Sealing and lubrication elements – system KIT

With their extensive range of standard accessories, the linear guidance systems can be easily used in numerous areas. Since the guidance systems are used in an extremely wide variety of applications, however, additional requirements are often placed on the sealing and lubrication components.

Application-oriented complete package

If the standard components are not adequate for reliable operation and a long operating life, it is possible to draw on a finely graduated system of sealing and lubrication elements. These special access­ories protect the rolling element system of the guidance systems against contamination and ensure long relubrication intervals even under the most demanding operating conditions.

KIT structure

The elements are configured as the system KIT and are designed for various application conditions.

Starting from the degree of contamination, the best combination in each case can be quickly and easily compiled:

• Possible combinations, see link and link
• Description of sealing elements, see link
• Description of lubrication elements, see link
• Overview of lubrication elements, see link.

Degree of contamination

The degree of contamination will vary depending on the market sector, the application and the environmental conditions.

Definition of the degree of contamination

^**If this degree of contamination is present, a KIT can give only a restricted level of protection. Additional measures implemented by the customer, such as additional covers on the guidance system, will give a considerable increase in the operating life.

Sealing elements

Additional sealing elements are available both for open upper lubrication holes as well as for closed upper lubrication holes:

• End plates, see link
• End wipers, see link
• Additional wipers, see link
• Sealing strips, see link.

End plates

End plates are corrosion-resistant, non-contact components, ➤ Figure. They protect the end wipers located behind them against, for example, coarse contaminants and hot swarf. There is a narrow gap between the guideway and the seal.

A KIT.RWU..-E always contains an end plate.

End plate 
KIT.RWU..-210

 End plate,
non-contact

End wipers

End wipers are contact seals that are fixed to the end faces of the carriages. End wipers protect the guidance system against the ingress of contaminant particles and can extend the relubrication intervals. The selection of the suitable sealing system is based on the application of the guidance system. End wipers are available in single lip and double lip designs (double lip as standard) and are made from special high performance materials, ➤ Figure.

Single lip end wipers have a seal lip oriented outwards that protects the carriage against the ingress of contaminant particles. In combination with oil lubrication, the single lip end wiper facilitates the rinsing out of contaminant particles (flushing effect).

Double lip end wipers have one seal lip oriented outwards and one seal lip oriented inwards. The seal lip oriented inwards prevents the escape of lubricant from the carriage, which means that an increase in the relubrication interval can be achieved. Double lip end wipers are recommended for use with grease lubrication (reservoir lubrication).

End wiper Example KIT.RWU..-100, -200

 End wiper,
single lip, green ·

 End wiper,
double lip, black

Additional wipers

Additional wipers
with carrier plate

In addition to the standard seal, other additional wipers may be used behind each other (cascading arrangement). These are screw mounted with a carrier plate in front of the first wiper on the carriage, ➤ Figure.

The additional wipers are of a single or double lip design and are made from special high performance seal material. For protection against aggressive media (for example acids, alkalis), special end wipers made from FPM are available, ➤ Figure.

Additional wipers Example KIT.RWU..-130, -140, -350

 End wiper,
single lip, green ·

 End wiper,
double lip, black ·

 Carrier plate ·

 End wiper,
single lip, red (FPM)

Additional wipers with squeeze plate

Additional wipers for heavy contamination, such as dust or liquids, are used in combination with further seals and with a metallic squeeze plate.

Additional wipers are of a single lip design and are made from NBR, ➤ Figure.

Additional wiper Example KIT.RWU..-340

 Additional wiper with squeeze plate,
single lip

Sealing strips

Sealing strips are contact components that are fitted to the upper and lower longitudinal sides of the carriage, ➤ Figure. They protect the rolling element system against contamination and loss of lubricant.

Single lip and double lip

Linear recirculating roller bearing and guideway assemblies are supplied with a single lip upper sealing strip as well as a double lip lower sealing strip.

Sealing strips KIT.RWU..-910, -920, -930

 Lower sealing strip,
single lip ·

 Double lower sealing strip,
double lip ·

 Upper sealing strip

Lubrication elements

The following components are available:

• End piece with closed off upper relubrication hole, ➤ Figure
• Long term lubrication unit KIT series 400, see link
• Minimal lubricant quantity metering unit, KIT series 500, see link
• Lubricant quantity metering valves  SMDS , see link
• Lubrication adapter plate KIT series 600, see link.

