K-Series Universal Motor Mount Roller Screw Actuators
Contents
1. 38 K Series Manual doc 07 21 2013 PN 49269 Exlar Corporation Rev J 952 500 6200 Face Plate Screws Face Plate Rod Wiper Linear Retaining Ring Face Plate Gasket Face Plate 2 Loosen and remove the end cap screws and slide the end cap off the bearings You will then be able to remove the o ring from the end cap Note A shaft seal is used on KT actuators and can then be removed from the end cap if it needs to be replaced See figure below End Cap Bearing End Cap Screws 3 Remove the key from the input shaft 4 Slide roller screw assembly out of case See figure below Roller Screw Assembly 39 K Series Manual doc 07 21 2013 PN 49269 Exlar Corporation Rev J 952 500 6200 5 Remove the extend impact bumper by sliding it off the main rod See figure below Front Bumper 6 Remove both the anti rotates from the roller screw nut assembly by using a flat bladed screwdriver to pry between the anti rotates until they separate from the roller screw nut assembly Remove shim shims from the roller screw nut assembly Note that your actuator may have two one or no shims Remove the magnets by sliding them out of the magnet retaining slots Note that your K series actuator may use more than one magnet per magnet retaining slot See figure below a gt Anti Rotate pr 7 Remove the gasket that is located by the bearing pack and slide it over the roller screw assembly Se2. 3 7 Linear Bearing Every standard K Series actuator is equipped with a linear bearing which is designed to guide the main rod in a linear motion The linear bearing will not need to be replaced on a regular basis but if it should become damaged or excessively worn it can be replaced See figure below Linear Bearing Replacement see Section 3 8 Disassembly Reassembly Procedure Face Plate S reren 3 8 Disassembly amp Reassembly Procedure The general disassembly and reassembly procedures are general guidelines Individual designs may differ from these procedures and any questions should be verified with Exlar before reassembling and 21 K Series Manual doc 07 21 2013 PN 49269 Exlar Corporation Rev J 952 500 6200 reinstalling the actuator into your machine or application For both procedures refer to the drawings included in the disassembly procedure for reference only For torque values see chart in Section 3 9 Parallel Motor and Actuator Dismounting Motor Plate Motor Pulley Timing Belt Pulley Box Cover Gasket Pulley Box Cover Sealing Washers Actuator Pulley Figure Parallel Motor Mount Drive Train Assembly 1 Remove power 2 Dismount the actuator from the application if necessary 3 Remove pulley box cover by removing cover screws and sealing washers and pulling cover away from the motor plate 4 Remove pulley box cover gasket 22 K Series Manual doc 07 21 2013 PN 4926
3. Adder for aclevis plate 61 K Series Manual doc PN 49269 Rev J 07 21 2013 Exlar Corporation 952 500 6200 Base Unit zero stroke Adder per inch of stroke Adder for inline excluding motor Adder for parallel drive excluding motor and pulleys Adder for 2 foot plate mounts Adder for 2 trunnions Adder for a front flange plate Adder for a rear flange plate Adder for 2 angle plates Adder for an eye plate Adder for aclevis plate 62 K Series Manual doc 07 21 2013 PN 49269 Exlar Corporation Rev J 952 500 6200 6 0 Troubleshooting 6 1 Mechanical Problems The following table offers suggestions to answer questions and offer solutions to issues that may arise during the installation or operation of your K Series actuator Symptom Problem Possible Cause Problem Solution Check alignment with Seemingly excessive noise Misalignment or Side Load application remount actuator if necessary Remove side load i Consult tuning guidelines for Seemingly excessive noise Improper servo tuning servo motor and drive Disconnect power to motor remove belt cover and inspect belt or inline coupling Replace if necessary Actuator motor rotates but output rod does not extend or retract Belt or inline coupling failure Motor does not operate Motor electrical problem Consult motor manufacturer Output rod has excessive rotation Anti rotate failure Replace anti rotate mechanism or rotates but does no
4. Motor Mount 80 67 9 Screw M10 x 1 5 x 60mm SHCS SS 4X Inline Housing Coupling Clamp Screw 41 3mm OD Coupling M4Alloy 407 34 46 Coupling Clamp Screw 50 8mm OD Coupling MSAlloy 84 7 95 Screw M10 x 1 5 x 25mm SHCS SS AX Front Mounts sy Parallel Motor Mount Unit OOO Y o yoo Screw M10 x 1 5 x 60mm SHCS SS 8X Face Plate and End Cap Screw M5 x 0 8x 18mm SHCS SS 4X Motor Mount 56 47 64 Screw M x 1 0 x 25mm SHCS SS 4X Motor Mount 96 8 n Screw M8x1 25 x 30mm SHCS SS 4X Motor Mount Screw 10 24 x 75 SHCS SS 4X Motor Mount 80 67 9 Screw M10 x 1 5 x 60mm SHCS SS 6X Pulley Cover Screw M5 x 0 8 x 8 SHSS cup pt Pulley Set screw 4 7 64 Screw M6 x 1 0 x 10 SHSS cup pt Pulley Set screw Screw 10 24 x 375 SHSS cup pt PulleySetscew 40 33 45 Nut M16 x 2 0 Flange Serrated Pulley Nut Screw M10x1 5x25mm SHCS SS 8X Rear amp Frt Mnts and Motor Plat 456 38 515 Screw 6mmx20mm Shoulder Bolt Idler Pulley screw 15mm Wide Bl 56 47 64 Screw 8mmx20mm Shoulder Bolt Idler Pulley screw 25mm Wide Bl 96 8 1 Screw M6x1 0x10mm SBHCS SS Idler Adj screw 96 8 1 Screw M8X1 25 SHCS T Slot Screws 51 K Series Manual doc 07 21 2013 PN 49269 Exlar Corporation Rev J 952 500 6200 4 0 Optional Equipment 4 1 Mounting Options Standard mounting configurations are adjustable foot plat
5. Screw M6 x 1 0 x 25mm SHCS SS 4X Motor Mount 96 8 a Screw M8 x 1 25 x 30mm SHCS SS 4X Motor Mount 228 19 258 Screw 10 24 x 75 SHCS SS 4X Motor Mount eo er s Screw M8 x 1 25 x 55mm SHCS SS 6X Pulley Cover 228 19 258 Screw M10 x 1 5 x 60mm SHCS SS 6X Pulley Cover 456 38 515 Screw M5 x 0 8 x 8 SHSS cup pt Pulley Set screw se a7 I 64 Screw M6 x 1 0 x 10 SHSS cup pt Pulley Set screw 9 8 m Screw 10 24 x 375 SHSS cup pt Pulley Set Screw 40 33 45 Nut M12 x 1 75 Flange Serrated Pulley Nut Lzm m ss Screw M8 x 1 25 x 25mm SHCS SS 8X Rear amp Frt Mnts and MotorPl 228 19 258 _ Screw 6mm x 20mm Shoulder Bolt Idler Pulley screw 15mm Wide WMA ES Screw 8mm x 20mm Shoulder Bolt Idler Pulley screw 25mm Wide d 96 NUM 264 HEE i I 50 K Series Manual doc 07 21 2013 PN 49269 Exlar Corporation Rev J 952 500 6200 K90 Fastener Torque Values OOOO ins ftibs Nm Base Uns poo Screw M10 x 1 5x60mm SHCS SS 8X Face Plate and End Cap Nut M10 x 1 5 Hex Nylon Insert Rod End Bushing LLL LLL LLL LLL Inline Motor Mount Unit Screw M10 x 1 5 x 60mm SHCS SS 8X Face Plate and End Cap Screw M5 x 0 8 x 18mm SHCS SS 4X Motor Mount 56 47 64 Screw M x 1 0 x 25mm SHCS SS 4X Motor Mount 96 8 n Screw 10 24 x 75 SHCS SS 4X
