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Tsubaki ZIP CHAIN ACTUATOR ZCA25 Instruction Manual

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ZCA01TSE
Printed June 1, 2020
ZIP CHAIN ACTUATOR
Instruction Manual
【NOTE】
Ensure that this instruction manual is delivered properly to the end
user of this product.
This manual uses SI units.
Figure in ｛ ｝ are gravitational units and are for reference only.

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Summary of Contents for Tsubaki ZIP CHAIN ACTUATOR ZCA25

  • Page 1 ZCA01TSE Printed June 1, 2020 ZIP CHAIN ACTUATOR Instruction Manual 【NOTE】 Ensure that this instruction manual is delivered properly to the end user of this product. This manual uses SI units. Figure in ｛ ｝ are gravitational units and are for reference only.
  • Page 2 ZIP CHAIN ACTUATOR Safety Points  Before using this product (installation, operation, maintenance, inspection, etc.) please thoroughly read this instruction manual and the other attached documents, and operate the product correctly. Familiarize yourself with the equipment, safety information, and precautions listed herein thoroughly before operation. After reading, keep this manual in a convenient place for reference.
  • Page 3 Warning ・ Do not release the brake when the unit is supporting a load. If the brake is released under loaded conditions, suspended objects may fall or movable parts may suddenly move. ・ Do not operate the ZIP CHAIN ACTUATOR in an explosive atmosphere to avoid risk of ignition, explosion, fire, or injury.

  • Page 4: Table Of Contents

    This instruction manual provides all information from unpacking and installation to maintenance. Read the manual thoroughly so as to ensure satisfactory performance. Should you have any questions, please contact your distributor or a Tsubaki representative. When inquiring, please give us the information on the ZIP CHAIN ACTUATOR nameplate.

  • Page 5: Unpacking

    1. Unpacking 1. When unpacking, ensure that the right side is up to avoid injury. 2. Please check the following when you receive your Tsubaki ZIP CHAIN ACTUATOR (herein referred to as “ZCA”) （１） Check the packing list included with product to verify that you received what you ordered.

  • Page 6: Installation

    End Fitting bracket ZIP CHAIN 【NOTE】 Housing section ZCA25N(M)30□□ Input shaft ZCA35N(M)050 □□ Drive section feature a snap-fit construction and do not come with bolts. Fig. 1 ZCA (Figure above shows the ZCA35) 3. Installation 1. Ambient Condition Table 1 Ambient Conditions Usage Location Indoors where rain and moisture are not present Ambient Environment...
  • Page 7 Be sure to align the input shaft and transmission shaft to avoid risk of damage to the shaft. Tsubaki recommends its line-up of couplings for connecting the shaft. Fig. 3 Example of improper connection to ZCA (misalignment) 8.
  • Page 8 Table 2 Coefficient of PT element (f) Table 3 Coefficient – Load Position (Lf) 0.25 0.75 Gear Chain V-Belt 1.15 1.25 Toothed Belt 1.25 O.H.L. : Overhang load N {kgf} (Table 4) 2×T×f×Lf : Load torque N‧m {kgf‧m} Allowable O.H.L.≧ : Pitch diameter of sprocket, gear and pulley (m) : Coefficient of PT element (Table 2) : Coefficient –...
  • Page 9 16. Always install safety equipment on the equipment side when using hanging equipment to prevent falling. Falling objects pose a risk of injury or death and damage to the equipment. Tsubaki will not manufacture or sell ZCA units for situations where there is a danger that can lead to injury or death.

  • Page 10: Operation

    4. Operation 1. Verify that any load, whether static or dynamic, applied to the ZCA falls within basic capacity, allowable input shaft torque, and allowable overhang load. Table 7 Basic Performance Max. Allowable ZIP CHAIN Allowable Max. Input Input Shaft Movement per Approx.

  • Page 11: Maintenance & Inspection

    8. In sub-zero temperatures, the unit experiences decreased efficiency due to a change in grease viscosity. Ensure that the drive source can accommodate this change. 9. Keep away from the input shaft and ZIP CHAIN when the ZCA is in operation to avoid injury. 10.
  • Page 12 Table 8 Pin‧Bush wear limit Model Pin/Bush Outer Dia. Pin/Bush Outer Dia. Catalog Values (mm) Limit (mm) ZCA25 φ3.30 (bushing) φ3.20 (bushing) ZCA35 φ5.08 (bushing) φ4.95 (bushing) ZCA45 φ8.28 (pin) φ8.00 (pin)  Ensure that the engaged chain has not suffered extremely decreased rigidity. Should any of the above occur, stop use immediately.
  • Page 13 5.2. Maintenance 1. The ZIP CHAIN and drive unit are pre-greased and ready to be used upon delivery. Use the recommended grease shown in Table 9 below. The lubrication cycle with normal use is 12 months for ZCA25 and ZCA35, and 3.5 months for ZCA45, but this will vary depending on the frequency of operation and ambient conditions.
  • Page 14 ・ Greasing Procedure  Remove all loads  Stop the equipment and perform lock-out-tag-out safety measures  Shut off the power source and ensure that power cannot be turned on accidentally  Fully extend the ZIP CHAIN and wipe away any old grease using a brush ...