End piece with closed upper relubrication hole

The designation of the KITs can also be used to order end pieces of the carriage with a closed upper relubrication hole (end number -..3), ➤ Figure.

End piece with closed off upper relubrication hole  KIT.RWU..-..3

 Closed off upper relubrication hole in the end piece

Long term lubrication unit KIT series 400

For linear recirculating roller bearing and guideway assemblies RUE..-E, KITs with a long term lubrication unit are available.

Operating life of the linear guidance system

The operating life is defined as the life actually achieved by a linear guidance system. This may deviate significantly, however, from the basic rating life.

A sufficiently long operating life is only achieved, assuming the bearing arrangement is correctly designed, through optimum lubrication and sealing. This can be achieved using the long term lubrication unit, ➤ Figure.

Grease operating life and relubrication interval

If guidance systems cannot be relubricated, the grease operating life becomes the decisive factor. This indicates the length of time for which a grease can be used without its function being impaired.

As the load increases, the grease is subjected to increasing strain. As a result, it ages more quickly. Premature destruction of the grease structure has an adverse effect on the performance characteristics of the grease. The grease operating life declines and relubrication must be carried out earlier.

If the shortened relubrication intervals are not observed, the guidance system will fail before the end of the expected operating life. With decreasing grease operating life, the operating life of the linear guidance system is thus reduced.

Longer operating life by means of a long term lubrication unit

The volume of grease in the carriage is increased by the lubrication pockets in the saddle plate. If a long term lubrication unit of KIT series 400 is also fitted, this gives an additional improvement in the lubricant balance, ➤ Figure. The lubricant is stored in a high capacity reservoir and continuously released to the raceways via a transfer medium. Depending on the operating and environmental conditions, it is possible to achieve long relubrication intervals or even complete freedom from maintenance.

Function irrespective of position

Long term lubrication units are particularly suitable in applications where lubrication is of critical importance. They are screw mounted between the end piece and the wiper and function with equal reliability in either a horizontal or vertical mounting position.

Long term lubrication unit

 Fixing screws ·

 End plate ·

 End wiper, double lip ·

 Carrier plate ·

 Long term lubrication unit

With initial greasing

Due to their initial greasing, long term lubrication units are ready for immediate operation. If they are ordered together with an RUE, the RUE and long term lubrication unit are greased.

Double lip end seal

Integrated double lip end seals give protection against grease loss and contamination.

Minimal lubricant quantity metering unit KIT series 500

The lubricant metering device is screw mounted to the end face of the carriage and can be connected to all conventional central lubrication systems.

The piston distributors in the aluminium body lubricate all four raceways evenly, irrespective of position, economically and with the smallest possible quantities of precisely metered lubricant.

The lubrication is fed in from the side via one line. The pressure must be measured directly at the metering unit: 

Pressure ranges for oil

• p_min = 6 bar (minimum pressure for initiation of a lubrication impulse)
• p_max = 38 bar.

In idle mode, the pressure level present must not exceed 0,5 bar.

Pressure ranges for flowable grease

• p_min = 12 bar (minimum pressure for initiation of a lubrication impulse)
• p_max = 38 bar. .

Coupling piece

The coupling piece for connection to the central lubrication system has a union nut similar to DIN 3871-A, is fitted on the left or right side of the metering unit and is suitable for connecting pipes with an outside diameter of 4 mm.

Minimal lubricant quantity metering unit  KIT.RWU..-500

KIT series 500

 Minimal lubricant quantity metering unit ·

 The lateral relubrication hole in the end piece must not be used

End piece

The lubrication adapter plate SMVT for the minimal lubricant quantity metering unit differs from the lubrication adapter plate for a carriage of standard design.

If the minimal lubricant quantity metering unit is to be fitted by the customer, the lubrication adapter plate included in the scope of delivery must always be replaced. The lubrication adapter plate must be replaced very carefully, taking account of the mounting manual MON 41.

