Bosch 3842549802 User manual

Assembly instructions

3 842 549 802/2016-04

Replaces: 2014-05

ENGLISH

Chain conveyor system

VarioFlow

plus

Modules

Valid for the following types:

3 842 998 291 + …742

3 842 998 776

3 842 546 120 – …125

3 842 547 380 + …381

3 842 547 516 – …531

3 842 547 712 + …713

3 842 549 023 – …026

3 842 552 940 – …942

3 842 552 984 + …985

3 842 553 914 + …915

ENGLISH

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The following information only describes the product. Any information on how to use the product is only an example and a

recommendation. Catalog information is not binding. This information does not release users from their duty to exercise their own

judgment and conduct their own tests. Our products are subject to a natural process of wear and aging.

reproduced or distributed to third parties without our consent.

The title page depicts a sample conﬁ guration. The actual product may vary from what is shown in the illustration.

The original assembly instructions are in German.

DE

Die vorliegende Montageanleitung ist in den hier angebenen Sprachen verfügbar. Weitere Sprachen auf Anfrage.

Als gedruckte Version (print) oder als PDF-Datei (media) zum Download aus dem Medienverzeichnis:

www.boschrexroth.com/medienverzeichnis

Geben Sie in die Suchmaske (oben rechts, unter „Suche“) 3 842 549 801 ein, dann klicken Sie auf „Suche“.

EN

These assembly instructions are available in the languages indicated here. Other languages on request.

They come in a hard copy (print) or a PDF ﬁ le (media) that can be downloaded at:

www.boschrexroth.com/mediadirectory

Enter 3 842 549 802 in the search mask (at the top right, under “Search”), then click “Search”.

FR

Les présentes instructions de montage sont disponibles dans les langues mentionnées ici.

Disponible au téléchargement en version imprimée (print) ou en ﬁ chier PDF (media) à partir du répertoire médias :

www.boschrexroth.com/mediadirectory

Saisissez 3 842 549 803 dans le champ de recherche (en haut à droite, sous « Search ») puis cliquez sur « Search ».

IT

Le presenti istruzioni di montaggio sono disponibili nelle lingue seguenti. Altre lingue su richiesta.

Scaricabile come versione stampata (print) o come ﬁ le PDF (media) dal Media Directory:

www.boschrexroth.com/mediadirectory

Digitare il codice 3 842 549 804 nel campo di ricerca “Search” (in alto a destra), quindi fare clic su “Search”.

ES

Las presentes instrucciones de montaje están disponibles en los idiomas indicados. Hay más idiomas a petición.

Las instrucciones están disponibles como versión impresa (print) o como archivo PDF (media) para descargar del archivo de medios:

www.boschrexroth.com/mediadirectory

En el buscador (en la parte superior derecha, donde pone “Search”) introduzca 3 842 549 805, a continuación haga clic en

“Search”.

PT

O manual de montagem está disponível nos idiomas aqui indicados. Demais idiomas, sob consulta.

A versão impressa (print) ou o arquivo PDF(media) para download no diretório de mídias:

www.boschrexroth.com/mediadirectory

Insira a máscara de pesquisa (parte superior direita, em “Search”) 3 842 549 806, e clique em “Search”.

Search 3 842 546 353 Search

3 842 549 801

print media Kettenfördersystem VarioFlow plus Baugruppen DE Deutsch

3 842 549 802

print media Chain conveyor system VarioFlow plus Modules EN English

3 842 549 803

print media Système de transport à chaîne VarioFlow plus Modules FR Français

3 842 549 804

print media Sistema di trasferimento a catena VarioFlow plus Moduli IT Italiano

3 842 549 805

print media Sistema de transporte por cadenas VarioFlow plus Módulos ES Español

3 842 549 806

print media Sistema de transportador de corrente VarioFlow plus Módulos PT Português

