Isel LES4 User manual

Assembly instruction
linear unit LES4, 5, 6
ball screw unit with spindle drive.
Serial number:

Item number: 234xxx xxxx

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Assembly instruction
Manufacturer:
isel Germany AG
Bürgermeister-Ebert-Str., 40
D-36124, Eichenzell
[phone]
[phone]
[e-mail]
www.isel.com
Board: Hugo Isert, Werner Kister
Supervisory board: Gunter Zumpf, Lars Rohrlack-Soth, Marcus Walter-Krisch
Commercial Register, Register Court Fulda
Registry number: 5468

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Assembly instruction
revision
index
date of change
reason for change
changed by
1
05.07.2019
first version
Bley.Christian

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Contents
1General information.................................................................................................... 10
1.1 Importance of the documentation .............................................................................................. 10
1.2 Scope of delivery ........................................................................................................................10
1.3 Co-Applicable Documents .......................................................................................................... 11
1.4 Declaration of incorporation according to Machinery directive 2006/42/EC Annex II B..............12
1.5 General data, contact persons....................................................................................................13
1.6 User requirements ......................................................................................................................13
1.7 Explanation of symbols and instructions .................................................................................... 14
1.8 List of abbreviations ...................................................................................................................15
1.9 Symbols used in the operating instructions and on the machine ..............................................16
2Overview..................................................................................................................... 17
2.1 General information ................................................................................................................... 17
2.2 Functionality of the linear unit....................................................................................................17
2.3 Versions of the linear units of theLES series ...............................................................................18
2.3.1 Linear unit LES 4....................................................................................................................................18
2.3.2 Linear unit LES 5....................................................................................................................................19
2.3.3 Linear unit LES 6....................................................................................................................................20
2.4 Technical data ............................................................................................................................ 21
2.4.1 Mechanical data and dimensions ..........................................................................................................21
2.4.1.1 Linear unit LES 4.............................................................................................................................21
2.4.1.2 Linear unit LES 5.............................................................................................................................25
2.4.1.3 Linear unit LES 6.............................................................................................................................29
2.4.2 Ambient conditions ...............................................................................................................................33
2.4.3 Sound pressure......................................................................................................................................33
2.5 Type plate................................................................................................................................... 33
3Safety .......................................................................................................................... 35
3.1 Operator’s liability ......................................................................................................................35
3.2 Intended use .............................................................................................................................. 36
3.2.1 Reasonably foreseeable misuse.............................................................................................................37
3.3 Safety instructions ...................................................................................................................... 37
3.3.1 General safety instructions ....................................................................................................................37
3.3.2 Special safety instructions .....................................................................................................................38
3.3.3 Fire protection .......................................................................................................................................39
3.4 Personal Protective Equipment ................................................................................................... 40
4Transport..................................................................................................................... 41
5Assembly and commissioning .................................................................................... 42
5.1 Assembly .................................................................................................................................... 42
5.2 Commissioning...........................................................................................................................46
6Mounting parts ........................................................................................................... 48
6.1 Motor modules ........................................................................................................................... 48
6.2 Sliding plates.............................................................................................................................. 50
6.3 Other options ............................................................................................................................. 51
6.3.1 External limit switches...........................................................................................................................51
6.3.2 Gas pressure spring...............................................................................................................................51
6.3.3 Angular transmission.............................................................................................................................53

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7Maintenance, repair.................................................................................................... 54
7.1 Cleaning ..................................................................................................................................... 54
7.2 Lubrication.................................................................................................................................. 54
7.3 Maintenance plan.......................................................................................................................56
7.4 Troubleshooting ......................................................................................................................... 57
8Dismantling and disposal ........................................................................................... 58
9Spare parts overview.................................................................................................. 59

