Maintenance Schedule & Acceptance Certificate PDF

igus GmbH
e-chainsystems®
Maintenance schedule and acceptance certificate Spicher Straße 1 a,
51147 Cologne (Porz-Lind)
e-chainsystems® Germany
Telephone +49 - 22 03 / 96 49 - 0 Fax +49 - 22 03 / 96 49 - 222

e-chainsystems
Project name:
Location:
Customer:
Customer project:
igus project:
Order No.:
AB:
Comments:
Please note:
The maintenance log must be completed after each inspection by the responsible technician!
Warranty claims are not valid without inspection certificates.
igus GmbH
e-chainsystems®
Maintenance schedule Spicher Straße 1 a,
Telephone +49 - 22 03 / 96 49 - 0 Fax +49 - 22 03 / 96 49 - 222
Table of contents:
Chapter: Description: Page
General rules 2
Inspection intervals 3
Maintenance log 4-8
Acceptance certificate with Annex A
chain assignment Interior separation Drw. no.
Strain relief
System drawing Annex B

System drawing Drw.no./Art.no
Storage basket
Moving end Annex Drw.no B

Assembly drawing
Department: After-sales service Page 1 / 21

Author: T. Grohmann Approval:
Issued by: Date of issue: Project:
Checked by: Date of examination: File: Doku_Zickzack 12-05-20_EN
igus GmbH
e-chainsystems®
Telephone +49 - 22 03 / 96 49 - 0 Fax +49 - 22 03 / 96 49 - 222
General rules for the commissioning & maintenance of the igus e-chainsystems®
General rules
1 Assembly and operation must be made in accordance with the igus drawings and specifications. If changes are necessary,
please contact igus for technical approval. igus shall not be liable for accidents resulting from modifications made without
technical approval.
2 Observe both ends of the chain very closely when moving to the end positions for the first time: if the chain is too short or
too long for the travel path for any reason, it can break!
3 The e-chain and the storage basket must be free of debris and foreign bodies. This also includes freezing or blocking by ice
or snow.
4 Foreign bodies which could cause damage must not enter the work range of the igus system. For example, it may be
necessary to install covering hoods or drainage channels in certain areas to prevent ice formation and snow accumulation
at temperatures below the freezing point.
5 The basket must always be free from interference edges, be free of screw connections and installed free of misalignment to
each other. This must be checked especially after all maintenance work.
6 Check the chain and the storage basket periodically according to the following table, and also after bad weather (outdoors),
extreme conditions or after a downtime.

igus GmbH
e-chainsystems®
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The maintenance work must be carried out in the intervals listed in Table 1. These points are explained in detail in Table 2. The inspection intervals always apply
from the time of commissioning.
This table is intended as a guide. Each installation is different and may require more or less frequent inspection intervals.
Table 1 - Inspecton schedule
Date of commissioning Running-in Plant in operation

phase
Inspection interval, specified in weeks / working hours 2 6 24 48
Item Description 200h 600h 2400h 4800h
1. Inspection of the chain X** X X
2. Checking for blockages / obstacles X** X X
3. Inspection of the chain end points X** X X
4. Inspection of the strain relief X** X X
5. Inspection of cables and hoses X** X X X
6. Inspection of the storage basket X** X X
7. Inspection of the moving end X** X X Error! Reference source not found.
** If dirt or sand accumulates in the storage basket or if significant wear marks have been found, the causes should be removed immediately at the
source (example: remove all sharp edges that can bump against the e-chain). This is particularly applicable in the running-in phase.

igus GmbH
e-chainsystems®
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Table 2 – Check list

Item Description Execution: Condition Defects
Remedial action
1 Inspection of the Visual inspection of chain links for wear and Pin-hole clearance on the Clearance is too big Work done:
chain. damage first 5 freely movable chain Replace chain yes
Executed: links within tolerance? no (enter remark)
yes yes
no no
Are the chain links and Damaged chain links or Work done:
opening crossbars in proper opening crossbars yes
condition? Replace defective parts no (enter remark)
yes and eliminate the cause of
no the damage
Other defects?
yes (enter remark)
no
2 Checking for Visual inspection of the e-chain and the Is the storage basket free of If there is ice, snow, dirt, Work done:
blockages / storage basket for foreign objects and ice, snow, dirt, forgotten forgotten tools or other yes
obstacles mechanical blockages. tools or other foreign foreign objects in the no
Executed: objects? storage basket.
yes yes Removal before further
no no operation. Installation of
protective devices, guard
plates or grills as
required.

