Medium Type : ZR-M
Operating Manual
ZR Unit
Small Type : ZR-S
Third Edition
IAI America, Inc.
Please Read Before Use
Thank you for purchasing our product.
This Operation Manual explains the handling methods, structure and maintenance of this product, among
others, providing the information you need to know to use the product safely.
Before using the product, be sure to read this manual and fully understand the contents explained herein to
ensure safe use of the product.
The CD that comes with the product contains operation manuals for IAI products.
When using the product, refer to the necessary portions of the applicable operation manual by printing
them out or displaying them on a PC.
After reading the Operation Manual, keep it in a convenient place so that whoever is handling this product
can reference it quickly when necessary.
[Important]
This Operation Manual is original.
The product cannot be operated in any way unless expressly specified in this Operation Manual. IAI
shall assume no responsibility for the outcome of any operation not specified herein.
Information contained in this Operation Manual is subject to change without notice for the purpose of
product improvement.
If you have any question or comment regarding the content of this manual, please contact the IAI
sales office near you.
Using or copying all or part of this Operation Manual without permission is prohibited.
The company names, names of products and trademarks of each company shown in the sentences
are registered trademarks.
1
Safety Guide
When designing and manufacturing a robot system, ensure safety by following the safety Guides
provided below and taking the necessary measures.
Regulations and Standards Governing Industrial Robots
Safety measures on mechanical devices are generally classified into four categori es un der the
International Industrial Standard ISO/DIS 12100, “Safety of machinery,” as follows:
Safety measures Inherent safety design
Protective guards --- Safety fence, etc.
Additional safety measures --- Emergency stop device, etc.
Information on use --- Danger sign, warnings, operation manual
Based on this classification, various standards are established in a hierarchical manner under the
International Standards ISO/IEC. The safety standards that apply to industrial robots are as follows:
Type C standards (individual safety standards) ISO10218 (Manipulating industrial robots – Safety)
JIS B 8433
(Manipulating industrial robots – Safety)
Also, Japanese laws regulate the safety of industrial robots, as follows:
Industrial Safety and Health Law Article 59
Workers engaged in dangerous or harmful operations must receive special education.
Ordinance on Industrial Safety and Health
Article 36 --- Operations requiring special education
No. 31 (Teaching, etc.) --- Teaching and other similar work involving industrial robots
(exceptions apply)
No. 32 (Inspection, etc.) --- Inspection, repair, adjustment and similar work involving industrial
robots (exceptions apply)
Article 150 --- Measures to be taken by the user of an industrial robot
Requirements for Industrial Robots under Ordinance on Industrial Safety and Health
Work area Work condition Cutoff of drive source Measure Article
Outside
movement
range
Inside
movement
range
During
automatic
operation
During
teaching, etc.
During
inspection, etc.
Not cut off
Cut off (including
stopping of
operation)
Not cut off
Cut off
Not cut off (when
inspection, etc., must
be performed during
operation)
Signs for starting operation Article 104
Installation of railings, enclosures,
etc.
Sign, etc., indicating that work is in
progress
Preparation of work rules Article 150-3
Measures to enable immediate
stopping of operation
Sign, etc., indicating that work is in
progress
Provision of special education Article 36-31
Checkup, etc., before
commencement of work
To be performed after stopping the
operation
Sign, etc., indicating that work is in
progress
Preparation of work rules Article 150-5
Measures to enable immediate
stopping of operation
Sign, etc., indicating that work is in
progress
Provision of special education
(excluding cleaning and lubrication)
Article 150-4
Article 150-3
Article 150-3
Article 150-3
Article 151
Article 150-5
Article 150-5
Article 150-5
Article 150-5
Article 36-32
3
Applicable Models of IAI’s Industrial Robots
Machines meeting the following conditions are not classified as industrial robots according to Notice of
Ministry of Labor No. 51 and Notice of Ministry of Labor/Labor Standards Office Director (Ki-Hatsu No.
340):
(1) Single-axis robot with a motor wattage of 80 W or less
(2) Combined multi-axis robot whose X, Y and Z-axes are 300 mm or shorter and whose rotating
part, if any, has the maximum movement range of within 300 mm
part
(3) Multi-joint robot whose movable radius and Z-axis are within 300 mm
Among the products featured in our catalogs, the following models are classified as industrial robots:
1. Single-axis ROBO Cylinders
RCS2/RCS2CR-SS8 whose stroke exceeds 300 mm
2. Single-axis robots
The following models whose stroke exceeds 300 mm and whose motor capacity also exceeds 80 W:
ISA/ISPA, ISDA/ISPDA, ISWA/ISPWA, IF, FS, NS
3. Linear servo actuators
All models whose stroke exceeds 300 mm
4. Cartesian robots
Any robot that uses at least one axis corresponding to one of the models specified in 1 to 3
5. IX SCARA robots
IX-NNN (NNW, NNC) 3515 (H)
IX-NNN (NNW, NNC) 50 (H) /60 (H) /70 (H) /80 (H)
IX-NSN5016(H) /6016 (H)
IX-TNN (UNN) 3015 (H)/3515 (H)
IX-HNN (INN) 50 (H) /60 (H) /70 (H) /80 (H)
3
including the tip of the rotating
Notes on Safety of Our Products
Common items you should note when performing each task on any IAI robot are explained below.
No. Task Note
1 Model
selection
2 Transportation When transporting the product, exercise due caution not to bump or drop the product.
3 Storage/
preservation
4 Installation/
startup
This product is not planned or designed for uses requiring high degrees of safety.
Accordingly, it cannot be used to sustain or support life and must not be used in the
following applications:
[1] Medical devices relating to maintenance, management, etc., of life or health
[2] Mechanisms or mechanical devices (vehicles, railway facilities, aircraft facilities, etc.)
intended to move or transport people
[3] Important safety parts in mechanical devices (safety devices, etc.)
Do not use this product in the following environments:
[1] Place subject to flammable gases, ignitable objects, flammables, explosives, etc.
[2] Place that may be exposed to radiation
[3] Place where the surrounding air temperature or relative humidity exceeds the
specified range
[4] Place subject to direct sunlight or radiated heat from large heat sources
[5] Place subject to sudden temperature shift and condensation
[6] Place subject to corrosive gases (sulfuric acid, hydrochloric acid, etc.)
[7] Place subject to excessive dust, salt or iron powder
[8] Place where the product receives direct vibration or impact
Do not use this product outside the specified ranges. Doing so may significantly shorten
the life of the product or result in product failure or facility stoppage.
Use appropriate means for transportation.
Do not step on the package.
Do not place on the package any heavy article that may deform the package.
When using a crane with a capacity of 1 ton or more, the crane must be operated by
personnel qualified to operate cranes and perform slinging operations.
When using a crane or other equipment, never use it to hoist any article exceeding the
rated load of the applicable crane, etc.
Use hoisting accessories suitable for the article to be hoisted. Select appropriate
hoisting accessories by making sure there is an ample allowance for safety in their
cutting load, etc.
Do not climb onto the article being hoisted.
Do not keep the article hoisted.
Do not stand under the hoisted article.
The storage/preservation environment should conform to the installation environment.
Among others, be careful not to cause condensation.
