Isel LEZ 1 Installer manual

isel Germany AG
Linear units with toothed belt drive
LEZ 1 –LEZ 2 –LEZ 3 –LEZ 9
Assembly instructions with:
- Installation instructions
- Maintenance instructions
- Declaration of incorporation
for a drive system
(A partly completed machinery as defined in Machine Directive 2006/42/EG)

isel Germany AG
About these assembly instructions
Abbreviations
MD = Machine Directive 2006/42/EG
LEZ = Linear unit with toothed belt drive
AC = Alternating Current, AC servomotor (always synchronous motor)
BDC = Brushed DC, brush type Direct Current (DC) servomotor
BLDC = Brushless DC servomotor
PDF = Portable Document Format
Terminology
In these assembly instructions, "Product" always means linear unit with toothed belt drive.
Symbols used
In these instructions you will find various symbols which are there to alert you to important information /
facts and hazards:
Symbol
Signal word
Meaning
Danger
Warning of possible serious to fatal injuries to persons
Caution!
Fatal Voltage!
The lightning symbol is a clear warning of danger from electric
current!
Failure to heed 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.
Failure to take account of the circumstances indicated by this
symbol (text, picture or table) can result in serious damage to
property.
Important
information or
piece of advice
This is important information or a piece of advice on the functioning
of this product.
Observing the safety instructions
Before commissioning the axis system (as a partly completed machine), working with it or making any
additions or modifications to the electrical installation of the linear units, it is essential that you carefully
read:
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 control used.
Copyright
© isel Germany AG, January 2013
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
unclear formulation of facts and illustrations.

isel Germany AG
Note on CE compliance for partly completed machines:
isel linear units are CE compliant. They are deemed partly completed machines as defined in Machine
Directive 2006/42/EG and are accordingly not marked explicitly with the CE symbol.
Only after the compliance 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.
No other machine parts and/or machine components to which the CE safety guidelines apply may be
commissioned until all the relevant requirements of Machinery Directive 2006/42/EC are met.
isel Germany AG does not accept any responsibility once modifications have been made to the linear
unit.
Manufacturer: isel Germany AG
Bürgermeister-Ebert-Straße 40
D-36124 Eichenzell, Germany
Tel: [phone]
Fax: [phone]
Email: [email protected]
Website: www.isel-germany.com
Version of this documentation: October 2011
Other documentation 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 appropriate 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:
http://www.manuals.isel.com
In your own interest:
Please read these assembly instructions carefully and keep them in a safe place. These
instructions are part of the product "Linear unit with toothed belt drive LEZ 1 –LEZ 2 –LEZ 3
–LEZ 9", regardless of whether these instructions are supplied/available on an electronic storage
medium (as PDF file on a CD, DVD or USB memory stick) or in printed form.
Please read and follow the safety guidelines in these assembly instructions.

isel Germany AG
Contents
1General.......................................................................................................................................................... 5
1.1 Safety guidelines .................................................................................................................................. 6
1.2 Proper use............................................................................................................................................. 8
1.3 Deliverables........................................................................................................................................... 8
2Installation instructions and overview of functions.......................................................................... 9
2.1 Operation............................................................................................................................................... 9
2.2 Construction of the toothed belt unit/drive elements..................................................................... 11
2.3 Motor module connection assignment............................................................................................. 27
3Commissioning, general information ................................................................................................. 29
4Assembly and servicing of the toothed belt unit............................................................................. 30
4.1 Setting up and servicing the shaft slot............................................................................................. 30
4.2 Setting up and servicing the trolley.................................................................................................. 31
4.3 Adjustingthebeltdrive.......................................................................................................................... 31
4.4 Purpose/Assembly/Cleaning/Lubrication ........................................................................................ 33
4.5 Assembling drive modules on LEZ 1 –LEZ 2 –LEZ 3 –LEZ 9.................................................. 34
4.6 Assembly / disassembly as individual components....................................................................... 36
5Fault list...................................................................................................................................................... 37
6Technical specification........................................................................................................................... 38
6.1 Electrical specification........................................................................................................................ 38
6.2 Mechanical specification.................................................................................................................... 38
6.3 Load figures for the trolley/shaft slots.............................................................................................. 39
7Decommissioning / Disposal ................................................................................................................ 40
8CE Compliance ......................................................................................................................................... 41
9Service ........................................................................................................................................................ 42
10 Warranty ................................................................................................................................................. 43
11 Declaration of incorporation in accordance with MD 2006/42/EG.......................................... 44
12 Index........................................................................................................................................................ 45
13 Appendix ................................................................................................................................................ 46
13.1 A1: Accessories.............................................................................................................................. 46
13.2 A2 Miscellaneous ........................................................................................................................... 47

