Tsubaki ZIP CHAIN ACTUATOR ZCA25 Instruction Manual Download

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ZCA01TSE

Printed June 1, 2020

ZIP CHAIN ACTUATOR

Instruction Manual

【

NOTE

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Ensure that this instruction manual is delivered properly to the end

user of this product.

This manual uses SI units.

Figure in

｛｝

are gravitational units and are for reference only.

Summary of Contents for ZIP CHAIN ACTUATOR ZCA25

Page 1: ...2020 ZIP CHAIN ACTUATOR Instruction Manual NOTE Ensure that this instruction manual is delivered properly to the end user of this product This manual uses SI units Figure in are gravitational units an...

Page 2: ...After reading keep this manual in a convenient place for reference Safety precautions in this manual are classified into two categories Warnings and Cautions Death or serious injury may result from m...

Page 3: ...l laws and regulations such as electrical equipment standards and internal wiring rules and follow all cautions Especially follow instructions with regard to grounding to prevent electric shock Shut d...

Page 4: ...you have any questions please contact your distributor or a Tsubaki representative When inquiring please give us the information on the ZIP CHAIN ACTUATOR nameplate Contents 1 Unpacking P 1 2 Transpor...

Page 5: ...th TERVO With bellows ZCA45 If you find any defective or missing items please contact your distributor 2 Transportation 1 Take care when transporting the packaged product as the weight is unbalanced l...

Page 6: ...hain pulling into the tapped end fitting bracket hole and slowly pull up Remove the bolt after pulling up the chain and dispose of properly It is dangerous to operate the input shaft under load since...

Page 7: ...ides of the housing section together snap fit construction There are no bolts for these holes Do not use these holes to mount the unit as they lack the strength to hold the unit and may break prematur...

Page 8: ...mounting apply an adhesive agent to prevent bolts from loosening Use the brands shown in Table 6 or their equivalent Follow instruction provided with each product before applying Table 6 Adhesive Agen...

Page 9: ...ds on the installation direction and load size so calculate maximum coasting distance As a precaution install a mechanical external stopper within the stroke range 22 Check the direction of the input...

Page 10: ...ecommended 5 There will be bearing and chain sliding frictions regardless of load so torque is essential even when unloaded When the ratio for the average unloaded operating torque is higher than the...

Page 11: ...tes Outer circumference of the bushings ZCA45 pins Extended pins Ensure that bushings and extended pins are not cracked or broken Note The bush is curled and therefore has a seam This is not a crack I...

Page 12: ...not be turned on accidentally Check the following unrelated to ZIP CHAIN I Check the end fitting bracket for cracks distortion rust etc II Check the drive unit for cracks distortion rust etc III Check...

Page 13: ...ZCA45 2000 2700 day 6 months 4 months 1 5 months 1000 2000 day 8 months 5 months 2 months 1 1000 day 12 months 12 months 3 5 months Regular lubrication interval is 500 000 strokes for ZCA25 350 000 s...

Page 14: ...CHAIN using a different brush Refer to Table 12 and Fig 7 Turn on the power and return the ZCA to normal operation Table 12 ZIP CHAIN Lubrication Points Part Range Note Bushing Pin All links Especiall...

Page 15: ...kage point Coupling misalignment Refer to Input Shaft Breakage point Coupling adjustment in the axial direction Adjust the position and length of the coupling so the input shaft is not subjected to lo...

Page 16: ...12 8 Diagram of External Dimensions Fig 8 External Diagram ZCA25 Table 14 Diagram Model No Stroke mm A mm B mm Lmax mm ZCA25N030EL 300 105 275 390 ZCA25N050EL 500 149 363 590...

Page 17: ...13 Fig 9 External Diagram ZCA35 Table 15 Diagram Model No Stroke mm A mm B mm Lmax mm ZCA35N050EL 500 156 404 631 ZCA35N075EL 750 218 5 529 881 ZCA35N100EL 1000 281 654 1131...

Page 18: ...14 Fig 10 External Diagram ZCA45 Table 16 Diagram Model No Stroke mm A mm B mm Lmax mm ZCA45N100EL 1000 298 758 1250 ZCA45N150EL 1500 423 1008 1750 ZCA45N200EL 2000 548 1258 2250...

Page 19: ...10 50 400 40 8 48 58 9 10 60 400 40 8 40 48 8 9 009 90W 10 166 17 0 243 292 10 10 15 274 28 0 162 195 10 10 20 382 39 0 122 145 10 10 25 400 40 8 97 117 10 10 30 400 40 8 82 97 10 10 500 006 60W 40 33...

