IS Series Actuator Operating Manual

Transcription

1 IS Series Actuator Operating Manual IS ISP ISA ISPA Fifteenth Edition

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3 Please Read Before Use Thank you for purchasing our product. This Operation Manual describes all necessary info rmation to operate this product safely such as the operation procedure, structure and maintenance procedure. Before operation, read this manual carefully and fully understand it to operate this product safely. The enclosed DVD in this product package includes the Operation Manual for this product. For the operation of this product, print out the necessary sections in the Operation Manual or display them using the personal computer. After reading through this manual, keep this Operation Manual at hand so that the operator of this product can read it whenever necessary. [Important] This Operation Manual is original. The product cannot be operated in any way unless expressly specified in this Operation Manual. IAI shall assume no responsibility for the outcome of any operation not specified herein. Information contained in this Operation Manual is subject to change without notice for the purpose of product improvement. If you have any question or comment regarding the content of this manual, please contact the IAI sales office near you. Using or copying all or part of this Operation Manual without permission is prohibited. The company names, names of products and trademarks of each company shown in the sentences are registered trademarks.

4 CE Marking

5 Table of Contents Safety Guide... 1 Handling Precauti ons... 8 International Standards Compliances Names of the Parts Checking the Product Components Operation Manuals for Controllers Supported by This Product How to Read the Model Nameplate How to Read the Model Number Specification ISA/ISPA IS/ISP Life How to Calculate Operaition Life Operation Life Installation and Storage/Preservation Environment Installation Environment Storage/Preservation Environment Installation Installation Installing the Actuator Installing the Load on the Slider Reference Surface and Mounting Surface Using T-slots Connecting the Controller Wiring Using the Dedicated St and-alone Table (ICS Series) Setting the Home Position Home Return Fine-tuning the Home Position Changing the Home Direction How to Use the Homing Mark Stickers Options AQ Seal Brake Creep Sensor Limit Switch

6 8.5 Synchronized Specification (When X-SEL or SSEL Controllers are Used) Reversed-home Specification Guide with Ball Retention Mechanism Metal Connector Specification Double-slider Specification Motor/Encoder Cables Standard Metal Connector Specification (Option Indicated by EU in Model Number) Maintenance/Inspection Inspection Items and Intervals Visual Inspection of the Machine Exterior External Cleaning Interior Check Cleaning the Interior Grease Supply Applicable Grease Grease Supply Motor Replacement Proc edures Replacing the Motor of the ISA/ISPA Series Removing the Motor Unit Removing the Screw Cover Removing the Seat Cover Removing the Motor Cover Removing Wire/Cable Lines for the Motor Unit Removing the Motor Unit Installing a New Motor Unit New Motor Unit Aligning the Slider Position Aligning the Motor Position Installing the Motor Unit Temporarily Centering and Securing the Motor Unit Assembling the Motor Cover Installing the Screw Cover Correcting for Position Deviation Operation Check after Replacing the Motor Replacing the Motor of the ISA-W/ISPA-W Series How to Set the Home Preset and Home Return Offset XSEL and SSEL Controllers ECON and SCON Controllers P-Driver Controllers...102

7 12. Appendix External Dimensions ISA-SXM, ISPA-SXM ISA-SXM, ISPA-SXM Double Slider ISA-SYM, ISPA-SYM ISA-SZM, ISPA-SZM ISA-MXM-100, ISPA-MXM ISA-MXM-100, ISPA-MXM-100 Double Slider ISA-MXM-200, ISPA-MXM ISA-MXM-200, ISPA-MXM-200 Double Slider ISA-MXMX, ISPA-MXMX ISA-MYM-100, ISPA-MYM ISA-MYM-200, ISPA-MYM ISA-MZM-100, ISPA-MZM ISA-MZM-200, ISPA-MZM ISA-LXM-200, ISPA-LXM ISA-LXM-200, ISPA-LXM-200 Double Slider ISA-LXM-400, ISPA-LXM ISA-LXM-400, ISPA-LXM-400 Double Slider ISA-LXMX-200, ISPA-LXMX ISA-LXMX-400, ISPA-LXMX ISA-LXUWX-200, ISPA-LXUWX ISA-LXUWX-400, ISPA-LXUWX ISA-LYM-200, ISPA-LYM ISA-LYM-400, ISPA-LYM ISA-LZM-200, ISPA-LZM ISA-LZM-400, ISPA-LZM ISA-WXM-600, ISPA-WXM ISA-WXM-750, ISPA-WXM ISA-WXMX-600, ISPA-WXMX ISA-WXMX-750, ISPA-WXMX How to Perform An Absolute Encoder Reset (Absolute Specification) X-SEL Controller SCON Controllers Adding Grease When the Screw Cover Cannot Be Removed (Not Covered under Warranty) Adding Grease to the Guide of the ISA/ISPA/IS/ISP Adding Grease to the Ball Screw of the ISA/ISPA/IS/ISP

8 13. Warranty Warranty Period Scope of Warranty Honoring the Warranty Limited Liability Conditions of Conformance with Applicable Standards/Regulations, Etc., and Applications Other Items Excluded from Warranty Change History

9 Safety Guide Safety Guide has been written to use the machine safely and so prevent personal injury or property damage beforehand. Make sure to read it before the operation of this product. Safety Precautions for Our Products The common safety precautions for the use of any of our robots in each operation. Operation No. Description 1 Model Selection Description This product has not been planned and designed for the application where high level of safety is required, so the guarantee of the protection of human life is impossible. Accordingly, do not use it in any of 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 (For vehicle, railway facility or air navigation facility) 3) Important safety parts of machinery (Safety device, etc.) Do not use the product outside the specifications. Failure to do so may considerably shorten the life of the product. Do not use it in any of the following environments. 1) Location where there is any inflammable gas, inflammable object or explosive 2) Place with potential exposure to radiation 3) Location with the ambient temperature or relative humidity exceeding the specification range 4) Location where radiant heat is added from direct sunlight or other large heat source 5) Location where condensation occurs due to abrupt temperature changes 6) Location where there is any corrosive gas (sulfuric acid or hydrochloric acid) 7) Location exposed to significant amount of dust, salt or iron powder 8) Location subject to direct vibration or impact For an actuator used in vertical orientation, select a model which is equipped with a brake. If selecting a model with no brake, the moving part may drop when the power is turned OFF and may cause an accident such as an injury or damage on the work piece. 1

10 No. Operation Description Description 2 Transportation When carrying a heavy object, do the work with two or more persons or utilize equipment such as crane. When the work is carried out with 2 or more persons, make it clear who is to be the leader and who to be the follower(s) and communicate well with each other to ensure the safety of the workers. When in transportation, consider well about the positions to hold, weight and weight balance and pay special attention to the carried object so it would not get hit or dropped. Transport it using an appropriate transportation measure. The actuators available for transportation with a crane have eyebolts attached or there are tapped holes to attach bolts. Follow the instructions in the operation manual for each model. Do not step or sit on the package. Do not put any heavy thing that can deform the package, on it. When using a crane capable of 1t or more of weight, have an operator who has qualifications for crane operation and sling work. When using a crane or equivalent equipments, make sure not to hang a load that weighs more than the equipment s capability limit. Use a hook that is suitable for the load. Consider the safety factor of the hook in such factors as shear strength. Do not get on the load that is hung on a crane. Do not leave a load hung up with a crane. Do not stand under the load that is hung up with a crane. 3 Storage and Preservation The storage and preservation environment conforms to the installation environment. However, especially give consideration to the prevention of condensation. Store the products with a consideration not to fall them over or drop due to 4 Installation and Start an act of God such as earthquake. (1) Installation of Robot Main Body and Controller, etc. Make sure to securely hold and fix the product (including the work part). A fall, drop or abnormal motion of the product may cause a damage or injury. Also, be equipped for a fall-over or drop due to an act of God such as earthquake. Do not get on or put anything on the product. Failure to do so may cause an accidental fall, injury or damage to the product due to a drop of anything, malfunction of the product, performance degradation, or shortening of its life. When using the product in any of the places specified below, provide a sufficient shield. 1) Location where electric noise is generated 2) Location where high electrical or magnetic field is present 3) Location with the mains or power lines passing nearby 4) Location where the product may come in contact with water, oil or chemical droplets 2

11 Operation No. Description 4 Installation and Start Description (2) Cable Wiring Use our company s genuine cables for connecting between the actuator and controller, and for the teaching tool. Do not scratch on the cable. Do not bend it forcibly. Do not pull it. Do not coil it around. Do not insert it. Do not put any heavy thing on it. Failure to do so may cause a fire, electric shock or malfunction due to leakage or continuity error. Perform the wiring for the product, after turning OFF the power to the unit, so that there is no wiring error. When the direct current power (+24V) is connected, take the great care of the directions of positive and negative poles. If the connection direction is not correct, it might cause a fire, product breakdown or malfunction. Connect the cable connector securely so that there is no disconnection or looseness. Failure to do so may cause a fire, electric shock or malfunction of the product. Never cut and/or reconnect the cables supplied with the product for the purpose of extending or shortening the cable length. Failure to do so may cause the product to malfunction or cause fire. (3) Grounding The grounding operation should be performed to prevent an electric shock or electrostatic charge, enhance the noise-resistance ability and control the unnecessary electromagnetic radiation. For the ground terminal on the AC power cable of the controller and the grounding plate in the control panel, make sure to use a twisted pair cable with wire thickness 0.5mm 2 (AWG20 or equivalent) or more for grounding work. For security grounding, it is necessary to select an appropriate wire thickness suitable for the load. Perform wiring that satisfies the specifications (electrical equipment technical standards). Perform Class D Grounding (former Class 3 Grounding with ground resistance 100Ω or below). 3

12 Operation No. Description 4 Installation and Start Description (4) Safety Measures When the work is carried out with 2 or more persons, make it clear who is to be the leader and who to be the follower(s) and communicate well with each other to ensure the safety of the workers. When the product is under operation or in the ready mode, take the safety measures (such as the installation of safety and protection fence) so that nobody can enter the area within the robot s movable range. When the robot under operation is touched, it may result in death or serious injury. Make sure to install the emergency stop circuit so that the unit can be stopped immediately in an emergency during the unit operation. Take the safety measure not to start up the unit only with the power turning ON. Failure to do so may start up the machine suddenly and cause an injury or damage to the product. Take the safety measure not to start up the machine only with the emergency stop cancellation or recovery after the power failure. Failure to do so may result in an electric shock or injury due to unexpected power input. When the installation or adjustment operation is to be performed, give clear warnings such as Under Operation; Do not turn ON the power! etc. Sudden power input may cause an electric shock or injury. Take the measure so that the work part is not dropped in power failure or emergency stop. Wear protection gloves, goggle or safety shoes, as necessary, to secure safety. Do not insert a finger or object in the openings in the product. Failure to do so may cause an injury, electric shock, damage to the product or fire. When releasing the brake on a vertically oriented actuator, exercise precaution not to pinch your hand or damage the work parts with the actuator dropped by gravity. 5 Teaching When the work is carried out with 2 or more persons, make it clear who is to be the leader and who to be the follower(s) and communicate well with each other to ensure the safety of the workers. Perform the teaching operation from outside the safety protection fence, if possible. In the case that the operation is to be performed unavoidably inside the safety protection fence, prepare the Stipulations for the Operation and make sure that all the workers acknowledge and understand them well. When the operation is to be performed inside the safety protection fence, the worker should have an emergency stop switch at hand with him so that the unit can be stopped any time in an emergency. When the operation is to be performed inside the safety protection fence, in addition to the workers, arrange a watchman so that the machine can be stopped any time in an emergency. Also, keep watch on the operation so that any third person can not operate the switches carelessly. Place a sign Under Operation at the position easy to see. When releasing the brake on a vertically oriented actuator, exercise precaution not to pinch your hand or damage the work parts with the actuator dropped by gravity. * Safety protection Fence : In the case that there is no safety protection fence, the movable range should be indicated. 4

13 No. Operation Description Description 6 Trial Operation When the work is carried out with 2 or more persons, make it clear who is to be the leader and who to be the follower(s) and communicate well with each other to ensure the safety of the workers. After the teaching or programming operation, perform the check operation one step by one step and then shift to the automatic operation. When the check operation is to be performed inside the safety protection fence, perform the check operation using the previously specified work procedure like the teaching operation. Make sure to perform the programmed operation check at the safety speed. Failure to do so may result in an accident due to unexpected motion caused by a program error, etc. Do not touch the terminal block or any of the various setting switches in the power ON mode. Failure to do so may result in an electric shock or malfunction. 7 Automatic Operation Check before starting the automatic operation or rebooting after operation stop that there is nobody in the safety protection fence. Before starting automatic operation, make sure that all peripheral equipment is in an automatic-operation-ready state and there is no alarm indication. Make sure to operate automatic operation start from outside of the safety protection fence. In the case that there is any abnormal heating, smoke, offensive smell, or abnormal noise in the product, immediately stop the machine and turn OFF the power switch. Failure to do so may result in a fire or damage to the product. When a power failure occurs, turn OFF the power switch. Failure to do so may cause an injury or damage to the product, due to a sudden motion of the product in the recovery operation from the power failure. 5

14 Operation No. Description 8 Maintenance and Inspection Description When the work is carried out with 2 or more persons, make it clear who is to be the leader and who to be the follower(s) and communicate well with each other to ensure the safety of the workers. Perform the work out of the safety protection fence, if possible. In the case that the operation is to be performed unavoidably inside the safety protection fence, prepare the Stipulations for the Operation and make sure that all the workers acknowledge and understand them well. When the work is to be performed inside the safety protection fence, basically turn OFF the power switch. When the operation is to be performed inside the safety protection fence, the worker should have an emergency stop switch at hand with him so that the unit can be stopped any time in an emergency. When the operation is to be performed inside the safety protection fence, in addition to the workers, arrange a watchman so that the machine can be stopped any time in an emergency. Also, keep watch on the operation so that any third person can not operate the switches carelessly. Place a sign Under Operation at the position easy to see. For the grease for the guide or ball screw, use appropriate grease according to the Operation Manual for each model. Do not perform the dielectric strength test. Failure to do so may result in a damage to the product. When releasing the brake on a vertically oriented actuator, exercise precaution not to pinch your hand or damage the work parts with the actuator dropped by gravity. The slider or rod may get misaligned OFF the stop position if the servo is turned OFF. Be careful not to get injured or damaged due to an unnecessary operation. Pay attention not to lose the cover or untightened screws, and make sure to put the product back to the original condition after maintenance and inspection works. Use in incomplete condition may cause damage to the product or an injury. * Safety protection Fence : In the case that there is no safety protection fence, the movable range should be indicated. 9 Modification and Dismantle Do not modify, disassemble, assemble or use of maintenance parts not specified based at your own discretion. 10 Disposal When the product becomes no longer usable or necessary, dispose of it properly as an industrial waste. When removing the actuator for disposal, pay attention to drop of components when detaching screws. Do not put the product in a fire when disposing of it. The product may burst or generate toxic gases. 11 Other Do not come close to the product or the harnesses if you are a person who requires a support of medical devices such as a pacemaker. Doing so may affect the performance of your medical device. See Overseas Specifications Compliance Manual to check whether complies if necessary. For the handling of actuators and controllers, follow the dedicated operation manual of each unit to ensure the safety. 6

15 Alert Indication The safety precautions are divided into Danger, Warning, Caution and Notice according to the warning level, as follows, and described in the Operation Manual for each model. Level Degree of Danger and Damage Symbol Danger This indicates an imminently hazardous situation which, if the product is not handled correctly, will result in death or serious injury. Danger Warning This indicates a potentially hazardous situation which, if the product is not handled correctly, could result in death or serious injury. Warning Caution This indicates a potentially hazardous situation which, if the product is not handled correctly, may result in minor injury or property damage. Caution Notice This indicates lower possibility for the injury, but should be kept to use this product properly. Notice 7