3 842 546 353

print media plus ZH

e

ke

zat

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3/120 Contents

1 About this documentation 6

1.1 Validity 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

2 Safety instructions 8

2.1 About this section 8

2.2 Intended use 8

2.3 Improper use 8

2.4 Personnel qualiﬁ cations 8

2.5 General safety information 9

2.6 Product-speciﬁ c safety instructions 9

2.7 Personal protective equipment 11

2.8 Operator's obligations 11

3 General information regarding damage to property and the product 11

4 Scope of delivery 11

4.1 Condition on delivery 11

5 About this product 12

5.1 Speciﬁ cations 12

5.1.1 Use of VarioFlow plus modules 12

5.1.2 Design of VarioFlow plus modules 12

5.2 Product description 12

5.3 Identiﬁ cation of the product 13

6 Transport and storage 13

6.1 Transporting the product 13

6.2 Storing the product 13

7 Assembly 14

7.1 Unpacking 14

7.2 Installation requirements 14

7.2.1 Installation position 14

7.3 Required tools 14

7.4 Symbols used 15

7.5 Installing the product 16

7.5.1 AL system 17

Section supports 17

Open-type section proﬁ les 18

Section on section supports 19

Straight section 20

Curve wheel 21

Installing the curve wheel drive 22

Sliding curve horizontal 24

Horizontal roller curve in section 25

Horizontal roller curve in base unit / return unit 26

Vertical sliding curve, VF 65 / VF 90 / VF 120 27

Vertical sliding curve, VF 160 / VF 240 / VF 320 28

Contents

ENGLISH

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Vertical sliding curve in base unit / return unit 31

Assembly module 32

Return unit 33

Base unit 34

Connection drive 36

Center drive 42

7.5.2 STS system 43

Section supports 43

Preassembling section proﬁ les 44

Section on section supports 45

Straight section 46

Curve wheel 47

Horizontal roller curve in section 48

Horizontal roller curve in base unit / return unit 49

Vertical sliding curve, VF 65 / VF 90 / VF 120 50

Vertical sliding curve in base unit / return unit 54

Assembly module 55

Return unit 56

Base unit 57

Connection drive 59

Center drive 65

7.5.3 Alpine conveyor 66

90° return unit AL, STS 66

Alpine conveyor connection kit 67

7.5.4 Slide rail 68

Slide rail, (section proﬁ le) 69

Slide rail (section proﬁ le, chain return) 70

Slide rail (support proﬁ le), only for VF 160 / VF 240 / VF 320 71

Slide rail (end-to-end joint for connecting slide rails) 72

Slide rail, AL system assembly module, only for VF 65 / VF 90 / VF 120 73

Slide rail, STS system assembly module, only for VF 65 / VF 90 / VF 120 74

STS slide rail, section proﬁ le 75

STS slide rail, 90° curve wheel 76

STS slide rail, 180° curve wheel 77

7.5.5 Conveyor chain 78

Conveyor chain, VF 65 / VF 90 / VF 120 78

Conveyor chain, VF 160 / VF 240 / VF 320 79

Closing (extending) conveyor chain, VF 65 / VF 90 / VF 120 80

Closing (extending) conveyor chain, VF 160 / VF 240 / VF 320 81

Opening (shortening) conveyor chain, VF 65 / VF 90 / VF 120 82

Opening (shortening) conveyor chain, VF 160 / VF 240 / VF 320 83

7.5.6 Connection kit 84

Passive connection kit 84

Active connection kit 85

Active connection kit, machine connection 88

7.5.7 Lateral guide 91

Installing lateral guide 91

Lateral guide accessories 92

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7.5.8 Gear motor 96

Base unit, AL system, gear motor GM = 1 installation 96

Base unit, AL system, gear motor GM = 2 installation 97

Base unit, STS system, gear motor installation 98

Center drive, AL/STS system, gear motor GM = 1 installation 99

Transmission drive, AL system, gear motor GM = 1 installation 100

Curve wheel drive, gear motor installation 102

Safety coupling adjustment 103

Safety coupling modiﬁ cation 105

7.6 Making the electrical connection to the product 106

8 Commissioning 108

8.1 Initial start-up 108

8.2 Re-commissioning after a standstill period 108

9 Operation 109

9.1 Notes regarding operation 109

9.1.1 Wear 109

9.1.2 Steps for reducing wear 109

9.1.3 Environmental inﬂ uences 109

10 Maintenance and servicing 111

10.1 Cleaning and care 111

10.2 Inspection 112

Conveyor chain 112

Slide rails 113

Sliding curves 113

Roller curves 113

System as a whole 113

Wear of conveyor chains 114

10.3 Maintenance 115

Bearings 115

Transmission 115

Motor 115

10.4 Replacement of wear parts 115

Required tools 115

Conveyor chain 115

Slide rails 115

Drive gears 116

10.5 Spare parts 117

11 Decommissioning 117

12 Disassembly and replacement 117

12.1 Preparing the product for storage/later use 117

13 Disposal 118

14 Upgrading and modiﬁ cation 118

15 Troubleshooting and repair 118

16 Technical data 119

16.1 Ambient conditions 119

ENGLISH

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1 About this documentation

1.1 Validity of documentation

This documentation applies to the following products:

