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404LXR Series Product Manual

Chapter 6 - Maintenance and Lubrication

39

Chapter 6 - Maintenance and Lubrication

Internal Access Procedure

The following procedure outlines the steps required to access the interior of the positioner.

•

Remove carriage end caps by removing four (4) M3 Socket
Head Cap Screws (2pc/carriage side) using a 2.5 mm Allen
wrench.

•

Pull carriage end caps off. Carriage end caps on both sides
of carriage must be removed.

•

Remove the two (2) strip seals clamps by removing four (4)
Phillips Head Screws.

•

Remove strip seal cover plate.

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Summary of Contents for 404LXR Series

Page 1: ...Manual No 100 5319 01 Rev J 404LXR Series Product Manual Effective June 13 2018 Supersedes December 20 2017 Electromechanical Positioning Systems Automation ...

Page 2: ...ed disclosed or used for any purpose not expressly authorized by the owner thereof Since Parker Hannifin Corporation constantly strives to improve all of its products we reserve the right to change this product manual and equipment mentioned therein at any time without notice For assistance contact Parker Hannifin Corporation 1140 Sandy Hill Road Irwin PA 15642 Phone 724 861 8200 800 245 6903 Fax ...

Page 3: ...HE 404LXR 26 MOUNTING SURFACE REQUIREMENTS 26 MOUNTING METHODS 26 SIDE AND INVERTED MOUNTING CONCERNS 27 SETTING TRAVEL LIMIT SENSORS 27 SETTING HOME SENSOR 27 Z CHANNEL POSITION REFERENCE 28 GROUNDING SHIELDING 28 CABLING 29 CHAPTER 4 PERFORMANCE 30 ACCELERATION LIMITS 30 SPEED LIMITS 31 ENCODER ACCURACY AND SLOPE CORRECTION 31 THERMAL EFFECTS ON ACCURACY 33 THERMAL EFFECTS ON REPEATABILITY 34 CA...

Page 4: ...ensor Module Adjustement page from Chapter 6 was page 41 Updated connector release torx screws p 41 Rev 5 October 1 2009 Added Aries and Compax3 Cable option p 23 24 Updated Chapter 5 Connecting the Drive Amplifier to include Aries and Compax3 p 35 Rev 6 April 10 2013 Clarified warnings to sync with CE risk assessments P 5 Unpacking p 6 General Safety Rev 7 February 16 2017 Updated Cable Managemen...

Page 5: ...and mounting of your new positioner Product may be heavy Standard handling and lifting practices should be employed DO NOT allow the positioner to drop onto the mounting surface Dropping the positioner can generate impact loads that may result in flat spots on bearing surfaces or misalignment of drive components DO NOT drill holes into the positioner Drilling holes into the positioner can generate...

Page 6: ...take apart or touch any internal components of the positioner while unit is plugged into an electrical outlet SHUT OFF power before replacing components to avoid electrical shock High Magnetic Field Unit may be HAZARDOUS to people with Pace Makers or any other magnetically sensitive medical devices Unit may have an effect on magnetically sensitive applications Ferrous Materials The positioner s pr...

Page 7: ...on of a standard unit before failure is 5 40 Degrees C Specifications are Mounting Surface Dependent Catalog specifications are obtained and measured when the positioner is fully supported bolted down to eliminate any extrusion deviation and is mounted to a work surface that has a maximum flatness error of 0 013mm 300mm 0 0005 ft Specifications are Point of Measurement Dependent Catalog specificat...

Page 8: ...404LXR Series Product Manual Chapter 1 Introduction 8 Assembly Diagrams Strip Seal Version ...

Page 9: ...404LXR Series Product Manual Chapter 1 Introduction 9 Hardcover Version ...

Page 10: ...404LXR Series Product Manual Chapter 2 404LXR Series Table Specifications 10 Chapter 2 404LXR Series Table Specifications Order Number Nomenclature ...

Page 11: ...404LXR Series Product Manual Chapter 2 404LXR Series Table Specifications 11 Dimensional Drawings ...

Page 12: ... Continuous 50 N 11 lb Carriage Weight 1 4 kg Travel Dependent Specifications Travel mm Accuracy Strip Seal Version Unit Weight kg Hard Cover Version Unit Weight kg Positional Straightline Accuracy um 0 1 0 5 1 0 resolution um 5 0 resolution um 50 6 16 6 4 4 4 4 100 7 17 7 4 8 4 9 150 8 18 9 5 2 5 4 200 10 20 11 5 6 5 8 250 12 22 14 6 0 6 3 300 14 24 17 6 4 6 7 350 16 26 19 6 8 7 2 400 18 28 22 7 ...