6. the end cap See figure next page 36 K Series Manual doc 07 21 2013 PN 49269 Exlar Corporation Rev J 952 500 6200 12 Insert the shaft of the motor into the inline housing with the motor coupling aligned to mate with the actuator coupling Slide the motor in so the motor gasket and face plate flange is flush with the inline motor adapter plate pilot face See figure below Inline Motor Adapter Plate a i yo G A GF S FF i A Inline Housing eL 13 Torque the motor screws to the designated torque value See Section 3 9 Fastener Torque Values 37 K Series Manual doc 07 21 2013 PN 49269 Exlar Corporation Rev J 952 500 6200 Actuator Disassembly End Cap Anti Rotate Roller Screw Assembly d Extend Impact Bumper ya c S o Retaining Ring Face Plate Rod Wiper Figure Actuator Disassembly 1 Remove the face plate screws and slide face plate and face plate gasket off the main rod Note to remove or replace rod wiper use a thin bladed screw driver on the outer edge of the wiper seal where it seats into the face plate and pry it out Also at this time you may remove the linear bearing To remove the linear bearing the retaining ring must be removed first using a thin bladed screw driver Note that not all K series actuators have a retaining ring to remove It is not necessary to remove the rod wiper or the linear bearing unless they need to be replaced See figures below
7. 1 252 x 107 2 03 x 10 2 292 x 107 2 82 x 10 3 186 x 107 5 28 x 10 5 962 x 10 NENNEN UE MMC EE IM CMM 2 1 Reduction Belt Drive 130 mm 6 80 x 10 7 686 x 10 6 93 x 10 7 831 x 10 10 mm Lead Ibf in sec kg m Adder per 25 mm 10 mm Lead Ibf in sec kg m 8 39 x 10 9 482 x 10 1 28 x 10 1 441 x 107 2 05 x 10 2 313 x 107 2 84 x 10 3 207 x 10 5 30 x 10 5 984 x 10 A A A 6 81 x 107 7 692 x 10 5 mm Lead Ibf in sec kg m Adder per 25 mm 5 mm Lead Ibf in sec kg m 2 10 mm Lead Ibf in sec kg m Adder per 25 mm 10 mm Lead Ibf in sec kg m K75 5 mm Lead Ibf in sec kg m Adder per 25 mm 5 mm Lead Ibf in sec kg m 60 K Series Manual doc 07 21 2013 PN 49269 Exlar Corporation Rev J 952 500 6200 5 7 Weights Base Unit zero stroke Adder per inch of stroke Adder for inline excluding motor Adder for parallel drive excluding motor and pulleys Adder for 2 foot plate mounts Adder for 2 trunnions Adder for a front flange plate Adder for a rear flange plate Adder for 2 angle plates Adder for an eye plate Adder for aclevis plate Base Unit zero stroke Adder per inch of stroke Adder for inline excluding motor Adder for parallel drive excluding motor and pulleys Adder for 2 foot plate mounts Adder for 2 trunnions Adder for a front flange plate Adder for a rear flange plate Adder for 2 angle plates Adder for an eye plate
8. 26 Ib 115N 26 Ib 115N 15 Ib 70N O le D O D 4000 RPM am Same tension is required for Tritex motors and gearmotors of equivalent size K Series Manual doc PN 49269 Rev J 29 07 21 2013 Exlar Corporation 952 500 6200 Ratio Max Cont Torque Max Speed Tension Required F aims 400RPM 322 b 38 Ib 169N aa isimibs 400RPM 1411b 171b 6N 39 Ib 440N 60 Ib 267N 137 in Ibs 500 RPM 82 9 Ib 109 Ib 485N a aa Li 75imibs 1000RPM 454lb TTT T i1 iSrimibs 3000RPM 6251b 791b GSIN 21 isimibs 400RPM i amp 1lb 161b IN a ins 4000RPM 35 01b 39 1b 17AN stes 24 7oinibse 100 RPM 4381b 491b 218N O le D oO D Belt Size Table Belt Length 60 T 47053 60 T 50980 Ratio Beltlength N34 30 K Series Manual doc 07 21 2013 PN 49269 Exlar Corporation Rev J 952 500 6200 Ratio Beltlength 25mm 25mm 15mm 11 M115 25mm 25mm 25mm 15mm Same belt is required for Tritex motors and gearmotors of equivalent size 31 K Series Manual doc 07 21 2013 PN 49269 Exlar Corporation Rev J 952 500 6200 Inline Motor and Actuator Dismounting Inline Housing Motor Adapter Plate Coupling Coupling Spider Coupling Figure 12 Inline Motor Mount Disassembly 1 Remove power 2 Dismount the actuator from the application if necess
9. 3 Insert actuator screws and tighten to the designated torque value See Section 3 9 Fastener Torque Values See figure below Actuator Mounting Screws 25 K Series Manual doc 07 21 2013 PN 49269 Exlar Corporation Rev J 952 500 6200 4 Place the key in the actuator shaft keyway Clamp the actuator shaft pulley and tighten the actuator shaft pulley nut See Section 3 9 Fastener Torque Values See figure below Actuator Shaft Pulley Nut Actuator Pulley 5 Place the motor gasket over the pilot diameter of the motor face plate so it is flush with the face of the end cap See figure below Motor Mounting Gasket 6 Place the motor output shaft through the output shaft hole on the motor plate until the motor gasket and motor face plate face are flush against the motor plate pilot face See figure next page 26 K Series Manual doc 07 21 2013 PN 49269 Exlar Corporation Rev J 952 500 6200 Motor Plate 7 Insert motor washers and screws and tighten to the designated torque value See Section 3 9 Fastener Torque Values See figure below Motor Mounting Screws 8 Place the key in the motor shaft keyway Slide the pulley on and align it with the screw shaft pulley Once aligned torque the pulley set screws See Section 3 9 Torque Values See figure below Motor Pulley E p MM 2 e Actuator Pulley 27 K Series Manual doc 07 21 2013 P
10. 8 1 467 Acme Screw 2 lead Ibs N 129 283 88 506 25 070 12 090 6 525 K90 102 734 93 551 58 684 28 611 15 447 home Screw ease 251250 25079 anson Cas anes Acme Screw 1 lead Ibs N 291 256 250 479 111 597 53 819 29 051 49 271 40 104 14 716 7 097 3 831 219 168 178 392 65 460 31 569 17 041 56 K Series Manual doc 07 21 2013 PN 49269 Exlar Corporation Rev J 952 500 6200 5 4 Overhung Loads K60 Max Radial Load Max Radial Load K60 uo c O Per gt Q 2 Wax Load Stroke Length mm K75 Max Radial Load 57 K Series Manual doc 07 21 2013 PN 49269 Exlar Corporation Rev J 952 500 6200 Newtons K90 Max Radial Load uv c O Per gt 9 2 K Series Manual doc PN 49269 Rev J Max Radial Load K75 Wax Load 1000 1200 Stroke Length mm Max Radial Load K90 Wax Load Stroke Length mm 58 07 21 2013 Exlar Corporation 952 500 6200 5 5 Critical Speed Critical Speeds Stroke inch mm 6 150 12 300 24 600 35 900 48 1225 Roller Screw 5 and 10mm leads rpm 7400 7400 5178 2467 1322 Acme Screw 1 lead rpm 61979 16535 4274 2031 1087 Acme Screw 2 lead rpm 61979 16535 4274 2031 1087 KS Critical Speeds Stroke inch mm 6 150 12 300 24 600 35 900 48 1225 Roller Screw 5 and 10mm leads rpm 7 000 7 000 6 633 3 200 1 728 Acme Screw 1 lead rpm 65 421 18 968 5 129 2 473 1 335 Acme Screw 2
11. 9 Exlar Corporation Rev J 952 500 6200 5 Loosen the idler pulley adjuster plate bolt and slide idler pulley assembly to the left and remove the belt See figure below Idler Pulley Assembly Timing Belt 6 Loosen the set screws on motor pulley and slide the pulley off the shaft Clamp the actuator shaft pulley and loosen actuator shaft pulley nut and remove Slide the pulley off the actuator shaft Take care not to lose the keys for each shaft See figure below Motor Pulley Set Screw Motor Pulley Set Screw AAN a a _ a 7 id CS 23 K Series Manual doc 07 21 2013 PN 49269 Exlar Corporation 952 500 6200 Rev J 7 Remove the motor mounting screws and washers and remove motor and gasket See figure below Motor Mounting Screws Motor Mounting Washers Motor Mounting Gasket Motor Plate Actuator Mounting Gasket 9 Proceed to the section on Actuator Disassembly Parallel Motor and Actuator Mounting 1 Place the actuator gasket over the pilot diameter of the actuator face plate so it is flush with the face of the end cap See figure below 24 K Series Manual doc 07 21 2013 PN 49269 Exlar Corporation Rev J 952 500 6200 a My gt Actuator Mounting Gasket 2 Place the actuator input shaft through the actuator hole on the motor plate until the actuator gasket and actuator face plate are flush against the motor plate pilot face See figure below Motor Plate a A