• 3 842 998 291, drive kit head drive, connection drive, center drive

(VFPLUS VAR)

• 3 842 998 742, drive kit curve wheel drive

(VFPLUS CURVE VAR)

This manual is intended for assemblers, operators, service engineers and system end

users.

This documentation contains important information relating to the safe and

proper assembly, transportation, commissioning, operation, use, maintenance and

disassembly of the product, and on how to rectify simple faults yourself.

 Read this manual in full, in particular Section 2 “Safety Instructions” and

Section 3, “General Information on Property and Product Damage” before

working with the product.

1.2 Required and supplementary documentation

 Only start up the product if the documentation marked with the book symbol

is available and you have understood and followed the instructions in it.

Table 1: Required and supplementary documentation

Title Document number Document type

Employee safety training 3 842 527 147

MTparts 3 842 529 770 Spare parts list on CD

1.3 Presentation of information

Standardized safety instructions, symbols, terms and abbreviations are used so that

you can use this document to work quickly and safely with your product. These are

explained in the following sections to help you understand them better.

1.3.1 Safety instructions

This document contains safety instructions in Section 2.6 “Product-speciﬁ c safety

instructions” and Section 3 “General Information on Property and Product Damage”,

as well as before any sequence of actions or any required action which involves a

risk of personal injury or property damage. Be sure to observe all safety precautions.

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Safety instructions are set out as follows:

SIGNAL WORD

Type and source of danger

Consequences of non-compliance

 Steps to prevent danger

 …

• Warning sign: points out the danger

• Signal word: indicates the severity of the danger

• Type and source of danger: indicates the type and source of the danger

• Consequences: describes the consequences of non-compliance

• Prevention: states how the danger can be avoided

Table 2: Risk classes according to ANSI Z535.6-2006

Warning sign, signal word Meaning

DANGER

Indicates a hazardous situation that will result in serious

injury or death if not avoided.

WARNING

Indicates a hazardous situation that may result in serious

injury or death if not avoided.

CAUTION

Indicates a hazardous situation that may result in minor

to moderate injury if not avoided.

NOTICE

Property damage: The product or the surrounding area

could be damaged.

1.3.2 Symbols

The following symbols indicate important information that is not safety-relevant but

makes the document easier to understand.

Table 3: Meaning of the symbols

Symbol Meaning

If this information is not heeded, the product cannot be used and/

or operated as designed.



Single, isolated step

1.

2.

3.

Numbered steps:

The numbers indicate that the steps must be performed in sequence.

ENGLISH

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2 Safety instructions

2.1 About this section

This product has been manufactured to be state-of-the-art. Nevertheless, there is a

risk of personal injury and property damage if you do not take note of this section

and follow the safety instructions in this document.

 Read this manual carefully and completely before you start working with the product.

 Keep these instructions accessible to all users at all times.

 Always include them when giving the product to a third party.

2.2 Intended use

The product is an incomplete machine.

It may be used as follows:

• for installation in a Rexroth VarioFlow plus transfer system

• Maximum load / section load: see Technical Data on page 119.

• Environmental conditions see page 119.

The product is strictly intended for professional use and not for private use.

The intended use also implies that you have read all this documentation and fully

understood it, in particular chapter 2 “Safety Instructions”.

2.3 Improper use

Any use other than that described as intended use is considered to be improper, and

therefore not permitted.

Bosch Rexroth AG is not liable for any loss or damage resulting from improper use.

The user alone bears any risks associated with improper use.

The following foreseeable abnormal uses are also considered improper use:

• Transporting goods other than those speciﬁ ed.

• The transporting of people on the product or the transported material.