Page 13: ...IAGE LIFE VS LOAD 1000 10000 100000 1 3 5 7 9 11 13 15 17 19 21 23 25 28 30 32 34 36 38 40 42 44 46 48 50 LOAD KG LIFE KM NORMAL LOAD CONTINOUS 55 N NORMAL LOAD CONTINUOS 28 N SIDE LOAD CONTINUOS 55 N SIDE LOAD CONTINUOUS 28 N BEARING LIFE NORMAL LOAD 1000 10000 100000 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 NORMAL LOAD PER BEARING N BEARING LIFE KM 55 N CONTINOUS 28 N CONTINUOS Table L...

Page 14: ... life if only 28 Newtons RMS is used d1 d2 da Strip Seal Model 108 5 60 0 48 5 Hardcover Model 108 5 60 0 53 5 BEARING LIFE SIDE LOAD 1000 10000 100000 10 20 30 40 50 60 70 80 SIDE LOAD PER BEARING N LIFE PER BEARING KM 55 N CONTINUOS 28 N CONTINOUS Side Bearing Load Chart The Side Bearing Load chart is to be used in conjunction with the corresponding formulas on the following pages to establish t...

Page 15: ...404LXR Series Product Manual Chapter 2 404LXR Series Table Specifications 15 ...

Page 16: ...surface 50 mm from carriage center Page 14 shows this configuration with dimensions given here 9 14 2 2 4 2 1 d d L P P tension Kgf d1 108 5 mm db 130 mm d2 60 0 mm d3 50 mm da 48 5 mm d4 da db 178 5 9 14 2 2 4 4 3 d d L P P compression Kgf 8 4 2 4 1 3 3 1 d d L L P P s s 2 0 2 4 1 3 4 2 d d L L P P s s The normal and side force components on each bearing block are computed from the equations as s...

Page 17: ...17 404LXR Series Technical Data Force Speed Charts The chart on this page illustrates the characteristics of the 404LXR linear motor The force speed chart shows the characteristics of the motor with either a 170 VDC or 340 VDC bus voltage Peak Peak Peak Continuous Continuous ...

Page 18: ... which utilizes ULPA filters to produce an environment having a cleanliness of class 1 prior to testing Tables were tested in a variety of orientations with sampling both below the table and at the carriage mounting surface Laminar flow rate is 0 65 inches W C Standard Clean Room Preparation Stringent cleaning and handling measures Clean room rated lubricant Strip seal replaced with hard shell cov...

Page 19: ...arriage 1 5 Kg Rated Winding Temp 90 C watt Winding Class H 1 25o C ambient 90o C winding temperature 2 Measured with a 0 70 mm gap 3 Measured line to line 10 4 Value is measured peak of sine 5 30 line to line inductance bridge measurement 1Khz 6 Initial winding temperature must be 60o C or less before peak current is applied 7 DC current through a pair of motor phases of a trapezoidal six state c...

Page 20: ...e Frequency 24V Keep Alive Optional 96 265 VAC 1Ø 50 60 Hz 24 VDC 20 Drive Output Power Bus Voltage Switching Frequency Continuous Current Peak Current Commutation 170 or 340 VDC 8 or 16 kHz 4 5 Amps 11 25 Amps Sinusoidal Command Inputs Velocity and Torque Position Mode Encoder Track Mode 10V Step Direction or CW CCW Allows post quadrature encoder to be used as command signals Inputs Enable Requir...

Page 21: ...UL CE LVD CE EMC Limit and Home Sensor Specifications Description Specification Input Power 5 to 24 VDC 60 mA Output Output form is selectable with product Normally Closed Current Sinking Normally Open Current Sourcing Normally Closed Current Sourcing Normally Open Current Sourcing All types Sink or Source maximum of 50 mA Repeatability Limits 5 microns unidirectional Home See Z channel specificat...

Page 22: ...404LXR Series Product Manual Chapter 3 How to Use the 404LXR 22 Cabling and Wiring Diagrams Connector Pin Out and Extension Cable Wire Color Codes ...

Page 23: ...Hall 2 White Orange 11 Hall 3 White Violet 12 Temp Yellow Orange 13 Temp Yellow Orange 14 Ground White Green 15 Shield Green Yellow Stripe Shield Cover Extension Cable Limit and Home Connections Function Cable Wire Color 404LXR Connector Male 5 Pin Connector 5 to 24 VDC Red A Negative Limit Blue B Positive Limit Orange C Home Green D Ground Black E Shield Shield Shield Case Extension Cable Auxilia...

Page 24: ...UE Z ORANGE Z BROWN TEMP YELLOW ORANGE TEMP YELLOW ORANGE 5 HALL WHITE BLUE GROUND WHITE GREEN HALL 1 WHITE BROWN HALL 2 WHITE ORANGE HALL 3 WHITE VIOLET SHIELD GREEN YELLOW OEM Gemini Encoder Connector Function Cable Wire Color Pin 5 RED 1 GROUND BLACK 3 A WHITE 5 A YELLOW 6 B GREEN 7 B BLUE 8 Z ORANGE 9 Z BROWN 10 TEMP YELLOW ORANGE 12 TEMP YELLOW ORANGE 13 5 HALL WHITE BLUE 14 GROUND WHITE GREE...

