M-235-UserManual-MP106-EN

MP106E
M-235 Linear Actuators

User Manual
Version: 1.2 Date: 31.08.2020
This document describes the following

high-load precision linear actuators with
recirculating ball screws:
 M-235.2DD:
Travel Range 20 mm, DC Direct Drive
 M-235.2DG:
Travel Range 20 mm, DC Gear Motor
 M-235.5DD:
Travel Range 50 mm, DC Direct Drive
 M-235.5DG:
Travel Range 50 mm, DC Gear Motor
Physik Instrumente (PI) GmbH & Co. KG · Auf der Römerstr. 1 76228 Karlsruhe, Germany
Telephon +49 721 4846-0 · Telefax +49 721 4846-1019 · E-Mail [email protected]
Physik Instrumente (PI) GmbH & Co. KG is the owner of the following trademarks:
PI®, PIC®, PICMA®, PILine®, PIFOC®, PiezoWalk®, NEXACT®, NEXLINE®,
NanoCube®, NanoAutomation®, Picoactuator®, PInano®
© 2020 Physik Instrumente (PI) GmbH & Co. KG, Karlsruhe, Deutschland. The text,
photographs and drawings in this manual are protected by copyright. With regard
thereto, Physik Instrumente (PI) GmbH & Co. KG retains all the rights. Use of said
text, photographs and drawings is permitted only in part and only upon citation of the
source.
Original instructions
Document number: MP106E, MMa, Version 1.2
Subject to change without notice. This manual is superseded by any new release. The
latest release is available for download on our website (http://www.pi.ws).
Contents
1 About this Document 1

1.1 Goal and Target Audience of this Manual ............................................................1
1.2 Symbols and Typographic Conventions ...............................................................1
1.3 Other Applicable Documents ................................................................................2
2 Safety 3
2.1 Intended Use ........................................................................................................3
2.2 General Safety Instructions ..................................................................................3
2.2.1 Organizational Measures ....................................................................4
2.2.2 Measures for Handling Vacuum-Compatible Products ......................4
2.2.3 Safety Measures during Installation ...................................................4
2.2.4 Safety Measures during Start-Up .......................................................5
2.2.5 Safety Measures during Operation .....................................................6
2.2.6 Safety Measures during Maintenance ................................................6
3 Product Description 7
3.1 System Overview ..................................................................................................8
3.2 Features and Applications ....................................................................................9
3.3 Model Overview ....................................................................................................9
3.4 Product View.......................................................................................................11
3.5 Scope of Delivery ...............................................................................................12
3.6 Suitable Controllers ............................................................................................12
3.7 Accessories ........................................................................................................12
3.8 Technical Features .............................................................................................12
3.8.1 Rotary Encoder .................................................................................12
3.8.2 Limit Switches ...................................................................................12
3.8.3 Reference Point Switch ....................................................................13
4 Unpacking 15
5 Installation 17
5.1 General Notes on Installation .............................................................................17
5.2 Changing the Tip ................................................................................................18
5.3 Providing a Suitable Mechanical Mounting and Installation Environment ..........21
5.4 Installing the Actuator in a Mechanical Mounting ...............................................23
6 Start-Up 27
6.1 General Notes on Start-Up .................................................................................27
6.2 Starting Up the Actuator .....................................................................................29
6.2.1 M235 Entries in the Stage Database of PI ......................................30
7 Maintenance 31
7.1 General Notes on Maintenance ..........................................................................31
7.2 Lubricating the M235 .........................................................................................31
7.3 Cleaning the M235 ............................................................................................32
8 Troubleshooting 33
9 Customer Service 35
10 Technical Data 37
10.1 Specifications......................................................................................................37
10.1.1 Data Table ........................................................................................37
10.1.2 Ambient Conditions and Classifications ...........................................38
10.1.3 Limit Switch Specifications ...............................................................39
10.1.4 Reference Point Switch Specifications .............................................39
10.2 Dimensions .........................................................................................................40
10.2.1 Actuator ............................................................................................40
10.2.2 End Pieces........................................................................................41
10.3 Pin Assignment D-Sub 15 (Male) Connector .....................................................42
11 Old Equipment Disposal 43
12 EU Declaration of Conformity 45
1 About this Document
In this Chapter
Goal and Target Audience of this Manual ..................................................................... 1
Symbols and Typographic Conventions ........................................................................ 1
Other Applicable Documents ......................................................................................... 2
1.1 Goal and Target Audience of this Manual

This manual contains information on the intended use of the M235.
It assumes that the reader has a fundamental understanding of basic servo systems
as well as motion control concepts and applicable safety procedures.
For updated releases of this user manual, or if you have any questions, contact our
customer service department (p. 35).
1.2 Symbols and Typographic Conventions

