Parker 404 User manual

Manual No. 100-5320-01
Rev. 8
404/406XR Series
Product Manual
Effective: May 11, 2011
Supersedes: January 12, 2006
Electromechanical
Positioning Systems
www.comoso.com

404/406XR Series Product Manual
2
Parker Hannifin Corporation
1140 Sandy Hill Road
Irwin, PA 15642
www.parkermotion.com
Important User Information
The information in the product manual, including any apparatus, methods, techniques, and concepts
described herein, are the proprietary property of Parker Hannifin Corporation or its licensors, and may
not be copied, disclosed, or used for any purpose not expressly authorized by the owner thereof.
Since Parker Hannifin Corporation constantly strives to improve all of its products, we reserve the right
to change this product manual and equipment mentioned therein at any time without notice.
For assistance contact:
Parker Hannifin Corporation
1140 Sandy Hill Road
Irwin, PA 15642
Phone: [phone]
800/245-6903
Fax: [phone]
E-mail:[email protected]m
Web site: www.parkermotion.com
www.comoso.com

404/406XR Series Product Manual
3
Parker Hannifin Corporation
1140 Sandy Hill Road
Irwin, PA 15642
www.parkermotion.com
404/406XR Series Product Manual
Table of Contents
REVISION NOTES........................................................................................................................................................................................4
CHAPTER 1 - INTRODUCTION.................................................................................................................................................................5
PRODUCT DESCRIPTION .................................................................................................................................................................................5
UNPACKING...................................................................................................................................................................................................5
RETURN INFORMATION..................................................................................................................................................................................6
REPAIR INFORMATION ...................................................................................................................................................................................6
WARNINGS AND PRECAUTIONS ......................................................................................................................................................................6
SPECIFICATION CONDITIONS AND CONVERSIONS............................................................................................................................................6
ASSEMBLY DIAGRAMS...................................................................................................................................................................................7
CHAPTER 2 - 404/406XR SERIES TABLE SPECIFICATIONS..............................................................................................................8
ORDER NUMBER NOMENCLATURE .................................................................................................................................................................8
DIMENSIONAL DRAWINGS............................................................................................................................................................................12
GENERAL TABLE SPECIFICATIONS................................................................................................................................................................14
CHAPTER 3 - COMPONENT SPECIFICATIONS..................................................................................................................................19
LINEAR ENCODERS ......................................................................................................................................................................................19
Z-Channel Position Reference.........................................................................................................................................................................................19
Linear Encoder Speed Limit............................................................................................................................................................................................20
Linear Encoder Wiring Diagram ....................................................................................................................................................................................20
ROTARY ENCODERS.....................................................................................................................................................................................21
Rotary Encoder Wiring Diagram ....................................................................................................................................................................................21
BRAKES.......................................................................................................................................................................................................21
LIMIT &HOME SENSORS .............................................................................................................................................................................22
SENSOR PACK CABLE WIRING DIAGRAM .....................................................................................................................................................22
COUPLINGS..................................................................................................................................................................................................23
CHAPTER 4 - BASE MOUNTING PROCEDURES ................................................................................................................................24
MOUNTING SURFACE REQUIREMENTS..........................................................................................................................................................24
BASE MOUNTING METHODS ........................................................................................................................................................................24
Base thru holes................................................................................................................................................................................................................24
Toe clamp mounting........................................................................................................................................................................................................25
Riser Blocks.....................................................................................................................................................................................................................25
CHAPTER 5 - COMPONENT MOUNTING PROCEDURES ................................................................................................................26
CENTER DRIVE MOTOR MOUNTING .............................................................................................................................................................26
PARALLEL MOTOR MOUNTING ....................................................................................................................................................................26
LIMIT/HOME SENSOR MOUNTING PROCEDURE.............................................................................................................................................30
BRAKE MOUNTING ......................................................................................................................................................................................31
ROTARY ENCODER MOUNTING ....................................................................................................................................................................32
CHAPTER 6 - MAINTENANCE AND LUBRICATION.........................................................................................................................33
INTERNAL ACCESS PROCEDURE ...................................................................................................................................................................33
SQUARE RAIL BEARING LUBRICATION.........................................................................................................................................................35
GROUND BALLSCREW LUBRICATION............................................................................................................................................................36
AIR PURGE HOLE.........................................................................................................................................................................................37
APPENDIX A - INTERNAL PROTECTION............................................................................................................................................38
Using the "IP Ship Kit" ...................................................................................................................................................................................................39
APPENDIX B - ACCESSORIES & SPARE PARTS................................................................................................................................40
APPENDIX C - CLEAN ROOM.................................................................................................................................................................44
APPENDIX D - MULTI-AXIS CONFIGURATIONS...............................................................................................................................46
MOUNTING BRACKETS.................................................................................................................................................................................46
PINNING ......................................................................................................................................................................................................46
INDEX...........................................................................................................................................................................................................47
www.comoso.com

