Before Use Thank you for purchasing our product. This Operation Manual describes all necessary information 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 CD or DVD that comes with the product contains instruction manuals for IAI products.
CE Marking If a compliance with the CE Marking is required, please follow Overseas Standards Compliance Manual (ME0287) that is provided separately.
Table of Contents Safety Guide············································································································ 1 Caution in Handling ································································································· 8 Names of the Parts ·································································································· 9 1. 2. Specifications Check······················································································· 11 1.
7. Life·················································································································· 65 8. Warranty ········································································································· 66 8.1 8.2 8.3 8.4 8.5 8.
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. No.
No. 2 2 Operation Description Transportation 3 Storage and Preservation 4 Installation and Start Description Ɣ When carrying a heavy object, do the work with two or more persons or utilize equipment such as crane. Ɣ 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.
No. 4 Operation Description Installation and Start Description (2) Cable Wiring Ɣ Use our company’s genuine cables for connecting between the actuator and controller, and for the teaching tool. Ɣ 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.
No. 4 5 4 Operation Description Installation and Start Teaching Description (4) Safety Measures Ɣ 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. Ɣ 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.
No. 6 7 Operation Description Trial Operation Automatic Operation Description Ɣ 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. Ɣ After the teaching or programming operation, perform the check operation one step by one step and then shift to the automatic operation.
No. 8 9 Operation Description Maintenance and Inspection 10 Modification and Dismantle Disposal 11 Other 6 Description Ɣ 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. Ɣ Perform the work out of the safety protection fence, if possible.
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 This indicates an imminently hazardous situation which, if the Danger product is not handled correctly, will result in death or serious injury.
Caution in Handling 1. Do not have the settings of speed and acceleration/deceleration exceeding the rated values. An operation with speed and acceleration/deceleration beyond the allowable range may cause an abnormal noise, vibration, malfunction or shortened life. When having an interpolating operation for combined axes, set the smallest value among the combined axes for each of speed and acceleration/deceleration settings. 2. Set the allowable load moment within the allowable range.
Names of the Parts In this manual, the right and left sides of the actuator are expressed in the way it is placed horizontally as shown in the figure below, and is looked at from the motor side.
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1. Specifications Check 1.1 Product Check 1.1.1 No. 1 1. Specifications Check The standard configuration of this product is comprised of the following parts. See the component list for the details of the enclosed components. If you find any broken or missing parts, contact your local IAI distributor. Parts Part Name Main Body Model Refer to “How to read the model plate”, “How to read the model No.
1. Specifications Check 1.1.2 Operation Manuals related to this product, which are contained in the DVD. Shown below is a list of the operation manuals for the controllers related to this product which is recorded in Operation Manual (DVD). (1) XSEL-J/K Controller No.
(4) SCON Controller No. 1.1.3 Manual No.
1.1.4 How to read the model No. 1.
1.2 Specification Restriction on Speed (Unit: mm/s) Motor Type Type [W] 300 400 60 NM 100 Type WM Type LM HM Motor Type [W] 100 200 Motor Type [W] 400 400 300 400 500 600 Stroke [mm] 600 700 800 1 to 1250 1 to 1250 1. Specifications Check [1] Max. Speed There is a limit in the maximum speed of the actuators. 900 1000 Stroke [mm] 800 1000 1500 2000 2500 1 to 1250 1 to 1250 Stroke [mm] 1000 1500 2000 2500 3000 1 to 1250 1 to 2000 [2] Max.
[3] Driving System and Position Detector 1. Specifications Check Type NM NM WM WM LM HM [4] Motor Type [W] 60 100 100 200 400 400 Drive system 16384*1 Timing belt Positioning Accuracy Item Positioning Repeatability Lost Motion 16 No. of Encoder Pulses Specification ± 0.08mm 0.
1.3 Option 1.3.1 AQ Seal 1.3.2 Creep Sensor It is a sensor to enable a high-speed home-return operation. The model code is indicated with a C. 1.3.3 Home Limit Switch In ordinary home-return operation, “pressing method” which the actuator is pressed against the stopper and detects the Z-phase after reversed is adopted. “Home limit switch” is an option that does not adopt this pressing method but adopts a proximity sensor to perform the home-return operation. The model code is indicated with an L.