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List of figures
Fig. 1 - Linear guide LFS 12-2 with guide carriage WS 5 ......................................................................................................................18
Fig. 2 - LES 4with belt drive module or prepared for direct drive .........................................................................................................19
Fig. 3 - Ordering key LES 4...................................................................................................................................................................19
Fig. 4 - LES 5with integrated belt drive module or prepared for direct drive ........................................................................................20
Fig. 5 - Ordering keyLES 5.....................................................................................................................................................................20
Fig. 6 - LES 6 with belt drive module or prepared for direct drive ........................................................................................................21
Fig. 7 - Ordering key LES 6....................................................................................................................................................................21
Fig. 8 - Deflection data LES 4................................................................................................................................................................22
Fig. 9 - Load diagramLES 4 ...................................................................................................................................................................23
Fig. 10 - Deflection data LES 5..............................................................................................................................................................26
Fig. 11 - Load diagramLES 5 .................................................................................................................................................................26
Fig. 12 - Deflection data LES.................................................................................................................................................................31
Fig. 13 - Load diagram LES ...................................................................................................................................................................31
Fig. 14 - Type plate...............................................................................................................................................................................34
Fig. 15 - linear unit LES 4, 5, 6 for installation as free standing ...........................................................................................................42
Fig. 16 - linear unit LES 4, 5, 6 for rack mounting ................................................................................................................................42
Fig. 17 - linear unit LES 4, 5, 6 for foot mounting.................................................................................................................................43
Fig. 18 - linear unit LES 4, 5, 6 for mounting the carriage ....................................................................................................................44
Fig. 19 - linear unit LES 4, 5, 6 for slide plate mounting.......................................................................................................................44
Fig. 20 - linear unit LES 4, 5, 6 for slide plate mounting - frame ..........................................................................................................45
Fig. 21 - Mounting direct drive module ................................................................................................................................................45
Fig. 22 - Mounting belt drive module ...................................................................................................................................................46
Fig. 23 - external limit switches LES......................................................................................................................................................51
Fig. 24 - LES with gas pressure spring ..................................................................................................................................................51
Fig. 25 - Exploded drawing Assembly of the gas spring mounting kit to a LES 5.................................................................................52
Fig. 26 - Coupling housing set 90° and 0 .............................................................................................................................................53
Fig. 27 - Lubrication points of the linear unit LES .................................................................................................................................56

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List of tables
Table 1 - General faults on the linear unit ............................................................................................................................................57
Table 2 - Spare parts LES 4, 5, 6Direct drive.........................................................................................................................................59
Table 3 - Spare parts LES 4, 5, 6Belt drive ............................................................................................................................................59
Table 4 - Spare parts LES 4, 5, 6 Direct drive........................................................................................................................................60
Table 5 - Spare parts LES 4, 5, 6 Belt drive ...........................................................................................................................................60
Table 6 - Spare parts LES 4, 5, 6 Direct drive........................................................................................................................................60
Table 7 - Spare parts LES 4, 5, 6
Belt drive ..............................................................................................................................................................................................61

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1General information
Dear customer,
Dear operator,
with this Assembly instruction we would like to support you in your work on the linear unit LES 4, 5, 6, hereinafter
referred to as machine. It contains information and everything you need to know about the machine and will be a
helpful support to you.
NOTE
Before you put the machine into operation, work with the machine or make additions or
changes to the electrical installation of the machine/in the control cabinet of the machine,
you must read carefully:
˃the safety instructions in this Assembly instruction as well as
˃the safety instructions of the add-on components in the applicable documents.
If you still have questions, please contact us. Despite all care and attention, we cannot rule out misprints and
errors. If you notice misprints or errors or you see ways to improve our technical documentation, we are grateful
for any hint or suggestion!
© isel Germany AG, 2021-02-23. All rights reserved.
1.1 Importance of the documentation
These Assembly instruction and the associated documentation are an integral part of the linear unit. The operator
is obliged to keep the Assembly instruction for the entire service life of the linear unit and to grant access to the
personnel working with the machine.
If the linear unit is modified, the Assembly instruction and the associated documentation must be revised
accordingly. If the linear unit is dismantled and reassembled at a new location, the owner is obliged to pass on the
Assembly instruction and the associated documentation to the new owner.
The Assembly instruction in German language is the original Assembly instruction. All other language versions are
translations of the original Assembly instruction.
These Assembly instruction and the associated documentation are an integral part of the linear unit. The operator
is obliged to keep the Assembly instruction for the entire service life of the linear unit and to grant access to the
personnel working with the machine.
If the linear unit is modified, the Assembly instruction and the associated documentation must be revised
accordingly. If the linear unit is dismantled and reassembled at a new location, the owner is obliged to pass on
the Assembly instruction and the associated documentation to the new owner.
The Assembly instruction in German language is the original-Assembly instruction. All other language versions are
translations of the original-Assembly instruction.
1.2 Scope of delivery
The scope of delivery of the linear unit LES 4, 5, 6 234xxx xxxx includes:
●Assembly instructions with installation declaration according to Machinery directive 2006/42/EC