Linear units with toothed belt drive: LEZ 1/LEZ 2/LEZ 3/LEZ 9
Assembly instruction Page 5
1 General
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 LEZ 1 –LEZ 2 –LEZ 3 –LEZ 9 are linear modules with toothed belt drives, ready
for installation, which are used mainly in factory automation, handling systems and in light engineering.
These linear units are available in various standard lengths and can be fitted with special motor con-
nections.
The wide range of configuration and combination options gives the user plenty of scope to implement
his design ideas.
Please note:
The product is classed as an 'partly completed machine' and not a (complete) machine accord-
ing to MD 2006/42/EC.

Linear units with toothed belt drive: LEZ 1/LEZ 2/LEZ 3/LEZ 9
Assembly instructions Page 6
1.1 Safety guidelines
The following guidelines on safety and hazards are intended to protect you, third parties and
the product. Itistherefore essential youfollowthem.
Operating environment
The product must not come directly into contact with moisture or water. The system (ma-
chine/system, in which the product is installed) is only suitable for dry premises indoors.
When moving the product from cold to warm conditions, allow the product to adjust to the
change in temperature for a few hours, to avoid possible damage from condensation.
Do not install the product near devices which generate powerful electromagnetic fields. This
could impair itsoperation.
Avoid environments exposed to direct solar radiation, extreme heat, cold, humidity or mois-
ture.
Power supply (only applies to products with multiphase motors, brushed DC/brushless DC or AC
servomotors and a suitable motor output stage/controller)
Connect the power supply for the output stage of the multiphase motor/output stage of the
iMD10/iMD20 servomotor, the intermediate circuit of the final stage of the iMD40 servomo-
tor(L, N and PE terminals) or the isel single axis/multi-axis controller (e.g. iMC-P/iMC-S8,
MC-1-series, iPU-series, etc.) only to a grounded mains socket with a mains voltage of 230V
AC/50…60 Hz (single phase of the AC grid).
It is preferable to use for the output stage of the multiphase motor or the output stage of the
iMD10/iMD20 servomotor the original power supply recommended by isel Germany AG
(primary switching-mode power supply: 230V AC, secondary: 48V DC). Using a different,
inappropriate power supply renders the warranty null and void. In addition, using an unsuit-
able power supply is associated with risks from electrical currents, such as electric shock,
fire or short circuit!
If you observe faults, operate the EMERGENCY STOP button on the (single axis) controller,
the CNC control panel/CNC control console, the switchgear cabinet/switchgear box or a
manual control device. Activating the EMERGENCY STOP button interrupts the power
supply to the motor output stage. If the power supply used is damaged, you must not use it.
Have a qualified technician check and if necessary repair the product.
The linear unit
For safety reasons, in-house rebuilding and/or changing of the linear unit is forbidden.
In operation, the linear unit must not be covered by supplies (electricity or compressed air),
objects (e.g. tools) or tarpaulins, packaging or other materials etc. (e.g. clothing), because
this can lead to mechanical damage or heat obstruction and sometimes fire.
If using a single-axis/multi-axis controller to control a linear unit (equipped with an AC,
brushed DC (BDC) or a 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.