The following symbols and typographic conventions are used in this user manual:
CAUTION
Dangerous situation
If not avoided, the dangerous situation will result in minor injury.
 Actions to take to avoid the situation.
NOTICE
Dangerous situation
If not avoided, the dangerous situation will result in damage to the equipment.
 Actions to take to avoid the situation.
INFORMATION
Information for easier handling, tricks, tips, etc.
M-235 Linear Actuators MP106E Version: 1.2 1

Symbol Meaning
1. Action consisting of several steps whose sequential
2. order must be observed
 Action consisting of one or several steps whose

sequential order is irrelevant
 List item
p. 5 Cross-reference to page 5
RS-232 Labeling of an operating element on the product
(example: socket of the RS-232 interface)
1.3 Other Applicable Documents

The devices and software tools which are mentioned in this documentation are
described in their own manuals.
For the latest versions of the user manuals contact our customer service department
(p. 35).
Product Document
Linear actuators Short Instructions MP122EK
Suiting controller User Manual of the applied controller
2 Version: 1.2 MP106E M-235 Linear Actuators

2 Safety
2 Safety
In this Chapter
Intended Use ................................................................................................................. 3
General Safety Instructions ........................................................................................... 3
2.1 Intended Use

The M235 is a laboratory device as defined by DIN EN 61010-1. It is intended to be
used in interior spaces and in an environment which is free of dirt, oil, and lubricants.
Based on its design and realization, the M235 is intended for positioning, adjusting
and shifting loads in one axis at various velocities.
The intended use of the M235 is only possible when installed and with a suitable
controller (p. 12). The controller is not included in the scope of delivery of the M235.
2.2 General Safety Instructions

The M235 is built according to state-of-the-art technology and recognized safety
standards. Improper use can result in personal injury and/or damage to the M235.
 Only use the M235 for its intended purpose, and only use it if it is in a good
working order.
 Read the user manual.
 Immediately eliminate any faults and malfunctions that are likely to affect
safety.
The operator is responsible for the correct installation and operation of the M235.

2 Safety
2.2.1 Organizational Measures

User manual
 Always keep this user manual next to the M235.
If the user manual is lost or damaged, contact our customer service
department (p. 35).
 Add all information given by the manufacturer to the user manual, for example
supplements or Technical Notes.
 If you pass the M235 on to other users, also turn over this user manual as
well as all other relevant information provided by the manufacturer.
 Only use the device on the basis of the complete user manual. Missing
information due to an incomplete user manual can lead to slight injury as well
as property damage.
 Only install and operate the M235 after having read and understood this user
manual.
Personnel qualification
The M235 may only be started up, operated, maintained and cleaned by authorized
and qualified staff.
2.2.2 Measures for Handling Vacuum-Compatible Products

When handling the vacuum version of the linear actuator, attention must be paid to
appropriate cleanliness. At PI, all parts are cleaned before assembly. During assembly
and measurement, powder-free gloves are worn. Afterwards, the linear actuator is
cleaned once again by wiping and shrink-wrapped twice in vacuum-compatible film.
 Only touch the linear actuator with powder-free gloves.
 If necessary, wipe the linear actuator clean after unpacking.
2.2.3 Safety Measures during Installation

A cable break leads to a failure of the linear actuator.
 Install the linear actuator so that the cable is not bent or squeezed too
severely during operation.

2 Safety
The motion of the pusher can be hindered by a mounting nut that has been tightened
too strongly. This reduces the positioning accuracy.
 Tighten the mounting nut to a maximum torque of 1 Nm.
Lateral forces that affect the pusher of the linear actuator increase the friction on the
internal drive components. Increased friction impairs the motion of the pusher and
increases wear on the drive components.
 Avoid lateral forces on the tip and on the pusher of the M235.
While the end piece is being screwed on or off, the torque is transferred to the drive of
the linear actuator via the pusher and can damage the drive.
 Avoid torques to the pusher.
 When screwing an end piece on or off, attach the pusher to the wrench flats
using an open-end wrench.
The heat produced during operation of the M235 can affect your application.
 Install the M235 so that your application is not affected by the dissipating
heat.
2.2.4 Safety Measures during Start-Up

A motorized linear actuator can generate powerful forces depending on the gear ratio.
Connecting a linear actuator to an unsuitable controller can cause damage to the

linear actuator or controller.
 Connect a linear actuator with DC motor to a DC motor controller only.
 Connect a linear actuator with stepper motor to a stepper motor controller
only.
Faulty motor controllers can cause unintentional motor motion and run the M235 into
the hard stop.