Page 25: ...5 HALL 2 WHITE ORANGE 6 A YELLOW 7 A WHITE 8 HALL 3 WHITE VIOLET 9 TEMP YELLOW ORANGE 10 B BLUE 11 B GREEN 12 Z ORANGE 13 Z BLOWN 14 GROUND BLACK 15 SHIELD SHIELD SHIELD CASE OEM Gemini and Aries Limit and Home Connections Function Cable Wire Color Flying Leads 5 24 VDC RED LIMIT ORANGE LIMIT BLUE HOME GREEN GROUND BLACK SHIELD GREEN YELLOW OEM Compax3 Limit and Home Connector Function Cable Wire ...

Page 26: ...ace does not met these specifications the surface can be shimmed to comply with these requirements If mounting conditions require that the table base is overhung table specifications will not be met over that portion of the table Additionally in X Y Systems the overhung portion of the Y axis may not met specifications due to the additional error caused by deflection and non support of the base Con...

Page 27: ...be known from your application requirements Velocity limits should be set in your program or in your amplifier to cause a fault if the speed exceeds this value The maximum deceleration is a factor of load and available peak force of the table Using F ma calculate maximum acceleration and then required deceleration distance See the following example for calculating maximum deceleration for an appli...

Page 28: ...oward the positive side of the table See Chapter 2 Dimensional Drawing for positive direction definition The repeatability of the Z channel is equal to 2 resolution counts of the encoder except for 0 1 micron scales which have a repeatability of 1 microns Thus the repeatability of the Z channel equals Encoder Resolution Z Channel Repeatability 5 micron 10 micron 1 micron 2 micron 0 5 micron 1 micr...

Page 29: ... See Chapter 6 Cable Management Module Replacement for replacement P N s and a detailed procedure of the replacement process Un harnessed OEM Cable System This option provides high flex round cables directly from the carriage This option is provided for applications where the design of the machine already has a cable management system Four cables come from the carriage connector motor encoder Hall...

Page 30: ...ting factor unless loading is significantly cantilevered causing high moment loads during accelerations Chapter 2 404LXR Series Technical Data to determine bearing load life for your application Available Motor Force This is the primary factor that reduces acceleration This is simply the amount of motor force available to produce acceleration The larger the inertial and or frictional load the lowe...

Page 31: ...d increases Chapter 2 404LXR Series Technical Data Encoder Accuracy and Slope Correction Encoder Accuracy The 404LXR Series makes use of an optical linear tape encoder for positional feedback This device consists of a readhead which is connected to the carriage and a steel tape scale which is mounted inside the base of the 404LXR The linearity of this scale is 3 microns per meter however the absol...

Page 32: ...R PROGRAM DEF SLCORR DEFINE SLCORR PROGRAM VAR2 VAR1 1000 0 085 VAR2 EQUALS DESIRED DISTANCE IN METERS TIMES THE SLOPE FACTOR mm meter Step 3 VAR3 VAR1 VAR2 SUBTRACT SLOPE ERROR FROM DESIRED DISTANCE Step 4 D VAR3 SET DISTANCE AS VAR3 END END SUBROUTINE In the example above the required move distance is 880 mm But the LXR has a slope error of 0 085mm per meter This is a positive slope error meanin...

Page 33: ...mm Accuracy microns Travel mm Accuracy microns 50 6 400 18 100 7 500 21 150 8 600 25 200 10 700 28 250 12 800 31 300 14 900 33 350 16 1000 35 Thermal Effects on Accuracy All specifications for the 404LXR are taken at 20 C Variation from this temperature will cause additional positional errors If the base of the 404LXR varies from this temperature the encoder scale will expand or contract thus chan...

Page 34: ...ent Temperature This is the air temperature that surrounds the 404LXR Application or Environment Sources These are mounting surfaces or other items which produce a thermal change that effect the temperature of the 404LXR base i e Machine base with motors or other heat generating devices that heat the mounting surface and thus thermally effect the 404LXR base Motor heating from 404LXR Since the 404...

Page 35: ...is case the system must be exercised through its normal operating cycle The temperature of the base should be measured and recorded from the beginning cold until the base becomes thermally stable This base temperature should be used in a compensation equation Below is the fundamental thermal compensation equation Cd Id Id Te T Cd Corrected displacement mm Id Incremental displacement mm Te Thermal ...

