Isel LES4 User manual

© isel Germany AG, April 2019, english
Linear units with spindle drive
LES4 - LES5 –LES6
Assembly instructions with:
- Installation instructions
- Maintenance instructions
- Installation explanation
for a drive system
(an incomplete machine as defined in the Machinery Directive 2006/42/EC)

Linear units with spindle drive LES 4, 5, 6
2 / 52 April 2019
About these assembly instructions
Abbreviations
MD = Machinery Directive 2006/42/EC
LES = Linear unit with (ball circulation) spindle
AC = Alternating current, AC servo motor (always synchronous motor)
BDC = Brushed DC,brushed direct current (DC) servo motor
BLDC = Brushless DC, brushless direct current (DC) servo motor
PDF = Portable document format
Terminology
In these assembly instructions 'product' always refers to a linear unit with spindle drive
Symbols used
In these instructions you will find various symbols which are there to alert you to important
information/facts and hazards.
Symbol
Warning
Meaning
Danger
Warning of possible serious or fatal injuries to persons
Caution!
Fatal Voltage !
The flash symbol is a clear warning of danger from electric current.
Not heeding 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.
Not heeding the facts following this symbol (text, picture or table) can
result in serious damage to property.
Important
information or
note
Important information or note on how the product works.
Reading the safety guidelines
Before commissioning the linear units (as incomplete machines), working with them, or making any
additions or modifications to the electrical installation, it is essential you read carefully:
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 controls used.
Copyright
© isel Germany AG, 2018
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.

Linear units with spindle drive LES 4, 5, 6
3 / 52 April 2019
Note on CE conformity with incomplete machines:
isel linear units comply with CE guidelines. They are classed as incomplete machines as defined in the
Machinery Directive 2006/42/EC and therefore do not explicitly bear the CE mark.
Only after the conformity 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.
All other machine parts and/or machine components to which the CE safety guidelines apply must not
be commissioned until all the relevant requirements of Machinery Directive 2006/42/EC are met.
isel Germany AG does not accept any responsibility for any modifications you make to the linear unit.
Manufacturer: isel Germany AG
Bürgermeister-Ebert-Straße 40
D-36124 Eichenzell, Germany
Tel: [phone]
Fax: [phone]
Email: [e-mail]
Internet: www.isel.com
Processing date of this documentation: April 2019
More documents 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 relevant 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:
https://www.isel.com/en/support-downloads/manuals.html
In your own interest:
Please read these assembly instructions carefully and keep them in a safe place. These instructions
form an integral part of the product Linear Unit with Spindle Drive LES4 –LES5 –LES6, regardless of
whether these instructions are supplied/available in the form of an electronic storage medium (as PDF
file on a CD, DVD or memory stick) or as a printed version.
Please read and follow the safety guidelines in these assembly instructions.
Index revision
Date of
change
Reason of change
Amended by
02.04.2019
Adaption Low Voltage Directive
KJ
15.01.2019
Adaption Layout
KJ
21.04.2016
Adaption Installation Explanation
CB

Linear units with spindle drive LES 4, 5, 6
4 / 52 April 2019
Contents
1General information ........................................................................................................................5
1.1 SAFETY GUIDELINES....................................................................................................................................... 6
1.2 PROPER USE................................................................................................................................................ 8
1.3 SCOPE OF DELIVERY ...................................................................................................................................... 8
2Installation instructions and overview of functions....................................................................9
2.1 FUNCTIONS................................................................................................................................................. 9
2.2 STRUCTURE/ASSEMBLY OF THE LINEAR UNIT .................................................................................................... 10
3Commissioning, general information..........................................................................................37
4Assembly/disassembly as individual components ...................................................................38
4.1 MOUNTING ON THE LINEAR GUIDE RAIL .......................................................................................................... 38
4.2 MOUNTING ON THE GUIDE SLIDES.................................................................................................................. 39
5Fault list..........................................................................................................................................40
6Technical data ...............................................................................................................................41
6.1 MECHANICAL DATA .................................................................................................................................... 41
6.2 ELECTRICAL DATA ....................................................................................................................................... 43
7Maintenance and cleaning ...........................................................................................................44
7.1 MAINTENANCE INSTRUCTIONS ...................................................................................................................... 44
7.2 CLEANING................................................................................................................................................. 45
8Decommissioning/disposal..........................................................................................................45
9CE Conformity ...............................................................................................................................46
10 Service........................................................................................................................................46
11 Warranty .....................................................................................................................................47
12 Installation explanation according to MD 2006/42/EC ...........................................................48
13 Index ...........................................................................................................................................49
14 Appendices ................................................................................................................................50
14.1 A1: ACCESSORIES....................................................................................................................................... 50
14.2 A2: MISCELLANEOUS.................................................................................................................................. 52