404/406XR Series Product Manual Revision Notes
4
Parker Hannifin Corporation
1140 Sandy Hill Road
Irwin, PA 15642
www.parkermotion.com
Revision Notes
Rev. 2 –Effective May 29, 2002 –Added Revision Notes, updated order number nomenclature, dimensional drawings,
table specifications, life/load charts, brake information, accessories and spare parts, added limit and home sensor
pack information and easy lube information.
Rev. 3 –Effective August 22, 2002 –Updated brake mounting procedure.
Rev. 4 –Effective November 17, 2004 - Modified Limit & Home Sensors section to include new 4 wire sensor.
Changed all logos to Parker only. Changed web address to www.parkermotion.com and removed division name from
company address.
Rev. 5 –Effective January 12, 2006 –Section 6 –Maintenance and Lubrication - Changed grease from Mobil XHP222
to Multemp PS#2 for lubricating square rail bearings, and ball screws in the R1 and R5 (R5 only available for 404XR)
class 1000 clean room preparation. Updated specifications on page 14, deleted screw speed chart previously on page
19, Changed pictures for internal access pages 33 and 34, updated encoder wiring information for RGH24 on page 20.
Rev. 6 –Effective March 5, 2007 - Section 6 –Maintenance and Lubrication –Added Alvania RL 2 for lubricating
square rail bearings, and ball screws in the R1 and R5 class 1000 clean room preparation for 406XR Series Tables.
Rev. 7 –Effective June 12,2012- Section 6- Maintenance and Lubrication –Changed the name of Alvania RL 2 to
GADUS S2 V100 2 for lubricating square rail bearings, and ball screws in the R1 and R5 class 1000 clean room
preparation for 406XR Series Tables.
www.comoso.com

404/406XR Series Product Manual Chapter 1 - Introduction
5
Parker Hannifin Corporation
1140 Sandy Hill Road
Irwin, PA 15642
www.parkermotion.com
Chapter 1 - Introduction
Product Description
404XR Positioner
The 404XR is a sleek compact positioner (47.3 x 95 mm) capable of carrying relatively high loads up to
a distance of 600 mm. Its quick and accurate positioning capability can be attributed to a high strength
extruded housing, square rail ball bearing system, and precision ground ballscrew drive. With its low
profile design, the 404XR is ideal for space restricted applications and its light weight construction
makes it well suited for multi-axis systems.
406XR Positioner
The 406XR is the rugged big brother of the 404XR Series. It can position greater loads (up to 630 kgf)
over longer (2 meters) travels. Because of its size and strength (28 kg-m, 200 lb-ft. moment load
capacity) this durable table is ideal as the base unit in a multi-axis system. From high resolution to high
throughput, selectable ballscrew leads (5, 10, 20, 25 mm) make the desired resolution/velocity ratio
easy to achieve, and stainless steel seal strips alleviate environmental concerns.
400XR Product Family
‘Modular Flexibility’ is the attribute that clearly distinguishes the 400XR family of linear tables from all
others. This product family allows each unit to be easily configured to meet unique requirements, from
the very basic to the highly complex. Field upgrades and redesigns are easily accommodated; simply
follow the mounting procedure that ships with the desired assembly or individual part. This compatible
family of positioners offers reliable accuracy, versatility and strength. Adapters and brackets make it
easy to combine 404XR and 406XR positioners, as required, to form multi-axis systems without special
design or manufacturing. The 400XR family of products are rugged enough to perform well in the
industrial automation environment (automotive, packaging) and yet they’re precise enough to excel in
the high end semi-conductor and instrumentation markets.
Unpacking
Unpacking
Carefully remove the positioner from the shipping crate and inspect the unit for any evidence of shipping
damage. Report any damage immediately to your local authorized distributor. Please save the shipping
crate for damage inspection or future transportation.
Incorrect handling of the positioner may adversely affect the performance of the unit in its application.
Please observe the following guidelines for handling and mounting of your new positioner.
DO NOT allow the positioner to drop onto the mounting surface. Dropping the positioner can generate impact
loads that may result in flat spots on bearing surfaces or misalignment of drive components.
DO NOT drill holes into the positioner. Drilling holes into the positioner can generate particles and machining
forces that may effect the operation of the positioner. Parker Hannifin Corporation will drill holes if necessary;
contact your local authorized distributor.
DO NOT subject the unit to impact loads such as hammering, riveting, etc. Impacts loads generated by
hammering or riveting may result in flat spots on bearing surfaces or misalignment of drive components.
DO NOT push in magnetically retained strip seals when removing positioner from shipping crate. Damaging
strip seals may create additional friction during travel and may jeopardize the ability of the strip seals to
protect the interior of the positioner.
DO NOT submerge the positioner in liquids.
DO NOT disassemble positioner. Unauthorized adjustments may alter the positioner’s specifications and void
the product warranty.
www.comoso.com

