Mechanical Edition for Unloader

CZ-1700
CZ-1700s
Operation Manual
INTRODUCTION
Thank you for purchase of the Star Traverse Automatic Unloader <CZ-1700(s) >.
When linked to a molding machine, the unloader will automatically remove products from the
mold and transport them to a conveyor belt to other designated location.
This manual describes the unloader's functions and presents important information about
operating methods and precautions.
Please read through this manual carefully so that you will be able to use the unloader safely and
effectively. Keep this manual in a place of easy access.

* This manual describes the standard model. For optional specifications, refer to corresponding
separate manuals.
CONTENTS

1. FOR SAFE OPERATION .................................................................. 1

1-1. Manual Organization ......................................................................................... 1
1-2. Safety-Precaution Indications ............................................................................ 1
1-3. Safety-Precaution............................................................................................... 2
1-4. Locations of Warning Labels ............................................................................. 6
1-5. Mechanical Specifications ................................................................................. 7

2. NAMES OF THE PARTS AND THEIR FUNCTIONS ...................... 8

2-1. Configuration Diagram ...................................................................................... 8
2-2. Motion Patterns.................................................................................................. 8
2-3. Product-Side Vertical Unit ................................................................................. 9
2-4. Runner-Side Vertical Unit (S model) ............................................................... 12
2-5. Crosswise Unit ................................................................................................. 14
2-6. Traverse Rail Unit ............................................................................................ 15
2-7. Valve Unit ........................................................................................................ 16
2-8. Locations of Limit Switches ............................................................................ 18

3. MAINTENANCE AND INSPECTION.............................................. 20

„ Maintenance and Inspection Table ............................................................................ 21
„ Lubrication diagram .................................................................................................. 22
„ Oiling ......................................................................................................................... 23
„ Grease ........................................................................................................................ 23

4. PARTS LIST..................................................................................... 24

5. EXPENDABLE PARTS LIST .......................................................... 26

6. LIST OF DRIVE COMPONENTS FOR EACH AXIS ..................... 27

7. AIR CIRCUIT DIAGRAM................................................................. 30

8. OVERALLDIAGRAM....................................................................... 34
1. FOR SAFE OPERATION
1-1. Manual Organization
This manual includes important safety precautions relating to unloader functions, settings,
maintenance, and operation. Please observe these precautions so as to ensure safe operation at
the unloader.
For this machine, in addition to the operation manual for the unloader, the control box "Operation
Guide," "Operation Edition" and "Technical Edition" are provided. Please read through all of
these manuals carefully before beginning use of the unloader.
* Only the operation guide for the CZ type (STEC-NA1a) is available.

1-2. Safety-Precaution Indications

z Symbol of danger levels
Cautions are classified depending into the following three levels on risks or damage that
may arise from improper operation.

Indicates that misapplication of the machine will

DANGER lead to death or critical injury.

Indicates that misapplication of the machine might

WARNING lead to death or critical injury.

Indicates that misapplication of the machine may

CAUTION lead to bodily injury or property damage.

z Point
Important points for operation procedures are displayed with mark in this manual.

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1-3. Safety-Precaution

DANGER
z Do not enter the operation range.

Do not enter the operation range of the machine. You may be caught or lodged in the
machine resulting in injury.

z Do not maintain the machine during operation.

Do not maintain the machine while it is in operation. When performing maintenance

tasks, ensure that the air supply has been cut off, the power to the controller and pendant
has been switched off, and the power breaker has been cut.

WARNING
z Clothing must be proper for working.

Wear proper clothes for working. To avoid injury from trapping, do not wear too large
clothes or costume jewelry/accessories.

z Do not modify the machine.

Do not modify the machine. STAR assumes no responsibility for accidents or failures
caused by modifications to the machine by users.

z Ground the machine.

To avoid electric shock, ground the machine in accordance with the relevant regulation in
your country. When a routine inspection is made or the conveyor is relocated, check that
the machine is grounded appropriately.

z Use a non-fuse circuit breaker.

To prevent fire resulting from overcurrent, use a non-fuse circuit breaker for wiring to the
power source.

z Do not open the electric box.