Lubricant and metering quantities

The lubricant quantity is determined by the number of lubrication impulses. The metering unit is supplied with metering quantities of 0,03 cm³ per impulse and metering unit. A metering unit contains four metering elements.

Suitable lubricants

Oils CLP to DIN 55517 and HLP to DIN 51524 should be used in preference.

At operating temperatures between 0 °C and +70 °C, the viscosity should be between ISO VG 32 and ISO VG 68.

When using oil, the permissible viscosity range is from 20 to 2 000 mm^²/s (cSt). A 25 µm oil filter is recommended.

Flowable greases of the NLGI grade 00 and 000 are used for operation of the minimal lubricant quantity metering unit.

The maximum operating temperature is +80 °C.

Lubricant quantity metering valves

Lubricant quantity metering valves for oil lubrication

The lubricant quantity metering valves SMDS are, when supplied with oil as the lubricant, an economical solution for reducing lubricant consumption while also achieving high functional security.

Optimum lubricant supply

The lubricant quantity metering valves replace the conventional O rings in the return guides of the rolling element return channels. The lubricant quantity metering valves exactly fit the position of the O rings and replace these while retaining the design envelope of the carriage, ➤ Figure.

Lubricant quantity metering valves SMDS

The metering valves seal off the lubrication ducts and only open during the lubrication impulse. Between the lubrication impulses, the lubricant quantity metering valves prevent the lubrication ducts from running dry irrespective of position. This and the uniform opening pressure facilitate an optimum supply of lubricant.

Lubricant distribution

Where the mounting position is at an angle of 90° (wall mounting), the lubricant quantity metering valves offer an optimum supply of lubricant.

If the lubrication ducts are initially filled with oil, the lubricant quantity metering valves seal off the lubrication ducts, thus preventing the ducts from running dry, and support the optimum and uniform supply of lubricant to the rows of rolling elements. The lubricant quantity metering valves give effective prevention of damage to the raceways and rolling elements up to failure of the guidance system.

Lubricant consumption

A linear recirculating roller bearing and guideway assembly RUE35-E with a load ratio C/P = 4 and a velocity of 2 m/s can, with the aid of the lubricant quantity metering valves, save approx. 0,025 cm³ of lubricant per hour in comparison with the standard design while using an identical design envelope.

Design

The guidance systems must be ordered for delivery with the lubricant quantity metering valves, for example RUE35-E-SMDS-L. Retrofitting by the customer is not possible. The delivery of RUE..-E includes a mounting set M-Satz. This M-Satz contains one lubrication connector. The use of SMDS does not require a further lubrication connector. One lubrication connector per carriage is sufficient. Optionally, other lubrication connectors are available, see link.

Lubrication adapter plate KIT series 600

The lubrication adapter plate is screwed to the end face of the carriage. It comprises an aluminium body with integrated lubrication ducts and, on each side, 2 lateral threads M6. The useful thread length is max. 8 mm for accommodating the lubrication connectors. Depending on the design, connectors for manual lubricators or central lubrication systems and screw plugs are already fitted.

Contact surface for bellows

The screw heads for locating the lubrication adapter plate and the screw plug for sealing off the end face relubrication adapter plate are arranged countersunk in the body of the lubrication adapter plate. This gives a flat contact surface on the end face of the carriage, which can be used as an interface for the location of fasteners such as bellows.

Lubrication adapter plate KIT series 600

 Fixing screw ·

 Grub screw for closing off the relubrication hole ·

 Aluminium body ·

 Lubrication connector to DIN 71412-A ·

 Central lubrication connector with sealing ring ·

 Screw plug with sealing ring

Configuration of KIT.RWU

Unless indicated otherwise, the locating face is defined as being at the top. The KIT designation is given in the sequence left/centre/right. If no KIT numbers are indicated, the standard version will be supplied, see link.

KIT components can be fitted on the left, centre and right of the carriage, ➤ Figure.

Example of KIT configuration

RWU..-E-130/900/120

 Locating face ·

 KIT.RWU..-E-130 ·

 KIT.RWU..-E-900 ·

 KIT.RWU..-E-120

Retrofitting by the customer

The KITs available for retrofitting by the customer are indicated accordingly as retrofittable in the KIT tables, see link.