Linear units with toothed belt drive: LEZ 1/LEZ 2/LEZ 3/LEZ 9
Assembly instructions Page 7
Operation
(applies only to products supplied with a motor and a suitable motor output stage or a suitable
controller, e.g. a single-axis controller)
Only if the motor, the tactile or inductive limit switches, the brake and the incremental mea-
suring system (encoder) to the motor output stage/controller are correctly assembled, will
parameterisation, commissioning and operation/programming of the product (as a fully-
functioning drive system) function correctly. If the product malfunctions or you are unclear
about its operational status, you should consult the relevant operating instructions/assembly
instructions. http://www.manuals.isel.com
Here you will find instructions and information on how to check the functions you require and
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 en-
sure the product functions correctly.
Never allow children or other persons who are vulnerable or at risk to operate the product
unsupervised.

Linear units with toothed belt drive: LEZ 1/LEZ 2/LEZ 3/LEZ 9
Assembly instructions Page 8
1.2 Proper use
Linear units are used for linear movement of loads mounted firmly on the shaft slots/trolley in an
environment where there is no risk of explosion under the defined operating and environmental
conditions for this product. The device can be installed in any position (horizontally, vertically or at an
angle).
The toothed belt drives in linear units do not generally lock automatically.
With vertical installation, the linear unit's motor (in this case, the weight of the shaft slot/trolley and the
load to be moved must be calculated) should have a brake, which locks the movable shaft slots of the
linear axis to prevent crashing/pancaking when the power is turned off. If no brake (e.g. magnetic
brake) is fitted to the motor, another (electro-)mechanical brake must be used, e.g. on the toothed belt
wheel.
The linear units referred to in these assembly instructions are considered partly completed machines
(see article 2g of MRL 2006/42/EG). An partly completed machine is also defined here as follows
(quote):
"An partly completed machine is a unit which almost forms a machine, but cannot fulfil any given
function independently".
A drive system represents a partly completed machine.
A partly completed machine is only intended to be installed in other machines or in other partly
completed machines or equipment or be combined with it to form a machine together with it as defined
in this directive.“
The linear unit LEZ 1 –LEZ 2 –LEZ 3 –LEZ 9 is intended for installation in a machine or in other
partly completed machines.
The product is not intended for use outside and for transporting people, nor in food handling areas and
in clean rooms.
Any use other than as described above is improper and can lead to personal injury and damage to
property.
1.3 Deliverables
The deliverables include:
Assembly instructions and Declaration of incorporation according to MD 2006/42/EC
Fixing material
Limit switch cable
Accessories (if any)

Linear units with toothed belt drive: LEZ 1/LEZ 2/LEZ 3/LEZ 9
Assembly instructions Page 9
2 Installation instructions and overview of functions
This will give you an initial overview of the mechanical structure, the installation and assembly of linear
units and a description of how they work.
The instructions for commissioning/configuring the axis system and its programming by users depend
on the motors used and the relevant controllers with output stages and can be found in the respective
documentation.
2.1 Operation
Linear units in the LEZ series (toothed belt drive) are built as modules.
The basic carriers of these linear units are linear guide rails (LFS) with the corresponding shaft slots
and trolley, the toothed belt drive and the optional motor drive module.
The linear guide rails (LFS) made by isel consist of rigid aluminum sections with precision steel shafts.
Isel shaft slots rely on the rolling action of steel balls on steel inserts in aluminium sections and on
precision steel shafts . 4 ball recirculations are used in each shaft slot. The recirculating ball steering
systems are glass fibre reinforced.
Shaft slots
1) Lubrication on both sides for the ball
recirculations.
2) The basic supports for all linear guides are
extruded aluminium sections to DIN17615,
which are fitted with T-groove slots for
fastening in the base of the section or have
mounting holes.
3) Precision steel shafts with a hardness of
60±2 HRC are used as guide rails.
4) Glass fibre reinforced recirculating ball
steering.
5) There are patented ball recirculation
systems in the linear slot. Load-bearing balls
run between two ground steel pins and the guidance shaft respectively.
6) The slot is adjusted by means of self-locking screws. For this, the rows of balls and shafts or pins
are in contact with each other and thus pre-stressed.
The slots are set to the relevant pre-stress at the factory. All shaft slots are available as an option in
stainless steel.
7) To fasten the transport loads, slot plates, etc., the shaft slots are fitted with T-groove slots and
mounting holes.
Trolley
1) The ground steel fastening plate with a
thickness of 8 mm is used simultaneously for
housing the rollers and the load and is fitted
with M6 fastening threads for this purpose.
2) Central rollers
3) All linear units can be fitted both with shaft
slots and with a trolley.
4) Roller principle similar to a two-row ball
bearing with ogival tracks.
5) Eccentric rollers for adjusting the trolley. All
trolleys are preset in the factory.