12. Bearings 15 K Series Manual doc 07 21 2013 PN 49269 Exlar Corporation Rev J 952 500 6200 3 5 Drive Train Parallel Drive The parallel motor mount option for the K Series actuators provides a fiberglass reinforced timing belt and pulley drive train to transmit the motors rotation and torque to the actuator s roller screw mechanism The drive train does not require lubrication The belt and pulley transmission is in a protective housing to help prevent contamination by dirt and debris The belt housing and cover should be kept in place at all times during operation and should only be removed for motor mounting and drive train inspection The belt and pulley system should be inspected periodically for wear and proper tensioning Removing the protective housing from the belt and pulley drive train during operation of the actuator may cause damage to the actuator components or severe injury Power should be removed and locked out from the actuators motor at any time the protective drive train cover is removed Failure to do so can result in damage to the actuator or cause serious injury Improper belt tension can cause premature belt wear and failure belt noise and slippage The following picture is an example of a typical belt and pulley drive train in a K Series actuator Actual drive trains will vary in configuration depending on exact actuator and motor configuration Contact Exlar application engineers with any questions regarding the ins
13. K Series Universal Motor Mount Roller Screw Actuators Installation Service Manual Information furnished by Exlar Corporation is believed to be accurate and reliable however no responsibility is assumed by Exlar Corporation for its use Exlar reserves the right to change the design or operation of the equipment described herein and any associated motion products that may appear in this document Information in this document pertaining to equipment not furnished by Exlar should be confirmed by that equipment manufacturer Exlar assumes no responsibility for changes to information by other manufacturers or errors in that information or the description of that information Information in this document is subject to change without notice K Series Manual doc 07 21 2013 PN 49269 Exlar Corporation Rev J 952 500 6200 Table of Contents 1 0 Introduction 1 1 Warranty and Limitations of Liability ooo o o o o 3 1 2 Safety Considerations cis Ber T E E O 4 1 3 K Series Linear Actuators Overview 22 2 cc eee en 5 1 4 Actuator Configurations errre dead e eee ence RII 5 2 0 Installation 2 1 Mounting Configurations 0 00 ccc eee RR 6 2 2 Mounting Hardware Installation o oooooooooo o teens 8 2 3 Mounting Considerations 0 eee n 9 3 0 Maintenance amp Service 3 1 Roller Screw and Lubrication 2 llle 9 3 2 Anti Rotate BearlligS usus is ir A Ra e vt ic Eg 11 Be DC AI
14. N 49269 Exlar Corporation Rev J 952 500 6200 9 Install and tension timing belt See Belt Tensioning below Belt Tensioning Proper Belt Tension See Tension Table Force on Idler The idler pulley plate slot allows moving the idler pulley so the belt can be placed followed by placing a force directly over the idler pulley to obtain the proper tension to tighten the belt See table next page The standard K Series timing belt is a GT2 5mm pitch that comes in various lengths depending on the configuration See table next page 28 K Series Manual doc 07 21 2013 PN 49269 Exlar Corporation Rev J 952 500 6200 Belt Tension Table SLM 60 SLG 60 Max Cont Torque Max Speed Tension Required F S00RPM 141b 18 Ib 80N 36 Ib 160N 10 Ib 53N 2000 RPM 2006 4000 RPM 14 11b 20 Ib 89N 14 Ib 62N 18 Ib 80N 11 Ib 58N 18 Ib 80N 5000 RPM 5000 RPM 8 4 Ib 4000 RPM mari O le D O 2 D Same tension is required for Tritex motors and gearmotors of equivalent size K75 SLM 60 SLG 60 10 1 SLG 60 5 1 SLM 75 SLM 90 SLM115 SLM 60 SLM 75 Max Cont Torque Max Speed Tension Required F 98 in Ibs 500 RPM 39 7 Ib 75 in Ibs 1000 RPM S3inibs 4000 RPM 98 in Ibs 5000 RPM 39 Ib 104N 66 Ib 293N 50 Ib 225N 39 Ib 104N 3000 RPM 31 Ib 138N 16 Ib 71N 3000 RPM 5000 RPM 3000 RPM 4000 RPM 39 Ib 173N
15. S SS 4X Motor Mount go 67 9 Screw 10 24 x 75 SHCS SS 4X Motor Mount 80 67 9 Screw M6 x 1 0x90mm SHCS SS 4X Inline Housing 96 8 1 Coupling Clamp Screw 41 3mm OD Coupling M4Alloy 41 34 46 Screw M6 x 1 0 x 10mm SHCS SS T Slot Screws Screw M6 x 1 0x 14mm SHCS SS 4X FrontMounts 96 8 n ee Parallel Motor Mount Unit OO Y Screw M x 1 0x40mm SHCS SS 8X Face Plate and End Cap 96 8 11 Nut M6 x 1 Hex Nylon Insert Rod End Bushing 96 8 n Screw M5 x 0 8 x 18mm SHCS SS 4X Motor Mount 56 47 64 Screw M6 x 1 0x25mm SHCS SS 4X Motor Mount 96 8 1 Screw 10 24 x 625 SHCS SS 4X Motor Mount 80 67 9 Screw M6 x 1 0 x 40mm SHCS SS 4X Motor Mount 80 67 9 Screw M6 x 1 0 x 50mm SHCS SS 6X Pulley Cover 96 Screw M10 x 1 5 x 65mm SHCS SS 6X Pulley Cover Screw M5 x 0 8 x 8SHSS cup pt Pulley Setscrew______ 56 47 64 Screw 10 24 x 375 SHSS cup pt Pulley Set Screw 40 33 45 Nut M10 x 1 5 Flange Serrated Pulley Nut Screw M6x 1 0x 14mm SHCS SS 8X Rear amp Frt Mntsand Motor Pla 96 8 11 Screw 6mm x 20mm Shoulder Bolt Idler Pulley screw 56 47 64 Screw M6 x1 0x 10mm SBHCS SS Idler Adj screw 96 8 1 49 K Series Manual doc 07 21 2013 PN 49269 Exlar Corporation Rev J 952 500 6200 Screw M6 X 1 0
16. S a boa ear ee es EE Ee ae Fe ek cadet chad 12 se ThPdstBedElBgsr ale d voe aper oie demic adres na ob Laie oe dont ace 14 2 5 DRIVE TESI Sou ini tont ta eet ote a ito ts Bodo d aa ae ae ea god 16 3 6 End of Stroke CUSHIONS s ori ua kad as edad 18 3 7 Linear DearS s 24 ate ura i s po DRE E ee ee a 21 3 8 Disassembly amp Reassembly Procedure oooooooooooooooooooo 21 3 9 Fastener Torque Values oss id dup a aa Ae 49 4 0 Optional Equipment 2 1 MODs OPTIONS lt dans Rik qd et Re eee bea we A d IRURE On Rd 52 4 2 Standard Motor Mounting Configurati0NS o o o oooooooooo ooo 52 A ILMI SWItCIeS x ta AA AA At A CR t EO 52 AV ARO OCB INOS wh i 50 25 3 5 dense loo v nk EN SQL aee afe qe M REOR RR P Edo 53 5 0 Specifications Sl Travel Life Calcula a da 53 5 2 Load Torque and Linear Speed Calculati0nS ooooooooo o 55 5 3 ColummStrenglhs is ere Dy Pede eis 56 S 4 Overhung Loads idad ac Vedi 57 5 5 Critical SDeeds icis Ca opea ove dr deditum E Eat dpud a desta aq qois 59 SOMENI Sas RENE E TT T TER TITTEN D 59 A c T I m 61 6 0 Troubleshooting bal Mechanical Problems isis basis iria 63 6 2 Returning a Product for Repair o eee teens 64 2 K Series Manual doc 07 21 2013 PN 49269 Exlar Corporation Rev J 952 500 6200 1 0 Introduction 1 1 Warranty and Limitations of Liability Products are warranted for two years from date
17. act Bumper Replacement see Section 3 8 Disassembly amp Reassembly Procedure 18 K Series Manual doc 07 21 2013 PN 49269 Exlar Corporation Rev J 952 500 6200 Retract Impact Bumper Plate Replacement see Section 3 8 Disassembly Reassembly Procedure Stroke 10mm Travel Bumper to Bumper Crash to Crash 0 50 Magnet _ Length Extension Retraction Bumper Bumper Figure Actuator Shown in fully retracted crash position with contact on the Retraction Bumper 19 K Series Manual doc 07 21 2013 PN 49269 Exlar Corporation Rev J 952 500 6200 K60 1 297 K75 1 585 0 50 K90 2 247 Magnet m ne Retraction Sensor Length should detect magnet at this position from end of case Extension Bumper Note Clearance between bumper and rod end Figure Actuator Shown in maximum recommended retract position with 5mm of clearance on retract impact bumper 20 K Series Manual doc 07 21 2013 PN 49269 Exlar Corporation Rev J 952 500 6200 K60 1 023 64 K75 1 6 K90 1 698 x Be 0 50 Extension Sensor Ve should detect A gt Ps Length magnet at this position from end of case M N Extension Bumper Retraction Bumper Note Clearance between bumper and face plate where the bumper can contact the face plate Figure Actuator shown in maximum recommended extension position with 5mm of clearance on extend impact bumper