  • Page 15: Troubleshooting Guide

    6. Troubleshooting Guide Most problems with the ZCA stem from insufficient lubrication, inappropriate selection, or improper installation. In the event of trouble, carry out appropriate measures in accordance with this troubleshooting guide. Table 13 Troubleshooting Problem Possible Cause Solution  Reduce the load or replace with a new ZCA with sufficient ①...

  • Page 16: Diagram Of External Dimensions

    8. Diagram of External Dimensions Fig. 8 External Diagram (ZCA25) Table 14 Diagram Stroke Lmax Model No. (mm) (mm) (mm) (mm) ZCA25N030EL ZCA25N050EL - 12 -...
  • Page 17 Fig. 9 External Diagram (ZCA35) Table 15 Diagram Stroke Lmax Model No. (mm) (mm) (mm) (mm) ZCA35N050EL ZCA35N075EL 218.5 ZCA35N100EL 1000 1131 - 13 -...
  • Page 18 Fig 10 External Diagram (ZCA45) Table 16 Diagram Stroke Lmax Model No. (mm) (mm) (mm) (mm) ZCA45N100EL 1000 1250 ZCA45N150EL 1500 1008 1750 ZCA45N200EL 2000 1258 2250 - 14 -...
  • Page 19 9. With Motor, TERVO Thoroughly read the separate hypoid motor operating instructions before performing any operations. Table 17 List of Models with Motor (ZCA25M030, 050) Model No. Hypoid Motor Allowable start-up Speed frequency Rated Thrust (mm/sec) Model (times/min.) N｛kgf｝ Size Stroke Motor Reduction...
  • Page 20 Table 18 list of Models with Motor (ZCA35M050, 075, 100) Model No. Hypoid Motor Allowable start-up Speed frequency Rated Thrust (mm/sec) Model (times/min) N｛kgf｝ Size Stroke Motor Reduction 50Hz 60Hz 50Hz 60Hz Capacity Ratio ※1000 ｛※102.0｝ ※1000 ｛※102.0｝ (0.2kW) ※1000 ｛※102.0｝...
  • Page 21 Table 19 List of Models with Motor (ZCA45M100, 150, 200) Model No. Hypoid Motor Allowable start-up Speed frequency Rated Thrust (mm/sec) Model (times/min) N｛kgf｝ Size Stroke Motor Reduction 50Hz 60Hz 50Hz 60Hz Capacity Ratio ※2000 ｛※204.0｝ ※2000 ｛※204.0｝ (0.4kW) ※2000 ｛※204.0｝...
  • Page 22 Table 20 List of Models with TERVO (ZCA25K030, 050) Model No. Reducer for Servo Motor Rated Thrust Model Speed Size Stroke N｛kgf｝ (mm/sec) Motor Reduction Capacity Ratio ｛8.0｝ ｛20.0｝ 476.5 (0.2kW) 317.7 ｛33.6｝ 238.3 ※400 ｛※40.8｝ ZCA25 ｛8.0｝ 476.5 ｛20.0｝ (0.2kW) 317.7 ※330...
  • Page 23 Table 21 List of Models with TERVO (ZCA35K050, 075, 100) Model No. Reducer for servo motor Rated Thrust Model Speed N｛kgf｝ Size Stroke (mm/sec) Motor Reduction Capacity Ratio 178.6 ※1000 ｛※102.0｝ (0.4kW) ｛24.0｝ ★1000 ｛55.0｝ 714.5 (0.75kW) 476.3 ｛86.0｝ 357.3 ※1000 ｛※102.0｝...
  • Page 24 Table 22 List of Models with TERVO (ZCA45K100, 150, 200) Model No. Reducer for Servo Motor Rated Thrust Model Speed N｛kgf｝ Size Stroke (mm/sec) Motor Reduction Capacity Ratio ※2000 ｛※204.0｝ (0.4kW) ｛59.0｝ ★500 ｛78.0｝ 1000 ｛96.0｝ 1500 1240 ｛126.0｝ (0.75kW) 1578 ｛160.0｝...
  • Page 25 4. When a motor is attached with the ZCA25M and ZCA35M, the motor unit and fan cover’s bottom surface will extend beyond the bottom surface of the housing section. Contact a Tsubaki representative if the motor area will be used without attachments or if an attachment plate is needed.
  • Page 26 Approximate mass (kg) Motor Capacity Model No. ZCA25M030EL□□ 10.0 10.5 ZCA25M050EL□□ 10.5 11.0 ※Motor unit bottom surface will extend beyond the bottom surface of the housing section. Fig. 11 External Diagram with Motor (ZCA25M) - 22 -...
  • Page 27 Approximate mass (kg) Motor Capacity Model No. 0.2kW 0.4kW ZCA35M050EL□□ 14.0 18.0 ZCA35M075EL□□ 15.0 19.0 ZCA35M100EL□□ 16.0 20.0 Unit (mm) Motor Capacity 0.2kW 80.8 240.2 134.5 244.5 211.5 0.4kW 91.8 274.7 134.5 11.5 248.5 215.5 ※Motor unit bottom surface will extend beyond the bottom surface of the housing section.
  • Page 28 Approximate mass (kg) Motor Capacity Model No. 0.4kW 0.75kW ZCA45M100EL□□ 35.5 47.5 ZCA45M150EL□□ 40.0 51.5 ZCA45M200EL□□ 44.5 56.0 Unit (mm) Motor Capacity 0.4kW 252.5 225.5 268.5 0.75kW Fig. 13 External Diagram with Motor (ZCA45M) - 24 -...