404/406XR Series Product Manual Chapter 1 - Introduction
6
Parker Hannifin Corporation
1140 Sandy Hill Road
Irwin, PA 15642
www.parkermotion.com
Return Information
Returns
All returns must reference a “Return Material Authorization”, (RMA), number. Please call your local
authorized distributor or Parker Hannifin Corporation Customer Service Department at 800-245-6903 to
obtain a “RMA” number. See Parker Hannifin Corporation Catalog #8080/USA, page D34, for additional
information on returns and warranty.
Repair Information
Out-of-Warranty Repair
Our Customer Service Department repairs Out-of-Warranty products. All returns must reference a
“RMA” number. Please call your local authorized distributor or Parker Hannifin Corporation Customer
Service Department at 800-245-6903 to obtain a “RMA” number. You will be notified of any cost prior to
making the repair.
Warnings and Precautions
Vertical Operation
Depending upon your load and ballscrew selection the carriage and load may ‘backdrive’ in power loss
situations potentially causing product damage or personal injury. An electro-mechanical brake, which
will activate in response to a loss of power (option ‘B2’), can be used to prevent potential product
damage or personal injury.
Strain Relieve Electrical Components
All electrical components (such as brakes, encoders, and limit/home switches) must be strain relieved.
Failure to strain relieve electrical wires or cables may result in component failure and/or possible
personal injury.
Specification Conditions and Conversions
Specifications are Temperature Dependent
Catalog Specifications are obtained and measured at 20 Degrees C. Specifications at any other
temperature may deviate from catalog specifications. Minimum to Maximum continuous operating
temperature range (with NO guarantee of any specification except motion) of a standard unit before
failure is 5 - 70 Degrees C. Certain components can be eliminated or substituted to improve operation at
these temperatures. Positioners with low temperature or high temperature components will be handled
as specials, contact your local distributor.
Specifications are Mounting Surface Dependent
Catalog Specifications are obtained and measured when the positioner is fully supported, bolted down
(to eliminate any extrusion deviation), and is mounted to a work surface that has a maximum flatness
error of 0.013mm/300mm (0.0005”/ft).
Specifications are Point of Measurement Dependent
Catalog Specifications and Specifications in this manual are measured in the center of the carriage,
37.5mm above the carriage surface. All measurements taken at any other location may deviate from
these values.
www.comoso.com

404/406XR Series Product Manual Chapter 1 - Introduction
7
Parker Hannifin Corporation
1140 Sandy Hill Road
Irwin, PA 15642
www.parkermotion.com
Assembly Diagrams
BALLSCREW
CARRIAGE
IN LINE MOTOR
BLOCK
LINEAR ENCODER
PARALLEL
MOUNTING
ASSEMBLY
STRIP SEAL
TOP COVER
ROTARY BRAKE
SHAFT BRAKE
RISER BLOCK
TOE CLAMP
LIMIT/HOME
ASSEMBLY
www.comoso.com