igus GmbH
e-chainsystems®
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Remedial action
3 Inspection of the Inspection of the screw connections at both Does the e-chain run cleanly Noises when moving the Work done:
chain end points ends of the chain. Checking the support and without noise? chain / loose screws. yes
yes plate for tight fit. yes Tighten all loose screws. no (enter remark)
no no
Other defects?
no
4 Inspection of the Inspection of the strain relief at the moving Are the cables in faultless Cables have chafe marks, Work done:
strain relief end and at the fixed end. condition? Are the strain cables are loose, strain yes
Executed: relief units all available and relief is missing. no (enter remark)
yes firmly fixed? Replace or tighten.
no yes Replace missing parts.
no
Other defects?
no

igus GmbH
e-chainsystems®
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Remedial action
5 Inspection of Retract chain system. In this state, the Are the cables lying neatly in Cables are tight against the Work done:
cables and hoses cables must be freely movable and must not their chambers and are set inner opening crossbars or yes
Executed: rest against the inner opening crossbars. according to igus' shelves. no (enter remark)
yes specifications? Loosen strain relief at the
no yes fixed end. Insert the
no cables into the chain until
the cables have reached
igus in the e-chain.
Tighten strain relief.
Cables lie in shafts and not Work done:
smoothly on the lower yes
opening crossbars. no (enter remark)
Loosen strain relief at the
fixed end. Pull the cables
of the chain, until the
cables are placed in the e-
chain in accordance with
igus' specifications.
Tighten strain relief.
Other defects?
no

igus GmbH
e-chainsystems®
Telephone +49 - 22 03 / 96 49 - 0 Fax +49 - 22 03 / 96 49 - 222

Remedial action
6 Inspection of the Inspection of the basket segments for Are all segments without Basket segments are bent. Work done:
storage basket possible damage. damage? Straighten or replace if yes
Executed: yes necessary. no (enter remark)
yes no
no Inspection of the vertical mounting angles Are all screws present on Screws are loose or Work done:
the mounting angles and missing. yes
fixed? Exchange or tighten the no (enter remark)
yes screws according to the
no torque specification.
Are all mounting angles Mounting angle is bent. Work done:
without damage? Replace or straighten. yes
yes no (enter remark)
no
Other defects?
no
7 Inspection of the Inspection of the screw connection. Are all screws present and Screws are loose or Work done:
moving end fixed properly? missing. yes
Executed: yes Replace or tighten the no (enter remark)
yes no screws. Use a torque
no wrench.
Other defects identifiable
no

igus GmbH
e-chainsystems®
Acceptance certificate Spicher Straße 1 a,
Telephone +49 - 22 03 / 96 49 - 0 Fax +49 - 22 03 / 96 49 - 222
Maintenance schedule
Maintenance performed according to Tables 1 and 2.
Main Hours / Executed on Operating System ready for Executed by: Inspection manager:
tena Weeks DATE: hours / operation: SIGNATURE SIGNATURE
nce Double
no.: strokes
1 200h / 2W
2 600h / 6W
3 2400h / 24W
4 4800h / 48W
5 7200h / 72W
6 9600h / 96W
7 12000h / 120W
8 14400h / 144W
9 16800h / 168W
10 19200h / 192W
11 21600h / 216W
12 24000h / 240W
13 26400h / 264W
14 28800h / 288W

igus GmbH
e-chainsystems®
Telephone +49 - 22 03 / 96 49 - 0 Fax +49 - 22 03 / 96 49 - 222
Annex A
Acceptance certificate and chain

assignment with interior separation

Acceptance certificate igus GmbH
e-chainsystems®
igus® Spicher Strasse 1 a,
e-chainsystems 51147 Cologne (Porz-Lind)
Germany
Telephone +49 - 22 03 / 96 49 - 0 Fax +49 - 22 03 / 96 49 - 222
e-chainsystem:
Summary of the acceptance test:
Item Description Position

1. Moving end Inspection + movement All
2. Fixed end Inspection Top end position
3. Storage basket Inspection + movement All
4. e-chain Inspection + movement All
5. End positions Inspection + movement Top / bottom end
position
6. Comments Defects list
7. Reason Approval conditions
Department: After-sales service Page: A10 / 21