(1) Installing the robot, controller, etc.
Be sure to firmly secure and affix the product (including its
If the product tips over, drops, malfunctions, etc., damage or injury may result.
Do not step on the product or place any article on top. The product may tips over or the
article may drop, resulting in injury, product damage, loss of/drop in product
performance, shorter life, etc.
If the product is used in any of the following places, provide sufficient shielding
measures:
[1] Place subject to electrical noise
[2] Place subject to a strong electric or magnetic field
[3] Place where power lines or drive lines are wired nearby
[4] Place subject to splashed water, oil or chemicals
work part).
5
No. Task Note
4 Installation/
startup
5 Teaching Whenever possible, perform teaching from outside the safety fences. If teaching must
(2) Wiring the cables
Use IAI’s genuine cables to connect the actuator and controller or connect a teaching
tool, etc.
Do not damage, forcibly bend, pull, loop round an object or pinch the cables or place
heavy articles on top. Current leak or poor electrical continuity may occur, resulting in
fire, electric shock or malfunction.
Wire the product correctly after turning off the power.
When wiring a DC power supply (+24 V), pay attention to the positive and negative
polarities.
Connecting the wires in wrong polarities may result in fire, product failure or malfunction.
Be sure to connect the cable connectors without fail and firmly. Failing to do so may
result in fire, electric shock or product malfunction.
Do not cut and reconnect the cables of the product to extend or shorten the cables.
Doing so may result in fire or product malfunction.
(3) Grounding
Be sure to provide class D (former class 3) grounding for the controller. Grounding is
required to prevent electric shock and electrostatic charges, improve noise resistance
and suppress unnecessary electromagnetic radiation.
(4) Safety measures
Implement safety measures (such as installing safety fences, etc.) to prevent entry into
the movement range of the robot when the product is moving or can be moved.
Contacting the moving robot may result in death or serious injury.
Be sure to provide an emergency stop circuit so that the product can be stopped
immediately in case of emergency during operation.
Implement safety measures so that the product cannot be started only by turning on the
power. If the product starts suddenly, injury or product damage may result.
Implement safety measures so that the product will not start upon cancellation of an
emergency stop or recovery of power following a power outage. Failure to do so may
result in injury, equipment damage, etc.
Put up a sign saying “WORK IN PROGRESS. DO NOT TURN ON POWER,” etc., during
installation, adjustment, etc. If the power is accidently turned on, electric shock or injury
may result.
Implement measures to prevent the work part, etc., from dropping due to a power
outage or emergency stop.
Ensure safety by wearing protective gloves, protective goggles and/or safety shoes, as
necessary.
Do not insert fingers and objects into openings in the product. Doing so may result in
injury, electric shock, product damage, fire, etc.
When releasing the brake of a vertically installed actuator, be careful not to pinch your
hand or damage the work part, etc., due to the slider dropping by its dead weight.
be performed inside the safety fences, prepare “work rules” and make sure the operator
understands the procedures thoroughly.
When working inside the safety fences, the operator should carry a handy emergency
stop switch so that the operation can be stopped any time when an abnormality occurs.
When working inside the safety fences, appoint a safety watcher in addition to the
operator so that the operation can be stopped any time when an abnormality occurs.
The safety watcher must also make sure the switches are not operated inadvertently by
a third party.
Put up a sign saying “WORK IN PROGRESS” in a conspicuous location.
When releasing the brake of a vertically installed actuator, be careful not to pinch your
hand or damage the work part, etc., due to the slider dropping by its dead weight.
* Safety fences --- Indicate the movement range if safety fences are not provided.
No. Task Note
6 Confirmation
operation
7 Automatic
operation
8 Maintenance/
inspection
9 Modification The customer must not modify or disassemble/assemble the product or use
10 Disposal When the product becomes no longer usable or necessary, dispose of it properly as an
After teaching or programming, carry out step-by-step confirmation operation before
switching to automatic operation.
When carrying out confirmation operation inside the safety fences, follow the specified
work procedure just like during teaching.
When confirming the program operation, use the safety speed. Failure to do so may
result in an unexpected movement due to programming errors, etc., causing injury.
Do not touch the terminal blocks and various setting switches while the power is
supplied. Touching these parts may result in electric shock or malfunction.
Before commencing automatic operation, make sure no one is inside the safety fences.
Before commencing automatic operation, make sure all related peripherals are ready to
operate in the auto mode and no abnormalities are displayed or indicated.
Be sure to start automatic operation from outside the safety fences.
If the product generated abnormal heat, smoke, odor or noise, stop the product
immediately and turn off the power switch. Failure to do so may result in fire or product
damage.
If a power outage occurred, turn off the power switch. Otherwise, the product may move
suddenly when the power is restored, resulting in injury or product damage.
Whenever possible, work from outside the safety fences. If work must be performed
inside the safety fences, prepare “work rules” and make sure the operator understands
the procedures thoroughly.
When working inside the safety fences, turn off the power switch, as a rule.
When working inside the safety fences, the operator should carry a handy emergency
stop switch so that the operation can be stopped any time when an abnormality occurs.
When working inside the safety fences, appoint a safety watcher in addition to the
operator so that the operation can be stopped any time when an abnormality occurs.
The safety watcher must also make sure the switches are not operated inadvertently by
a third party.
Put up a sign saying “WORK IN PROGRESS” in a conspicuous location.
Use appropriate grease for the guides and ball screws by checking the operation
manual for each model.
Do not perform a withstand voltage test. Conducting this test may result in product
damage.
When releasing the brake of a vertically installed actuator, be careful not to pinch your
hand or damage the work part, etc., due to the slider dropping by its dead weight.
* Safety fences --- Indicate the movement range if safety fences are not provided.
maintenance parts not specified in the manual without first consulting IAI.
Any damage or loss resulting from the above actions will be excluded from the scope of
warranty.
industrial waste.
When disposing of the product, do not throw it into fire. The product may explode or
generate toxic gases.
7
Indication of Cautionary Information
The operation manual for each model denotes safety guides under “Danger,” “Warning,” “Caution” and
“Note,” as specified below.
Level Degree of danger/loss Symbol
Danger
Warning
Caution
Note
Failure to observe the instruction will result in an
imminent danger leading to death or serious injury.
Failure to observe the instruction may result in death
or serious injury.
Failure to observe the instruction may result in injury
or property damage.
The user should take heed of this information to
ensure the proper use of the product, although failure
to do so will not result in injury.
Danger
Warning
Caution
Note
Handling Precautions
1. Handling the Actuator Unit
1.1 Handling the Packed Actuator
Unless otherwise specified, the actuator of single-axis configuration is packed individually and shipped.
When transporting or handling the packed actuator, exercise due caution not to hit the package against
other object or drop the package.
If the packed actuator is to be let stand for a while, place it on a flat floor.
Do not step onto the package.
Do not place on the package any heavy article that may deform the package or have concentrated
loads.
1.2 Handling the Unpacked Actuator
When handling the unpacked actuator, hold it by the base at the bottom.
(For the name of each part of the actuator, refer to 1, "Names of the Parts.")
When transporting the actuator, be ca reful not to hit it against structure s a nd objects o r drop t he actu ator
or otherwise apply any excessive impact or force on it.
