IAI America, Inc. Nut Rotary Actuator NS Series
Contents
1. 20 14 6 2 How to Apply Grease 21 14 7 Greasing the Ball eae eee 22 14 7 T Applica e Gea E 22 14 7 2 How to Apply Grease 22 14 8 Adjusting the Tension of the Mid Support 23 14 9 Replacing the Mid support Wire 25 31 15 1 What to Do When You Suspect a Fallure 000 2c AAs ieee okies 31 15 2 Encoder Open Error Error Code 2 31 15 3 Driver Overload Error Error Code DOA 32 15 4 Deviation Overflow Error Error Code 6 33 6 Gable Drawings iieiaei daia aie 34 INTELLIGENT ACTUATO 1 Foreword Thank you for purchasing an IAI product This manual explains the structure correct operation and maintenance of the actuator Please read this manual carefully before using the actuator Keep this manual so that the necessary sections can be referenced whenever necessary For more complete operational information please refer to the controller s operating manual 2 Over2. Type Capacity W Lead mm Stroke mm Maximum speed mm sec Horizontal 20 500 1200 1800 40 2400 400 Mid support 20 1300 3000 1308 40 2400 Vertical 20 500 1000 1000 Multi slider specification Type Capacity W Lead mm Stroke mm Maximum speed mm sec Horizontal 400 20 250 2250 1800 40 2400 Vertical 400 20 250 950 1000 Caution e Use each actuator by observing its maximum speed e Take note that resonance may still occur at speeds below the applicable limit specified above depending on the installation condition or operating conditions e Resonance of the ball screw shaft may increase the noise level or cause vibration resulting in a shorter service life of the machine If each actuator is used independently write a program conforming to the maximum speed of the actuator refer to the table above If multiple actuators are used synchronized operation write a program conforming to the lowest of the maximum speeds applicable to all synchronized actuators e In either way always check the maximum speed of each applicable actuator when writing a program AN INTELLIGENT ACTUATO 11 Load Applied to the Actuator e The load specified in the specification table must not be exceeded In particular pay attention to the moments applied to the slider allowable overhang length and loaded mass e f the actuator is us
3. 8 8 3 9 rot 9 8 5 Installing Load the 10 9 Connecting to The 11 91 Wiring an Actuator of Standard Specification Wiring between the controller and 11 952 OT o E 12 10 Maximum cr reo 13 11 Load Applied to the 14 INTELLIGENT ACTUATO 13 Setting the Home 15 13 1 Operating Principles of Home 24 44000 0 15 13 2 Fine tuning the Home etd 15 13 3 Changing the Direction of HOME dened st lacus 15 14 Maintenance 16 14 1 Maintenance Schedule 16 14 2 External Visual 16 16 14 4 2 17 14 5 Internal Cleaning 25 19 14 6 Greasi g the Guide 20 14 6 1 Applicable
4. White blue in the Color field indicates that the cable is white and the insulator is blue 35 INTELLIGENT 3 Encoder cable with LS Model CB X2 PLANOO 41 14 13 14 1 9 i 26 13 Actuator Front view Gontrollerend 15 Wire size Color Signal E Eee Color Wire size AWG26 crimped Rsv _ whiteGray a Se ae No Signal Color Wire size AWG 26 5 White Black __ 6 z __ WhteGray crimped BS Green SRD 8 Dan 16 Bkr 74 Drain wire braided shield wire 17 BK Bue White blue in the Color field indicates that the cable is white and the insulator is blue 36 37 38 39 Catalog No RCS2 Actuator MJ3663 1A Mar2007 1 IAI Quality and Innovation America Inc Head Office 2690 W 237th Street Torrance CA 90505 TEL 310 891 6015 FAX 310 891 0815 Chicago Office 1261 Hamilton Parkway Itasca IL 60143 TEL 630 467 9900 FAX 630 467 9912 Website www intelligentactuator com GmbH Ober R th 4 D 65824
5. 2 8H7 depth 10 8 8 depth 22 0 6 oO 80 20 110 _ _ 20 10 MAN INTELLIGENT ACTUATO 9 Connecting to the Controller How to wire the actuator with the controller is explained based on a single axis configuration 9 1 Wiring an Actuator of Standard Specification Wiring between the controller and actuator If you ordered a single axis actuator your actuator should have a 3 meter or 5 meter single axis cable preassembled with the actuator body Plug the connector at the end of the cable directly into the connector If the actuator is of multi slider specification make sure the connectors are joined correctly by referring to the marker tubes M1 M2 PG1 PG2 at the cable ends Do not extend or shorten the cable by cutting or reconnect the cable e Although the standard cable offers excellent flexibility it is not a robot cable Use a robot cable if the cable is to be stored in a moving cable duct cable bearer etc If you wish to change the cable specification contact IAI Connecting to the controller An example of connection with a XSEL controller is shown below The actuator can also be connected to SSEL and SCON controllers XSEL controller Host system PLC Teaching pendant PC software lt 101 gt
6. Controller connection cables Motor cable Encoder cable Standard CB X MADOO 2 With LS creep sensors 000 2 00 INTELLIGENT ACTUATO 9 2 Cable Bearer You can choose the standard cable bearer or expanded cable bearer 120 Standard cable bearer KSH 24W THK Expanded cable bearer optional Take note of the following points when storing cables hoses in the expanded cable bearer 1 Provide a minimum clearance of 2 mm between the outer diameter of the cable hose bundle and the interior wall of the cable bearer and also between the individual cables and hoses 2 outer diameter of the cable hose bundle shall not exceed 216 8 and the cables hoses shall be laid side by side not stacked on top of each other If the cables hoses are stored in the cable bearer without observing the precautions above excessive force may be applied to the cables hoses to significantly shorten the service life of the cables hoses 12 INTELLIGENT ACTUATO 10 Maximum Speed The maximum speed of this actuator is limited to prevent resonance of the ball screw shaft while conforming to the speed limit of the motor Take heed of the maximum speed limits specified in the table bellow Strokes and maximum speed limits unit mm sec Single slider specification
