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7 Maintenance 

M-235 Linear Actuators  

 

MP106E

 

Version: 1.2

 

31

 

In this Chapter 

General Notes on Maintenance ................................................................................... 31 
Lubricating the M-235 .................................................................................................. 31 
Cleaning the M-235 ..................................................................................................... 32 

 

 

7.1  General Notes on Maintenance 

  

 

NOTICE 

 

Damage due to improper maintenance! 

The M-235 can become misaligned as a result of improper maintenance. 

  Do not loosen any sealed screws. 

  

 

7.2  Lubricating the M-235 

Depending on the operational conditions and the period of use of the linear actuator, 
the following maintenance measures are required. 

Spreading lubricant 

  If you operate the M-235 continuously on a small travel range (<20% of the 

entire travel range), perform a maintenance run every 2000 motion cycles 
across the entire travel range. 

Lubrication 

Under laboratory conditions, the linear actuator needs extra lubrication in exceptional 
cases only. For continuous industrial use the lubrication intervals must be defined 
individually. 

  Do not lubricate the M-235 without consulting our customer service 

department (p. 35). 

  To lubricate, follow the instructions given in the maintenance manual which 

you can obtain from our customer service department. 

 

7 

Maintenance 

Summary of Contents for M-235

Page 1: ...6E M 235 Linear Actuators User Manual Version 1 2 Date 31 08 2020 This document describes the following high load precision linear actuators with recirculating ball screws M 235 2DD Travel Range 20 mm DC Direct Drive M 235 2DG Travel Range 20 mm DC Gear Motor M 235 5DD Travel Range 50 mm DC Direct Drive M 235 5DG Travel Range 50 mm DC Gear Motor ...

Page 2: ... and drawings in this manual are protected by copyright With regard thereto Physik Instrumente PI GmbH Co KG retains all the rights Use of said text photographs and drawings is permitted only in part and only upon citation of the source Original instructions Document number MP106E MMa Version 1 2 Subject to change without notice This manual is superseded by any new release The latest release is av...

Page 3: ...e Products 4 2 2 3 Safety Measures during Installation 4 2 2 4 Safety Measures during Start Up 5 2 2 5 Safety Measures during Operation 6 2 2 6 Safety Measures during Maintenance 6 3 Product Description 7 3 1 System Overview 8 3 2 Features and Applications 9 3 3 Model Overview 9 3 4 Product View 11 3 5 Scope of Delivery 12 3 6 Suitable Controllers 12 3 7 Accessories 12 3 8 Technical Features 12 3 ...

Page 4: ... Database of PI 30 7 Maintenance 31 7 1 General Notes on Maintenance 31 7 2 Lubricating the M 235 31 7 3 Cleaning the M 235 32 8 Troubleshooting 33 9 Customer Service 35 10 Technical Data 37 10 1 Specifications 37 10 1 1 Data Table 37 10 1 2 Ambient Conditions and Classifications 38 10 1 3 Limit Switch Specifications 39 10 1 4 Reference Point Switch Specifications 39 10 2 Dimensions 40 10 2 1 Actu...

Page 5: ... applicable safety procedures For updated releases of this user manual or if you have any questions contact our customer service department p 35 1 2 Symbols and Typographic Conventions The following symbols and typographic conventions are used in this user manual CAUTION Dangerous situation If not avoided the dangerous situation will result in minor injury Actions to take to avoid the situation NO...

Page 6: ... reference to page 5 RS 232 Labeling of an operating element on the product example socket of the RS 232 interface 1 3 Other Applicable Documents The devices and software tools which are mentioned in this documentation are described in their own manuals For the latest versions of the user manuals contact our customer service department p 35 Product Document Linear actuators Short Instructions MP12...

Page 7: ...ntended use of the M 235 is only possible when installed and with a suitable controller p 12 The controller is not included in the scope of delivery of the M 235 2 2 General Safety Instructions The M 235 is built according to state of the art technology and recognized safety standards Improper use can result in personal injury and or damage to the M 235 Only use the M 235 for its intended purpose ...