Page 20: ...794 81 0 292 351 8 10 15 941 96 0 243 292 10 10 20 1000 102 0 183 291 10 10 25 1000 102 0 146 175 10 10 30 1000 102 0 122 146 10 10 1000 020 0 2kW 40 600 61 2 91 110 10 10 50 600 61 2 73 88 8 10 60 6...

Page 21: ...25 1765 180 0 245 294 10 10 30 2000 204 0 204 245 10 10 40 2000 204 0 153 183 9 10 50 2000 204 0 122 147 7 8 2000 040 0 4kW 60 1200 122 5 102 122 6 7 80 1200 122 5 76 91 4 5 5 5 100 1200 122 5 61 73...

Page 22: ...0 33 6 317 7 20 400 40 8 238 3 500 020 0 2kW 5 86 8 0 953 10 199 20 0 476 5 15 330 33 6 317 7 20 330 33 6 238 3 Values on the above table are for operation at 3000 r min of the input shaft rotation sp...

Page 23: ...1000 102 0 357 3 1000 040 0 4kW 40 600 61 2 178 6 075 0 75kW 5 236 24 0 1000 10 549 55 0 714 5 15 600 61 2 476 3 20 600 61 2 357 3 Values on the above table are for operation at 3000 r min of the inp...

Page 24: ...0 2000 204 0 150 2000 040 0 4kW 120 1200 122 5 100 075 0 75kW 20 586 59 0 500 25 765 78 0 480 30 946 96 0 400 40 1200 122 5 300 50 1200 122 5 240 60 1200 122 5 200 80 1200 122 5 150 Values on the abov...

Page 25: ...irmly Mounting bolts not included Refer to Table 5 on page 4 for mounting bolt size Bolts should have a strength classification of 10 9 JIS B 1051 or over Bolt penetration depth should be in considera...

Page 26: ...ernal Diagram with Motor ZCA25M Approximate mass kg Model No Motor Capacity 60W 90W ZCA25M030EL 10 0 10 5 ZCA25M050EL 10 5 11 0 Motor unit bottom surface will extend beyond the bottom surface of the h...

Page 27: ...acity 0 2kW 0 4kW ZCA35M050EL 14 0 18 0 ZCA35M075EL 15 0 19 0 ZCA35M100EL 16 0 20 0 Unit mm Motor Capacity C D E F G H 0 2kW 80 8 240 2 134 5 3 5 244 5 211 5 0 4kW 91 8 274 7 134 5 11 5 248 5 215 5 Mo...

Page 28: ...am with Motor ZCA45M Approximate mass kg Model No Motor Capacity 0 4kW 0 75kW ZCA45M100EL 35 5 47 5 ZCA45M150EL 40 0 51 5 ZCA45M200EL 44 5 56 0 Unit mm Motor Capacity C D G H 0 4kW 114 252 5 225 5 268...

Page 29: ...CA25K Approximate mass kg Model No Motor Capacity 0 2kW ZCA25K030EL 7 0 ZCA25K050EL 7 5 Unit mm Motor Capacity C D E F G H 0 2kW 69 8 123 2 96 3 166 142 Motor unit bottom surface will extend beyond th...

Page 30: ...tor Capacity C D E F G H 0 4kW 91 8 132 7 128 5 3 5 203 5 170 5 0 75kW 102 8 160 2 136 14 227 5 194 5 Be aware that dimensions are different depending on the mounting code Above values are obtained fr...

Page 31: ...kW 0 75kW ZCA45K100EL 30 0 39 0 ZCA45K150EL 34 0 43 0 ZCA45K200EL 38 5 47 5 Unit mm Motor Capacity C D G H 0 4kW 114 110 5 223 5 180 5 0 75Kw 125 138 247 5 204 5 Be aware that dimensions are different...

Page 32: ...the power during blackouts Wire Connection and Rotation Direction Table 23 Wire Connection and relation to chain direction of travel Three Phase Motor 60W to 0 75kW A B Chain Direction of Travel Rela...

Page 33: ...oid Motor Size Motor Capacity Reduction Ratio Wire Connection A Wire Connection B ZCA 25 90W 10 15 20 25 30 60W 40 50 60 35 0 4kW 10 12 5 15 20 25 30 0 2kW 40 50 60 45 0 75kW 10 12 5 15 20 25 30 40 50...

Page 34: ...ection of travel with TERVO Size Motor Capacity Reduction Ratio Wire Connection A Wire Connection B ZCA 25 0 2kW 5 10 15 20 35 0 75kW 5 10 15 20 0 4kW 40 45 0 75kW 20 25 30 40 50 60 80 0 4kW 120 Model...

