RE 83 400/06.99

STAR Linear Actuator ESK

2

STAR Linear Motion Technology

REG. No.1617 - 03

Deutsche Star GmbH

D-97419 Schweinfurt

Ball rail systems Standard Ball Rail Systems

Ball Rail Systems with Aluminum Runner Blocks

Super Ball Rail Systems

Wide Ball Rail Systems

Miniature Ball Rail Systems

Cam Roller Guides

Accessories

Roller Rail Systems

Linear Bushings and Shafts Linear Bushings

Linear Sets

Shafts

Shaft Support Rails

Shaft Support Blocks

Ball Transfer Units

Screw Drives Precision Ball Screw Assemblies

End Bearings and Housings

Linear Motion Systems Linear Motion Slides

Linear Modules

Compact Modules

Ball Rail Tables

Linear Actuators

ALU-STAR Profile System

Controllers, Motors, Electrical Accessories

RE 83 400/06.99

Roller Rail is a trademark ofDeutsche Star GmbH, Germany.

STAR, Ball Rail and are trademarks registered forDeutsche Star GmbH, Germany.

3RE 83 400/06.99

Product Overview 4

Components and Ordering Data 10

Dimension Drawings 12

Electric Connections 14

STAR Linear Actuator ESK

STAR Linear Actuator ESK

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Product OverviewSTAR Linear Actuators are powerful and intelligent drive systems.The drive unit is a STAR Precision Ball Screw Assembly. The heart is anelectronically commutated motor. The rotational direction and speed of therotor are monitored by sensors and are regulated by the controller. Digitalprocessing of the information permits functions previously unrealizable insuch an integrated and compact form.

STAR Linear Actuator

Mounting eyes continuouslyrotatable through 360°

Twist-locked thrust tube for transmissionof the push and pull forces

Splash-proof unit(protection IP54)

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Integrated speed controlor positioning control

Integrated motor, gear andelectronically regulatedholding brake

Rugged aluminum housing for gear,motor, holding brake and controller

Ball screw as drive unit for push andpull forces up to 20 000 N

Integrated safety limit switches in theend positions

Rectangular aluminum profile to protectthe drive and all the sensors

Integrated end position sensors and userswitches adjustable from the outside

STAR Linear Actuator ESK

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Product OverviewMechanically adjustableswitches

Type

Used by the controller to sense the end position.If one of the two end position sensors is active,the drive unit can move only in the oppositedirection.

movable by 100 mm from the absoluteend positions

The two safety limit switches operate only incase of a fault. If a safety limit switch is reached,the power supply to the drive unit is interruptedand the drive unit is immediately brought to astop. The drive unit can be released from theend position by rotating the rotor shaft (emer-gency manual adjustment).

The two user switches are electrically isolatedfrom the controller. They are changeoverswitches and are provided for external circuitryfor installation by the user.

coupled mechanically to the respectiveend position sensors and adjustedtogether with them

movable from the respective absoluteend position to the stroke mid point

End position sensors 2

Safety limit switches 2(option)

User switches 2(option)

Number ApplicationAdjustment range

Standard control functions

Type Description

Digital signal inputsand outputs

Digital signal inputs and outputs to control and monitor the drive unit

Adjustable speeds Two adjustable speeds, selectable by means of input signal

Adjustable times Different times, adjustable over broad ranges, for braking and acceleration

Force monitoring Force monitoring through regulated motor current

Outputs Outputs to feed back the end position

Emergency stop input Emergency stop input with self-locking function to avoid uncontrolled restarts

“Enable” input

Minimum configuration possible with only two external sensor switchesMinimum operation

“Enable” input to interrupt an ongoing drive movement

Self-protection, with fault signals for overload and over- or undervoltageSelf protection

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5

10

15

0

20

0

25

10 20 30 40 50 60 70 80 90 100 110

Ball screw 32 x 5

Ball screw 20 x 20

Ball screw 25 x 10

Type

Used to limit the stroke, but are more precisethan the mechanically adjustable end positionsensors.If the drive unit is in the programmed endposition, it can move only in the oppositedirection.

within the adjustment range of themechanically adjustable end positions

within the range of the programmedend positions

It is possible to program as many as 4positions. These programmed positionscan be approached one after the otherin a fixed sequence.

