Energy Chain Installation - 2500 Series

Installation of the Igus 2500 Energy chain on Stuga machines

Energy_Chain_Installation_-_2500_Series_Mk3_Igus_1.jpg

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
2	Use Cable Separators, two are needed at each location (every 10 links) Beckhoff cable in centre
3	Untwist the Beckhoff cable before installation
4	Fasten the bracket down, NOT the Cable tie comb
5	Cable tie all cables and pipes BOTH ends
6	Ensure the first two links are reversed on the servo end

Components

Part No	Igus Code	Photo	Description	Notes
A0001113	2500.03.055.0		Energy Chain: Series 2500.03 55mm Bend Radius	Supplied in metre units
A0001110	2030.12PZB		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 With Cable Tie connection
A0001112	25.1.1		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.
Special Notes
Photos

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

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
Photos

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

Installation ZX3 / ZX4 - Machining Side

Upgrade PartNo	R0019253
Links	6.0m - ?? 6.5m - 108
Special Notes
Photos

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Draft