IAI IF User manual

IF Actuator
Operating Manual
Eighth Edition
IAI America, Inc.

INTELLIGENT ACTUATOR
Safety Precautions (Please read before using the product.)
Before installing, operating, maintaining or inspecting this product, please peruse this operating manual as
well as the operating manuals and other related documentations for all equipment and peripheral devices
connected to this product in order to ensure the correct use of this product and connected
equipment/devices. Those performing installation, operation, maintenance and inspection of the product
must have sufficient knowledge of the relevant equipment and their safety. The precautions provided
below are designed to help you use the product safely and avoid bodily injury and/or property damage.
In this operating manual, safety precautions are classified as “Danger,” “Warning,” “Caution” and
“Note,” according to the degree of risk.
Danger Failure to observe the instruction will result in an imminent danger leading to
death or serious injury.
Warning Failure to observe the instruction may result in death or serious injury.
Caution Failure to observe the instruction may result in injury or property damage.
Note The user should take heed of this information to ensure the proper use of the
product, although failure to do so will not result in injury.
It should be noted that the instructions under the Caution and Note headings may also lead to
serious consequences, if unheeded, depending on the situation.
All instructions contained herein provide vital information for ensuring safety. Please read the contents
carefully and handle the product with due caution.
Please keep this operating manual in a convenient place for quick reference whenever needed, and also
make sure that the manual will get to the end-user.
Danger
[General]
Do not use this product for the following applications:
1. Medical equipment used to maintain, control or otherwise affect human life or physical health
2. Mechanisms and machinery designed for the purpose of moving or transporting people
3. Important safety parts of machinery
This product has not been planned or designed for applications requiring high levels of safety. Use of
this product in such applications may jeopardize the safety of human life. The warranty covers only the
product as it is delivered.
[Installation]
Do not use this product in a place exposed to ignitable, inflammable or explosive substances. The
product may ignite, burn or explode.
When installing the product, be sure to securely support and affix it (including the work). Failure to do so
may cause the product to tip over, drop or malfunction, resulting in injury.
●
●
●

INTELLIGENT ACTUATOR
Avoid using the product in a place where the main unit or controller may come in contact with water or
oil droplets.
●
●
Never cut and/or reconnect the cables supplied with the product for the purpose of extending or
shortening the cable length. Doing so may result in fire.
[Operation]
●Do not enter the machine’s range of operation while the product is operating or standing by. The
actuator may move suddenly, causing injury.
●Do not pour water onto the product. Spraying water over the product, washing it with water or using it in
water may cause the product to malfunction, resulting in injury, electric shock, fire, etc.
[Maintenance, Inspection, Repair]
●Never modify the product. Unauthorized modification may cause the product to malfunction, resulting in
injury, electric shock, fire, etc.
●Do not disassemble and reassemble the components relating to the basic structure of the product or its
performance and function. Doing so may result in injury, electric shock, fire, etc.
Warning
[General]
●Do not use the product outside the specifications. Using the product outside the specifications may
cause it to fail, stop functioning or sustain damage. It may also significantly reduce the service life of the
product. In particular, observe the maximum loading capacity and speed.
[Installation]
●If the machine will stop in the case of system problem such as emergency stop or power failure, design
a safety circuit or other device that will prevent equipment damage or injury.
●Be sure to provide Class D grounding for the controller and actuator (formerly Class 3 grounding:
Grounding resistance at 100 Y or less). Leakage current may cause electric shock or malfunction.
●Before supplying power to and operating the product, always check the operation area of the equipmen
to ensure safety. Supplying power to the product carelessly may cause electric shock or injury due to
contact with the moving parts.
●Wire the product correctly by referring to the operation manual. Securely connect the cables and
connectors so that they will not be disconnected or come loose. Failure to do so may cause the product
to malfunction or cause fire.
[Operation]
●Before operating the moving parts of the product by hand (for the purpose of manual positioning, etc.),
confirm that the servo is turned off (using the teaching pendant). Failure to observe this instruction may
result in injury.
●Do not scratch the cables. Scratching, forcibly bending, pulling, winding, crushing with heavy object or
pinching a cable may cause it to leak current or lose continuity, resulting in fire, electric shock,
malfunction, etc.
●Turn off the power to the product in the event of power failure. Failure to do so may cause the product
to suddenly start moving when the power is restored, thus resulting in injury or product damage.
●If the product is generating heat, smoke or a strange smell, turn off the power immediately. Continuing
to use the product may result in product damage or fire.
●If noise or abnormally high vibration is detected, stop the operation immediately. Continuing to use the
product may result in product damage, malfunction due to damage, runaway machine, etc.
●If any of the product’s protective functions (alarms) has actuated, turn off the power immediately.
Continuing to use the product may result in injury due to product malfunction, or cause product
breakdown or damage. After the power has been cut off, identify and remove the cause of the problem,
and then reconnect the power.