2 Safety
The linear actuator can perform an unintentional motion when connecting it to the
motor controller.
 Do not place any objects in areas where they can get caught by moving parts.
 Keep your fingers at a safe distance from the motion range of the M235.
The collision of moving parts with the hard stop (end of travel range), as well as high
acceleration, can cause damage to, or considerable wear on the mechanical system.
 In the event of a malfunction of the motor controller, stop the motion
immediately.
 Ensure that theend of the travel range is approached at low velocity.
 Set your control signal so that the moving part does not stop abruptly or try to
continue moving at the end of the travel range.
 Determine the maximum velocity for your application.
 Ensure that the automatic limit switch halt is supported by the controller, or
that it is activated in the controller.
2.2.5 Safety Measures during Operation

For models with DC motors:
Unsuitable settings made to the servo-control parameters can impair the performance
of the M235. The consequences of this can be expressed as follows:
 Oscillations
 Imprecise approach of the position
 Settling time is too long
 If the performance of the M235 is not satisfactory, check the settings for the
servo-control parameters of your controller.
2.2.6 Safety Measures during Maintenance

The M235 is precisely aligned.
 Do not loosen any sealed screw.

3 Product Description
In this Chapter
System Overview ........................................................................................................... 8
Features and Applications ............................................................................................. 9
Model Overview ............................................................................................................. 9
Product View ............................................................................................................... 11
Scope of Delivery ........................................................................................................ 12
Suitable Controllers ..................................................................................................... 12
Accessories ................................................................................................................. 12
Technical Features ...................................................................................................... 12

3.1 System Overview

The following figure shows an overview of the total system.
Figure 1: Overall system, overview
To operate the actuator in your application, the following components are necessary:
Component Task Supplied by or available from PI

Peripheral control Loads configurations and control PC software (e.g. PIMikroMove)
equipment commands to the controller (e.g. PC included in the scope of delivery of
in connection with PC software). PI controllers.
Controller Controls the motions of the actuator. Stand-alone device or motor
controller card (PC add-on card).
Available separately, see section
"Suitable Controllers" (p. 12).
Actuator Produces the motions of the part to Here: linear actuator, type M235.
be driven or the load in your Present product.
application.
Cables  Peripheral control equipment to  Transmission cable between PC
controller: and controller.
Ensures the data Included in the scope of delivery
communication. of PI controllers.
 Controller to actuator:  Transmission cable between
Ensures the data communication controller and actuator:
and the power source of the Part of the actuator or included
actuator. in the scope of delivery of the
piezo actuator.

Component Task Supplied by or available from PI

Mechanical structure Ensures among other things the Only mounting nut (for mechanical
secure fixation of the actuator and connection) included in the scope of
thus a high repeatability. delivery of the actuator.
Mechanical coupling Establishes the connection between Also in case exchangeable parts can
the actuator and the load (pusher be used, all options are included in
with a separate end piece, the scope of delivery of the actuator
depending on the model). (e.g. end pieces).
Load Part to be driven. This is to be -
moved in your application.
If a motor controller card is used, the "controller" component and the connection
between the peripheral control equipment and the controller ("cable") are physically
inside of the PC.
3.2 Features and Applications

The motorized precision drives of the M235 series are linear actuators with travel
ranges of 20 mm or 50 mm. They stand out thanks to their high positioning resolution,
load capacity, velocity and lifetime in industrial applications. Their design with a low-
friction and backlash-free ball screw enables loads of up to 120 N to be moved with
minimum incremental motions of up to 100 nm (M-235.xxG and M-235.xxS models) or
500 nm (M-235.xxD models). The non-rotating end piece avoids wobbles and
supports very uniform motions.
Integrated limit and reference point switches, plus line drivers enable the simple
installation in automation solutions and protect the mechanical system of the actuator.
3.3 Model Overview

Ten standard versions of the M235 are available. All models are high-performance
linear actuators with a ball screw. They differ in terms of:
 Travel range
 Drive type

Model Travel range Drive type

20 mm 50 mm DC direct DC gearhead
M-235.2DD + +
M-235.2DG + +
M-235.5DD + +
M-235.5DG + +
 .For further technical data, see the specifications (p. 37).

PI also produces custom designs upon request. Custom designs can differ from the
described standard products in respect to dimensions, characteristics or other
technical data.
 If necessary, contact our customer service department (p. 35) directly.

3.4 Product View
Figure 2: Product view M-235 (in front: M-235.22S versio( no longer available)n, behind: M-235.5DG
version)
1 Wrench flat of the pusher

2 Pusher, non-rotating
3 M20 thread for mounting nut
4 Mounting nut for clamp connection
5 Mounting shaft
6 Window with position display
7 Sleeve for micrometer assembly
8 Sleeve for DC motor
9 Cable for connecting to the controller
10 Hand wheel for manually moving the pusher inwards and outwards
11 Stepper motor case with panel plug (not visible here) for connecting to
the controller
12 End piece, flat
13 Hole with M6 thread, 10 mm deep for integrating the end piece

3.5 Scope of Delivery

Order Number Items
M235 Linear actuator according to order (p. 9), with flat end piece
(assembled on delivery) and spherical end piece
MP122EK Short Instructions
3.6 Suitable Controllers