404/406XR Series Product Manual Chapter 3 - Component Specifications
8
Parker Hannifin Corporation
1140 Sandy Hill Road
Irwin, PA 15642
www.parkermotion.com
Chapter 2 –404/406XR Series Specifications
Order Number Nomenclature
www.comoso.com

404/406XR Series Product Manual Chapter 3 - Component Specifications
9
Parker Hannifin Corporation
1140 Sandy Hill Road
Irwin, PA 15642
www.parkermotion.com
www.comoso.com

404/406XR Series Product Manual Chapter 3 - Component Specifications
10
Parker Hannifin Corporation
1140 Sandy Hill Road
Irwin, PA 15642
www.parkermotion.com
www.comoso.com

404/406XR Series Product Manual Chapter 3 - Component Specifications
11
Parker Hannifin Corporation
1140 Sandy Hill Road
Irwin, PA 15642
www.parkermotion.com
www.comoso.com

404/406XR Series Product Manual Chapter 3 - Component Specifications
12
Parker Hannifin Corporation
1140 Sandy Hill Road
Irwin, PA 15642
www.parkermotion.com
Dimensional Drawings
404XR
www.comoso.com

404/406XR Series Product Manual Chapter 3 - Component Specifications
13
Parker Hannifin Corporation
1140 Sandy Hill Road
Irwin, PA 15642
www.parkermotion.com
406XR
www.comoso.com

404/406XR Series Product Manual Chapter 3 - Component Specifications
14
Parker Hannifin Corporation
1140 Sandy Hill Road
Irwin, PA 15642
www.parkermotion.com
General Table Specifications
404XR
406XR
Common Characteristics
Precision
Standard
Precision
Standard
Performance
Bidirectial Repeatability (m)
+/-1.3
+/-3.0
+/-1.3
+/-3.0
Duty Cycle
100%
100%
100%
100%
Max Acceleration –m/sec2 (in/sec2)
20 (773)
20 (773)
20 (773)
20 (773)
Rated Capacity
Normal load –kgf (lbs)
170 (375)
170 (375)
630 (1390)
630 (1390)
Axial load –kgf (lbs) Ballscrew
Leadscrew
90 (198)
n/a
90 (198)
25 (55)
90 (198)
90 (198)
Motor Sizing
Drive Screw Efficiency Ballscrew
Leadscrew
90%
30%
90%
30%
90%
80%
Max Break-Away Torque –Nm (in-oz)
0 to 600 mm Travel
600 to 2000 mm Travel
0.13 (18)
na
0.18 (26)
na
0.13 (18)
na
0.18 (26)
0.39 (55)
Max Running Torque –Nm (in-oz)
0 to 600 mm Travel
600 to 2000 mm Travel
0.11 (16)
na
0.17 (24)
na
0.11 (16)
na
0.17 (24)
0.34 (48)
Linear Bearing –Coefficient of Friction
0.01
0.01
0.01
0.01
Ballscrew Diameter (mm)
16
16
Refer to chart on page 13
Carriage Weight –kg (lbs)
0.70 (1.55)
0.70 (1.55)
2.7 (5.94)
2.7 (5.94)
404XR
Travel
(mm)
Positional (2)
Accuracy (m)
Straightness &
Flatness Accuracy
(m) Prec./Std.
Input Inertia 10-5 kg-m2
Max Screw Speed
(Revs Per Second)
Prec./Std.
Total Table
Weight (kg)
Prec./Std.
Prec.
Std.
5 mm
10 mm
20 mm
50
8
12
6
1.68
1.81
2.34
60
2.8
100
8
12
6
1.93
2.07
2.60
60
3.0
150
10
14
9
2.19
2.32
2.85
60
3.3
200
12
20
10
2.44
2.57
3.11
60
3.6
250
12
22
12
2.69
2.83
3.36
60
3.9
300
14
24
13
2.95
3.08
3.61
60
4.2
350
14
26
15
3.20
3.33
3.87
60
4.5
400
16
26
16
3.46
3.59
4.12
60
4.8
450
19
28
18
3.71
3.84
4.37
60
5.1
500
21
34
19
3.96
4.10
4.63
60
5.4
550
23
36
21
4.22
4.35
4.88
60
5.7
600
25
40
22
4.47
4.60
5.14
54
6.0
406XR
Travel
(mm)
Positional (2)
Accuracy (m)
Straightness &
Flatness Accuracy
(m) Prec./Std.
Input Inertia 10-5 kg-m2
Max Screw Speed
(Revs Per Second)
Prec./Std.
Total Table
Weight (kg)
Prec./Std.
Prec.
Std.
5 mm
10 mm
20 mm
25 mm
100
8
12
6
3.34
3.85
5.90
-
60
8.7
200
12
20
10
3.92
4.43
6.48
-
60
10.0
300
14
24
13
4.50
5.01
7.06
-
60
11.3
400
16
26
16
5.08
5.59
7.64
-
60
12.6
500
21
34
19
5.65
6.17
8.22
-
55
13.9
600
25
40
22
6.23
6.75
8.80
-
44
15.2
700
-
92
25
36.51
37.02
-
40.61
47
19.2
800
-
94
29
39.96
40.47
-
44.07
47
20.7
900
-
103
32
43.41
43.93
-
47.52
47
22.2
1000
-
105
35
46.87
47.38
-
50.97
47
23.7
1250
-
118
42
55.50
56.01
-
59.61
35
27.6
1500
-
134
50
64.14
64.65
-
68.24
26
31.4
1750
-
154
57
72.77
73.28
-
76.88
20
35.2
2000
-
159
65
81.40
81.92
-
85.51
16
39.1
(2) Positional accuracy applies to in-line motor configurations only. Contact factory for parallel motor specifications.
www.comoso.com