• Persons climbing onto the product – the product must not be walked on or

climbed onto.

• Private use.

2.4 Personnel qualiﬁ cations

The activities described in this document require a basic knowledge of mechanical,

electrical and pneumatic systems, as well as familiarity with the corresponding

technical terms. Additional knowledge of using lifting gear and the associated slings

is required for transporting and handling the product. To ensure safe use, these

activities should therefore only be performed by a properly qualiﬁ ed operative, or by

an instructed person acting under the direction of such a person.

“Qualiﬁ ed operative” means someone who can recognize possible hazards and take

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

and experience, and his knowledge of the relevant regulations. A qualiﬁ ed operative

must comply with the relevant speciﬁ c professional rules and have the necessary

expertise.

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Expertise means, in the case of pneumatic products for example:

• The ability to read and fully understand pneumatic diagrams,

• in particular, fully understanding the interrelationships between the safety

equipment, and

• having a knowledge of the function and design of pneumatic components.

Bosch Rexroth offers measures to support training in speciﬁ c areas. You can ﬁ nd

an overview of the training content online at:

http://www.boschrexroth.de/didactic

2.5 General safety information

• Observe applicable accident prevention and environmental safety regulations.

• Observe the safety rules and regulations of the country in which the product is

being used.

• Only use Rexroth products that are in good working order.

• Heed all the notices on the product.

• People who install/assemble, operate, disassemble or service Rexroth products

must not be under the inﬂ uence of alcohol, drugs or pharmaceutical medications

that affect their reactions.

• Use only original accessories and spare parts from Rexroth in order to prevent

hazards to people due to unsuitable spare parts.

• Observe the technical data and ambient conditions speciﬁ ed in the product

documentation.

• Only start up the product if it has been determined that the end product (e.g. a

machine or system) into which the Rexroth products have been installed complies with

the country-speciﬁ c provisions, safety regulations and standards relating to its use.

2.6 Product-speciﬁ c safety instructions

• Never attempt to modify the product.

• Do not overload the product under any circumstances. Never use the product as

a handhold or step. Do not place any objects on the product.

• Always ensure that the product cannot topple over.

• Follow the transportation instructions on the packaging.

• Inspect the product for evident shipping 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 depressurized and de-energized

before assembling the product or inserting or removing plugs.

• Ensure that the system component cannot be switched back on.

• Before commissioning, make sure that all plug-in connection seals and caps are

correctly installed and undamaged in order to prevent ﬂ uids and extraneous

material from getting into the product.

General

During transport

During installation

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• Allow the product to acclimatize for a few hours prior to start-up in order to

prevent condensation from forming in the housing.

• Make sure that all the electrical and pneumatic connections are either in use

or covered.

• Review safety requirements under DIN EN 619.

• Only start up a product which has been fully installed.

• Make sure that all the safety equipment which forms part of the product is present,

has been properly installed, and is fully functional. Do not move, bypass or disable

any safety equipment.

• Do not reach into moving parts.

• Check the product for malfunctions.

• Make sure that only authorized personnel perform the following tasks as part of

the intended use of the product:

– starting or operating the system, or intervening in its normal functioning.

– operating adjustment devices on components or parts.

• Only allow people to be in the immediate vicinity of the product when it is

operating if they are authorized by the operator to be there. This also applies while

the product is at a standstill.

• Make sure that:

– there are no obstacles preventing access to the EMERGENCY STOP controls.

– all delivery points, workstations and passages are kept clear.

• Do not use EMERGENCY STOP controls for routine stopping.

• Regularly check the EMERGENCY STOP controls to ensure that they are functioning

properly.

• Following an EMERGENCY STOP or in the event of a fault or other irregularity, turn

the product off and secure it against being switched back on.

• Do not reach into moving parts.

• An idle system is not necessarily a safe system, as stored energy can be released

unintentionally or through improper maintenance procedures.

• After an EMERGENCY STOP or a fault, only switch the system back on when you

have established and rectiﬁ ed the cause of the fault.

• Make sure that access to maintenance and inspection points is kept free of

obstacles.

• Perform the prescribed maintenance work at the intervals speciﬁ ed in

chapter 10.3 “Maintenance”.