INTELLIGENT ACTUATOR
●Do not step on the product, use it as a footstool or place any object on it. You may slip and fall or the
product may tip over or drop, resulting in injury. Malfunction, runaway product, etc., may also result due
to product breakdown or damage.
[Maintenance, Inspection, Repair]
●Before commencing maintenance/inspection, servicing, replacement or any other work on the product,
be sure to completely cut off the power supply to the product. Also take heed of the following
precautions:
1. Put up a sign bearing “WORK IN PROGRESS. DO NOT TURN ON POWER” or other warning
statement to that effect, to prevent a bystander from accidentally turning on the power.
2. If multiple operators work together to perform maintenance/inspection work, the operators should
always give verbal cues to one another to ensure safety before turning on/off the power or
moving any axis.
[Disposal]
●Do not throw the product into flames. The product may explode or toxic gases may generate.
Caution
[Installation]
●Do not use the product in a place exposed to direct sunlight (ultraviolet ray), dusty place or place where
air contains salt or iron powder, humid place, or in any ambience where the product may come in
contact with organic solvent, hydraulic oil containing phosphate ester, etc. If used in these places,
the product may lose its function over a short period of time or suffer rapid performance deterioration,
or the service life of the product may be reduced.
●Do not use the product in an area where it may come in contact with corrosive gases (sulfuric acid,
hydrochloric acid, etc.). The product may lose its strength due to rust.
●Provide sufficient shielding measures if the product is used in any of the following places. If proper
measures are not taken, the product may malfunction:
1. Place where large current or strong magnetic field generates
2. Place where arc discharge occurs due to welding work, etc.
3. Place where noise generates due to electrostatic, etc.
4. Place where the product may come in contact with radiation
●Do not install the product in a place subject to vibration or shock.
●Provide an emergency stop device in an easily accessible position so the device can be immediately
actuated should danger occur during operation. Failure to do so may result in injury.
●Provide sufficient maintenance space when installing the product. If sufficient space is not available,
daily inspection, maintenance and other necessary work cannot be carried out, resulting in system
shutdown or product damage.
●When transporting or installing the product, support the product using a lift or suspension equipment or
carry it with multiple operators working together, and exercise due caution to ensure safety.
●When installing the product, do not hold the moving parts or cables of the product. Doing so may result
in injury.
●Use IAI’s genuine cables to connect the actuator and controller. Also use IAI’s genuine components for
the actuator, controller, teaching pendant, etc.
●The brake mechanism is designed to prevent the slider from dropping upon turning off the power when
the actuator is installed vertically. Do not use the brake mechanism as a safety brake.
●When installing, adjusting or carrying out any other work on the actuator, put up a sign bearing “WORK
IN PROGRESS. DO NOT TURN ON POWER” or other warning statement to that effect, to prevent the
product from being powered on accidentally. If the power is turned on accidentally, injury may result due
to electric shock or sudden movement of the actuator.