The M235 must be connected to a suitable controller (see data table, p.37).
The required PC software is included in the scope of delivery of the PI controllers. The
operation of the controllers is described in the corresponding user manuals.
3.7 Accessories
Order Description
Number
C-842.AP1 Adapter box PWM analog to operate M235 linear actuators with PWM
signals
To order, contact our customer service department (p. 35).
3.8 Technical Features

3.8.1 Rotary Encoder
The models with DC motors are equipped with a rotary encoder. A rotary encoder,
also called an incremental or incremental rotary encoder, is implemented at a rotating
point in the drivetrain, e.g. the motor shaft. To determine the relative position, the
controller counts the encoder signals, the so-called impulses.
3.8.2 Limit Switches

The M235 is equipped with non-contact, Hall-effect limit switches.
Each limit switch sends an overtravel signal on a dedicated line to the controller. The
controller then stops the motion. If the controller does not stop the motion in time, the
linear actuator runs into the hard stop.
See "Limit Switch Specifications" (p. 39) for more information.

3.8.3 Reference Point Switch

The M235 is equipped with a direction-sensing reference point switch, which is
located at about the midpoint of the travel range. This sensor sends a TTL signal
indicating whether the linear actuator is on the positive or negative side of the
reference point switch.
The rising or falling edge of this signal can be used to indicate a known reference
position. The difference in the reference points when approached from the positive or
the negative side is about 0.2 mm to 0.4 mm.
See the controller user manual and/or associated software manuals for the commands
which make use of the reference point signal.
For further details, refer to the "Specifications" section (p. 37).

4 Unpacking
4 Unpacking
INFORMATION
When handling the vacuum version of the linear actuator, attention must be paid to
appropriate cleanliness. At PI, all parts are cleaned before assembly. During
assembly and measurement, powder-free gloves are worn. Afterwards, the linear
actuator is cleaned once again by wiping and shrink-wrapped twice in vacuum-
compatible film.
 If necessary, wipe the linear actuator clean after unpacking.
1. Unpack the M235 with care.

2. Compare the contents against the items covered by the contract and against
the packing list.
3. Inspect the contents for signs of damage. If parts are missing or you notice
signs of damage, contact PI immediately.
4. Keep all packaging materials in case the product needs to be returned.

5 Installation
5 Installation
In this Chapter
General Notes on Installation ...................................................................................... 17
Changing the Tip ......................................................................................................... 18
Providing a Suitable Mechanical Mounting and Installation Environment ................... 21
Installing the Actuator in a Mechanical Mounting ........................................................ 23
5.1 General Notes on Installation

NOTICE
Torque on pusher!
While the end piece is being screwed on or off, the torque is transferred to the drive
of the linear actuator via the pusher and can damage the drive.
 Avoid torques to the pusher.
 When screwing an end piece on or off, attach the pusher to the wrench flats
using an open-end wrench.
NOTICE
Cable break!
A cable break leads to a failure of the linear actuator.
 Install the linear actuator so that the cable is not bent or squeezed too severely
during operation.
NOTICE
Increased friction!
Lateral forces that affect the pusher of the linear actuator increase the friction on the
internal drive components. Increased friction impairs the motion of the pusher and
increases wear on the drive components.
 Avoid lateral forces on the tip and on the pusher of the M235.

5 Installation
NOTICE
Heating up of the M-235 during operation!
The heat produced during operation of the M235 can affect your application.
 Install the M235 so that your application is not affected by the dissipating heat.
INFORMATION
Linear actuators with DC gear motors are equipped with integrated signal drivers for
cable lengths of ≤10 m between linear actuator and motor controller.
5.2 Changing the Tip

INFORMATION
The supplied end pieces make it possible to realize different mechanical connections
to a load:
 A flat end piece allows a wide-area connection to a load.
 A spherical end piece allows a punctiform connection to a load.
To achieve optimum repeatability:
 Use an end piece.
Make sure that the selected end piece is completely screwed in and does not have
any backlash.

5 Installation
The end piece is used to establish contact with the load. A flat end piece is delivered
pre-assembled; a spherical end piece is also provided.
Figure 3: Mounted end piece (flat)
1 End piece with

(a) wrench flat
2 Pusher with
(b) wrench flat
Prerequisites
 You have read and understood the General Notes on Installation (p. 17).
 You have made the M235 accessible for changing the end piece.
 The pusher has been moved out so far that you can easily reach the wrench
flat with a open-end wrench. Upon delivery, the pusher has been moved out
far enough.
Tools and accessories

 Supplied end piece (p. 12)
 Two AF 8 open-end wrenches

5 Installation
Figure 4: Changing the end piece, schematic
1 End piece (flat) with

(a) wrench flat
2 Non-turning pusher with
(b) wrench flat
3 Mounting shaft with
(b) thread (for clamp connection, M20)
(c) mounting nut
4 Sleeve
Changing the end piece

1. Attach the pusher: apply an AF 8 open-end wrench to the wrench flats of the
pusher.
2. Manually unscrew the end piece to be replaced from the pusher of the M235.
If this is not successful, use a second AF 8 open-end wrench.
3. Screw the new tip by hand into the pusher of the M235.
4. Remove the pusher from the open-end wrench.