Do not transport the actuator by holdin g the cables or move it by pulling the cables.
Do not transport the actuator by holdin g the ball scre w or cover.
1.3 Precautions for Tentative Set-down
When tentatively setting down the unpacked actuator, provide a pedestal, as shown below, to prevent the
cables at the rear from receiving loads.
100 mm or more
r = 50 mm or more
9
2. Handling the Actuator Assembly
Pay attention to the following instructions when transporting the assembled actuator axes.
2.1 When Shipped Pre-assembled from IAI
The specified machine assembly has been assembled by IAI, subjected to shipping test, and then packed
inside a frame driven by nails onto a base of square timbers.
If the combined actuator unit is of slider type, the slider is secured during packaging so that it will not move
accidentally during transport. In the case of a combined unit, the actuator ends are secured to prevent
swinging due to external vibration.
The package is not designed with speci al conside rations for prote ction against impact due to drop ping or
collision. Handle the package with care. Also, do not place any heavy object on the outer frame, as it is
not strong enough to withstand loads.
When suspending the package using belts, etc., support it by the reinforced frame at the bottom of the
base of square timbers. Also when lifting the package using a forklift, insert the forks below the base of
square timbers.
When unloading the pa ckage, do so without applying any impact.
2.2 Handling the Unpacked Actuator
When transporting an unpacked machine that has been shipped pre-assembled from IAI, observe the
following handling precautions:
Secure each slider to prevent unexpected movement during transportation.
If any actuator end is protruding, secure it to prevent swinging due to external vibration. If the actuator
ends are not secured, do not apply any impact force exceeding 0.3 G during transportation.
When suspending the actuator-assembl ed peripheral equipment using belts, etc., make sure the belts do
not contact the actuators directly.
Pass the belts over appropriate cushion materials, and make sure the loads from the belts will be
received by the base of each actuator.
Secure the end of the Y-axis using a separate belt to maintain the axis in a stable horizontal position. At
this time, be careful not to apply loads on the screw cover.
Be careful not to allow the brackets, covers and connector box of each actuator to receive loads.
Also protect the cables from pinching or excessive deformation.
3. Handling after Assembly with Peripheral Equipment
The precautions in 2, "Handling the Unpacked Actuator" also apply when the act uator has be en asse mbled
at your facility and transported in the assembled state. Handle the actuator according to the specified
precautions.
Table of Content
1. Names of the Parts ................................................................................................1
2. External Dimensions ..............................................................................................3
2.1 ZR-S................................................................................................................................ 3
2.2 ZR-M
3. Accessories............................................................................................................7
4. Options...................................................................................................................9
4.1 Flanges ........................................................................................................................... 9
4.2 Absolute Reset Adj
5. Cable Drawings....................................................................................................11
............................................................................................................................... 5
ustment Jigs.................................................................................... 10
5.1 Types of Encoder Cables
5.2 About Incremental Type and
5.3 Motor cable
................................................................................................................... 12
.............................................................................................. 11
Absolute Type ................................................................. 11
6. Product Check......................................................................................................12
6.1 Operation Manuals Relating to This Pr
6.2 How to Read Model Nameplate
6.3 ZR Unit model
............................................................................................................... 13
oduct................................................................. 12
.................................................................................... 13
7. Specifications.......................................................................................................14
8. Installation Environment, Storage Environment ...................................................15
8.1 Installation E
8.2 Storage Environment
nvironment................................................................................................ 15
.................................................................................................... 15
9. Installation............................................................................................................16
9.1 Installation of the Unit
9.2 Actuator Ins
9.3 Installation of Tool and Load
9.4 Installation of User Components
9.5 Mounting Holes for Connector Box
tallation Posture ......................................................................................... 16
.................................................................................................... 16
......................................................................................... 17
................................................................................... 19
............................................................................... 19
10. Wiring...................................................................................................................20
10.1 Wiring Diagram (Incremental)
10.2 Wiring Diagram (Absolute)
10.3 Wiring Method
10.4 Prohibited Wiring Practice
10.5 Notes on use of cable track
10.6 Wiring in the Duct
10.7 Checking after Installatio
............................................................................................................ 22
...................................................................................................... 26
......................................................................................... 21
s........................................................................................ 24
....................................................................................... 25
n and Wiring ....................................................................... 26
.................................................................................... 20
11
11. Operation Adjustment ..........................................................................................27
11.1 Guide for Acceleration Setting
11.2 Notes on Transferring Load
11.3 Push Force
................................................................................................................ 28
................................................................................... 27
....................................................................................... 28
12. Notes on Operation..............................................................................................29
12.1 About Brake
12.2 About Home Return (Incre
12.3 Position Gai
............................................................................................................... 29
mental Type) .................................................................. 29
n ............................................................................................................. 30
13. Maintenance and Inspection................................................................................31
13.1 Inspection In
13.2 Visual Inspe
13.3 Cleaning
13.4 Inspection of Interior
13.5 Greasing
tervals and Items................................................................................... 31
ction of Exterior...................................................................................... 32
.................................................................................................................... 32
.................................................................................................. 32
.................................................................................................................... 33
14. Appendix..............................................................................................................34
14.1 Absolute Reset Method (Absolute Type Only)
........................................................... 34
15. Warranty...............................................................................................................49
16. Change History....................................................................................................50
1. Names of the Parts
Mounting flange
Mounting hole
4 locations, tap size
ZRS: M6, ZRM: M8
Positioning pin hole
2 locations
Hole diameter 6H7
(+0.012)
ZR-S: 7 mm from back side
ZR-M: 8 mm from back side
* Not a through hole
Base
* For the detailed dimensions, refer to 2, "External Dimensions."
Z-axis stopper
Ball screw
spline shaft
Z-axis
(Vertical axis)
Cover
Base
R-axis (Rotational axis)
Mounting flange
Tapped holes for installing user
components
(Tap size: M4 x 12 on both sides)
Z-axis stopper
Positioning pin hole for ball
screw spline adjustment
Connector box
Mounting hole, 4 locations
Tap size: M5 x 8
Z-axis, R-axis
(Motor cable, encoder cable)
1
Coordinate system
Z-axis (vertical axis): The downward direction represents the positive direction.
R-axis (rotational axis): The clockwise direction as viewed from the bottom represents
the positive direction.
2
(
)
2. External Dimensions
2.1 ZR-S
4-6.6, 11, counterbore
2-6H7
Depth 7 from back side
4 (Mechanical end)
4-M4 depth 12
(Same on both sides)
(16)
Mechanical end
4
3
35
B-B section
11 (inner diameter)
16h7
Detail View of Tip
4
(
)
2.2 ZR-M
4-9, 14, counterbore
-
Depth 8 from back side
5 (Mechanical end)
4-M4 depth 12
(Same on both sides)
20
5 (Mechanical end)
5
)
44
B-B section
14 (inner diameter
Detail View of Tip
6
3. Accessories
Brake box
[4] Actuator 1
Connector
[6] Controller 1
Connector
4-5
Note:
The BK1 and BK2
switches are not
available for a 24-V
brake.
[3] External
switch
connector
[1] 24-V power
connector
[5] Actuator 2
Connector
[7] Controller 2
Connector
[2] Power ON
LED
7
[1] 24-V power connector
This connector is used to supply 24-V power to the external brake box.