INTELLIGENT ACTUATOR
[Operation]
●Turn on the power to individual equipment one by one, starting from the equipment at the highest level
in the system hierarchy. Failure to do so may cause the product to start suddenly, resulting in injury or
product damage.
●Do not insert a finger or object in the openings in the product. It may cause fire, electric shock or injury.
●Do not step on the product, use it as a footstool or place any object on it. It may cause scoring, dents or
deformation of the driving part, resulting in product damage, unintended stopping due to damage, or
performance drop.
[Maintenance, Inspection, Repair]
●Wear protective goggles when applying grease to the actuator. Failure to do so may result in eye
inflammation due to spattered grease.
Note
[Installation]
●If the product is used in a vertical setup, be sure to use the vertical specification (with brake).
●Protection covers or other guards must be provided for the moving parts of the equipment to avoid
direct contact with the operators.
●Do not configure a control circuit that will cause the work to drop in case of power failure. Configure a
control circuit that will prevent the table or work from dropping when the power to the machine is cut off
or an emergency stop is actuated.
●The following conditions must be met in order to improve the straightness of the table movement and
ensure the smooth movement of the ball screw and linear guides:
[Installation, Operation, Maintenance]
●When handling the product, wear protective gloves, protective goggles, safety shoes or other necessary
gear to ensure safety.
[Maintenance, Inspection, Repair]
●When performing maintenance, apply the specified grease to the guides and ball screw. Pay special
attention not to let fluoride grease mix with lithium grease. The machine may be damaged due to poor
lubrication, increased resistance, etc.
[Disposal]
●When the product becomes no longer usable or necessary, dispose of it properly as an industrial waste.
Others
■IAI shall not be liable whatsoever for any loss or damage arising from a failure to
observe the items specified in “Safety Precautions.”
Flatness of the mounting surface must be within 0.05 mm.
The mounting surface area must be large enough to ensure the rigidity of the actuator.
1.
2.

INTELLIGENT ACTUATOR
Prohibited Handling of Cables
When designing an application system using IAI’s actuators and controllers, incorrect wiring or connection
of each cable may cause unexpected problems such as a disconnected cable or poor contact, or even a
runaway system. This section explains prohibited handling of cables. Read the information carefully to
connect the cables properly.
1. Do not let the cable flex at a single point.
2. Do not let the cable bend, kink or twist. 3. Do not pull the cable with a strong force.
4. Do not let the cable receive a turning force at a
single point.
6. Do not pinch, drop a heavy object onto or cut
the cable.
5. When fixing the cable, provide a moderate slack
and do not tension it too tight.
Steel band
(piano wire)
Bundle loosely.
Use a curly
cable.
Do not use a spiral tube where
the cable flexes frequently.

INTELLIGENT ACTUATOR
7. Notes on using cable bearers
●Do not let the cable get tangled or kinked in a cable bearer or flexible tube. When bundling the cable,
keep a certain degree of flexibility (so that the cable will not become too taut when bent).
Do not cause the cables to occupy more than
60% of the space in the cable bearer.
●● Do not lay signal lines together with circuit lines
that create a strong electric field.
Cable
Cable bearer
Power line
Signal lines (flat cable)
Duct
●The supplied cables are not robot cables. Accordingly,
never store the cables in a cable bearer.
●Always use a robot cable
for each relay cable. Bending radius (r)
●Use a cable bearer with a bending
radius (r) of 50 mm or greater.

