ISWA/ISPWA Dust-proof/ Splash-proof Type Actuator Operating Manual. Second Edition

Transcription

1 ISWA/ISPWA Dust-proof/ Splash-proof Type Actuator Operating Manual Second Edition

2 Safety Precautions (Please read before using the product.) Before installing, operating, maintaining or inspecting this product, please peruse this operating manual as well as the operating manuals and other related documentations for all equipment and peripheral devices connected to this product in order to ensure the correct use of this product and connected equipment/devices. Those performing installation, operation, maintenance and inspection of the product must have sufficient knowledge of the relevant equipment and their safety. The precautions provided below are designed to help you use the product safely and avoid bodily injury and/or property damage. In this operating manual, safety precautions are classified as Danger, Warning, Caution and Note, according to the degree of risk. Danger Warning Caution Note Failure to observe the instruction will result in an imminent danger leading to death or serious injury. Failure to observe the instruction may result in death or serious injury. Failure to observe the instruction may result in injury or property damage. The user should take heed of this information to ensure the proper use of the product, although failure to do so will not result in injury. It should be noted that the instructions under the Caution and Note headings may also lead to serious consequences, if unheeded, depending on the situation. All instructions contained herein provide vital information for ensuring safety. Please read the contents carefully and handle the product with due caution. Please keep this operating manual in a convenient place for quick reference whenever needed, and also make sure that the manual will get to the end-user. 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. Never cut and/or reconnect the cables supplied with the product for the purpose of extending or shortening the cable length. Doing so may result in fire.

3 [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. If you are using a pace maker or other mechanical implant, do not come within one meter of the product. The strong magnetic field generated by the product may cause the pace maker, etc., to malfunction. [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] If the 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. Be sure to provide Class D grounding for the controller and actuator (formerly Class 3 grounding: Grounding resistance at 100 Ω or less). Leakage current may cause electric shock or malfunction. Before supplying power to and operating the product, always check the operation area of the equipment to ensure safety. 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. The cables supplied with the product offer excellent flexibility, but they are not robot cables. Do not store these cables in a movable cable duct (cable bearer, etc.) of a radius smaller than the specified dimension. 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. If the 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. If 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.

4 If any of the internal protective devices (alarms) of the product has actuated, stop the operation immediately. Continuing to operate the product by ignoring alarms may result in product damage or injury due to malfunction. Investigate the cause of the problem, remove the identified cause, and then reconnect the power. 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. Caution [Installation] Do not use the product in an atmosphere of organic solvent, phosphate-ester machine oil, etc. The product may lose its function over a short period of time, or exhibit a sudden drop in performance or its service life may be 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 the product in a place subject to large vibration or impact (4.9 m/s 2 or more). Doing so may result in the malfunctioning of the product. 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 of the product or its cables during installation. It may result in injury. Always use IAI s genuine cables for connection between the controller and the actuator. Also use IAI s genuine products for the key component units such as the actuator, controller and teaching pendant. 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.

5 [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 bring a floppy disk or other magnetic media within one meter of the product. The magnetic field generated by the magnet may destroy the data in the floppy disk, etc. 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. Note [Installation] Protection covers or other guards must be provided for the moving parts of the equipment to avoid direct contact with the operators. The following conditions must be met in order to improve the straightness of the table movement and ensure the smooth movement of the ball screw and linear guides: 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] Apply the specified grease to each part of the product. In particular, pay attention not to let fluoridebased grease mix with lithium-based grease. The machine may be damaged due to poor lubrication, increased resistance, etc. [Disposal] When the product becomes no longer usable or necessary, dispose of it properly as an industrial waste. Others IAI shall not be liable whatsoever for any loss or damage arising from a failure to observe the items specified in Safety Precautions. If you have any question regarding the product, please contact your nearest IAI sales office. The addresses and phone numbers of our sales offices are provided at the end of this operation manual.