Issued by: Date of issue: Project
e-chainsystems®
Germany
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1. Moving end
1.1 Does the support plate correspond to the drawing?  yes  no

Drawing no.:  
 
1.2 Type of mounting brackets?  KMA  pivoting
 steel  rigid

1.3 Are the mounting brackets correctly screwed on the  yes  no
moving end?
 
1.4 Does the interior separation correspond to the  yes  no
drawing? Drawing no.:
1.5 Are the strain relief elements correctly installed?  yes  no
1.6 Type of strain relief?  CFX  Tiewrap clamps

 CFY  other:
1.7
 Double  Single

1.8 Does the cable reserve correspond to the setpoint?  yes  no

2% of the chain length (or at least 0.5m)
__________m
1.9 Is the centre axis of the  yes  no

moving end aligned with
the centre axis of the
storage basket?
 
1.10 Is the moving end  yes  no
horizontal?
1.11 Is the position of the  yes  no

moving end to the storage
e-chainsystems®
Germany
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basket executed according

to the drawing?
Tolerance +/- 15 mm Drawing no.: Set X _____________mm
Error! Reference source Set Y _____________mm
not found.
1.12 Is the moving end centerd  yes  no

over the basket?
Tolerance +/- 5 mm
2. Fixed end

e-chainsystems®
Germany
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2.1 Are the strain relief elements correctly installed?  yes  no

Drawing no.:
Type of strain relief:  CFX  Tiewrap clamps

 CFY  other:
2.2  Double  Single

 
2.3 Does the cable reserve correspond to the  yes  no
setpoint?
2% of the chain length (or at least 0.5m)
__________m
 

e-chainsystems®
Germany
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3. Storage basket  
 
3.1 Check the storage basket for the following points:
- Is the basket constructed horizontally and angular  yes  no

- The basket is firmly screwed to the floor  yes  no
- None of the side plates are bent  yes  no
- None of the countersunk screws are protruding  yes  no
- No excessive dirt deposit  yes  no
- Is the chain guided without constraints or  yes  no
blockages?
3.2 Check the screw connections at different points for  yes  no

proper tightening torque. Are requirements complied
with?

e-chainsystems®
Germany
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3.3 Inner width of the storage basket corresponds to the  yes  no

drawing specification
Dawing no.: Set b __________________mm

e-chainsystems®
Germany
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4. e-chain  
4.1 All separators and opening crossbars are in place  yes  no

and locked.
4.2 Check the e-chain for the following points:  yes  no

- Cables are not twisted.
- Separators are not too far apart.
- Separators are not too close.
- Cables or hoses are in perfect condition.
4.3 Check the structure of the chain according to

drawing
Drawing no.:
Chain Link Chain

section number side

e-chainsystems®
Germany
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5. "End positions"
5.1 Are the end stops mounted?  yes  no

 
5.2 Move the e-chain up to the upper end position and  yes  no
make sure that the end stops are in the correct
position.
Attention: Both ends of the e-chain must be
observed carefully in order to avoid damage!
The end stops must be positioned in such a
way that the e-chain cannot be damaged.
When the top end position is reached, at least one
chain link must be at the fixed point.
Drawing no.:
Hmax set: _________

Hmax actual: _________

e-chainsystems®
Germany
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5.3 Move the e-chain to the bottom end position and  yes  no
make sure that the end stops are in the correct
position.
Attention: The e-chain must be observed
carefully in order to avoid damage! The end
stops must be positioned in such a way that
the e-chain cannot be damaged.
Drawing no.:
Hmin set: _________

Hmin actual: _________
 
5.4 Check the cable and hose lengths in the e-chain.  yes  no
They must be adjusted in such a way that the
cables pass through the radius slightly outside
the e-chain centre (see sketch). This adjustment
can also be carried out at the moving end, if this
is easier.
Are the cables set?
Remark: This setting must be repeated shortly

after commissioning and repeated after approx.
4 weeks of operation.
Procedure: Loosen strain relief and then push or

pull the cables to effect the desired effect in the
chain, then re-tighten the strain relief.

e-chainsystems®
Germany
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8. Full speed test