Programmable 2end positions

Programmable 4intermediate positions

Number ApplicationAdjustment range

Forc

e (k

N)

Speed (mm/s)

Working range

Additional functions ofthe positioning control

non adjustable Used to synchronize the controller’s internalposition counter with the drive unit. (Auto-matic position check each time the referencesensor is passed over.)

Reference sensor 1

The position of the drive unit is stored in thenon-volatile memory.

Memory for 1drive unit position

The programmable end and intermediate positions are stored through teach-in cycles during start-up.

STAR Linear Actuator ESK

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Type designation (size)

Linear modules are designated accordingto type and size.

Linear Actuator ESK (example) =

System = Linear actuator (ES)

Drive unit = Ball screw (K)

Frame dimensions =e.g. x = 100 mm

Size

ES K 00- 100

Type Drive unit Linear Actuator

STARLinear Actuator

ESKBall screw

Product OverviewType

x

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Permissible loads

Duty cycle (S3 10 minutes) fornominal load of 20 %.

Linear Actuator max. push/pull force

(N)

ESK-00-100

Ball screw

20 x 20

No lateral loads or torquespermissible.

Dimensions A x H

(mm)

25 x 10

32 x 5

5000

10000

20000

100 x 193

HA

STAR Linear Actuator ESK

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Ordering data

Order exampleDescription

Available upon request: - Safety nut

- Corrosion-resistant thrust tube

- Communication modulefor CAN-open and RS232

Components and Ordering Data

20 x 20 03

25 x 10 12

32 x 5 21

Stroke

01

Ball screw withstandardcontrol

withpositioning

control

01 01 02

Linear actuator ESK(Part number): 1167-200-00, 500

Guideway =01

Drive unit =03

Motor attachment =01Motor =01

Switches =01

Documentation =01

linear actuatorESK, stroke = 500 mm

frame

with ball screw 20 x 20

with gearmotor with standard control

with two limit switches

with standard report

Part number Guideway = .. Drive unit = .. Motor attach- Motor = ..

1167-200-00, .... mmment = ..

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Stroke = 700 mm maximum

Linear actuator available in stroke increments of 100 mm.Intermediate lengths upon request.

Stroke of the linear actuator

with two limit switches 01

with two limit switchesand two user switches

02

with two limit switchesand two safety limit switches

03

with two limit switches,two user switches and 04two safety limit switches

with standard report

01

Accessories (upon request): - 0.8 mm connecting cablewith circular plug and coupling

- Operator control panel

- Mounting bracket

Switches = .. Documentation = ..

approx. 20 kgMass

Repeat accuracyfor identical load conditions andtemperature

Ball screw Standard control Positioning control

20 x 20 ± 0.4 mm max.± 4 mm max.

25 x 10 ± 0.2 mm max.± 2 mm max.

32 x 5 ± 0.1 mm max.± 1 mm max.

STAR Linear Actuator ESK

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Dimension Drawings

175

497

48.5

22.5

ø25 +0.003

-0.013

ø62

72±1

SW40

-2+20

ø25 +0.124+0.040

30

24

12

ø20 +0.1

137

SW36

20 0 -0.12

30 0-0.3

Stroke + 283 (with safety nut, stroke + 333)

Stroke + 420 (with safety nut, stroke + 470)Stroke + 473 (with safety nut, stroke + 523)

Power supply connection (accessory)

Signal connection (accessory)

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S1

S4S3

S2

100

35

(ø5...12)PG 11

112

193

50

(ø5...12)PG 11

Signal connection

Power supplyconnection

S1= End position sensor retracted(with safety limit switch)

S2= End position sensor extended(with safety limit switch)

S3= User switch retractedS4= User switch extended

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Electric ConnectionsData

Signal inputs and outputs The linear actuator has 5 signal inputs and5 signal outputs. These connections areelectrically isolated from the power system

Control voltage connection

+24 V output supplies 24 V, 200 mA max., electrically isolated from the power system for the drive

+24 V input can be powered by +24 V external supply

GND signal ground

Description of the signalinputs

Enable If this signal is deactivated, ongoing movement is interrupted either as an immediate stopor after a set braking ramp. Once this signal is re-applied, the drive unit resumes theinterrupted movement.