INTELLIGENT ACTUATOR
Table of Contents
1. Foreword
2. Safety Precautions
2.1 Basic Operating Instructions
2.2 Maintenance and Inspection
3. Warranty
3.1 Warranty Period
3.2 Scope of Warranty
4. Names of the Parts
5. Transporting • Handling
5.1 Handling of the Single Unit
5.1.1 Handling of the Packed Unit
5.1.2 Handling the Actuator After It is Unpacked
5.2 Handling of the Assembled Unit
5.2.1 Shipping of the Assembled Unit from Our Company
5.2.2 Handling of the Assembled Unit with Peripheral Equipment
6. Installation and Storage Enviroment
6.1 Installation Environment
6.2 Storage Environment
7. Installation
7.1 Installing the Main Body
7.2 Mounting Surface
7.3 Clamp Screws
7.4 Mounting and the T-Slot (Option)
7.5 Attaching the Slider Carrying the Pay load
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INTELLIGENT ACTUATOR
8. Connecting the Controller
9. Load On the Actuator
10. Setting the Home Position
10.1 Principle of the Homing Operation
10.2 Fine Control of the Home Position
10.3 Changing the Home Direction
10.4 Counter Mark Affixation
11. Maintenance
11.1 Inspection check points and timing
11.2 Visual Inspection of the Machine Exterior
11.3 Cleaning
11.4 Inspecting the Interior
11.5 Cleaning the Interior
11.6 Grease Replenishment for the Guide
11.6.1 What Grease to Use
11.6.2 How to Lubricate
11.7 Timing Belt
11.7.1 Inspecting the Belt
11.7.2 Best to be used
11.7.3 Belt Tension Adjustment Method
11.7.4 Driving Belt Replacement
11.7.5 Deceleration Belt Replacement
11.8 Motor Replacement
Appendix
How to Use the Origin Marks
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INTELLIGENT ACTUATOR
1. Foreword
2. Safety Precautions
2.1 Basic Operating Instructions
2.2 Maintenance and Inspection
1
Thank you for purchasing the IF Actuator. This manual explains the structure, correct operation, assembly and maintenance
of the IF Actuator. Please read this manual carefully before using the actuator. For more complete information on operating
the actuator, please refer to the controller operating manual.
• Please do not attempt to use or operate the actuator in any manner not indicated in this manual or the controller manual.
• Please be sure to use only the cable provided by IAI to connect the actuator and controller.
• Please do not allow people within the moving range of the unit when it is in operation or when the power is ON since this
is dangerous.
• When doing maintenance and inspection work, always shut down the controller power first.
• When doing inspection, make sure that no one can inadvertently turn the power ON.
• Make sure that a sign indicating work in progress is clearly visible.
• If several persons are working, be sure to watch out for each other's safety. In particular, check before turning power ON
or OFF and let others know if you are doing work involving axis movement.
(Note)
• The content of this manual is subject to change without notice for the purpose of improvement.
• This manual was created with utmost attention to accuracy. Should you find any error, however, or if you have any question,
please contact IAIÅfs Sales Engineering or Technical Service Section.

INTELLIGENT ACTUATOR
3. Warranty
3.1 Warranty Period
3.2 Scope of Warranty
Warranty period shall be either of the following periods whichever ends first:
• 18 months after shipment from our factory
• 12 months after delivery to a specified location
• 2500 hours of operation time
If a breakdown occurs within the period specified above and is due to the manufacturer's error, we will repair the unit at no
cost. However, the following items are not covered by this warranty.
• Faded paint or other changes that occur naturally over time.
• Consumable components that wear out with use (stainless sheet, etc.).
• Unit seems to be noisy or similar impressions that do not affect machinery performance.
• Damage resulting from improper handling by the user or lack of proper maintenance.
• Any alterations made by other than IAI or its representatives.
• Breakdowns caused by using controllers made by other manufacturers.
• Any damages caused by fire and other natural disasters or accidents.
The warranty pertains to the purchased product itself and does not cover any damages that might arise from a breakdown
of the supplied product.
Any repairs will be done at our factory. Even if the product is still covered under the warranty period, we will assess a
separate charge for sending technicians to the customer's site.
2

3
INTELLIGENT ACTUATOR
4. Names of the Parts
In this manual, the left and right sides are indicated by viewing the actuator from the upper and the motor sides with the
actuator set down horizontally. The front side shown in this manual is the opposite from the motor side.
Front Side
(Reversed motor side) Slider
Thumb
Motor Side
Right Side
Left Side
Pulley bracket
T-slotBase
Pulley cover
Motor cover
Belt cover
Front cover
Caution
The Thumb is turned at high speed. Do not touch it during the actuator operation. Otherwise, your finger might be
caught and you might get injured.