Page 8: ...e M 235 after having read and understood this user manual Personnel qualification The M 235 may only be started up operated maintained and cleaned by authorized and qualified staff 2 2 2 Measures for Handling Vacuum Compatible Products When handling the vacuum version of the linear actuator attention must be paid to appropriate cleanliness At PI all parts are cleaned before assembly During assembl...

Page 9: ...ctuator via the pusher and can damage the drive Avoid torques to the pusher When screwing an end piece on or off attach the pusher to the wrench flats using an open end wrench The heat produced during operation of the M 235 can affect your application Install the M 235 so that your application is not affected by the dissipating heat 2 2 4 Safety Measures during Start Up A motorized linear actuator...

Page 10: ...ty Set your control signal so that the moving part does not stop abruptly or try to continue moving at the end of the travel range Determine the maximum velocity for your application Ensure that the automatic limit switch halt is supported by the controller or that it is activated in the controller 2 2 5 Safety Measures during Operation For models with DC motors Unsuitable settings made to the ser...

Page 11: ...ear Actuators MP106E Version 1 2 7 In this Chapter System Overview 8 Features and Applications 9 Model Overview 9 Product View 11 Scope of Delivery 12 Suitable Controllers 12 Accessories 12 Technical Features 12 3 Product Description ...

Page 12: ...trollers Controller Controls the motions of the actuator Stand alone device or motor controller card PC add on card Available separately see section Suitable Controllers p 12 Actuator Produces the motions of the part to be driven or the load in your application Here linear actuator type M 235 Present product Cables Peripheral control equipment to controller Ensures the data communication Controlle...

Page 13: ...ipment and the controller cable are physically inside of the PC 3 2 Features and Applications The motorized precision drives of the M 235 series are linear actuators with travel ranges of 20 mm or 50 mm They stand out thanks to their high positioning resolution load capacity velocity and lifetime in industrial applications Their design with a low friction and backlash free ball screw enables loads...

Page 14: ... 235 2DD M 235 2DG M 235 5DD M 235 5DG For further technical data see the specifications p 37 PI also produces custom designs upon request Custom designs can differ from the described standard products in respect to dimensions characteristics or other technical data If necessary contact our customer service department p 35 directly ...

Page 15: ...0 thread for mounting nut 4 Mounting nut for clamp connection 5 Mounting shaft 6 Window with position display 7 Sleeve for micrometer assembly 8 Sleeve for DC motor 9 Cable for connecting to the controller 10 Hand wheel for manually moving the pusher inwards and outwards 11 Stepper motor case with panel plug not visible here for connecting to the controller 12 End piece flat 13 Hole with M6 thread...

Page 16: ... linear actuators with PWM signals To order contact our customer service department p 35 3 8 Technical Features 3 8 1 Rotary Encoder The models with DC motors are equipped with a rotary encoder A rotary encoder also called an incremental or incremental rotary encoder is implemented at a rotating point in the drivetrain e g the motor shaft To determine the relative position the controller counts th...

Page 17: ...inear actuator is on the positive or negative side of the reference point switch The rising or falling edge of this signal can be used to indicate a known reference position The difference in the reference points when approached from the positive or the negative side is about 0 2 mm to 0 4 mm See the controller user manual and or associated software manuals for the commands which make use of the r...

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Page 19: ...eaned once again by wiping and shrink wrapped twice in vacuum compatible film Only touch the linear actuator with powder free gloves If necessary wipe the linear actuator clean after unpacking 1 Unpack the M 235 with care 2 Compare the contents against the items covered by the contract and against the packing list 3 Inspect the contents for signs of damage If parts are missing or you notice signs ...

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Page 21: ...d can damage the drive Avoid torques to the pusher When screwing an end piece on or off attach the pusher to the wrench flats using an open end wrench NOTICE Cable break A cable break leads to a failure of the linear actuator Install the linear actuator so that the cable is not bent or squeezed too severely during operation NOTICE Increased friction Lateral forces that affect the pusher of the lin...

