Installation Guide

Installation Guide
plastics for longer life
igus E-ChainSystem - Installation Guide

E-Chain
Guide trough
Fixed point
Cable reserve
Support structure
Guide trough
E-Chain Moving end
Support structure
Fixed point
Moving end
igus E-ChainSystem - Installation Guide

Endposition I Fixed point Endposition II
Moving end
Guide trough with glide bar
Guide trough without glide bar
Total length of Guide trough Fixed point
max. 3mm Guide trough with glide bar Guide trough without glide bar
Check Installation Space

Space requirement for E-ChainSystem L
Use igus System Drawings

Installation has to be done according to igus system drawings
b E-Chain has to be free movable along the entire travel length. Other obstacles or crane parts must not disturb operation area! wrong!
h b
6
Support Structure for Guiding Trough

L-Profile oblong hole drillpattern c-profile Support structure has to be aligned and level wrong!
z = 2000 3 x5 L-profile Level the support structure y5 x5 wrong! Center line Crane rail = reference Level the L-profile Crane rail and support structure have to be aligned. wrong! wrong! right wrong!
x5 Crane rail
8
Center line
Check support strukture before trough installation. Necessary reworks to be corrected before next installation step.
Guiding Trough Installation

Prepare a spacer tool, to adjust the inner trough width. E-Chain outer width = Ba No gap = wrong!
Ba
No gap = wear on chain links. E-Chain is blocked. 2 +1mm Ba +4 Ba + 4 = L L L /2 Spacer tool Big gap = wear on chain links and cross bar.
+2
2 +1mm
Big gap = wrong!
10
E-Chain Pre-Assembly
Check part no. on E-Chain, before assembly. For example: 5050C- 4040C- Series Chain s number 5050C.30.300.0 5050C 30 300 0
Series Number Width Radius of chain Colour
E-Chain assembly Lay the fixed point (part 3) into the trough and assemble part 2 until you reach the mounting end.
part 3
part 2
part 1 Signed with orange flag Three links turned
Fixed point (KMA+ 11.Links)
E-Chain parts (11links each)
Moving end (rest length + KMA)
12
E-Chain Pre-Assembly
Make sure that fixed point position is according to igus drawings, relative to the travel stroke. Lay thee preassembled E-Chain into the guiding tough.
Fixed point
Moving end Turned links
Details see igus long travel drawing
Red flag
Fixed point
Moving end
Check fixed point position relative to the travel stroke.
14
Pull Cables Into E-Chain

Cable arrangement has to be according to igus interior shelving drawing Possible instalation: Pull cables into E-Chain Possible faults: Corkscrew or Cable damage right wrong!
wrong!
All crossbars snapped in? Any broken parts? right wrong!
Alternative instalation: Open the crossbars, lay the cables in the E-Chain and close it.
Check the interior separation of E-Chain. All seperators plumb and tight? right wrong!
16
Attach E-Chain
Leave a spare cable loop for cable adjustment at fixed point and moving end.
Level Moving End

Moving end has to be installed according to system drawing. Support plate has to be in level! Height according to drawing.
max. 3mm Spare cable min 0,5m h h h h
Make shure that fixed point is at correct position and fix it with allan screws (DIN 912 / EN ISO 7462).
wrong!
for E4.80/5050C h= 242mm +10 for E4.56/4040C/400 h= 266mm +10
18
Installl Moving End

Flip chain radius, move it to the moving arm and fix it with allan screws (DIN 912 / EN ISO 7462).
Adjust Cables
Correct cable adjustment
Cable has to run slightly outside the centerline
wrong!
wrong!
wrong!
Cable too tight
Cable too loose
20
Install Strain Relief

Install strain relief clambs at moving end and fixed point. Swing strain relief clamps in the c-rail and theighten the screw.
Check Installation Before First Movement

All screws in place and fixed Moving end height and with toque spanner E-Chain fixation OK?
Any obstacles / tools in the guiding trough?
All strain relief clamps installed
wrong! Check height
Cable arrangement OK?
Move the E-Chain slow and carefull to both end positions and check cable arrangement. Doublecheck after a few test cycles.
22
MAT0071536.2 Issue 02/2010

Installation Guide

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Installation Guide

plastics for longer life

igus E-ChainSystem - Installation Guide

E-Chain Moving end

igus E-ChainSystem - Installation Guide

Guide trough with glide bar

Guide trough without glide bar

Total length of Guide trough Fixed point

Check Installation Space

Use igus System Drawings

Support Structure for Guiding Trough

Guiding Trough Installation

Big gap = wrong!

part 1 Signed with orange flag Three links turned

Fixed point (KMA+ 11.Links)

E-Chain parts (11links each)

Moving end (rest length + KMA)

Moving end Turned links

Details see igus long travel drawing

Check fixed point position relative to the travel stroke.

Pull Cables Into E-Chain

All crossbars snapped in? Any broken parts? right wrong!

Level Moving End

max. 3mm Spare cable min 0,5m h h h h

for E4.80/5050C h= 242mm +10 for E4.56/4040C/400 h= 266mm +10

Installl Moving End

Cable has to run slightly outside the centerline

Cable too tight

Cable too loose

Install Strain Relief

Check Installation Before First Movement

Any obstacles / tools in the guiding trough?

All strain relief clamps installed

wrong! Check height

Cable arrangement OK?

MAT0071536.2 Issue 02/2010

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