!! Before the test, care must be taken that no tools or other blockages are in the
way.
Start with a slow speed and then gradually increase to full speed.
!! Important: Stay out of the danger zone!
8.1 Is the moving end arm strong enough to press and  correction  OK
pull the e-chain®?
8.2 Does the e-chain® work without problems or is it  correction  OK
caught / hooked somewhere?
8.3 Are the cables or hoses tangled during the  correction  OK

movement?
8.4 If hoses are present, the position must also be  correction  OK
checked under pressure. Do the hoses stretch or
wear out? Do one or more hoses stretch
excessively?
8.5 Does the pressure of the hoses affect the bend  correction  OK
radius of the e-chain®? Is the chain stable or can it
fall over?
8.6 After the maximum speed is reached, perform a few  correction  OK
cycles and then check the cable setting, then adjust
the cables if necessary.

e-chainsystems®
Germany
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7. Comments/ Open points
No. Description Section Date: Executed by

e-chainsystems®
Germany
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8. Reason
The following measures must be undertaken before commissioning:
Operational readiness:
1. The system is enabled for operation. 
Observe the remarks under items 7 & 8.
Operation according to igus' maintenance schedule.
2. The system is approved for operation with limits. 

To avoid damage, observe the remarks in point 7 & 8.
The defects under point 7 & 8 must be eliminated:
within 2 weeks
up to_____________________.
The limited approval will expire on that day, if the
elimination of the defects has not been proved.
Operation according to igus' maintenance schedule.
3. The system is not approved for operation. 

Operation in this condition constitutes a risk to the system
and/or the safety. Observe the remarks under point 7 & 8.
Maintenance schedule:
1. The maintenance schedule for the igus e-chain system was 

handed over today.
2. The maintenance schedule for the igus e-chain system was 

already available.
Inspected:
Representative of igus GmbH: Date:
Signature igus GmbH:
Customer representative:
Customer signature:
Company stamp:

igus GmbH
e-chainsystems®
Telephone +49 - 22 03 / 96 49 - 0 Fax +49 - 22 03 / 96 49 - 222
Annex B
System drawing


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System drawing Annex B

Moving end Annex Drw.no B

Department: After-sales service Page 1 / 21

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Department: After-sales service Page 2 / 21

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Table 1 - Inspecton schedule

Date of commissioning Running-in Plant in operation

Department: After-sales service Page 3 / 21

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Table 2 – Check list

Department: After-sales service Page 4 / 21

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Item Description Execution: Condition Defects

Department: After-sales service Page 5 / 21

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Item Description Execution: Condition Defects

Department: After-sales service Page 6 / 21

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Item Description Execution: Condition Defects

Department: After-sales service Page 7 / 21

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Department: After-sales service Page 8 / 21

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Acceptance certificate and chain

Department: After-sales service Page 9 / 21

Summary of the acceptance test:

Item Description Position

Department: After-sales service Page: A10 / 21

1.1 Does the support plate correspond to the drawing?  yes  no

1.5 Are the strain relief elements correctly installed?  yes  no

1.6 Type of strain relief?  CFX  Tiewrap clamps

1.8 Does the cable reserve correspond to the setpoint?  yes  no

1.9 Is the centre axis of the  yes  no

1.11 Is the position of the  yes  no

basket executed according

1.12 Is the moving end centerd  yes  no

Department: After-sales service Page: A12 / 21

2.1 Are the strain relief elements correctly installed?  yes  no

Type of strain relief:  CFX  Tiewrap clamps

Department: After-sales service Page: A13 / 21

- Is the basket constructed horizontally and angular  yes  no

3.2 Check the screw connections at different points for  yes  no

Department: After-sales service Page: A14 / 21

3.3 Inner width of the storage basket corresponds to the  yes  no

Department: After-sales service Page: A15 / 21

4.1 All separators and opening crossbars are in place  yes  no

4.2 Check the e-chain for the following points:  yes  no

4.3 Check the structure of the chain according to

Chain Link Chain

Department: After-sales service Page: A16 / 21

5.1 Are the end stops mounted?  yes  no

Hmax set: _________

Department: After-sales service Page: A17 / 21

Hmin set: _________

Remark: This setting must be repeated shortly

Procedure: Loosen strain relief and then push or

Department: After-sales service Page: A18 / 21

8. Full speed test

8.3 Are the cables or hoses tangled during the  correction  OK