16 Handling Precautions 1. Do not set speeds and accelerations/decelerations equal to or greater than the respective ratings. Do not set speeds and accelerations/decelerations equal to or greater than the respective ratings. Doing so may result in vibration, failure or shorter life. In synchronized operation of combined axes, adjust the speed and acceleration/deceleration to the maximum speed and minimum acceleration/deceleration among the combined axes, respectively. In particular, note that if an acceleration/deceleration equal to or greater than the rated acceleration/deceleration is set, a creep phenomenon or slipped coupling may occur. 2. Keep the load moment within the allowable value. Keep the load moment within the allowable value. If a load equal to or greater than the allowable load moment is applied, the life may be shortened. In an extreme case, flaking may occur. 3. Keep the overhang length to within the allowable value. Keep the overhang length of the load to within the allowable value. If the overhang length is equal to or greater than the allowable value, vibration or abnormal noise may occur. 4. If the actuator is moved back and forth over a short distance, grease film may run out. If the actuator is moved back and forth continuously over a short distance of 30 mm or less, grease film may run out. As a guide, move the actuator back and forth repeatedly for around 5 cycles over a distance of 50 mm or more after every 5,000 to 10,000 cycles. 5. Make sure to attach the actuator properly by following this operation manual. Using the product with the actuator not being certainly retained or affixed may cause abnormal noise, vibration, malfunction or shorten the product life. 8

17 6. Use your actuator at duties not exceeding the calculated reference duty. Duty indicates the utilization rate of an actuator (time during which the actuator operates in a cycle). Use your actuator at duties not exceeding the reference duty calculated as follows. If the actuator is used at duties exceeding the reference duty, the actuator may receive an overload or its motor may generate heat. In extreme cases, motor damage or other undesired result may follow. Duty = Operating time / Operating time + Standstill time (%) Caution: If an overload error occurs, increase the standstill time to lower the duty or decrease the acceleration/deceleration. [How to Calculate Duty] [1] Calculate the load factor LF using the calculation formula below: [When commanded acceleration speed is lower than the rated acceleration speed] Load factor : LF = M α/ M r αr [%] Maximum payload capacity at rated acceleration : M r [kg] [When commanded acceleration speed is higher than the rated acceleration speed] Load factor : LF = M α / M d α= M / M d [%] Transportable weight in commanded acceleration : M d [kg] Rated acceleration/deceleration : αr [G] Transfer weight during operation : M [kg] Transfer weight during operation : M [kg] Acceleration/deceleration during operation : α [G] Acceleration/deceleration during operation : α [G] (Note) For the maximum payload capacity at rated acceleration, and rated acceleration/deceleration, refer to 2, Specifications. [2] Calculate the acceleration/deceleration time ratio t od using the calculation formula below: Acceleration/deceleration time ratio t od = Acceleration time + Deceleration time / Operating time (%) Acceleration time = Speed (mm/s) / Acceleration (mm/s 2 ) (sec.) Acceleration (mm/s 2 ) = Acceleration (G) x 9,800 mm/s 2 Deceleration time = Speed (mm/s) / Deceleration (mm/s 2 ) (sec.) Deceleration (mm/s 2 ) = Deceleration (G) x 9,800 mm/s 2 [3] Find the reference duty on a graph of calculated load factor LF vs. acceleration/deceleration time ratio tod. Example) If the load factor LF is 80% and acceleration/deceleration time ratio t od is 80%, the reference duty is approx. 75%. 100 LF = Less than 50% 80 LF = 60% Reference duty (%) Approx. 75% LF = 70% LF = 80% LF = 90% LF = 100% Load factor (%) Acceleration/deceleration time ratio tod (%) 9

18 7. Transport 7.1 Handling a Single Axis Take note of the following points when transporting each actuator alone Handling the Packed Unit Unless otherwise instructed, each actuator axis is packed individually and shipped. Do not bump or drop the package. The package is not specially designed to withstand the impact of dropping or bumping. The operator should not carry heavy shipping boxes by himself. (Transport the package using an appropriate transport means.) If the shipping box is to be left standing, it should be in a horizontal position. (If the packing specification is instructed, follow the instruction.) Do not climb on top of the shipping box. Do not place heavy objects, or objects having a section where loads concentrate, on top of the shipping box. When hanging an actuator with its stroke more than 1200mm with ropes, hook up in ranges between 1/3 and 2/3 of the whole length. Hooking ropes near the center may cause warpage. Range for hanging 1/3L 2/3L L Range for hanging Handling an Actuator after Unpacking Do not transport the actuator by holding the cables or move it by pulling the cables. When transporting the actuator, do so by holding the base. Be careful not to bump the actuator during transport. Do not exert an excessive force on any part of the actuator. When transporting an actuator with its stroke more than 1200mm, have three or more operators to carry it. Hold around the center of the actuator as well as the both ends. Not holding around the center may cause warpage. When hanging an actuator with its stroke more than 1200mm with ropes, hook up in ranges between 1/3 and 2/3 of the whole length. Hooking ropes near the center may cause warpage. Range for hanging 1/3L 2/3L L Range for hanging 7.2 Handling Combined Axes Take note of the following points when transporting a set of axes that have been combined Handling a Package Before shipment, combined axes are packed in an outer frame nailed to the base made of square lumbers. Each slider is secured to prevent accidental movement during transport. Each actuator end is also secured to prevent oscillating due to external vibration. 10

19 Do not bump or drop the package. The package is not specially designed to withstand the impact of dropping or bumping. An operator must not attempt to carry a heavy package alone. Transport the package using an appropriate transport means. When hoisting the package using ropes, etc., support the square lumber base at the reinforcements at the bottom. Similarly when lifting the package with a forklift, insert the forks at the bottom of the square lumber base. When setting down the package, be careful not to let the package receive shock or bounce. Do not step onto the package. Do not put any article on the package which may deform or damage the package. When hanging an actuator with its stroke more than 1200mm with ropes, hook up in ranges between 1/3 and 2/3 of the whole length. Hooking ropes near the center may cause warpage. Range for hanging 1/3L 2/3L L Range for hanging Handling an Actuator after Unpacking Secure the sliders to prevent sudden movement during transport. If any end of the actuator is overhanging, secure it properly to avoid significant movement due to external vibration. If the actuator assembly is transported without the ends being secured, do not apply an impact of 0.3G or more. When transporting an actuator with its stroke more than 1200mm, have three or more operators to carry it. Hold around the center of the actuator as well as the both ends. Not holding around the center may cause warpage. When hoisting the actuator using ropes, etc., use appropriate cushioning materials to protect the actuator against strain or distortion. Also keep a stable, horizontal posture. If necessary, use the tapped mounting holes provided on the bottom face of the base to install hoisting jigs. When hanging an actuator with its stroke more than 1200mm with ropes, hook up in ranges between 1/3 and 2/3 of the whole length. Hooking ropes near the center may cause warpage. Range for hanging 1/3L 2/3L L Range for hanging Be careful not to apply a load on any of the actuator brackets or covers or on the connector box. Also, do not allow the cable to be pinched or deformed excessively. 7.3 Handling an Actuator Assembled to a Mechanical System When transporting an actuator that has been assembled to a mechanical system, take note of the following points. Secure the sliders to prevent sudden movement during transport. If any end of the actuator is overhanging, secure it properly to avoid significant movement due to external vibration. If the actuator assembly is transported without the ends being secured, do not apply an impact of 0.3G or more. When hoisting the mechanical system using ropes, etc., prevent the actuator, connector box, etc., from receiving a load. Also make sure the cables are not pinched or deformed unnaturally. 11

20 International CE MarkingStandards Compliances This actuator complies with the following overseas standard. Refer to Overseas Standard Compliance Manual (ME0287) for more detailed information. RoHS Directive CE Marking (Note 1) Note 1 The following models comply with CE Marking. ISA/ISPA-SXM, SYM, SZM ISA/ISPA-MXM, MXMX, MYM, MZM ISA/ISPA-LXM, LXMX, LXUMX, LYM, LZM 12

21 Names of the Parts 1. ISA/ISPA/IS/ISP In this operating manual, the left and right sides are indicated by looking at the actuator from the motor end, with the actuator placed horizontally, as shown in the figure below. Right side Screw cover Counter-motor side Motor side Left side Motor housing Slider Encoder cover Front cover Base Reference plane Bottom face Actuator cable [Refer to 12.1, External Dimensions for details on the reference surface.] For details on the reference surfaces of IS/ISP series actuators, refer to General Catalog for Small Industrial Robots 2003 (back number). You can download catalogs from IAI s website

22 2. ISA-W/ISPA-W/ISP-W Screw cover Right side Motor cover Counter-motor side Motor side Actuator cable Left side Front cover Slider Rear cover Base Reference plane Bottom face Actuator cable [Refer to 12.1, External Dimensions for details on the reference surface.] For details on the reference surfaces of IS/ISP series actuators, refer to General Catalog for Small Industrial Robots 2003 (back number). You can download catalogs from IAI s website

23 1. Checking the Product If based on a standard configuration, this product consists of the items listed below. Check the packed items against the packing specification. Should you find a wrong model or any missing item, please contact your IAI dealer or IAI. 1.1 Components No. Name Remarks 1 Actuator Accessories 2 Home making seals 3 Dedicated washers for high-tension bolts 4 Quick Step Guide 5 Operation Manual (DVD) 6 Safety Guide Refer to How to Read the Model Nameplate and How to Read the Model Number. Supplied with the following models of ISP/ISPA/IS/ISP with mounting holes pre-machined on the base: Medium M M, M MX Large L M, L MX, LXUWX Super-large WXM, WXMX 1. Checking the Product 1.2 Operation Manuals for Controllers Supported by This Product (1) XSEL-J/K controllers No. Name Control No. 1 Operation Manual for XSEL-J/K Controller ME Operation Manual for PC Software IA-101-X-MW/IA-101-X-USBMW ME Operation Manual for Touch Panel Teaching TB-01, TB-01D, TB-01DR Applicable for Program Controller ME Operation Manual for Teaching Pendant SEL-T/TD/TG ME Operation Manual for Teaching Pendant IA-T-X/XD ME Operation Manual for DeviceNet ME Operation Manual for CC-Link ME Operation Manual for ProfiBus-DP ME Operation Manual for X-SEL Ethernet ME Operation Manual for Multi-point I/O Board ME Operation Manual for Dedicated Multi-point I/O Board Terminal Block ME

24 (2) XSEL-P/Q, XSEL- /R/S controllers 1. Checking the Product No. Name Control No. 1 Operation Manual for XSEL-P/Q Controller ME Operation Manual for XSEL-R/S Controller ME Operation Manual for XSEL-P/Q/PX/QX RC Gateway Function ME Operation Manual for PC Software IA-101-X-MW/IA-101-X-USBMW ME Operation Manual for Touch Panel Teaching TB-01, TB-01D, TB-01DR Applicable for Program Controller ME Operation Manual for Teaching Pendant SEL-T/TD/TG ME Operation Manual for Teaching Pendant IA-T-X/XD ME Operation Manual for DeviceNet ME Operation Manual for CC-Link ME Operation Manual for PROFIBUS-DP ME0153 (3) SSEL controllers No. Name Control No. 1 Operation Manual for SSEL Controller ME Operation Manual for PC Software IA-101-X-MW/IA-101-X-USBMW ME Operation Manual for Touch Panel Teaching TB-01, TB-01D, TB-01DR Applicable for Program Controller ME Operation Manual for Teaching Pendant SEL-T/TD/TG ME Operation Manual for Teaching Pendant IA-T-X/XD ME Operation Manual for DeviceNet ME Operation Manual for CC-Link ME Operation Manual for PROFIBUS-DP ME

25 (4) SCON, MSCON controllers No. Name Control No. 1 Operation Manual for SCON Controller ME Operation Manual for SCON-CA Controller ME Operation Manual for MSCON Controller ME Operation Manual for PC Software RCM-101-MW/RCM-101-USB ME Operation Manual for Teaching Pendant CON-T/TG ME Operation Manual for Touch Panel Teaching Pendant CON-PT/PD/PG ME Operation Manual for Simple Teaching Pendant RCM-E ME Operation Manual for Data Setter RCM-P ME Operation Manual for Touch Panel Teaching TB-01, TB-01D, TB-01DR Applicable for Position Controller Operation Manual for Touch Panel Display RCM-PM-01 Operation Manual for DeviceNet Operation Manual for CC-Link Operation Manual for PROFIBUS-DP ME0324 ME0182 ME0124 ME0123 ME Checking the Product 1.3 How to Read the Model Nameplate Model Serial number 17

26 1. Checking the Product 1.4 How to Read the Model Number <Series> Standard precision IS, ISA High precision ISP, ISPA <Type> Smallest TXS Small, X-axis SXM Small, Y-axis SYM Small, Z-axis SZM Medium, X-axis MXS MXM Medium, X-axis With intermediate support MXMX Medium, Y-axis MYS MYM Medium, Z-axis MZS MZM Large, X-axis LXS LXM Large, X-axis With intermediate support LXMX Large, X-axis Intermediate support Double-sliders LXUWX Large, Y-axis LYS LYM Large, Z-axis LZS LZM Super-large, X-axis With intermediate support WXMX ** (Note 1) Identification for IAI use only <Options> AQ: AQ seal B: Brake C: Creep sensor CL: Creep sensor, opposite side L: Limit switch LL: Limit switch, opposite side LLM: Synchronized specification, sensor on opposite side LM: Synchronized specification, master axis NM: Reversed-home specification RT: Guide with ball retention mechanism S: Synchronized specification, slave axis EU: Metal connector specification W: Double slider <Cable length> N: None S: 3 m M: 5 m X : Length specification <Applicable controller> T1: XSEL-J/K T2: SCON SSEL XSEL-P/Q/R/S, MSCON <Stroke> <Lead> 4: 4 mm 5: 5 mm 8: 8 mm 10: 10 mm 16: 16 mm 20: 20 mm 25: 25 mm 30: 30 mm 40: 40 mm 50: 50 mm <Encoder type> A: Absolute I: Incremental 18 <Motor type> 60: 60 W 100: 100 W 200: 200 W 400: 400 W 600: 600 W 750: 750 W Note 1 It may be displayed for IAI use. It is not a code to show the model type.

27 2. Specification 2.1 ISA/ISPA (1) Maximum speed The maximum speed of the actuator is limited to prevent resonance of the ball screw shaft and also by the motor speed limit. The maximum performance of ISA/ISPA controllers has been improved following their revision. Be sure to observe the applicable maximum speed shown in the table below. Strokes and maximum speed limits (Unit: mm/s) 2. Specification Size Motor capacity (W) Lead (mm) Stroke (mm) Size Motor capacity (W) Lead (mm) Stroke (mm) 19 19

28 2. Specification Caution: Do not set speeds equal to or greater than the respective ratings. Doing so may result in vibration, failure or shorter life. In synchronized operation of combined axes, adjust the speed and acceleration/deceleration to the maximum speed and minimum acceleration/deceleration among the combined axes, respectively. 20

29 (2) Acceleration and payload capacity Type Motor output (W) Lead (mm) Rated acceleration (G) Payload capacity at rated acceleration (kg) Maximum acceleration (G) Payload capacity by acceleration (kg) 0.3G 0.4G 0.5G.0.6G 0.7G 0.8G 0.9G 1.0G Horizontal Vertical SXM 0.3 Horizontal SYM 0.3 Vertical Horizontal Vertical SZM Vertical Vertical Horizontal Vertical MXM 0.3 Horizontal MYM 0.3 Vertical Horizontal Vertical MZM Vertical Vertical Horizontal Vertical MXM 0.3 Horizontal MYM Vertical Horizontal Vertical MZM Vertical MXMX Horizontal Horizontal Horizontal LXM 0.3 Vertical LYM Vertical Horizontal LZM Vertical Horizontal LXM 0.3 Vertical LYM Horizontal Vertical LZM Vertical Horizontal LXMX Horizontal Horizontal Horizontal LXUWX Horizontal Horizontal Horizontal Vertical Horizontal Vertical WXM Horizontal Vertical Horizontal Vertical Horizontal Vertical WXMX Horizontal Horizontal Horizontal Horizontal Specification Caution: 1. The figures of payload capacity by acceleration other than those at the rated acceleration of 0.3 G and 0.15 G are reference values and not guaranteed. Use these values only as a reference. 2. Even when the acceleration is less than the rated acceleration, the payload capacity will not exceed the payload capacity at the rated acceleration. 3. In synchronized operation of combined axes, adjust the speed and acceleration/deceleration to the maximum speed and minimum acceleration/deceleration among the combined axes, respectively. 21

30 2. Specification (3) Rated thrust Type Motor output (W) Lead (mm) Rated thrust (N) SXM SYM SZM MXM MYM MZM MXM MYM MZM MXMX LXM LYM LZM LXM LYM LZM LXMX LXUWX WXM WXMX