Linear units with spindle drive LES 4, 5, 6
5 / 52 April 2019
1 General information
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 LES4 –LES5 –LES6 are linear modules with ballscrew drives, which are ready to
install. They are for use mainly in factory automation, handling technology and light machinery con-
struction.
These linear units are available in different standard lengths and can be fitted with special direct motor
connections.
The many options for configuring and combining the units mean users can build a wide variety of con-
structions to suit their requirements.
Please note:
The product is classed as an 'incomplete machine' and not a (complete) machine according to
MD 2006/42/EC.

Linear units with spindle drive LES 4, 5, 6
6 / 52 April 2019
1.1 Safety guidelines
The following guidelines on safety and danger are intended to protect you, third parties and the
product. It is essential you follow them.
Operating environment
The product must not be directly exposed to moisture or water. The system (the machine/system in
which the product is installed) is only suitable for use in dry indoor areas.
When moving the product from a cold to warm conditions, allow the product to adjust to the change in
temperature for a few hours before operation, to avoid possible damage from condensation.
Do not install the product near devices which generate powerful magnetic fields. This could disturb its
functions.
Avoid environments exposed to direct solar radiation, considerable heat, cold, humidity or moisture.
Power supply (only applies to products with stepper motors, brushed DC/brushless DC or AC
servo motors and a suitable motor output stage/controller)
Only connect the mains adapter of the stepper motor/servo motor output stage IMD10/IMD20, the link
to the servo motor output stage IMD40 (terminals L, N, PE) or the single-axle controller iMC1-10/iMC1-
20 or multi-axle controller iMC-M/iMC-P (stepper) or iMC-V/iMC-VP (servo) to an earthed mains socket
with a mains voltage of 230 V AC/50…60 Hz (1-phase AC power supply).
You are advised to use the original mains adapter recommended by isel Germany AG (primary switch-
ing power supply: 230 V AC, secondary: 48 V DC) for the stepper motor or servo motor output stage
IMD10/IMD20. Using a different, inappropriate mains adapter renders the warranty null and void. In
addition, using an inappropriate mains adapter entails risks caused by electric current, such as electric
shock, fire or short circuits.
If you notice faults, activate the EMERGENCY STOP button on the (single axle) controller, the CNC
operating panel/CNC console, the control panel/control cabinet or a handheld device. Activating the
EMERGENCY STOP button interrupts the power supply to the motor output stage. If the mains adapt-
er used is damaged you must not operate it. Have a qualified technician check and if necessary repair
the product.
The linear unit
For safety reasons you must not convert and/or modify the linear unit on your own.
When in operation, the linear unit must not be covered by supply lines (electric or pneumatic), objects
(e.g. tools) or canvas covers, packaging materials or cloth etc. (e.g. clothing), which could cause me-
chanical damage or a build-up of heat, and a possible fire.
If using a single-axle/multi-axle controller to control a linear unit (equipped with an AC, brushed DC
(BDC) or 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 spindle drive LES 4, 5, 6
7 / 52 April 2019
Operation
(applies only to products supplied with a motor and a suitable motor output stage or a suitable
controller, e.g. a single-axle controller)
Only if the product is assembled correctly and the motor, the tactile or inductive limit switches, the
brake and the incremental measuring system (encoder) are correctly connected to the motor output
stage/controller, 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.
https://www.isel.com/en/support-downloads/manuals.html
Here you will find instructions and information on how to check the functions you require, 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 ensure the
product functions correctly.
Never allow children or other persons who are vulnerable or at risk to operate the product unsuper-
vised.