Page 35: ...or more The maximum operating frequency is 120Hz and the low Hz range low frequency should be used within the allowable range of the inverter The 0 75kW motor type is also capable of constant torque o...

Page 36: ...ith micro surge protection However with levels in excess of 1200V a suppression filter or reactor should be installed on the inverter side Other points to note Compared with standard power supplies gr...

Page 37: ...e Fig 18 Attaching and removing the plastic terminal box cover 5 Wiring the brake ZCA units are shipped standard with AC internal wiring but response times will differ by connection Please select your...

Page 38: ...ier N Protection element varistor 1 After wiring and before turning on the power make sure the lead wire of the DC rectifier is yellow or red on the power side and black on the brake side 2 The DC rec...

Page 39: ...ipment Motor Brake MC Magnetic contactor MCa Auxiliary relay OCR Overcurrent relay DM200D DC rectifier N Protection element varistor 1 The brake voltage is 90VDC When inputting 200VAC to DM200D 2 When...

Page 40: ...200V 90VDC Three phase 400V 90VDC 180VDC Current at 20 A 0 178 0 232 0 273 0 142 Capacity at 20 W 16 0 20 9 24 6 25 5 Initial gap mm 0 15 to 0 20 0 15 to 0 20 0 15 to 0 20 Limit gap mm 0 5 0 5 0 5 To...

Page 41: ...ic friction torque N m kgf m 0 48 4 8 0 8 8 1 Operating voltage V Three phase 90VDC Single phase Current A Three phase 0 076 0 111 Single phase Capacity W 6 8 10 Gap amount mm Initial value 0 05 to 0...

Page 42: ...on the motor nameplate Caution The hypoid motor mini series and hypoid motor series will be incredibly hot during operation Do not touch them to avoid risk of burns Cease operation immediately when a...

Page 43: ...the gap is at its limit Inspect and replace the brake as necessary every year or every one million rotations whichever comes first As the motor specifications for ZCA25 ZCA35 and ZCA45 are different m...

Page 44: ...ce motor Heavy vibration Gear bearing wear Repair or replace motor Improper installation loose bolts Tighten all bolts Leaking grease Loose fastenings Tighten all fastenings Damaged oil seal Repair or...

Page 45: ...plings for shaft connection There will be individual differences in backlash when using synchronized ZCA units resulting in some mis positioning Be sure to install a separate mechanism to adjust phase...

Page 46: ...shaft specifications Can be used interlocked when used in parallel with an input shaft passed through the units Position can be controlled by attaching an encoder to the input and opposite side shaft...

Page 47: ...rque will be transmitted by the input shaft to the ZCAon the drive source side Confirm that the two units worth of torque is belowthe allowable input torque T1 Necessary input torque for ZCA only T2 N...

Page 48: ...c capacity N kgf ZCA25N050 J1 180 680 500 300N 30 6 ZCA35N100 J1 270 1270 1000 431N 44 0 ZCA45N200 J1 465 2465 2000 900N 91 8 2 Periodic inspection Check for damage to the bellows during the regular m...

Page 49: ...ir vents with filter Fig 23 With bellows attached 1 left ZCA25 middle ZCA35 right ZCA45 Fig 24 With bellows attached 2 left ZCA25 middle ZCA35 right ZCA45 Stainless steel band on top and bottom Stainl...

Page 50: ...ubricate the chain using the grease plate alone Periodically apply grease directly to the chain See pg 9 Table 10 1 Caution Grease plate cannot be added later ZCA35 ZCA45 Grease using four nipples Nip...

Page 51: ...47 Fig 25 With grease nipples ZCA25...

Page 52: ...48 Fig 26 With grease nipples ZCA35...

Page 53: ...49 Fig 27 With grease nipples ZCA45 Fig 28 Greasing method using grease nipples figure above shows ZCA35 100m 100m Grease all 4 nipples 2 nipples for ZCA25...

Page 54: ...uyer 3 Free warranty exclusions Seller will charge for any investigation and repair of Goods caused by Improper installation by failing to follow the instruction manual Insufficient maintenance or imp...

Page 55: ...51 MEMO...

Page 56: ...52...

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Page 58: ...tp tsubaki com au India Tsubaki India Power Transmission Private Limited 91 44 7101 2000 http tsubaki in Indonesia PT Tsubaki Indonesia Trading 62 21 8945 8898 http tsubakimoto co id Malaysia Tsubaki...

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