31 (4) Driving method Type Motor output Lead (W) (mm) SXM 16 SYM SZM MXM 10 MYM MZM MXM 20 MYM MZM 10 MXMX LXM 20 LYM LZM 10 LXM 40 LYM LZM LXMX LXUWX WXM WXMX Encoder Driving method pulses ISA series ISPA series Ball screw 12 mm Ball screw 16 mm Ball screw 20 mm Ball screw 25 mm Ball screw 20 mm Ball screw 25 mm Rolled, C10 Rolled, C10 Rolled, C10 Rolled, C10 Rolled, C10 Rolled, C10 Rolled, C5 or equivalent Rolled, C5 or equivalent Rolled, C5 or equivalent Rolled, C5 or equivalent Rolled, C5 or equivalent Rolled, C5 or equivalent 2. Specification (5) Common specifications Item ISA series ISPA series (Note 1) Positioning repeatability 0.02 mm 0.01 mm Backlash (Note 1) 0.05 mm or less 0.02 mm or less Base Material: Aluminum with white alumite treatment (Note 1) The values shown above are the accuracy at the delivery from the factory. It does not include the consideration of time-dependent change as it is used. 23

32 (6) Loads applied to the actuator Dynamic allowable moments and allowable overhang load lengths of each actuator are shown below. Make sure the applicable allowable values are not exceeded. 2. Specification ISA/ISPA Actuator Dynamic allowable moments (Nm) Allowable Ma (N m) Mb (N m) Mc (N m) overhang load (L) SXM SYM SZM MXM MXMX MYM MZM LXM LXMX LXUWX LYM LZM WXM WXMX SXM double-slider span: 30 mm SXM double-slider span: 90 mm MXM double-slider span: 35 mm MXM double-slider span: 120 mm LXM double-slider span: 35 mm LXM double-slider span: 150 mm Mb or Mc direction Ma direction Direction of moment Direction of allowable overhang 24

33 Caution: Make sure the load installed on the actuator is not longer than the allowable overhang load length (L). If the load is longer than L, vibration may occur or the settling time may increase. If the allowable load moment is applied, not only the life of the guide will become shorter but vibration or longer settling time may also result. : If X and Y-axes are combined in a cantilever configuration, the base may deform. Accordingly, keep the Ma and Mc moments to no more than one half the rated moment. Y-axis 2. Specification X-axis Keep the Ma and Mc moments applied to this slider to no more than one half the rated moment. * The IS (P) A-W is shown above, but the same also applies to other actuators

34 2.2 IS/ISP 2. Specification (1) Maximum speed The maximum speed of the actuator is limited to prevent resonance of the ball screw shaft and also by the motor speed limit. The maximum performance of IS/ISP controllers has been improved following their revision. Be sure to observe the applicable maximum speed shown in the table below. [IS/ISP] Strokes and maximum speed limits (Unit: mm/s) Size Motor capacity (W) Lead (mm) Stroke (mm) Size Motor capacity (W) Lead (mm) Stroke (mm) Size Motor capacity (W) Lead (mm) Stroke (mm) 26 26

35 [ISP] Stroke and maximum speed limits (Unit: mm/s) Size Size Motor capacity (W) Motor capacity (W) Lead (mm) Lead (mm) Stroke (mm) Stroke (mm) 2. Specification Size Motor capacity (W) Lead (mm) Stroke (mm) Caution: Do not set speeds equal to or greater than the respective ratings. Doing so may result in vibration, failure or shorter life. In synchronized operation of combined axes, adjust the speed and acceleration/deceleration to the maximum speed and minimum acceleration/deceleration among the combined axes, respectively. 27

36 (2) Acceleration and payload capacity [IS] 2. Specification Size Motor capacity (W) Lead (mm) Maximum speed (mm/s) Rated acceleration (G) Payload capacity (kg) 600 Horizontal Vertical TXS Horizontal Vertical SXM Horizontal SYM SZM MXS MYS MZS 100 MXM MYM Horizontal Horizontal Vertical Vertical Horizontal Horizontal Horizontal Vertical Vertical Horizontal Horizontal Horizontal MXM Horizontal MYM Horizontal MZM Vertical MXMX Horizontal LXS Horizontal LYS Horizontal LZS Vertical LXM Horizontal LYM Horizontal LXM LYM Horizontal LZM Vertical LXMX Horizontal LXMX Horizontal LXUWX Horizontal LXUWX Horizontal Caution: 1. Even when the acceleration is less than the rated acceleration, the payload capacity will not exceed the payload capacity at the rated acceleration. 2. In synchronized operation of combined axes, adjust the speed and acceleration/deceleration to the maximum speed and minimum acceleration/deceleration among the combined axes, respectively. 28

37 [ISP] Size Motor capacity (W) WXM 600 WXM 750 WXMX 600 WXMX 750 Lead (mm) Maximum speed (mm/s) Rated acceleration (G) Payload capacity at rated acceleration (kg) Maximum acceleration (G) Payload capacity by acceleration (kg) 0.3G 0.4G 0.5G.0.6G 0.7G 0.8G 0.9G 1.0G Horizontal Vertical Horizontal Vertical Horizontal Vertical Horizontal Vertical Horizontal Vertical Horizontal Horizontal Horizontal Horizontal Specification Caution: 1. Even when the acceleration is less than the rated acceleration, the payload capacity will not exceed the payload capacity at the rated acceleration. 2. In synchronized operation of combined axes, adjust the speed and acceleration/deceleration to the maximum speed and minimum acceleration/deceleration among the combined axes, respectively. 29

38 (3) Rated thrust [IS/ISP] 2. Specification Size Motor type (W) Lead (mm) Rated thrust N) TXS SXM SYM SZM 60 MXS MYS 100 MZS 100 MXM MYM MXM MYM MZM MXMX LXS LYS LZS LXM LYM LXM LYM LZM LXMX LXMX LXUWX LXUWX [ISP] Size Motor type (W) Lead (mm) Rated thrust N) WXM WXM WXMX WXMX

39 (4) Driving method [IS/ISP] Type Motor type Lead (W) (mm) TXS SXM 60 8 SYM 16 SZM MXS MYS 20 MZS MXM MYM 20 MXM MYM 20 MZM MXMX LXS LYS 20 LZS LXM LYM 20 LXM LYM LZM LXMX LXMX LXUWX LXUWX Encoder Driving method pulses IS series ISP series Ball screw Rolled, C5 or Rolled, C10 10 equivalent Ball screw 12 Ball screw 16 Ball screw 20 Rolled, C10 Rolled, C10 Rolled, C10 Rolled, C5 or equivalent Rolled, C5 or equivalent Rolled, C5 or equivalent 2. Specification 31

40 [ISP] 2. Specification Size Motor type (W) WXM 600 WXM 750 WXMX 600 WXMX 750 Lead (mm) Encoder pulses Ball screw 20 Driving method Rolled, C5 or equivalent (5) Common specifications Item IS series ISP series Positioning repeatability (Note 1) 0.02 mm 0.01 mm Lost motion (Note 1) 0.05 mm or less 0.02 mm or less Base (Note 1) Material: Aluminum with white alumite treatment The values shown above are the accuracy at the delivery from the factory. It does not include the consideration of time-dependent change as it is used. 32

41 (6) Loads applied to the actuator Allowable load moments and allowable overhang load lengths of each actuator are shown below. Make sure the applicable allowable values are not exceeded. IS/ISP ISP Actuator Allowable load moment (Nm) Ma (N m) Mb (N m) Mc (N m) TXS Allowable overhang load (L) Ma direction: 300 Mb or Mc direction: 220 SXM SYM SZM MXM MXMX MYM MZM LXM LXMX LXUMX LYM LZM WXM WXMX Specification Mb or Mc direction Ma direction Direction of moment Direction of allowable overhang 33 33

42 2. Specification Caution: Make sure the load installed on the actuator is not longer than the allowable overhang load length (L). If the load is longer than L, vibration may occur or the settling time may increase. If the allowable load moment is applied, not only the life of the guide will become shorter but vibration or longer settling time may also result. : If X and Y-axes are combined in a cantilever configuration, the base may deform. Accordingly, keep the Ma and Mc moments to no more than one half the rated moment. Y-axis X-axis Keep the Ma and Mc moments applied to this slider to no more than one half the rated moment. * The ISP-W is shown above, but the same also applies to other actuators

43 3. Life The mechanical life of the actuator is represented by that of the guide receiving the greatest moment load.operation life of the linear guide is to be determined by the total driving distance which can reach without having 90% flaking (peeling on rail surface). Operation life can be figured out with the calculation method shown below. 3.1 How to Calculate Operaition Life For the operation life of the linear guide, use the dynamic allowable moment stated in 2. Specifications, and figure out with the formula below. 3 C M L = 10000km M L : Operaition life (km) C M : Dynamic allowable moment (N m) M : Moment to work (N m) 10000km : Standard rated life of single axis robot In addition, have a calculation for the drop of life with the formula below if there is a concern that the life could drop due to the condition of vibration or way to be attached. 3. Life 3 C M f ws 1 L = 10000km M f w f L : Operaition life (km) C M : Dynamic allowable moment (N m) M : Moment to work (N m) f ws : Standard operational coefficient f w : Load coefficient f : Attachment coefficient 10000km : Standard rated life of single axis robot Explained below is regarding the standard operational coefficient f ws, load coefficient f w and attachment coefficient f. Refer to the contents below to set them up. [Standard operational coefficient f ws ] For ROBO Cylinders described in this manual, f ws = 1.2. It is a coefficient defined for each model, some models such as RCS3 high-speed type is

44 3. Life [Load coefficient f w ] It is a coefficient to consider the life drop due to operational conditions. Load coefficient f w Operation Condition Reference for acceleration/deceleration 1.0 to 1.5 Small vibration or impact in slow operation 1.0G or less [Attachment coefficient f ] Attachment coefficient f is a coefficient to consider the life drop due to the condition of actuator attachment. Attachment coefficient f Attached condition Attachment in whole area Attachment on both ends Attachment on spots * As the figures are those in common for each manual, they are not for IS (P) A Type. Replace to figures for IS (P) A Type and select the attachment coefficient. * Even when in attachment in whole area, and the actuator is seated in the whole length of the product, select 1.2 or 1.5 for the attachment coefficient depending on the position of screw fixing. * For attachment in whole area, use all of the tapped holes (counterbored holes) on the seat surface to fix. 3.2 Operation Life The operation life depends on the moment to work.with light load, it will be longer than 10,000km, the standard rated life. With no consideration of vibration and attachment condition, the operation life is 80,000km according to the calculation with formula in the previous page underassumption that 0.5C M (half of dynamic allowable moment) of moment is applied on. It shows that it can be 8 times longer than the standard rated life, which is 10,000km. 36

45 4. Installation and Storage/Preservation Environment 4.1 Installation Environment The actuator should be installed in an environment meeting the following criteria: Avoid direct sunlight. The machine should not receive radiant heat from strong heat sources such as a furnace. The ambient temperature should be 0 to 40ºC. The relative humidity should be 85% or below 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. Avoid exposure to splashed chemical solutions. The actuator should not be subject to impact or vibration. Avoid extreme electromagnetic waves, ultraviolet rays and radiation. Enough work space shall be available to carry out maintenance/inspection. In general, the environment should be one in which an operator can work without protective gear. 4.2 Storage/Preservation Environment The storage/preservation environment should be similar to the operating environment. In addition, take precautions against condensation if the actuator is to be stored/preserved for a long period of time. Unless otherwise specified, we do not include drying agents when shipping the actuator. If you are storing the actuator in an environment where condensation might occur, you must treat the entire shipping box, or treat the actuator itself after unpacking, to prevent condensation. The unit can withstand temperatures up to 60ºC during a short storage period, but only up to 50ºC if the storage period is longer than one month. Keep the actuator horizontal during storage/preservation. 4. Installation and Storage/Preservation Environment 36 37

46 5. Installation This chapter explains how to install your actuator on a mechanical system. 5.1 Installation Install the actuator as explained below, as a rule. Pay attention to these items when installing the actuator (except for custom-order models). 5. Installation : Installable : Installable if the stroke is less than 1,300 mm x: Not installable Type Horizontal installation Vertical installation Sideway installation Hanging from ceiling SXM SYM SZM MXM MXMX x x MYM MZM LXM LXMX x x LXUWX x x LYM LZM WXM WXMX x x Installation postures Horizontal Sideway Vertical 38

47 Caution: 1. When installing the actuator vertically, make sure the motor comes to the top. When the actuator is installed with the motor at the bottom, there shouldn t be any problems during normal operations. If the actuator is not operated for an extended period of time, however, depending on the ambient environment (especially at high temperature) grease may separate and base oil may flow into the motor unit, causing problems on rare occasions. In the case of Sideway installation, base oil may flow out from the aperture on the side of the actuator, causing problems on rare occasions. 2. If the actuator is installed in horizontally oriented wall mount, it is easy for a foreign object to get inside the actuator from the opening on the side of the actuator. 3. In the Ceiling mount installation, the screw cover may bend, and it will be likely to interfere with the work part. When it exceeds the stroke 600mm, separate the work etc from slider seating surface and install. Type Stroke Distance 600mm or more ISA less than 1000mm 5mm or more ISPA 1000mm or more less than 1300mm 10mm or more 5. Installation A Work seating surface 5.2 Installing the Actuator (1) X-axis Mounting holes are provided at the base. Remove the screw cover and install the actuator from its top face. Intermediate support types (M-X-MX, L-X-MX, L-X-UMX) are installed in the same manner as actuator types without intermediate support. When installing any intermediate support type, however, be careful not to remove or hook the wire ropes installed inside the actuator. Heed the same precautions when assembling the actuator that has been shipped pre-assembled. When using positioning pins, use a pin that possesses the fit tolerance stated in 12.1 External Dimensions. When press-fitting a pin, be careful not to press it down further than the depth of the reamed hole. (2) Y or Z-axis If the axis is used as a combination axis and installed using a base, use the tapped holes at the back of the base. If the stroke is 700 mm or more, the Z-axis has mounting holes pre-machined on the base. Remove the screw cover and install the axis from above. If the axis is used as a combination axis and installed using a slider, install the axis according to 5.3, Installing the Load on the Slider When using the axis alone, install it by using the tapped holes at the back of the base. When using positioning pins, use a pin that possesses the fit tolerance stated in 12.1 External Dimensions. When press-fitting a pin, be careful not to press it down further than the depth of the reamed hole. 39

48 Smallest type TXS The installation method is shown by a section view. 5. Installation Axis Applicable bolt Tightening torque X-axis M5 3.4 N m (0.35 kg m) Small type S M The installation method is shown by a section view. X-axis Y or Z-axis M6, depth 16 Axis Applicable bolt Tightening torque X-axis M6 5.4 N m (0.55 kg m) Axis Applicable bolt Bolt seating surface is steel Tightening torque Bolt seating surface is aluminum Y or Z-axis M N m (1.26kg m) 5.4 N m (0.55 kg m) Bolt seating surface Bolt Seating surface Seating surface 40

49 Medium type M M, M MX The installation method is shown by a section view. X-axis Y or Z-axis (Stroke less than 700 mm) Z-axis (Stroke 700 mm or more) M8, depth 20 Axis Applicable bolt Tightening torque X-axis Z-axis (Stroke 700 mm or more) M N m (1.17 kg m) 5. Installation Tightening torque Axis Applicable bolt Bolt seating surface is steel Bolt seating surface is aluminum Y-axis Z-axis (Stroke less than 700 mm) M N m (3.06 kg m) 11.5 N m (1.17 kg m) Large type L M, L MX, LXUWX The installation method is shown by a section view. X-axis Y or Z-axis (Stroke less than 700 mm) Z-axis (Stroke 700 mm or more) M8, depth 20 Axis Applicable bolt Tightening torque X-axis Z-axis (Stroke 700 mm or more) M N m (1.17 kg m) Tightening torque Axis Applicable bolt Bolt seating surface is steel Bolt seating surface is aluminum Y-axis Z-axis (Stroke less than 700 mm) M N m (3.06 kg m) 11.5 N m (1.17 kg m) 40 41

50 Super-large type WXM, WXMX 5. Installation Axis Applicable bolt Tightening torque X-axis M N m (1.17 kg m) Warning: The tapped holes are not through, so exercise caution when selecting the bolt length. Use of inappropriate bolts may damage the tapped holes or result in insufficient mounting strength of the actuator, leading to a lower precision or unexpected accident. About tightening screws Use high-tension bolts conforming to ISO 10.9 or higher. If a tapped hole is used, use a screw not longer than the engagement length. The length of thread engagement should be 1.8 times more than the nominal diameter, when you utilize the tapped holes. If the tapped hole is through, be careful not to let the end of the bolt project from the hole. Make sure to have length stated below for that of the effective thread engagement of a bolt and a female screw when a through hole is to be applied. If the female screw is made of steel, same as the nominal diameter If the female screw is made of aluminum, 1.8 times of nominal diameter When installing the actuator on a frame, etc., using a base and M8 or larger bolts are used, also use dedicated washers for high-tension bolts to protect the base. These washers are not required for M6 and smaller bolts. Also note that general spring washers must not be used. Dedicated washer for high-tension bolt (supplied) Dedicated washer for high-tension bolt (supplied) 42