  • Page 29 Approximate mass (kg) Motor Capacity Model No. 0.2kW ZCA25K030EL□□ ZCA25K050EL□□ Unit (mm) Motor Capacity 0.2kW 69.8 123.2 ※Motor unit bottom surface will extend beyond the bottom surface of the housing section. Fig. 14 External Diagram with TERVO (ZCA25K) - 25 -...
  • Page 30 Approximate mass (kg) Motor Capacity Model No. 0.4kW 0.75kW ZCA35K050EL□□ 12.0 21.5 ZCA35K075EL□□ 13.5 23.0 ZCA35K100EL□□ 14.5 24.0 Unit (mm) Motor Capacity 0.4kW 91.8 132.7 128.5 203.5 170.5 0.75kW 102.8 160.2 227.5 194.5 ※Be aware that dimensions are different depending on the mounting code.
  • Page 31 Approximate mass (kg) Motor Capacity Model No. 0.4kW 0.75kW ZCA45K100EL□□ 30.0 39.0 ZCA45K150EL□□ 34.0 43.0 ZCA45K200EL□□ 38.5 47.5 Unit (mm) Motor Capacity 0.4kW 110.5 223.5 180.5 0.75Kw 247.5 204.5 ※Be aware that dimensions are different depending on the mounting code. Above values are obtained from “E4HC”...
  • Page 32 9.3. Wiring ■ General Precautions 1. Do not operate the unit with the terminal box cover removed. 2. Double check that the motor has been wired correctly before performing a test operation. An incorrect phase will cause the ZIP CHAIN to run backwards, causing damage to the equipment. 3.
  • Page 33 Table 24 Wire Connection and relation to chain direction of travel (with Hypoid Motor) Motor Reduction Size Wire Connection A Wire Connection B Capacity Ratio 12.5 0.4kW 0.2kW 12.5 0.75kW 0.4kW ※Model number to be referred to Table 17 to 20 on page 15 to 20 - 29 -...
  • Page 34 Table 25 Wire Connection and relation to chain direction of travel (with TERVO) Motor Reduction Size Wire Connection A Wire Connection B Capacity Ratio 0.2kW 0.75kW 0.4kW 0.75kW 0.4kW ※Model No, to be referred to Table 20 to 22 on page 15 to 20 - 30 -...
  • Page 35 ■ Standard Terminal Box Specifications Table 26 Standard Terminal Box Motor size: 0.2kW / 0.4kW (resin) ZCA35 / ZCA45 Terminal box dimensions Terminal box position Motor size: 0.75kW (steel) ZCA45 Terminal box dimensions Terminal box position ■ Inverter Drive ・ ZCA25M motors (60W, 90W) A 200V class motor can be driven from the inverter unless it is operated at low frequency or a frequency of 60Hz or higher.
  • Page 36 (microsurges) generated from the inverter switching. As a result, measures against microsurges are generally required for such motors. Tsubaki 400V class of motor comes standard with micro surge protection. However, with levels in excess of 1200V, a suppression filter or reactor should be installed on the inverter side.
  • Page 37 4. Attaching and removing the plastic terminal box cover  Removing the cover Grasp the side of the terminal box cover as shown in the figure below and pull away to remove the cover  Attaching the cover Press the terminal box cover into the terminal box case from above until it snaps into place. Fig.
  • Page 38 Table 27 Wiring for Hypoid motor mini with brake (60W, 90W) ※ Applies to ZCA25 Three-phase motor, standard voltage Application (200V class)  General use  Standard shipping specifications  To shorten the stop time  When operating the brake individually Note: Use an auxiliary relay MCa with a rated load of...
  • Page 39 Table 28 Wiring for Hypoid motor with brake (200V class, ※ for ZCA35 and ZCA45) Three-phase motor 200V Three-phase motor 200V Application (0.2kW / 0.4kW) (0.75kW)  General use  Standard shipping specifications  To shorten the stop time  For inverters Place the inverter in the MC section ...
  • Page 40 Table 29 Models of varistor Model Product name Manufacturer For DM200D Surge Absorber Panasonic ERZV14D471 Zetrap Fuji Electric Device Technology ENE471D-14A Ceramic Varistor Nippon Chemi-Con TND14V-471KB00AAA0 ■ Hypoid Brake Motor Characteristics Table 30 Characteristics of hypoid motor with brake (Motor size: 0.2kW, 0.4kW, 0.75kW, three-phase motor as standard ※...