Linear units with spindle drive LES 4, 5, 6
8 / 52 April 2019
1.2 Proper use
The linear units serve to move securely attached loads along the guide slides/slide plates or
supporting profiles in a linear direction in an environment where there is no danger of explosions and
in accordance with the operational and environmental conditions specified for this product. The product
can be installed as required (in a horizontal, vertical or diagonal) position.
In general, the ballscrew drives in the linear units are not self-locking.
If installed vertically, the linear unit motor (in this case the spindle of the ballscrew spindle and the
weight of the loaded slide plate must be calculated) should therefore have a holding brake to secure
the movable guide slide of the linear axle from falling/sinking when the power is off. If no holding brake
(e.g. magnetic brake) is fitted to the motor, another (electric) mechanical brake must be used, e.g. on
the end support of the ball spindle.
The linear units are incomplete machines (compare Article 2g of MD 2006/42/EC). Here an incomplete
machine is defined as follows (quote):
'An incomplete machine is a unit which almost forms a machine but which cannot fulfil any specific
function on its own.
A drive system is an incomplete machine.
An incomplete machine is only intended to be installed into other machines or other incomplete
machines or equipment, or joined together with these to form a machine as defined in this directive.'
The linear units LES4 –LES5 –LES6 are intended for installation into a machine or into other
incomplete machines.
The product should not be used outdoors or to transport people or in the food industry and clean
rooms.
Any other use than those described above is not considered correct and can lead to personal injuries
and damage to property.
1.3 Scope of delivery
The delivery contents include:
Assembly instructions and installation explanation according to MD 2006/42/EC
Mounting materials
Limit switch cable
Motor module if required
Accessories if required

Linear units with spindle drive LES 4, 5, 6
9 / 52 April 2019
2 Installation instructions and overview of functions
Firstly, this section provides an overview of the mechanical structure, installation or assembly of the
linear units and a description of their functions.
The instructions for commissioning/parameterising the axle system and its programming by users
depend on the motors used and the relevant controllers with output stages; they can be found in their
documentation.
2.1 Functions
The LES series linear units (spindle drive) have a modular design.
These linear units are based on linear guide rails (LFS) and appropriate guide slides (FS), a ballscrew
drive and motor module (optional).
The linear guide rails made by isel consist of rigid aluminium profiles with precision steel shafts.
Isel FS guide slides are based on rolling steel balls on steel inserts and precision shafts guided
through aluminium profiles. Four ballscrews are used in each FS guide slide. The recirculating balls
are glass-fibre reinforced.
Ballscrew drives transform rotational movement into linear movement. They consist of a ballscrew
spindle (6), the ballscrew nuts (7) with ball recirculation system (1) and the balls (4) as rolling
elements. The balls establish the connection between the spindle and the nuts by rolling in the tracks
of the ballscrew spindle and the ballscrew nuts. Isel ballscrew nuts circulate several times with internal
ball recirculation. Set screws (3) enable the balls to circulate on the spindles without slack.

Linear units with spindle drive LES 4, 5, 6
10 / 52 April 2019
2.2 Structure/assembly of the linear unit
The following illustrations, drawings and item lists illustrate the structure of the linear units.
Overview of the functions using LES5 as an example
Ball circulation in the aluminium Slack-free pre-set Spindle support
linear slide Ballscrew nuts with wipers Profile length
L=1,500+
Glass fibre-reinforced
recirculation elements Centralised lubrication
With wipers for ballscrew nuts and slides
Buffers at both ends Integrated overtravel limit switches Belt recirculation
End support with needle bearing Spindle positioning with diagonal Electrical connections
balls covered with cap
Zero slack of axle due to self-
securing slotted nuts

Linear units with spindle drive LES 4, 5, 6
11 / 52 April 2019
Ordering key
Ordering key
Ordering key
2 3 4 X X X 0 X X X
2 3 4 X X X 0 X X X
2 3 4 X X X 0 X X X
Drive
Drive
Drive
0 = Preparation
3 = Preparation
6 = Preparation
Direct drive module
Direct drive module
Direct drive module
1 = Preparation
4 = Preparation
7 = Preparation
Belt drive module
Belt drive module
Belt drive module
Shaft slide
Shaft slide
Shaft slide
0 = 1 shaft slide 70 mm
0 = 2 shaft slides 70 mm
0 = 2 shaft slides 70 mm
2
2
2
= 2 shaft slides 70 mm
= 4 shaft slides 70 mm
= 4 shaft slides 70 mm
Ball screw drive
Ball screw drive
Ball screw drive
0 = non
0 = non
0 = non
1 = Pitch 2.5 mm
1 = Pitch 2.5 mm
1 = Pitch 2.5 mm
2 = Pitch 4.0 mm
2 = Pitch 4.0 mm
2 = Pitch 4.0 mm
3 = Pitch 5.0 mm
3 = Pitch 5.0 mm
3 = Pitch 5.0 mm
4 = Pitch 10 mm
4 = Pitch 10 mm
4 = Pitch 10 mm
5 = Pitch 20 mm
5 = Pitch 20 mm
5 = Pitch 20 mm
Profile length (L1)
Profile length (L1)
Profile length (L1)
e.g.: 029 = 290 mm (min.)
e.g.: 029 = 290 mm (min.)
e.g.: 029 = 290 mm (min.)
299 = 2990 mm (max.)
299 = 2990 mm (max.)
299 = 2990 mm (max.)
Standard profile lengths can be
Standard profile lengths can be
Standard profile lengths can be
ordered in steps of 100 mm!
ordered in steps of 100 mm!
ordered in steps of 100 mm!
(reduced by the last digit)
(reduced by the last digit)
(reduced by the last digit)
for direct drive module
for direct drive module
for direct drive module
for belt drive module
for belt drive module
for belt drive module
Options
isel linear units LES4-5-6 are usually supplied without a drive module.
They are prepared either for mounting flanged direct drive modules or lateral or integrated belt drive
modules.
However, appropriate direct drives can be mounted on request.