51 5.3 Installing the Load on the Slider The slider has tapped holes, so affix the load using these holes. The affixing method shall conform to the method for installing the actuator. Similarly when the slider is affixed and actuator is moved, install the slider using the tapped holes on the slider. The slider has two reamed holes, so use these holes if repeatability is required after removal/re-installation. If fine adjustment of squareness, etc., is required, use one reamed hole on the slider to make adjustment. Smallest type TXS 5. Installation 2-5H10, depth 6 4M5, depth 15 Tightening torque Applicable bolt Bolt seating surface is steel Bolt seating surface is aluminum M5 7.3 N m (0.74 kg m) 3.4 N m (0.35 kg m) Small type S M X-axis Y or Z-axis 2-6H7, reamed, depth 10 4-M6, depth H7, reamed, depth 10 4-M6, depth 16 Tightening torque Applicable bolt Bolt seating surface is steel Bolt seating surface is aluminum M N m (1.26 kg m) 5.4 N m (0.55 kg m) 42 43

52 Medium type M M, M MX X-axis Y or Z-axis 5. Installation Applicable bolt 2-8H7, reamed, depth 10 4-M6, depth 20 4-M8, depth 20 4-M8, depth 20 4-M6, depth 20 Tightening torque Bolt seating surface is steel Bolt seating surface is aluminum M N m (1.26 kg m) 5.4 N m (0.55 kg m) 2-8H7, reamed, depth 10 M N m (3.06 kg m) 11.5 N m (1.17 kg m) Large type L M, L MX, LXUWX X-axis Y or Z-axis 2-8H7, reamed, depth 10 (tolerance 2-8H7, reamed, depth 10 (tolerance for reamed hole pitch 0.02) for reamed hole pitch 0.02) 8-M8, depth 20 8-M8, depth 20 Tightening torque Applicable bolt Bolt seating surface is steel Bolt seating surface is aluminum M N m (3.06 kg m) 11.5 N m (1.17 kg m) 44 43

53 Super-large type WXM, WXMX 2-8H7, reamed, depth 10 4-M8, depth 30 Seating surface Seating surface Seating surface Seating surface Bolt Bolt Bolt seating surface 5. Installation Tightening torque Applicable bolt Bolt seating surface is steel Bolt seating surface is aluminum M N m (3.06 kg m) 11.5 N m (1.17 kg m) About tightening screws Use high-tension bolts conforming to ISO 10.9 or higher. If a tapped hole is used, use a screw not longer than the engagement length. The length of thread engagement should be 1.8 times more than the nominal diameter. 45

54 5.4 Reference Surface and Mounting Surface The mounting frame should have sufficient rigidity to avoid generation of vibration. The surface where the actuator will be mounted should be machined or be equally level, and the flatness between the actuator and the frame should be within 0.05 mm. Provide enough space around the actuator so that maintenance work can be carried out. In view of the following and the motor sides, the measurement basis of the running accuracy of the slider seen from the upper part is a right side. If accuracy for its run is required, use these surfaces as a datum of the installation. In view of the motor side, the parallelism of the quasi-reference surface of left side to the reference surface is 0.1mm or less. 5. Installation Quasi-reference surface Reference surface Quasi-reference surface Reference surface Motor Side Top View As shown in the figure above, each side face of the base provides a reference surface for traveling alignment of the slider. If precision is required, install the actuator with reference to this surface. When installing the actuator on a frame using a reference surface of the base, follow the figure below. The front cover and rear cover on both ends of the actuator may contact the frame. When machining the mounting surface, be sure to provide enough relief for the thickness of the covers to prevent contact. R0.3 or less Dimension A (mm) 3 to 5 46

55 5.5 Using T-slots M4 T-slots are provided on the side face of the base for installing the connector box or other item that must be combined. (See the figure below.) If a wiring kit is combined, use these T-slots to install the kit. You can also use these T-slots freely for installing sensors, securing wires or for other purposes as necessary. Distance from bolt end Bolt 5. Installation Square nut (or hexagonal nut) Installed part Caution: Square nuts are recommended for use with T-slots, but general hexagonal nuts can also be used. When installing blots in T-slots, pay attention to the length of each bolt to prevent the bolt end from contacting the bottom of the T-slot

56 6. Connecting the Controller The controller wiring is explained using a single-axis actuator. 6.1 Wiring The actuator and controller are connected via the motor cable and encoder cable (genuine parts) using connectors. Motor cable Controller 6. Connecting the Controller Actuator Encoder cable Example of connection with XSEL Controller [For details on extension cables, refer to 9, Motor/Encoder Cables. ] Caution: Although we use a cable resistant to bending fatigue, it is not a robot cable. Accordingly, avoid housing the cable in a wire duct with a small bending radius. Do not cut the cable for the purpose of extension, shortening, or reconnection. Do not pull on the cable or apply an excessive force to bend it. The cables may break

57 6.2 Using the Dedicated Stand-alone Table (ICS Series) If you specify a single-axis actuator of ICS series with a stand-alone cable that comes with a connector box, we ship the specified cable along with a 0.3-m actuator cable. (If the actuator is shipped pre-assembled, re-wire/connect each part before shipment.) Using the dedicated stand-alone cable kit, connect the cable from the actuator to the connector box. Twelve service wires (or ten wires) and two air hoses are supplied with the dedicated stand-alone cable. All these wires/hoses remain unconnected inside the connector box, so connect them as necessary before use. [For wiring, refer to the Assembly Procedures for ICS (P) A Cartesian Robot.] Dedicated self-supporting cable 6. Connecting the Controller Connector box 48 49

58 When designing an application system using IAI actuators and controllers, incorrect wiring or connection of each cable may cause unexpected problems such as a disconnected cable or poor contact. The following explains examples of prohibited handling of cables. Read the information carefully to connect the cables properly. Do not let the cable flex at a single point. Steel band (piano wire) 6. Connecting the Controller Bundle loosely. Do not let the cable bend, kink or twist. Do not pull the cable with a strong force. Do not let the cable receive a turning force at a single point. When fixing the cable, provide a moderate slack and do not tension it too tight. Use a curly cable. Do not pinch, drop a heavy object onto or cut the cable. Do not use a spiral tube where the cable flexes frequently

59 Cautions for use of a cable track The supplied cable is not a robot cable, so never store it in a cable track. Always use a robot cable for motor/encoder cables. Bending radius r Make sure the bending radius of the cable track is at least the minimum bending radius of the cable. (Refer to 9, Motor/Encoder Cables. ) Do not lay signal lines together with circuit lines that create a strong electric field. 6. Connecting the Controller Power line Signal lines (flat cable) Duct Follow the instructions below when using a cable track. If there is an indication to the cable for the space factor in a cable track, refer to the wiring instruction given by the supplier when storing the cable in the cable track. Avoid the cables to get twined or twisted in the cable track, and also to have the cables move freely and do not tie them up. (Avoid tension being applied when the cables are bent.) Do not pile up cables. It may cause faster abrasion of the sheaths or cable breakage. 51

60 7. Setting the Home Position 7.1 Home Return Home return involves the operation explained below: [1] When a home return command is issued, the actuator moves in the direction set by the parameter for moving direction. [2] The software senses the mechanical end in the return operation. [3] The slider reverses its direction when this end is reached, after which the position where the Z-phase signal is detected becomes the reference point. [4] The slider travels further by the offset amount set by the parameter, and this position becomes home. 7.2 Fine-tuning the Home Position 7. Setting the Home Position The number of motor revolutions from the time the slider hits the stopper until the Z-phase signal is generated has been adjusted before the actuator is shipped. The standard value of the reversing distance when the slider hits the stopper, reverses its direction, and then stops at the home position, is shown in the table below. Model name Distance from mechanical stopper to home (approx. in mm) IS/ISP/ISA/ISPA-S 4 IS/ISP/ISA/ISPA-M, L 5 IS/ISP/ISA-W, ISPA-W 7 ISA/ISPA-M, L with intermediate support 5 IS/ISP/ISA/ISPA-W with intermediate support 15 As long as the home direction is the same, you can fine-tune the home position for each actuator by changing the parameter based on this value. Fine-tuning is made as follows: [1] Perform homing operation and confirm home. [2] Thereafter, the actuator moves to the desired home, after which the difference is checked. In the case of a XSEL or SSEL controller, the parameter for home preset is corrected accordingly. In the case of a SCON, MSCON controller, the parameter for home reset offset is corrected accordingly. Specifically, add or subtract the difference to/from the value currently current. [3] If you allow for a large offset, the movement range is limited by the amount of offset. If the offset is greater than 1 mm, you must also adjust the stroke soft limits. 7.3 Changing the Home Direction If the home direction is changed after the actuator has been delivered, the home direction parameter must be changed, and the encoder s Z-phase may also need to be adjusted on some models. Contact IAI. 52

61 7.4 How to Use the Homing Mark Stickers Attach these stickers to the product, as necessary, to indicate the home direction of the actuator, etc. Sticker details Homing mark stickers x 1 sheet Examples of use Graduation mark sticker x 4 Mark sticker x 4 (The graduations are provided for 10 mm at a 1-mm pitch.) Remove each sticker from the backing paper when use. Notes 1. The back side is adhesive. 2. Remove dirt and oil from the attaching surface beforehand. 3. Avoid attaching the stickers over the caution labels. [1] For marking the home direction of the actuator Attach to the slider. Motor 7. Setting the Home Position Attach on the home side of the base. [2] As positioning marks Attach to the slider. Motor Attach at desired moving positions. [3] For displacement check Attach to the slider. Attach to the base. Attach two stickers when the actuator is stopped at home

62 8. Options 8.1 AQ Seal (Features) The AQ seal is a lubrication unit that uses a lubricating member made of resin-solidified lubricating oil. The AQ seal is a porous member containing a lot of lubricating oil, so lubricating oil oozes out to the surface by means of capillary phenomenon. When the AQ seal is pressed against the guide and ball screw surface (steel-ball rolling surface), lubricating oil is supplied and this, combined with use of grease, keeps the actuator maintenance-free for a long time. Change in Oil Content of AQ Seal (Figures after 1.5 years are projections.) Oil content Ambient temperature 20 C Ambient temperature 30 C 8. Options (Effects) Combined with the effect of grease charged before shipment, the actuator can remain maintenance-free for 5,000 km or 3 years. However, it is recommended that the actuator be greased regularly according to the standard maintenance schedule to ensure a stable use for a long term. Elapsed years Based on 12 hours of operation a day, 250 days a year Aging of lubricating oil content and factors relating to driving of the actuator are excluded. Life of guide (with/without AQ Seal) Ball screw With AQ seal No lubrication Stopped after 1,800 km due to large wear Driven distance (km) No problem was found after 15,000 km AQ seal Base integrated type guide Life of Ball Screw (with/without AQ Seal) AQ seal With AQ seal No lubrication Stopped after 20 km due to large wear No problem was found after 5,000 km Ball screw Nut Driven distance (km) 54 53

63 8.2 Brake The brake is a mechanism to retain the slider of a vertically installed actuator so that the slider will not drop when the power is cut off or servo turns off. The model numbers of Z-axes set for ISA/ISPA/IS/ISP-series actuators of S, M and L types are basically designed for vertical installation and thus include a brake. If any axis other than Z is used vertically, an optional brake is required. Brakes of S, M and L types are installed outside the end cover on the counter-motor side, but brakes of W types are built into the actuator. 8.3 Creep Sensor This sensor is used to perform home return at high speed. Normally home return is implemented with the slider contacting the stopper at the stroke end on the motor side and then reversing its direction, and therefore the home return speed is kept to a range of 10 to 20 mm/s. Accordingly, sliders of long strokes require a longer time to complete the home return. The creep sensor is a proximity sensor used to move the slider at high speed until halfway and then reduce its speed to the normal home return speed before the home, in order to shorten the time required for home return. The standard installation position of this sensor is on the right side of the actuator as viewed from the motor ( C in model number). A cover similar to the one used for limit switches is provided on the outside of the sensor (just like the one shown in the home limit switch drawing). If CL (installation position on opposite side) is specified, the sensor is installed on the other (opposite) side. 8. Options Home return of an axis with a long stroke requires a longer time for the axis to move to the mechanical end. Creep sensor Speed A sensor is provided before the mechanical end and once this sensor actuates, the speed is reduced to perform normal home return operation. High speed With creep sensor Without creep sensor Creep sensor Mechanical end Distance 54 55

64 8.4 Limit Switch Normal home return operation uses the stopper method wherein the slider contacts the stopper and reverses, after which Z-phase is detected and defined as the home. The home limit switch (L) is an option which is designed to perform this reversing operation using a proximity sensor, not a stopper. Use the home limit switch if you want to finely adjust the reversing position. If this option is selected, three proximity sensors are installed including the home detection sensor (HOME), overtravel sensor on counter-motor side (+OT) and overtravel sensor on motor side (-OT). (HOME and OT are integrated as twin sensors.) Take note that moving the home sensor significantly may shorten the stroke. The standard installation position of the home limit switch and cover is on the right side of the actuator as viewed from the motor ( L in model number). If LL (installation position on opposite side) is specified, the limit switch is installed on the other (opposite) side. 8. Options * The limit switch is a standard accessory for ISA/ISPA-W/ISDACR/ISPDACR-W actuators. Also note that the limit switch is built into the actuator and thus there is no cover on the actuator surface. (The creep sensor is also built into the actuator.) Limit switch cover Limit switch cover Limit switch cover Stroke-end side Motor side 56 55

65 8.5 Synchronized Specification (When X-SEL or SSEL Controllers are Used) This option applies to ISA/ISPA actuators when X-SEL or SSEL controllers are used. The synchronized operation function operates two actuator axes at the same time, with one axis serving as the master (symbol: M) and the other as the slave (symbol: S). Two actuator axes performing synchronized operation must have exactly the same specifications (type, lead, motor output and stroke). The master axis adopts the limit switch specification and is indicated by LM for limit-specification master axis in its model number. On the other hand, the slave axis has S for slave axis in its model number. The standard installation position of the limit switch and cover is on the right side of the actuator as viewed from the motor. If the limit switch of the master axis is to be installed on the other (opposite) side, LLM is specified in the model number. Controller Y-axis Slave axis (S) 8.6 Reversed-home Specification X-axis Master axis (LM) 8. Options In the reversed-home specification, the home is located on the counter-motor side. This is indicated by NM in the model number. If you wish to change the home direction after the delivery, consult IAI because the moving direction parameter must be adjusted, as well as the encoder s Z-phase on certain models

66 8.7 Guide with Ball Retention Mechanism (Structure) A spacer (retainer) is inserted between adjacent balls (steel balls) in the guide to reduce noise and achieve smooth operation. This specification is indicated by RT in the model number. Ball 8. Options (Features) [1] Reduced noise There is no longer metal noise generated by colliding balls and thus noise is reduced. Since balls are aligned by retainers, annoying noise decreases. Ball Spacer (retainer) [2] Smooth operation Wear caused by friction between balls decreases, oil no longer runs out due to contact, and lubricating oil collects at the retainers. Accordingly, operation becomes smooth. 8.8 Metal Connector Specification With the metal connector specification, the actuator connectors are not made of plastics, but of metal. This specification is indicated by EU in the model number. 8.9 Double-slider Specification The double-slider specification means there are two, or double, sliders. The applicable model code is W. 58

67 9. Motor/Encoder Cables 9.1 Standard The same cables are used regardless of the actuator model. The applicable cables vary depending on the combined controller. Correspondence table of controllers and motor/encoder cables Controller XSEL-J/K XSEL-P/Q/R/S SSEL SCON, MSCON LS Without LS With LS Without LS With LS Without LS With LS Without LS With LS Applicable cables [1], [2] [1], [2], [3] [1], [4] [1], [5] [1], [4] [1], [5] [1], [4] [1], [5] [1] Motor cable CB-X-MA (Front vies) Controller end [2] Encoder cable CB-X-PA (Front vies) Actuator end (Front vies) (Front vies) * indicates the cable length (L). Up to 30 m can be specified. Example) 080 = 8 m [Minimum bending radius] Movable: 51 mm Fixed: 34 mm Wiring Color Signal Signal Color Wiring Green Red White Black Red White Black Green * indicates the cable length (L). Up to 30 m can be specified. Example) 080 = 8 m [Minimum bending radius] Movable: 44 mm Fixed: 29 mm U V W PE 9. Motor/Encoder Cables Controller end Actuator end Wiring Color Signal 0.15 sq Blue (crimped) Orange Black Yellow Green Brown Gray Red The shield is clamped to the hood. Ground wire and braided shield wires Signal Color Wiring Black Yellow Blue Orange 0.15 sq Green (crimped) Brown Ground Gray Red 59