6 Prohibited Handling of Cables When designing an application system using IAI s actuators and controllers, incorrect wiring or connection of each cable may cause unexpected problems such as a disconnected cable or poor contact, or even a runaway system. This section explains prohibited handling of cables. Read the information carefully to connect the cables properly. Ten Rules for Handling Cables (Must be Observed!) 1. Do not let the cable flex at a single point. Steel band (piano wire) Bundle loosely. 2. Do not let the cable bend, kink or twist. 3. Do not pull the cable with a strong force. 4. Do not let the cable receive a turning force at a single point. 5. When fixing the cable, provide a moderate slack and do not tension it too tight. Use a curly cable. 6. Do not pinch, drop a heavy object onto or cut the cable. Do not use a spiral tube where the cable flexes frequently.

7 7. Do not let the cable get tangled or kinked in a cable bearer or flexible tube. When bundling the cable, keep a certain degree of flexibility (so that the cable will not become too taut when bent). 8. Do not cause the cables to occupy more than 60% of the space in the cable bearer. 9. Do not lay signal lines together with circuit lines that create a strong electric field. Cable bearer Cable Power line Signal lines (flat cable) Duct 10. Always use a robot cable if the cable is likely to flex significantly. [Standard structure of cable] The standard structure of cable will vary depending on the manufacturer and type of cable. Cover Shield Protective layer Signal line (copper + tin) Absorbing material (When the cable is bent, this material is crushed by the surrounding signal lines to maintain the shape of the signal lines.) Need for Robot Cables A cable connected to a moving part of an actuator system will inevitably receive repeated bending loads at the base of the cable. As a result, the cores in the cable may break over time. To minimize the risk of cable breakage, we strongly recommend that a robot cable offering significantly higher flexibility be used in this type of application. Caution: The cable directly connected to the actuator is not robot cable even when ordered with robot cable option. When designing, please be sure not to give repeated bending loads to this cable. The robot cable is applicable only to the connecting cables.

8 Table of Contents 1. Foreword Safety Precautions Basic Operating Instructions Maintenance and Inspection Warranty Warranty Period Scope of Warranty Names of the Parts Transporting and Handling Handling the Actuator Handling the Packed Unit Handling the Actuator After It is Unpacked Handling the Actuator Assembly Condition of Shipment from IAI (Assembled) Handling after Assembly with Peripheral Equipment Operating and Storage Environment Operating Environment Air Purge Storage Environment Installation Installing the Actuator Body Installing the Load to the Slider Mounting Surface Tightening Screws T-slots for Installing Optional Parts Connection to the Controller... 13

9 9. Notes on Use Maximum Speed Load on the Actuator Duty Setting the Home Principles of Home Return Operation Fine Adjustment of the Home Position Changing the Direction of Home Maintenance Maintenance Schedule Visual Inspection of the Machine Exterior Cleaning Interior Inspection Internal Cleaning Greasing the Guides Guide Grease How to Apply Grease Greasing the Ball Screw Ball Screw Grease How to Apply Grease Greasing the Wiper Seals Wiper Seal Grease How to Apply Grease Appendix How to use the home mark... 25

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11 1. Foreword Thank you for purchasing the ISWA/ISPWA Dust-proof/Splash-Proof Type Actuator. This actuator is equipped with wiper seals to seal the interior against foreign matters and thereby ensure high dust-proof/splash-proof performance. Therefore, the ISWA/ISPWA can be used in an adverse environment where the actuator comes in contact with dust or water. *Caution: The actuator ensures a degree of protection conforming to IP65 only when air purge is provided. If air purge is not provided, the actuator only meets IP54. Refer to 6.2, Air Purge. The actuator must always be installed in the horizontal direction. Water will enter the interior if the actuator is positioned on its side face or vertically. This manual explains the structure, correct operation and maintenance of the actuator. Please read this manual carefully before using the actuator. Keep this manual in a convenient place so that you can refer to the applicable sections whenever a need arises. For more complete information on operating the actuator, please refer to the controller operating manual. 2. Safety Precautions 2.1 Basic Operating Instructions Please do not attempt to use or operate the actuator in any manner not indicated in this manual or the controller manual. Please be sure to use only the cable provided by IAI to connect the actuator and controller. 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. 2.2 Maintenance and Inspection When doing maintenance and inspection work, always shut down the controller power first. When doing inspection, make sure that no one can inadvertently turn the power ON. Make sure that a sign indicating work in progress is clearly visible. 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. *Caution: The content of this manual is subject to change without notice for the purpose of improvement. This manual was created with utmost attention to accuracy. Should you find any error, however, or if you have any question, please contact IAI s Sales Engineering or Technical Service Section. 1