Linear units with toothed belt drive: LEZ 1/LEZ 2/LEZ 3/LEZ 9
Assembly instructions Page 10
Belt drive
In linear units, toothed belts are used as the drive means for positioning and handling tasks. Compared
with conventional chain drives, the belt drive is zero maintenance and needs no lubricating. In a
circulating belt drive, there is a distinction between a stationary Ω-drive and a travelling Ω-drive for
large distances. In the linear units LEZ 1 –LEZ 2 –LEZ 3 –LEZ 9, only the recirculating belt drive
modus operandi is used. Linear guide rails also facilitate support for the top trunk, which leads to
improved positioning accuracy with large axis lengths.
On the inside of the belt, there are rubber teeth which engage in a gearwheel. The positive fit of the
gearing means that high forces can be transferred. Because the teeth preclude slippage, toothed belts
are used to control or position the shaft slot/trolley.
The actual force is transferred by a rope under tension embedded in the toothed belt.
Recirculating belt drive
Stationary Ω-drive
Travelling Ω-drive

Linear units with toothed belt drive: LEZ 1/LEZ 2/LEZ 3/LEZ 9
Assembly instructions Page 11
2.2 Construction of the toothed belt unit/drive elements
The appended drawings and part lists clarify the structure of linear units.
Example: LEZ 9
1) Toothed belt, HDT 3 M, 15 mm wide; 2) central lubrication option; 3) simple
tensioning of the belt via locking bolts under the slot; 4) buffers on both sides with parabolic springs; 5
drive motor flanged on both sides; 6) variable fixing options; 7) 2 steel shafts Ø 8 mm pressed into the
section and calibrated; 8) patented isel shaft slots with T-groove slots, plane milled; 9) rigid aluminium
sections in lengths up to 6 m; 10) embedded steel pinions on both sides

Linear units with toothed belt drive: LEZ 1/LEZ 2/LEZ 3/LEZ 9
Assembly instructions Page 12
Alternative designs
Normally, isel linear units LEZ1-2-3-9 are delivered without drive modules.
They are prepared for use with flanged direct drive modules. However, the relevant drive modules can
also be mounted to order.
LEZ 1
LEZ 1 with shaft slots LEZ 1 with trolley
LEZ 2
LEZ 2 with shaft slots LEZ 2 with trolley

Linear units with toothed belt drive: LEZ 1/LEZ 2/LEZ 3/LEZ 9
Assembly instructions Page 13
LEZ 3
LEZ 3 with shaft slots LEZ 3 with trolley
LEZ 9
LEZ 9 with shaft slots LEZ 9 with trolley

Linear units with toothed belt drive: LEZ 1/LEZ 2/LEZ 3/LEZ 9
Assembly instructions Page 14
LEZ 1 dimensions sheet
with shaft slots
Travel = Section length X –150mm
*Profillänge = section length
withtrolley
Travel = Section length X –131mm
*Profillänge = section length / Laufrolle =roller

Linear units with toothed belt drive: LEZ 1/LEZ 2/LEZ 3/LEZ 9
Assembly instructions Page 15
LEZ 1 with shaft slots - exploded view
Item 4 also availableas LW9
Part number: 623047 0001
LEZ 1 parts list
ITEM
NO.
Part number
Quantity
DESCRIPTION
1
635005 xxxx
1
DZ0223 - Linear guide LFS-8-2
2
632125 0000
1
DZ0220 - LEZ1 deflector
3
632125 0001
1
DZ0221 - Drive block without LEZ1 motor
4
623070 0103
1
TE 2862-4 WS1 for LEZ 1
5
632125 2400
1
TE2400 clamp
6
632900
1
Toothed belt HTD-3M - B=9
7
892366 0121
2
Threaded bushing M9-M6
8
609011 xxxx
1
Threaded rail 10 x 4 -M6
9
891134 0101
1
Countersunk screw DIN 7991, M 6 x 10