68 [3] Limit switch cable CB-X-LC (Front vies) Controller end [4] Encoder cable CB-X1-PA Actuator end (Front vies) * indicates the cable length (L). Up to 30 m can be specified. Example) 080 = 8 m [Minimum bending radius] Movable: 33 mm Fixed: 22 mm Wiring Color Signal Signal Color Wiring Skyblue Pink Light green Orange Gray 1B/skyblue Note) 1B indicates one black dot mark. Skyblue Pink Light green Orange Gray 1B/skyblue * indicates the cable length (L). Up to 30 m can be specified. Example) 080 = 8 m [Minimum bending radius] Movable: 44 mm Fixed: 29 mm 9. Motor/Encoder Cables (Front vies) Controller end Plug housing: XMP-09V (JST) Socket contact: BXA 001T-P0.6 (JST) x 9 Retainer: XMS-09V (JST) Note 6: Use the crimper recommended by the connector manufacturer. Actuator end (Front vies) Wiring Color Signal AWG26 (soldered) Orange Green Purple Gray Red Black Blue Yellow The shield is clamped to the hood. Signal Color Ground wire and braided shield wires Wiring Black Yellow Blue Orange AWG26 Green (crimped) Brown Ground Gray Red [5] Encoder cable with LS CB-X1-PLA L 14 LS end * indicates the cable length (L). Up to 30 m can be specified. Example) 080 = 8 m [Minimum bending radius] Movable: 54 mm Fixed: 36 mm (Front vies) Controller end Actuator end (Front vies) Wiring Color Signal AWG26 (soldered) White/blue White/yellow White/red White/black White/purple White/gray Orange Green Purple Gray Red Black Blue Yellow E24V 0V LS CLEEP OT RSV A+ A B+ B Z+ Z SRD+ SRD BKR BKR+ The shield is clamped to the hood. No No Signal Color Wiring E24V 0V White/blue White/yellow LS White/red AWG26 CLEEP White/black (soldered) OT RSV White/purple White/gray No. Signal Color Wiring 1 Purple 2 Gray 3 Orange 4 Green AWG Red Black (soldered) 7 Ground 8 9 Blue Yellow (As for wire color, White/blue indicates that Ground wire and braided shield wires the band is white and insulator is blue. 60

69 9.2 Metal Connector Specification (Option Indicated by EU in Model Number) The same cables are used regardless of the actuator model. The applicable cables vary depending on whether or not LSs are used. Correspondence table of controllers and motor/encoder cables Controller XSEL-P/Q/R/S, SSEL, SCON, MSCON LS Without LS With LS Applicable cables [1], [2] [1], [3] [1] Motor cable CB-XEU-MA * indicates the cable length (L). Up to 30 m can be specified. Example) 080 = 8 m [Minimum bending radius] Movable: 48 mm Fixed: 48 mm Wiring Color Signal Signal Color Wiring Green Red White Black Green Red White Black 0.15 sq (crimped) [2] Encoder cable CB-XEU1-PA * indicates the cable length (L). Up to 30 m can be specified. Example) 080 = 8 m [Minimum bending radius] Movable: 44 mm Fixed: 29 mm Wiring Color Signal 9. Motor/Encoder Cables AWG26 (soldered) Signal Color Wiring Orange Green Orange Green Purple Gray Red Black Blue Yellow The shield is clamped to the hood. Red Black Purple Gray Blue Yellow AWG26 (soldered) The shield is connected to the earth sleeve. Ground wire and braided shield wires (As for wire color, White/blue indicates that the band is white and insulator is blue. 61

70 [3] Encoder cable with LS CB-XEU1-PLA * indicates the cable length (L). Up to 30 m can be specified. Example) 080 = 8 m [Minimum bending radius] Movable: 58 mm Fixed: 38 mm Signal Color Wiring Wiring Color Signal White/blue White/yellow White/blue White/yellow White/red White/black White/red AWG26 White/black (crimped) White/purple White/gray White/purple White/gray Signal Color Wiring Orange AWG26 (soldered) Green AWG26 (crimped) Green Purple Gray Red Black Red Black Purple Gray 9. Motor/Encoder Cables Blue Yellow The shield is clamped to the hood. The shield is connected to the earth sleeve. Ground wire and braided shield wires (As for wire color, White/blue indicates that the band is white and insulator is blue. Blue Yellow 62

71 10. Maintenance/Inspection (Note) Replacement of the brake is basically held at our site. Please contact us when a replacement of the brake is required Inspection Items and Intervals Perform maintenance/inspection according to the following timetable. The operating time is assumed to be 8 hours a day. If the actuator is used continuously for 24 hours or the utilization rate is otherwise high, shorten the inspection intervals accordingly. Visual inspection of Period machine exterior At start of operation After 1 month of operation After 3 month of operation After 3 month of operation thereafter (Note 2) After 6 month of operation Interior check Grease Supply (Note 1) Period of Grease Supply (reference) (Note 2) Every 6 months thereafter (Note 1) When the actuator is moved back and forth continuously over a distance of 30 mm or less, grease film may disappear. As a guide, move the actuator back and forth over a distance of 50 mm or more for five cycles or so after every 5,000 to 10,000 back-and-forth operations over a short distance. This will restore the oil film. (Note 2) Check the condition of grease and wipe it off in case it is extremely dirty before supplying new grease. [Period of Grease Supply (reference)] Supply grease in the earlier timing of either the operation distance or months described in the table below. Max. Velocity of Use [mm/s] Period of Grease Supply (reference) Operation Distance Months 0 to 750 or less 1,250 km 750 to 1500 or less 2,500 km 12 months 1500 to 2400 or less 5,000 km For the actuators with the guide equipped with the ball retainer (option code RT), implement grease supply in the frequency of the period of grease supply (reference) described in the table below. Max. Velocity of Use [mm/s] Period of Grease Supply (reference) Operation Distance Months 0 to 750 or less 625 km 750 to 1500 or less 1500 to 2400 or less 1,250 km 2,500 km 6 months 10. Maintenance/Inspection Caution: The grease may be degraded if the actuator has got stored for 6 months or more. Supply grease before starting to use. [Reference to 10.6 Grease Supply] The speed of grease degradation differs depending on the environment of use (temperature, humidity and ambient environment). It is recommended to shorten the period of grease supply in case of use in bad environment with high temperature, high humidity, high rate of dust and so on. Also, it is recommended to improve the environment in case the color of the grease changes remarkably due to bad environmental condition. 63

72 10.2 Visual Inspection of the Machine Exterior Check the following items visually. Main body Cables General Loose mounting bolts Damage to cables, connection of connectors Noise, vibration 10.3 External Cleaning Clean the exterior surfaces from time to time. Wipe off dirt with a soft cloth. Depending on the situation, base oil of grease may ooze out to the actuator surface. If oil has oozed out, wipe it off using a soft cloth, etc. Do not spray compressed air on the actuator that might force dust into the crevices. Do not use petroleum-based solvents as they damage plastic parts and painted surfaces. If the unit gets badly soiled, moisten a soft cloth with a neutral detergent or alcohol and wipe the soiled area gently. 10. Maintenance/Inspection 10.4 Interior Check Turn off the power, remove the screw cover and visually inspect the interior. For the interior inspection, check the following items. Actuator Loosening of actuator mounting bolts, etc. Guide Lubrication condition, soiling Ball screw Lubrication condition, soiling Visually check the condition of the interior. Specifically, see if there is any dust or foreign object inside the actuator and also check the condition of lubrication. Even if the grease has turned brown, lubrication is fine as long as the traveling surface appears shiny. If the grease becomes dirty and dull due to dust, or if the grease has worn away due to an extended operating time, lubricate the parts after cleaning them. The procedure for checking the interior is explained below. [1] Remove the screw cover using an Allen wrench of 1.5 mm across flats for a small type, or 2 mm across flats for a medium or large type. With a large type, use an Allen wrench of 2.5 mm across flats to remove the screw cover. Do not remove the front cover since it supports the ball screw. Do not remove the motor cover since precision instruments are housed inside. [2] Check the interior. 64

73 [3] When the inspection/maintenance is complete, tighten the mounting screws for the screw cover. The tightening torque is 10.3 N cm for a small type, 21.1 N cm for a medium type, or 43.1 N cm for a large type. Warning: Do not disassemble the front cover because the ball screw is supported by the front cover. If a proper adjustment of the front cover is lost, the shaft center may become offset and the traveling resistance may increase or life of each part may become shorter, or abnormal noises may generate. An encoder is built into the encoder cover. The encoder not only detects the rotation angle and home signal, but it also performs a critical function in the AC control and the encoder and motor phases have been adjusted precisely. Never touch the encoder Cleaning the Interior Wipe off dirt with a soft cloth. If constituents of grease have separated and base oil has accumulated on both ends of the guide rail, wipe off the oil using a soft cloth, etc. If the accumulated oil is not wiped off, it may seep out to the exterior of the actuator. Do not spray compressed air on the actuator that might force dust into the crevices. Do not use petroleum-based solvents, neutral detergents or alcohol. Caution: If grease contains a large amount of foreign matter, be sure to wipe off the dirty grease before adding new grease Grease supply Applicable Grease The following blends of grease are charged before shipment (except for custom-order models). In addition to the factory-charged grease blends, you can also use corresponding products available from each company. For details, inform the names of factor-set grease blends to each manufacturer and request selecting corresponding products. 10. Maintenance/Inspection Guide Location Daphne Eponex Grease No. 2 Factor-set grease Corresponding products Name Manufacturer Name Manufacturer Idemitsu Kosan Ball screw Multemp LRL No. 3 Kyodo Yushi Intermediate support Multemp LRL No. 3 Kyodo Yushi Albania Grease S2 UNIREX N2 Showa Shell Sekiyu Mobil Sekiyu Warning: Never use fluorine grease. If fluorine grease is mixed with lithium grease, not only the performance of grease will be affected, but the actuator may also be damaged depending on the condition. 65

74 Grease Supply (1) Grease supply to the ISA/ISPA/IS/ISP guide How to remove the screw cover and add grease A grease nipple is provided on the slider. [1] Remove the screw cover. (Use an Allen wrench of 1.5 mm across flats for a small type, or 2 mm across flats for a medium or large type.) [2] Squirt the grease in from one grease nipple using a grease gun. (See the figure below for the positions of grease nipples.) Model S M M M Grease Supply (reference) 1 cc to 1.5 cc 2 cc to 2.5 cc Model L M/LXMX LXUWX Grease Supply (reference) 3 cc to 3.5 cc 1.5 cc to 2 cc [3] Rotate the slider several times manually to spread out the grease evenly. Confirm that the ball tracks on the ball screw and guide look glossy with oil of grease. Supply grease again if it is not spread enough. [4] Wipe off any excess grease. 10. Maintenance/Inspection Caution: Charging too much grease may increase the agitation resistance and cause the ball screw to generate heat easily or allow excess grease on the ball screw to scatter around and dirty the surroundings as the screw turns. Be sure to wipe off excess grease. It is difficult to move actuators of short leads by hand. With these actuators, do not try to move the acuter by force, but connect a controller and move the actuator by jog operation. In case the grease got into your eye, immediately go see the doctor to get appropriate care. After finishing the grease supply work, wash your hands carefully with water and soap to rinse the grease off. Grease nipple (Note) Follow the grease nipple diameter shown in the list below when preparing a grease gun. Model Nipple diameter (mm) IS (P) A-S 3.5 IS (P) A-M 6.0 IS (P) A-L 6.0 N type Grease Gun Attachment Screw R1/8 (Example) GC-57K Nozzle N type + Dedicated Nozzle U Type Dedicated Nozzle U Type Maker Yamada Corporation Maker Connect N type to the tip of the dedicated nozzle U type and attach a grease gun to use. THK N type Dedicated Nozzle U Type Attachment Screw R1/8 on Grease Gun Attachment Side 66

75 (2) Adding grease to the ISA-W/ISPA-W/ISP-W guide Remove the screw cover to access two grease nipples, one each on the left and right of the slider. [1] Use an Allen wrench of 2.5 mm across flats to remove the screws affixing the screw cover. [2] Add grease from the grease nipples on the end faces of the slider (refer to the drawing below). Grease Supply (reference) 3.5 cc to 4 cc [3] Rotate the slider several times manually to spread out the grease evenly. Confirm that the ball tracks on the ball screw and guide look glossy with oil of grease. Supply grease again if it is not spread enough. [4] Wipe off any excess grease. Slider Gease nipple (Note) Follow the grease nipple diameter shown in the list below when preparing a grease gun. Model Nipple diameter (mm) IS (P) A-W 6.6 The figure with remove the screw cover (Top view) (3) Adding grease to the ball screw Remove the screw cover and add grease. After cleaning the screw, apply grease using a finger and then move the slider back and forth to let the grease spread evenly. Finally, wipe off excess grease that has overflowed from the nut. Caution: Grease Gun Attachment Screw R1/8 (Example) GC-57K (Yamada Corporation) Nozzle Maker of Nozzle H type Charging too much grease may increase the agitation resistance and cause the ball screw to generate heat easily or allow excess grease on the ball screw to scatter around and dirty the surroundings as the screw turns. Be sure to wipe off excess grease. It is difficult to move actuators of short leads by hand. With these actuators, do not try to move the actuator by force, but connect a controller and move the actuator by jog operation. In case the grease got into your eye, immediately go to see the doctor to get an appropriate care. After finishing the grease supply work, wash your hands carefully with water and soap to rinse the grease off. THK 10. Maintenance/Inspection (4) Adding grease to the intermediate support Applicable models: IS (P) (A)-MXMX, IS (P) (A)-LXMX, IS (P) (A)-LXUWX, IS (P) (A)-WXMX [Connecting rods] After cleaning the two connecting rods at the intermediate support, apply grease to the rods using a finger. Thereafter, move the slider back and forth to let the grease spread evenly. Connecting rod 67

76 [Support bushes] After cleaning the support bushes at both ends of the intermediate support, apply grease to the areas around the bushes using a finger while turning each support bush. Thereafter, move the slider back and forth to let the grease spread evenly. Support bush [Top of slider and intermediate support] After cleaning the top of the slider and top of the intermediate support at both ends, apply grease to these areas using a finger. This is to protect the top of the slider and intermediate support against contact with the screw cover. 10. Maintenance/Inspection Top of slider Top of intermediate support Caution: In case the grease got into your eye, immediately go to see the doctor to get an appropriate care. After finishing the grease supply work, wash your hands carefully with water and soap to rinse the grease off. 68

77 11. Motor Replacement Procedures (Note) Motors of IS/ISP series actuators cannot be replaced by the customer. Should you require motor replacement on any of these models, consult IAI Replacing the Motor of the ISA/ISPA Series The procedures provided herein describe the motor replacement methods for the ISA series. If a need arises to replace the motor of your ISA actuator, do so by following the applicable procedure explained below. Prepare a storage box, etc., and keep in this box, etc., all screws and other parts you have removed to replace the motor, because they will be needed during the reassembly. Caution: When replacing the motor, you must turn on/off the power and servo to perform the following tasks: [1] Position the coupling on the motor alone [2] Install the motor [3] Operate the brake Exercise due caution when carrying out each task with the power being supplied. The purpose of [1] and [2] is to correlate the motor/encoder and actuator positions. If these tasks are not performed, home return may not be implemented normally. [3] is performed because the brake, which is a non-excitation brake, cannot be released (= the slider cannot be moved) without excitation. 11. Motor Replacement Procedures 67 69

78 Removing the Motor Unit Removing the Screw Cover Turn off the power supply to the controller, and then disconnect the motor cable and encoder cable. Remove the four thin-head screws used for mounting the screw cover, and take out the cover. If the cover cannot be taken out completely, move the screw cover out of the way so that the procedure described in Section can be performed. Motor cable Encoder cable Controller Connector Thin-head mounting screw Screw cover 11. Motor Replacement Procedures Thin-head mounting screw The ISA-SXM model is shown above

