/C-H, BS 2/R-H, BS 4/R-V-1200 28

7.6.10 BS 2/R-300, -700, BS 4/R-300, -700:

Assembling the accelerating element (only if lWT = 160/240) 29

7.6.11 Electrically connecting the product 31

8 Commissioning 33

8.1 Commissioning for the ﬁrst time 33

8.2 Residual hazards 34

8.3 Recommissioning after shutdowns 34

9 Operation 35

9.1 Notes on operation 35

9.1.1 Wear 35

9.1.2 Measures to reduce wear 35

9.1.3 Loading the workpiece pallet 36

9.1.4 Ambient inﬂuences 36

10 Maintenance and Repair 37

10.1 Cleaning and care 38

10.2 Inspection 38

10.2.1 Conveyor chain (ﬂat top chain/accumulation roller chain) 38

10.3 Maintenance 38

10.3.1 Bearings 38

10.3.2 Gears 38

10.3.3 Motor 38

10.3.4 Conveyor chain (ﬂat top chain/accumulation roller chain) 39

10.3.5 Options to lubricate the conveyor chain manually 40

10.3.6 LU 2 automatic lubrication unit 41

10.4 Replacing wear parts 42

10.4.1 Designations 42

10.4.2 Required tools 42

10.4.3 Required accessories 42

10.4.4 Notes for mounting: Finding the master link on a functional chain 43

10.4.5 Notes for mounting: securing the chain tensioner for

BS 2/C-100, BS 2/C-250, BS 2/R-300,

BS 4/R-300, BS 2/R-700, BS 4/R-700 44

10.4.6 Notes for mounting: Securing the chain tensioner for

BS 2/C-H, BS 2/R-H, BS 2/R-V-1200 44

10.4.7 Checking the chain elongation for

BS 2/C-100, BS 2/C-250, BS 2/R-300,

BS 4/R-300, BS 2/R-700, BS 4/R-700 45

10.4.8 Checking the chain elongation for

BS 2/C-H, BS 2/R-H, BS 2/R-V-1200 45

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10.4.9 Shortening the conveyor chain:

BS 2/C-100, BS 2/R-300, BS 4/R-300, BS 2/C-250, BS 2/R-700,

BS 4/R-700, motor mounting (MA) = R/L 46

10.4.10 Shorten conveyor chain:

BS 2/C-100, BS 2/R-300, BS 4/R-300, motor mounting (MA) = M 48

10.4.11 Shortening the conveyor chain:

BS 2/C-H, BS 2/R-H, BS 2/R-V-1200, motor mounting (MA) = R/L 50

10.4.12 Shortening the conveyor chain:

BS 2/R-H, reversible, BS 2/R-V, reversible, motor mounting (MA) = R/L 52

10.4.13 Notes for mounting: Exchanging the chain and wear parts 54

10.4.14 Notes for mounting: Direction of movement of the chain 56

10.4.15 Notes for mounting: Lubrication points 56

10.4.16 Exchanging the conveyor chain:

BS 2/C-100, BS 2/R-300, BS 4/R-300

BS 2/C-250, BS 2/R-700, BS 4/R-700, motor mounting (MA) = R/L 57

10.4.17 Exchanging the conveyor chain:

BS 2/C-100, BS 2/R-300, BS 4/R-300 motor mounting (MA) = M 59

10.4.18 Exchanging the conveyor chain:

BS 2/C-H, BS 2/R-H, BS 2/R-V-1200, motor mounting (MA) = R/L 62

10.4.19 Exchanging the conveyor chain:

BS 2/R-H, reversible, BS 2/R-V, reversible, motor mounting (MA) = R/L 65

10.4.20 Exchanging the relief roller/connection roller toothed belt:

BS 2/C-H, BS 2/R-H, BS 2/R-V-1200, motor mounting (MA) = R/L 67

10.4.21 Exchanging the motor and/or gear:

BS 2/C-100, BS 2/R-300, BS 4/R-300, motor mounting (MA) = R/L 68

10.4.22 Exchanging the motor and/or gear:

BS 2/C-100, BS 2/R-300, BS 4/R-300, motor mounting (MA) = M 69

10.4.23 Exchanging the gear motor:

BS 2/C-H, BS 2/R-H, BS 2/R-V-1200, motor mounting (MA) = R/L 70

10.4.24 Exchanging the gear motor:

BS 2/C-H, BS 2/R-H, BS 2/R-V-1200, motor mounting (MA) = M 71

10.4.25 Exchanging the glide proﬁles:

BS 2/C-100, BS 2/C-250, BS 2/C-H 72

10.5 Spare parts 73

11 Decommissioning 73

12 Disassembly and Exchange 73

12.1 Preparing the product for storage/further use 73

13 Disposal 74

14 Extension and Conversion 74

15 Troubleshooting and Resolution 74

16 Technical Data 75

16.1 Ambient conditions 75

ENGLISH

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6/76 About This Documentation