1. Specifications Check 1.4 Motor • Encoder Cables 1.4.1 Standard The cables are in common for the actuators no matter the model type. The cables differ depending on the corresponding controller.
2) Encoder Cable CB-X-PAƑƑƑ 1.
CB-X-LCƑƑƑ 1.
4) Encoder Cable CB-X1-PAƑƑƑ 1.
CB-X1-PLAƑƑƑ 1.
1.4.2 CE Type (Option Model code: EU) 1. Specifications Check The cables are in common for the actuators no matter the model type. The cables differ depending on whether it is with or without LS.
CB-XEU1-PAƑƑƑ 1. Specifications Check (φ8) 2) Encoder Cable Wiring AWG26 (Soldered) Color Signal No. - - 10 - - 11 - E24V 12 OV 26 - LS 25 - CREEP 24 - OT 23 - RSV - 9 18 - - 19 1 SD Orange - A+ 1 2 SD Green - A- 2 3 - - - B+ 3 4 - - - B- 4 5 - - - Z+ 5 6 - - - Z- 6 7 - - 7 8 9 - - Orange SRD+ Green SRDPurple BAT+ Gray No.
CB-XEU1-PAƑƑƑ Wiring Color - Signal - No. 1 Signal E24V Color White/Blue No. 10 2 OV White/Yellow 3 - - 11 4 LS White/Red CREEP White/Black White/Blue E24V 12 5 White/Yellow OV 13 6 OT White/Red LS Wiring AWG26 White/Purple (Solderless) 26 7 RSV White/Gray White/Black CREEP 25 8 - - White/Purple OT 24 9 - - White/Gray RSV 23 10 - - - - 9 - - 18 No.
2. Installation 2. Installation 2.1 Transportation [1] Handling of the Robot Pay attention to the following when carrying an actuator by itself. (1) Handling of the Packed Product Unless otherwise specified, the single axes at the delivery are packaged individually. Please concern the handling of the unit so you would not hit or drop it while carrying. x An operator should never attempt to carry a heavy package on their own.
[3] Handling of the Robot Mounted on Mechanical Equipment (System) When peripheral devices were attached by the customer and the unit is to be carried, also follow the instructions described in [5.2.2 handling in unpackaged condition] for appropriate handling. 27 2. Installation (2) Handling after Unpackaged After unpackaged, handle the product that axes were attached in IAI factory following the instructions below: x Fix the sliders during transportation so they would not move accidently.
2.2 Installation and Storage Environment 2. Installation [1] Installation Do not use this product in the following environments. It is generally the environment where a worker can work without any protection gear. Also make sure to keep enough work space necessary for maintenance.
2.3 How to Install Shown below is how to install the actuators to the machinery equipment. 2.3.1 Orientation of the Actuator Installation 2. Installation Shown below are the basic concepts for the product attachment. Pay special attention when deciding how to install the product (Except with custom-order models).
2.3.2 Installation 2. Installation [1] Installation of Main Unit (1) Datum Surface x The mounting table should have sufficient rigidity to avoid generating vibration. x The surface where the actuator will be mounted should be a machined surface or that with an accuracy equivalent to it, and the flatness should be 0.05mm or below. x Have enough space for the maintenance work.
(2) Mounting method x There is a set hole on the actuator base. Fix the actuator using this set hole. x The belt cover can be removed using the hexagon wrench with the distance to the opposite side of 2 mm. x For the set bolt, use hexagon socket head cap screw with the intensity classification of 10.9 or more and fasten it with the attached special washer. 2. Installation Model S Type M Type A 50mm 70mm B 7 9 C 5mm 6mm Mounting screw M6 M8 Caution: Make sure to use the attached special washer.