7. Nut Rotary Actuator NS Series LXMS LXMM LXMXS LZMS LZMM Operating Manual First Edition IAI America Inc INTELLIGENT Safety Precautions Please Read Before Use Before installing operating maintaining or inspecting this product peruse this operating manual as well as operating manuals and related documentations for all equipment and peripherals connected to this product to ensure the correct use of the product Also keep in mind that these tasks must be performed by individuals who possess sufficient knowledge of the applicable equipment and safe operation thereof The precautions provided below are intended to prevent bodily injury and or property damage by making sure the product is used correctly and safely In this operating manual safety precautions are classified as danger warning caution and note D Failure to observe the instruction will result in an imminent danger leading to anger death or serious injury Warning Failure to observe the instruction may result in death or serious injury Caution Failure to observe the instruction may result in injury or property damage Not The user should take heed of this information to ensure the proper use of the ote product although failure to do so will not result in injury Take note that depending on the situation a failure to heed the directions accomp
8. an excessive force on any part of the actuator Pay particular attention to the screw cover and cables Supplement Refer to 5 Names of the Parts for the name of each actuator part INTELLIGENT ACTUATO 6 2 Handling the Assembled Actuator Take heed of the following precautions when transporting the actuator after each axis has been assembled 6 2 1 Preassembled Actuator If specified Al assembles the mechanical components at our factory conducts a shipping inspection on the assembly and ships the assembled actuator by packing it with skid plates bolted to the exterior frame The slider is secured to prevent sudden movement during transport If the actuator is of combination type the extremities are also secured to prevent excessive swinging caused by external vibration e The above packing specification does not reflect special considerations for protection against impact resulting from dropping or bumping the box Handle the box carefully The outer frame is not designed to withstand loads from the above so do not place heavy objects on the frame e lf the box is suspended using ropes etc pass the ropes around the reinforcement frame at the bottom face of skid plates Similarly when lifting the actuator with a forklift place the forks below the skid plates e Set down the box carefully to prevent application of impact or bouncing of the box upon landing Once the actuator is unpacked handle the actuator by ob
9. indicated by looking at the horizontally positioned actuator from the home side in top view The front side corresponds to the counter home side Note On an actuator of single slider specification the home side corresponds to the side where the IAI logo is shown Cable Screw cover Counter home side IAI logo IAI Corporation End cover End cover Counter home side End bracket End bracket The installation direction of the cable bearer varies depending on the specification of the delivered product INTELLIGENT 6 Transporting and Handling 6 1 Handling the Unassembled Actuator 6 1 1 Handling the Packed Unit Unless otherwise specified each single axis actuator is packed and shipped individually When transporting the packed actuator exercise due caution to avoid dropping the box or hitting it against an object structure etc Heavy shipping boxes should be carried by two or more persons If the shipping box is left standing it should be in a horizontal position Do not climb on top of the shipping box Do not place heavy objects on top of the shipping box 6 1 2 Handling the Actuator After It is Unpacked When handling the unpacked actuator always hold the base e When carrying the actuator exercise care not to hit it against an object structure etc Pay particular attention to the end bracket end cover and guide rail e Do not exert
10. intended lubrication property and the machine may be damaged 14 7 2 How to Apply Grease Clean the ball screw before applying grease Apply grease by hand and then move the slider back and forth to let grease spread evenly Finally wipe off excess grease that has overflowed from the nut Move the slider If the actuator is equipped Apply grease on the ball screw with a brake release the brake Caution Adding too much grease may increase the agitation resistance and cause the ball screw to generate heat easily or the excess grease attached to the ball screw may scatter and dirty the surrounding area Be sure to wipe off excess grease 22 INTELLIGENT ACTUATO 14 8 Adjusting the Tension of the Mid support Wire Items required for adjustment e Allen wrenches e Tension gauge capable of exerting a push force of at least 1 kg 9 800 N Procedure 1 Remove the end cover using an Allen wrench of 1 5 mm across flats 2 2 Remove the screw cover using Allen wrench of 2 0 mm across flats 3 Loosen the two screws x 5 affixing one wire hook base side of the mid support wire located at the center of the base so that the wire hook can be moved Loosen the screws for only one wire hook on either the home side or counter home side Wire hook base side Loosen the wire hook on one side 23 AN INTELLIGENT ACTUATO 4 Use a tension gauge to push