KIT left, right

The KIT components are identical for all carriage designs, with the exception of KIT series 500. The KIT end number -..3 describes the closed upper relubrication hole in the end piece, ➤ Figure. The end piece (lubrication distributor plate) is not a KIT component, so the KIT end number -..3 is not taken into consideration in retrofitting by the customer.

KIT components for retrofitting by the customer must be ordered for all types and designs using the designation KIT.RWU..-E as well as the suffix -OS and the KIT end number -..0.

The scope of delivery includes the wear components and fixing screws required for retrofitting.

Example: KIT.RWU35-E-OS-340.

KIT centre

If retrofitting is to be carried out by the customer, attention must be paid to the carriage length.

KIT components for retrofitting by the customer of long carriages must be ordered using the designation KIT.RWU..-E-L.

Example: KIT.RWU35-E-L-930.

Sealing and lubrication elements KIT (left, right)
for RUE..-E

Designation and KIT end number		Image	Description	Degree of contamination			Size	Retrofittable	Tolerances			Increased displacement force				Designation and KIT end number
				slight	medium	heavy			K1	LS	S	none	slight	moderate	heavy
KIT.RWU..-E****																KIT.RWU..-E****
Upper lubrication hole, open																Upper lubrication hole, open
yes	no									mm	mm					yes	no
100	103		Fixing screw K1 End plate, non-contact End seal, single lip.	█	█	–	–	█	–	–	–	–	–	█	–	100	103
							35		M4×25	2,2	0
							45		M4×30	2,2
							55		M5×30	2,75
							–		–	–	–
							–		–	–	–
120**	123		Fixing screw K1 End plate, non-contact End seal, double lip.	█	█	–	25	█	M4×20	2,2	0	–	–	█	–	120**	123
							35		M4×25	2,2
							45		M4×30	2,2
							55		M5×30	2,75
							65		M5×35	2,75
							100		M6×40	4,5
130	133		Fixing screw K1 End plate, non-contact End seal, single lip End seal, double lip Carrier plate.	█	█	█	25	█	M4×20	2,2	4,2	–	–	–	█	130	133
							35		M4×30	2,2	5,8
							45		M4×35	2,2
							55		M5×35	2,75
							–		–	–	–
							–		–	–	–
140	143		Fixing screw K1 End plate, non-contact End seal, single lip Carrier plate.	█	█	█	25	█	M4×20	2,2	0	–	–	–	█	140	143
							35		M4×30	2,2	5,8
							45		M4×35	2,2
							55		M5×35	2,75
							–		–	–	–
							–		–	–	–
Designation and KIT end number		Image	Description	Degree of contamination			Size	Retrofittable	Tolerances			Increased displacement force				Designation and KIT end number
				slight	medium	heavy			K1	LS	S	none	slight	moderate	heavy
KIT.RWU..-E****																KIT.RWU..-E****
Upper lubrication hole, open																Upper lubrication hole, open
yes	no									mm	mm					yes	no
210	213		Fixing screw K1 End plate, non-contact.	█	–	–	25	█	M4×20	2,2	0	█	–	–	–	210	213
							35		M4×25	2,2
							45		M4×30	2,2
							55		M5×30	2,75
							65		M5×35	2,75
							100		M6×40	4,5
220	223		Fixing screw K1 End plate, non-contact End seal, single lip, smooth running.	█	█	–	–	█	–	–	–	–	█	–	–	220	223
							35		M4×25	2,2	0
							45		M4×30	2,2
							55		M5×30	2,75
							–		–	–	–
							–		–	–	–
300	303		Fixing screw K1 End seal, single lip End seal, single lip, NBR with pressing plate.	█	█	–	–	█	–	–	–	–	–	–	█	300	303
							35		M4×30	2,2	5,4
							45		M4×35	2,2
							55		M5×35	2,75
							–		–	–	–
							–		–	–	–
340	343		Fixing screw K1 End seal, double lip End seal, single lip, NBR with pressing plate.	█	█	█	25	█	M4×20	2,2	4,2	–	–	–	█	340	343
							35		M4×30	2,2	5,4