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1.3 Co-Applicable Documents
Apart from the Assembly instruction the following documents for the use of the machine are necessary. These
documents are partially submitted in annexe in the printed form of the machine or are contained as PDF document
on the data support for the installation data of the provided control software / . The number specified in
/<number>/ can be found as the leading number in the file name of the document.
Applicable documentsisel Germany AG
No.
Document
/1/
Dimensional drawing
/3/
Operating Instructions Positioning module IMD20/ IMD40 with CANopen interface:
isel Germany AG, 12/2018
Applicable documents from other manufacturers

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1.4 Declaration of incorporation according to Machinery directive 2006/42/EC
Annex II B
The manufacturer
isel Germany AG
Bürgermeister-Ebert-Str., 40
D-36124, Eichenzell
hereby declares that the following product
product description:
ball screw unit with spindle drive LES 4, 5, 6
model name:
LES 4, 5, 6
item number:
234xxx xxxx
serial number:
meets the essential health and safety requirements of Machinery directive 2006/42/EC Annex II.
The following harmonized norms were applied:
DIN EN ISO 12100:2011-03
Safety of machinery - General principles for design - Risk assessment and risk reduction.
EN 60204-1:2006/A1:
2009/AC:2010
Safety of machinery - Electrical equipment of machines - Part 1: General requirements.
The technical documentation for this machine has been prepared in accordance with Annex VII, part B. The manufacturer undertakes to electronically transmit
these specific technical documentations to national authorities on request.
The authorized representative for the compilation of the special technical documentation is:
name:
Christian Bley
capacity:
CE Beauftragter
company:
isel Germany AG
address:
Bürgermeister-Ebert-Str., 40, D-36124, Eichenzell
The product (incomplete machine) is intended for incorporation into a machine or for assembly with other incomplete machines into a machine within the
meaning of MRL, 2006/42/EC, Article 1, Section (1), letter a.
The commissioning of the incomplete machine (product) is prohibited until the machine in which this product has been incorporated or of which it
is a component complies with the requirements of all relevant directives (especially MRL ) and this complete machine has a CE marking.
Eichenzell, 23.02.2021
Werner Kister, Chairperson isel Germany AG

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1.5 General data, contact persons
Client
Operator (if different from the client)
Manufacturer
isel Germany AG
Bürgermeister-Ebert-Str., 40
D-36124, Eichenzell
[phone]
[phone]
[e-mail]
You can reach our contact persons for the technical consultancy and the sale as well as the service under the
following contact data.
Technical advice and sales
[phone]
[phone]
Service and Support
[phone]
[email protected]m
1.6 User requirements
User groups
Capacity
Training, qualification
Operator/skilled worker
Instruction in the operation of the machine
Machine setter
Instruction in the operation of the machine
Instruction in the safety functions of the machine
Electrical maintenance engineer
Electrician
Instruction in the operation of the machine
Instruction in the safety functions of the machine
Mechanical maintenance engineer
Specialist in pneumatics
Instruction in the operation of the machine
Instruction in the safety functions of the machine

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1.7 Explanation of symbols and instructions
Notes on hazards that occur in connection with work on the machine are marked as follows in these operating
instructions. They warn you of possible personal injury or property damage or give you work aids.
NOTE
If, in the event of a dangerous situation, the maximum result of an accident is a damage to
property, the notice bears the "NOTE" mark.
CAUTION
If, in the event of a dangerous situation, the maximum result of an accident is at most a
minor injury, the note bears the "CAUTION" mark.
WARNING
If, in the event of a dangerous situation, an accident resulting in serious or fatal injury is
possible, the notice bears the "WARNING" mark.
Information
Indicates important information, application tips and useful information for proper work.
Environment
In this way, information regarding the environment is identified.
/1/
Refers to a document in the list of applicable documents. See Chapter 1.3

