Energy Chain Installation - 2500 Series

This page contains changes which are not marked for translation.

Author avatarGareth Green | Last edit 25/09/2024 by Gareth Green being drafted

Introduction

There have been reliability problems with the use of the energy chain type "B15" (15.050.048..), prompting the sourcing of a more rigid structural type. The following design points have been taken into account

  • The 2500 type chain from Igus is the correct system for our application. It is a standard type and generally stocked
  • Using the 2500.03 type from this range is has a taller yet narrower cross section, but is ample for the application
  • A bend radius of 100mm is specified by Beckhoff for the cable, but the decision has been made to reduce down to 55mm. This decision is based on the success / longevity of upgrades done in the field with 55mm radius and the fact that the 100mm bend radius will not fit in all applications. Using the 55mm bend radius allows a "one size fits all" for all Stuga applications
  • The chain should be "Openable Outside" to enable a drag-style application on the inner faces
  • Cable separators should be added every 10 links to help keep the cables separate and the Beckhoff cable as central as possible
  • Cable tie points on the brackets are 100% essential. These "combs" are a clip on addition
  • A rigid chain, coupled with a smaller bend radius removes the need for the "anti-rise" trays and the vertical members holding this assembly in the air
  • The Beckhoff cable should be untwisted before feeding into the energy chain

Installation Rules

1 Check the correct components have been sent before assembly - the Igus part numbers are moulded into the side
...This photo shows the Non-Pivotable brackets part (should be 2030.1PZ and 2PZ) to highlight the potential errors here

Energy Chain Installation - 2500 Series Moulded.png
2 Use Cable Separators, two are needed at each location (every 10 links)

Beckhoff cable in centre

Energy Chain Installation - 2500 Series Separator.png
3 Untwist the Beckhoff cable before installation
Energy Chain Installation - 2500 Series Untwist.png
4 Fasten the bracket down, NOT the Cable tie comb
Energy Chain Installation - 2500 Series fasten.png
5 Cable tie all cables and pipes BOTH ends
Energy Chain Installation - 2500 Series fasten.png
6 Ensure the first two links are reversed on the servo end
Energy Chain Installation - 2500 Series rev links.png
Components
Part No Igus Code Photo Description Notes
A0001113 2500.03.055.0
Energy Chain 2500.03.055.0.png
Energy Chain: Series 2500.03 55mm Bend Radius Supplied in metre units
A0001110 2030.12PZB
Energy Chain Installation - 2500 Series Moulded.png
Energy Chain Bracket Set Non-Pivotable With Cable Tie connection Supplied as a Pair

Flowline and ZX3/4 uses NON-PIVOTABLE

ZX5 uses Pivotable type


...Do not use the mounting holes in the clip on cable tie addition. This is not strong enough to hold the energy chain
...The 2500 series has a different mounting hole pattern to the existing B15 chain, so the plate that the energy chain is mounted on will need to be redrilled

A0001114 2030.34PZB
Energy Chain Bracket Set Pivotable 2030.34PZB.png
Energy Chain Bracket Set Pivotable With Cable Tie connection
A0001112 25.1.1
Energy Chain Separator 25.1.png
Energy Chain Separator for 2500 Chain Two separators required every 10 links

Installation ZX5 - Machining Centre Side

Upgrade PartNo R0015143B
Links 6.0m -111

6.5m - 116

Disposal Remove the upper "Anti-rise" trays if fitted The anti-rise system has taller brackets that will need to be cut down level with the tray, as these upstands create a vertical barrier that the chain could feasibly hit.
Energy Chain Installation - 2500 Series Upstand Anti-Rise.png
Energy Chain Installation - 2500 Series Cut Bracket.png

Special Notes
Photos
Energy Chain Installation - 2500 Series ZX5 MH.png

Installation ZX5 - Saw Centre Side

Upgrade PartNo R0015144B
Links 6.0m - 94

6.5m - 99

Disposal Remove the upper "Anti-rise" trays if fitted
Special Notes Remove anti rise tray and trim taller brackets (see Machining Centre side above)
Photos
Energy Chain Installation - 2500 Series ZX5 Saw.png

Installation Flowline - Machining Centre Side

Upgrade PartNo R0019175B
Links 6.0m - 87

6.5m - 92

Disposal

ONLY if anti-rise trays fitted

ONLY IF the anti-rise trays are fitted

Note: this only allies to a specific set of recently upgraded flowlines that have a tray modification and the "B15" energy chain.

THIS DOES NOT APPLY TO THE MAJORITY OF FLOWLINES Cut down the upper "Anti-rise" trays if fitted or replace with the original trays from a flowline 6.0mtr

H0006746      1 off

H0006747        1 off

H0006751          1 off


6.5 mtr

add   H0007897 1 off

Special Notes Very important to use the Non-Pivot brackets on this machine to ensure the energy chain passes over the datum switch
Energy Chain Installation - 2500 Series Flow Pivot.png

Photos
Energy Chain Installation - 2500 Series Mk3 Igus 1.jpg

Installation Flowline / ZX3 / ZX4 - Saw Side

Upgrade PartNo R0019176B
Links 6.0m - 87

6.5m - 92

Disposal

ONLY if anti-rise trays fitted

ONLY IF the anti-rise trays are fitted

Note: this only allies to a specific set of recently upgraded flowlines that have a tray modification and the "B15" energy chain.

THIS DOES NOT APPLY TO THE MAJORITY OF FLOWLINES


Cut down the upper "Anti-rise" trays if fitted or replace with 6.0mtr

H0006747   or o/h H0007631

H0006748   or o/h H0007411

H0006751  or o/h h0007363


6.5 mtr

add   H0007897 1 off

Special Notes
Photos
Energy Chain Installation - 2500 Series Mk3 Igus Saw 1.jpg


Installation ZX3 / ZX4 - Machining Side

Upgrade PartNo R0019253
Links 6.0m - ??

6.5m - 108

Special Notes
Photos



Comments

Draft