79 Removing the Seat Cover Peel off the seat cover provided on the motor side. You can now see the ball screw side of the coupling. The coupling is visible. The seat cover need not be removed if the cover is already separated from the hole, as shown to the left. If the actuator is equipped with a brake, connect the encoder cable and apply power to the controller to release the brake. Then move the slider so that the coupling bolts on the ball screw side can be removed. After moving the slider, deactivate the brake release, turn off the power to the controller and disconnect the encoder cable. Caution: If the actuator is vertically mounted (Z axis), exercise due caution so that the slider doesn t fall when the brake is released. If you attempt to move the slider with the motor cable connected, the slider movement will become heavy due to regenerative braking. Disconnect the motor cable before moving the slider. Motor unit 11. Motor Replacement Procedures Ball screw Coupling on the ball screw side Coupling on the motor side 69 71

80 Removing the Motor Cover Remove the four bolts that secure the motor cover. Top side Bottom side <List of Cover Mounting Bolts> Bolt used Motor Type Location Nominal output (W) Length Quantity diameter S 60 Common M Top side Bottom side 45 2 M Top side Bottom side 60 2 M4 Top side Bottom side 60 2 Top side L 400 Bottom side Removing Wire/Cable Lines for the Motor Unit (1) Remove the ground line, which is bolted to the motor bracket. 11. Motor Replacement Procedures (2) Disconnect the encoder signal line connector and the motor power line connector. * If a brake is provided, the brake lead connector should also be disconnected

81 The photo below shows how the motor looks when the motor cover and all connectors are removed. Motor power line Encoder signal line Brake lead line Caution: If the actuator is equipped with a brake, exercise caution not to pull out the brake lead line. If the connector is engaged inside the actuator, forcibly pulling out the brake lead line may cause the connector to come off inside the actuator Removing the Motor Unit (1) Move the slider to a position in which the coupling bolts on the ball screw side can be loosened. If a brake is provided, this procedure should be completed before the seat cover is removed as described in Section (2) Loosen the coupling bolts on the ball screw side. 11. Motor Replacement Procedures 71 73

82 (3) Remove the motor mounting bolts, and then pull the motor unit and coupling out of the motor housing. Motor mounting bolts (four locations) Coupling 11. Motor Replacement Procedures [Motor housing] [Motor unit] 74 72

83 Installing a New Motor Unit New Motor Unit The new motor unit will be supplied together with the coupling installed as shown below. The coupling is already installed. Caution Caution: With the coupling installed, align the home mark on the motor with the slit in the coupling, and then install the motor/coupling into the motor housing. Never loosen the coupling on the motor side. [Refer to , Aligning the Motor Position. ] The slit in the coupling is provided to help correlate the actuator and encoder positions. If the coupling is loosened, home return may not achieve a normal home position Aligning the Slider Position (1) Connecting the Motor Unit Connect the motor cable and encoder cable provided with the motor cover (which has been removed) to the motor unit, and then connect them to the controller using trunk cables (motor cable and encoder cable). 11. Motor Replacement Procedures 73 75

84 (2) Action to Be Taken upon Error If the code display on the front panel of the controller does not show rdy or Ardy but an alarm generates instead when the controller power is turned on, check the operating manual and take proper actions. If the problem persists, contact IAI. * If the code display shows Erg, it means an emergency stop has been actuated. * If the code display shows ECA1, an absolute reset must be performed. Code display (3) Adjusting the Slider Position Place a spacer (jig or block gauge) having a specified thickness between the mechanical end of the home position and the slider, and then press them firmly against one another so as not to allow for gaps. If the actuator is equipped with a brake, apply power to the controller to release the brake before moving the slider. After moving the slider, deactivate the brake release, turn off the power to the controller and disconnect the brake lead line connector. The thickness of the spacer will differ according to the home offset distance, the SE (stroke end) to ME (mechanical end) distance and the actuator type. (See Attachment 1 on Page 79.) If the actuator is of reversed home specification, see Attachment 2 on Page Motor Replacement Procedures 76 74

85 Standard Home Specification [When the slider jigs, etc., can be removed] Spacer See Attachment 1 on Page 79 for the distance of the gap. 11. Motor Replacement Procedures 75 77

86 Standard Home Specification [When the jigs on the slider cannot be removed] Adjust this section to the appropriate dimension shown in the table in the attachment. In this case, use of a block gauge, etc., is also recommended. (See Attachment 2 on Page 80 for the distance.) 11. Motor Replacement Procedures 78 76

87 Reversed Home Specification (Single-slider Specification) [When the slider jigs, can be removed] * The photograph shows a brake type actuator (optional). Spacer See Attachment 1 on Page 79 for the distance of the gap. Motor Reversed Home Specification (Single-slider Specification) [When the jigs on the slider, etc., cannot be removed] X or Z-axis Y-axis 11. Motor Replacement Procedures Adjust this section to the appropriate dimension shown in the table in the attachment. In this case, use of a block gauge, etc., is also recommended. (See Attachment 2 on Page 80 for the distance.) 77 79

88 Reversed Home Specification (Double-slider Specification) [When the slider jigs on the slider, etc., can be removed] This slider is directly connected Spacer Span to the ball screw. Affixed. Free slider Driving slider Motor See Attachment 1 on Page 79 for the distance of the gap. * In the case of a double-slider actuator (custom order) of reversed home specification, the driving slider is on the motor end and the slider on the other end becomes a free slider. * On a double-slider actuator of reversed home specification, the driving slider and free slider must be affixed. (See the custom order drawings for the span between the two sliders. If you are not sure, contact IAI.) 11. Motor Replacement Procedures Reversed Home Specification (Double-slider Specification) [When the jigs on the slider, etc., cannot be removed] Adjust this section to the appropriate dimension shown in the table. In this case, use of a block gauge, etc., is also recommended. (See Attachment 2 on Page 80 for the distance.) Free slider Span Driving slider This slider is directly connected to the ball screw. Motor * In the case of a double-slider actuator (custom order) of reversed home specification, the driving slider is on the motor end and the slider on the other end becomes a free slider. * On a double-slider actuator of reversed home specification, the driving slider and free slider must be affixed. (See the custom order drawings for the span between the two sliders. If you are not sure, contact IAI.) 80 78

89 (Attachment 1) Spacer Thickness by Model ~ Thickness of Spacer Used When Installing the Motor ~ The thickness of the spacer differs according to the actuator type and ball screw lead. Prepare a spacer by referring to the charts below. To determine the actuator type and ball screw lead length, check the model number indicated on the label affixed to the actuator. [How to Read the Model Number and Select a Spacer] Series Type Encoder type Motor output Lead Stroke Applicable controller Cable length Option ISA LYM A T1 M AQ-NM Since the above code includes the L type and 20 mm lead, the spacer 4.0 mm in thickness should be used. <Standard> Type Lead (mm) Spacer thickness (mm) S M Other than L All 4.0 <Equipped with a limit switch = Equipped with a home position sensor> Type Lead (mm) Spacer thickness (mm) S All 3.5 M All 4.0 L All Motor Replacement Procedures * The above charts also apply to the models in which the home position is set on the opposite side of the motor

90 (Attachment 2) Dimension Table by Model Standard home specification <Not equipped with a limit switch = Not equipped with a home position sensor> Adjust dimension to: Type Lead (mm) 4 36 S M M M MXMX L M LXMX LXUWX <Equipped with a limit switch = Equipped with a home position sensor> Type Lead Adjust dimension to: (mm) S M All 37.5 M M All 51 MXMX All 99 L M All 54 LXMX LXUWX All Motor Replacement Procedures Reversed home specification <Not equipped with a limit switch = Not equipped with a home position sensor> Adjust dimension to: Type Lead (mm) 4 21 S M M M MXMX L M LXMX LXUWX <Equipped with a limit switch = Equipped with a home position sensor> Type Lead Adjust dimension to: (mm) S M All 22.5 M M All 31 MXMX All 79 L M All 32 LXMX All LXUWX All

91 Aligning the Motor Position Apply power to the controller, and then run the motor with the jog control using the PC software or teaching pendant to align the home position marked on the motor and the slit in the coupling. (Jog at 1 mm per second (minimum speed)). * In certain situations such as when the controller is away from the motor, you can turn on the servo after aligning the coupling and slit positions by hand Installing the Motor Unit Temporarily (1) With the motor servo turned on, fit the motor unit s coupling in the end of the ball screw shaft and fasten the motor housing and motor unit temporarily. (Tighten manually for this temporary purpose.) When fastening the motor and motor housing temporarily, be sure to place them next to each other with no gaps or play. Install the motor unit so that the motor power line is located on the right side. Motor output Tightening Type Bolt used (W) torque (N cm) Quantity S 60 M4 x M 200 M5 x L 400 Power line 11. Motor Replacement Procedures Motor mounting bolts (Four locations) 81 83

92 (2) With the motor fastened temporarily, tighten the coupling bolts on the ball screw side. (3) Turn off the power to the controller, disconnect all connectors (including the motor cable and encoder cable connectors), but this time tighten the bolts in place to the specified torque. <Tightening Torques by Coupling Bolt Type> Coupling for S 2 N m Coupling for M 2 N m Coupling for L 4 N m Centering and Securing the Motor Unit Loosen the motor affixing screws you have tightened only loosely in an earlier step, move the slider back and forth by hand for three to four laps (over as long an operation stroke as possible) and eventually move the slider to near the mechanical end on the motor side and find a position at which the motor vibration becomes the smallest. Affix the motor unit in the motor housing at this position. 11. Motor Replacement Procedures Bolt Tightening Torques for Securing the Motor Unit Motor Tightening torque (N cm) Type Bolt used output (W) Standard Stainless steel type S 60 M4 x M 200 M5 x L 400 * If the actuator is equipped with a brake, connect the encoder cable, connect only the connector of the brake lead line and apply power to the controller. Then release the brake and move the slider. After securing the motor unit, deactivate the brake release, turn off the power to the controller and disconnect the encoder cable connector

93 Assembling the Motor Cover (1) Reconnect the motor cable and encoder cable connectors provided with the motor cover to the motor unit. For the brake type, twist the brake cables around the M cables. brake cables (2) Bolt the ground line to the motor bracket as it was previously secured. (3) Store the motor connector beneath the motor and the encoder connector on the left side of the motor, and put all the wire/cable lines where they were previously. 11. Motor Replacement Procedures The encoder connector should be stored in a space on the left side of the motor. * The brake connector should be stored in the same manner. The motor connector should be stored in a space beneath the motor. 85

94 Caution : The left side (where is circled below) of the encoder is a point that is weak in noise durability. Do not attempt to put the M cables and brake cables near the left side (where is circled below) of the encoder, and store the cables at the bottom of the motor. Putting the cables near the encoder may lead the encoder to cause an operational error. Encoder Weakness Point Encoder Weakness Point (4) Secure the motor cover in place. 11. Motor Replacement Procedures Caution 1: Caution 2: Be careful not to pinch wires between the main body and the cover. The motor cover is made of plastic. When securing the cover, be careful not to damage the cover by tightening the bolts too much. 86

95 Installing the Screw Cover (1) Install the seat cover. [1] [2] If the original condition was pattern [1], change it to pattern [2]. Install the seat cover so that the coupling check window becomes visible. (2) Install the screw cover in the manner it was previously installed. Screw cover Thin head screw x 2 Thin head screw x Motor Replacement Procedures 87

96 Correcting for Position Deviation (1) Connect the motor cable and encoder cable and turn on the controller power. (2) Use the PC software or teaching pendant to perform homing and check the home position. Repeat homing several times to confirm that the actuator returns to the same position. (If the actuator is of absolute specification, perform an absolute reset.) (3) Check the amount of position deviation. The position may have changed slightly from where it was before the motor was replaced. Accordingly, select a desired position number that allows you to check the amount of deviation before and after the replacement, and then perform positioning to that position and measure the amount of deviation. (4) Reflect the deviation in the home preset parameter in the case of an X-SEL/SSEL controller, or in the home return offset parameter in the case of an SCON, MSCON controller. [For the setting method, refer to 11.3, How to Set the Home Preset and Home Return Offset. ] * If the two positions differ significantly (one ball screw revolution or more = lead or more) or if the actuator does not return to the same position when homing is repeated, install the motor unit again by following the procedure described in this manual. When the motor unit was installed, a wrong spacer size may have been used or the slider may have moved instead of remaining stationary at the mechanical end Operation Check after Replacing the Motor 11. Motor Replacement Procedures After replacing the motor, perform continuous operation to confirm absence of vibration or abnormal noise. 88

97 11.2 Replacing the Motor of the ISA-W/ISPA-W Series This manual details the procedure for replacement of an ISA-W/ISPA-W Series motor. When you need to replace your motor, please follow the steps described below. Because the screws and other components removed during replacement of the motor will be needed for reassembly, prepare a storage box in advance to keep those components so that you don t lose or misplace them. Caution: When replacing the motor, you must turn on/off the power and servo to perform the following tasks: [1] Position the coupling on the motor alone [2] Install the motor [3] Operate the brake Exercise due caution when carrying out each task with the power being supplied. The purpose of [1] and [2] is to correlate the motor/encoder and actuator positions. If these tasks are not performed, home return may not be implemented normally. [3] is performed because the brake, which is a non-excitation brake, cannot be released (= the slider cannot be moved) without excitation. (1) Remove the motor cover and rear cover. Use an Allen wrench of 2.5 mm across flats to remove the hexagonal socket head button bolts affixing the motor cover. Use an Allen wrench of 3 mm across flats to remove the hexagonal socket head bolts affixing the rear cover. 11. Motor Replacement Procedures Caution: Even when the motor cover does not come off easily, do not attempt to take it off forcefully with hand.it is because the anti-vibration rubber on the seat is stuck on the motor cover. Hit the cover with a tool such as a rubber hammer, which does not damage the cover or give excessive impact, to release the anti-vibration rubber from the cover before detaching the motor cover. Pulling the cover off forcefully with hand may cause injury with sharp edges, protruded parts or corners on the motor cover. 89

98 (2) Adjust the slider position so that the coupling bolt comes to the position directly above. Use a scale to adjust the distance as shown in the photograph below. Warning: In the case of a vertical axis, turn on the controller power and forcibly release the brake to move the axis. Note, however, that the work part may drop suddenly to create a dangerous situation. Be sure to prepare a frame to support the robot hand and take other appropriate measures to prevent the work part from dropping suddenly, to make sure the work part will not be damaged. Adjust the slider position so that the coupling bolt comes to the position directly above. Standard home specification (home on the motor side) Motor bracket Slider 11. Motor Replacement Procedures 13 mm (or 98 mm if there is an intermediate support) Distance between the end face on the inner side of the motor bracket and end face of the slider Without intermediate support mm With intermediate support mm Reversed-home specification (home on the counter-motor side) Slider Front cover 16 mm (or 142 mm if there is an intermediate support) Distance between the end face of the slider and end face on the inner side of the front cover Without intermediate support mm With intermediate support mm 90 87

99 (3) Loosen the coupling (ball screw side). Use an Allen wrench of 4 mm across flats to loosen the hexagonal socket head bolt affixing the coupling. Affixing bolt (4) Cut off the power and then unplug all extension cable connectors. (Motor cable, encoder cable, LS cable and brake connectors) (5) Remove the motor. Use an Allen wrench of 5 mm across flats to remove the four hexagonal socket head bolts affixing the motor. Hold the motor with both hands and pull it out slowly. 11. Motor Replacement Procedures 88 91

100 (6) Plug the motor connector and encoder connector on the extension cables into the new motor. The new motor is delivered with the coupling preassembled, as shown below. Caution: With the coupling installed, align the home mark on the motor with the slit in the coupling, and then install the motor/coupling into the motor housing. Never loosen the coupling on the motor side. [Refer to step (7).] The slit in the coupling is provided to help correlate the actuator and encoder positions. If the coupling is loosened, home return may not achieve a normal home position. 11. Motor Replacement Procedures (7) Adjust the motor shaft position. Turn on the controller power and turn the motor in the jog mode using a PC or teaching pendant until the home countermark on the motor flange aligns with the position of the slit in the coupling. * Keep the jog speed at the lowest level (1 mm/s). Align the countermark on the motor flange with the slit in the coupling

