OPERATING INSTRUCTIONS

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1 Handling Components OPERATING INSTRUCTIONS Intermediate stop: (For use with rotary units DAP-3) DZA-3 Issue:

2 Contents Important information EU Certificate of conformity (CE)...1 Scope of the instructions...2 Technical data...3 Pressure-torque diagram...4 Commissioning Installation...5 Compressed air input...7 Setting the intermediate stop...8 Setting variants...9 Connecting and setting the inductive proximity switches...10 Maintenance...11 Spare parts list DZA List of suppliers and materials...14 General information Environmental compatibility and disposal...15

3 Important information EU Certificate of conformity (as per MRL Appendix II A) Regulations and standards taken into account: Guidelines for machines 89/392/ECC, 91/368/ECC Manufacturer Montech AG Tel. 032 / Gewerbestrasse 12 Fax. 032 / CH-4552 Derendingen Description of product and use Intermeditate stops DZA-3 may only be used in conjunction with rotary drives type DAP-3. They enable an additional stopping position to be approached between 90 0 or At the most two intermediate stops may be used per rotary drive. Retrofitting can be carried out without difficulty. Risks The use of intermediate stops DZA-3 as supplements to rotary drives DAP-3 is generally harmless. When an intermediate stop is fitted to a rotary drive, the driving force is increased considerably, so that the risk of squeezing which exists when working without the cover fitted increases in proportion. Additional information The present operating instructions are intended to ensure that the DZA-3 intermediate stops are installed expertily and safely. Should information you need for your particular application be missing, please contact the manufacturer. When operating instructions are obtained later, it is essential to quote the serial number. Single copies can be obtained free of charge. Fig. 1 DZA-3 / Serial number Montech AG Management U. D. Wagner / A. Trenner 1

4 Important information Scope of the instructions Montech makes every effort to ensure that products conform to the present state of the art. The operating instructions are continuously updated to keep pace with modifications to the products. To avoid mistakes, make sure these operating instructions apply to the intermediate stop you intend to commission. Every instruction manual has an issue number, e.g The label on the plastic bag indicates which product serial number the issue number on the instructions apply. Fig. 2 Edition Edizione Utgåva Edition Ausgabe Valable pour Valido per Giltig för Valid for Gültig für Serie... 2

5 Important information Technical data Angle of rotation ( ) 0 90 Torque DAP-3 with DZA-3 (Nm) see pressure-torque diagram Piston diameter (mm) 60 Repeatability 1) ( ) 0.05 Weight (kg) 1.4 Operating pressure (bar) 2 6 Ambient temperature ( C) Driving medium oiled or unoiled air, filtered to 5 µm Damping in end position 2) air column compression Check on end position 3) inductive proximity switch Compressed air input R1/8" female thread Speed regulation 3) adjustable exhaust throttle valves with push-on union for hose 4 ID/6 mm O.D. Service life > 10 7 double strokes Ref. No ) Difference in 100 successive strokes 2) Only in the active position 3) See special accessories Special accessories Inductive proximity switch PNP, 6.5 mm dia. with LED, proof against short circuit and wrong polarity, with a switching clearance of 2 mm and a cable 2.5 m long, Ref.No ; cable 5 m long, Ref.No ; plug-in Ref.No Adjustable exhaust throttle valve with push-on union for hose 2.7 ID/4 mm O.D. (Ref.No ). 3

6 Important information Pressure-torque diagram DAP/DZA-3 p [bar] 4) 2) 1) 3) 6) 7) 5) 6 Fig p 2 M H M B M [Nm] = Pneumatic operating pressure. = Holding torque, corresponding to that which can be exerted externally on the stationary pinion shaft without moving it. = Moving torque, corresponding to that made available by the pneumatic drive on the moving pinion shaft. DAP left-/right-hand end position P M H M B M H =p * M B =p * ) ) DAP against DZA moved out M H =p * M B =p * ) ) P P M B P M H DZA moved out DAP depressurized M H =p * M B =p * ) ) P P M BMH DAP supported by DZA M B =p * ) P P P M B 4

7 Important information Installation Preparing the DAP-3 Fig (DAP) 90 (DAP) P 1 Dismantle the compressed air input(s) P 1 and/or P 2 *. Dismantle the skirted nut (100, DAP) and pull the cover (90, DAP) out of the cylindrical tube. * All compressed air connections not illustrated below refer to the opposite end of the rotary unit or intermediate stop. 5

8 Commissioning Fitting the intermediate stop Fig P P' (DAP) P 5 LED induktiver inductive Näherungsschalter proximity switch P' 1 Screw the cylindrical tube (10; DZA-3) on to the cylindrical tube (80, DAP) and tighten by hand. 6