2. Installation [2] Load Installation x Do not exceed the load shown in the load specification column. Please make note of the slider moment, allowable overhang length and the load weight. x When it is used as the Y-axis in the cantilever X-Y combination, it is easy to deform the base itself. Therefore, use it with the Mc moment lowered to 1/2 or less of the rated value. (Refer to table below.) Allowable Load Moment Model Ma S Type 28.4N·m (2.9kgf·m) M Type 69.6N·m (7.
Slider Tap Hole Diameter and Reamer Diameter Model S Type M Type Tapped Holes M6 M6 M8 90mm Reamed Hole I6H10 Reamed Depth 10mm 120mm I8H10 10mm Tap depth A B C 20mm 20mm 20mm 70mm 90mm 70mm - 2. Installation x There are tapped holes in the slider where you can affix the payload. The way to affix follows the installation of the main unit. x If you are anchoring the slider and moving the main body, attach the slider using the tapped holes.
[3] Mounting and the T-Slot (Option) Bolt 7.3 4.3 2. Installation There is a T-groove on the side surface of the base provided to mount a connector box or cable track retainer that is necessary when assembling the system. When using the cable wiring kit for assembly, utilize the T-groove for mounting. Use the slots as necessary to mount sensors or to anchor cables. 4.5 Space between bolt tip 1.
3. Connection to the controller For the controller, only the dedicated controller manufactured by our company can be used. Use the dedicated cable enclosed in the package when connecting the actuator and the controller. [1] Standard cable [Connection to the XSEL-J/K controller] 3.
[2] CE Compliance Cable [Connection to the XSEL-P/Q, SSEL and SCON controller] Dedicated Cable (Connect actuator with the dedicated controller) 3. Connection to the controller Actuator r r Dedicated Controller XSEL-P/Q, SSEL, SCON x Motor Cable B-XEU-MAƑƑƑ x Encoder Cable CB-XEU1-PAƑƑƑ x Encoder Cable with LS CB-XEU1-PLAƑƑƑ ƑƑƑ shows the cable length. The max. length should be 30m.
Warning : For wiring, please follow the warnings stated below. When constructing a system as the machinery equipment, pay attention to the wiring and connection of each cable so they are conducted properly. Not following them may cause not only a malfunction such as cable breakage or connection failure, or an operation error, but also electric shock or electric leakage, or may even cause a fire. x Make sure to turn the power off in the process of power line or cable connection or disconnection.
3. Connection to the controller x Do not let the cable bend, kink or twist. x Do not pull the cable with a strong force. x Pay attention not to concentrate the twisting force to one point on a cable. x Do not pinch, drop a heavy object onto or cut the cable. x When a cable is fastened to affix, make sure to have an appropriate force and do not tighten too much.
x PIO line, communication line, power and driving lines are to be put separately from each other and do not tie them together. Arrange so that such lines are independently routed in the duct. 3. Connection to the controller x If using a cable track, make sure to use robot cables so the cables do not get twisted or entangled inside the cable track or flexible tube, and also make the cables free to avoid the cables getting tied. (Make sure the cables do not get pulled when being bent.
4. Setting the Home Position [1] The Principle of the Homing Operation 4. Setting the Home Position The Actuator performs homing in the following manner: 1) The moving direction is determined by the parameters set by the homing command. 2) It detects the mechanical end with the software in the home return operation. 3) The slider reverses direction when this end is reached and the place where the Z-phase signal is detected becomes the reference point.
5㧚 5.1 Maintenance inspection Inspection Items and Inspection Schedule Have maintenance inspections following the intervals below. 8 hours per day is assumed as operation condition Have inspections more frequently if the operation frequency is high for night and day continuous operation, etc. *1 5.
5.4 Internal Inspection Turn the power OFF. Remove the belt cover and pulley cover, and visually inspect the interior. Conduct he item below in the internal inspection. Main Body Guide Part 5.
5.6 (1) Grease Supply Applied Grease Use lithium grease no. 2. The following grease is applied when the product is shipped out from IAI factory. Guide Idemitsu Kosan Daphne Eponex Grease No. 2 Apart from above, there are equivalent sorts of grease sold in the market. For details contact a grease supplier, provide the grease name shown above and ask them to select an equivalent. Listed below are some equivalents for an example. Alvania Grease No.