18. ain rod and place it against the bumper plate See figure below 43 K Series Manual doc 07 21 2013 PN 49269 Exlar Corporation Rev J 952 500 6200 7 Insert the four limit switch magnets into the anti rotates magnets holes Insert the 2 or 1 shims onto the roller screw nut assembly Note that there may be no shims used on your actuator Insert both anti rotates onto the roller screw nut assembly See figure next page Anti Rotates 8 Slide the extend impact bumper over the main rod See figure below 9 Insert the main rod assembly into the case rod end first until the anti rotate mechanism touches the case end The case ends are identical in diameter mounting hole anti rotate t slot and limit switch size and orientation therefore there isn t a wrong orientation to inserting the main rod assembly into the case Rotate the anti rotate mechanism until it aligns with an anti rotate groove that allows the main rod assembly to slide in with ease Keep rotating until the easiest sliding groove is found and slide it the rest of the way into the case until the main rod assembly reaches the retract bumper plate See figure next page 44 K Series Manual doc 07 21 2013 PN 49269 Exlar Corporation Rev J 952 500 6200 Main Rod Assembly 10 Insert the shaft seal into the end cap with the open side of the shaft seal facing toward the retract impact bumper plate using a press or pressing tools See figure below Shaft S
19. anual doc 07 21 2013 PN 49269 Exlar Corporation Rev J 952 500 6200 Mounting Configurations Eye Plate Mount Trunnion Mount Angle Plate Mount Rear Flange Plate Mount Front Flange Plate Mount Clevis Plate Mount K Series Manual doc 07 21 2013 PN 49269 Exlar Corporation Rev J 952 500 6200 2 2 Mounting Hardware Installation ngle into the t nut rail slot Step 1 Insert T nuts at an a WS rt and tighten scre nd inse mounting holes a up T nut tapped holes with the trunnion Step 2 Line Torque Values Section 3 9 Fastener 2 3 Mounting Considerations Care should be taken to mount the K Series actuator such that its linear travel is aligned with the travel of its load Misalignment imparts direct side load on the actuator s extending rod Side loading of the actuator s extending rod leads to accelerated seal wear bearing wear and roller screw wear and should be avoided Also when using the Angle Mount Option the load needs to be restricted to the max load indicated in the table below Standard K Series Max Load Ibf kN K60 1350 Ibf 6 00 K75 2000 Ibf 8 90 K90 2100 Ibf 9 34 A Excessive side load on the output rod of the actuator may reduce the travel and seal life of the actuator T slot mounting hardware should be attached perpendicular to the axis of linear motion All T Nuts and associated flathead cap screws should be tightened to the appropriate torque level in
20. ary 3 Loosen and remove motor screws Remove motor from actuator by pulling motor in the opposite direction of actuator until the coupling separates See figure next page 32 K Series Manual doc 07 21 2013 PN 49269 Exlar Corporation Rev J 952 500 6200 Motor Mounting Gasket Motor Mounting Screws 4 Loosen and remove screws from the motor adapter plate and inline housing See figure below Inline Housing Motor Adapter Plate Coupling Coupling 5 Loosen clamping screw for each coupling and slide coupling off the shafts It is not required to remove the couplings from the shafts unless further work will be done with the motor or actuator Take care not to lose the keys for each shaft 6 Proceed to the section on Actuator Disassembly Inline Motor and Actuator Mounting 1 Place the key in the keyway of the roller screw at the input end 33 K Series Manual doc 07 21 2013 PN 49269 Exlar Corporation Rev J 952 500 6200 2 Slide the coupling onto the input shaft of the roller screw shaft until the end of the shaft touches the red spider See figure below Red Spider End of shaft meets Red Spider 3 Torque the coupling clamp screw See Section 3 9 Torque Values 4 Place an inline gasket over the pilot feature of the end cap so it is flush with the end cap Ensure that the correct face of the gasket is mated with the face of the end cap otherwise the mounting holes will not line up See figu
21. ase on the roller screw and spread it into the threads and wipe away the extra grease Move the roller screw nut assembly back to the retract impact bumper plate in order to apply the new grease into the rollers of the roller screw nut assembly Once the roller screw nut assembly has been re greased follow the assembly process for the actuator in Section 3 8 Disassembly amp Reassembly Procedure See figure following In applications that require continuous use within a short stroke distance grease lubrication should be checked more often The roller screw assembly does not have the distance needed to circulate viable grease to the rotating components when traveling under 1 inch of stroke Heavy loads and high speed will further degrade the small amount of grease left within the short stroke path In these conditions it is best to run the actuator for the full length of stroke from back to front a minimum of two to three times at slow speed to regather grease that has migrated during operation The frequency of this operation will depend upon the severity of the applied load and temperature Higher temperatures will require more frequent short stroke refreshing 10 K Series Manual doc 07 21 2013 PN 49269 Exlar Corporation Rev J 952 500 6200 Assembly Take care to prevent foreign objects from entering the actuator or contaminating the grease Excessive grease is unnecessary and will increase the torque required to rotate the actuato
22. bf in N m 11000 48 9 Do not exceed the maximum load rating Doing so may cause damage to the actuator or injury Lio C F 3 S F F1 3s F2A 352 F34353 S1 S2 S3 11 3 Where Lio Travel life in millions of inches mm C Dynamic load rating of roller screw Ibf N 54 K Series Manual doc PN 49269 Rev J 07 21 2013 Exlar Corporation 952 500 6200 F Cubic mean load applied Ibf N S Roller screw lead inches mm F1 2 3 Force applied for corresponding S 2 3 length of travel distance lbf N S1 2 3 Length of travel distance for corresponding F 2 3 applied force in mm 5 2 Load Torque and Linear Speed Calculations Do not exceed the maximum load rating Doing so may cause damage to the actuator or injury The thrust load applied by the K Series actuator is dependent on the torque applied to the roller screw input shaft and the lead of the roller screw Any belt and pulley or gear reduction that increases motor torque should be factored into the calculation below The equation below defines the amount of torque required for a corresponding thrust force F T 2 62831 N S Where T Torque applied to roller screw shaft in Ibf N m S Roller screw lead inches mm F Thrust for required Ibf N N Efficiency of system 0 8 for standard K Series actuator assemblies unitless Motor torque will be required to accelerate the inertial components