404/406XR Series Product Manual Chapter 3 - Component Specifications
15
Parker Hannifin Corporation
1140 Sandy Hill Road
Irwin, PA 15642
www.parkermotion.com
404/406XR Series Engineering Reference
The following performance information is provided as a supplement to the product specifications pages. The following graphs
and formulas are used to establish the table life relative to the applied loads. The useful life of a linear table at full catalog
specifications is dependent on the forces acting upon it. These forces include both static components resulting from payload
weight, and dynamic components due to acceleration/deceleration of the load. in multi-axes applications, the primary
positioner at the bottom of the stack usually establishes the load limits for the combined axes. When determining life/load, it is
critical to include the weight of all positioning elements that contribute to the load supported by the primary axis.
Table Life/Load Chart
Compression (normal load)
This graph provides a “rough cut”
evaluation of the support bearing
life/load characteristics. The curves
show the life/load relationship when the
applied load is centered on the carriage,
normal (perpendicular) to the carriage
mounting surface. For final evaluation
of life vs. load, including off center,
tension, and side loads refer to the
charts and formulas found on our web
site www.parkermotion.com.
Table Life/Load Chart
Thrust (axial load)
This graph illustrates table ballscrew life
relative to the axial load.
Life with Compression Load
1000
10000
100000
1000000
10000000
01000 2000 3000 4000 5000 6000 7000
N
Life (Km)
404XR
406XR
Thrust Load
1000
10000
100000
1000000
10000000
100 600 1100 1600 2100
N
Life (Km)
404-406XR 16 x20
404-406XR 16 x10
404-406XR 16 x5
404-406XR 25 x25
404-406XR 25 x10
404-406XR 25 x5
www.comoso.com

404/406XR Series Product Manual Chapter 3 - Component Specifications
16
Parker Hannifin Corporation
1140 Sandy Hill Road
Irwin, PA 15642
www.parkermotion.com
These charts are to be used in
conjunction with the corresponding
formulas found under Product
Information at www.parkermotion.com
to establish the life / load for each
bearing (4 per table).
Several dimensions, which are specific
to each linear positioning table model,
and the load geometry are required for
these computations. These dimensions
are supplied in the catalog information
for each positioner. The dimensions are
referenced as follows:
d1 –bearing block center-to-
center longitudinal spacing
d2 –bearing rail center-to-center
lateral spacing
da –rail center-to-carriage
mounting surface
d1
d2
da
404XR
80
50
28
406XR
114
90.3
42.5
Life with Compression Load
1000
10000
100000
1000000
10000000
100000000
0200 400 600 800 1000 1200 1400 1600
Load per Bearing (N)
Life (Km)
404XR
406XR
Life with Tension Load
1000
10000
100000
1000000
10000000
100000000
0100 200 300 400 500 600 700 800
Load per Bearing (N)
Life (Km)
404XR
406XR
Life with Side Load
1000
10000
100000
1000000
10000000
100000000
0200 400 600 800 1000 1200 1400
Load per Bearing (N)
Life (Km)
404XR
406XR
www.comoso.com

