Linear units with spindle drive - Isel · 2019. 3. 7. · The isel-linear units LES4 – LES5 – LES6 are linear modules with ballscrew drives, which are ready to install. They are

© isel Germany AG, January 2018, english

Linear units with spindle drive

LES4 - LES5 – LES6

Assembly instructions with: - Installation instructions

- Maintenance instructions - Installation explanation

for a drive system (an incomplete machine as defined in the Machinery Directive 2006/42/EC)

Linear units with spindle drive LES 4, 5, 6

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About these assembly instructions Abbreviations MD = Machinery Directive 2006/42/EC LES = Linear unit with (ball circulation) spindle AC = Alternating current, AC servo motor (always synchronous motor) BDC = Brushed DC, brushed direct current (DC) servo motor BLDC = Brushless DC, brushless direct current (DC) servo motor PDF = Portable document format Terminology In these assembly instructions 'product' always refers to a linear unit with spindle drive Symbols used In these instructions you will find various symbols which are there to alert you to important information/facts and hazards.

Symbol Warning Meaning

Danger Warning of possible serious or fatal injuries to persons

Caution! Fatal Voltage !

The flash symbol is a clear warning of danger from electric current.

Not heeding this warning can lead to personal injuries with fatal consequences.

Warning, caution !

Warning of possible minor injuries to persons, of possible faults or destruction of the product or possible damage to property.

Not heeding the facts following this symbol (text, picture or table) can result in serious damage to property.

Important information or

note

Important information or note on how the product works.

Reading the safety guidelines

Before commissioning the linear units (as incomplete machines), working with them, or making any additions or modifications to the electrical installation, it is essential you read carefully:

the safety guidelines in these assembly instructions

the safety guidelines for electric drives and control systems in the instruction manual of the positioning module, drive controller, drive module or drive controls used.

Copyright © isel Germany AG, 2018 All rights reserved Although every care has been taken to avoid printing errors and mistakes, these cannot be ruled out. We would be grateful for any suggestions for improvements or information on possible mistakes or un-clear formulation of facts and illustrations.


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Note on CE conformity with incomplete machines: isel linear units comply with CE guidelines. They are classed as incomplete machines as defined in the Machinery Directive 2006/42/EC and therefore do not explicitly bear the CE mark. Only after the conformity assessment procedures for the machine have been completed is the (com-plete) machine or system in which these linear units are installed awarded the CE mark by the manu-facturer or distributor of the machine. All other machine parts and/or machine components to which the CE safety guidelines apply must not be commissioned until all the relevant requirements of Machinery Directive 2006/42/EC are met. isel Germany AG does not accept any responsibility for any modifications you make to the linear unit. Manufacturer: isel Germany AG

Bürgermeister-Ebert-Straße 40 D-36124 Eichenzell, Germany

Tel: +49 (0)6659 981-0

Fax: +49 (0)6659 981-776

Email: [email protected]

Internet: www.isel.com

Processing date of this documentation: June 2010 More documents from isel Germany AG: 'Nothing is so good it can't be improved upon.' In accordance with this motto, as the manufacturer, we are constantly improving all our manuals (including operating instructions and assembly instructions) at considerable cost to ourselves. We are committed to doing so since this is of benefit to both you as our customers and us: We want you to be able to work efficiently with the relevant manuals and find the information you are looking for quickly. Many details in the manuals are the result of information we have received from our customers. To support you, all the manuals are available to download in PDF format on our homepage:

https://www.isel.com/en/support-downloads/manuals.html

In your own interest:

Please read these assembly instructions carefully and keep them in a safe place. These instructions form an integral part of the product Linear Unit with Spindle Drive LES4 – LES5 – LES6, regardless of whether these instructions are supplied/available in the form of an electronic storage medium (as PDF file on a CD, DVD or memory stick) or as a printed version.

Please read and follow the safety guidelines in these assembly instructions.

mailto:[email protected]?subject=assembly%20instruction%20LES%204,%205,%206

https://www.isel.com/en/



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Contents

1 General information ........................................................................................................................ 4

1.1 SAFETY GUIDELINES....................................................................................................................................... 6 1.2 PROPER USE ................................................................................................................................................ 8 1.3 SCOPE OF DELIVERY ...................................................................................................................................... 8

2 Installation instructions and overview of functions .................................................................... 9

2.1 FUNCTIONS ................................................................................................................................................. 9 2.2 STRUCTURE/ASSEMBLY OF THE LINEAR UNIT ...................................................................................................... 9

3 Commissioning, general information ..........................................................................................28

4 Assembly/disassembly as individual components ...................................................................29

4.1 MOUNTING ON THE LINEAR GUIDE RAIL .......................................................................................................... 29 4.2 MOUNTING ON THE GUIDE SLIDES.................................................................................................................. 30

5 Fault list ..........................................................................................................................................31

6 Technical data ...............................................................................................................................32

6.1 MECHANICAL DATA .................................................................................................................................... 32 6.2 ELECTRICAL DATA ....................................................................................................................................... 34

7 Maintenance and cleaning ...........................................................................................................35

7.1 MAINTENANCE INSTRUCTIONS ...................................................................................................................... 35 7.2 CLEANING ................................................................................................................................................. 36

8 Decommissioning/disposal ..........................................................................................................36

9 CE Conformity ...............................................................................................................................37

10 Service ........................................................................................................................................37

11 Warranty .....................................................................................................................................38

12 Installation explanation according to MD 2006/42/EC ...........................................................39

13 Index .......................................................................................... Fehler! Textmarke nicht definiert.

14 Appendices ................................................................................................................................41

14.1 A1: ACCESSORIES ....................................................................................................................................... 41 14.2 A2: MISCELLANEOUS .................................................................................................................................. 43

1 General information

This manual contains all important information about the assembly/installation, commissioning and maintenance of your linear units. In addition, it provides information and important notes for your safety.