5 Installation
5.3 Providing a Suitable Mechanical Mounting and

Installation Environment
Figure 5: Relevant components and dimensions for installation in the mechanical mounting (schematic)
1 Mounting nut, M20

2 Mounting shaft with
(a) diameter: 20 mm
(b) clamping width: 12 mm to 18 mm usable

5 Installation
Figure 6: Example for the installation of a linear actuator (here: an M-235)
A suitable mechanical mounting and installation environment are necessary for the
proper use of the actuator.
 Make sure that the following conditions have been met:
− Material and statics of the mounting are designed so that the static and
dynamic forces that occur can be safely and continuously managed.
− The dimensions of the mounting are adapted to the dimensions of the

actuator (see above figures and dimensions (p. 40)).
− The intended motions of the pusher and the load must not be inhibited by
the dimensions of the installation environment.
 Take into account the following specifications as well when planning the
application and installing the actuator:
− Dimensions of the selected end piece (see Dimensions (p. 40))
− Travel range: maximum 20 mm (M235.2xx models) or 50 mm

(M235.5xxmodels)
− Space requirements for a kink-free and proper guiding of the connection

cable and additional motor cables
− Length of the connection cable (approx. 0.5 m) and additional motor

cables (3 m or 10 m)
− Position of the position display of the actuator when it is to be read during

operation.
 If the limit switches of the actuator cannot be reached with the planned
minimum and maximum displacements: Make sure that the actuator and the
load only move within the planned range. Suitable measures:

5 Installation
− Corresponding programming of the controller
− Emergency off switch
− Automatic shutdown systems

 Avoid or label danger areas that result from the installation of the actuator and
from use, in accordance with the legal regulations (e.g. risk of crushing in the
case of heavy moving loads, fast actuator motions and/or high drive torques).
The complete dimensions of the actuator and relevant individual parts can be found in
the figures in the section Dimensions (p. 40).
5.4 Installing the Actuator in a Mechanical Mounting

NOTICE
Incorrect tightening torque of the mounting nut!
The motion of the pusher can be hindered by a mounting nut that has been tightened
too strongly. This reduces the positioning accuracy.
Tighten the mounting nut to a maximum torque of 1 Nm.
INFORMATION
To achieve an optimum repeatability, the mounting shaft must not have any
backlash.
 During mounting, make sure that there is a faultless connection between the
actuator and the mechanical mounting.

5 Installation
Figure 7: Clamp connection (schematic)
1 Mechanical mounting
2 Sleeve
3 Mounting nut, M20
4 Mounting shaft with thread
5 Pusher with end piece (flat)
We recommend installing the actuator in the mechanical mounting with a clamp

connection. The following instructions refer to this case.
Prerequisites
 You have read and understood the General Notes on Installation (p. 17).
 You have provided your application with a suitable mounting for the mounting
shaft of the actuator (p. 21).
Tools and accessories

 Open-end wrench SW 24
Installing the actuator

1. Loosen the mounting nut on the mounting shaft of the actuator.
2. Position the actuator in the mounting of your application.
3. If necessary, stick a suitable flat washer or a suitable spring washer on the
mounting shaft.

5 Installation
4. Manually screw the mounting nut into the thread of the mounting shaft with a
few rotations.
5. To clamp the actuator in the mounting, tighten the mounting nut using the
open-end wrench until you feel a resistance. The torque must not exceed
1 Nm!
6. Check that the actuator is correctly fitted in the mounting.

6 Start-Up
6 Start-Up
In this Chapter
General Notes on Start-Up .......................................................................................... 27
Starting Up the Actuator .............................................................................................. 29
6.1 General Notes on Start-Up
CAUTION
Unintentional motion of the linear actuator while connecting it to the motor
controller!
 Do not place any objects in areas where they can get caught by moving parts.
 Keep your fingers at a safe distance from the motion range of the linear actuator.
NOTICE
Damage if a wrong motor controller is connected!
Connecting a linear actuator to an unsuitable controller can cause damage to the
linear actuator or controller.
 Connect a linear actuator with DC motor to a DC motor controller only.
 Connect a linear actuator with stepper motor to a stepper motor controller only.
NOTICE
Damage due to the pusher crashing into the hard stop!
When the limit switches are deactivated, the motion of the pusher is aborted by the
hard stop and the M235 can be damaged.
 Do not deactivate the limit switches in the software.
 Test limit switch operation at low velocities only.