Linear units with spindle drive LES 4, 5, 6
12 / 52 April 2019
75
L2
75
75
47,1
10,5
33,23
25
75
6
78
2,5 7,5
Ø 8 h7 -0
0,015
Ø 44,4-0
0,05
Travels
Preparation direct drive module
Preparation belt drive module
Step motor
Servo motor
LES4 dimension sheet

Linear units with spindle drive LES 4, 5, 6
13 / 52 April 2019
Space for your notice

Linear units with spindle drive LES 4, 5, 6
14 / 52 April 2019
LES4 explosion diagram –Preparing a direct drive module

Linear units with spindle drive LES 4, 5, 6
15 / 52 April 2019
Item list LES 4
LES 4 –Preparing a direct drive module / Item-No.: 2340xx 0xxx
Pos no.
Item number
quantity
Name
1
635400 xxxx
1
LFS-12-4 Linear guide
2
632505
1
TE0275 –Cover profile SK593
3
693001
2
TE0398 –Fringe for seals
4
623063
1
TE1557 - Cover 75x75x33mm for LES4
5
623065 0001
1
TE1972 –Locking nut for ball screw nut ø16
6
623051 1000
1
TE1999 - End plate direct drive and counter bearing side (LES4-6) right
7
21113x xxxx
1
Ball screw spindle - ø16
8
635014 0002
2
TE2328 –Overlap plate limit switch LES4-5-6 - L=57
9
623051 2000
1
TE2342 - End plate direct drive and counter bearing side (LES4-6) left
10
623063 1000
1
TE2452 - Cover 75x75x33 for direct drive LES4
11
61310x xxxx
1
Ball screw nut ø28
12
623072 0014
1
TE2797 –Wave carriage WS5 - for ball crew nut
13
623072 0013
1
TE3796 - Wave carriage WS5 - without ball crew nut
14
632126 2816
2
TE2816 - Swing metal parabolic spring
15
623065 6913
1
SZ6913 - Bearing flange counter bearing LES 4 5 6 - incl. Deep groove
ball bearing
16
623065 6916
1
SZ6916 - Flange for direct drive (LES 4-6)
17
623056 1002
2
TE5925 - LES4 belt drive - end plate - limit switch plate
18
See drive
modules page 30
1
Motor module (see page 30)
19
613502
1
TP0104 - wiper balls screw nut
20
610110 3745
4
SZ3745 –Mounting plate micro switch
21
611999 2000
1
Screw support - from L=1490mm
22
610016
4
Kapsto cover GPN 300 F-Type 300
23
630900
2
Sealing lip
24
397030 1012
1
Position indicator switch L=400
25
397014 xxxx
1
Position indicator switch L= xxxx
26
622002 0001
1
TE1409 Stud M8x0.75x10mm with cone
27
891189 0121
4
Countersunk screw DIN 965 4.8 VZ M 2 x 10
28
891123 0121
4
Cylinder screw DIN 6912 8.8 M 5 x 12
29
891123 0161
4
Cylinder screw DIN 6912 8.8 M 5 x 16
30
891124 0161
6
Cylinder screw DIN 6912 8.8 M 6 x 16
31
891181 0051
4
Oval-head screw DIN 7985 4.8 VZ M 2,5 x 5
32
891181 0060
4
Oval-head screw DIN 7985 4.8 VZ M 3 x 6
33
891181 0281
8
Oval-head screw DIN 7985 4.8 VZ M 3 x 28
34
893307 0000
1
Shirm ring DIN 988 ST 10 x 1
35
890257 0011
1
Locknut DIN 981 M10x0,75