11. the loosened wire hook with the specified push force and tighten the two wire hook screws M3 x 5 Tightening torque 1 5 Nem 5 After the check assemble the parts by following the same steps in reverse When installing the screw cover make sure the side face bearing the IAI logo is on the same side as the serial number label on the base Screw cover affixing bolt M4 x 5 Tightening torque 0 6 Nem End cover affixing bolt M3 x 6 Tightening torque 0 4 Nem Caution The hollow shaft motor has been adjusted at the factory prior to installation Never loosen the mounting bolts of the hollow shaft motor Bolt 24 INTELLIGENT ACTUATO 14 9 Replacing the Mid support Wire Items required for adjustment e Mid support wire Model WR LXMXS stroke Wire hook base side As a replacement when the wire catch of the original hook is deformed Wire hook motor side replacement when the wire catch of the original hook is deformed Allen wrenches Tension gauge capable of exerting a push force of at least 1 kg 9 800 N Procedure 1 Remove the end cover using an Allen wrench of 1 5 mm across flats 2 Remove the screw cover using an Allen wrench of 2 0 mm across flats 25 INTELLIGENT ACTUATO 3 Loosen the two screws x 5 affixing one wire hook base side of the mid support wire located at the center of the base so that the wire hook can be move
12. the product has actuated turn off the power immediately Continuing to use the product may result in product damage or injury due to malfunction Once the power supply is cut off investigate and remove the cause and then turn on the power again Do not step on the product use it as a footstool or place any object on it You may lose your footing or the product may tip over resulting in a fall and consequent injury product damage malfunction due to damage runaway machine etc Maintenance Inspection Repair Before conducting maintenance inspection parts replacement or other operations on the product completely shut down the power supply At this time take the following measures 1 Display a sign that reads WORK IN PROGRESS DO NOT TURN ON POWER at a conspicuous place in order to prevent a person other than the operator from accidentally turning on the power while the operation is working 2 When two or more operators are to perform maintenance inspection together always call out every time the power is turned on off or an axis is moved in order to ensure safety Disposal Do not throw the product into fire The product may burst or generate toxic gases 210 Caution Installation Do not use the product under direct sunlight ultraviolet ray in a place exposed to dust salt or iron powder in a humid place or in an atmosphere of organic solvent phosphate ester machine oil etc The produc
13. 4 Warranty 4 1 Warranty Period The warranty period corresponds to one of the following periods whichever elapses first 18 months after the shipment from IAI 12 months after the delivery to the specified location 2 500 hours of operation 4 2 Scope of Warranty All defects in materials or craftsmanship found during the warranty period specified above will be repaired free of charge Note however that the following items are excluded from the scope of this warranty Natural fading of exterior paint and other changes due to aging Wear of consumable parts from use Noises and other subjective conditions that do not affect function Inappropriate handling by the user or failure to conduct maintenance inspection Modification not performed by IAI or its authorized dealer Breakdown resulting from using a controller not manufactured by IAI Anything caused by an act of God accident fire etc This warranty covers only the product delivered IAI shall not be liable for any secondary loss or damage arising from a defect in the product To enjoy free warranty repairs the customer must bring the defective product to 5 factory Should you require an onsite repair by our engineer separate fees will be chargeable even during the warranty period INTELLIGENT 5 Names of the Parts The names of the actuator parts are indicated below In this manual the left and right sides are
14. Schwalbach am Taunus Germany TEL 06196 88950 FAX 06196 889524 The information contained in this document is subject to change without notice for the purpose of product improvement Copyright 2007 IAI Corporation All rights reserved
15. all be a machined surface or a flat surface having equivalent accuracy e Mounting holes are provided in the actuator base so use these holes to install the actuator Use M8 bolts conforming to strength category 10 9 or above together with the dedicated washers that came with the actuator to prevent buckling Applicable bolt Remarks M8 Use the dedicated washer e On an actuator of single slider specification the home is located on the end where the IAI log is attached on the side face of the screw cover Pay attention to the direction when installing the actuator IAI logo Corporation INTELLIGENT 8 2 Installation Surface e The frame shall have sufficient structural rigidity to prevent vibration e The surface on which to install the actuator shall be a machined surface or a flat surface having equivalent accuracy where the surface flatness shall be within 0 05 mm e Provide the space needed to carry out maintenance work e The side and bottom faces of the actuator base are used as reference surfaces for slider travel alignment e If high traveling accuracy is required install the actuator using these surfaces as a reference Reference surface Reference surface As shown above the side faces of the base are used as reference surfaces for slider travel alignment If high traveling accuracy is required install th