INTELLIGENT ACTUATOR
5. Transporting • Handling
5.1 Handling of the Single Unit
When a single actuator is carried, follow the instructions below.
Unless there are special instructions, the actuator is shipped with each axis packed separately. Please take care that the
shipping box is not dropped or subjected to strong impact during transport.
• The operator should not carry heavy shipping boxes by himself.
• If the shipping box is left standing, it should be in a horizontal position.
• Do not climb on top of the shipping box.
• Do not place heavy objects on top of the shipping box.
Lift the actuator up by the base to remove it from the packing.
* Please refer to Section 4 regarding the names of the actuator parts.
5.1.1 Handling the Packed Unit
5.1.2 Handling the Actuator After It is Unpacked
• When carrying the actuator, take care not to bump it. In particular, take care of the pulley cover and motor cover.
• Do not exert excessive force on any part of the actuator. Take particular care with the screw cover and cable.
• Take care not to pull the cable.
4

INTELLIGENT ACTUATOR
5.2 Handling of the Assembled Unit
5
When the actuator is carried with all the axes installed, follow the instructions below.
5.2.1 Shipping of the Assembled Unit from Our Company
5.2.2 Handling of the Assembled Unit with Peripheral Equipment
For the specified machine, after it is assembled in our company, the delivery inspection is performed and the machine is
packed with the outer frame nailed onto the skid. The carton is fixed so that the slider does not move unexpectedly during
the transportation. For the combined actuator unit, it is fixed so that the pointed end does not swing greatly due to the
external vibration.
When the machine is transported after it is assembled in and shipped from our company, or assembled in your company,
handle it following the instructions below.
• There is no special accommodation for this carton to endure the impact due to drop or bump. Therefore, take the greatest
care in handling it. Because the outer frame can not stand the load on it, do not put any heavy thing on it.
• When it is suspended using a rope, support it from the reinforced frame under the skid. When it is lifted using the forklift, lift
it also from the skid bottom.
• When it is lowered, handle it so that no impact is given or it does not bounce.
• Fix the slider section, so that the slider does not move unexpectedly.
• When the actuator end is projected, fix it appropriately so that the projected end does not swing greatly due to the external
vibration.
• In the transportation of this machine without fixing the pointed end, do not give any impact of 0.3G or more.
• When the actuator and its peripheral equipment are suspended using a rope, arrange the rope so that it does not touch the
machine body directly.
• Arrange it so that the load of the rope is given directly to the base body through the appropriate buffer material.
• Support the front end of the Y-axis and keep its stable horizontal setup. At that time, take care not to give any load onto the
belt cover.
• Take care not to give any load onto the bracket, the cover or connector box on each section in the main machine. Also,
make sure that the cable is not caught or deformed forcibly.
After it is unpacked, handle it following the instructions below.

INTELLIGENT ACTUATOR
6. Installation and Storage Environments
6.1 Installation Environment
The actuator should be set up in an environment which meets the following criteria:
6.2 Storage Environment
The storage environment should be similar to the operating environment. In addition, you must take precautions
against condensation if the unit is to be stored for a long period of time.
Unless there are special instructions, we do not include moisture absorption agents when shipping the unit. If you are
storing the unit where condensation might occur, then you must treat the entire packing or treat the unit itself after it is
unpacked to prevent condensation.
The unit can withstand up to 60ºC during a short storage interval but only up to 50ºC if the storage period is longer than one
month.
• Avoid direct sunlight.
• Avoid radiant heat from strong heat sources such as a furnace.
• Ambient temperature should be 0 ~ 40º C.
• The humidity should be less than 85% and there should be no condensation.
• Avoid exposure to corrosive or combustible gases.
• The area should have very little dust and be suitable for normal assembly operations.
• Avoid exposure to oil mist or fluids used in cutting.
• The unit should not be subject to vibrations greater than 0.3G.
• Avoid surroundings with extreme electromagnetic waves, ultraviolet rays and radiation.
In This product, any chemical resistance has not been considered. In general, the environment should be one in which an
operator can work without protective gear or clothes.
6