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1.8 List of abbreviations
Declaration
EN
European Norm
Harmonised European Standard
ISO
International Organization for
Standardization
International Organization for Standardization
LES
Linear unit with spindle drive (LES4, LES5
and LES6)
Components used in the machine.
Gantry
also called gantry mode or gantry axis
Two synchronously running linear or rotary units
with separate drives which can be mechanically
connected to each other are considered as one
drive axis. Both drives are operated angle-
synchronously via the controller and the control
software.
PSA
Personal protective equipment
e.g. gloves, work shoes, safety goggles, hearing
protection

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1.9 Symbols used in the operating instructions and on the machine
The use of the symbols is in accordance with the valid regulations of the country of operation.
warning symbol
description
General warning sign
Warning against hand injuries
Warning of danger of pulling in
Warning against hot surfaces
mandatory sign
description
Use eye protection!
Use hand protection!
Use foot protection!
Request to read instructions and regulations

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2Overview
2.1 General information
In this chapter you will first get an overview of the mechanical design, the installation or assembly of the linear
units as well as a description of the mode of operation. Then the various linear units are explained in detail.
The instructions for commissioning / parameterization and user programming of the axis system depend on the
motors used, the corresponding controllers with output stages and their documentation.
General structure of the linear units of the LES series
The structure of the linear units is shown in the following pictures, drawings and parts lists.
1. Plastic cap electromagnetically
shielded
2. Clamping surface face milled
3. Abrasion-resistant sealing lips
to protect the guide elements
4. Motor integrated in profile
5. Profile bottom side face milled
6. Shaft mounting contour
precision milled
-Ball circulation in aluminium linear slide
-Glass fibre reinforced deflection parts with
wipers
-Backlash-free pre-set KG nut with wipers
-Central lubrication device for KG nut and slide
-Spindle support from profile length L=1500
-End position buffering on both sides
-Counter bearing with needle bearing
-Integrated overrun limit switches
-Spindle bearing arrangement with angular
contact ball bearings
-Axially backlash-free due to self-locking locknut
-Belt deflection and connection electronics
covered by protective cap
2.2 Functionality of the linear unit
The linear units of the LES series (spindle drive) are of modular design.
These linear units are based on linear guide rails (LFS) with the corresponding shaft slides (WS), a ball screw drive
and the optional motor drive module. The linear guide rails consist of rigid aluminium profiles with precision steel
shafts. The shaft slides are based on the rolling of steel balls on steel inserts guided in aluminium profiles and the

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precision steel shafts. 4 recirculating ball bearing units are used per shaft slide. The ball deflections are glass fibre
reinforced.
Fig. 1 - Linear guide LFS 12-2 with guide carriage WS 5
Ball screws convert a rotary motion into a linear motion. They consist of the ball screw spindle (6), the ball screw
nut (7) with ball return system (1) and the balls (4) as rolling elements. The balls make the connection between
spindle and nut by rolling in the raceways of the ball screw spindle and the ball screw nut. Ball screw nuts of isel
Germany AG have several ball circuits with internal ball returns. Backlash-free adjustment of the run on the
spindles is made possible by set screws (3).
2.3 Versions of the linear units of theLES series
2.3.1 Linear unit LES 4
Normally the linear unit LES 4 are delivered without drive module. They are either prepared for mounting flange-
mounted direct drive modules or lateral belt drive modules. However, the respective drive modules can also be
mounted on request.

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Design variants LES 4
Fig. 2 - LES 4with belt drive module or prepared for direct drive
Ordering key LES 4
Fig. 3 - Ordering key LES 4
2.3.2 Linear unit LES 5
Normally the linear unit LES 5 are delivered without drive module. They are either prepared for mounting flange-
mounted direct drive modules or integrated belt drive modules. However, the respective drive modules can also be
mounted on request.

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Design variants LES 5
Fig. 4 - LES 5with integrated belt drive module or prepared for direct drive
Ordering key LES 5
Fig. 5 - Ordering keyLES 5
2.3.3 Linear unit LES 6
Normally the linear unit LES 6 are delivered without drive module. They are either prepared for mounting flange-
mounted direct drive modules or integrated belt drive modules. However, the respective drive modules can also be
mounted on request.