16. anied by A Caution or Note may still result in serious consequences All instructions provide important information Read them carefully and handle the product with due care Keep this operating manual in a convenient place so that it can be readily referenced whenever necessary and also make sure the manual gets to the hands of the end users A Danger General Do not use this product for the following applications 1 Medical equipment used to maintain control or otherwise affect human life or physical health 2 Mechanisms and machinery designed for the purpose of moving or transporting people 3 Important safety parts of machinery This product has not been planned or designed for applications requiring high levels of safety Use of this product in such applications may jeopardize the safety of human life The warranty covers only the product as it is delivered Installation Do not use this product in a place exposed to ignitable inflammable or explosive substances The product may ignite burn or explode When installing the product be sure to securely support and affix it including the work Failure to do so may cause the product to tip over drop or malfunction resulting in injury AN INTELLIGENT ACTUATO Avoid using the product in a place where the main unit or controller may come in contact with water or oil droplets Never cut and or reconnect the cables suppli
17. d Loosen the screws for only one wire hook on either the home side or counter home side Wire hook base side Loosen the wire hook on one side ee 999999 4 If the wire catch of the hook base side is deformed replace the wire hook as follows Replace the wire hook on one side base side with a replacement hook and tighten the two screws x 5 by keeping approx 5 mm between the slot end and each screw as shown below Also replace the wire hook on the other side base side with a replacement hook and loosely tighten the two screws x 5 so that the wire hook can be moved Approx 5 mm Loosely tighten the screws Tighten the screws Tightening torque 1 5 26 INTELLIGENT ACTUATO 4 5 Remove the wire from the wire hook whose screws have been loosened Remove the wire from the wire hook base side Next pull out the wire through the delrin bearing at the mid support and remove it from the wire hook motor side Remove the wire Pull out the wire through the delrin bearing Remove the wire Follow the same steps to also remove the wire from the wire hook base side whose screws have not been loosened 27 AN INTELLIGENT ACTUATO 6 Hook one end of the replacement wire on the wire hook base side whose screws have not been loosened Guide the other end of the wire under the m
18. d above Examples of equivalent grease products are listed below Showa Shell Sekiyu Albania Grease 2 Mobil Sekiyu Mobilux 2 Warning Never use fluorine grease If fluorine grease is mixed with lithium grease lithium grease will lose its intended lubrication property and the machine may be damaged 20 INTELLIGENT 14 6 2 How Apply Grease Two grease nipples are found one each on the right and left sides of the slider Apply grease from these nipples 1 Using a grease gun apply grease from the grease nipples located on the end faces of the slider Refer to the figure below for the positions of grease nipples Grease nipple positions on the slider 2 Move the slider back and forth several times by hand 3 Repeat the above steps to apply more grease 4 Use waste cloth etc to wipe off grease that has overflowed from the slider 21 INTELLIGENT 14 7 Greasing the Ball Screw 14 7 1 Applicable Grease The following lithium grease has been applied prior to shipment Kyodo Yushi Multemp LRL 3 This grease has excellent properties including low heat generation and is suitable for ball screws For information on equivalent products lithium greases refer to the section on greasing the guide A Warning Never use fluorine grease If fluorine grease is mixed with lithium grease lithium grease will lose its
19. e 0 40 C The humidity should be less than 85 and there should be no condensation Avoid exposure to corrosive or combustible gases The area should have very little dust and be suitable for normal assembly operations Avoid exposure to oil mist or fluids using in cutting The actuator should not be subject to vibration or shock The actuator should not be subject to significant levels of electromagnetic waves ultraviolet rays or radiation e This product is not designed for use in a chemical environment In general the environment should be one in which an operator can work without protective gear 7 2 Storage Environment The storage environment should be similar to the operating environment In addition you must take pre cautions against condensation if the unit is to be stored for a long period of time Unless there are special instructions we do not include moisture absorption agents when shipping the unit If you are storing the unit where condensation might occur then you must treat the entire package or treat the unit itself after it is unpacked to prevent condensation The unit can withstand up to 60 C during a short storage interval but only up to 50 C if the storage period is longer than one month INTELLIGENT 8 Installation How to install the actuator is explained based single axis configuration 8 1 Installing the Body The surface on which to install the actuator sh
20. e actuator using these surfaces as a reference When installing the actuator on a frame using the reference surfaces of the base provide the required machining by following the figure below When machining the surface provide a margin corresponding to the thickness of the cover to prevent the ends of the actuator from contacting the front cover and rear cover 55 Dimension A mm 0 3 lt INTELLIGENT 8 3 Tightening Screws e Use hexagonal socket head bolts as the male threads with which to install the actuator base e Use of high strength bolts conforming to ISO 10 9 or above is recommended e The effective engagement length between the bolt and female thread shall be at least the value specified below When the female thread is made of steel Same as the nominal diameter When the female thread is made of aluminum __ Twice the nominal diameter e If the bolt bearing surface is made of aluminum also use a dedicated washer for high strength bolt If the bolt is applied without an appropriate washer the bearing surface may buckle The recommended tightening torque is specified below Tightening torque Nominal thread size 9 g Steel bolt bearing surface Aluminum bolt bearing surface M8 31 3 3 19 14 N m 1 43 8 4 Mounting T slot A M4 T groove is provid