Page 36: ...es are shown for the A4 drive only and the A5 drive controller options Drive Cable Encoder Cable Limit Cable Feedback cable Aries or Gemini GV Drive Motor power cable 6K Controller With an Aries or Gemini GV Drive and a 6K controller With a Gemini GV6 Drive Controller Feedback cable Gemini GV6 Drive Motor power cable Limit cable GEM VM50 Breakout Module With a Compax3 Drive Controller Compax3 Driv...

Page 37: ...ive Function Wire Color Pin Encoder Wires Ch A White 5 Ch A Yellow 6 Ch B Green 7 Ch B Blue 8 Ch Z Orange 9 Ch Z Brown 10 Ground Black 3 4 5 VDC Red 1 2 Shield Green Yellow Shield Cover Hall Signal Wires Hall Gnd White Green 15 Hall 5V White Blue 14 Hall 1 White Brown 16 Hall 2 White Orange 17 Hall 3 White Violet 18 Shield Green Yellow Shield Cover Temperature Switch Temp Switch Yellow 12 Temp Swi...

Page 38: ...l even pins are connected to logic ground Function Wire Color LXR Pin 5 to 24VDC Red A Limit Blue B Limit Orange C Home Green D Ground Black E LXR Limit Home Cable P N 006 1742 0X VM25 Module Color scheme of the flying leads from the Limit Home Cable P N 006 1742 0X Axes 1 4 use the first 25 pin limits home connector and axes 5 8 use the second limits home connector on the 6K External 24 VDC Suppl...

Page 39: ...the steps required to access the interior of the positioner Remove carriage end caps by removing four 4 M3 Socket Head Cap Screws 2pc carriage side using a 2 5 mm Allen wrench Pull carriage end caps off Carriage end caps on both sides of carriage must be removed Remove the two 2 strip seals clamps by removing four 4 Phillips Head Screws Remove strip seal cover plate ...

Page 40: ...Chapter 6 Maintenance and Lubrication 40 Carefully pull the strip seal through the carriage Caution The strip seal ends are VERY SHARP Remove both wear bars that are located on the carriage Reassemble positioner by reversing steps ...

Page 41: ...he rails down the entire length with a clean cloth Apply lubrication on the rails allowing a film of fresh grease to pass under the wipers and into the recirculating bearings After bearings are relubricated clean encoder tape scale located on inside wall of table Clean with lint free cloth removing all dirt and grease Using a lint free cloth wipe down linear tape scale with isopropyl alcohol Note ...

Page 42: ...e two 2 M3 Flat Heat Screws from the top of the cable carrier by using a 2 5 mm Allen wrench Pull the carriage connector off taking care to pull straight off to avoid bending the connectors Remove the strip seal clamp on the connector end by removing two 2 Phillips Head Screws Remove two 2 M3 Button Head Screws from connector end by using a 2 5 mm Allen wrench Replacement modules are mounted by re...

Page 43: ... the cable carrier by using a 2 5 mm Allen wrench Pull the carriage connector off taking care to pull straight off to avoid bending the connectors Locate the limit home wire connection and disengage the connector Remove the two 2 T6 Torx flat head screws that attach the limit home switch to the cable carrier Replacement switches are mounted by reversing steps ...

Page 44: ...n a linear motor increasing the stiffness is simply a matter of gain and current Thus the spring rate of a linear motor driven system can be many times that of a ball screw driven device However it must be noted that this is limited by the motor s peak force the current available and the resolution of the feedback Zero Backlash Since there are no mechanical components there is no backlash There ar...

Page 45: ...or fatigue failures Light Weight Forcer Because of its aluminum body construction the slotless linear motor forcer weight is approximately 2 3 that of an equivalent iron core linear motor Thus resulting in higher throughput in light load applications Lower Attractive Forces The slotless design has a backiron causing attractive forces between the forcer and the rail However this attractive force is...

Page 46: ...n objects of 12 5 mm diameter and larger 3 Protection against access to hazardous parts with a tool and protection against solid foreign objects of 2 5 mm diameter and larger Second Number The second number indicates protection of internal equipment against harmful ingress of water 0 No special protection provided Note Number Indicators above represent only a partial list of IP Rating specificatio...

Page 47: ... as follows Using the supplied aluminum foil disks cover all counter bored base mounting holes that are not covered by your mounting surface The disks should be installed from the outside of the unit Depending on the travel length some disks will not be used Using the supplied aluminum foil disks plug all unused carriage mounting holes that are not covered by the load or load plate Using the suppl...

Page 48: ... Wires 37 Specifications 20 Home Sensor Connections 25 Replacement 43 Setting 28 Specifications 21 Home Switch 10 Horizontal Translation 16 Ingress Protection Rating 46 Internal Access Procedure 39 Internal Protection 46 Limit Sensor Connections 25 Replacement 43 Specifications 21 Limit Switch 10 Linear Motor 44 Specifications 19 Lubrication 39 41 Maintenance 39 Maximum Obtainable Deceleration Rat...

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