A high voltage is applied in the electric box. Opening it may result in electric shock or injury.

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z Do not touch the machine during operation.

To prevent trapping accidents, do not insert your hand in the machine while it is running.

z Shut down operation during periods of frequent power outage.

The machinery should be shut down during times when power supply is frequently going
off due to thunderstorm or other such external event. Operating with an irregular power
supply may lead to equipment damage.

CAUTION
z Determine the supervisor for performing operation.

Determine the supervisor when teaming up with one or more operators for making
machine adjustments, etc. Under the supervision of the person, the members must give
signals before performing each step and must make sure of safety to avoid accidents or
mistakes due to carelessness during operation.

z Pneumatic source

To protect pneumatic components from damage, supply dry air using a dryer. After-coolers and
air dryers are available from STAR. Contact your local distributor when necessary.

z Read this instruction manual thoroughly.

Read and follow the operational procedures and precautionary remarks provided in this manual.

z Provide an enough maintenance room around the machine.

Provide a 1-m-wide or larger maintenance room around the machine for safe operation.

z Tidy up the area around the machine.

Tidy up the area around the machine, and keep the area well illuminated.

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z Perform maintenance daily.

Perform maintenance daily and check that the machine is in normal conditions. Contact
your local distributor in the event of failure.

z Stop operation in the event of failure or abnormality.

If an abnormality or failure is found during operation, stop the machine and follow the
directions from your local distributor.

z When running the machinery...

Never touch keys or switches with wet or dirty hands.

z Do not use the machine under the following environment.

• Place where ambient temperature is 0° and less or 40° and more.

• Place where the machine is exposed to dust, chemicals or steam.
• Place where it is highly humid and condensation occurs.
• Place where strong electric field or magnetic field occurs.
• Place where it is poorly ventilated.
• Place where heavy vibration occurs.

z Post clear indication of ongoing maintenance and repair work.

When carrying out inspection, repair, adjustment, cleaning, or lubrication work within the
unloader's movement range, be sure to lock the POWER switch. Post an appropriate sign
on the operation Panel to ensure that no one switches on the machinery while work is in
progress.

z Use secure scaffolding.

Some inspection, repair, adjustment, cleaning, and lubrication work must be carried out
while standing on a platform or scaffold. Be sure that the stand is securely set up, and wear
a safety belt.

z Stop all linked devices when working on the unloader.

Before carrying out inspection, repair, adjustment, cleaning, or lubrication work within
the unloader's movement range, you must shut down not only the unloader itself but also
all devices that are linked to it (such as the molding machine and conveyor).

-4-
List of hexagon wrench size and min. tightening torque

Dim. Min. Tightening Tightening Point of

Bolt Hexagon Length
C torque Nm force F as a application of
size wrench size L1 x L2 (mm)
(mm) (kgf•cm) guide (kgf) force L3 (mm)

M4 3 3.0 20 x 125 3.0 (30) 6.0 50

M5 4 4.0 25 x 150 6.2 (63) 6.3 100
M6 5 5.0 28 x 165 9.9 (101) 10.1 100
M8 6 6.0 32 x 180 22.0 (224) 14.9 150
M10 8 8.0 36 x 200 48.0 (490) 16.3 300
M12 10 10.0 40 x 225 86.0 (878) 14.6 600
M14 12 12.0 50 x 125 114.0 (1163) 19.3 600
M16 14 14.0 50 x 140 142.0 (1449) 24.2 600
M20 17 17.0 60 x 180 276.0 (2816) 21.7 1300
M24 19 19.0 80 x 180 495.0 (5051) 38.8 1300

<Caution>
z Tighten bolts at least with the standard torque specified above.
z After tightening a bolt, be sure to check that it is secured on the tightening
surface.
Shallow tightening tap or clogged chips inside the tap may prevent a bolt
from being tightened even when it's been tightened with the specified torque.
z Use values of the tightening force F and the point of application of force L3
as guides.
z Check bolts for looseness every month.