101 (8) Install the new motor. Confirm that the slider position is the same as in (2). If the slider position has deviated, readjust the position. With the servo turned on, press the motor coupling into the end of the ball screw shaft and affix the motor to the motor bracket. Insert the bottom affixing bolts beforehand. Use an Allen wrench of 5 mm across flats to tighten the hexagonal socket head bolts (M6 x 22 x 4 pcs). Insert the bolts beforehand. Cable side Tightening torque: 536 N cm (54.7 kgf cm) * If the slider positioned in (2) has moved before the motor is pressed into position, readjust the slider position. (9) Affix the coupling. Use an Allen wrench of 4 mm across flats to loosely tighten the hexagonal socket head bolts (M5 x 15) to affix the coupling, and then turn off the servo and tighten the bolts to the specified torque. Tightening torque: 700 N cm (71.4 kgf cm) 11. Motor Replacement Procedures (10) Cut off the controller power

102 (11) Plug in the LS connectors on the extension cables, and also the brake connector if there is a brake. (12) Install the rear cover. Store the connectors in the space below the motor, and use an Allen wrench of 3 mm across flats to loosely tighten the hexagonal socket head bolts (M4 x 15 x 4 pcs) by paying attention not to pinch the cables. Store the connectors in the space below the motor. Only loosely tighten the bolts here, because the motor cover will be installed later. (13) Install the motor cover. Use an Allen wrench of 2.5 mm across flats to tighten the hexagonal socket head button bolts (M4 x 5 x 4 pcs). 11. Motor Replacement Procedures (14) Securely tighten the rear cover bolts. Tightening torque: 176 N cm (18.0 kgf cm) Tightening torque: 191 N cm (19.5 kgf cm) 94 91

103 (15) Correcting the position deviation [1] Turn on the controller power. Next, use a PC software or teaching pendant to perform home return and confirm the home position. Repeat this several times to confirm that the actuator returns to the same home position every time. [2] Checking the position deviation The actuator may have moved slightly from the position assumed before replacing the motor. Accordingly, select any position number that lets you check the deviation between the positions before and after replacing the motor, and perform positioning to this position to measure the deviation. [3] Reflect the deviation in the home preset parameter in the case of an X-SEL/SSEL controller, or in the home return offset parameter in the case of an SCON, MSCON controller. [For the setting method, refer to 11.3, How to Set the Home Preset and Home Return Offset. ] * If the position is deviated significantly (by at least one rotation of the ball screw = at least the lead length), or if the actuator does not return to the same home position in each of the repeated home return operations, reinstall the motor according to the procedure explained herein. The slider may have been positioned at a wrong distance from the reference surface. (16) Operation check after replacing the motor After replacing the motor, perform continuous operation to confirm absence of vibration or abnormal noise. 11. Motor Replacement Procedures 95

104 11.3 How to Set the Home Preset and Home Return Offset Correct the position deviation by changing the parameter for home preset in the case of a XSEL or SSEL controller, or by changing the parameter for home return offset in the case of a SCON, MSCON controller. How to set these parameters is explained below XSEL and SSEL Controllers (1) Open the position edit screen. On the PC software screen, click the following screen., select a desired position number, and then click OK to display Click this button to open the position edit screen. The current value is displayed. Position number 11. Motor Replacement Procedures (2) Compare the current value and the value achieved by positioning the actuator to the selected position number, and check the amount of deviation. [2] Click MV. [1] Select the position to move the actuator to. 96

105 (3) Open the parameter screen. Click this button to open the parameter edit screen. (4) Select the axis-specific parameter tab. Select Specific Axis. (5) In the axis-specific parameter tab, select No. 12, Home preset value. (6) Change the setting of axis-specific parameter No. 12 (home preset value). Add or subtract the value measured in (2) to/from the value currently input. The setting unit is mm. Example: When subtracting 1 mm Current preset value = Current setting 1000 (7) Write the new data. Select No. 12, Home Direction. 11. Motor Replacement Procedures Click the SEL button to write the data to the controller

106 (8) Transfer the data to the controller. (9) Click OK. (10) Write the data to the flash ROM. 11. Motor Replacement Procedures (11) Restart the controller. Select the Parameters check box. Select Yes

107 ECON and SCON, MSCON Controllers (1) Open the position edit screen. On the PC software screen, click the following screen., select a desired position number, and then click OK to display Click this button to open the position edit screen. The current value is displayed. Point number (2) Compare the current value and the value achieved by positioning the actuator to the selected position number. [1] Select the position. [2] Click this button to make a step movement. 11. Motor Replacement Procedures 99

108 (3) Open the parameter screen. Click this button to open the parameter screen. (4) The user parameter screen appears. 11. Motor Replacement Procedures (5) Change user parameter No. 22 (home offset). * The setting unit is mm. Add or subtract the value measured in (2) to/from the value currently input. Example: When subtracting 0.5 mm Home offset = Current setting 0.5 mm

109 (6) Write the new data. Click the controller transfer button, and then click OK. * After the data has been written, turn off the controller power. Click the controller transfer button. Click OK. 11. Motor Replacement Procedures

110 P-Driver Controllers (1) Open the jog screen. Click the jog button on the PC software screen. Next, select the pulse mode. Jog button 11. Motor Replacement Procedures (2) Position the actuator to a desired position and compare the command pulse position and the position actually achieved, and write down the difference. Adjust the position by jogging the actuator or by turning off the servo and moving the actuator manually. Compare against this position. Servo ON/OFF button

111 (3) Open the parameter edit screen. Click this button to open the parameter screen. Click this button to open the parameter screen. (4) Change the setting of No. 13, Home offset. * The setting unit is pulse. Add or subtract the value measured in (2) to/from the value currently input. Example: When subtracting 150 pulses Home offset = Current setting 150 (5) Write the new data. Click the driver transfer button, click OK, and then click Yes. (The controller will restart.) Driver transfer button 11. Motor Replacement Procedures

112 12. Appendix 12.1 External Dimensions (Note) For the external dimensions of your IS/ISP series actuator, refer to the catalog of the corresponding old product. You can download the catalogs of old products from IAI s website ISA-SXM, ISPA-SXM F-7 drill, 11 counterbores for bolts, depth 1 2-6H7, reamed (back) 2-6H7, reamed, depth 10 (tolerance for reamed hole pitch 0.02 mm) 4-M6, depth 20 Cable joint connector *1 2-M3, depth 6 (same on the opposite side) Home At least 100 or more 12. Appendix * The brake-equipped type is longer in 25.5mm and heavier in 0.3kg. SE: Stroke end ME: Mechanical end (with brake) (with brake) A Reference surface Detail view of A Detail view of base installation part Detail view of T-slot at G base Dimension and Mass by Stroke Stroke Weight (kg)

113 ISA-SXM, ISPA-SXM Double Slider 4-M6, depth H7, reamed, depth 10 ST (Stoke at minimum span) 2x2-M3, depth 6 (same on the opposite side) 30 (Minimum span) Home F-7 drill, 11 counterbores, depth 1 (back) 2-6H7, reamed SE: Stroke end ME: Mechanical end Detail view of T-slot at G base Dimension and Mass by Stroke Detail view of base installation part Stroke Effective stroke at minimum span Weight (kg) 12. Appendix * The brake-equipped type is longer in 25.5mm and heavier in 0.3kg

114 ISA-SYM, ISPA-SYM 2-6H7, reamed, depth 10 (tolerance for reamed hole pitch 0.02 mm) 4-M6, depth 16 Cable joint connector *1 2-M3, depth 6 (same on the opposite side) Home E-M6, depth H7, reamed, depth 10 At least 100 or more SE: Stroke end ME: Mechanical end 12. Appendix A Detail view of T-slot at G base Reference surface Detail view of A Dimension and Mass by Stroke Stroke Weight (kg) * The brake-equipped type is longer in 27mm and heavier in 0.5kg

115 ISA-SZM, ISPA-SZM 2-6H7, reamed, depth 10 (tolerance for reamed hole pitch 0.02 mm) 4-M6, depth 20 Cable joint connector *1 2-M3, depth 7 (same on the opposite side) Home At least 100 or more 4-6H7, reamed 12-M6, depth 16 SE: Stroke end ME: Mechanical end A Detail view of T-slot at G base Reference surface Detail view of A 12. Appendix Dimension and Mass by Stroke Stroke Weight (kg)

116 ISA-MXM-100, ISPA-MXM-100 F-9 drill, 16 counterbores, depth 1 2-8H7, reamed, depth 10 (tolerance for reamed hole pitch 0.02 mm) 4-M6, depth 20 4-M8, depth H10, reamed (back) Cable joint connector *1 2-M3, depth 6 (same on the opposite side) Home At least 100 or more SE: Stroke end ME: Mechanical end 12. Appendix * The brake-equipped type is longer in 27mm and heavier in 0.5kg. (with brake) (with brake) A Reference surface Detail view of A Detail view of T-slot at G base Detail view of base installation part Dimension and Mass by Stroke Stroke Weight (kg) Stroke Weight (kg)

117 ISA-MXM-100, ISPA-MXM-100 Double Slider F-9 drill, 16 counterbores, depth 1 2-8H7, reamed, depth 10 4-M6, depth 20 4-M8, depth H7, reamed (back) 275 (At minimum span) 2-M3, depth 6 (same on the opposite side) 35 (Minimum span) Detail view of base installation part Detail view of T-slot at G base Dimension and Mass by Stroke Stroke Effective stroke at minimum span Weight (kg) 12. Appendix Stroke Effective stroke at minimum span Weight (kg) * The brake-equipped type is longer in 27mm and heavier in 0.5kg

118 ISA-MXM-200, ISPA-MXM-200 F-9 drill, 16 counterbores, depth 1 2-8H7, reamed, depth 10 (tolerance for reamed hole pitch 0.02 mm) 4-M6, depth 20 4-M8, depth H7, reamed (back) Cable joint connector *1 2-M3, depth 6 (same on the opposite side) Home At least 100 or more SE: Stroke end ME: Mechanical end 12. Appendix * The brake-equipped type is longer in 27mm and heavier in 0.5kg. (with brake) (with brake) A Reference surface Detail view of A Detail view of T-slot at G base Detail view of base installation part Dimension and Mass by Stroke Stroke Weight (kg) Stroke Weight (kg)

119 ISA-MXM-200, ISPA-MXM-200 Double Slider F-9 drill, 16 counterbores, depth 1 2-8H7, reamed, depth 10 4-M6, depth 20 4-M8, depth H7, reamed (back) 2-M3, depth 6 (same on the opposite side) (Minimum span) (At minimum span) Detail view of base installation part (2:1) Detail view of T-slot at G base (2:1) Dimension and Mass by Stroke Stroke Effective stroke at minimum span Weight (kg) 12. Appendix Stroke Effective stroke at minimum span Weight (kg) * The brake-equipped type is longer in 27mm and heavier in 0.5kg

120 ISA-MXMX, ISPA-MXMX H-9 drill counterbores, 16 counterbores, depth 1 2-8H7, reamed (back) 2-8H7, reamed, depth 10 (tolerance for reamed hole pitch 0.02 mm) 4-M6, depth 20 4-M8, depth 20 Cable joint connector *1 2-M3, depth 6 (same on the opposite side) Home At least 100 or more 12. Appendix A Detail view of T-slot at J base Dimension and Mass by Stroke Stroke Detail view of base installation part Reference surface Detail view of A SE: Stroke end ME: Mechanical end Weight (kg) * The brake-equipped type is longer in 27mm and heavier in 0.5kg

121 ISA-MYM-100, ISPA-MYM H7, reamed, depth 10 (tolerance for reamed hole pitch 0.02 mm) 4-M6, depth 20 4-M8, depth 20 Cable joint connector *1 2-M3, depth 6 (same on the opposite side) Home A At least 100 or more 2-8H7, reamed, depth 10 F-M8, depth 20 Provide a sufficient dimension. Reference surface 12. Appendix Detail view of A Detail view of T-slot at E base SE: Stroke end ME: Mechanical end Dimension and Mass by Stroke Stroke Weight (kg) Stroke Weight (kg) * The brake-equipped type is longer in 27mm and heavier in 0.5kg

122 ISA-MYM-200, ISPA-MYM H7, reamed, depth 10 (tolerance for reamed hole pitch 0.02 mm) 4-M6, depth 20 4-M8, depth 20 Cable joint connector *1 2-M3, depth 6 (same on the opposite side) Home A At least 100 or more 2-8H7, reamed, depth 10 F-M8, depth Appendix Reference surface Detail view of A Detail view of T-slot at E base SE: Stroke end ME: Mechanical end Dimension and Mass by Stroke Stroke Weight (kg) Stroke Weight (kg) * The brake-equipped type is longer in 27mm and heavier in 0.5kg

123 ISA-MZM-100, ISPA-MZM H7, reamed, depth 10 (tolerance for reamed hole pitch 0.02 mm) 4-M6, depth 20 4-M8, depth 20 Cable joint connector *1 2-M3, depth 6 (same on the opposite side) Home A At least 100 or more 12-M8, depth H7, reamed Reference surface Detail view of A Dimension and Mass by Stroke Detail view of T-slot at G base SE: Stroke end ME: Mechanical end 12. Appendix Stroke Weight (kg) Stroke Weight (kg) If the stroke is 700 or longer, use the base of the MXM type. For the installation dimensions, refer to the drawing on p

124 ISA-MZM-200, ISPA-MZM H7, reamed, depth 10 (tolerance for reamed hole pitch 0.02 mm) 4-M6, depth 20 4-M8, depth 20 Cable joint connector *1 2-M3, depth 6 (same on the opposite side) Home A At least 100 or more 12-M8, depth H7, reamed 12. Appendix Reference surface Detail view of A Dimension and Mass by Stroke Detail view of T-slot at G base SE: Stroke end ME: Mechanical end Stroke Mass (kg) Stroke Mass (kg) If the stroke is 700 or longer, use the base of the MXM type. For the installation dimensions, refer to the drawing on p

125 ISA-LXM-200, ISPA-LXM-200 F-9 drill, 16 counterbores, depth 1 2-8H7, reamed (back) 2-8H7, reamed, depth 10 (tolerance for reamed hole pitch 0.02 mm) 8-M8, depth 20 Cable joint connector *1 2-M3, depth 6 (same on the opposite side) Home A At least 100 or more Detail view of A SE: Stroke end ME: Mechanical end * The brake-equipped type is longer in 27mm and heavier in 0.8kg. (with brake) (with brake) Reference surface Detail view of A Detail view of T-slot at G base Detail view of base installation part 12. Appendix Dimension and Mass by Stroke Stroke Weight (kg) Stroke Weight (kg)

126 ISA-LXM-200, ISPA-LXM-200 Double Slider F-9 drill, 16 counterbores, depth 1 2-8H7, reamed (back) 2-8H7, reamed, depth 10 8-M8, depth 20 2-M3, depth 6 (same on the opposite side) 335 (At minimum span) 35 (Minimum span) Detail view of T-slot at G base (2:1) 12. Appendix Detail view of base installation part (2:1) Dimension and Mass by Stroke Stroke Effective stroke at minimum span Weight (kg) Stroke Effective stroke at minimum span Weight (kg) * The brake-equipped type is longer in 27mm and heavier in 0.8kg

127 ISA-LXM-400, ISPA-LXM-400 F-9 drill, 16 counterbores, depth 1 2-8H7, reamed (back) 2-8H7, reamed, depth 10 (tolerance for reamed hole pitch 0.02 mm) 8-M8, depth 20 Cable joint connector *1 2-M3, depth 6 (same on the opposite side) Home At least 100 or more SE: Stroke end ME: Mechanical end (with brake) (with brake) A 12. Appendix Reference surface Detail view of A Detail view of T-slot at G base Detail view of base installation part Dimension and Mass by Stroke Stroke Weight (kg) Stroke Weight (kg) * The brake-equipped type is longer in 27mm and heavier in 0.8kg

128 ISA-LXM-400, ISPA-LXM-400 Double Slider F-9 drill, 16 counterbores, depth 1 2-8H7, reamed (back) 2-8H7, reamed, depth 10 8-M8, depth 20 2-M3, depth 6 (same on the opposite side) 335 (At minimum span) 35 (Minimum span) Detail view of T-slot at G base (2:1) 12. Appendix Detail view of base installation part (2:1) Dimension and Mass by Stroke Stroke Effective stroke at minimum span Weight (kg) Stroke Effective stroke at minimum span Weight (kg) * The brake-equipped type is longer in 27mm and heavier in 0.8kg

129 ISA-LXMX-200, ISPA-LXMX-200 K-9 drill, 16 counterbores, depth 1 2-8H7, reamed (back) 8-M8, depth H7, reamed, depth 10 (tolerance for reamed hole pitch 0.02 mm) Cable joint connector *1 2-M3, depth 6 (same on the opposite side) Home SE: Stroke end ME: Mechanical end At least 100 or more At least 100 or more Reference surface A Detail view of A Detail view of base installation part Detail view of T-slot at G base 12. Appendix Dimension and Mass by Stroke Stroke Mass (kg) Stroke * The brake-equipped type is longer in 27mm and heavier in 0.8kg. Mass (kg)