12 3. Warranty 3.1 Warranty Period Warranty period shall be either of the following periods whichever ends first: 18 months after shipment from our factory 12 months after delivery to a specified location 2500 hours of operation time 3.2 Scope of Warranty If a breakdown occurs within the period specified above and is due to the manufacturer's error, we will repair the unit at no cost. However, the following items are not covered by this warranty. Faded paint or other changes that occur naturally over time. Consumable components that wear out with use. Unit seems to be noisy or similar impressions that do not affect machinery performance. Damage resulting from improper handling by the user or lack of proper maintenance. Any alterations made by other than IAI or its representatives. Breakdowns caused by using controllers made by other manufacturers. Any damages caused by fire and other natural disasters or accidents. The warranty pertains to the purchased product itself and does not cover any damages that might arise from a breakdown of the supplied product. Any repairs will be done at our factory. Even if the product is still covered under the warranty period, we will assess a separate charge for sending technicians to the customer's site. 2

13 4. Names of the Parts The name of the actuator parts are indicated below. The left and right sides are indicated by looking at the actuator from the motor end with the actuator set down horizontally. Front end means the side opposite the motor end. Screw cover Right side Cable Left side Front cover Slider Rear cover 3

14 5. Transporting and Handling 5.1 Handling the Actuator Pay attention to the following instructions when transporting the actuator alone Handling the Packed Unit Unless otherwise specified, each actuator (axis) is shipped individually. Please take care that the shipping box is not dropped or subjected to strong impact during transport. The operator should not carry heavy shipping boxes by themselves. 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 Handling the Actuator After It is Unpacked Lift the actuator up by the base to remove it from the packaging. When carrying the actuator, exercise caution not to bump it against any object or structure. Do not exert excessive force on any part of the actuator. Exercise due caution not to drop the actuator while unpacking. Injury may result or the machine may be damaged. 4

15 5.2 Handling the Actuator Assembly Pay attention to the following instructions when transporting an assembly of actuator axes Condition of Shipment from IAI (Assembled) The actuators you have ordered are assembled at IAI, after which the assembly receives a shipping inspection and is shipped in an outer frame with skids. The assembly is packed with the sliders securely affixed so that they will not move unexpectedly during transportation. In the case of a combined unit, the actuator ends are secured to prevent swinging due to external vibration. The package is not designed with special considerations for protection against impact due to dropping or collision, so please handle the package with care. Also, do not place any heavy object on the outer frame, as it is not strong enough to withstand loads. When suspending the package using ropes, etc., pass the ropes from underneath the reinforcement frames at the bottom of the skids. When lifting with a forklift, also place the forks underneath the skids. Set down the package carefully so as not to apply impact to the assembly or cause it to bounce. After unpacking, handle the actuator assembly correctly by observing the instructions given below Handling after Assembly with Peripheral Equipment When transporting the actuators that have been assembled with peripheral equipment either at IAI or on your site, observe the instructions given below. Secure each slider to prevent unexpected movement during transportation. If any actuator end is protruding, secure it to prevent swinging due to external vibration. If the actuator ends are not secured, do not apply any impact force exceeding 0.3 G during transportation. When suspending the actuator-assembled peripheral equipment using ropes, etc., make sure the ropes do not contact the actuators directly. Pass the ropes over appropriate cushion materials, and make sure the loads from the ropes will be received by the base of each actuator. Be careful not to allow the brackets, covers and connector box of each actuator to receive loads. Also protect the cables from pinching or excessive deformation. 5

16 6. Operating and Storage Environment 6.1 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 be 0 40 C. Except when purge air is being supplied, the humidity should not exceed 85% and there should be no condensation. Avoid exposure to corrosive or combustible gases, combustible dust particles, flammable liquids, etc. The actuator should not be subject to impacts or vibrations greater than 0.3 G. Avoid extreme electromagnetic waves, ultraviolet rays and radiation. There should be sufficient space for teaching the actuator and carrying out maintenance/inspection in a safe manner. The actuator should not be submerged in liquids. The environment should be free from shavings that may damage the wiper seals. Avoid exposure to cutting oils. Avoid exposure to vapors of cutting or grinding fluids containing sulfur. * Please contact IAI for the splash-proof performance of the actuator against liquids other than water. 6