-5-
1-4. Locations of Warning Labels
The following diagram shows the location and content of caution plates affixed to the unloader.

z Example of caution plates disposition

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1-5. Mechanical Specifications
Model CZ-1700 CZ-1700s

Power supply 200-220VAC ±10% 50/60Hz

Power facility capacitance 5.3kVA 7.6kVA

Required power 2.75kW 3.9kW

0.49MPa [5kgf/cm2]
Normal air pressure
(No water content or dust allowed in air)

Maximum permissible air pressure 0.69MPa [7kgf/cm2]

Product-side AC servo motor

Vertical
Runner-side

Driving Product-side AC servo motor AC servo motor

Crosswise
method Runner-side

Traverse AC servo motor

Posture Air cylinder

Product-side
1700 (2000)
[mm]
Vertical
Runner-side
1750 (2050)
[mm]

Product-side
Stroke 1300 1132
[mm]
Crosswise
Runner-side
1132
[mm]

Traverse [mm] 2500 (3000)

Posture 90°

Cylinder Maxi. Load weight (kg)

25 (35)
output *(including weight of chuck)
(at 0.49MPa) Posture torque (Nm) 88

Air consumption (N /cycle) 53.05

* The details written in parenthesis indicate optional.
* These specifications are subject to change without prior notice.

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2. NAMES OF THE PARTS AND THEIR FUNCTIONS
2-1. Configuration Diagram
Runner-side vertical unit
Product-side vertical unit

Driver box

Solenoid valve unit

Crosswise unit

Traverse rail unit

2-2. Motion Patterns

zProduct side zRunner side

2003

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2-3. Product-Side Vertical Unit

1 First stage vertical slider

This slider moves up and down driven by the AC servomotor.
2 Vertical link-less cable chain
Protects the first stage vertical slider's pipe and wire guide.
3 First stage vertical toothed belt(Iron rubber AT belt)
The first stage vertical slider move up and down.
4 Second stage vertical toothed belt (Iron rubber AT belt)
The second stage vertical slider and the posture section move up and down.
5 Crosswise link-less cable chain
Protects the crosswise pipe and wire guide.
6 First stage vertical LM guide
This guide supports the first stage vertical movements of the vertical slider.
7 Balancer cylinder
This cylinder lifts always the vertical slider with air pressure set with the regulator to make the
load to the AC servo motor uniform at the time of ascent and descent.
8 Vertical AC servo motor
This motor drives the vertical slider.
9 Second stage vertical LM guide
This guide supports the second stage vertical movements of the vertical slider.
10 Crosswise home position proximity switch (LHW)
This switch detects the home position (0 mm) of the crosswise stroke.
11 Interference prevention proximity switch dog(for L33, S model)
Detects interference with the product side and runner side vertical units.

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1 Chuck mounting plate (link bracket)
The chuck is mounted on this plate.

CAUTION
Do not use a bolt that is longer than necessary for securing the chuck plate to
the link bracket. A bolt protruding from the back of the link bracket may cause
damage to the bearing holder or other articles.

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2 Joint for chuck section air piping (half union)
Connects the air piping in the chuck section.

POINT
When removing the air piping (hose) from the joint, remove the hose while pressing the
ring at the port in the parallel direction. Since a joint with check valve is used, when the air
piping is removed, air feeding stops.

3 Vertical home position proximity switch (LHV)

This switch detects the home position (0 mm) of the vertical stroke.
4 Ascent end proximity switch (L3)
This switch confirms the completion of the ascending of the vertical slider.
5 Posture action speed controller
This controller controls the posture action speed.
6 Posture action limit auto switch (L9)
This switch confirms the completion of the posture action.
7 Posture return limit auto switch (L8)
This switch confirms the completion of the posture return.
8 Posture return speed controller
This controller controls the posture return speed.
9 Ascent and vertical home position proximity switch dog (for LHV and L3)
This dog is used for activation of the ascent end vertical home position proximity switch.
10 Posture cylinder
This cylinder turns the posture section 90°.