The isel-linear units LES4 – LES5 – LES6 are linear modules with ballscrew drives, which are ready to install. They are for use mainly in factory automation, handling technology and light machinery construc-tion. These linear units are available in different standard lengths and can be fitted with special direct motor connections. The many options for configuring and combining the units mean users can build a wide variety of con-structions to suit their requirements. Please note:


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The product is classed as an 'incomplete machine' and not a (complete) machine according to MD 2006/42/EC.


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1.1 Safety guidelines

The following guidelines on safety and danger are intended to protect you, third parties and the product. It is essential you follow them.

Operating environment

The product must not be directly exposed to moisture or water. The system (the machine/system in which the product is installed) is only suitable for use in dry indoor areas. When moving the product from a cold to warm conditions, allow the product to adjust to the change in temperature for a few hours before operation, to avoid possible damage from condensation. Do not install the product near devices which generate powerful magnetic fields. This could disturb its functions. Avoid environments exposed to direct solar radiation, considerable heat, cold, humidity or moisture.

Power supply (only applies to products with stepper motors, brushed DC/brushless DC or AC servo motors and a suitable motor output stage/controller)

Only connect the mains adapter of the stepper motor/servo motor output stage IMD10/IMD20, the link to the servo motor output stage IMD40 (terminals L, N, PE) or the single-axle controller iMC1-10/iMC1-20 or multi-axle controller iMC-M/iMC-P (stepper) or iMC-V/iMC-VP (servo) to an earthed mains socket with a mains voltage of 230 V AC/50…60 Hz (1-phase AC power supply). You are advised to use the original mains adapter recommended by isel Germany AG (primary switching power supply: 230 V AC, secondary: 48 V DC) for the stepper motor or servo motor output stage IMD10/IMD20. Using a different, inappropriate mains adapter renders the warranty null and void. In addition, using an inappropriate mains adapter entails risks caused by electric current, such as electric shock, fire or short circuits. If you notice faults, activate the EMERGENCY STOP button on the (single axle) controller, the CNC operating panel/CNC console, the control panel/control cabinet or a handheld device. Activating the EMERGENCY STOP button interrupts the power supply to the motor output stage. If the mains adapter used is damaged you must not operate it. Have a qualified technician check and if necessary repair the product.

The linear unit

For safety reasons you must not convert and/or modify the linear unit on your own. When in operation, the linear unit must not be covered by supply lines (electric or pneumatic), objects (e.g. tools) or canvas covers, packaging materials or cloth etc. (e.g. clothing), which could cause me-chanical damage or a build-up of heat, and a possible fire. If using a single-axle/multi-axle controller to control a linear unit (equipped with an AC, brushed DC (BDC) or brushless DC (BLDC) servo motor), you need to ensure that the controller or motor output stage used (in a control cabinet or on a mounting rack) is placed in a well ventilated environment.


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Operation

(applies only to products supplied with a motor and a suitable motor output stage or a suitable controller, e.g. a single-axle controller)

Only if the product is assembled correctly and the motor, the tactile or inductive limit switches, the brake and the incremental measuring system (encoder) are correctly connected to the motor output stage/con-troller, will parameterisation, commissioning and operation/programming of the product (as a fully-func-tioning drive system) function correctly. If the product malfunctions or you are unclear about its opera-tional status, you should consult the relevant operating instructions/assembly instructions.

https://www.isel.com/en/support-downloads/manuals.html Here you will find instructions and information on how to check the functions you require, remove the causes of a possible malfunction or have these removed. You must always carry out the instructions you find completely and correctly in order to ensure the product functions correctly. Never allow children or other persons who are vulnerable or at risk to operate the product unsupervised.



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1.2 Proper use

The linear units serve to move securely attached loads along the guide slides/slide plates or supporting profiles in a linear direction in an environment where there is no danger of explosions and in accordance with the operational and environmental conditions specified for this product. The product can be installed as required (in a horizontal, vertical or diagonal) position.

In general, the ballscrew drives in the linear units are not self-locking.

If installed vertically, the linear unit motor (in this case the spindle of the ballscrew spindle and the weight of the loaded slide plate must be calculated) should therefore have a holding brake to secure the movable guide slide of the linear axle from falling/sinking when the power is off. If no holding brake (e.g. magnetic brake) is fitted to the motor, another (electric) mechanical brake must be used, e.g. on the end support of the ball spindle.

The linear units are incomplete machines (compare Article 2g of MD 2006/42/EC). Here an incomplete machine is defined as follows (quote):

'An incomplete machine is a unit which almost forms a machine but which cannot fulfil any specific function on its own.

A drive system is an incomplete machine.

An incomplete machine is only intended to be installed into other machines or other incomplete machines or equipment, or joined together with these to form a machine as defined in this directive.'

The linear units LES4 – LES5 – LES6 are intended for installation into a machine or into other incomplete machines.

The product should not be used outdoors or to transport people or in the food industry and clean rooms.

Any other use than those described above is not considered correct and can lead to personal injuries and damage to property.

1.3 Scope of delivery

The delivery contents include:

Assembly instructions and installation explanation according to MD 2006/42/EC Mounting materials Limit switch cable Motor module if required Accessories if required


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2 Installation instructions and overview of functions

Firstly, this section provides an overview of the mechanical structure, installation or assembly of the linear units and a description of their functions.

The instructions for commissioning/parameterising the axle system and its programming by users depend on the motors used and the relevant controllers with output stages; they can be found in their documentation.

2.1 Functions

The LES series linear units (spindle drive) have a modular design.

These linear units are based on linear guide rails (LFS) and appropriate guide slides (FS), a ballscrew drive and motor module (optional).

The linear guide rails made by isel consist of rigid aluminium profiles with precision steel shafts.

Isel FS guide slides are based on rolling steel balls on steel inserts and precision shafts guided through aluminium profiles. Four ballscrews are used in each FS guide slide. The recirculating balls are glass-fibre reinforced.