21. ed as the Y axis in a cantilever robot the base becomes vulnerable to deformation Accordingly keep the Ma and Mc moments to one half the rated moment or below Refer to the figure below Allowable load moments Ma Mb Mc 104 9 N m 10 7 kgf m 149 9 15 3 kgfm 248 9 N m 25 4 Ma direction Allowable overhang lengths Mb direction Mc direction 750 max 750 max 750 max The allowable overhang lengths are based on a configuration where the center of gravity of the installed article is positioned at one half the overhang length Mb Mc directions Ma direction Directions of moment Directions of overhang Application of an excessive load moment may lead to unwanted outcomes such as a shorter service life of the guide If the overhang length exceeds the allowable value vibration may occur or the service life of the guide may be negatively affected 12 Duty Keep the duty to 50 or below so that the actuator will last for a long time without stopping due to errors Duty Operating time Operating time Stopped time x 100 If the duty is too high an overload error and other errors may generate If the actuator generated an error increase the stopped time to lower the duty 14 INTELLIGENT ACTUATO 13 Setting the Home 13 1 Operating Principles of Home Return This actuator implements a home return in
22. ed in each side face of the base for installing a connector box cable bearer catch or any other necessary component Refer to the figure below If the combined specification requires a wiring kit use this T slot to install the kit The T slot can also be used to install sensors or secure wires or for various other purposes as deemed necessary Caution Although square nuts are recommended general hexagonal nuts can also be used with the T slot e When installing a bolt in the T slot pay attention to the bolt length to make sure the tip of the bolt will not contact the bottom of the T slot INTELLIGENT 8 5 Installing Load the Slider e Tapped holes are provided in the slider so use these holes to securely affix a load The affixing method varies depending on how the actuator is installed f the slider is affixed to move the actuator body also use the slider s tapped holes for installation When installing a heavy object also use pins e Two reamed holes are provided in the slider so use these holes if position accuracy must be maintained after removal reinstallation If the application requires fine tuning of the squareness etc use one of the slider s reamed holes for adjustment e Keep the screw in depth to 20 mm or less If the bolt is screwed in beyond the above dimension the tip of the bolt may damage the side cover and consequently the actuator
23. ed with the product for the purpose of extending or shortening the cable length Doing so may result in fire Operation Do not enter the machine s range of operation while the product is operating or standing by The actuator may move suddenly causing injury Do not pour water onto the product Spraying water over the product washing it with water or using it in water may cause the product to malfunction resulting in injury electric shock fire etc Maintenance Inspection Repair Never modify the product Unauthorized modification may cause the product to malfunction resulting in injury electric shock fire etc Do not disassemble and reassemble the components relating to the basic structure of the product or its performance and function Doing so may result in injury electric shock fire etc Warning General Do not use the product outside the specifications Using the product outside the specifications may cause it to fail stop functioning or sustain damage It may also significantly reduce the service life of the product In particular observe the maximum loading capacity and speed Installation machine will stop in the case of system problem such as emergency stop or power failure design a Safety circuit or other device that will prevent equipment damage or injury Before supplying power to and operating the product always check the operation area of the equipment to ensure saf
24. er guards must be provided for the moving parts of the equipment to avoid direct contact with the operators Do not configure a control circuit that will cause the work to drop in case of power failure Configure a control circuit that will prevent the table or work from dropping when the power to the machine is cut off or an emergency stop is actuated Take the following precautions to increase the linear traveling accuracy of the table and ensure smooth movement of the ball screw and linear guide 1 Flatness of the mounting surface must be within 0 05 mm 2 The mounting surface area must be large enough to ensure the rigidity of the actuator Installation Operation Maintenance When handling the product wear protective gloves protective goggles safety shoes or other necessary gear to ensure safety Maintenance Inspection Repair To grease the guide and ball screw during maintenance use the specified grease particular do not mix fluorine grease and lithium grease as it may cause insufficient lubrication higher resistance or other unwanted outcomes and ultimately damage the machine Disposal When the product becomes no longer usable or necessary dispose of it properly as an industrial waste Others shall not be liable whatsoever for any loss or damage arising from a failure to observe the items specified in Safety Precautions INTELLIGENT ACTUATO Table o