17 6.2 Air Purge One way to improve the environmental resistance of the actuator (against coolant and powder dust) is to supply dry, compressed air into the actuator. Supply of clean air into the actuator will improve the dust-proof/splash-proof performance of the machine. The air-purge procedure to implement this is explained below. Connect a tube to the quick-connector joint (outer diameter: φ6) provided on the rear cover of the actuator, and supply air through the tube/joint in accordance with the conditions and instructions provided below. The quick-connector joint at the bottom serves as a drain port (water drain hole) through which water is discharged. If water enters the interior of the actuator, connect a φ6 tube to the bottom drain port and extend the tube to a location where the opening of the tube is not exposed to water or powder dust. Air supply joint: φ6 Drain: φ6 1. Actuator air pressure MPa to 0.2 MPa (approx. 1 kgf/cm 2 to 2 kgf/cm 2 ) 2. Air flow rate --- Approx. 20 to 40 Nl/min 3. Air --- Instead of supplying air directly from a compressor, always pass the air supply through an air dryer so that dry, compressed air is fed into the actuator. Use clean, dry air free from compressor oil, etc., and conforming to an air filtration rating of 10 µm or below. The dry air should have a dew point of - 20 C or below at the atmospheric pressure. By satisfying the above conditions, this actuator ensures a dust-proof/splash-proof construction that provides levels of protection against water and powder dust corresponding to JIS B8438 and IP65. <Explanation of IP65> A degree of protection against intrusion of solid objects. Powder dust will not enter the structure A degree of protection against water intrusion. Water injected from arbitrary angles will not have harmful effects on the structure. Under the IP specification, conformance to this protection level is evaluated by injecting water compressed to 30 kpa (30 kn/m 2 or 0.3 kgf/cm 2 ) at an injection speed of 12.5 liters per minute for a period of 3 minutes. 7

18 6.3 Storage Environment The storage environment of the actuator should conform to the installation environment. As an additional note, take proper precautions not to allow condensation inside the actuator, especially when the actuator is stored for a long period of time. Unless specified, the actuator is shipped without any drying agent placed inside the package. If the actuator is to be stored in an environment where condensation is likely to occur, place drying agent around the package or unpack the actuator and place drying agent directly around the actuator. The actuator is designed to withstand temperatures up to 60 C for a short period of time. If the actuator is to be stored for one month or longer, ensure that the ambient temperature will not exceed 50 C. 8

19 7. Installation This section explains how to install the actuator in a single-axis configuration. 7.1 Installing the Actuator Body As a rule, this actuator should be placed in the horizontal direction in order to achieve the designed dustproof/splash-proof performance. If the actuator is positioned in any other manner (such as being positioned on a side face, upside down or vertically), water will enter the interior of the actuator. Tapped holes are provided on the back of the actuator base. Use these holes to install the actuator. Model Tap size Effective tap depth A Small M6 17 mm 70 mm Medium M8 20 mm 90 mm Large M8 20 mm 120 mm *Caution: The tapped holes are not through holes, so exercise caution when selecting the bolt length. If the bolts are too long or too short, the bottoms of tapped holes may be pierced through or the actuator may not be mounted securely. These conditions may lead to lower accuracy or even accidents. 9

20 7.2 Installing the Load to the Slider Tapped holes are provided on the slider, so use these holes to affix the load. The method of affixing the load should conform to the actuator installation method. Two reamed holes are provided on the slider. Use these holes if repeatability of mounting and dismounting is required. When fine adjustment is necessary to achieve the specified accuracies such as squareness, use one reamed hole to make the necessary adjustment. Sizes and depths of tapped holes and reamed holes on slider (top face) Model Tap size Tap depth A B C Size of reamed hole Depth of reamed hole Small M6 13 mm 70 mm mm φ6h10 10 mm Medium M6 18 mm - 70 mm M8 18 mm 90 mm mm φ8h10 10 mm Large M8 20 mm 120 mm 90 mm 170 mm φ8h10 10 mm Top view Sizes and depths of tapped holes and reamed holes on slider (side face) Model Tap size Tap depth D E F Size of reamed hole Depth of reamed hole Small M6 12 mm 40 mm - - φ6h10 8 mm Medium M6 13 mm 50 mm 30 mm 35 mm φ6h10 8 mm Large M6 13 mm 40 mm 50 mm 50 mm φ6h10 8 mm Side view 10