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2-4. Runner-Side Vertical Unit (S model)

1 First stage vertical slider

This slider moves up and down driven by the AC servomotor.
2 Vertical home position proximity switch (LHVS)
This switch detects the home position (0 mm) of the vertical stroke.
3 Ascent end proximity switch (L3S)
This switch confirms the completion of the ascending of the vertical unit.
4 Crosswise home position proximity switch (LHS)
This switch detects the home position (0 mm) of the crosswise stroke.
5 Second stage vertical toothed belt(Iron rubber AT belt)
The second stage vertical slider move up and down.
6 First stage vertical toothed belt(Iron rubber AT belt)
The first stage vertical slider move up and down.
7 Vertical AC servo motor
This motor drives the vertical slider.
8 Crosswise home position proximity switch dog (LHS)
This dog is used for activation of the crosswise home position proximity switch.
9 Interference prevention proximity switch (L33)
Detects interference with the product side and runner side vertical units.
10 Vertical link-less cable chain
Protects the first stage vertical slider's pipe and wire guide.
11 Balancer cylinder
This cylinder lifts always the vertical slider with air pressure set with the regulator to make the
load to the AC servo motor uniform at the time of ascent and descent.

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1 First stage vertical LM guide
This guide supports the first stage vertical movements of the vertical slider.
2 Second stage vertical LM guide
This guide supports the second stage vertical movements of the vertical slider.
3 Runner-side crosswise toothed belt (Iron rubber AT belt)
This belt advanced and returns the runner-side vertical slider.
4 Runner confirmation sensor in chuck (L4S)
This sensor confirms the chucking of the runner.
5 Runner chuck
This chuck chucks the runner.

- 13 -
2-5. Crosswise Unit

1 Runner-side AC servo motor for crosswise movement (S model)

This motor drives the runner-side vertical unit in the crosswise direction.
2 Product-side AC servo motor for crosswise movement
This motor drives the product-side vertical unit in the crosswise direction.

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2-6. Traverse Rail Unit

1 Valve unit
2 AC servo driver
For the details, refer to the controller Operation Manual <Technical Edition>.
3 Carriage unit relay circuit (NA1 I/O)
4 Vacuum generator (TACOVAM)
(Refer to the corresponding operation manual.)
5 Traverse drive AC servo motor
This motor drives the traverse movements.
6 Traversal toothed belt (Iron rubber AT belt)
7 Traverse LM guide
8 Precision regulator
Balances air in the product side vertical cylinder.
9 Filter regulator
(Refer to the corresponding operation manual.)
10 Traverse home position proximity switch (L1)
This switch detects the traverse home position.
11 Traverse home position proximity switch dog (for L1)
This dog is used for activation of the traverse home position proximity switch.
12 Interlock box

- 15 -
2-7. Valve Unit

CAUTION
• Never attempt to adjust the air cylinder while automatic operation is
in progress, as this can be dangerous. Switch operation to
MANUAL mode before making the adjustment.

• Do not set the air cylinder speed too high, as this may result in
equipment damage. Begin adjustment at slow speed, and increase
the speed gradually to the appropriate level.

• When possible, avoid using the manual operation button on the

solenoid valve. Instead, execute operation from the control box.
If you cannot avoid using the switch on the valve, proceed with
care. Note that wiring and piping may move in unison with the air
cylinder: be careful to avoid entanglement.

• Note that the solenoid valve may become hot during operation, and
may remain hot for some time after power is shut off. Don't touch
the solenoid until you are sure it has cooled off.

POINT
Be sure to set the controller POWER switch to OFF before using the manual
operation button on the solenoid.
Note that forward and return operation may not be available.

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1 Posture action manual operation button
Pressing this button causes the posture of the product-side chuck to action.
2 Posture return manual operation button
Pressing this button causes the posture of the product-side chuck to return.
3 Product-side chuck open manual operation button
Pressing this button opens the product-side chuck, and releasing it closes the chuck.
4 Runner-side chuck open manual operation button
Pressing this button opens the runner-side chuck, and releasing it closes the chuck.
5 Sprue chuck open manual operation button
Pressing this button opens the sprue chuck, and releasing it closes the chuck.
6 Pressure switch (PS30)
Pressing this button opens the sprue chuck, and releasing it closes the chuck.