25. ernal inspection procedure is specified below INTELLIGENT ACTUATO 1 Remove the end cover using an Allen wrench of 1 5 mm across flats 2 Remove the screw cover using an Allen wrench of 2 0 mm across flats 3 Check the interior Ball screw 4 After the check assemble the parts by following the same steps in reverse When installing the screw cover make sure the side face bearing the IAI logo is on the same side as the serial number label on the base Screw cover affixing bolt x 5 Tightening torque 0 6 Nem End cover affixing bolt M3 x 6 Tightening torque 0 4 Nem Caution The hollow shaft motor has been adjusted at the factory prior to installation Never loosen the mounting bolts of the hollow shaft motor Bolt 18 INTELLIGENT ACTUATO 14 5 Internal Cleaning e Clean each area using a soft cloth etc Do not blow compressed air onto the internal parts as dust may enter through gaps and openings e Do not use petroleum solvent neutral detergent or alcohol INTELLIGENT ACTUATO 14 6 Greasing the Guide 14 6 1 Applicable Grease Lithium grease is used The following grease has been applied prior to shipment Kyodo Yushi Daphne Eponex 2 Other manufacturers offer different greases equivalent to the above product Contact each manufacturer and ask them to suggest equivalent greases corresponding to the product specifie
26. ety Supplying power to the product carelessly may cause electric shock or injury due to contact with the moving parts Wire the product correctly by referring to the operation manual Securely connect the cables and connectors so that they will not be disconnected or come loose Failure to do so may cause the product to malfunction or cause fire Operation Before operating the moving parts of the product by hand for the purpose of manual positioning etc confirm that the servo is turned off using the teaching pendant Failure to observe this instruction may result in injury Do not scratch the cables Scratching forcibly bending pulling winding crushing with heavy object or pinching a cable may cause it to leak current or lose continuity resulting in fire electric shock malfunction etc Turn off the power to the product in the event of power failure Failure to do so may cause the product to suddenly start moving when the power is restored thus resulting in injury or product damage 1 product is generating heat smoke or a strange smell turn off the power immediately Continuing to use the product may result in product damage or fire f noise or abnormally high vibration is detected stop the operation immediately Continuing to use the product may result in product damage malfunction due to damage runaway machine etc INTELLIGENT ACTUATO f any of the internal protective devices alarms of
27. f Contents Ws 1 2 1 3 PNCCAUMOMS 1 3 1 Basic Operating 1 3 2 Maintenance and Inspector 1 46 Warranty 2 44 Waranty PMO 2 4 2 Waa 2 Ds Naimes 3 6 Transporting 4 6 1 Handling the Unassembled 4 6 11 Hlandlingithe Packed 4 6 1 2 Handling the Actuator After It is Unpacked 4 6 2 Handling the Assembled Actuator lt 5 6 21 lt 5 6 2 2 Handling the Actuator Assembled with Peripherals 2 5 7 Operating Storage Environment 6 7 1 oe 6 7 2 Storage 6 7 8 1 Installing tne BOY 7 6 277 Installati n SUM ACG soc
28. f the product or its cables during installation It may result in injury Always use 1 genuine cables for connection between the controller and the actuator Also use IAl s genuine products for the key component units such as the actuator controller and teaching pendant Do not use the brake mechanism as a safety brake etc Before installing or adjusting the product or performing other operations on the product display a sign that reads WORK IN PROGRESS DO NOT TURN ON POWER If the power is turned on inadvertently injury may result due to electric shock or sudden activation of an actuator INTELLIGENT ACTUATO Operation Turn on the power to individual equipment one by one starting from the equipment at the highest level in the system hierarchy Failure to do so may cause the product to start suddenly resulting in injury or product damage Do not insert a finger or object in the openings in the product It may cause fire electric shock or injury Do not step on the product use it as a footstool or place any object on it It may cause scoring dents or deformation of the driving part resulting in product damage unintended stopping due to damage or performance drop Maintenance Inspection Repair Wear protective goggles when applying grease to the actuator Failure to do so may result in eye inflammation due to spattered grease 1 Installation Protection covers or oth
29. he controllers and check the operation Faulty controller YES Replace the controller If the problem still persists contact IAI 31 AN INTELLIGENT ACTUATO 15 3 Driver Overload Error Error Code DOA Driver overload error Review the operating conditions by referring to the High operation duty operating manual 10 Selection Conditions YES Slider receiving an external Remove the external force or force or resistance resistance Turn off the power and move the slider by hand to check Mechanical movement of the actuator heavy YES replacement controller is available swap the controllers and check the operation YES Replace the controller If the problem still persists contact IAI 32 INTELLIGENT 15 4 Deviation Overflow Error Error Code C6B Deviation overflow error YES Excessive acceleration deceleration relative Reduce the to the load capacity acceleration deceleration YES Replace the motor cable YES 1 The connector is not securely connected E 2 Loose pins 3 Wrong addresses the motor and encoder connectors are connected in reverse 5 gt Remove the contacting object Slider contacting any peripheral equipment If a replacement controller is available swap the controllers and c