  • Page 41 Table 31 Characteristics of hypoid motor mini with brake (Motor size: 60W, 90W, three-phase motor as standard, ※ Applies to ZCA25) Hypoid motor mini Motor size Three-phase Single-phase Three-phase Brake model BXW-04-10M-05-90V BXW-04-10M-10-90V Single-phase Three-phase DM200D DC rectifier Single-phase DM100A Static friction torque 0.6 ｛6.1｝...
  • Page 42 9.5. Operation 9.5.1 Operation Warning ・ Do not operate the unit without the terminal box cover attached (if a terminal box is provided). Once maintenance work is complete, always return the cover to its original position to avoid shocks. ・ Do not come near any rotating parts while in operation to avoid risk of catching body parts in the unit and injury.
  • Page 43 4. Inspection immediately following first startup after installation or maintenance. In addition to the preceding points, check the following points immediately following first startup after installation or maintenance. a. Is the direction of rotation correct? b. Is the maximum current within the values indicated on the nameplate? c.
  • Page 44 Table 32 Motor troubleshooting guide Trouble Cause Solution Low voltage Check the length of the wiring ① Doesn’t turn over when a Gear wear Repair or replace motor. load is applied ② (chain doesn’t move) Overloaded operation Decrease the load ③...
  • Page 45 ZCA input shafts, leading to shaft damage. We recommend Tsubaki brand couplings for shaft connection. ・ There will be individual differences in backlash when using synchronized ZCA units, resulting in some mis-positioning.
  • Page 46 ・ Can be used interlocked when used in parallel with an input shaft passed through the units. ・ Position can be controlled by attaching an encoder to the input and opposite side shafts. *Encoder motors also available (ZCA35, ZCA45), contact a Tsubaki representative for more information. ※Same for ZCA25, ZCA45 Fig.
  • Page 47 1. Caution ZCA35N050☐T （ZCA①） ZCA35N050□L （ZCA②） The two units’ worth of the required input shaft torque will be transmitted by the input shaft to the ZCA on the drive source side. Confirm that the two units’ worth of torque is below the allowable input torque. T1: Necessary input torque for ZCA①...
  • Page 48 ・ The bellows will protrude slightly from the ZCA unit. Confirm that there is no interference especially when attaching a pulley, sprocket, or coupling to the input shaft. (See Fig. 23) ・ Bellows can be attached after installation. Contact a Tsubaki representative if you need to attach them later.
  • Page 49 Bellows Specification Thermoplastic polyurethane (black) comes with air vents with filter Fig. 23 With bellows attached – 1 (left: ZCA25, middle: ZCA35, right: ZCA45) Stainless steel band on top and bottom Stainless steel band on top and bottom Stainless steel band on top and bottom Fig.
  • Page 50 ・ The dimensions of the mounting base will vary depending on the combination of motor and options like bellows or grease plate. Contact a Tsubaki representative with the combination of options you are requesting to learn more about the dimensions.
  • Page 51 Fig. 25 With grease nipples (ZCA25) - 47 -...
  • Page 52 Fig. 26 With grease nipples (ZCA35) - 48 -...
  • Page 53 Fig. 27 With grease nipples (ZCA45) 100m 100m Grease all 4 nipples *2 nipples for ZCA25 Fig. 28 Greasing method using grease nipples (figure above shows ZCA35) - 49 -...

  • Page 54: Warranty

    Goods are returned to the Seller. This Warranty is only for the single piece of Tsubaki product, and does not cover the following: １) Any costs related to removal of Goods from the Buyer’s equipment for part repair or replacement.
  • Page 55 MEMO - 51 -...
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  • Page 58 The Tsubaki Eco Link logo is used only on products. that satisfy the standards for environmental friendliness set by the Tsubaki Group ■ Copyright All content in this manual is the copyright of Tsubakimoto Chain Co. Unauthorized reproduction is strictly prohibited.

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