Ballscrew drives transform rotational movement into linear movement. They consist of a ballscrew spindle (6), the ballscrew nuts (7) with ball recirculation system (1) and the balls (4) as rolling elements. The balls establish the connection between the spindle and the nuts by rolling in the tracks of the ballscrew spindle and the ballscrew nuts. Isel ballscrew nuts circulate several times with internal ball recirculation. Set screws (3) enable the balls to circulate on the spindles without slack.

2.2 Structure/assembly of the linear unit


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The following illustrations, drawings and item lists illustrate the structure of the linear units.

Overview of the functions using LES5 as an example

Ball circulation in the aluminium Slack-free pre-set Spindle support

linear slide Ballscrew nuts with wipers Profile length L=1,500+

Glass fibre-reinforced

recirculation elements Centralised lubrication

With wipers for ballscrew nuts and slides

Buffers at both ends Integrated overtravel limit switches Belt recirculation End support with needle bearing Spindle positioning with diagonal Electrical connections balls covered with cap Zero slack of axle due to self- securing slotted nuts Options isel linear units LES4-5-6 are usually supplied without a drive module.


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They are prepared either for mounting flanged direct drive modules or lateral or integrated belt drive modules. However, appropriate direct drives can be mounted on request.


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LES4 dimension sheet LES4 explosion diagram – Preparing a direct drive module


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LES4 explosion diagram – Preparing a belt drive module LES4 item list

LES4 - Preparing a direct drive module - Item 2340xx 0xxx

POS no. Item number QUAN-

TITY NAME Drawing no. Note

1 635400 XXXX 1 LFS 12 - 4 linear guide

2 623072 001x 1 Shaft slide WS5

3 623051 1000 1 TE1999 - Direct drive end support (LES 4 - 6) right TE1999

4 623051 2000 1 TE2342 - Direct drive end support (LES 4 - 6) left TE2342

5 632126 2816 2 TE2816 - Anti-vibration parabolic spring TE2816

6 623063 1000 1 TE2452 - Covering cap 75 x 75 x 33 for LES4 direct drive TE2452

7 623063 1 TE1557 - Covering hood 75 x 75 x 33 mm for LES4 line guide TE1557

8 632505 1 TE0275 - Covering profile TE0275

9 635014 2 TE2328 - Overtravel plate for limit switches TE2328

10 623065 0001 1 TE1972 - Clamping bush for WS5 TE1972

11 61310 . . . 1 Ballscrew nut d = 28 - 16 x (2.5-20)

12 21113X 5XXX 1 TE2305 - Ballscrew spindle 16 x (2.5-20) TE2305

13 611999 2000 1 Spindle support L = 1,500 and

up

14 623065 0103 1 TE2933 - Flange for direct drive (LES 4 - 6) TE2933

15 623065 0104 1 TE2932 - End support flange (LES 4 - 6) TE2932

16 630900 2 Sealing lip

17 639001 2 End trim

18 3970XX 1012 2 Micro snap action switch with roller lever

19 610016 4 Kapsto cover GPN 300 F type 300 F4_9_2 14 6_5

20 891371 0060 4 Threaded pin DIN 913 - M3 x 6

21 891123 0121 4 Cylinder screw DIN 6912 8.8 M5 x 12



24 891530 0101 4 Tapping screw DIN 7981 VZ 2.2 x 9.5

25 891181 0281 8 Lens head screw DIN 7985 4.8 VZ M3 x 28

26 622002 0001 1 Threaded pin M8 x 0.75

27 890257 0011 1 Grooved nut DIN 981 M10 x 0.75


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LES4 - Preparing belt drive module - item 2341xx 0xxx

POS no. Item number QUAN-

TITY NAME

Drawing no.

Note

1 635400 xxxx 1 LFS 12 - 4 linear guide



4 623056 1000 1 TE2324 - Belt drive end plate for lateral mounting on right TE2324


6 623062 1 TE1555 - Covering hood 150 x 75 x 80 mm for line guide LES4 TE1555

7 623063 1 TE1557 - Covering hood 75 x 75 x 33 mm for LES4 line guide TE1557


9 635014 2 TE2328 - Overtravel plate for limit switches TE 2328


11 61310 . . . 1 Ballscrew nut d = 28 - 16 x (2.5-20)

12 21113X 5XXX 1 TE2305 - Ballscrew spindle 16 x (2.5-20) TE2305

13 611999 2000 1 Spindle support L = 1,500 and

up

14 623065 0104 1 TE2935 - Bearing flange for belt drive TE2935



17 639001 2 End trim

18 3970XX 1012 2 Micro snap action switch with roller lever


20 616503 0280 1 Toothed belt 16ST5/280

21 635001 2 Collet d = 8 mm TE0561

22 616002 2 Toothed belt wheel TE0562

23 616400 1 Tension roller TE0507

24 891371 0060 4 Threaded pin DIN 913 - M3 x 6



27 891134 0121 2 Countersunk screw DIN 7991 M6 x 12

28 891134 0351 1 Countersunk screws DIN 7991 M6 x 35




32 622002 0001 1 Threaded pin M8 x 0.75



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LES5 explosion diagram – Preparing a belt drive module Item list LES5

LES5 - Preparing a direct drive module - item 2343xx 0xxx POS no. Item number

Quan-tity Name Drawing no. Note

1 635500 xxxx 1 LFS -12-5 line guide


3 623072 001x 1 Shaft slide WS5 for ballscrew nuts 623072 0015/623072 0012



6 623052 1001 2 TE2436 - Cover plate 150 x 72 x 5 for LFS 4 – 6 TE2436


8 623059 2000 1 TE0090 - Covering cap 225 x 75 x 33 for direct drive LFS5 TE0090

9 623059 1000 1 TE2334 - Covering hood 225 x 75 x 33 TE2334




13 61310x xxxx 1 Ballscrew nut Ø28 16 x (2.5-20)