404/406XR Series Product Manual Chapter 3 - Component Specifications
17
Parker Hannifin Corporation
1140 Sandy Hill Road
Irwin, PA 15642
www.parkermotion.com
www.comoso.com

404/406XR Series Product Manual Chapter 3 - Component Specifications
18
Parker Hannifin Corporation
1140 Sandy Hill Road
Irwin, PA 15642
www.parkermotion.com
www.comoso.com

404/406XR Series Product Manual Chapter 3 - Component Specifications
19
Parker Hannifin Corporation
1140 Sandy Hill Road
Irwin, PA 15642
www.parkermotion.com
Chapter 3 - Component Specifications
Linear Encoders
Description
Specification
Input Power
5 VDC +/- 5% 150mA
Output (incremental)
Square wave differential line driver (EIA RS422) 2
channels A and B in quadrature (90) phase shift
Reference (Z channel) –see Section 2.312
for additional information
Synchronized pulse, duration equal to one resolution
bit. Repeatability of position is unidirectional moving
toward non-motor end.
Positional Accuracy
+/- 3 microns after linear slope correction
Maximum Speed –see Chapter 2 for
additional information
1.0 micron resolution = 3.0 meters/sec
0.5 micron resolution = 1.5 meters/sec
0.1 micron resolution = 0.3 meters/sec
Z-Channel Position Reference
The Z channel is an output on the encoder. Many Servo Controllers support this input. The Z channel on
the 404XR is located at Mid Travel. The Z channel is a unidirectional device. This means that the final
homing direction must occur in one direction. The 404XR is set that the final home direction is to be
toward the non-motor end of the table. The repeatability of the Z channel is equal to +/- 2 resolution
counts of the encoder (except for 0.1 micron scales which have a repeatability of +/-1 microns). Thus
the repeatability of the “Z” channel equals:
Encoder Resolution
Z Channel Repeatability
1 micron
+/- 2 micron
0.5 micron
+/- 1 micron
0.1 micron
+/- 1 micron
NOTE: Home Repeatability is also very dependent on Controller input speed and Homing algorithms.
The above repeatability does not include possible controller tolerance. Additionally, to achieve the
highest repeatability the final homing speed must be slow. Slower final speed usually results in higher
repeatability.
NOTE: The “Z” channel output is only one resolution count wide. Thus the on-time may be very brief.
Due to this some controllers may have difficulty reading the signal. If you are experiencing the positioner
not finding the “Z” channel during homing, try reducing final homing speed; also refer to your controller
manual for frequency rates of the “Z” channel input.
www.comoso.com

404/406XR Series Product Manual Chapter 3 - Component Specifications
20
Parker Hannifin Corporation
1140 Sandy Hill Road
Irwin, PA 15642
www.parkermotion.com
Linear Encoder Speed Limit
The linear encoder has speed limits relative to encoder resolution; these limits are listed below:
Encoder Resolution
Maximum Velocity (2)
Required Post Quadrature Input
Bandwidth (1)
1 micron
3 meters/second
6.7 Mhz
0.5 micron
1.5 meters/second
6.7 Mhz
0.1 micron
0.3 meters/second
10 Mhz
(1) This is the bandwidth frequency that the amplifier or servo control input should have to operate properly with the encoder output at
maximum speeds. This frequency is post-quadrature, to determine pre-quadrature divide above values by 4. Above frequencies include a
safety factor for encoder tolerances and line loses.
(2) Maximum encoder speed may exceed maximum speed of positioner –See Section 2.51, General Table Specifications, for maximum
screw speed.
Linear Encoder Wiring Diagram
Termination: Flying Leads
Function
Signal Name
Wire Color
Power
+5V
0V
Brown
White
Incremental Signal
A+
A-
B+
B-
Green
Yellow
Blue
Red
Reference
Z+
Z-
Pink
Grey
Inner Shield
Inner Shield
Bare (Connect to White Lead - 0V Ground)
Outer Shield
Outer Shield
Bare (Connect to Earth Ground)
www.comoso.com