• Make sure that no line connectors, connections or components are disconnected

as long as the system is supplied with pressure and voltage. Secure the system

against being switched back on.

• Dispose of the product in accordance with the applicable national regulations in

your country.

During commissioning

During operation

EMERGENCY STOP,

malfunction

During maintenance and

servicing

During disposal

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2.7 Personal protective equipment

• Appropriate protective clothing is to be worn when handling/using the product

(e.g. safety shoes, close-ﬁ tting clothing, a hair net for long, loose hair).

As the system user or operator, you are personally responsible for ensuring the use

of appropriate protective equipment when the product is used.

All components of the personal protective equipment must be intact.

2.8 Operator's obligations

• Before ﬁ rst use or re-commissioning of a conveyor system, run a risk assessment in

accordance with DIN EN ISO 12100.

• Provide safety-related instructions to the operating personnel before ﬁ rst use or

re-commissioning, and then at regular intervals.

3 General information regarding damage to

property and the product

The warranty only applies to the delivered conﬁ guration.

• The warranty is void in the event of faulty installation, commissioning and

operation, as well as improper use and/or improper handling.

• Prevent cleaning agents from getting into the system.

• Never use solvents or aggressive cleaning agents.

• Do not use a high-pressure cleaner for cleaning.

4 Scope of delivery

The scope of delivery includes the following:

• Various VarioFlow plus modules in accordance with your order. Please use the

shipping documents to check that the consignment is complete.

• 1 assembly instructions “VarioFlow plus modules”

4.1 Condition on delivery

• Modules fully or partially assembled

During cleaning

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5 About this product

5.1 Speciﬁ cations

5.1.1 Use of VarioFlow plus modules

• Standardized modules for assembly into a conveyor system for use in the food &

packaging industries, healthcare, assembly lines, the automotive & electronics

industries, or the interlinking of machines.

5.1.2 Design of VarioFlow plus modules

• Basic version made of aluminum (AL system)

• Stainless steel version for more stringent hygiene requirements (STS system)

• Workpiece pallet system for parts that cannot be transported directly on the

conveyor chain.

5.2 Product description

Fig. 1:

549 801-01

VF 65

VF 90

1

)

VF 120

U

E

M (N)

O

E

O

W

P

B

A

V

E

H

R

V

K

Q

VarioFlow plus modules

A: Foot

B: Strut profile

E: straight section

H: Holder

K: Curve wheel

M: horizontal sliding

curve

N: Roller curve

O: vertical sliding curve

P: Assembly module

Q: Return unit

R: Base unit

U: Conveyor chain

V: Lateral guide

W: Drive kit

1

) Size shown

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5.3 Identiﬁ cation of the product

Fig. 2: Nameplate

6 Transport and storage

• Follow the transport instructions on the packaging.

• See the shipping documents for transport weight

• Secure the product to prevent toppling!

• Always maintain ambient conditions during storage and transport, see page 119.

6.1 Transporting the product

WARNING

Raised loads may fall!

Falling objects can result in serious injury (or even death).

 Only use slings with a sufﬁ ciently high load-bearing capacity (see shipping

documents for product weight).

 Make sure the lifting straps are correctly fastened before lifting the product.

 Secure the product to prevent it from toppling during lifting.

 Make sure that no one but the operator is in the danger zone during lifting and

lowering!

6.2 Storing the product

• Only set the product down on a ﬂ at surface.

• Protect the product from mechanical stress.

• Protect the product from environmental inﬂ uences such as dirt and humidity.

• Ensure the correct ambient conditions, see page 119.

• Support the product so that there is no load on motors that are installed in

a suspended position.

........

.....

...

A

Typschild_klein

.......

C B

A: Material number

(order number)

B: Designation

C: Production date

ENGLISH

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7 Assembly

7.1 Unpacking

 Lift the product out of its packaging.

 Dispose of the packaging material in accordance with the applicable regulations

in your country.

7.2 Installation requirements

 Be sure to maintain the ambient conditions speciﬁ ed in the Technical Data

(see page 119) during installation.

7.2.1 Installation position

 Install the product level and plumb, at right angles, and axially parallel.

This ensures proper functioning and prevents premature wear.