14 21113x 5xxx 1 TE2305 - Ballscrew spindle 16 x (2.5-20)

15 611999 2000 1 Spindle support TE2305

16 623065 0103 1 TE2933 - Flange for direct drive (LFS 4 - 6)


18 630900 4 Sealing lip TE2932

19 639001 4 End trim

20 562015 2001 2 Micro snap action switch with roller lever


22 891371 0060 4 Threaded pin DIN 913 M3 x 6






28 622002 0001 1 Threaded pin M8 x 0.75



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LES5 - Preparing belt drive module - item 2344xx 0xxx POS no. Item number

Quan-tity Name Drawing no. Note

1 635500 xxxx 1 LFS 12-5 Linear guide




5 623056 1000 1 TE2324 - Belt drive end plate LFS 4 – 6 TE2324










15 21113x 5xxx 1 TE2305 - Ballscrew spindle 16 x (2.5-20) TE2305

16 611999 2000 1 Spindle support

17 623065 0102 1 TE2935 - Flange for belt drive (LFS 4 - 6) TE2935


19 616002 2 TE0562 - Toothed belt wheel Z25 AT5 for collet Ø8 mm TE0562

20 635001 2 TE0561 - Collet 8 mm TE0561

21 616400 1 Tension roller for toothed belt FS4-LFS5

22 616503 0280 1 Toothed belt 16AT5-280

23 610110 2471 1 TE2471 - Blank plate for covering hood 225 x 75 x 80 TE2471


25 639001 4 End trim












37 622002 0001 1 Threaded pin M8 x 0.75



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LES6 explosion diagram – Preparing a belt drive module LES6 item list

LES6 - Preparing a direct drive module - item 2346xx 0xxx POS no. Item number

Quan-tity Name

Drawing no. Note

1 635700 xxxx LFS 12-6 linear guide







8 623064 2000 1 TE2453 - Covering cap 75 x 150 x 33 for direct drive LFS6 TE2453

9 623064 1 TE1557 - Covering hood 150 x 75 x 33 mm for linear guide LES4 TE1556




13 61310... 1 Ballscrew nut Ø28 16 x (2.5-20)

14 21113x 5xxx 1 TE2305 - Ballscrew spindle 16 x (2.5-20) TE2305

15 611999 2000 1 Spindle support L = 1,500 and up

16 623065 0103 1 TE2933 - Flange for direct drive (LFS 4 - 6)

17 623065 0104 1 TE2932 - End support flange (LES 4 - 6)


19 639001 4 End trim









28 622002 0001 1 Threaded pin M8 x 0.75



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LES6 - Preparing a belt drive module - item 2347xx 0xxx POS no. Item number

Quan-tity Name

Drawing no. Note

1 635700 xxxx 1 LFS 12-6 linear guide




5 623056 1000 1 TE2324 - Belt drive end plate LFS 4 – 6 TE2324



8 623064 1 TE1557 - Covering hood 150 x 75 x 33 mm for linear guide LES4 TE1556






14 21113x 5xxx 1 TE2305 - Ballscrew spindle 16 x (2.5-20)

15 611999 2000 1 Spindle support L = 1,500 and up

16 623065 0102 1 TE2935 - Flange for belt drive (LFS 4 - 6) TE2935


18 616002 2 TE0562 - Toothed belt wheel Z25 AT5 for collet Ø8 mm TE0562

19 610500 0800 2 TE3565 - Small collet 8 mm TE3565

20 616400 1 Tension roller for toothed belt LFS4-LFS5

21 616503 0280 1 Toothed belt 16AT5-280

22 610110 2471 2 TE2471 - Blank plate for covering hood 225 x 75 x 80 TE2471


24 639001 4 End trim












36 622002 0001 1 Threaded pin M8 x 0.75



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Drive modules Various drive modules with stepper motors, brushed servo motors (BDC) and brushless servo motors (BLDC) are available for the linear units LES4-6 as standard. These can be mounted:

- directly above a coupling, spacing bracket and adapter flange in extension of the ballscrew spindle

- sideways or integrated by means of a toothed belt step.

Direct drive System / Z axle /

Circular connector Circular connector with

brake

DC servo motor DC 100 396112 0060 -

Stepper motor MS 135HT 396055 0060 396055 0360


EC servo motor EC 60S 396415 0060 396415 0260

EC servo motor EC 60L 48 V 396423 0060 -

EC servo motor EC 60L 310 V 396423 0070


EC servo motor EC 86 L 396466 0070 -

EC servo motor EC 86 S 396444 0070 -

Stepper motor MS 600 HT 396085 0060 -

Stepper motor MS 900 HT 396088 0060 -

LES 5 integrated System / Z axle /

Circular connector Circular connector with

brake







LES 4 / LES 6 System / Z axle /

Lateral mounting Circular connector Circular connector with

brake








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Connector pin assignment M23 12 pin for stepper motors Motor connector M23 12 pin

View of pin insertion on the plug-in side

1 Motor phase 1A 2 Motor phase 1B 3 Motor phase 2A 4 Motor phase 2B 5 +24 V switch 6 +24 V brake 7 GND switch 8 GND brake 9 Limit switch 1 10 Limit switch 2 11 --- 12 --- Housing - cable shield

Connector pin assignment Sub-D 9 pin for stepper motors

Motor connector Sub-D 9 pin


1 Motor phase 1A 2 Motor phase 1B 3 Motor phase 2A 4 Motor phase 2B 5 +24 V switch 6 +24 V brake 7 Limit switch 2 8 GND brake 9 Limit switch 1 Housing - cable shield

Connector pin assignment Amphenol 15 pin for stepper motors

Motor connector Amphenol 15 pin


1 Motor phase 2B 2 Motor phase 2A 3 Motor phase 1B SL Motor phase 1A 4 +24 V brake 5 +24 V switch 6 GND brake 7 Cable shield 8 GND switch 9 Limit switch 1 10 Limit switch 2