Applicable cable AWG28~16
Terminal
24 V +24-V power input
0 V GND
[2] Power ON LED
The LED becomes lit when +24-V power is supplied to the external brake box.
[3] External switch connector
The brake can be forcibly released by connecting a switch to the external switch connector and then
shorting pins 1 and 2.
Cable-end
connector
Terminal
XAP-02V-1
(Contact: BXA-001T-P0.6) (JST)
1 BKMRL Brake release switch input
2 COM Power output for brake release switch input
* An optional brake release switch cable is available for connecting the switch and external switch
connector.
Model:
Brake release switch cable (optional)
CB-XBB-SW020 (2 m)
* The length can be changed.
Housing: XAP-02V-1 (JST)
Socket contact: BXA-001T-P0.6 (JST) x 2
Wiring diagram
Wire size Color Signal
Orange1Black
Orange1Red
Sunrex 24 1PxAWG26 (Taiyo Cabletec)
No connector
No connector
[4] Actuator 1 connector [5] Actuator 2 connector
These connectors are used to connect the encoder cables on the actuator end.
[6] Controller 1 connector [7] Controller 2 connector
These connectors are used to connect the encoder cables on the controller end.
8
4. Options
4.1 Flanges
Use a flange to install a work at the tip of the Z-axis.
ZR-S flange: IX-FL-2
ZR-M flange: IX-FL-1
5H7
+0.012
0
35
16
25h7
60
25 0.012
M5
4-5.5
4-
50
5H7
44
20
34h7
70
5.5
60
9
4.2 Absolute Reset Adjustment Jigs
These jigs are used if an absolute reset is required due to loss of absolute encoder data.
* For the absolute reset adjustment procedure, refer to the operation manual for the controller
(XSEL-P/Q).
* The size is different between the ZR-S and ZR-M types.
Absolute reset adjustment jig Model: JG-ZRS (ZR-S)
JG-ZRM (ZR-M)
10
5. Cable Drawings
5.1 Types of Encoder Cables
Different encoder cables are used for the absolute encoder and incremental encoder types.
Incremental type
Be sure to use the LS type encoder cable (CB-X1-PLA) for the R-axis.
Absolute type
Either the normal type (CB-X1-PA) or LS type (CB-X1-PLA) can be used.
5.2 About Incremental Type and Absolute Type
Incremental encoder type
Since the position data is cleared when the power is turned off, home return is required every time the
power is turned off and then on again.
Incremental cable
Model
CB-X1-PLA
LS end
Controller end
Actuator end
(Front view)
Absolute encoder type
Since the position data is retained even after the power is turned off, home return is not required when
the power is turned off and turned on again.
An absolute reset must be performed first.
Absolute cable
Model
CB-X1-PA
(Front view)
Controller end
Actuator end
Plug housing: XMP-09V (JST)
Socket contact: BXA-001T-P0.6 (JST) x 9
Retainer: XMS-09V (JST)
Note 6: Use the crimpling machine recommended by
the connector manufacturer.
(Front view)
* Enter the applicable cable length (L) in .
A desired length up to 30 m can be specified.
Example) 080 = 8 m
Wire size
White/Blue
White/Yellow
White/Red
White/Black
White/Purple
White/Grey
(soldered)
Orange
Green
Purple
Gray
Red
Black
Blue
Yellow
Clamp the shield to the hood.
No.
Drain wire or
braided shield wire
(“White/blue” in the “Color” field
indicates that the cable is white and
the insulator is blue.)
Signal
Color
* Enter the applicable cable length (L) in .
A desired length up to 30 m can be specified.
Example) 080 = 8 m
Color
Orange
Green
Purple
Gray
Red
Black
Blue
Yellow
Signal
Drain wire or braided shield wire
Wire size
AWG26
(soldered)
Clamp the shield to the hood.
Signal
Signal
Signal
Color
White/Blue
White/Yellow
White/Red
White/Black
White/Purple
White/Grey
Color
Purple
Gray
Orange
Green
Red
Black
Drain
Blue
Yellow
Color
Purple
Gray
Orange
Green
Red
Black
Drain
Blue
Yellow
11
Wire size
(crimped)
Wire size
(crimped)
Wire size
(crimped)
5.3 Motor cable
Model
CB-X-MA
* Enter the applicable cable length (L) in .
A desired length up to 30 m can be specified.
Example) 080 = 8 m
(Front view)
Controller end
Actuator end
(Front view)
Wire size
Color
Green
Red
White
Black
Signal
6. Product Check
Check the condition of the unpacked product as well as the included items.
No. Item Model
1 Actuator Refer to "How to Read Model Nameplate."
Accessories
2 Brake box RCB-110-RA13-0
3 Brake box-controller connection cable CB-RCS2-PLA010
4 Operation manual
6.1 Operation Manuals Relating to This Product
Signal
Color
Red
White
Black
Green
Wire size
(crimped)
No. Item Model
1 XSEL-P/Q Controller Operation Manual ME0148
2 XSEL-Controller P/Q/PX/QX RC Gateway Function Operation Manual ME0188
3 PC Software IA-101-X-MW/IA-101-X-USBMW Operation Manual ME0154
4 Teaching Pendant SEL-T/TD Operation Manual ME0183
5 Teaching Pendant IA-T-X/XD Operation Manual ME0160
6 DeviceNet Operation Manual ME0124
7 CC-Link Operation Manual ME0123
8 ProfiBus-DP Operation Manual ME0153
9 Ethernet Operation Manual ME0140
12
6.2 How to Read Model Nameplate
Model
Serial number
6.3 ZR Unit model
Series Type Encoder
type
Z-axis motor
type
Z-axis
lead
Z-axis
stroke
Applicable
controller
Cable
length
Options
Small (Z-axis 100 W/R-axis 100 W)
Medium (Z-axis 200 W/R-axis 200 W)
Incremental specification
Absolute specification
100 W (S type fixed)
200 W (M type fixed)
16 mm (S type fixed)
20 mm (M type fixed)
150 stroke (S type fixed)
200 stroke (M type fixed)
None
Specified length
Z-axis brake
(Standard feature on the Z-axis/R-axis)
Limit switch
(Standard feature on R-axis)
13
7. Specifications
Item Specification
Model ZR-S ZR-M
Z-axis (vertical axis) -
Drive method
R-axis (rotational axis) Motor capacity
Operation range
speed (Note 1)
Repeatability
(Note 2)
Loading capacity
Z-axis (vertical axis)
maximum force
R-axis
allowable load
Home detection
Operating
environment
Actuator weight - kg 5.5 8
Controller
Note 1) Speed when each axis is moved independently to the target position at the specified speed.
Note 2) When the surrounding temperature is constant at 20C.
Note 3) Forces up to three times the maximum force may generate momentarily.
Note 4) Equivalent allowable inertial moment (maximum value) at the center of the rotational axis.
(Refer to 9.3 (2), "Conditions of transferring load.")