Page 22: ...otors are equipped with integrated signal drivers for cable lengths of 10 m between linear actuator and motor controller 5 2 Changing the Tip INFORMATION The supplied end pieces make it possible to realize different mechanical connections to a load A flat end piece allows a wide area connection to a load A spherical end piece allows a punctiform connection to a load To achieve optimum repeatabilit...

Page 23: ... 1 End piece with a wrench flat 2 Pusher with b wrench flat Prerequisites You have read and understood the General Notes on Installation p 17 You have made the M 235 accessible for changing the end piece The pusher has been moved out so far that you can easily reach the wrench flat with a open end wrench Upon delivery the pusher has been moved out far enough Tools and accessories Supplied end piec...

Page 24: ... thread for clamp connection M20 c mounting nut 4 Sleeve Changing the end piece 1 Attach the pusher apply an AF 8 open end wrench to the wrench flats of the pusher 2 Manually unscrew the end piece to be replaced from the pusher of the M 235 If this is not successful use a second AF 8 open end wrench 3 Screw the new tip by hand into the pusher of the M 235 4 Remove the pusher from the open end wren...

Page 25: ... Providing a Suitable Mechanical Mounting and Installation Environment Figure 5 Relevant components and dimensions for installation in the mechanical mounting schematic 1 Mounting nut M20 2 Mounting shaft with a diameter 20 mm b clamping width 12 mm to 18 mm usable ...

Page 26: ...load must not be inhibited by the dimensions of the installation environment Take into account the following specifications as well when planning the application and installing the actuator Dimensions of the selected end piece see Dimensions p 40 Travel range maximum 20 mm M 235 2xx models or 50 mm M 235 5xxmodels Space requirements for a kink free and proper guiding of the connection cable and ad...

Page 27: ...ons of the actuator and relevant individual parts can be found in the figures in the section Dimensions p 40 5 4 Installing the Actuator in a Mechanical Mounting NOTICE Incorrect tightening torque of the mounting nut The motion of the pusher can be hindered by a mounting nut that has been tightened too strongly This reduces the positioning accuracy Tighten the mounting nut to a maximum torque of 1...

Page 28: ...g instructions refer to this case Prerequisites You have read and understood the General Notes on Installation p 17 You have provided your application with a suitable mounting for the mounting shaft of the actuator p 21 Tools and accessories Open end wrench SW 24 Installing the actuator 1 Loosen the mounting nut on the mounting shaft of the actuator 2 Position the actuator in the mounting of your ...

Page 29: ...ounting nut into the thread of the mounting shaft with a few rotations 5 To clamp the actuator in the mounting tighten the mounting nut using the open end wrench until you feel a resistance The torque must not exceed 1 Nm 6 Check that the actuator is correctly fitted in the mounting ...

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Page 31: ... NOTICE Damage if a wrong motor controller is connected Connecting a linear actuator to an unsuitable controller can cause damage to the linear actuator or controller Connect a linear actuator with DC motor to a DC motor controller only Connect a linear actuator with stepper motor to a stepper motor controller only NOTICE Damage due to the pusher crashing into the hard stop When the limit switches...

Page 32: ...facturers before starting up the actuator check the technical data to make sure that they are suitable INFORMATION The maximum velocity for a linear actuator with a stepper motor should be determined in the application If the commanded velocity is too high the stepper motor might stop without the controller detecting this condition INFORMATION The handwheel of a linear actuator with stepper motor ...

Page 33: ...the positive direction of motion 6 2 Starting Up the Actuator In the following a PC with PC software is used as the peripheral control equipment of the controller Prerequisites You have read and understood the General Notes on Start Up p 27 You have correctly installed the actuator p 17 You have read and understood the user manual of the used controller You have read and understood the manual of t...

Page 34: ...or cable c Secure all connections with the integrated screws against accidental disconnection d Remove or label resulting danger areas in accordance with the valid legal regulations and directives 5 Start up the controller see user manual of the controller 6 Configure the controller using the PC software for the used actuator see the user manual of the controller and the PC software If you use a P...