6 Start-Up
NOTICE
Damage or major wear to the mechanical system as a result of high
acceleration!
 In the event of a malfunction of the motor controller, stop the motion
immediately.
 Ensure that the end of the travel range is approached at low velocity.
 Set your control signal so that the moving part does not stop abruptly or try to
continue moving at the end of the travel range.
 Determine the maximum velocity for your application.
NOTICE
Damage from unsuitable controllers and PC software!
Unsuitable controllers and PC software can cause damage to the actuator.
 If you use controllers and software from other manufacturers, before starting up
the actuator, check the technical data to make sure that they are suitable!
INFORMATION
The maximum velocity for a linear actuator with a stepper motor should be
determined in the application. If the commanded velocity is too high, the stepper
motor might stop without the controller detecting this condition.
INFORMATION
The handwheel of a linear actuator with stepper motor can be used to manually
retract and extend the pusher. Manually triggered changes in the position of the
pusher are not recognized by the connected controller.
INFORMATION
The repeatability of the positioning is only ensured when the reference point switch is
always approached from the same side. Motor controllers from PI fulfill this
requirement with their automatic direction detection for reference moves to the
reference point switch.
28 Version: 1.2 MP106E 5

6 Start-Up
INFORMATION
For models with DC motors:
Unsuitable settings made to the servo-control parameters can impair the
performance of the M235. The consequences of this can be expressed as follows:
 Oscillations
 Imprecise approach of the position
 Settling time is too long
 If the performance of the M235 is not satisfactory, check the settings for the
servo-control parameters of your controller.
INFORMATION
Moving the pusher outwards corresponds to the positive direction of motion.
6.2 Starting Up the Actuator

In the following, a PC with PC software is used as the peripheral control equipment of
the controller.
Prerequisites
 You have read and understood the General Notes on Start-Up (p. 27).
 You have correctly installed the actuator (p. 17).
 You have read and understood the user manual of the used controller.
 You have read and understood the manual of the used PC software.
Accessories
 Suitable controller (p. 12) - motor controller card for PC installation or stand-
alone device incl. connection cable to PC.
 PC
 PC software for the controller (for PI controllers: included in their scope of
delivery)
 If necessary, suitable motor (extension/adapter) cable from PI.

6 Start-Up
Starting up the actuator

1. If you use a motor controller card (e.g. C-843 from PI), make sure that it is
properly installed or install it (see the user manual of the motor controller
card).
2. If suitable and current PC software for the controller is not on your PC yet,
install the PC software (see the user manual of the controller or the software).
3. If you do not use a motor controller card, connect the PC with the external
controller using a suitable cable.
For PI products: the cable required for this is included in the scope of delivery.
4. Connect the actuator with the controller:
a) Determine the minimum necessary cable length between the actuator and
the controller.
b) Connect the connector of the connection cable with the Sub-D socket of
the controller or a corresponding adapter (according to the determined
length, see above) either directly or by interposing an additional motor
cable.
c) Secure all connections with the integrated screws against accidental
disconnection.
d) Remove or label resulting danger areas in accordance with the valid legal
regulations and directives.
5. Start up the controller (see user manual of the controller).
6. Configure the controller using the PC software for the used actuator (see the
user manual of the controller and the PC software):
− If you use a PI controller: select the entry in the stage database that
precisely matches the actuator version used.
− If you use a controller from another manufacturer: Enter the parameters in

the corresponding PC software that precisely match the actuator version
used.
7. Start a few motion cycles for testing purposes (see user manual of the
controller).
6.2.1 M-235 Entries in the Stage Database of PI

For motor controllers from PI you can select the connected linear actuator from a
stage database in the respective PC software. The appropriate operating parameters
are thus loaded into the motor controller. You can find a detailed description in the
user manual for the motor controller or in the manual for the PC software used.
30 Version: 1.2 MP106E 5

7 Maintenance
7 Maintenance
In this Chapter
General Notes on Maintenance ................................................................................... 31
Lubricating the M235 .................................................................................................. 31
Cleaning the M235 ..................................................................................................... 32
7.1 General Notes on Maintenance
NOTICE
Damage due to improper maintenance!
The M235 can become misaligned as a result of improper maintenance.
 Do not loosen any sealed screws.
7.2 Lubricating the M-235

Depending on the operational conditions and the period of use of the linear actuator,
the following maintenance measures are required.
Spreading lubricant
 If you operate the M235 continuously on a small travel range (<20% of the
entire travel range), perform a maintenance run every 2000 motion cycles
across the entire travel range.
Lubrication
Under laboratory conditions, the linear actuator needs extra lubrication in exceptional
cases only. For continuous industrial use the lubrication intervals must be defined
individually.
 Do not lubricate the M235 without consulting our customer service
department (p. 35).
 To lubricate, follow the instructions given in the maintenance manual which
you can obtain from our customer service department.

7 Maintenance
7.3 Cleaning the M-235

Prerequisites
 You have disconnected the linear actuator from the controller.
Cleaning the linear actuator

Only when the linear actuator is not used in vacuum:
 When necessary, clean the linear actuator surface with a towel lightly
dampened with a mild cleanser or disinfectant.
 Do not use any organic solvents.
Only when the linear actuator is used in vacuum:
 If necessary, wipe the linear actuator clean.