Emergency stop In the event of a voltage drop at this input, the drive unit makes an emergency stop.

Fast/slow Switches between the two variable speeds fast and slow.

Input Mode 4 (pulse)Mode 3 (continuous)

As long as this inputis active, the driveunit extends.

As long as this inputis active, the driveunit retracts.

If the voltage signal is applied briefly, thedrive unit extends. Renewed application ofthe signal will stop the movement again.

If the voltage signal is applied briefly, thedrive unit retracts. Renewed application ofthe signal will stop the movement again.

If the voltage signal is applied briefly toboth inputs, the drive unit moves to thenext of the 4 programmed positions.

Extend

Retract

The Extend and Retract inputs have different functions, depending on the mode switch setting.

Description of the signaloutputs

End positionretracted

Fault

If the position of the drive unit is either end position sensor retracted or programmedend position retracted, a +24 V signal is emitted.

End positionextended

If the position of the drive unit is either end position sensor extended or programmedend position extended, a +24 V signal is emitted.

If a drive fault occurs, a +24 V signal is emitted.

Ready When the drive is ready to operate, a +24 V signal is emitted.If a drive unit warning occurs, a +24 Vsignal is emitted at both outputs.

Drive unit in motion As long as the drive unit is in motion, a +24 V signal is emitted either as a static signal oras pulses from an incremental encoder.

by optocouplers. They are operated on24 V DC.

Power supply 230 V AC, 50 to 60 HzPower consumption approx. 1000 W

Current consumption approx. 6 amperes

Service temperature range -10 °C to +40 °C

Protection class / insulation class I / B

Protection IP54

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To be completed by customer: Inquiry / OrderLinear actuator ESK

(Part number): ______-______-______, stroke __________mm

Guideway =

Drive unit =Motor attachment =Motor =Switches =Documentation =

Order example: Linear actuator ESK

STAR Linear Actuator ESK

Ordering data Description

Quantity ____ pcs, _____ per month, ______ per year, per order, or ____________________

Remarks:

FromCompany: __________________________________________ Name: _________________________________________

Address: __________________________________________ Department: _________________________________________

__________________________________________ Telephone: _________________________________________

__________________________________________ Telefax: _________________________________________

Telephone + 49 - 97 21- 9 37- 0Telefax + 49 - 97 21- 9 37- 350(direct)

Deutsche Star GmbH

D-97419 Schweinfurt

linear actuatorESK, stroke = 500 mmframewith ball screw 20 x 20with gearmotor with standard controlwith two limit switcheswith standard report

Linear actuator(Part number): 1167-200-00, 500 mmGuideway =01Drive unit =03Motor attachment =01Motor =01Switches =01Documentation =01

Inquiry/Order Form

Great care has been taken during the compilation ofthis publication to ensure all the information containedis accurate. We accept no responsibility however forany damage resulting from incorrect or incompleteinformation contained.

For deliveries and other services in the course of com-mercial business, the general terms and conditions forsupplies and services contained in the valid price listsand the confirmations of order apply.

As our products are constantly in the process of furtherdevelopment, they are subject to alteration without notice.

STAR, Ball Rail and are trademarks registered forDeutsche Star GmbH, Germany.

Roller Rail is a trademark ofDeutsche Star GmbH, Germany.

Reproduction of this document, even in extract form,is only permitted with our approval.

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Deutsche Star GmbHD-97419 Schweinfurt

Telephone +49-97 21-9 37-0Telefax +49-97 21-9 37-275(general)

Telefax +49-97 21-9 37-350(direct)

Linear Actuator ESKRE 83 400/06.99

Printed in Germany - p 99/03/3/S