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Connector pin assignment for brushed DC servo motors (BDC)

Motor connector M23 9 pin (8+1) pin Encoder connector D-sub 15 pin


1 Motor phase 1 (U+) 2 Motor phase 2 (U-) 3 Motor phase 1 U+)* 4 Motor phase 2 (U-)*

+24 V brake 6 GND brake 7 --- 8 --- 9 Protective earth PE Housing - cable shield

* Motor phases are partly con-

nected via two wires


1 --- 2 +5 V encoder 3 Encoder track /Z 4 Encoder track /B 5 Encoder track /A 6 +24 V switch 7 Limit switch 1 8 ND switch 9 --- 10 GND encoder 11 Encoder track Z 12 Encoder track B 13 Encoder track A 14 Reference switch 15 imit switch 2 Housing - cable shield

Connector pin assignment for brushless DC servo motors (BLDC) 48 V

Motor connector M23 9 pin (8+1) pin Encoder connector D-sub 15 pin


1 Motor phase U 2 Motor phase V 3 Motor phase W 4 --- 5 +24 V brake 6 GND brake 7 8 9 Protective earth PE Housing - cable shield


1 Hall signal A 2 +5 V en-

coder/Hall 3 Encoder track /Z 4 Encoder track /B 5 Encoder track /A 6 +24 V switch 7 Limit switch 1 8 GND switch 9 Hall signal B 10 GND encoder 11 Encoder track Z 12 Encoder track B 13 Encoder track A 14 Hall signal C 15 Limit switch 2 Housing - cable shield

Connector pin assignment for brushless DC servo motors (BLDC) 310 V

Motor connector M23 9 pin (4+3+1) pin Encoder connector D-sub 15 pin


1 Motor phase U PE Protective earth PE 3 Motor phase W 4 Motor phase V A +24 V brake B GND brake 7 --- 8 --- Housing - cable shield


1 Hall signal A 2 +5 V en-

coder/Hall 3 Encoder track /Z 4 Encoder track /B 5 Encoder track /A 6 +24 V switch 7 Limit switch 1 8 GND switch 9 Hall signal B 10 GND encoder 11 Encoder track Z 12 Encoder track B 13 Encoder track A 14 Hall signal C

15 Limit switch 2 Housing - cable shield


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Mounting of direct drive module on LES4 – LES5 – LES6

The above diagram illustrates mounting of the direct drive module to the linear units. Ensure that the parts to be connected are free of burrs, rust and dirt. Make sure the spindle and motor axle are well aligned before tightening the coupling halves. The tightening torque of the coupling clamp screws is 3 Nm.


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Mounting of belt drive module on LES4 – LES5 – LES6

The above diagram shows mounting of a belt drive module The belt pulleys must have the same spac-ing as the toothed belts. The two shaft ends and the belt pulleys should be free of burrs, rust and dirt. We recommend force-fit connections using clamping bushes as shaft-hub connections. The shaft ends must be aligned before mounting the toothed belt and belt pulleys. The toothed belt must be mounted by hand without using force . In addition, the distance between the axles must be reduced, using flanged discs, and the two belt pulleys mounted together. On no account must the toothed belt be mounted onto the belt pulleys using force or mounting levers, since this can cause damage to the belt which is not often visible. The initial tension of the belt depends on the power to be transmitted and the drive properties. How-ever, because the power transmission of the toothed belt is positive and interlocked, little initial tension is necessary. We recommend using eccentric tension rollers to set the initial tension or correct the tolerances.

Too much initial tension produces higher running noise, premature belt wear and can even cause the shaft ends to break off. Too little initial tension causes uneven running and encourages the belt teeth to skip. We recommend the following for setting the initial tension: Test force F 16.5 N Belt deflection d 3.5 mm


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Mounting the gas pressure spring attachment kit (accessories) The gas pressure spring serves to compensate the weight in vertical linear units. The gas pressure spring attachment kit can be mounted subsequently as an accessory. The force of the gas pressure spring remains constant across its entire hub. Two sizes with different hubs and spring forces are available.

Note the maximum permissible speed of the gas pressure spring since safe guidance is not guaranteed if this is exceeded.

Item number Linear unit length

Spring force

Hub v max.

216450 0001 490 mm 170 N 200 mm 150 mm/s

216451 0001 690 mm 250 N 300 mm 150 mm/s

The adjacent explosion diagram shows mounting the gas pressure spring attachment kit to the linear unit LES 5. Note that the connecting plate VP2 (4) is already mounted or must be mounted on the guide slide (accessories - slide plates). Remove the bottom cover (10) of the linear unit with the lens head screws (9). Push the mounting block (1) with the double glide nut (5) and cylinder screws M6 x 25 (6) into the lateral nut from below and attach this only loosely. Take the connecting plate (4) right to the bottom and attach the mounting block (2) to it with the lens head screw M6 x 22 (8). The cylinder screw M6 x 30 (7) goes through the connecting plate (4) and makes it possible to disassemble the whole of the linear unit, without removing the gas pressure spring attachment kit. Insert the gas pressure spring (3) loosely into the top mounting block (1) and attach the piston rod with the thread to the bottom mounting block (2). Make sure that the piston rod is screwed in only approx. ½ a turn before screwing tightly, to prevent tilting. Lower the top mounting block (1) onto the gas pressure spring (3) and attach it with the cylinder screws M6 x 25 (6).


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3 Commissioning, general information

The linear unit is commissioned after mounting the relevant drive modules and any necessary cables.

Follow the relevant instructions in the documentation of the motor modules, output stages or controls used.

Incorrect assembly (including loading on the axle system), cabling or commissioning increases the risks.




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4 Assembly/disassembly as individual components

Before you can assemble your new linear units you must remove any securing devices used in their transport.

4.1 Mounting on the linear guide rail

You have several options for mounting the components individually:

A) Free-standing linear unit

You can place the linear unit on a rack, work table or any other suitable, i.e. sturdy base.