30. heck the operation YES gt Replace the controller If the problem still persists contact IAI 33 AN INTELLIGENT ACTUATO 16 Cable Drawings 1 Motor cable Model CB X MAO 00 18 Front view Actuator end Front view Controller end Wire size Color Signal No Signal Color Wire size 110 Rea U 2 ae 07559 4 34 INTELLIGENT 2 Encoder cable Model 2 15 see 90599909990 25 9 Front view 7 2 Actuator end 15 Front view Plug housing 09 JST Socket contact BXA 001T P0 6 JST x 18 Retainer 5 09 JST 6 Use the crimping machine recommended by the connector manufacturer Wire size Color Signal No Maine ae dees ed A Boe SS aa a aS ae SSS eS 22201 2 White Blue ancz a T e soldered S 3 24 61 PEPA m ES ee Orange SRD 7 ee Bue BKR 20 Ed Ya ek 21 Clamp the shield to the hood 257821 Drain wire or braided shield wire Yellow
31. nspection 2 Carry out the required adjustment if the actuator has a mid support 14 2 External Visual Inspection Check the following items in the external visual inspection Loose mounting bolts Cables Damage to cables or connection to connector box General Unusual noise or vibrations 14 3 Cleaning Clean the exterior as needed Wipe off dirt with a soft cloth Do not use strong compressed air on the actuator as it may force dust into the crevices Do not use petroleum based solvents as they may damage resin or coated surfaces If the unit is badly soiled apply a neutral detergent or alcohol to a soft cloth and wipe lightly 16 INTELLIGENT ACTUATO 14 4 Internal Inspection Turn off the power and remove the screw cover to visually inspect the interior Check the following items in the internal inspection Body Loose mounting bolts Guide Lubrication condition okay Soiling Ball screw Lubrication condition okay Soiling Visually check the condition inside the actuator Specifically check for entry of dust and other foreign matters and the lubrication condition Even if the grease on the guide and ball screw has turned brown a good lubrication condition is maintained if the traveling surface is wet and glossy If the grease has become dirty and is no longer glossy or when you notice a shortage of grease after a long period of use clean each area and add grease The int
32. otor and bring it to the mid support and hook the wire on the delrin bearing at the mid support Next pull the wire further to the motor and hook it on the wire hook at the motor Hook one end of the replacement lt wire the wire hook Guide the replacement wire under the motor Hook the replacement wire on the delrin bearing by looping the wire over the bearing from below Hook the replacement wire on the wire hook motor side 28 INTELLIGENT When hooking the wire in step 6 you may find the wire catch of the hook motor side deformed In this case replace the wire hook as follows Replace the wire hook with a replacement wire hook motor side and tighten the two screws M3 6 Tighten the screws Tightening torque 1 5 7 Follow the same steps to also attach the wire to the wire hook base side whose screws have been loosened Specifically guide the wire from the wire hook base side to the delrin bearing at the mid support and attach it to the wire hook motor side When hooking the wire in step 7 you may find the wire catch of the hook motor side deformed In this case replace the wire in the same manner 29 INTELLIGENT 8 Use a tension gauge to push the wire hook base side whose screws have been loosened with the specified push force and tighten the two wire hook screws x 5 Tightening
33. serving the instructions below 6 2 2 Handling the Actuator Assembled with Peripherals When transporting the unpacked machine preassembled at IAI or customer assembled machine take heed of the following handling precautions e Secure the slider to prevent sudden movement during transport e lf the actuator has any overhung extremity properly secure the extremity to prevent excessive swinging caused by external force e lf the actuator must be transported with its extremities not secured make sure the actuator does not receive impact loads greater than 0 3 G e When suspending the actuator peripherals using ropes etc do not allow the ropes to contact the actuator directly e When passing ropes guide them around the base by inserting an appropriate buffer material between the rope and base e Support the tip of the Y axis using a separate rope so that the axis will remain stable in a horizontal position When roping the axis tip exercise caution not to exert a load on the screw cover e Exercise caution not to apply loads on the brackets covers and connector box Also protect the cables against pinching or excessive deformation INTELLIGENT 7 Operating and Storage Environment 7 1 Operating Environment The actuator should be set up in an environment which meets the following criteria Avoid direct sunlight Avoid radiant heat from strong heat sources such as a furnace Ambient temperature should b
34. sitive moving direction of the actuator The position cannot be corrected in the negative direction 3 Increasing the offset will narrow the moving range of the actuator If an offset exceeding 1 mm has been set also adjust the stroke soft limits 13 3 Changing the Direction of Home Should you require changing the direction of home on the actuator after its delivery contact because the change will require resetting of the moving direction parameter replacement of sensors and adjustment of encoder phase Z Warning The encoder not only detects angles of rotation and home signals but it also serves an important role in the switching of phases in the AC servo power line For this reason the encoder phases have been adjusted precisely Never touch the encoder to change the home INTELLIGENT ACTUATO 14 Maintenance 14 1 Maintenance Schedule Perform maintenance work according to the schedule below The schedule is set assuming eight hours of operation a day When the operation time is long such as 24 hour operation shorten the maintenance intervals as needed Eo Grease supply Mid support wire Start of operation After 1 month of operation Every 3 months After 6 months of operation After 1 year of operation Every 6 months thereafter O 2 1 Add grease if degradation of grease is observed in the internal i