7.3 Required tools

• Hex wrench SW13

• Hex key SW3, SW4, SW5

• Phillips screwdriver PZ2

• Hammer

• Spirit level

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7.4 Symbols used

Table 4: Symbols used

21

Connection with T-bolt and ﬂ ange nut.

Make sure the T-bolt is in the correct position when inserting into the slot and

tightening. The notch at the head of the bolt indicates the orientation of the T-head

bolt.

1 = T-bolt insertion position in the slot

2 = T-bolt clamping position in the slot

Tightening torque: 25 Nm

M

D

SW13

= 20Nm

Hex wrench

SW = wrench size … mm

M

D

= required tightening torque … Nm

M

D

= 8Nm

SW5

Hex key

SW = key size … mm

M

D

= required tightening torque … Nm

PH3

PZ2

Screwdrivers for cross-head screws

PZ … = Pozidriv screwdriver, size …

PZ … = Phillips screwdriver, size …

gleitmo 585 K Anti-Seize

Lubricate / Lubricate with speciﬁ c grease:

• gleitmo 585 K: gleitmo 585 K, www.fuchs-lubritech.com

• Anti-Seize: Food Grade Anti-Seize/Loctite 8014, www.henkel.com

Loctite 243 Loctite 601

Secure the screws with:

• Loctite 243: medium-strength (detachable), www.loctite.de

• Loctite 601: high-strength screw retention (non-detachable), www.loctite.de

The marked parts are not required for the described assembly. Dispose of the

parts or use them for other purposes.

213

Graphical depiction of assembly sequence.

The numbers correspond to the sequence of assembly steps, in accordance with

the instructions in the accompanying text.

ABCX

Designation of components in graphics.

The letters denote the components mentioned in the accompanying text.

Detail view from a different direction, for example of the back or the bottom side

of the product.

Assembly videos are available for downloading at www.boschrexroth.com,

 service  downloads  VarioFlow plus assembly of the system

• http://dc-emea.resource.bosch.com/media/de/service_4/downloads_2/

montagetechnik_2/VFplus_Service_-_Allgemein_SD_480p.m4v

• http://dc-emea.resource.bosch.com/media/de/service_4/downloads_2/

montagetechnik_2/VFplus_Service_-_Detail_SD_480p.m4v

ENGLISH

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16/120 Assembly

Bosch Rexroth AG, MIT: VarioFlow plus, 3 842 549 802/2016-04

7.5 Installing the product

Assembly sequence for a VarioFlow plus system:

1. Pre-assemble the conveyor supports

(AL system see page 17, STS system see page 43).

2. Pre-assemble the open-type section proﬁ les

(AL system see page 18, STS system see page 44).

3. Mount the section modules on supports.

– Straight section (AL system see page 20, STS system see page 46).

– Curve wheel (AL system see page 21, STS system see page 47).

– Curve wheel drive (only for AL system, see page 23).

– Horizontal curve (AL system see page 24, STS system see page 48).

– Vertical curve (AL system see page 27, STS system see page 50).

– Assembly module (AL system see page 32, STS system see page 55).

– Connection drive (AL system see page 36, STS system see page 59).

– Center drive (AL system see page 42, STS system see page 65).

– Return unit (AL system see page 33, STS system see page 56).

– Base unit (AL system see page 34, STS system see page 57).

Please note:

In the course of assembly the user must drill holes in the section proﬁ le and support

proﬁ le for subsequent retention of the slide rail.

• In the case of the section proﬁ le, you can drill the holes before or after assembly.

• In the case of the support proﬁ le, you should drill the holes before assembly.

• In the case of the AL system, there is a groove in the section proﬁ le and support

proﬁ le to guide drilling.

• In the case of the STS system, you need the 3842 553 518 drilling jig which can be

attached on both sides ﬂ ush with the end of the section proﬁ le or support proﬁ le.

4. For VarioFlow plus 160, ..240, ..320 only:

Install the support proﬁ le (see straight section, curves, return unit, head drive).