21 7.3 Mounting Surface The mounting table should have sufficient rigidity to avoid generating vibration. The surface where the actuator will be mounted should be machined or be equally level and the flatness tolerance between the actuator and the table should be within 0.05 mm. Provide enough space around the actuator to permit maintenance work to be done. The slider traveling plane is the reference plane for the actuator base and the lower surface. When traveling precision is required, use this as the reference plane for mounting. Reference plane Reference plane As shown above, the side faces of the base provide the reference planes for slider travel. When precision is required, use these surfaces as the reference planes for mounting. When using the base as the reference planes for mounting the actuator to the machine frame, follow the machining dimensions shown below. R0.3 or less Dimension A (mm) 3 to 5 11

22 7.4 Tightening Screws When installing the base, use hexagon socket-head bolts, etc., as the male screws. For the bolts, we recommend high strength bolts of ISO-10.9 or higher. The recommended screw torque is given below. Screw nominal diameter M6 M8 Screw Torque 6.7 N m (0.68 kgf m) 14 N m (1.43 kgf m) 7.5 T-slots for Installing Optional Parts M4 T-slots are provided on the side faces of the base for installing the connector box, cable bearer or other optional parts required by your actuator specification. (See the figure below.) If the actuator is used in conjunction with a wiring kit, use these T-slots to install the kit. The T-slots can also be used for other purposes as may be deemed necessary, such as installing sensors and affixing cables. *Caution: Use of square nuts is recommended for the T-slots, but general hexagon nuts can also be used. When installing bolts into the T-slots, select bolts of an appropriate length so that the tip of the bolt will not contact the bottom of the T-slot. 12

23 8. Connection to the Controller This section explains how to wire the actuator and controller in a single-axis configuration. Unless specified, all actuators ordered for single-axis configuration are shipped with a 3 or 5-meter singleaxis controller cable attached to the actuator body. Plug the connector on the open end of this cable directly into the socket on the controller side. This cable offers excellent flexibility, but it is not a robot cable. Do not store this cable in a movable cable duct of a small radius. In an application where the cable cannot be anchored, try to place the cable so that it sags only under its own weight or use self-standing type cable as large radial wire duct to limit the load on the cable. Never cut and/or reconnect the cables supplied with the product for the purpose of extending or shortening the cable length. For cable modification, please contact your IAI sales representative. 13

24 9. Notes on Use 9.1 Maximum Speed The maximum speed of the IS dust-proof/splash-proof specification is limited by the motor speed and also by the constraint set to prevent resonance of the ball screw shaft. Make sure that the maximum speed of your actuator does not exceed the applicable limit specified in the table below. Model Capacity W Small 60 Medium Large Strokes and maximum speed limits (unit: mm/s) Lead Stroke (mm) mm < *Caution: If the actuator is operated at speeds beyond its maximum speed limit, the ball screw shaft may resonate and the noise level will increase or vibration will generate and the service life of the machine may be shortened. If two or more actuators are operated independently, operate each actuator within the maximum speed specified for that actuator (refer to the table above). If the operations of multiple actuators are synchronized, create operation programs based on the lowest maximum speed among the speed limit settings of all actuators. Always check the maximum speed of each actuator to be used, before creating operation programs. 14

25 9.2 Load on the Actuator Do not exceed the load shown in the load specification column. Please make note of the slider moment, allowable overhang length and the load weight. Allowable load moments Model Ma Mb Mc Small 14.2 N m (1.45 kgf m) 20.1 N m (2.1 kgf m) 32.9 N m (3.4 kgf m) Medium 34.8 N m (3.5 kgf m) 49.5 N m (5.0 kgf m) 80.8 N m (8.2 kgf m) Large 52.5 N m (5.4 kgf m) 75.0 N m (7.6 kgf m) N m (12.7 kgf m) Allowable overhang lengths Model Ma direction Mb direction Mc direction Small 450 mm or less 450 mm or less 450 mm or less Medium 600 mm or less 600 mm or less 600 mm or less Large 750 mm or less 750 mm or less 750 mm or less The allowable overhang lengths are based on a configuration where the center of gravity of the load mounted on the actuator corresponds to the center of the overhang length. Mb, Mc directions Ma direction Directions of moment forces Directions of allowable overhangs *Caution: Allowing the slider to receive an excessive load moment will shorten the service life of the guides or cause other unwanted results. If the allowable overhang length is exceeded, vibration may generate or the service life of the guides may be reduced. 15