23. dicated in Section 3 9 Fastener Torque Values 3 0 Maintenance amp Service 3 1 Roller Screw and Lubrication The planetary roller screw used within the K Series actuators is a precision mechanism Shock load and radial load should be avoided to provide maximum life from the actuator Extending or retracting the roller screw into the ends of travel may cause damage to the actuator or the other components of the application See Section 3 6 End Of Stroke Cushions and Section 4 3 Limit Switches For roller screw life calculations and specifications see section 5 0 9 K Series Manual doc 07 21 2013 PN 49269 Exlar Corporation Rev J 952 500 6200 Degreasing Extend the roller screw nut assembly to the end of the screw shaft Using a brush and degreasing agent remove all old grease from the roller screw shaft See figure below See Section 3 8 Disassembly Reassembly Procedure Degrease Roller Screw Nut Assembly Lubrication The planetary roller screw shaft or acme screw shaft and nut assembly anti rotates linear bearing and rotary seal are factory lubricated The anti rotate and linear bearing does not need re lubrication If the roller screw shaft or acme screw shaft need re lubrication follow the disassembly process for the actuator in Section 3 8 Disassembly amp Reassembly Procedure Re greasing Extend the roller screw nut assembly to the end of the screw shaft Apply a line of grease SHC220 Mobile Gre
24. e figure next page 40 07 21 2013 Exlar Corporation 952 500 6200 K Series Manual doc PN 49269 Rev J 8 Remove the bearings using a bearing puller in order to replace the bearings and or the rear impact bumper plate if necessary See figure below Impact Bumper Plate Bearing Lock Nut Actuator Reassembly 1 Place the shoulder washer onto the screw shaft See figure bellow Shoulder Washer K Series Manual doc 07 21 2013 PN 49269 Exlar Corporation Rev J 952 500 6200 2 Place the retract bumper plate onto the screw shaft See figure below Impact Bumper Plate 3 Press the bearings onto the screw shaft Be sure to press only on the inner race of each bearing or press on both the inner and outer races of each bearing equally using a tool that can accommodate these pressing requirements DO NOT PRESS on the outer race of each bearing alone See figures below 4 Place the locking washer onto the screw shaft Make sure that the inner tang on the locking washer is placed into the keyway See figure below 42 07 21 2013 Exlar Corporation 952 500 6200 K Series Manual doc PN 49269 Rev J 5 Torque the bearing lock nut onto the screw shaft and lock down a tang on the locking washer into the closest aligning notch on the bearing lock nut See Section 3 9 Fastener Torque Values See figure below Bearing Lock Nut 6 Place the retract bumper plate gasket over the m
25. eal End Cap 11 Insert the o ring into the end cap o ring groove Use some lube to help retain the o ring so it doesn t fall out of the groove See figure above 12 Slide the end cap over the shaft and bearings until it contacts the bumper plate and case See figure next page 45 K Series Manual doc 07 21 2013 PN 49269 Exlar Corporation Rev J 952 500 6200 ul NI Bumper Plate Bumper Plate End Cap 13 Torque the four end cap screws and use the torque values provided in Section 3 9 Fastener Torque Values 14 Insert the linear bearing into the face plate bushing groove by folding in one end under the other and squeezing down the diameter of the bushing and placing it into the face plate until it snaps into place and is retained on both ends of the linear bushing in the face plate Note some K series actuators use a retaining ring Once the linear bearing is in place insert the retaining ring Insert the wiper seal into the wiper seal groove with the closed end facing toward the rod output end Lubricate the wiper seal See figure below Retaining Ring Rod Wiper End Cap 15 Place the face plate gasket onto the main rod and move it toward the case until the gasket is flush against the case See figure next page 46 K Series Manual doc 07 21 2013 PN 49269 Exlar Corporation Rev J 952 500 6200 16 Slide the face plate over the main rod and gently tap the face plate until the rod wiper rides onto
26. ease specify wi SS L1 12 13 Switch Type ExlarPartNumber o Normally Closed Switch 43404 Turck PN BIM UNT RP6X Normally Open Switch 43403 Turck PN BIM UNT AP6X For custom logic combinations contact Exlar applications engineering The magnetic inductive switch power is 10 30 VDC with a no load operating current of lt 10mA and a load current of less than or equal to 200 mA 4 4 Rod Ends Standard K Series Rod End Thread Specifications US Male US Female Metric Male Metric Female 1 2 20 1 2 20 M12 X 1 25 M12 X 1 25 3 416 3 416 M16X1 5 MI16X15 3 416 3 416 M20X15 M20X15 Please Contact Exlar for rod end drawings 5 0 Specifications 5 1 Travel Life Calculations Travel life estimates of a roller screw in a linear application cubic mean load should be used The mathematical formulas that define these values follow the chart below 53 K Series Manual doc 07 21 2013 PN 49269 Exlar Corporation Rev J 952 500 6200 Load Lead of Load Max Dynamic Ibf kN Torque 0 Load Max Ibf in N m Lead of Load Max Dynamic Screw Ibf kN Ibf kN Torque 0 Load Max Ibf in N m KM 5mm 2 500 11 1 3 620 16 1 98 0 11 0 KM 10mm 1 250 5 6 3 036 13 5 98 0 11 0 2 500 11 1 5 746 25 6 98 0 11 0 KX 10mm 1 250 5 6 4 820 21 4 98 0 11 0 1 355 6 0 98 0 11 0 1 139 5 1 98 0 11 0 Lead of Load Max Dynamic Screw Ibf kN Ibf kN Torque 0 Load Max I
27. es and trunnions angle plates front and rear flange mounts eye plates and clevis plates See Section 2 0 Installation for more details 4 2 Standard Motor Mounting Configurations The K Series actuators are offered in two standard motor mounting configurations parallel and inline Each standard motor mounting is designed to accommodate Exlar SLM SLG Servo motors Nema 23 and 34 motors and Exlar Tritex motors Custom motors can be accommodated with custom mounting although due to custom motor size torque and speed not all custom motors or reducers can be mounted to each standard actuator Contact Exlar Corporation application engineers for custom mounting considerations See section 5 0 Specifications for torque specifications required to drive application load levels 4 3 Limit Switches The K Series actuator is equipped for adjustable externally mounted limit switches Exlar offers magnetic inductive proximity switches that are triggered by a target magnet that is located in the anti rotate mechanisms inside of the actuator housing The location of the four target magnets allow switches to be mounted on any side of the actuator See figure 15 Target Magnet 52 K Series Manual doc 07 21 2013 PN 49269 Exlar Corporation Rev J 952 500 6200 The limit switches are available with normally open and normally closed output channel mount magnetic sensing prox LH options External Limit Switches channel mount magnetic sensing prox pl