35. t may lose its function over a short period of time or exhibit a sudden drop in performance or its service life may be significantly reduced Do not use the product in an atmosphere of corrosive gases sulfuric acid or hydrochloric acid Rust may form and reduce the structural strength of the product When using the product in any of the places specified below provide a sufficient shield Failure to do so may result in malfunction 1 Place where large current or high magnetic field is present 2 Place where welding or other operations are performed that cause arc discharge 3 Place subject to electrostatic noise 4 Place with potential exposure to radiation Do not install this product in places where the product may receive vibration or shock Provide an emergency stop device in a readily accessible position so the device can be actuated immediately upon occurrence of a dangerous situation during operation Lack of such device in an appropriate position may result in injury Provide sufficient maintenance space when installing the product Routine inspection and maintenance cannot be performed without sufficient space which will eventually cause the equipment to stop or the product to sustain damage When transporting or installing the product exercise due caution to prevent injury For example securely hold the product using a lift or support or engage multiple operators to carry the product Do not hold the moving parts o
36. the following steps 1 Upon receiving a home return command the actuator determines the moving direction based on the specified parameter 2 The actuator detects a home sensor signal during the return operation 3 After detecting the home sensor signal the actuator reverses its direction and operates until a phase Z signal is detected upon which the actuator defines the applicable position as the reference point 4 The actuator travels further by the offset specified by a parameter and defines the achieved position as the home 13 2 Fine tuning the Home Position The motor revolution after a home sensor signal is detected until a phase Z signal generates has been adjusted prior to shipment The table below shows the standard distances from the stopper reached by the slider when it reverses its direction upon detecting a home sensor signal and eventually stops at the home position Lead Distance from mechanical stopper mm 20 mm 5 1 40 mm 5 2 If the direction of home return remains the same the home position for each actuator can be fine tuned using the applicable distance shown above by changing the parameter Follow the steps below to fine tune the home position 1 Perform a home return operation to check the home 2 Calculate the difference between the current home position and desired home position and correct the parameter accordingly The value set in the parameter represents an offset in the po
37. torque 1 5 9 After the check assemble the parts by following the same steps in reverse When installing the screw cover make sure the side face bearing the IAI logo is on the same side as the serial number label on the base Screw cover affixing bolt M4 x 5 Tightening torque 0 6 Nem End cover affixing bolt M3 x 6 Tightening torque 0 4 Nem Caution The hollow shaft motor has been adjusted at the factory prior to installation Never loosen the mounting bolts of the hollow shaft motor 30 INTELLIGENT 15 Troubleshooting 15 1 What to Do When You Suspect a Failure If an encoder open error driver overload error deviation overflow error or any other error occurs do not hastily determine that the robot or controller is faulty Refer to the information below and check if the problem can be corrected by the applicable procedure the problem still persists after the troubleshooting procedure contact IAI and provide us with detailed information regarding the problem condition 15 2 Encoder Open Error Error Code D12 Encoder open error YES 1 The connector is not securely connected 2 Loose pins Connector wiring error 3 Wrong addresses the motor and encoder connectors are 11 T connected in reverse YES Broken cable Replace the cable If a replacement controller is available swap t
38. view This actuator adopts a nut rotary method to achieve high speed transfer action 3 Safety Precautions 3 1 Basic Operating Instructions e Please do not attempt to use or operate the actuator in any manner not indicated in this manual or the controller manual e Please be sure to use only the cable provided by IAI to connect the actuator and controller e Please do not allow people within the moving range of the unit when it is in operation or when the power is ON since this is dangerous 3 2 Maintenance and Inspection e When doing maintenance and inspection work always shut down the controller power first e When doing inspection make sure that no one can inadvertently turn the power ON When carrying out maintenance inspection put up a sign saying Work in Progress a conspicuous location e If several persons are working be sure to watch out for each other s safety In particular check before turning power ON or OFF and let others know if you are doing work involving axis movement Notes e The contents of this manual are subject to change without notice for the purposes of improvement e This manual has been written with the utmost attention to accuracy However it is possible that the manual may still contain technical inaccuracies or typographical or other errors Should you come across any inaccuracy or if you have any feedback regarding this manual please contact IAI AN INTELLIGENT ACTUATO
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