Choose the location carefully so that the product cannot fall or be knocked over by any impact or tug on the cables.

B) Rack mounting (recommended)

The shaft profiles for mounting the linear units on your rack have several T-nuts on the underside. These are for mounting the threaded rails or slide nuts (accessories). Use M6 securing screws to mount the linear units onto your rack from below.

Make sure the mounting surfaces are sufficiently clean.

The aluminium profiles used are extrusion profiles which can deviate in terms of their straightness and distortions as a result of the manufacturing process.

The deviation tolerance is set down in DIN EN 12020-2.

Isel linear units are plane-milled and any deviations generally fall below the tolerances.

However, to achieve the desired guide accuracies and running performance, the axle system must either be laid out over an appropriately flat surface or arranged over levelling plates. This achieves tolerances of minimal 0.1 mm/1,000 mm.

C) Foot mounting

If it is not possible or too costly to mount the linear units from below, they can be mounted from above, using special feet (accessories) or appropriate adapter plates.

The relevant adapters must be fixed to the linear guide rails via slide nuts or threaded rails and the units then mounted completely from above.

Make sure the fixing surfaces are sufficiently clean and sufficiently level.


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4.2 Mounting on the guide slides

A) Attaching the slides

The guide slides have M6 threaded bores for attaching any transport loads. 6h7 centering bores make it possible to position and reproduce the fixing location precisely.

The guide slide mounting surface is plane-milled.

Make sure the fixing surfaces are sufficiently clean and sufficiently level. Bracing the guide slides leads to reduced power, uneven running, louder running noises and premature wear.

B) Attaching the slide plates

Slide plates offer another option for attaching the transport loads (accessories).

These are made of steel, and have M6 fixing threads.

The slide plates are mounted on the guide slides with fixing screws and positioned with pins.

The flatness of the plane-parallel plates is below 0.2 mm.

Slide plates make it possible to further combine different linear units to form compound tables.

C) Attaching the slide plates to a rack

Slide plates which protrude sideways make it possible to fix the guide slides to the rack and therefore the linear guide rail to move in a linear direction relative to the rack.

The smoothed steel plates are fixed to the slides and positioned with M6 cylinder screws and pins again.

Facings for M6 cylinder screws make it possible to adjust the linear unit on the rack.


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5 Fault list

Only allow qualified technicians to carry out repairs on the electric components of the product. Otherwise there is a risk of electric current causing fatal injuries.

Problem/fault Possible cause(s) Help

Louder running sounds

Dirt Lack of lubricating film

Clean the linear unit

Shorten subsequent lubrication intervals

Stiffness Dirt Incorrect tension

Clean the linear unit

Alignment, adjustment

Increased wear

(abrasion)

Too great a load

Lack of lubricating film

Reduce load

Shorten service interval

Too much play on

guide slide

spindle drive

Wear

Too great a load

Reduce initial tension

Reduce load

Shorten service interval

Adjust initial tension

Important: in unfavourable electromagnetic conditions the effects of EMC can cause faults.

Do not attempt to manipulate the controller or output stage.


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6 Technical data

6.1 Mechanical data

Linear unit LES 4 LES 5 LES 6

Aluminium profile W x H [mm] 75 x 75 225 x 75 150 x 75

Guide weight [kg/m] 6.2 13.8 11.4

Moment of inertia lx [4 cm] 126 299 212

Moment of inertia ly [4 cm] 107 2,362 707

Weight with spindle [kg/m] 7.6 15.2 12.8

Guide slide 1 x WS 5 - 70 / 2 x WS 5 - 70 2 x WS 5 - 70 / 4 x WS 5 - 70

Slide weight [kg] 0.34 / 0.68 0.68 / 1.36

Spindle pitch [mm] 2.5 / 4 / 5 / 10 / 20

maximum permissible feed force [N] 2,625 / 3,450 / 3,450 / 3,150 / 1,425

Max. speed [mm/s] 125 / 200 / 250 / 500 / 1,000

Repeatability accuracy [mm] ±0.02

Travel [mm] L1 - 150 / L1 - 280

Noise level [dBA] < 85

Storage temperature range [°C] 0-40

Operating temperature range [°C] 0-60 (80)

Relative humidity [%] < 90

Ballscrew nut load ratings

Pit- Nominal dyn. stat.

ch Ø Rating Rating

(mm) (mm) (N) (N)

2.5 16 3,500 5,500

4 16 4,600 7,200

5 16 4,600 7,200

10 16 4,200 6,500

20 16 1,900 2,500


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Guide slide ratings

LES 4 - 1 x WS 5/70 LES 5 - 2 x WS 5/70 LES 6 - 2 x WS 5/70

Co 3,303 N Co 4,955 N Co 4,955 N

C 1,873 N C 2,810 N C 2,810 N

F1 stat. 2,821N F1 stat. 4,232N F1 stat. 4,232N

F1 dyn. 1,599 N F1 dyn. 2,399 N F1 dyn. 2,399 N

F2 stat. 3,303 N F2 stat. 4,955 N F2 stat. 4,955 N


M0x 30 Nm M0x 317 Nm M0x 159 Nm

M0y 105 Nm M0y 127 Nm M0y 127 Nm

M0z 123 Nm M0z 149 Nm M0z 149 Nm

Mx 17 Nm Mx 180 Nm Mx 90 Nm

My 60 Nm My 72 Nm My 72 Nm

Mz 70 Nm Mz 84 Nm Mz 84 Nm

LES 4 - 2 x WS 5/70 LES 5 - 4 x WS 5/70 LES 6 - 4 x WS 5/70

Co 4,955 N Co 6,606 N Co 6,606 N

C 2,810 N C 3,746 N C 3,746 N

F1 stat. 4,232N F1 stat. 5,642 N F1 stat. 5,642 N


F2 stat. 4,955 N F2 stat. 6,606 N F2 stat. 6,606 N


M0x 45 Nm M0x 423 Nm M0x 212 Nm

M0y 275 Nm M0y 367 Nm M0y 367 Nm

M0z 322 Nm M0z 429 Nm M0z 429 Nm

Mx 25 Nm Mx 240 Nm Mx 120 Nm

My 156 Nm My 208 Nm My 208 Nm

Mz 183 Nm Mz 243 Nm Mz 243 Nm


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6.2 Electrical data

[Motor data, output stages mains values and connection values, controllers]

You can find the motor data, output stages mains values and connection values and controller data in the documentation




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7 Maintenance and cleaning

7.1 Maintenance instructions

The LES linear units function extremely accurately and reliably. Maintenance costs are therefore relatively low.