28. f the owner of the product Exlar will return ship all warranty repairs or replacements via UPS Ground at no cost to the customer For international customers Exlar will return ship warranty repairs or replacements via UPS Expedited Service and cover the associated shipping costs Any VAT or local country taxes are the responsibility of the owner of the product The foregoing warranty is in lieu of all other warranties except as Title whether expressed or implied including without limitation any warranty of merchantability or of fitness for any particular purpose other than as expressly set forth and to the extent specified herein and is in lieu of all other obligations or liabilities on the part of Exlar Seller s maximum liability with respect to these terms and conditions and any resulting sale arising from any cause whatsoever including without limitation breach of contract or negligence shall not exceed the price specified herein of the product s giving rise to the claim and in no event shall Exlar be liable under this warranty otherwise for special incidental or consequential damages whether similar or dissimilar of any nature arising or resulting from the purchase installation removal repair operation use or breakdown of the product s or any other cause whatsoever including negligence The foregoing warranty shall also apply to products or parts which have been repaired or replaced pursuant to such warranty and within the
29. lead rpm 63 484 18 407 4 977 2 400 1 296 Critical Speeds Stroke inch mm 6 150 12 300 24 600 35 900 48 1225 Roller Screw 5 and 10mm leads rpm 5 180 5 180 5 180 4 320 2 333 Acme Screw 1 lead rpm 92 214 26 737 7 230 3 486 1 882 Acme Screw 2 lead rpm 80 701 23 398 6 327 3 051 1 647 5 6 Inertias 5 mm Lead Ibf in sec kg m Adder per 25 mm 5 mm Lead Ibf in sec kg m Base Unit Input Drive Shaft Only 1 31x10 1 480 x 10 9 045 x 10 1 022 x 10 E 2 4 6 Inline Unit w Motor Coupling 2 39 x 107 2 702 x 10 9 045 x 10 1 022 x 10 1 1 Reduction Belt Drive 66 mm 3 84 x 10 4 339 x 10 9 045 x10 1 022 x 10 4 6 i 4 6 7 2 2 1 1 Reduction Belt Drive 96 mm 7 58x 10 8 564 x 10 9 045 x 10 1 022 x 10 6 i Me 1 1 Reduction Belt Drive 86 mm 6 53x10 7 378x 10 9 045 x 10 1 022 x 10 6 2 1 Reduction Belt Drive 96 mm 6 28 x 10 7 095 x 10 2 261 x 10 2 555 x 10 Base Unit Input Drive Shaft Only IN EA E 2 1 Reduction Belt Drive 96 mm 1 74 x 10 1 966 x 10 2 595 x 10 2 931x 10 See drawings for drive dimension reference 5 5 5 5 5 5 10 mm Lead Ibf in sec kg m Adder per 25 mm 10 mm Lead Ibf in sec kg m Base Unit Input Drive Shaft Only j 5 i 5 5 EST A 5 59 K Series Manual doc 07 21 2013 PN 49269 Exlar Corporation Rev J 952 500 6200 8 20 x 10 9 265 x 10 1 11 x 10
30. of manufacture as determined by the serial number on the product label Labels are generated and applied to the product at the time of shipment The first and second digits are the year and the third and fourth digits represent the manufacturing week Product repairs are warranted for 90 days from the date of the repair The date of repair is recorded within Exlar Corporation s database tracked by individual product serial number Exlar warrants its product s to the original purchaser and in the case of original equipment manufacturers to their original customer to be free from defects in material and workmanship and to be made only in accordance with Exlar s standard published catalog specifications for the product s as published at the time of purchase Warranty or performance to any other specifications is not covered by this warranty unless otherwise agreed to in writing by Exlar and documented as part of any and all contracts including but not limited to purchase orders sales orders order confirmations purchase contracts and purchase agreements In no event shall Exlar be liable or have any responsibility under such warranty if the product s has been improperly stored installed used or maintained or if Buyer has permitted any unauthorized modifications adjustments and or repairs to such product s Seller s obligation hereunder is limited solely to repairing or replacing at its opinion at the factory any product s or parts thereof which p
31. of the system in addition to the thrust Consult Exlar s sizing guidelines for further details The resultant linear speed of the K Series actuator s output rod is a function of rotational speed of the roller screw input shaft and roller screw lead Any gearbox reduction or belt and pulley speed reduction should be factored into the equation below The equation below defines the linear speed produced by a K Series actuator V nS Where V Linear speed in s mm s n Rotational speed of roller screw shaft rev s S Roller screw Lead in mm 35 K Series Manual doc 07 21 2013 PN 49269 Exlar Corporation Rev J 952 500 6200 Do not exceed the maximum load rating Doing so may cause damage to the actuator or injury 5 3 Column Strengths K60 polerScrew Sand zomm testeo 12031 85272 20150 zasa m Roller Screw 5 and 10mm leads Ibs N 120 911 85 272 26 151 12 463 6 681 pemeserew areais ces unse cimo s a com Acme Screw 1 lead Ibs N 76 944 41 934 11 810 5 613 3 002 Acme Screw 2 lead lbs N 76 944 41 934 11 810 5 613 3 002 ease A seta justo Stroke inch mm 6 150 12 300 24 600 35 900 48 1225 polerScrew and 10m reads bs qu 243 393 202506 Cmm 58310 20 68 Roller Screw 5 and 10mm leads Ibs N 243 193 202 345 79 418 38 316 20 688 PA AAA Acme Screw 1 lead Ibs N 138 326 97 545 28 272 13 633 7 357 a 29 064 19 897 5 636 2 71
32. period of time in accordance with Seller s stated warranty NO PERSON INCLUDING ANY AGENT OR REPRESENTATIVE OF EXLAR IS AUTHORIZED TO MAKE ANY REPRESENTATION OR WARRANTY ON BEHALF OF EXLAR CONCERNING ANY PRODUCTS MANUFACTURED BY EXLAR EXCEPT TO REFER PURCHASERS TO THIS WARRANTY 3 K Series Manual doc 07 21 2013 PN 49269 Exlar Corporation Rev J 952 500 6200 1 2 Safety Considerations As with any electro mechanical device safety should be considered during installation and operation of your K Series actuator Throughout this manual you will see paragraphs marked with a CAUTION sign as shown below CAUTION Pay particular attention to these paragraphs They are intended to provide you with helpful information to ensure a safe and trouble free installation and operation Care should be taken not to exceed the physical travel limits of K Series actuators Doing so will cause the actuator to impact its end travel bumpers Repeated end travel crashes can physically damage the roller screw and the internal components of the actuator Care should be taken to avoid high speed impact with objects of high rigidity that immediately stop the travel of the actuator with no deceleration or energy absorption An example would be a high speed impact of two solid steel parts The resulting impact will create a very short effective deceleration time Kinetic energy contained in the rotating inertia of the actuator and motor can possibly generate ext