9 Commissioning Compressed air input (see Fig.5) The compressed air union P 1 replaces the former connection P 1 (Fig.4). If a second intermediate stop is fixed to the cylindrical tube at the opposite end, P 2 replaces the former connection P 2 (Fig.4). The compressed air connections P 5 and P 6 (not illustrated) are used to move the intermediate stop into its active position. To ensure that the pneumatic hose is run optimally to the unions P 1, P5, P 2 and P 6, the cylinder head (60) can be turned into the optimum position by releasing the screw cover (110). Then screw the cover (110) tight again. 7

10 Commissioning Setting the intermediate stop (see Fig.5) Depressurize P 1 and/or P 2 Unscrew cap (90) Unscrew the hex screws (130) Apply pressure to P 5 and P 2 or P 2. Thus position W in Fig.6 is reached. If position W should be closer to the zero point, the stop nut (70) must be adjusted counterclockwise. This operation can usually only be carried out when P 5 is depressurized. One turn of the stop nut (70) corresponds to an angle correction of about 4.6. To check the corrected position W, P 5 must be pressurized. When position W has been definitively found, screws (130) must be retightened and the cover (90) closed. The setting of position E (Fig.6) is analogous. 8

11 Commissioning Setting variants Fig DAP-3 DAP-3 DAP-3 with one DZA-3 with two DZA Starting directions Pos. Q counterclockwise x x x Pos. W clockwise x x counterclockwise x x Pos. E clockwise x counterclockwise x Pos. R clockwise x x x Restrictions If ( ) or ( ) are 90, starting positions W and E are ineffective. 9

12 Commissioning Connecting and setting the inductive proximity switch Connecting DC Gleichspannung (DC) NPN brown braun black schwarz Z + A Fig. 7 blue blau OV DC Gleichspannung (DC) brown braun + PNP black schwarz blue blau Z A OV Setting (see Fig. 5) The proximity switch (6.5 mm dia.) is pushed through the clamping piece (100) into the cylinder head (60) as far as the bottom of the hole and secured with the screw (160). If the intermediate stop is now brought into its active position by applying compressed air to P 5 and/or P 6, the proximity switch operates about 3 before it reaches the set end position. When the switch is connected electrically, the LED lights up. The lead of 3 applies only to proximity switches supplied by Montech, it may be different if the distance Sn is not 2 mm. 10

13 Commissioning / Maintenance According to Fig.6 the proximity switch indicates the following states: When starting from DZA-3 Rotary shaft in position in position Pos. W clockwise W W Pos. W counterclockwise W W, E or R Pos. E clockwise E Q, W or E Pos. E counterclockwise E E Maintenance MONTECH intermediate stops DZA-3 need no maintenance. 11

14 Spare parts list DZA-3 (Fig. 8)

16 Spare parts list No. Part Ref.No. Supplier Material 10 Cylindrical tube Montech AG aluminium 20 Piston-rod Montech AG stainless steel 30 Piston Montech AG bronze 40 Piston Montech AG bronze 50 Cover Montech AG POM 60 Cylinder head Montech AG POM 70 Stop nut Montech AG stainless steel 80 Buffer Montech AG aluminium 90 Cap Montech AG POM 100 Clamping element Montech AG steel 110 Screw cover Montech AG aluminium 120 Disc Montech AG stainless steel 130 Chhd screw M5 x 14 stainless steel 140 Threaded insert Montech AG aluminium 160 Screw Bossard AG steel 190* Piston gasket Angst + Pfister AG NBR 200* Rod gasket Angst + Pfister AG NBR 210* Rod gasket Angst + Pfister AG NBR 220* O-ring Busak + Shamban AG NBR 230* O-ring Maag Technic AG NBR 250* O-ring Busak + Shamban AG NBR 300 Nameplate Montech AG metal.polyester 310 Instruction manual Montech AG paper All articles are available as spare parts. * The marked articles can be delivered within 24 hours. 14

17 General notes Environmental compatibility Materials used Aluminium Steel Bronze Acrylnitril butadiene rubber (NBR as per ISO 1629) POM Polyoxymethylene (polyacetal) Paraffinic mineral oil, synthetic hydrocarbon oil Surface finish Anodized aluminium Blackened steel Shaping processes Casting of steel Machining of aluminium, steel, bronze, POM Moulding NBR gaskets Emissions in operation None When operated with oiled air we recommend that the exhaust be returned to atmosphere through an oil separator or filter. Disposal Intermediate stops that are no longer fit for use should not be disposed of as complete units but stripped down into their components and recycled according to the kind of material. The kind of material used for each part is shown in the list of spare parts. Material which cannot be recycled should be disposed of appropriately. 15

OPERATING INSTRUCTIONS

Handling Components OPERATING INSTRUCTIONS Grippers: GPS-1 to GPS-4 GPSI-1 to GPSI-4 GPSL-1 to GPSL-4 Edition: 506 442 06.2008 Contents Important information EU Declaration of Conformity (EC)...1 Scope