Maintenance of the linear units is limited to cleaning them of coarse dirt particles and contaminants and lubricating them regularly.

Grease the ballscrew spindles, ballscrew nuts, guide slides and steel shafts of the guide rails.

Basic lubrication

The linear units are ex-factory lubricated with special isel grease for storage.

No further basic lubrication is necessary before the axle system is started up.

The EC Safety Data Sheet according to EEC Directive 93/112/EC and ISO 110 11014-4 can be obtained from the factory.

Procedure

Use only special isel grease or oil when relubricating.


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Grease: Item number: 299031

Lubricating oil: Item number: 299020

Push-type grease and oil gun: Item number: 931170

Lubricating with oil is possible and reduces heat development in faster spindle rotations; however, the installation site must be taken into account and the lubrication intervals are reduced to every 40 to 60 operating hours.

The advantages of grease lubrication are that it can be done regardless of the installation site and ensures long lubrication intervals (300 to 700 operating hours) up to a rotation speed of 800 1/min.

Maintenance interval Maintenance work

When necessary Clean the axle system

approx. 50 operating hours guide slides and ballscrew nuts

by lubrication with oil

300 – 700 operating hours guide slides and ballscrew nuts by lubrication

with special isel grease

1 month

Visual check of linear guide rails for wear

Visual check of toothed belts (initial tension, abrasion…)

Acoustic check for unusual noises developing

2 years Replace toothed belts

Check that guide slides and ballscrew drive are clearance free

7.2 Cleaning

Clean the surface of the aluminium mounting profile, the (flanged) motor modules, the sealing lips for sealing the profiles or the linear unit guide slides with a lint-free, dry/slightly damp cloth. Do not use harsh cleaning agents or abrasive cleaners.

8 Decommissioning/disposal

The symbol on the product or its packaging indicates that the product must not be disposed of with normal household waste. Users must deliver the products/used devices to a collection point for used electrical and electronic devices. The separate collection and proper disposal of your products/used devices helps to conserve natural resources and guarantees recycling, which in turn protects people's health and the environment. You can get information on where to find collection points for your used devices from your local borough council, local waste disposal companies or on the Internet.


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9 CE Conformity

The linear units with spindle drive LES4 – LES5 – LES6 are classified as 'incomplete machines' according to MD 2006/42/EC and therefore comply with CE guidelines (see installation explanation of the manufacturer, isel Germany AG).

As an 'incomplete machine' the product does not carry the CE mark, although it still conforms to the relevant European guidelines.

isel Germany AG hereby confirms that the product complies with the following directives:

EC Directive 2006/42/EC 'Machinery Directive' EC Directive 2006/95/EC 'Electrical Equipment Designed for Use within certain Voltage Limits'/'Low Voltage Directive' EC Directive 2004/108/EC 'Electromagnetic Compatibility (EMC)'

The installation explanation for the product linear units with spindle drive LES4 – LES5 – LES6 is an integral part of these assembly instructions.

10 Service

If you need customer service or have any questions regarding parameterisation of the controllers/motor output stages (if they are included in the scope of delivery), please consult:

Herr Frank Hecht (Dermbach-Thüringen plant):

Tel: +49 (0)6659 981-763

Email: [email protected] Herr Frank Jansen (Dermbach-Thüringen plant):

Tel: +49 (0)6659 981-765



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11 Warranty

Warranty:

Over and above the seller's statutory liability for material defects and according to the following conditions, as the manufacturer we guarantee flawless durability of products from isel Germany AG if used properly.

This guarantee extends to the functioning of isel Germany AG products and includes any fault which can be proved to have been caused by the manufacturing process or material defects.

Warranty exclusions:

All replaceable individual components, e.g. screws, connecting pins etc. are excluded from this warranty. Furthermore, we accept no liability for damage caused by:

Inappropriate or improper use Faulty or negligent handling Failure to observe installation instructions and instructions on care, as well as modifications or repairs carried out by users themselves The effects of chemical and physical influences and improper use on the surface of the materials, e.g. damage from sharp objects.

We do not accept any liability for consequential damage.

We do not accept any liability for damage to persons and property caused by improper handling or failure to observe the safety guidelines. In cases such as these no claim can be made against the warranty.

Warranty conditions:

Our warranty only covers at our discretion the repair or replacement of the product free of charge for first/end users within the warranty period.

Warranty period:

In accordance with our General Terms and Conditions (AGB of isel Germany AG, Section VI) our warranty lasts one year.

For claims please contact the seller or the manufacturer directly, quoting the number of your invoice/delivery note.