33. re below 5 Place the inline housing over the pilot feature of the end cap Take care to make sure that the correct end of the inline housing is mated with the inline gasket and end cap otherwise the mounting holes will not line up See figure next page 34 K Series Manual doc 07 21 2013 PN 49269 Exlar Corporation Rev J 952 500 6200 End Cap Inline Housing 6 Place an inline gasket so its face is flush with the inline housing end Ensure that the correct face of the gasket is mated with the face of the inline housing otherwise the mounting holes will not line up See figure below 7 Place the inline motor adapter plate so it pilots into the inline housing See figure below End Cap Inline Housing Motor Adapter Plate NE 8 Insert the 4 inline housing screws and tighten to the designated torque value see table in Section 3 9 See figure next page 35 K Series Manual doc 07 21 2013 PN 49269 Exlar Corporation Rev J 952 500 6200 Inline Housing Screws 9 Slide the coupling for the output motor shaft onto the motor output shaft until the inside surface of the coupling is flush with the end of the motor output shaft See figure below Coupling End of shaft is flush with inside surface of coupling 10 Torque the coupling clamp screw See Section 3 9 Fastener Torque Values 11 Place a motor gasket over the pilot feature of the motor face plate so it is flush with the face of
34. remely high impact forces that exceed the mechanical capacities of the actuator and cause physical damage to the actuator For applications requiring this type of impact contact Exlar application engineering to insure that the actuator is properly sized or provisions are made to absorb the induced energy K Series Manual doc 07 21 2013 PN 49269 Exlar Corporation Rev J 952 500 6200 1 3 K Series Linear Actuators Overview Exlar K Series actuators are offered in three standard nominal frame sizes of 60 75 and 90 millimeters Continuous duty thrust load rating for the K Series product range from 1 350 Ibf to 3 500 Ibf 6 000 15 569 N Intermittent load ratings for each actuator are twice the respective continuous duty load rating Exlar KM and KX Series actuators utilize a planetary roller screw mechanism to convert rotary to linear motion KA Series actuators use an acme screw 1 4 Actuator Configurations The K Series base unit actuator includes a high performance planetary roller screw assembly or acme screw bearing support anodized extruded aluminum housing precision internal anti rotate sliders extending rod and an input shaft for attachment to your drive system A K Series base unit is shown below Figure K Series Base Model Actuator The K Series actuators are also available with provisions for mounting various motors Standard motor mountings include parallel with belt drive and inline drive Parallel Drive K Series Ac
35. rove to Seller s satisfaction to be defective as a result of defective materials or workmanship and within the period of time in accordance with the Seller s stated product warranty see Terms and Conditions above provided however that written notice of claimed defects shall have been given to Exlar within thirty 30 days from the date of any such defect is first discovered The product s claimed to be defective must be returned to Exlar transportation prepaid by Buyer with written specification of the claimed defect Evidence acceptable to Exlar must be furnished that the claimed defects were not caused by misuse abuse or neglect by anyone other than Exlar Components such as seals wipers bearings brakes bushings gears splines and roller screw parts are considered wear parts and must be inspected and serviced on a regular basis Any damage caused by failure to properly lubricate Exlar products and or to replace wear parts at appropriate times is not covered by this warranty Any damage due to excessive loading is not covered by this warranty The use of products or components under load such that they reach the end of their expected life is a normal characteristic of the application of mechanical products Reaching the end of a product s expected life does not indicate any defect in material or workmanship and is not covered by this warranty Costs for shipment of units returned to the factory for warranty repairs are the responsibility o
36. rs roller screw 3 2 Anti Rotate Bearings K Series actuators have internal anti rotate bearings The anti rotate bearings travel in channels integral to the actuator case Care should be taken when loading rod end attachments to not apply unnecessary torque to the anti rotate bearings The wrench flats on the end of the main rod should be used when attaching rod end accessories or load attachments Below the anti rotate bearings may be shims There will be 2 1 or none The anti rotate bearings also contain the magnets that are sensed by the limit switches See Section 4 3 Limit Switches for more information on Limit Switches 11 K Series Manual doc 07 21 2013 PN 49269 Exlar Corporation Rev J 952 500 6200 Figure Anti Rotate Bearings can be placed into the anti rotate grooves using any orientation See Actuator Reassembly in Section 3 8 Disassembly 8 Reassembly Procedure to see how shims play a role in orientating the Anti Rotate Bearings into the anti rotate grooves 3 3 Seals K Series actuators are all IP65 sealed using gaskets at the joints of the actuator housing components and a Buna o ring at the end cap joint between the end cap and impact washer plate The extending rod is sealed with a wiper The input shaft is sealed with a rotary shaft seal that is contained within the back end cap of the actuator These seals are lubricated on initial assembly and do not need to be lubricated again See Section 3 8 Disassembly amp Rea
37. rt prior to requesting an RGA number to see if itis possible to resolve the issue prior to return e lf itis determined that an RGA number is required please do so by contacting the Returned Goods Administrator Phone 952 500 6200 or email returns exlar com e International Repairs Closely follow instructions provided by the Exlar Returned Goods Administrator Failure to comply with issued instructions may result in delays for repair and return e Exlarrequires a purchase order at the time of RGA SO on warranty returns or for the standard evaluation charge per unit on all non warranty units for the evaluation fee e Following the evaluation you will receive a quote from Exlar on the charges that will apply If the actuator repair is approved the evaluation fee will be waived and we will request an amended PO for the actual repair value 64 K Series Manual doc 07 21 2013 PN 49269 Exlar Corporation Rev J 952 500 6200
38. ssembly Procedure for replacement of rod wipers rotary shaft seals O rings or gaskets 12 K Series Manual doc 07 21 2013 PN 49269 Exlar Corporation Rev J 952 500 6200 Rod Wiper Rotary Shaft Seal Figure Base Unit Sealing Details Rod Wiper Rotary Shaft Seal Figure Inline Motor Mount Unit Sealing Details 13 K Series Manual doc 07 21 2013 PN 49269 Exlar Corporation Rev J 952 500 6200 a Rod Wiper Gasket Gasket Rotary Shaft Seal Figure Parallel Motor Mount Unit Sealing Details 3 4 Thrust Bearings KM and KA Series actuators use two deep groove ball bearings shown in Figure 8 KX Series actuators provide two angular contact bearings mounted in duplex arrangement shown in Figure 9 These bearings support the drive shaft within the K Series actuator The inner races of the angular contact bearings are pre loaded using a bearing jam nut and lock washer The outer races are pre loaded by the end cap and the impact washer plate Bearing Replacement see Section 3 8 Disassembly amp Reassembly Procedure K Series Manual doc 07 21 2013 PN 49269 Exlar Corporation Rev J 952 500 6200 Deep Groove Ball Bearing PA AA in 9 MAA n Deep Groove Ball Bearing Rotary Shaft Seal Figure Roller Screw Support Using Deep Groove Ball Bearings Angular Contact Bearing Angular Contact Bearing Rotary Shaft Seal Figure Roller Screw Support Using Angular Contact