26 9.3 Duty Use the actuator at duties of 50% or less in order to prolong the service life of the actuator and prevent unexpected stops due to errors. Acceleration / Deceleration Time Duty (%) = x 100 Motion time + Inactivity If the actuator is used at a high duty, overload and other errors may generate. In such a case, increase the stopped time and reduce the duty. 16

27 9.4 Setting the Home Principles of Home Return Operation This actuator implements home return in the steps specified below: [1] Determine the moving direction based on the parameter set by the home return command. [2] Move in the specified direction to detect the mechanical end using the software. [3] From the mechanical end, move in the reverse direction until a phase-z signal is detected and set this position as the reference point. [4] Move further by the offset amount specified by the parameter and set the achieved position as the home Fine Adjustment of the Home Position The motor revolution that occurs after the slider contacts the mechanical end (stopper) until a phase-z signal generates has been adjusted at the factory before shipment. The table below shows the standard distance to be traveled by the slider after the slider reverses direction following a contact with the stopper until it stops at the home. Model name ISWA (all axes) Travel after reversing at mechanical stopper 5 mm As long as the direction of home return remains the same, you can fine-adjust the home position of each actuator by changing the parameter based on this value. To implement fine adjustment of the home position, follow the steps below: [1] Perform home return operation to check the home. [2] Calculate the difference between the current home position and the desired home position and correct the parameter accordingly. The parameter setting can be changed only to a positive value in the moving direction of the slider (it cannot be a negative value). [3] If a large offset is set, the range of travel will decrease by the corresponding amount. If an offset exceeding 1 mm is set, change the stroke soft limits accordingly Changing the Direction of Home To change the factory-set direction of home after the delivery, the moving-direction parameter and the encoder s phase Z must be adjusted. Please contact IAI. 17

28 10. Maintenance 10.1 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. Start of operation After 1 month of operation Visual inspection Check interior Grease supply Every 3 months * After 6 months of operation After 1 year of operation Every 6 months thereafter Every 1 year * The grease applied to this actuator before shipment has a shorter life than regular greases. Therefore, perform this inspection promptly on schedule Visual Inspection of the Machine Exterior Check the following items when carrying out visual inspection. Body Cables General Loose mounting bolts? Damage to cables or connection to connector box? Unusual noise or vibrations? 10.3 Cleaning Clean the exterior as needed. Wipe off dirt with a soft cloth. Do not use strong compressed air on the actuator as this may force dust into the crevices. Do not use petroleum-based solvent on plastic parts or painted surfaces. If the unit is badly soiled, apply a neutral detergent or alcohol to a soft cloth, and wipe gently. 18

29 10.4 Interior Inspection Turn off the power, remove the screw cover, and then visually inspect the interior. Check the following items during interior inspection. Body Guides Ball screw Loose mounting bolts? Lubrication appropriate? Soiling? Lubrication appropriate? Soiling? Make a visual check of the interior to see if there is any dust or foreign matter in the unit, and also check the lubrication condition. Even if the grease is brown, the lubrication is fine as long as the traveling surface appears shiny. If the grease is dirty and its color is dull or when not much grease is left due to an extended period of operation, clean the parts and add grease. The interior inspection procedure is specified below. [1] Use an Allen wrench of 2.5 mm across flats to unscrew the screw-cover mounting bolts and remove the top screw cover. [2] Check the interior. [3] When the check is completed, install the screw cover and tighten the bolts. Screw-cover mounting bolt Do not remove the front cover. Do not loosen the bolts on the side covers. *Caution: The front cover is supporting the ball screw, so do not disassemble this cover. If a proper alignment of the front cover is lost, the shaft centers may become offset, thus increasing the traveling resistance, reducing the service life of each part, or generating noise. The bolts on the side covers are securing the gaskets, so do not loosen these bolts. Once these bolts are loosened, gaps may generate along the gaskets and water may enter. If you find cracks, peels or other abnormalities on the gasket at the back of the screw cover, replace the gasket. 19