Manufacturer: isel Germany AG Bürgermeister-Ebert-Straße 40 D-36124 Eichenzell, Germany

Tel: +49 (0)6659 981-0

Fax: +49 (0)6659 981-776


Internet: www.isel.com

mailto:[email protected]

https://www.isel.com/


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12 Installation explanation according to MD 2006/42/EC

Installation explanation according to EC Machinery Directive (MD) 2006/42/EC, Appendix II B

The manufacturer isel Germany AG Bürgermeister-Ebert-Straße 40 D-36124 Eichenzell, Germany hereby declares that the product (incomplete machine) Product description: Linear unit LES4 Item number: 2340xx xxxx Linear unit LES4 Item number: 2341xx xxxx Linear unit LES5 Item number: 2343xx xxxx Linear unit LES5 Item number: 2344xx xxxx Linear unit LES6 Item number: 2346xx xxxx Linear unit LES6 Item number: 2347xx xxxx complies with the fundamental health and safety requirements of EC Machinery Directive 2006/42/EC Appendix I. The following harmonised standards were applied: EN ISO 12100-1:2003 Safety of machinery - Basic concepts, general principles for design - Part 1:

Basic terminology, methodology EN ISO 12100-2:2003 Safety of machinery - Basic concepts, general principles for design - Part 2:

Technical principles EN 349:2008-09 Safety of machinery - Minimum gaps to avoid crushing of parts of the human

body EN 14121-1:2007 Safety of machinery – Risk assessment – Part 1: Principles EN 60204-1:2006 Safety of machinery - Electrical equipment of machines - Part 1: General re-

quirements The following additional EC Directives relevant to this product were applied: Low Voltage Directive 2006/95/EC The technical documentation for this incomplete machine was produced according to Appendix VII Part B. The manufacturer undertakes to pass on these technical documents to national authorities in electronic form on request. Member of staff responsible for producing the technical documents or assembly instructions/installa-tion explanation is: Mr Helmut Danz The product (incomplete machine) is intended for installation into a machine or combining with other incomplete machines to form a machine as defined in MD 2006/42/EC, Article 1, Section (1) a. This incomplete machine (product) must not be commissioned until the machine in which this product is installed or of which it forms a component meets the provisions of all the relevant directives (especially MD 2006/42/EC) and this (complete) machine carries a CE mark. Place, date: Dermbach, 17 June 2010 _____________________________ Werner Kister, Member of the Management Board


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13 Index

A

Abbreviations 2 Appendices 41 Assembly 29

C

CE Conformity 37 Cleaning 36 Copyright 2

D

Disposal 36

F

Fault list 31 Functions 9

I

Installation 9

Installation explanation 39

O

Operating environment 6

P

Proper use 8

S

Safety guidelines 6 Scope of delivery 8 Service 37 Structure/assembly 9 Symbols used 2

T

Technical data 32

W

Warrenty 38


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14 Appendices

14.1 A1: Accessories

Assembly kit with angle drives

90° attachment Item no: 216150 0002 0° attachment Item no: 216150 0001

Scope of delivery: 2 x (1), 2 x (2), 2 x (4) Scope of delivery: 2 x (1), 2 x (2), 2 x (4)

Transmission shaft (5)

Ltw = 1,000 mm Item no: 219001 0125 Ltw = 2,000 mm Item no: 219001 0225

Coupling (4) Item no: 218050 0002 Pedestal support (6) Item no: 896202 5562

Coupling housing Coupling housing 1 Coupling housing 2 Divided coupling housing Short sleeve Short sleeve Short sleeve Item no: 218100 0001 Item no: 218100 1001 Item no: 218100 1001 Long sleeve Long sleeve Long sleeve Item no: 218100 0002 Item no: 218100 1002 Item no: 218100 1002 Gas pressure spring mounting kit Limit switch mounting kit Hub 220 mm Mounting kit LES4 Item no: 216460 0001 Item no: 216450 0001 Mounting kit LES5 Item no: 216460 0002 Mounting kit LES6 Item no: 216460 0003 Hub 300 mm Item no: 216451 0001


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Angle plates

Threaded strips – Slide nuts

Slide plates/Connecting plates

Angle plates Item number

Angle plate WV 1 209110 0010







Cover plate for WV 2 209110 0021






Threaded strips – Slide nuts Item number Note

Threaded strip M6 (grid 50) 209011

Connecting ele-ment (VE) 3 piece

a 1m

Slide nut M6 209001 0005 VE 100 piece

Slide nut 2 x M6 209002 0004 VE 50 piece

Slide nut M5 209006 0001 VE 20 piece

Angle slide nut 2 x M6 209021 0003 VE 25 piece

Special angle slide nut 3 x M6 209022 0003 VE 25 piece

Slide plates/Connecting plates Item number Mounting on

Slide plate PS1 277001 LES4 with 1 x WS5/70











Connecting plate VP2 277006 LES5 with 4 x WS5/70

Connecting crosspiece 277007 2 x LES4


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Motor connecting cables

Shaft couplings Shaft coupling 30/40 Shaft coupling 40/60 Item No: 218002 xxxx Item no: 218003 xxxx Energy guide chain Energy guide chain 3 Connecting elements for E chain 3 VE 1 piece a 1m with strain relief VE 1 set Item No: 219204 1000 Item no: 219205 0002 Foot Foot Item no: 642003 Rubber blank Item no: 642001

14.2 A2: Miscellaneous

Assembly instructions [product] identification no: 970234 BE 0001 / 01-2011

Motor connecting cables Item number

3-metre stepper motor cable plug Sub-D9 - bush Sub-D9 392781 0300

5-metre stepper motor cable plug Sub-D9 - bush Sub-D 392781 0500

3-metre stepper motor cable plug Sub-D9 - bush M23 392755 0300

5-metre stepper motor cable plug Sub-D9 - bush M23 392755 0500

3-metre stepper motor cable plug M23 - bush M23 392750 0300

5-metre stepper motor cable plug M23 - bush M23 392750 0500

3-metre DC servo motor cable plug M23 - bush M23 392759 0300

5-metre DC servo motor cable plug M23 - bush M23 392759 0500

3-metre encoder cable plug Sub-D15 - bush Sub-D15 392740 0300

5-metre encoder cable plug Sub-D15 - bush Sub-D15 392740 0500

Documents

Linear units with spindle drive - Isel · 2019. 3. 7. · The isel-linear units LES4 – LES5 – LES6 are linear modules with ballscrew drives, which are ready to install. They are