39. t extend An internal mechanism binding application binding Excessive motor current to operate roller screw failure Consult Exlar actuator Operation over peak load rating Rapid Belt Wear Belt too loose or too tight Tighten or Loosen Belt Broken anti rotate jammed Replace anti rotates replace Main Rod Output Rod does not rollerscrew nut broken belt rollerscrew nut replace belt extend pulley loose or coupling tighten pulley or tighten loose coupling Seemingly excessive noise Bad roller screw or bearings Replace roller screw or bearings Hep Mesa ae ACES High over hung load Remove high overhung load bearing Mounting accessories slip on t nuts Too much load Reduce load and tighten screws 63 K Series Manual doc 07 21 2013 Exlar Corporation PN 49269 Rev J 952 500 6200 6 2 Returning a Product for Repair STANDARD REPAIR LEADTIME e Two weeks for written evaluation from Exlar e Two weeks from receipt of approval by fax or email for repair where parts are available e An evaluation charge per unit after evaluation applies if customer chooses not to repair or if product is found not in need of repair EXPEDITED REPAIR LEADTIME e An expedite charge per unit can be quoted e This provides one week for written evaluation from Exlar e This provides one week from receipt of approval by fax or email for repair where parts are available PROCEDURE e Please discuss the return with Exlar Technical Suppo
40. tallation or maintenance of the belt and pulley drive train on your K Series Actuator Timing Belt Replacement see Section 3 8 Disassembly amp Reassembly Procedure Pulley Replacement see Section 3 8 Disassembly amp Reassembly Procedure 16 K Series Manual doc 07 21 2013 PN 49269 Exlar Corporation Rev J 952 500 6200 Motor Pulley Motor Pulley Timing Belt Pulley Box Cover Figure Parallel Motor Mount Drive Train Assembly Inline Drive The inline motor mounting configuration uses a coupling attaching the motors output shaft to the actuators input shaft Spider Coupling and Components Replacement see Section 3 8 Disassembly Reassembly Procedure 17 K Series Manual doc 07 21 2013 PN 49269 Exlar Corporation Rev J 952 500 6200 Figure Inline Motor Mount Drive Train Assembly 3 6 End Of Stroke Cushions Every standard K Series actuator is equipped with rubber impact bumpers which are designed to protect the actuator from accidental over extension or retraction End of stroke cushions are provided for fail safe only and should not be used as an application limit of stroke K Series actuators are designed with an additional 10mm of length over nominal stroke This is to allow users to utilize the full nominal stroke without causing damage by end crashing See figures on pages 22 24 for information on stroke limits and how to position limit switches See Section 4 3 Limit Switches Extend Imp
41. the main rod Once the wiper seal is over the main rod continue to slide toward the case until it is flush with the case and gasket See figure below Face Plate Face Plate Screws 17 Torque the four face plate screws and use the torque values provided in Section 3 9 Fastener Torque Values 18 Place the key in the keyway and take care that the key does not fall out 47 K Series Manual doc 07 21 2013 PN 49269 Exlar Corporation Rev J 952 500 6200 Key 19 The drive train can now be reassembled On K Series that are parallel motor mount check the belt for wear If the belt has excessive wear it may be necessary to replace it See Parallel Motor and Actuator Mounting and Inline Motor and Actuator Mounting in Section 3 8 Disassembly and Reassembly Procedure 48 K Series Manual doc 07 21 2013 PN 49269 Exlar Corporation Rev J 952 500 6200 3 9 Fastener Torque Values K60 Fastener Torque Values Base Unit SoS o o o Screw M x 1 0x40mm SHCS SS 8X Face Plate and End Cap___ 96 8 11 Nut M6 x 1 Hex Nylon Insert Rod End Bushing 96 8 11 A E E NEN Inline Motor Mount Unit Screw M6 x 1 0x40mm SHCS SS 8X Face Plate and End Cap 96 8 1 Nut M6 x 1 Hex Nylon Insert Rod End Bushing 96 8 1 Screw M5x0 8x 18mm SHCS SS 4X Motor Mount 56 47 64 Screw M6 x 1 0x25mm SHCS SS 4X MotorMount 96 8 n Screw 10 24 x 625 SHC
42. tuator Parallel drives use a timing belt and pulleys come in ratios of 1 1 and 2 1 for the K60 K75 and K90 actuators A parallel unit is Shown below Figure K Series with Parallel Motor Mount K Series Manual doc 07 21 2013 PN 49269 Exlar Corporation Rev J 952 500 6200 Inline Drive K Series Actuator The inline motor mounting configuration uses a coupling attaching the motors output shaft to the actuators input shaft An inline unit is Shown below Figure K Series with Inline Motor Mount The inline option with a gear motor offers planetary gear reduction The planetary gearing is integral to the gear motor An inline unit with a gear motor is shown below Figure K Series with Inline Gear Motor Mount 2 0 Installation 2 1 Mounting Configurations The K Series actuators offer a variety of mounting accessories The standard mounting accessories are foot plate mounts or side mounted trunnions Each of these mounting components utilizes the T Slot tracks on the sides of the case for attachment Also available are flange plate mounts Flange plates can be bolted to the front and rear of the actuator depending on whether an inline motor mount actuator or a parallel motor mount actuator is used Also available are angle plate mounts for both inline and parallel motor mount actuators Also available for the parallel and inline motor mount actuators are eye plates and clevis plates See figures next page K Series M
43. x 10mm SBHCS SS Idler Adj Screw crew M8 x 1 25 SHCS T Slot Screws Torque Torque OOOO its fts Nm Base Umit a Screw M8 x 1 25x45mm SHCS SS 8X Face Plate and End Cap 228 19 258 Bearing Lock Nut CT 660 55 745 Nut M8 x 1 25 Hex Nylon Insert Rod End Bushing 120 10 135 LL LL LL Mine Motor Mountunit A te te Screw M8 x 1 25x45mm SHCS SS 8X Face Plate and End Cap 228 19 258 Bearing Lock Nut CT 660 55 745 Nut M8 x 1 25 Hex Nylon Insert Rod End Bushing 120 10 135 Screw M5 x 0 8 x 22mm SHCS SS 4X Motor Mount se ar 64 Screw M6 x 1 0 x 25mm SHCS SS 4X Motor Mount 96 8 11 Screw M8 x 1 25 x 30mm SHCS SS 4X Motor Mount 228 19 258 Screw 10 24 x 75 SHCS SS 4X Motor Mount s ez 9 Screw M8 x 1 25 x 100mm SHCS SS En mE Inline Housing 228 19 258 Coupling Clamp Screw 41 3mm OD Coupling MAlloy 407 34 46 Coupling Clamp Screw 50 8mm OD Coupling M5 Alloy s 7 Tas Screw MBx 1 25 SHCS T Slot Serews 264 22 30 Screw M8 x 1 25 x 20mm SHCS SS AX Front Mounts 228 19 258 Parallel Motor Mountunit I u Screw M8 x 1 25 x 45mm SHCS SS 8X Face Plate and End Cap 228 19 258 Bearing Lock Nut CT 660 55 745 Nut M8 x 1 25 Hex Nylon Insert Rod End Bushing 120 10 135 Screw M5 x 0 8 x 22mm SHCS SS 4X Motor Mount se ar 64
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