Z-axis (vertical axis) 100 200
R-axis (rotational axis)
Z-axis (vertical axis) mm 150 200
R-axis (rotational axis) degree
Z-axis (vertical axis) mm/s 1005 1256 Maximum operating
R-axis (rotational axis) deg/s 2200
Z-axis (vertical axis) mm
R-axis (rotational axis) degree
Rated 1 2
Maximum
Positioning operation
(Note 3)
Push-motion operation
Allowable inertial
moment (Note 4)
Allowable torque
Surrounding air
temperature/humidity
Power supply - 230 V 50/60 Hz 5 A
Allowable power
supply
W
kg
N (kgf)
kgm
Nm
(kgfcm)
-
%
AC servo motor with brake + Belt + Ball screw
spline
AC servo motor + Belt + Gear reducer +
Spline
100 200
360
0.010
0.005
3 6
107 (10.9) 171 (17.4)
74.8 (7.6) 120 (12.2)
2
0.015 0.03
1.9 (19) 3.8 (38.8)
Incremental encoder method/absolute
encoder method
Temperature 0 to 40C, humidity 20 to 85%
RH max. (non-condensing)
10
14
8. Installation Environment, Storage Environment
8.1 Installation Environment
Install the unit in an environment meeting the conditions listed below.
Not be exposed to direct sunlight.
Be free from irradiating heat coming from a heat treatment furnace or other equipment that generates a
large amount of heat.
Have surrounding air temperature of 0 to 40°C.
Have humidity of 85% or below (non-condensing).
Be free from corrosive or flammable gases.
Be free from excessive dust and suitable for normal assembly work.
Be free from oil mist or cutting oil.
Be free from chemicals such as sulfuric acid and hydrochloric acid. (Chemical resistance is not
considered in the design of this product.)
Be free from impact or vibration.
Be free from strong electromagnetic waves, ultraviolet light or radiation.
In general, the unit should be used in an environment where the operators can work without wearing any
protective equipment or gear.
8.2 Storage Environment
The storage environment should basically conform to the installation environment.
If the unit is to be stored for an extended period of time, provide appropriate measures to prevent dew
condensation.
The unit is not packed with drying agent, unless otherwise specified by the user. If the unit is to be stored
in an environment where dew condensation may occur, take appropriate measures to protect the entire
package, or the unit itself (after unpacking it), from the detrimental effects of dew condensation.
The unit can withstand a surrounding air temperature of up to 60C for a short period. If the unit must be
stored for over a month, keep the surrounding air temperature at 50C or below.
15
9. Installation
9.1 Installation of the Unit
Each mounting flange has mounting holes (refer to "Names of the Parts"). Install the flange using the
specified screws.
Type Specified screw
ZR-S M6 536 Ncm
ZR-M M8 1,148 Ncm
* Hexagonal socket head bolt of strength category 10.9
9.2 Actuator Installation Posture
This actuator is of vertical type (= the ball screw is oriented vertically). It cannot be used in the horizontal
direction.
If each axis has been assembled at IAI, positioning pin holes are provided. Two positioning pins are
available, so use them to position the actuator.
Vertical installation
* Recommended tightening torque
Bearing surface: Aluminum
Horizontal installation
16
9.3 Installation of Tool and Load
(1) Installing the tool
The tool mounting part must have sufficient strength and rigidity, along with adequate fastening power to
prevent positional shift.
It is recommended that a tool be installed over a split ring, power lock or other appropriate part.
(The flanges specified in 4, "Options" are available.)
To set the rotating direction using the D-cut surface and setscrews, be sure to use setscrews with resin
or brass pad or set pieces made of soft material.
An example of installation is shown below for your reference.
D-cut surface
R-axis (Center of the rotational axis)
Tool
Power lock
Pressure flange
Caution: Use the D-cut surface at the tip of the R-axis (rotational axis) to position the R-axis.
Avoid attachment of the tool at the D-cut surface via thread fastening. Doing so may
damage the D-cut positioning surface.
Design the tool so that it will not contact any device that secures the ZR unit.
17
(2) Conditions of transferring load
Transferring mass
Type Rated transferring mass Maximum transferring mass
ZR-S 1 kg 3 kg
ZR-M 2 kg 6 kg
Allowable load inertial moment
Type Allowable inertial moment Remarks
ZR-S 0.015 kgm2
ZR-M 0.03 kgm2
Maximum value
* If the load inertial moment exceeds one-third of the allowable inertial moment, vibration may occur
depending on the operating conditions. In this case, adjust the acceleration to a lower level. Also note
that adjusting the acceleration alone may affect the locus in case of interpolated operation. In this case,
also adjust the speed.
Load offset (from the center of the R-axis (rotational axis))
Type Offset
Center of the R-axis
ZR-S 40 mm
ZR-M 50 mm
* If the load gets offset, the unit becomes more
likely to cause vibration.
Design the tools so that the load’s center of
gravity aligns with the center of the R-axis
(rotational axis).
Center of gravity of load
If the load must be offset, make sure the
applicable offset in the table is not exceeded.
If vibration occurs, adjust the speed and
acceleration to lower levels.
Load offset
18
9.4 Installation of User Components
Tapped holes are provided on the side faces of the unit for installin g user comp onents. [Refe r to 1, "Nam es
of the Part."] Use these holes to install brackets for jigs or sensors provided by the user.
[For the detailed dimensions, refer to 2, "External Dimensions."]
Type
ZR-S
ZR-M
Tap
size
Effective depth
* Recommend ed tightening torque
Bearing surface: Aluminum
M4 12 mm 176 Ncm {18.0 kgfcm} 359 Ncm {36.7 kgfcm}
* Recommend ed tightening torque
Bearing surface: Steel
* Hexagonal socket head bolt of strength category 10.9
9.5 Mounting Holes for Connector Box
Tapped holes are provided for installing the connector box. [Refer to 1, "Names of the Parts."]
The connector box is already installed if the units have been shipped pre-assembled.
The connector box is not supplied if only a single axis has been shipped.
It is supplied if multiple axes have been shipped individually for subsequent assembly.
If the connector box is not installed, you can use these mounting holes for any desired purpose.
Use the specified screws.
Type Tap size Maximum screw length
ZR-S
ZR-M
M5 8 mm 727 Ncm {74.2 kgfcm}
* Recommended tightening torque
Bearing surface: Steel
* Hexagonal socket head bolt of strength category 10.9
Caution: The tapped holes are through holes, so pay attention to the maximum screw length at the
time of installation. If the internal mechanism is contacted, failure may occur.
19
g
10. Wiring
10.1 Wiring Diagram (Incremental)
ZR unit
Brake box
Encoder cable
Encoder cable
Motor cable
Motor cable
Ortho
onal axis
Motor cable
Encoder cable
Motor connector
Motor cable
Encoder cable
Brake box-controller
connection cable
(supplied)
Encoder connector
24-VDC
power input
Controller (with brake)
20
g
10.2 Wiring Diagram (Absolute)
ZR unit
Brake box
Encoder cable
Encoder cable
The LS connector is not connected.
Motor cable
Encoder cable
Ortho
onal axis
Motor cable
Motor cable
Motor connector
Motor cable
Encoder cable
Brake box-controller
connection cable
(supplied)
Encoder connector
24-VDC
power input
Controller (with brake)
21
10.3 Wiring Method
(1) Determine the control axis number (Axis No.) of each actuator according to the system (program)
and connect the actuator to the corresponding connector on the controller.