Linear units with toothed belt drive: LEZ 1/LEZ 2/LEZ 3/LEZ 9
Assembly instructions Page 16
LEZ 2 dimensions sheet
with shaft slots
Travel = Section length X –235 mm
*Profillänge = section length
withtrolley
Travel = Section length X –235 mm
*Profillänge = section length / Laufrolle =roller

Linear units with toothed belt drive: LEZ 1/LEZ 2/LEZ 3/LEZ 9
Assembly instructions Page 17
LEZ 2 with shaft slots - exploded view
LEZ 2 -parts list
ITEM
NO.
Part number
Quantity
DESCRIPTION
1
235008 0xxx
1
TE 3260-4 Linear guide MLF5
2
632902
1
Toothed belt HTD-5M B=25mm
3
632124 1592
2
TE 1592-3 Mounting block for ZF2
4
632124 1593
2
TE 1593-4 Toothed belt wheel HTD-5M-14 teeth
5
623073 0103
1
TE 2429-3 shaft slots WS3, completely assembled
6
896011 2322
4
Deep groove ball bearings, designation 6201-2Z
7
894030 0320
4
Locking ring DIN 473 D=32 mm S=1,2
8
632126 2816
4
TE 2816-4 rubber-bonded metal parabolic spring
9
632126 1982
1
TE 1982-4 clamp 2
10
632126 1984
1
TE 1984-4 Pressure plate for clamp 2
11
632126 1981
1
TE 1981-4 clamp 1
12
632126 1983
1
TE 1983-4 Pressure plate for clamp 1
13
632126 2421
1
TE 2421-4 Clamping bolt
14
891132 0121
4
Countersunk screw DIN 7991 M4x12
15
891124 0161
2
Cheese head screw DIN 6912 M6x16
16
891125 0301
4
Cheese head screw DIN 6912 M8x30
17
892025 0001
1
Hexagonal nut DIN 934 M6

Linear units with toothed belt drive: LEZ 1/LEZ 2/LEZ 3/LEZ 9
Assembly instructions Page 18
LEZ 3 dimensions sheet
with shaft slots
Travel = section length X –235mm * with feed rate 70 mm/rotation 51 = 63.8
*Profillänge = section length
withtrolley
Travel = section length X –235mm * with feed rate 70 mm/rotation 51 = 63.8
*Profillänge = section length / Laufrolle =roller

Linear units with toothed belt drive: LEZ 1/LEZ 2/LEZ 3/LEZ 9
Assembly instructions Page 19
LEZ 3 with shaft slots - exploded view
LEZ 3 -parts list
ITEM
NO.
Part number
Quantity
DESCRIPTION
1
235006 0xxx
1
TE 3259-4 Linear guide MLF4
2
632902
1
Toothed belt HTD-5M / 25 mm wide
3
632126 0003
2
DZ 0232-3 Drive ZF3 feed rate 150mm
4
623073 0103
1
TE 2429-3 shaft slots WS3, completely assembled
5
632126 1984
1
TE 1984-4 Pressure plate for clamp 2
6
632126 1982
1
TE 1982-4 clamp 2
7
632126 1981
1
TE 1981-4 clamp 1
8
632126 1983
1
TE 1983-4 Pressure plate for clamp 1
9
632126 2421
1
TE 2421-4 Clamping bolt
10
891132 0122
4
Countersunk screw DIN 7991 M4x12
11
891124 0161
2
Cheese head screw DIN 6912 M6x16
12
892025 0001
1
Hexagonal nut DIN 934 M6

Linear units with toothed belt drive: LEZ 1/LEZ 2/LEZ 3/LEZ 9
Assembly instructions Page 20
LEZ 9 dimensionssheet
with shaft slots
Travel = Section length X –135 mm
*Profillänge = section length
withtrolley
Travel = Section length X –135 mm
*Profillänge = section length / Laufrolle =roller