5.7 How to Inspect the Timing Belt 5. Maintenance inspection Visual inspection is done by removing the belt cover and pulley cover. Since the timing belt wear largely depends on the operational requirements, as a rule, replacement period can not be determined. Generally speaking, the life span of the timing belt is the life span of a couple hundred thousand revolutions. As an actual replacement period standard, the timing belt is replaced when the following symptoms are confirmed.
5.7.1 Belt Tension Adjustment Method Since inadequate belt tension will lead to location drift due to gear skipping, noise occurrence as well as cause the motor to breakdown, proper tension adjustment is required. [How to Adjust the Timing Belt:] 5. Maintenance inspection Remove the pulley cover, loosen the 4 tension adjustment bolts and lift the motor cover up to place the appropriate axis load onto the belt, and tighten the 4 tension adjustment bolts (see chart below).
[How to Adjust the Driver Belt Tension:] Driver belt tension adjustment is done using the front cover adjustment bolt. Since the adjustment bolt is fixed using the hexagonal nut, when adjusting, loosen the hexagonal nut, then adjust the adjustment bolt as is. Upon adjustment, tighten the hexagonal nut once again. Hexagonal nut (For loosening prevention: Use of 8 mm Spanner Wrench) Front cover 5.
5.8 How to Replace the Timing Belt [Items Required for Replacement Work] x x x x x x x x Replacement Driving Belt Packing Tape 8 mm Spanner Wrench Hexagon Wrench Set Push-Pull Gauge and Square Personal Computer or Teaching Pendant Tension Gauge (Tension of 10 kgf or more available) Strong Thread (or Long Harness Belt) 1) Loosen the tension adjusting bolt and replace the belt. Then, tighten the adjusting bolt until the specified tension value is reached. 2) Perform the homing operation.
5. Maintenance inspection 2) Remove the belt cover. Remove the machine set screw (4 locations) on the motor side and also the opposite side. (Use a hexagon wrench with the distance to the opposite side of 2 mm). 3) Loosen the belt tension until the pulley is turned without making contact. • Fix the hexagon nut using the 8 mm spanner wrench. 48 • Loosen the adjusting bolt.
4) Remove the belt holding plate (2 locations). (Use a hexagon wrench with the distance to the opposite side of 3 mm for IF-3 or 4 mm for IF-M). 5.
5) Replace the belt. • Connect the replacement belt to the current belt using the packing tape. 5. Maintenance inspection Replacement Belt Current Belt • Align the both ends of the replacement belts with the attachment teeth. (Confirm that they are aligned perfectly). • Pull out the current belt. Current Belt Replacement Belt • Separate the replacement belt from the current belt. • Attach the belt holding plate (2 locations).
6) Adjust the belt tension until the specified tension value is reached. • Move the slider to the mechanism end on the motor side. Measure the distance from the slider side to the pulley center and mark the central position. Measure this distance and find the central position. 5. Maintenance inspection • Press the push-pull gauge against the central position and tighten the adjusting bolt so that the specified values for the deflection load and deflection are reached.
8) Adjust it to recover the home position. • Remove the pulley cover and loosen the bolt fixing the motor bracket using the hexagon wrenches with the distance to the opposite side of 3 mm and 4 mm. Then, slide the motor belt until the pulley is turned without making any contact. Use of Hexagon Wrench with the Distance to the Opposite Side of 3 mm 5.
9) Attach the pulley cover. 10) Turn on the power to the controller and perform the homing operation from the personal computer or teaching pendant. (In the case that the absolute encoder has been mounted, the absolute reset is required). Confirm the deviation from the original home position. If there is any deviation, adjust it using the home offset value in the parameters. 5.
5.9 Deceleration Belt Replacement [Items Required for Replacement Work] Replacement Deceleration Belt Hexagon Wrench Set Personal Computer or Teaching Pendant Tension Gauge (Tension of 10 kgf or more available) Ring-shaped Strong Thread (or Long Harness Belt) x x x x x 5. Maintenance inspection [Replacement Operation Outline] 1) Loosen the bolt fixing the motor bracket and replace the belt. 2) Perform the homing operation. Move the slider to the mechanism end and fix it.