8 Troubleshooting
8 Troubleshooting
Problem Possible Causes Solution

Reduced positioning Mounting nut is fastened too  Tighten the mounting nut to a
accuracy tight maximum torque of 1 Nm.
Drive damaged due to torque  Contact our customer service
on pusher department
Functional impairment  Controller has been Controller from PI:
after system modification replaced  Load the parameters from the stage
 M235 has been replaced database that correspond to the
with another model combination of controller and M235
model (p. 29).
Controller from a third-party supplier:
 Check the operating parameters
The mechanical system The cable is not connected  Check the connecting cable.
does not move correctly or is faulty
Lateral forces are affecting the Lateral forces increase the friction on
pusher the internal drive components.
 Avoid lateral forces on the tip and
on the pusher of the M235.
The mechanical system Values for the velocity,  Reduce the velocity.
does not move, but acceleration and/or load are too  Reduce the acceleration.
generates operating high  Reduce the load on the mechanical
noise system.
The mechanical system  Velocity is too high (see 1. Stop the motor.
did not stop in time and chapter Limit Switches 2. Command the mechanical system
ran into the hard stop p. 12) away from the hard stop.
 Limit switch is defective 3. Check the settings of the controller
 Controller ignores the limit for the limit switch processing.
switch signal
If the problem that occurred with your system is not listed in the table above or it
cannot be solved as described, contact our customer service department (p. 35).

9 Customer Service
9 Customer Service
For inquiries and orders, contact your PI sales engineer or send us an e-mail
(mailto:[email protected]).
If you have questions concerning your system, have the following information ready:
 Product codes and serial numbers of all products in the system

 Firmware version of the controller (if present)
 Version of the driver or the software (if present)
 Operating system on the PC (if present)
The latest versions of the relevant user manuals for your system are available for
download on our website (http://www.pi.ws).

10 Technical Data
10 Technical Data
In this Chapter
Specifications .............................................................................................................. 37
Dimensions .................................................................................................................. 40
Pin Assignment ............................................................................................................ 42
10.1 Specifications
10.1.1 Data Table
Motion and positioning M-235.2DG / M-235.5DG M-235.2DD / M-235.5DD Unit Tolerance
Motion and positioning
Travel range 20 / 50 20 / 50 mm
Integrated sensor Rotary encoder Rotary encoder
Sensor resolution 2048 2048 cts./rev.
Design resolution 0.016 0.5 µm typ.
Minimum incremental motion 0.1 1.5 µm typ.
Backlash 2 2 µm typ.
Unidirectional repeatability ±0.1 ±0.5 µm typ.
Velocity 2 30 mm/s max.
Mechanical properties
Gear ratio 29.6:1 –

Push/pull force 120 50 N max.
Permissible lateral force 8 8 N max.
Drive properties
Motor type DC gear motor DC motor

Operating voltage 0 to ±12 0 to ±12 V
Motor power 4 17 W nominal
Reference and limit switches Hall effect Hall effect

10 Technical Data
Motion and positioning M-235.2DG / M-235.5DG M-235.2DD / M-235.5DD Unit Tolerance
Miscellaneous
Operating temperature range -20 to 65 -20 to 65 °C

Material Aluminum anodized, Aluminum anodized,
chrome steel chrome steel
Mass 0.55 / 0.7 0.5 / 0.65 kg ±5 %
Cable length 0.5 m 0.5 m m ±10 mm
Connector D-sub 15 (m), incl. D-sub 15 (m), incl.
encoder driver encoder driver
Recommended controllers / C-863 C-863
drivers C-884 C-884
10.1.2 Ambient Conditions and Classifications

The following ambient conditions and classifications must be observed for the M235:
Area of application For indoor use only

Maximum altitude 2000 m
Relative humidity Highest relative humidity 80% for temperatures
up to 31°C
Decreasing linearly to 50% relative humidity at
40°C
Storage temperature 0°C to 80°C
Transport temperature 0°C to 80°C
Supply fluctuations Not more than ±10% of the nominal voltage
Degree of pollution 2
Degree of protection IP40
according to IEC 60529

10 Technical Data
10.1.3 Limit Switch Specifications

Type Magnetic (Hall-effect) sensor
Supply voltage +5 V/ground
Signal output TTL level
Signal logic The signal level changes when passing the limit switch.
The signal logic depends on the model type:
 Models with DC motor: active high. That means:
− Normal motor operation:
low (0 V)
− Limit switch reached: high (+5 V)
 Models with stepper motor: active low. That
means:
− Normal motor operation:
high (+5 V)
− Limit switch reached: low (0 V)
10.1.4 Reference Point Switch Specifications