5. Install the slide rail (see page 69 and following).

6. Install the conveyor chain (see page 78 and following).

7. Install the lateral guide (see page 91 and following).

8. Install the drive unit (see page 96 and following).

Fig. 3:

549 801-02

3 842 553 518

Drilling jig

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Assembly 17/120

3 842 549 802/2016-04, MIT: VarioFlow plus, Bosch Rexroth AG

7.5.1 AL system

Section supports

Fig. 4:

549 801-11

A

1

A

2

B

1

C

1

L

B

2

C

2

L = max. 2000

SW13

Ø 8

73

M = 25 Nm

3x

D

SW13

M

D

=25 Nm

1

3

2

SW13

M

D

=25 Nm

AL system, installing section supports

Required accessories:

• Foot (A)

• Strut proﬁ le (B)

• Mounting hole plug (C)

A

1

: 3842 544 875

A

2

: 3842 540 173

B

1

: 3842 990 350/L

B

2

: 3842 993 133/L

C

1

: 3842 511 876

C

2

: 3842 529 039

D: 3842 540 668

 Install the supports.

Please note:

Make sure that the conveyor

supports and the

VarioFlow plus modules

cannot topple over during

installation until you screw

the system to the ﬂ oor.

ENGLISH

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18/120 Assembly

Bosch Rexroth AG, MIT: VarioFlow plus, 3 842 549 802/2016-04

Open-type section proﬁ les

Fig. 5:

SW4

M

D

=8 Nm

549 801-18

max.

100

max.

100

max.

500

E

F

max.

100

max.

500

max.

100

SW4

M

D

=8 Nm

E

F

VF 65

VF 90

1

)

VF 120

VF 160

VF 240

1

)

VF 320

SW4

M

D

=8 Nm

G

F

AL system, pre-assembling open-type section proﬁ les

Required accessories:

• Section proﬁ le (E)

• Cross connector (F)

• Support proﬁ le (G, only for

VF 160 / VF 240 / VF 320)

– Lens head screw with

ﬂ ange according to

ISO 7380,

MLF-M6X14-10.9-VZ (X, to

be provided by user)

– Hexagon nut

ISO 4035-M6-A2-70 (Y, to

be provided by user)

E,

6070 mm:

3000 mm:

L mm:

3842 546 647

3842 546 670

3842 996 026/L

F, VF 65: 3842 546 672

F, VF 90: 3842 546 673

F, VF 120: 3842 546 674

F, VF 160: 3842 546 675

F, VF 240: 3842 546 676

F, VF 320: 3842 546 677

 Pre-assemble the open-

type section proﬁ les.

Please note:

• Install the support proﬁ le

(G) last, after the curves,

return unit, and drive.

• The support proﬁ le (G)

extends into the curves,

see pages 24, 27.

• In order to ﬁ x the slide rail

in place, drill holes must

be made in the support

proﬁ le prior to assembly,

positions as shown on

pages 24, 27, 33.

G,

6070 mm:

3000 mm:

L mm:

3842 546 705

3842 547 904

3842 996 028/L

1

) Size shown

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Assembly 19/120

3 842 549 802/2016-04, MIT: VarioFlow plus, Bosch Rexroth AG

Section on section supports

Fig. 6:

549 801-12

max.

500

H

max.

500

SW13

M

D

=22 Nm

VF 65

VF 90

1

)

VF 120

VF 160

VF 240

1

)

VF 320

SW13

M

D

=22 Nm

3

2

H

1

3

H

AL system, installing section on section supports

Required accessories:

• Holder (H)

H, VF 65: 3842 546 625

H, VF 90: 3842 546 626

H, VF 120: 3842 546 627

H, VF 160: 3842 546 628

H, VF 240: 3842 546 629

H, VF 320: 3842 546 630

 Install the section proﬁ le

on the supports.

Please note:

Make sure that the conveyor

supports and the

VarioFlow plus modules

cannot topple over during

installation until you screw

the system to the ﬂ oor.

1

) Size shown

ENGLISH

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20/120 Assembly

Bosch Rexroth AG, MIT: VarioFlow plus, 3 842 549 802/2016-04

Straight section

Fig. 7:

549 801-17

J

max.

500

8x

SW4

M

D

=8 Nm

8x

SW4

M

D

=8 Nm

max.

500

J

VF 65

VF 90

1

)

VF 120

VF 160

VF 240

1

)

VF 320

AL system, installing straight section

Required accessories:

•Proﬁ le connector (J)

J:

3842 530 277

1

) Size shown

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Bosch 3842549802, Rexroth VarioFlow plus User manual

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