Encoder cable connector Motor cable connector
Control axis number
(Axis No.)
Display on
controller front
panel
1 PG1 1 M1
2 PG2 2 M2
3 PG3 3 M3
4 PG4 4 M4
5 PG5 5 M5
6 PG6 6 M6
Caution: If connector numbers are not shown on the cables, mark the connector numbers or other
identification information on the cables to prevent mis-wiring during maintenance. Wrong
connections may result in damage or malfunction of the motor/board.
(2) Both the left and right brake boxes are connected to one axis, respectively.
The Z-axis and R-axis encoder cables can be connected to either side, but certain rules apply. If the
Z-axis is connected to the connector (ACTUATOR2) on the left box, for example, the cable
connecting the left brake box and XSEL controller should be the one whose axis number
corresponds to the Z-axis on the X-SEL side, and accordingly this cable should be connected to the
applicable connector (CONTROLLER2).
CONTROLLER2
Controller
connectors
Left side
ACTUATOR2
ZR unit connector
Control axis number
(Axis No.)
Display on
controller front
panel
Right side
CONTROLLER1
Controller
connectors
ACTUATOR1
ZR unit connector
22
(3) Connect a 24-VDC power supply to the brake box and controller and supply the power.
Brake box
Controller (with brake)
24-VDC power input
24-VDC power input
Caution: Before connecting each cable/connector, confirm that the connector pins are not bent or
broken and the cable is not damaged, and then plug in the connector firmly.
When connecting the encoder cable, be sure to confirm the orientation of the connector first.
Use a dedicated 24-VDC power supply for the brake power, because sharing the I/O power or
secondary circuit power may cause noise to enter the I/O signals or otherwise the brake
operation may become unstable.
The power supply for the brake must have an output voltage of 24 VDC 10% and power
capacity of 20 to 30 W.
23
10.4 Prohibited Wiring Practices
Connect the connector at the end of the cable, to the controller.
For the connection methods of the I/O cable, controller power cable, PC connection cable, etc., refer to the
operation manuals for your controller and PC software.
When designing an application system using actuators and controllers, incorrect wiring or connection of
each cable may cause unexpected problems such as a disconnected cable or poor contact. This section
explains prohibited handling of cables.
Do not cut any of the cables to extend, reduce its length or reconnect the cut cable.
If the cables cannot be mounted, connect them within the range in which the cables bend with their own
weight or in a big radius of a standing cable hose, etc, so that the cable loads will be reduced.
Do not let the cable flex at a single point.
Do not let the cable bend, kink or twist.
Do not pull the cable with a strong force.
Do not let the cable receive a turning force at a single point.
Steel band
(piano wire)
Bundle loosely.
24
Do not pinch, drop a heavy object onto or cut the cable.
When fixing the cable, provide a moderate slack and do not tension it too tight.
Do not use a spiral tube
where the cable flexes
frequently.
10.5 Notes on Use of Cable Track
The supplied cables are not robot cables.
Accordingly, never store the cables in a cable track.
Always use a robot cable for
each relay cable.
Use a cable track with a bending
radius (r) of 50 mm or more.
25
Do not let the cable got tangled or kinked in a cable track or flexible tube. Do not bundle the cables to
allow a certain degree of flexibility (so that the cable will not become too taut when bent).
Do not cause the cables to occupy more than 60% of the space in the cable track.
Cable track
Cable
10.6 Wiring in the Duct
Separate the I/O and communication lines from the power and drive lines. Do not guide them together in
the duct.
Power line
Signal lines
(flat cable etc.)
Duct
10.7 Checking after Installation and Wiring
Check the following items after installation and wiring:
Visually examine the actuator, controller and cables for scratches, dents and other abnormalities.
Confirm that the cables are connected correctly and the connectors are attached securely.
Warning
Before connecting or disconnecting any cable, be sure to turn off the controller power.
If a cable is connected/disconnected while the controller power is on, the actuator may malfunction
and cause serious injury accident or damage to the machine.
Incompletely connected connectors may cause the actuator to malfunction and create a dangerous
situation. Be sure to confirm that all connectors are connected properly.
26
A
A
11. Operation Adjustment
11.1 Guide for Acceleration Setting
When setting the acceleration, use the following graph as a guide.
This graph provides a guide when each axis is operated separately. If interpolated operation is
performed, adjust the acceleration according to the acceleration/deceleration of the slower axis.
Continuous operation (duty: 100%)
Refer to 11.2, "Notes on Transferring Load."
Precautions for the R-axis
If the load inertial moment exceeds one-third of the allowable inertial moment, vibration may occur
depending on the operating conditions.
In this case, adjust the acceleration to a lower level. Also note that adjusting the acceleration alone may
affect the locus in case of interpolated operation. In this case, also adjust the speed.
Continuous operation of the Z-axis (vertical axis)
cceleration
Load
Continuous operation of the R-axis (rotational axis)
cceleration
Allowable inertia
27
11.2 Notes on Transferring Load
Set an appropriate acceleration according to the mass and inertial moment at the tip.
Failure to do so may result in premature consumption of life, damage or vibration of drive parts.
If vibration occurs, lower the acceleration.
To raise the acceleration, adjust it to an appropriate level by gradually raising the set value.
If the load gets offset, the unit becomes more likely to cause vibration.
Design the tools so that the load’s center of gravity aligns with the center of the R-axis (rotational axis).
If an overload error occurs, lower the acceleration setting or provide a stopping time following each
acceleration/deceleration or perform other appropriate adjustment.
The transferring load indicates a load above the rotational center of the R-axis (rotational axis).
To move the robot horizontally at high speed, perform teaching so that the vertical axis stays as close to
the top position as possible.
To operate the unit with its vertical axis at the bottom position, the speed and acceleration must be
reduced.
* For other detailed adjustment methods, refer to the operation manual for your controller (XSEL-P/Q).
11.3 Push Force
The push force can be adjusted using Driver Card Parameter No. 38 (Push Torque Limit during
Positioning).
(Max. 70%)
The R-axis cannot perform push operation. Only the Z-axis can perform this operation.
28
12. Notes on Operation
12.1 About Brake
The brake is provided to retain the load in position should the servo turn off for some reason.
It cannot be used as an emergency stop brake.
Loads equivalent to or heavier than the maximum loading capacity cannot be retained. (For the
maximum loading capacity, refer to 7, "Specifications.")
Use the brake release switch on the controller to release the brake manually.
No brake release switch is provided on the robot side.
Controller (brake-type specification)
12.2 About Home Return (Incremental Type)
24-VDC power input
Brake release switch
The operating steps of home return are as follows:
[1] Z-axis mechanical end search 1
[2] Z-axis offset movement 1
[3] R-axis LS search (CCW)
[4] R-axis phase Z search (CW)
[5] R-axis offset movement (CCW)
[6] Z-axis mechanical end search 2
[7] Z-axis offset movement 2
[8] End
Caution: During R-axis LS search in operating step [3], the axis always turns counterclockwise and
does not take a short cut.
Depending on the position before the home return, the axis may turn nearly one rotation,
in which case the cables, etc., may be damaged if guided through the opening aperture.