Type Magnetic (Hall-effect) sensor
Supply voltage +5 V/GND
Signal output TTL level
Signal logic Direction sensing by means of different signal levels on the left and
right side of the reference point switch: The signal level changes
from 0 to +5 V when the reference point switch is passed

10 Technical Data
10.2 Dimensions
10.2.1 Actuator
Dimensions in mm. Note that the decimal places are separated by a comma in the
drawings.
Figure 8: M-235.xDx and M-235.xVx, dimensions in mm

10 Technical Data
10.2.2 End Pieces

Dimensions in mm. Note that the decimal places are separated by a comma in the
drawings.
Figure 9: Low-profile top piece (left) and spherical end piece (right)

10 Technical Data
10.3 Pin Assignment D-Sub 15 (Male) Connector
Pin no. Function

1 Internal
9 Input: Motor (-)
2 Input: Motor (+)
10 Internal
3 Internal
11 Internal
4 Input: +5 V supply from controller
12 Output: Limit switch signal, negative side
5 Output: Limit switch signal, positive side
13 Output: Reference point switch signal
6 GND (limit switch and logic)
14 Output: Encoder A (+)
7 Output: Encoder A (-)
15 Output: Encoder B (+)
8 Output: Encoder B (-)

11 Old Equipment Disposal
11 Old Equipment Disposal
Since 13 August 2005, in accordance with the EU directive 2002/96/EC (WEEE),

electrical and electronic equipment can no longer be disposed of in the member states
of the EU with other wastes.
When disposing of your old equipment, observe the international, national and local
rules and regulations.
To meet the manufacturer’s product responsibility with regard to this product, Physik
Instrumente (PI) GmbH & Co. KG ensures environmentally correct disposal of old PI
equipment that was first put into circulation after 13 August 2005, free of charge.
If you have old PI equipment, you can send it postage-free to the following address:
Physik Instrumente (PI) GmbH & Co. KG

Auf der Römerstr. 1
D-76228 Karlsruhe, Germany

12 EU Declaration of Conformity
12 EU Declaration of Conformity

M-235-UserManual-MP106-EN

Uploaded by

Copyright:

Available Formats

M-235-UserManual-MP106-EN

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

M-235-UserManual-MP106-EN

Uploaded by

Copyright:

Available Formats

MP106E

M-235 Linear Actuators

Version: 1.2 Date: 31.08.2020

This document describes the following

1 About this Document 1

11 Old Equipment Disposal 43

1 About this Document

1.1 Goal and Target Audience of this Manual

1.2 Symbols and Typographic Conventions

M-235 Linear Actuators MP106E Version: 1.2 1

 Action consisting of one or several steps whose

1.3 Other Applicable Documents

2 Version: 1.2 MP106E M-235 Linear Actuators

2.1 Intended Use

2.2 General Safety Instructions

M-235 Linear Actuators MP106E Version: 1.2 3

2.2.1 Organizational Measures

2.2.2 Measures for Handling Vacuum-Compatible Products

2.2.3 Safety Measures during Installation

4 Version: 1.2 MP106E M-235 Linear Actuators

2.2.4 Safety Measures during Start-Up

Connecting a linear actuator to an unsuitable controller can cause damage to the

M-235 Linear Actuators MP106E Version: 1.2 5

2.2.5 Safety Measures during Operation

2.2.6 Safety Measures during Maintenance

6 Version: 1.2 MP106E M-235 Linear Actuators

M-235 Linear Actuators MP106E Version: 1.2 7

3.1 System Overview

Figure 1: Overall system, overview

Component Task Supplied by or available from PI

8 Version: 1.2 MP106E M-235 Linear Actuators

Component Task Supplied by or available from PI

3.2 Features and Applications

3.3 Model Overview

M-235 Linear Actuators MP106E Version: 1.2 9

Model Travel range Drive type

 .For further technical data, see the specifications (p. 37).

10 Version: 1.2 MP106E M-235 Linear Actuators

3.4 Product View

1 Wrench flat of the pusher

M-235 Linear Actuators MP106E Version: 1.2 11

3.5 Scope of Delivery

3.6 Suitable Controllers

To order, contact our customer service department (p. 35).

3.8 Technical Features

3.8.2 Limit Switches

12 Version: 1.2 MP106E M-235 Linear Actuators

3.8.3 Reference Point Switch

M-235 Linear Actuators MP106E Version: 1.2 13

1. Unpack the M­235 with care.

M-235 Linear Actuators MP106E Version: 1.2 15

5.1 General Notes on Installation

M-235 Linear Actuators MP106E Version: 1.2 17

5.2 Changing the Tip

18 Version: 1.2 MP106E M-235 Linear Actuators

Figure 3: Mounted end piece (flat)

1 End piece with

Tools and accessories

M-235 Linear Actuators MP106E Version: 1.2 19

Figure 4: Changing the end piece, schematic

1. Unpack the M235 with care.

− Travel range: maximum 20 mm (M235.2xx models) or 50 mm