Bosch Rexroth AG, MIT: BS 2/C-… + BS 2/R-…, 3 842 358 724/2013-04

1 About This Documentation

1.1 Scope of documentation

This documentation applies to the following products:

• 3 842 998 096, BS 4/R-700

• 3 842 998 097, BS 4/R-300

• 3 842 998 238, BS 2/R-H

• 3 842 998 239, BS 2/C-H

• 3 842 998 492, BS 2/R-V

• 3 842 999 901, BS 2/R-700

• 3 842 999 904, BS 2/R-300

• 3 842 999 917, BS 2/C-100

• 3 842 999 985, BS 2/C-250

This documentation is intended for installers, operators, service technicians, and

system owners.

This documentation contains important information on the safe and appropriate

assembly, transportation, commissioning, operation, use, maintenance, disassembly,

and simple troubleshooting of the product.

Read this documentation completely, especially chapter 2 “Notes on Safety”and

chapter 3 “General Notes on Equipment and Product Damage”, before working

with the belt section.

1.2 Required and supplementary documentation

Only commission the product once you have obtained the system documentation

that is marked with a book symbol and understood and complied with its

contents.

Table 1: Required and supplementary documentation

Title Document number Document type

Instructions for Employees on Safety 3 842 527 147

MTparts 3 842 529 770 Spare parts list on CD

1.3 Presentation of information

Uniform safety instructions, symbols, terms, and abbreviations have been used in

this documentation in order to ensure that you can get to work quickly and safely

with your product. They are discussed in more detail in the following sections.

1.3.1 Safety instructions

This documentation contains safety instructions in section 2.6 “Product-speciﬁc

safety instructions”and chapter 3 “General Notes on Equipment and Product

Damage” and before any actions or steps whenever there is a danger of personal

injury or damage to the equipment. The measures described to avoid these hazards

must be observed.

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Safety instructions are set out as follows:

SIGNAL WORD

Hazard type and source

Consequences

Precautions:

…

•Safety sign: draws attention to the risk

•Signal word: identiﬁes the degree of hazard

•Type and source of the risk: identiﬁes the type and source of the hazard

•Consequences: describes what occurs when the safety instructions are not

complied with

•Precautions: states how the hazard can be avoided

Table 2: Hazard classes acc. to ANSI Z535.6-2006

Safety sign, signal word Meaning

DANGER Indicates an imminently hazardous situation which, if not

avoided, will certainly result in death or serious injury.

WARNING Indicates a potentially hazardous situation which, if not

avoided, could result in death or serious injury.

CAUTION Indicates a potentially hazardous situation which, if not

avoided, could result in minor or moderate injury.

NOTICE Damage to equipment: The product or surrounding

equipment may be damaged.

1.3.2 Symbols

The following symbols identify information that is not relevant for safety, but which

increases the comprehensibility of the documentation.

Table 3: Meaning of the symbols

Symbol Meaning

If this information is disregarded, the operating procedure may be

impaired.

Individual, independent action

Numbered steps:

The numbers indicate the order for the steps.

ENGLISH

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1.3.3 Designations

This documentation uses the following designations:

Table 4: Designations

Designation Meaning

BS 2/C-100

BS 2/C-250

BS 2/C-H

BS 2: Belt section from the Rexroth TS 2plus transfer system

/C: Conveyor medium: ﬂat top chain

-100: Permissible load, cumulative load [kg]

-250: Permissible load, cumulative load [kg]

-H: Heavy load version, permissible load, cumulative load 400 kg

BS 2/R-300

BS 2/R-700

BS 2/R-H

BS 2/R-V-1200

BS 2: Belt section from the Rexroth TS 2plus transfer system

/R: Conveyor medium: accumulation roller chain

-300: Permissible load, cumulative load [kg]

-700: Permissible load, cumulative load [kg]

-H: Heavy load version, permissible load, cumulative load 1200 kg

-V: Conveyor medium accumulation roller chain Vplus,

permissible load, cumulative load 1200 kg

1.3.4 Abbreviations

This documentation uses the following abbreviations:

Table 5: Abbreviations

Abbreviation Meaning

Chain Conveyor chain with conveyor medium:

• Flat top chain (…/C-…)

• Accumulation roller chain (…/R-…)

• Accumulation roller chain Vplus (…/R-V-…)

2 Notes on Safety

2.1 About this chapter

The product has been manufactured according to the accepted rules of current

technology. Even so, there is a risk of injury or damage if this chapter and the safety

information in these instructions are not observed.