							45		M4×35	2,2
							55		M5×35	2,75
							65		M5×45	2,75
							100		M5×50	4,5
Designation and KIT end number		Image	Description	Degree of contamination			Size	Retrofittable	Tolerances			Increased displacement force				Designation and KIT end number
				slight	medium	heavy			K1	LS	S	none	slight	moderate	heavy
KIT.RWU..-E****																KIT.RWU..-E****
Upper lubrication hole, open																Upper lubrication hole, open
yes	no									mm	mm					yes	no
350	353		Fixing screw K1 End plate, non-contact End seal, double lip Carrier plate End seal, single lip, FPM.	█	█	█	25	█	M4×20	2,2	4,2	–	–	–	█	350	353
							35		M4×30	2,2	5,8
							45		M4×35	2,2
							55		M5×35	2,75
							65		M5×40	2,75
							–		–	–	–
380	383		Fixing screw K1 End plate, non-contact End seal, single lip, FPM.	█	█	–	–	█	–	–	–	–	–	█	–	380	383
							35		M4×25	2,2	0
							45		M4×30	2,2
							55		M5×30	2,75
							65		M5×35	2,75
							100		M6×40	4,5
410	413		Fixing screw K1 End plate, non-contact End seal, double lip Carrier plate LZU housing unit.	█	█	–	25	█	M4×30	2,2	13,2	–	–	–	█	410	413
							35		M4×45	2,2	17,5
							45		M4×45	2,2	17,5
							55		M5×45	2,75	18,2
							65		M5×50	2,75	18,4
							–		–	–	–
420	423		Fixing screw K1 End seal, double lip Carrier plate End seal, single lip, NBR with pressing plate LZU housing unit.	█	█	█	25	█	M4×30	2,2	13,2	–	–	–	█	420	423
							35		M4×45	2,2	20,25
							45		M4×45	2,2	20,25
							55		M5×45	2,75	21,2
							65		M5×50	2,75	21,4
							–		–	–	–
Designation and KIT end number		Image	Description	Degree of contamination			Size	Retrofittable	Tolerances			Increased displacement force				Designation and KIT end number
				slight	medium	heavy			K1	LS	S	none	slight	moderate	heavy
KIT.RWU..-E****										mm	mm					KIT.RWU..-E****
510			Fixing screw K1 End plate, non-contact End seal, double lip Carrier plate SMDE unit, lubrication connector on right side.	█	█	–	–	█	–	–	–	–	–	█	–	510
							35		M4×55	4	31,8
							45		M4×60	4
							55		M5×60	5
							65		M5×65	5
							–		–	–	–
511			Fixing screw K1 End plate, non-contact End seal, double lip Carrier plate SMDE unit, lubrication connector on left side.	█	█	–	–	█	–	–	–	–	–	█	–	511
							35		M4×55	4	31,8
							45		M4×60	4
							55		M5×60	5
							65		M5×65	5
							–		–	–	–
530			Fixing screw K1 End seal, double lip Carrier plate End seal, single lip, NBR with pressing plate SMDE unit, lubrication connector on right side.	█	█	█	–	█	–	–	–	–	–	–	█	530
							35		M4×55	4	37,2
							45		M4×60	4
							55		M5×60	5
							65		M5×65	5
							–		–	–	–
531			Fixing screw K1 End seal, double lip Carrier plate End seal, single lip, NBR with pressing plate SMDE unit, lubrication connector on left side.	█	█	█	–	█	–	–	–	–	–	–	█	531
							35		M4×55	4	37,2
							45		M4×60	4
							55		M5×60	5
							65		M5×65	5
							–		–	–	–
540			Fixing screw K1 End plate, non-contact End seal, double lip Carrier plate SMDE unit, lubrication connector closed on both sides.	█	█	–	–	█	–	–	–	–	–	█	–	540
							35		M4×55	4	31,8
							45		M4×60	4
							55		M5×60	5
							65		M5×65	5
							–		–	–	–
Designation and KIT end number		Image	Description	Degree of contamination			Size	Retrofittable	Tolerances			Increased displacement force				Designation and KIT end number
				slight	medium	heavy			K1	LS	S	none	slight	moderate	heavy
KIT.RWU..-E****										mm	mm					KIT.RWU..-E****