Pay attention to twisting and other forces that may exert upon the cables.
29
12.3 Position Gain
If the position gain is different for each axis during CP operation (interpolated operation) involving an
orthogonal axis and the Z-axis or R-axis of a ZR unit, the locus may be affecte d depending on the op erating
conditions.
Accordingly, it is recommended that the same position gain be set for all axes.
Adjust the position gain using Axis-specific Parameter No. 60 of your controller (XSEL-P/Q). For the
method to change this parameter, refer to the operation manual for your PC software.
* CP operation commands:
“PATH, CIR, ARC, PSPL, CIR2, ARC2, ARCD, ARCC, CIRS, ARCS, ARCH, PACH, MOVL, MVLI,
PMVL, etc.”
However, each position gain must be the same for the Z-axis and R-axis of the ZR regardless of the
operating conditions such as presence/absence of an orthogonal axis, CP operation, or PTP operation.
30
13. Maintenance and Inspection
Daily and periodic inspections are needed to make sure the actuator you purchas ed can be used safely
and efficiently.
Perform the following maintenance and inspection items.
13.1 Inspection Intervals and Items
These inspection intervals assume that the actuator is operated eight hours a day. If the utilization ratio is
higher, such as when the actuator is operated continuously 24 hours a day, reduce the inspection intervals
according to the operating hours.
Startup inspection
1 month after start of operation
6 months after start of operation
1 year after start of operation
Every 6 months thereafter
Every year
Do not inspect, adjust, repair, replace parts or perform any other item not specified in this operating
manual.
Do not perform the following disassembly tasks or cut t he cables. Any unwanted outcome resulting from
such prohibited tasks is not covered by the warranty:
Disassembly of servo motor
Disassembly of reduction gears
Disassembly of ball screw spline
Disassembly of bearing
Disassembly of brake
Cutting of cable
Visual inspection of
exterior
Inspection of
interior
Greasing
Caution: Before performing any inspection, thoroughly confirm safety.
Periodic inspection may be performed with the controller power turned off or on.
In either case, put up a sign that says, “Work in progress. Do Not Enter” or the like
and disable power supply operations by other operators.
Performing inspection or maintenance work without a thorough understanding of the specific tasks
If inspection is not carried out regularly, the drive part may reach its life prematurely.
Warning
involved many result in a serious injury accident.
31
13.2 Visual Inspection of Exterior
Inspect the following items before and after operating the robot every day.
Inspection location Inspection item
Safety feature installed by
the user (safety cage, etc.)
Robot
Cables
Emergency stop switches Whether emergency stop switches operate normally
Should you find any damage or abnormality of the robot, please contact IAI.
Correct the cage for deformation or displacement.
Operation of safety circuits
Whether interlock mechanisms operate normally
Looseness of robot installation bolts
External abnormality (Check the cables for looseness, damage, dent, etc.)
Abnormal operation, vibration or abnormal noise
Cable damage
Looseness of cable securing points
13.3 Cleaning
Clean the exterior surface as deemed necessary.
Wipe off soiling using a soft cloth, etc.
Do not blow highly compressed air onto the unit, because it may cause dust to enter the interior through
the gaps.
Do not use petroleum-based solvents, because they can damage resin and coated surfaces.
To remove any significant soiling, moisten a soft cloth, etc., with neutral detergent or alcohol and wipe
the area with the cloth gently.
13.4 Inspection of Interior
Inspect the robot for the following items every six months during the daily inspection.
Inspection location Inspection item
Looseness of ball spline
Ball screw spline
R-axis reduction gears
Connector Looseness of connector
Contact IAI for any damage, looseness or any other abnormality of the robot.
32
Apply new grease after removing old grease with waste cloths, etc. (*1)
Applicable grease: Multemp LRL No. 3 by Kyodo Yushi or equivalent
Apply grease while turning the gears. After grease has been applied,
move the gears back and forth several times to spread the grease
evenly. Once the brake is released, the gears can be turned by manually
rotating the output shaft. Release the brake using the switch on the
controller.
* Be sure to release the brake. If the R-axis is rotated without releasing the
brake, failure may occur.
Applicable grease: Multemp AC-D No. 2 by Kyodo Yushi or equivalent
13.5 Greasing
Greasing procedure for the R-axis (How to remove the cover)
Remove the hexagonal
socket head bolts.
M3 x 6, 4 pcs
Apply grease on
the R-axis gears.
Procedure
[1] Remove the hexagonal socket head bolts on the top and bottom faces.
[2] Loosen the cross-recessed countersunk head machine screws on the rear face.
[3] Shift the cover upward to remove.
[4] Apply grease on the R-axis gears.
[5] Install the cover.
* Install the cover carefully by preventing it from catching the cables on the side face.
* Install the cover so that it fits between the inner frame and rear panel.
[6] Tighten all screws.
Store the cables within the available space by paying attention not to overlap each other. Do not forcibly
secure them while the panel is still moving.
Tightening torque (M3 screw: 0.74 Nm, M4 screw: 1.76 Nm)
* The Z-axis motor may be hot. Perform this task after confirming that the Z-axis has cooled sufficiently.
Shift the cover upward.
Loosen the
cross-recessed
countersunk head
machine screws.
M3 x 10, 6 pcs
Remove the hexagonal
socket head bolts.
M3 x 6, 2 pcs
Cover
Inner frame
Install the cover so that
it fits between the inner
frame and rear panel.
Rear panel
Loosen the cross-recessed
countersunk head machine screws.
M3 x 10, 6 pcs
Warning
Never use fluorine grease. If fluorine grease mixes with lithium grease, grease performance may be lost
and in some cases the actuator may be damaged.
33
14. Appendix
14.1 Absolute Reset Method (Absolute Type Only)
When the ZR unit is connected to the controller for the first time, an absolute encoder battery voltage error
generates, or the encoder cable is removed, an encoder battery error will generate. In this case, an
absolute reset is required.
14.1.1 Preparation for Absolute Reset Perform teaching pendant). Also note that a jig is required to perform an absolute reset.
Versions supporting absolute reset of ZR unit:
Absolute reset adjustment jig Model: JG-ZRS (for ZRS)
JG-ZRM (for ZRM)
Connect the robot, controller and PC cables so that the robot can be operated from the PC software. Be
sure to check the operation of the EMG switch beforehand.
an absolute reset of the ZR unit from the ball screw spline adjustment m enu of the PC softwa re (or
PC software (IA-101-X-**) Version V7.4.0.0 or later
Teaching pendant main application (IA-T-X/IA-T-XD) Version 1.5.0 or later
Teaching pendant main application (SEL-T/SEL-TD) Version 1.0.9 or later
Plate
Pin
Performing this procedure without a full understanding of inspection and maintenance tasks may
Put up a sign that says “WORK IN PROGRESS” to prevent other operators from inadvertently
Back up the parameters before the absolute reset.
34
Warning
result in a serious accident causing injury or death.
operating the controller, operation panel, etc.
14.1.2 Starting the Absolute Reset Menu (Ball Screw Spline Adjustment Window)
Open the ball screw spline adjustment window in the PC software.
(1)
(2) The ball screw spline adjustment window opens.