Read these instructions completely and thoroughly before working with the

product.

Keep this documentation in a location where it is accessible to all users at all

times.

Always include the operating instructions when you pass the product on to third

parties.

2.2 Intended use

This product is an incomplete machine.

The product may be used as follows:

• For installation in a Rexroth TS 2plus transfer system

• For transporting Rexroth WT 2 workpiece pallets.

• Maximum load/section load: see Technical data on page 75.

• For ambient conditions, see page 75.

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Notes on Safety 9/76

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The product is intended exclusively for professional applications and not designed

for private use.

Intended use includes having read and understood these instructions, especially

chapter 2 “Notes on Safety”.

2.3 Improper use

Any use other than that described in section “Intended use” is considered improper

and is not permitted.

Bosch Rexroth AG is not liable for any damages resulting from improper use.

The user alone bears the risks of improper use of the product.

The following foreseeable cases of misuse are also considered improper use:

• Transport of goods other than those speciﬁed.

• Persons riding on the product or transported material.

• Persons climbing on the product

– walking on the product is not permitted.

• Operation of the product without a safety device to prevent toppling.

• Personal use of the product.

2.4 Personnel qualiﬁcations

The work described in this documentation requires basic mechanical, electrical,

and pneumatics knowledge, as well as knowledge of the appropriate technical

terms. Additional knowledge of the lifting device’s usage and of the associated lifting

equipment are necessary to transport and handle the product. In order to ensure

operating safety, these activities may therefore only be carried out by qualiﬁed

technical personnel or an instructed person under the direction and supervision

of qualiﬁed personnel.

Qualiﬁed personnel are those who can recognize possible hazards and institute

the appropriate safety measures due to their professional training, knowledge,

and experience, as well as their understanding of the relevant conditions pertaining

to the work to be done. Qualiﬁed personnel must observe the rules relevant

to the subject area and carry the necessary technical expertise.

For pneumatic products such expertise would, for example, involve:

• Being able to read and fully understand pneumatic diagrams,

• Especially understanding completely the complexity and interactions of safety

equipment, and

• Having knowledge of the function and structure of pneumatic components.

Bosch Rexroth offers training for special ﬁelds. You can ﬁnd an overview

of the training contents on the Internet at http://www.boschrexroth.de/didactic

ENGLISH

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2.5 General safety instructions

• Observe the regulations for accident prevention and environmental protection.

• Observe the safety instructions and regulations applicable in the country in which

the product is used.

• Exclusively use Rexroth products in good technical order and condition.

• Follow all instructions printed on the product.

• Persons who assemble, operate, disassemble or maintain Rexroth products must

not consume any alcohol, drugs, or pharmaceuticals that may affect their ability

to respond.

• To avoid injuries due to unsuitable parts, only use original accessories and spare

parts from Rexroth.

• Comply with the technical data and ambient conditions listed in the product

documentation.

• The installation or use of unsuitable products in safety-relevant applications

can result in unanticipated operating states in the application that can lead to

personal injury or damage to equipment. The product should thus only be used in

applications relevant to safety if this use is explicitly speciﬁed and permitted in the

product documentation, for example in explosion protection areas or safety-related

control components (functional safety).

• Only commission the product after verifying that the end product (e.g. machine or

system) in which Rexroth products are installed complies with national regulations,

safety guidelines, and norms.

2.6 Product-speciﬁc safety instructions

The following safety instructions apply to chapters 6 to 14.

• Do not modify or convert the product.

• Do not expose the product to any mechanical loads under any circumstances.

Never use the product as a handle or step. Do not place any objects on

the product.

• Always secure the product to prevent toppling.

• Observe the transport instructions on the packaging.

• Check the product for visible transport damage.

• Lay cables and lines so that they cannot be damaged and no one can trip

over them.

• Make sure the relevant system component is not under pressure or voltage

before assembling the product or when connecting and disconnecting plugs.

• Protect the system component against being switched on.

• Before commissioning, make sure that all seals and caps for the screwed

connections are correctly installed and undamaged to prevent ﬂuids and foreign

bodies from penetrating the product.

• Let the product acclimate itself for several hours before commissioning,

otherwise water may condense in the housing.

• Make sure that all electrical and pneumatic connections are either used or covered.

• Check the safety requirements in accordance with DIN EN 619.

• Commission the product only if it is installed completely.

• Make sure that all safety equipment belonging to the product is present, has been

installed properly, and is fully functional. Do not modify the position of, bypass,

or disable the safety equipment.

General

During transport

During assembly

During commissioning

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