550			Fixing screw K1 End plate, non-contact End seal, double lip Carrier plate SMDE unit, lubrication connector on right side End seal, single lip, FPM.	█	█	█	–	█	–	–	–	–	–	–	█	550
							35		M4×55	4	37,2
							45		M4×60	4
							55		M5×60	5
							65		M5×65	5
							–		–	–	–
551			Fixing screw K1 End plate, non-contact End seal, double lip Carrier plate SMDE unit, lubrication connector on left side End seal, single lip, FPM.	█	█	█	–	█	–	–	–	–	–	–	█	551
							35		M4×55	4	37,2
							45		M4×60	4
							55		M5×60	5
							65		M5×65	5
							–		–	–	–
560			Fixing screw K1 End plate, non-contact End seal, single lip End seal, double lip Carrier plate SMDE unit, lubrication connector on right side.	█	█	█	–	█	–	–	–	–	–	█	–	560
							35		M4×55	4	37,2
							45		M4×60	4
							55		M5×60	5
							–		–	–	–
							–		–	–	–
561			Fixing screw K1 End plate, non-contact End seal, single lip End seal, double lip Carrier plate SMDE unit, lubrication connector on left side.	█	█	█	–	█	–	–	–	–	–	█	–	561
							35		M4×55	4	37,2
							45		M4×60	4
							55		M5×60	5
							–		–	–	–
							–		–	–	–
Designation and KIT end number		Image	Description	Degree of contamination			Size	Retrofittable	Tolerances			Increased displacement force				Designation and KIT end number
				slight	medium	heavy			K1	LS	S	none	slight	moderate	heavy
KIT.RWU..-E****																KIT.RWU..-E****
610			Fixing screw K1 End seal, double lip Seal plug with sealing washer Lubrication adapter plate, lubrication connector on right side for connection to a central lubrication system.	█	█	–	–	█	–	–	–	–	–	█	–	610
							35		M4×35	0	14,6
							45		M4×40		15,6
							55		M5×40		14,6
							65		M5×45		14
							–		–	–	–
611			Fixing screw K1 End seal, double lip Seal plug with sealing washer Lubrication adapter plate, lubrication connector on left side for connection to a central lubrication system.	█	█	–	–	█	–	–	–	–	–	█	–	611
							35		M4×35	0	14,6
							45		M4×40		15,6
							55		M5×40		14,6
							65		M5×45		14
							–		–	–	–
614			Fixing screw K1 End seal, double lip Seal plug with sealing washer Lubrication adapter plate, lubrication connectors closed on both sides.	█	█	–	–	█	–	–	–	–	–	█	–	614
							35		M4×35	0	14,6
							45		M4×40		15,6
							55		M5×40		14,6
							65		M5×45		14
							–		–	–	–
615			Fixing screw K1 End seal, double lip Seal plug with sealing washer Lubrication adapter plate, lubrication connector on right side for connection to a manual lubricator.	█	█	–	–	█	–	–	–	–	–	█	–	615
							35		M4×35	0	14,6
							45		M4×40		15,6
							55		M5×40		14,6
							65		M5×45		14
							–		–	–	–
616			Fixing screw K1 End seal, double lip Seal plug with sealing washer Lubrication adapter plate, lubrication connector on left side for connection to a manual lubricator.	█	█	–	–	█	–	–	–	–	–	█	–	616
							35		M4×35	0	14,6
							45		M4×40		15,6
							55		M5×40		14,6
							65		M5×45		14
							–		–	–	–

●

Standard lubrication connector

W = hexagon

Lubrication connectors for manual lubricators

W = hexagon · S = hexagon socket

Lubrication connectors for manual lubricators

^**Standard.

Definition of lubrication connectors

 Locating face top or

 Locating face bottom ·

 Alignment of the angled lubrication connectors from viewpoint of carriage

Lubrication connectors for central lubrication

W = hexagon · S = hexagon socket

Lubrication connectors for central lubrication

Definition of lubrication connectors

 Locating face top or

 Locating face bottom ·

 Alignment of the angled lubrication connectors from viewpoint of carriage