2) Loosen the deceleration belt. Loosen the bolt fixing the motor bracket using the hexagon wrenches with the distance to the opposite side of 3 mm and 4 mm. Then, slide the belt until the pulley is turned without making any contact. Use of Hexagon Wrench with the Distance to the Opposite Side of 3 mm 5. Maintenance inspection Use of Hexagon Wrench with the Distance to the Opposite Side of 4 mm 3) Remove the deceleration belt. 4) Attach the new deceleration belt manually.
5. Maintenance inspection 5) Adjust it to recover the home position. 6) Adjust the belt tension. • Go the ring-shaped strong thread (or long harness belt) around the motor cover and pull it using the tension gauge. • Pull it with the specified tension and tighten the bolt. (At that time, take care so that the slider or motor shaft does not move). Tension: 5 kgf for IF-S and 10 kgf for IF-M 7) Attach the pulley cover.
5.10 Motor Replacement Process [Items Required for Replacement Work] x Motor for Replacemen (Refer to the right picture). (Confirm that the counter mark is attached). x Personal Computer or Teaching Pendant x Tension Gauge (Tension of 10 kgf or more available) x Strong Thread (or Long Harness Belt) x Hexagon Wrench Set x 5.5 mm Spanner Wrench and Phillips Type Screwdriver 1) Remove the deceleration belt and replace the motor. 2) Perform the homing operation.
[Procedure] 1) Confirm the motor shaft rotating direction when the slider is moved from the home position to the mechanism end. (The rotating direction varies depending on the motor installation position. Therefore, the confirmation is always required). • Confirm the motor shaft rotating direction. 5. Maintenance inspection • Remove the pulley cover. (Use a hexagon wrench with the distance to the opposite side of 1.5 mm for IF-S or 2 mm for IF-M).
5) Loosen the bolt fixing the motor bracket using the hexagon wrenches with the distance to the opposite side of 3 mm and 4 mm). Then, slide the belt. Then, the deceleration belt tension is loosened. Remove the deceleration belt from the pulley on the actuator side. 5. Maintenance inspection 6) Remove the motor.
5. Maintenance inspection 7) Attach the new motor. Then, turn the motor shaft specified amount to the returning direction to the mechanism end (direction confirmed at the beginning) from the counter mark. 8) Attach the deceleration belt. Press the slider against the mechanism end and fix it. Then, taking care so that the motor shaft does not move (refer to the above picture), put the bet on the pulley on the motor side, and then on the opposite side.
6.
IF-SA-100 6. External Dimensions 6.
6.3 IF-MA-200 6.
IF-MA-400 6. External Dimensions 6.
7. Life The product life is 10,000km (reference) when operating the actuator with the maximum allowable load moment. 7.
8. Warranty 8.1 Warranty Period One of the following periods, whichever is shorter: x 18 months after shipment from our factory x 12 months after delivery to a specified location x 2,500 operational hours 8. Warranty 8.2 Scope of the Warranty Our products are covered by warranty when all of the following conditions are met.
8.4 Limit in Responsibility (1) We shall assume no liability for any special damage, consequential loss or passive loss such as a loss of expected profit arising from or in connection with our product. (2) We shall not be liable for any program or control method created by the customer to operate our product or for the result of such program or control method. 8.5 Conditions of Conformance with Applicable Standards/Regulations, Etc., and Applications 8.
Change History Change History Revision Date 68 Description of Revision 2012.01 Ninth Edition Page 7 Note of available and not available added to attachment orientation 2012.07 Tenth Edition Whole manual layout has been revised and corrected 2012.12 Eleventh Edition Page 46 G = 0.0032L ĺ G = 0.
Manual No.: ME3618-11A (December 2012) Head Office: 577-1 Obane Shimizu-KU Shizuoka City Shizuoka 424-0103, Japan TEL +81-54-364-5105 FAX +81-54-364-2589 website: www.iai-robot.co.jp/ Technical Support available in USA, Europe and China Head Office: 2690 W.