Page 35: ...wing maintenance measures are required Spreading lubricant If you operate the M 235 continuously on a small travel range 20 of the entire travel range perform a maintenance run every 2000 motion cycles across the entire travel range Lubrication Under laboratory conditions the linear actuator needs extra lubrication in exceptional cases only For continuous industrial use the lubrication intervals m...

Page 36: ... the linear actuator Only when the linear actuator is not used in vacuum When necessary clean the linear actuator surface with a towel lightly dampened with a mild cleanser or disinfectant Do not use any organic solvents Only when the linear actuator is used in vacuum Only touch the linear actuator with powder free gloves If necessary wipe the linear actuator clean ...

Page 37: ...nnecting cable Lateral forces are affecting the pusher Lateral forces increase the friction on the internal drive components Avoid lateral forces on the tip and on the pusher of the M 235 The mechanical system does not move but generates operating noise Values for the velocity acceleration and or load are too high Reduce the velocity Reduce the acceleration Reduce the load on the mechanical system...

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Page 39: ...rning your system have the following information ready Product codes and serial numbers of all products in the system Firmware version of the controller if present Version of the driver or the software if present Operating system on the PC if present The latest versions of the relevant user manuals for your system are available for download on our website http www pi ws 9 Customer Service ...

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Page 41: ...tary encoder Rotary encoder Sensor resolution 2048 2048 cts rev Design resolution 0 016 0 5 µm typ Minimum incremental motion 0 1 1 5 µm typ Backlash 2 2 µm typ Unidirectional repeatability 0 1 0 5 µm typ Velocity 2 30 mm s max Mechanical properties Gear ratio 29 6 1 Push pull force 120 50 N max Permissible lateral force 8 8 N max Drive properties Motor type DC gear motor DC motor Operating voltag...

Page 42: ...cl encoder driver Recommended controllers drivers C 863 C 884 C 863 C 884 10 1 2 Ambient Conditions and Classifications The following ambient conditions and classifications must be observed for the M 235 Area of application For indoor use only Maximum altitude 2000 m Relative humidity Highest relative humidity 80 for temperatures up to 31 C Decreasing linearly to 50 relative humidity at 40 C Stora...

Page 43: ...ve high That means Normal motor operation low 0 V Limit switch reached high 5 V Models with stepper motor active low That means Normal motor operation high 5 V Limit switch reached low 0 V 10 1 4 Reference Point Switch Specifications Type Magnetic Hall effect sensor Supply voltage 5 V GND Signal output TTL level Signal logic Direction sensing by means of different signal levels on the left and rig...

Page 44: ...ta 40 Version 1 2 MP106E M 235 Linear Actuators 10 2 Dimensions 10 2 1 Actuator Dimensions in mm Note that the decimal places are separated by a comma in the drawings Figure 8 M 235 xDx and M 235 xVx dimensions in mm ...

Page 45: ...a M 235 Linear Actuators MP106E Version 1 2 41 10 2 2 End Pieces Dimensions in mm Note that the decimal places are separated by a comma in the drawings Figure 9 Low profile top piece left and spherical end piece right ...

Page 46: ...l 9 Input Motor 2 Input Motor 10 Internal 3 Internal 11 Internal 4 Input 5 V supply from controller 12 Output Limit switch signal negative side 5 Output Limit switch signal positive side 13 Output Reference point switch signal 6 GND limit switch and logic 14 Output Encoder A 7 Output Encoder A 15 Output Encoder B 8 Output Encoder B ...

Page 47: ...observe the international national and local rules and regulations To meet the manufacturer s product responsibility with regard to this product Physik Instrumente PI GmbH Co KG ensures environmentally correct disposal of old PI equipment that was first put into circulation after 13 August 2005 free of charge If you have old PI equipment you can send it postage free to the following address Physik...

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Page 49: ...12 EU Declaration of Conformity M 235 Linear Actuators MP106E Version 1 2 45 12 EU Declaration of Conformity ...

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