130 ISA-LXMX-400, ISPA-LXMX-400 K-9 drill, 16 counterbores, depth 1 2-8H7, reamed (back) 8-M8, depth H7, reamed, depth 10 (tolerance for reamed hole pitch 0.02 mm) Cable joint connector *1 2-M3, depth 6 (same on the opposite side) Home SE: Stroke end ME: Mechanical end At least 100 or more A 12. Appendix Reference surface Detail view of A Detail view of base installation part Detail view of T-slot at G base Dimension and Mass by Stroke Stroke Weight (kg) Stroke * The brake-equipped type is longer in 27mm and heavier in 0.8kg. Weight (kg)

131 ISA-LXUWX-200, ISPA-LXUWX-200 K-9 drill, 16 counterbores, depth 1 2-8H7, reamed (back) 2-8 (hole) 4-M8, depth H7, reamed, depth 10 (tolerance for reamed hole pitch 0.02 mm) 4-M8, depth 20 Cable joint connector *1 2-M3, depth 6 (same on the opposite side) Home At least 100 or more SE: Stroke end ME: Mechanical end A Reference surface Dimension and Mass by Stroke Stroke Detail view of A Detail view of base installation part Detail view of T-slot at G base 12. Appendix Mass (kg) Stroke * The brake-equipped type is longer in 27mm and heavier in 0.8kg. Mass (kg)

132 ISA-LXUWX-400, ISPA-LXUWX-400 K-9 drill, 16 counterbores, depth 1 2-8H7, reamed (back) 2-8 (hole) 4-M8, depth H7, reamed, depth 10 (tolerance for reamed hole pitch 0.02 mm) 4-M8, depth 20 Cable joint connector *1 2-M3, depth 6 (same on the opposite side) Home At least 100 or more SE: Stroke end ME: Mechanical end A 12. Appendix Reference surface Detail view of A Dimension and Mass by Stroke Detail view of base installation part Detail view of T-slot at G base Stroke Weight (kg) Stroke * The brake-equipped type is longer in 27mm and heavier in 0.8kg. Weight (kg)

133 ISA-LYM-200, ISPA-LYM H7, reamed, depth 10 (tolerance for reamed hole pitch 0.02 mm) 8-M8, depth 20 Cable joint connector *1 2-M3, depth 6 (same on the opposite side) Home 8-M8, depth H7, reamed, depth 10 At least 100 or more SE: Stroke end ME: Mechanical end Reference surface A 12. Appendix Detail view of A Detail view of T-slot at E base Dimension and Mass by Stroke Stroke Weight (kg) Stroke Weight (kg) * The brake-equipped type is longer in 27mm and heavier in 0.8kg

134 ISA-LYM-400, ISPA-LYM H7, reamed, depth 10 (tolerance for reamed hole pitch 0.02 mm) 8-M8, depth 20 Cable joint connector *1 2-M3, depth 6 (same on the opposite side) Home At least 100 or more 8-M8, depth H7, reamed, depth Appendix A Reference surface Detail view of A Detail view of T-slot at E base SE: Stroke end ME: Mechanical end Dimension and Mass by Stroke Stroke Weight (kg) Stroke Weight (kg) * The brake-equipped type is longer in 27mm and heavier in 0.8kg

135 ISA-LZM-200, ISPA-LZM H7, reamed, depth 10 (tolerance for reamed hole pitch 0.02 mm) 8-M8, depth 20 Cable joint connector *1 2-M3, depth 6 (same on the opposite side) Home At least 100 or more 4-8H7, reamed 12-M8, depth 20 SE: Stroke end ME: Mechanical end Reference surface A 12. Appendix Detail view of A Detail view of T-slot at E base Dimension and Mass by Stroke Stroke Mass (kg) Stroke Mass (kg) If the stroke is 700 or longer, use the base of the LXM type. For the installation dimensions, refer to the drawing on p

136 ISA-LZM-400, ISPA-LZM M8, depth H7, reamed, depth 10 (tolerance for reamed hole pitch 0.02 mm) Cable joint connector *1 2-M3, depth 6 (same on the opposite side) Home 4-8H7, reamed At least 100 or more 12-M8, depth 20 SE: Stroke end ME: Mechanical end 12. Appendix A Reference surface Detail view of A Detail view of T-slot at E base Dimension and Mass by Stroke Stroke Mass (kg) Stroke Mass (kg) If the stroke is 700 or longer, use the base of the LXM type. For the installation dimensions, refer to the drawing on p

137 ISA-WXM-600, ISPA-WXM-600 Option code for exiting cables from right: A3 Stroke 2-8H7, reamed, depth 10 Home 8-M8, depth 30 Cable joint connector *1 2-M5, depth 10 same on the opposite side Option code for exiting cables from left: A1 L (stroke + 440) At least 100 or more 2-8H7, reamed 2-8H7, reamed SE: Stroke end ME: Mechanical end Reference surface Detail view of A Detail view of base installation hole Detail view of P 12. Appendix Dimension and Mass by Stroke Stroke Weight (kg) * The appearance diameters are the same if equipped with brake. The weight increases in 0.5kg

138 ISA-WXM-750, ISPA-WXM-750 Option code for exiting cables from right: A3 Stroke 2-8H7, reamed, depth 10 Home 8-M8, depth 30 Cable joint connector *1 2-M5, depth 10 same on the opposite side Option code for exiting cables from left: A1 L (stroke + 460) At least 100 or more 2-8H7, reamed 2-8H7, reamed SE: Stroke end ME: Mechanical end 12. Appendix Reference surface Detail view of P Detail view of A Detail view of base installation hole Dimension and Mass by Stroke Stroke Weight (kg) * The appearance diameters are the same if equipped with brake. The weight increases in 0.5kg

139 ISA-WXMX-600, ISPA-WXMX-600 Option code for exiting cables from right: A3 Stroke 2-8H7, reamed, depth 10 Home 8-M8, depth 30 Cable joint connector *1 2-M5, depth 10 same on the opposite side Option code for exiting cables from left: A1 L (stroke +666) At least 100 or more 2-8H7, reamed 2-8H7, reamed SE: Stroke end ME: Mechanical end Reference surface Detail view of A Detail view of base installation hole Detail view of P 12. Appendix Dimension and Mass by Stroke Stroke Weight (kg) Stroke Weight (kg) * The appearance diameters are the same if equipped with brake. The weight increases in 0.5kg

140 ISA-WXMX-750, ISPA-WXMX-750 Option code for exiting cables from right: A3 Stroke 2-8H7, reamed, depth 10 Home 8-M8, depth 30 Cable joint connector *1 2-M5, depth 10 (same on the opposite side) Option code for exiting cables from left: A1 L (stroke + 666) At least 100 or more 2-8H7, reamed 2-8H7, reamed SE: Stroke end ME: Mechanical end 12. Appendix Reference surface Detail view of A Detail view of base installation hole Detail view of P Dimension and Mass by Stroke Stroke Weight (kg) Stroke Weight (kg) * The appearance diameters are the same if equipped with brake. The weight increases in 0.5kg

141 12.2 How to Perform An Absolute Encoder Reset (Absolute Specification) X-SEL Controller When the absolute-encoder battery voltage of the X-SEL Controller is abnormal or when the battery or encoder cable is disconnected, an encoder battery error will occur and an absolute encoder reset must be performed. This chapter explains how to perform an absolute encoder reset using the PC software. For the absolute-encoder reset method using the teaching pendant, refer to the operation manual for the teaching pendant. [1] Preparation (1) PC A PC in which IAI s X-SEL PC software (X_SEL.exe) has been installed (2) Connection cable (the cable supplied with the PC software) RS232C cross cable (PC-end: female 9-pin, Controller-end: male 25-pin) (3) All adjustments other than the absolute reset must have been completed. [2] Procedure (1) Turn off the X-SEL Controller power. Turn on the PC power and wait for the operating system to be started. (2) Plug the 9-pin, D-sub connector on the connection cable into the COM port on the PC, and plug the 25-pin, D-sub connector into the 25-pin COM port on the controller. (3) Turn on the controller power. If an encoder battery error is present but no other adjustments are pending, the 7-segment LED display will show E914 or ECA2 indicating that the controller has detected an encoder battery error. (4) Start the X-SEL PC software (X_SEL.exe) on the PC. The following explains the operation steps in the X-SEL PC software. (5) When the [Connection Confirmation] dialog box is displayed, select the port name you are using on the PC. Click the [OK] button. (The software will automatically detect the baud rate.) 12. Appendix

142 (6) The X-SEL PC software window will be displayed. Clicking the [OK] button will clear the error message. 12. Appendix (7) From the [Monitor (M)] menu, select [Detailed Error Information (E)] to check the current error status. In the case of an encoder battery error, the following will be displayed (when axis 4 is using an absolute encoder). After checking the error status, close the [Detailed Error Information] window

143 (8) From the [Controller (C)] menu, select [Absolute Reset (A)]. (9) When a [Warning] dialog box is displayed, click the [OK] button. (10) The [Abs. Encoder Reset] dialog box will be displayed. Click hear and the axis number changes. Select an axis that requires an absolute reset. 12. Appendix (11) Clicking the [Encoder Rotation Data Reset 1] button will display a [Warning] dialog box. Click the [Yes] button. 135

144 (12) Another [Warning] dialog box will be displayed. Click the [Yes] button. (13) When the processing of encoder rotation data reset 1 is complete, the red arrow will move to the next item. Press the following processing buttons one by one (the red arrow will move to the next item when each process is completed): 1. Reset Controller Error 2. Servo ON 3. Returning Home 4. Servo OFF (Note) In the PC software version is or later, encoder rotation data reset 2 will be performed while the servo power is on. Accordingly, the servo-off step will be skipped. 5. Encoder Rotation Data Reset Appendix When the processing of encoder rotation data reset 2 is complete, the red arrow will return to the position in (10). If you are performing an absolute encoder reset for another axis, select the target axis and perform the steps after (10). To close the [Abs. Encoder Reset] dialog box, click the [Close] button. (Note) If you must perform an absolute encoder reset for multiple axes, always perform steps (10) through (13) for all axes before performing the software reset in step (14). (14) From the [Controller (C)] menu, select [Software Reset (R)]

145 (15) When the [Confirmation] dialog box is displayed, click the [Yes] button and restart the controller. (Note) If operation is started without performing a software reset or reconnecting the power, the following errors may generate: Error No. C70, ABS coordinates not yet confirmed Error No. C6F, Home return not yet complete (16) If no other error is present, the controller s 7-segment LED display will show rdy. (17) This completes the absolute encoder reset. To redo the absolute encoder reset, exit the X-SEL PC software and repeat the procedure from the beginning. (Note) On some models, the current value may not become 0 mm after completing the absolute reset. However, this is not abnormal. For the coordinate values achieved upon completion of absolute reset, see the list of models below. Model Lead Current value upon completion of absolute reset RCS2-SA7C (R) RCS2-SS7C (R) RCS2-SS8C (R) RCS2-RA5C (R) * On all other models, the current value will become 0 after the absolute reset. 12. Appendix

146 SCON Controllers [1] Connect the motor cable and encoder cable to the controller. [2] Connect the host PLC to the PIO connector using the supplied flat cable. [3] If two or more axes are linked together, set the address of each axis using the axis number setting switches. [4] Plug in the battery connector. [5] Supply the 24-V PIO power from the flat cable. [6] If the actuator has a brake, turn on the 24-V power for the brake. [7] Supply the control power and motor power at the same time (by distributing from the same power supply). * The alarm output signal (*ALM) will turn OFF, alarm code 0EE or 0EF will appear, PIO alarm output signals (PM8 to PM1) will become [1101], and ALM LED will turn on. Also, the message Absolute encoder error (2) will appear on the PC or teaching pendant screen, if a PC/teaching pendant is already connected. [8] Connect a PC or teaching pendant to set the minimum required initial parameters. Parameter No. 25, PIO pattern selection Air cylinder type: Parameter No. 27, Move command type 12. Appendix [9] Reset the alarm. Operation on the teaching pendant CON-T: Press the [ERROR RESET] key. RCM-T/RCM-E: Press the BEGIN/END key. Operation in the PC software Select desired position data on the main screen, and then click the [ALARM] button. * The message Absolute encoder error (2) will disappear. Also, the alarm output signal (*ALM) will turn ON and alarm output signals (PM8 to PM1) will turn OFF. (Note) The 0EE and 0EF alarms cannot be reset via PIO. [10] Turn on the servo. Use the Servo ON function of the PC software or teaching pendant to turn on the servo. If the actuator enters a servo-locked state and the SV LED on the front face illuminates in green, the controller is normal. * If the ALM LED turns on, some abnormality is present. Refer to the alarm list. [11] Perform home return operation. Overview of operation on the teaching pendant CON-T: From *EDIT, select 4, Teach/Play Screen and then select 1, Jog Screen. Press the [HOME] key. RCM-T: Select the Edit/Teach screen, bring the cursor to *HOME in the sub display area, and then press the Enter key. RCM-E: Select the Edit/Teach screen, scroll until you see *HOME RETURN, and then press the Enter key

147 12.3 Adding Grease When the Screw Cover Cannot Be Removed (Not Covered under Warranty) How to add grease when the screw cover cannot be removed is explained. Since grease must be applied without visually confirming the guide, this method does not ensure reliable greasing. In other words, greasing cannot be guaranteed. Warning: If grease is to be added without removing the power, check the amount of grease applied. Failure to do so may result in the following problems: If too much grease is applied or the actuator is installed vertically with the motor at the bottom, grease may enter the motor and cause an encoder count error or other abnormality. Similarly when the brake is located at the bottom, grease may also enter the brake, consequently disabling the brake and causing the slider to drop Adding Grease to the Guide of the ISA/ISPA/IS/ISP (1) Applicable grease The following blend of grease has been applied before shipment from IAI (except for custom-order models). Idemitsu Kosan Daphne Eponex Grease No. 2 In addition to the above, corresponding grease blends are also available from each company. For details, inform the name of the above grease to the applicable manufacturer and request selecting a corresponding product. Examples of corresponding products include the following. Showa Shell Sekiyu Albania Grease No. 2 Mobil Sekiyu Mobilux Appendix

148 (2) How to add grease With the ISA-W, ISPA-W and ISP-W types, the guide can be greased according to the method explained below. (Note 1) To make sure grease is applied to the guide, open the screw cover and add grease from the grease nipple. (Note 2) With all models other than the ISA-W, ISPA-W and ISP-W, open the screw cover and add grease from the grease nipple. [1] Turn the power OFF. Take an appropriate amount of grease on your finger, insert the finger from the space below the screw cover, and apply grease to the guide. Caution: Wear a finger cot when working. Working with a bare hand may cut your finger on the edge. 12. Appendix Apply grease in the area of each guide as shown in the photograph below. (The photograph shows a condition after removing the screw cover.) Guide Guide [2] Move the slider back and forth several times to let the grease spread evenly. Caution: If grease is not applied properly, grease may run out and an overload error or other alarm may generate. In case the grease got into your eye, immediately go see the doctor to get appropriate care. After finishing the grease supply work, wash your hands carefully with water and soap to rinse the grease off. 140

149 Adding Grease to the Ball Screw of the ISA/ISPA/IS/ISP (1) Ball screw grease Use lithium spray grease. Wako Chemicals Spray Grease No. A161 or equivalent Warning: Never use fluorine-based grease. If fluorine-based grease is mixed with lithium-based grease, the grease not only loses its performance but it can actually damage the actuator. 12. Appendix

150 (2) How to add grease The ball screw can be greased according to the method explained below. (Note) To make sure grease is applied to the ball screw, open the screw cover and add grease from the grease nipple. [1] Apply grease to the ball screw by spraying grease from the space below the screw cover. Apply grease in the area of the ball screw as shown in the photograph below. (The photograph shows a condition after removing the screw cover.) 12. Appendix Ball screw (Note) Be careful not to apply too much grease to cause dripping. Do this in several steps by applying a small amount each time and checking if a sufficient amount has been applied. [2] Move the slider back and forth several times to let the grease spread evenly. Caution: In case the grease got into your eye, immediately go to see the doctor to get an appropriate care. After finishing the grease supply work, wash your hands carefully with water and soap to rinse the grease off. 142