INTELLIGENT ACTUATOR
7. Installation
7.1 Installing the Main Body
7
We'll describe the installation process using a single axis unit.
Machine Type
Small 50mm
Medium 70mm
5mm
6mm
M6
M8
7
9
ABCMounting Bolt
• There is a set hole on the actuator base. Fix the actuator using this set hole.
• The belt cover can be removed using the hexagon wrench with the distance to the opposite side of 2 mm.
• For the set bolt, use hexagon socket head cap screw with the intensity classification of 10.9 or more and fasten it with the
attached special washer.
A
φB
C
Caution
Make sure to use the attached special washer. If the actuator is mounted without using this washer, the bolt might
be loosened due to the buckling on the bolt-seated surface.

INTELLIGENT ACTUATOR
7.2 Mounting Surface
Caution:
As the diagram above shows, the slider travelling plane is the reference plane for the actuator base and the lower
surface. When travelling precision is required, use this as the reference plane for mounting.
• The mounting table should have sufficient rigidity to avoid generating vibration.
• The surface where the actuator will be mounted should be machined or be equally level and the flatness tolerance between
the actuator and the table should be within 0.05mm.
• Provide enough space around the actuator to permit maintenance work to be done.
• The side and bottom surfaces of the actuator base are used as the reference surfaces for the slider run.
• In the case that the running accuracy is required, mount the slider using these surfaces as the reference.
Please follow the diagrams below for machining to mount on to the frame using the base surface:
8
Standard
side
Machine Type A dimensions (mm)
Small 2~5
Medium 2~5
A
Under R0.3
Standard
side
Standard
side

INTELLIGENT ACTUATOR
7.3 Clamp Screws
7.4 Mounting and the T-Slot (Option)
9
• Use hexagon bolts as the screws for mounting the base.
• For the bolts, we recommend high strength bolts of ISO- 10.9 or higher.
• Make sure the bolt and screw engagement length is the following value or greater:
Steel screw
Aluminum screw
• When attaching the base to a mounting table, use the special washer made for high strength bolts that comes with the
actuator if the bolt is M8 or larger. This is unnecessary for M6 or smaller bolts. Do not use a common spring washer.
There are T-slots (width of slot 4mm) in the base for mounting external devices such as a connector box (Please see
drawing below).
When using the wiring kit, mount the connector box using these T-slots.
Use the slots as necessary to mount sensors or to anchor cables.
Space between
bolt tip
Square Head Nut
(or Hexagon Nut)
Mounting part
Bolt
Screw nominal
diameter
Screw Torque
When the rod surface is steel When the rod surface is aluminum
7.5N • m (0.77kgf • m) 4.3N • m (0.44kgf • m)
12.9N • m (1.32kgf • m) 6.7N • m (0.68kgf • m)
31.3N • m (3.19kgf • m)
M5
M6
M8 14N • m (1.43kgf • m)
1.54.5
4.3
7.3
Caution:
We recommend a square nut for the T-slot but you can also use a hexagonal nut.
When mounting, check the bolt length to make sure the end does not touch the bottom of the T-slot.
twice as long as the nominal diameter
same length as the nominal diameter
The recommended screw torque is given below.

INTELLIGENT ACTUATOR
7.5 Attaching the Slider Carrying the Payload
Slider Tap Hole Diameter and Reamer Diameter
Machine Type
Small
Medium
Tap diameter
M6
M6
M8
Reamer hole
φ6H10
φ8H10 10mm
Reamer depth
10mm
Tap depth
20mm
20mm
20mm
A
70mm
---
90mm
B
---
70mm
---
C
90mm
120mm
• There are tapped holes in the slider where you can affix the payload.
• To do this, follow the mounting procedure used for the main body.
• If you are anchoring the slider and moving the main body, attach the slider using the tapped holes.
• The slider has two reamed holes which are used to reproduce the correct positioning when dismounting and reattaching
the slider. Use only one of the holes when fine adjustments to the perpendicularity are required.
10
A
B
Reamer hole