30 Grease nipple Wiper tool Guide Ball screw 10.5 Internal Cleaning Wipe off dirt with a soft cloth. Do not use strong compressed air on the actuator as this may force dust into the crevices. Do not use petroleum-based solvent, neutral detergent or alcohol. 20

31 10.6 Greasing the Guides Guide Grease The guides of this actuator are lubricated with composite aluminum-based grease. The following grease is applied before the actuator is shipped. Taiyo Petroleum Gas Medallion FM Grease, Grade No How to Apply Grease After the screw cover is removed, you will find one grease nipple each on the right and left sides of the slider. Add grease from these nipples. [1] Use an Allen wrench of 2.5 mm across flats to unscrew the bolts affixing the screw cover. [2] Using a grease gun, inject grease into the grease nipples on the end face of the slider. (See the figure below for the locations of grease nipples.) [3] Move the slider back and forth several times by hand. [4] Repeat the above steps to add more grease. [5] Use a waste cloth, etc., to remove the excess grease that came out of the slider. Grease nipple 21

32 10.7 Greasing the Ball Screw Ball Screw Grease The ball screw of this actuator is lubricated with composite aluminum-based grease. The following grease is applied before the actuator is shipped. Taiyo Petroleum Gas Medallion FM Grease, Grade No How to Apply Grease To grease the ball screw, clean the ball screw, apply grease using fingers, and then move the slider back and forth several times to let the grease spread evenly. Finally, remove the excess grease that came out from the nuts. *Caution: If too much grease is applied, the agitation resistance will increase and the ball screw will generate heat more easily, or the excess grease on the ball screw may spatter as the ball screw turns and attach to the surrounding parts. To prevent these problems, be sure to remove excess grease. 22

33 10.8 Greasing the Wiper Seals Wiper Seal Grease The wiper seals of this actuator are lubricated with the following composite aluminum-based grease before the actuator is shipped. Taiyo Petroleum Gas Medallion FM Grease, Grade No How to Apply Grease To grease the wiper seals, clean the wiper seals and then apply grease using fingers on the top face of each wiper seal, as shown in the photograph at left. Use a spatula, etc., to apply a thin coat of grease on the insides of the wiper seals. Move the slider back and forth several times to let the grease spread evenly over the wiper seals. Finally, remove the excess grease that came out from the seals. 23

34 Wiper seal Apply grease on a spatula, etc., and move the spatula along the wiper seals so that the grease will spread evenly over the seal surfaces. *Caution: If too much grease is applied, excess grease may spatter as the slider moves and attach to the surrounding parts. To prevent this problem, be sure to remove excess grease. 24

35 Appendix Appendix How to use the home mark Please affix these marks to the actuator as home markers as needed. Contents of sticker Home mark sticker x 1 sheet Home mark scale x 4 Home mark x 4 (Scale: 1 mm graduation mark, 10 mm width) Peel off the marks from the base sheet. Note. 1. Every mark has sticky back. 2. Remove smear and stain from the surface. 3. Avoid label or nameplate as a marking location. Example of Use [1] Used to mark the home of the actuator On the slider Motor At the home on the base [2] Used as stop positions On the slider Motor At stop positions on the base [3] Used as countermarks for checking position error On the slider Motor On the base Place the marks when the actuator is stopped at home position. 25

36 Catalog No.: ISWA-MJ3637-2A-Sep Head Office: 2690 W. 237th Street, Torrance, CA TEL (800) FAX (310) Chicago Office: 1261 Hamilton Parkway, Itasca, IL TEL (800) FAX (630) New Jersey Office: 7 South Main St., Suite-F, Marlboro, NJ TEL (877) FAX (732) Website: Ober der Röth 4, D Schwalbach am Taunus, Germany TEL FAX The information contained in this document is subject to change without notice for the purpose of product improvement. Copyright May. IAI Corporation. All rights reserved.