When a linear movement axis number is selected, the “Rotational Movement Axis No. (Mating Axis
No.)” and “Encoder Type” field appear.
Ball screw spline adjustment is performed for the linear movement axis and rotational movement
axis as a pair. The adjustment procedure includes steps that require operation of the robot, so
check the operating range of the actuator and confirm ab sence of obstructions, etc., to make the
actuator ready to operate.
35
14.1.3 Absolute Reset (Ball Screw Spline Adju
stment) Procedure
(1) Select the “Linear Movement Axis No.” to implement an absolute reset (ball screw spline adjustment)
for.
(2) Click the “Reset Encoder Rotation Data 1 (Linear Movement Axis, Rotational Movement Axis)”
36
(3) When the dialog box appears, click the “Yes” button.
(4) When the dialog box appears, click the “Yes” button.
37
(5) Click the “Reset Controller Error” button.
(6) Click the “Servo ON (Linear Movement Axis, Rotational Movement Axis)” button.
38
(7) Click the "Wait in Tentative Reference Position (Linear Movement Axis)” Button.
Exercise caution because the linear movement axis (Z-axis) will return home.
(8) Jog the rotational movement axis (R-axis) to the reference position (see “Reference Position
Drawing”), and then click the “End Jog” button.
Reference Position Drawing
D-cut surface
39
(9) Click the “Servo OFF (Linear Movement Axis, Rotational Movement Axis)” button.
(10) Press the emergency stop switch (emergency stop button on the PC cable).
(11) Release the brake. Release the brake using the switch on the controller.
40
(12) Set the plate and pin constituting the adjustment jig as shown below to affix the axis in the reference
position.
D-cut surface
a
d
a
Installation method
[1] Insert the ball screw spline into the hole in the jig from below.
[2] Cause the D-cut surface of the ball screw spline to contact surface a.
[3] Cause the side face of the ball screw spline to surface b.
[4] Tighten screw c to affix the jig on the ball screw spline.
* At this time, confirm that the adjustment jig is vertical to the ball screw spline and that the D-cut
* Applicable screw: Hexagonal socket head screw M5
* Tightening torque: 20 [Ncm] (Reference)
[5] Insert the supplied shaft into the hole in the ZR unit.
* Keep holding the shaft, because the shaft will drop once you release your hand.
[6] Turn the ball screw spline until the supplied shaft lightly contact surface d of the jig.
Shaft
c
b
surface and surface a are in close contact with each other.
c
b
d
Be sure to press the emergency stop switch before setting the adjustment jig. If not, the robot may
Warning
malfunction and a serious accident causing injury or death may occur.
41
(13) Click the “Confirm” button.
(14) Click the “Reset Encoder Rotation Data 2 (Rotational Movement Axis)” button.
42
(15) When the dialog box appears, click the “Yes” button.
(16) When the dialog box appears, click the “Yes” button.
43
(17) Click the “Auto Refresh of Home Preset (Required) (Rotational Movement Axis)” button.
(18) Remove the adjustment jig.
(19) Lock the brake (on the front panel of the controller).
(20) Cancel the emergency stop (by releasing the emergency stop button on the PC cable).
(21) Click the “Confirm” button.
44
(22) Click the “Servo ON (Linear Movement Axis, Rotational Movement Axis)” button.
(23) Click the “Wait in Reference Position (Linear Movement Axis) (Rotational Movement Axis 0)”
button.
● Exercise caution because once the rotational movement axis (R-axis) moves to the zero point, the
linear movement axis (Z-axis) will return home.
45
(24) Click the “Servo OFF (Linear Movement Axis, Rotational Movement Axis)” button.
(25) Click the “Reset Encoder Rotation Data 3 (Linear Movement Axis)” button.
46
(26) When the dialog box appears, click the “Yes” button.
(27) Click the “Auto Refresh of Home Preset (Required) (Linear Movement Axis)” button, and then click
“x” in the top right-hand corner of the window to close the window.
Be careful not to deviate from the specified steps, because it may result in position deviation.
Warning
47
(28) When the ball screw spline adjustment window is closed after performing ball screw spline
adjustment, the following screen appears. Click the “Yes” button.
(29) When all data has been written to the flash ROM, the following screen appears. Click the “Yes”
button.
48
15. Warranty
The ZR-series robot you have purchased passed IAI's strict shi pping inspection.
The warranty information is provided below.
(1) Warranty period
One of the following periods, whichever expires first:
18 months after shipment from IAI
12 months after delivery to the specified location
2,500 hours of operation
(2) Scope of warranty
The warranty covers only the purchased and delivered IAI product.
If any failure is found during the warranty period despite use in appropriate conditions and such failure
is clearly attributable to IAI, IAI will provide a replacement or repair the defective product free of
charge.
However, failures due to the following causes are excluded from the scope of warranty:
[1] Handling or use in any condition or environment not specified in the catalog, operation manual, etc.
[2] Anything other than IAI's product
[3] Modification or repair not performed by IAI or its agent
[4] Not foreseeable at the science and technology standards available at the time of shipment from IAI
[5] Act of God, natural disaster, accident or any other cause beyond IAI's control
[6] Natural discoloration of paint or other aging
[7] Wear of consumable parts (stainless sheet, etc.)
[8] Sound or other subjective feeling not affecting the facility
Take note that the warranty specified herein covers only the delivered product. Any losses arising from
a failure of the delivered product are excluded from the scope of warranty.
The defective product is delivered to IAI for repair service.
(3) Limited liability
IAI shall under no circumstance be held liable for any special, indire ct or passive losses ari sing from its
product.
(4) Scope of service
The price of the delivered product does not include the costs of programming, dispatching engineers,
etc.
Accordingly, separate fees are charged for the following services even durin g the warranty period:
Guidance of installation and adjustment, and witnessing of test operation
Maintenance and inspection
Technical guidance and training relating to operating methods, wiring methods, etc.
Technical guidance and training relating to programming and other matters relating to programs
Other services and tasks that are deemed subject to fees by IAI
49
16. Change History
Revision Date Description of Revision
January 2009
December 2009
April 2010
First edition
Added 14, “Appendix” and 14.1, “Absolute Reset Method.”
Added wiring diagrams for incremental and absolute specifications in 10,
“Wiring.”
50
Catalog No.: ME3668-3A
Head Office: 2690 W. 237th Street, Torrance, CA 90505
TEL (310) 891-6015 FAX (310) 891-0815
Chicago Office: 1261 Hamilton Parkway, Itasca, IL 60143
TEL (630) 467-9900 FAX (630) 467-9912
Atlanta Office: 1220 Kennestone Circle, Suite 108, Marietta, GA 30066
TEL (678) 354-9470 FAX (678) 354-9471
website: www.intelligentactuator.com
Ober der Röth 4, D-65824 Schwalbach am Taunus, Germany
TEL 06196-88950 FAX 06196-889524
IAI (Shanghai) Co., Ltd.
SHANGHAI JIAHUA BUSINESS CENTER A8-303, 808,Hongqiao Rd. Shanghai 200030, China
TEL 021+6448-4753 FX 021-6448-3992
website: www.iai-robot.com
The information contained in this document is subject to change without notice for the purpose of product improvement.
Copyright 2010. Apr. IAI Corporation. All rights reserved.
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