Linear units with spindle drive LES 4, 5, 6
16 / 52 April 2019
Pos.22 EC servo motor module
see page drive modules
LES 4 belt drive module
Pos. 22 - EC servo motor module Pos. 22 - Step motor module
Pos.22 - Step motor module MS 200 HT-2
Name
Step motor module MS 200 HT-2
TE1555 Cover 150x75x80 mm for linear guide LF 4
TE0562 - Thooted belt Z25 AT5 for collet D=8mm
TE3565 Collet small 8mm
Cylinder screw DIN 6912 8.8 M 6 x 16
Oval-head screw DIN 7895 4.8 VZ M 3 x 75
Countersunk screw DIN 7991, M6 x 12
QuantityItem-No.Pos.
LES4 explosion diagram –Preparing a belt drive module

Linear units with spindle drive LES 4, 5, 6
17 / 52 April 2019
Item list LES 4
LES 4 - Preparing a belt drive module –Item-No.: 2341xx 0xxx
Pos no.
Item number
quantity
Name
1
635400 xxxx
1
LFS12-4 –Linear guide
2
632505
1
TE0275 –Cover profile SK593
3
693001
2
TE0398 –Fringe for seals
4
616002
1
TE0562 –Thooted belt wheel Z25 AT5
5
623063
1
TE1557 - Cover 75x75x33mm for LES 4
6
623065 0001
1
TE1972 –Locking nut for ball screw nut ø16
7
623051 1000
1
TE1999 - End plate direct drive and counter bearing side (LES4-6) right
8
21113x 0xxx
1
TE2305 –Ball screw spindle ø16
9
635014 0002
2
TE2328 - Overlap plate limit switch LES4-5-6 - L=57
10
6131xx 00xx
1
Ball screw nut ø28
11
623072 0013
1
TE2796 –Wave carriage WS5 –without nut
12
623072 0014
1
TE2797 –Wave carriage WS5 - for ball screw nut
13
632126 2816
2
TE2816 - Swing metal parabolic spring
14
610500 0800
1
TE3565 - Collet ø8mm
15
623065 0102
1
TE2935 - Flange for belt drive (LES 4-6)
16
623056 1002
2
TE5925 - LES 4 Belt drive –End plate - Limit switch plate
17
623065 6913
1
SZ6913 - Bearing flange counter bearing LES 4 5 6 - incl. deep groove
ball bearing
18
610110 3745
4
SZ3745 - Mounting plate Mirco switch
19
613502
1
TP0104 –Wiper for ball screw nut
20
616503 0280
1
Thooted belt 16AT5-280
21
616400
1
Tension pulley for toothed belt LES 4 - LES 5
22
see page 30
1
Motor module (see page 30)
23
611999 2000
1
Spindle support - from L=1490mm
24
610016
4
Kapsto cover GPN 300
25
630900
2
Sealing lip L -480
26
397030 1012
1
Limit switches L=400
27
3970xx xxxx
1
Limit switches L=xxxx
28
622002 0001
1
TE1409 –Stud screw M8x0,75x10mm with cone
29
891191 0101
2
Countersunk screw DIN 965 4.8 VZ M 3 x 10
30
891123 0121
8
Cylinder screw DIN 6912 8.8 M 5 x 12
31
891124 0161
6
Cylinder screw DIN 6912 8.8 M 6 x 16
32
891181 0051
4
Oval-head screw DIN 7985 4.8 VZ M 2,5 x 5
33
891181 0060
4
Oval-head screw DIN 7985 4.8 VZ M 3 x 6
34
891181 0281
4
Oval-head screw DIN 7985 4.8 VZ M 3 x 28
35
891181 0750
4
Oval-head screw DIN 7985 4.8 VZ M 3 x 75
36
891134 0121
2
Countersunk screw DIN 7991, M 6 x 12
37
891134 0351
1
Countersunk screw DIN 7991, M 6 x 35
38
893307 0000
1
Shim ring DIN 988 ST 10 x 1
39
890257 0011
1
Locknut DIN 981 M10x0,75

Linear units with spindle drive LES 4, 5, 6
18 / 52 April 2019
150
225
150
225
10,5
78
25 6
75
4
6
2,5
7,5
Ø 8 h7 -0
0,015
Ø 44,40-0
0,05
Preparation direct drive module
Travels
Preparation belt drive module
LES5 dimension sheet

Linear units with spindle drive LES 4, 5, 6
19 / 52 April 2019
Space for your notice

Linear units with spindle drive LES 4, 5, 6
20 / 52 April 2019
LES 5 -direct drive
LES5 explosion diagram –Preparing a direct drive module