* The solenoid valve for opening the chuck on the runner-side is only available on unloaders
equipped with an arm on the runner side.

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2-8. Locations of Limit Switches

No. Symbol Name Remarks

1 L4S Runner-side confirmation sensor in chuck S model
2 LHV Product-side vertical home position proximity switch
3 L3 Product-side ascent end proximity switch
4 L9 Posture action-end auto switch
5 L8 Posture return-end auto switch
6 LHW Product-side crosswise home position proximity switch
7 LHS Runner-side crosswise home position proximity switch S model
8 L33 Interference prevention proximity switch S model
9 L3S Runner-side ascent end proximity switch

- 18 -
No. Symbol Name Remarks
1 L1 Traverse home position proximity switch

- 19 -
3. MAINTENANCE AND INSPECTION
To prolong the service life of the unloader and to prevent accidents, inspect the unloader regularly.

POINT
With the control box maintenance function, inspection list and lubrication information can
be displayed on the pendant operation panel screen regularly. For more information, refer
to the control box instruction manual (technical).

z Tightening loose nuts and bolts

The continuous strong vibration that occurs while the unloader is operating may cause nuts
and bolts to come loose. Loose nuts and bolts can in turn cause damage to the unloader. Bolts
that fall off may in addition cause damage to peripheral equipment.
To prevent such problems, check and tighten the following items.
• Bolts used for fixing vertical, crosswise, traverse and product limit switches
• Terminals inside the terminal box between the carriage unit and the control box
• Stoppers
• Bolts that fall off may in addition cause damage to peripheral equipment.
z Lubricating parts subject to friction
Apply grease periodically according to the lubrication diagram.
z Cleaning LM guide and traverse rail surfaces
Scratches, grease and dirt on the surface of the vertical and crosswise LM guides and the
traverse LM guide on the traverse rail top may impede smooth operation, so clean them off
periodically. If scratches or dents are present on the surface of the LM guides, replace them.
z Replacing damaged air tubes
Bent or damaged air tubes interfere with the proper flow of air. If there is air leak from any
joint or air tube, replace et immediately.
z Checking the filter regulator
For the adjustment method and precautions for pressure reducing valves, see the operation
manual for the filter regulator.
z Checking the vacuum generator (TACOVAM)
For the adjustment method and precautions for TACOVAM, see its operation manual.
z Checking expendable parts and sub expendable parts
Check and replace expendable parts in accordance with the expendable parts list.

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„ Maintenance and Inspection Table

Inspection
Work No.

Half-yearly

Every two
Monthly

Inspection point Method Item Action

Yearly

years
Daily

Pressure gauge
1 { Air pressure Visual
(0.5MPa)
Balance cylinder Pressure gauge
2 { Visual
of air pressure (0.35MPa)
Wrench, Damage,
3 { Bolt, nut Re-tighten.
spanner looseness
4 { Timing belt Visual Damage, tension Adjust.
Supply oil
5 { LM guide Visual Damage, dirt
and clean.
Clean or
6 { Pipes, wires Visual Damage
replace.
Replace
7 { Air cylinder Sound Air leakage
packing.
Element Dirt, blocking, Clean or
8 { Visual
(filter, regulator) drain replace.
Clean or
9 { Silencer Visual Dirt, blocking
replace.
Vacuum filter Suction Check suction Clean or
10 {
(suction unit) pressure pressure. replace.
General Consult
11 { By Star
diagnosis** with Star.
* If you gave any questions regarding inspection methods, items and actions, contact the
technical service staff at our sales office.
** General diagnosis will be provided at your company's expense. Please consult the sales staff
at our sales office.

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„ Lubrication diagram

- 22 -
 No. Name Place Type
1 Crosswise LM guide for product-side 4
2 Crosswise LM guide for runner-side 4 S type
3 Traverse LM guide 4
4 First stage vertical LM guide for runner-side 2 S type
5 Second stage vertical LM guide for runner-side 2 S type
6 First stage vertical LM guide for product-side 2
7 Second stage vertical LM guide for product-side 2

POINT
With the control box maintenance function, the lubrication interval for each axis can be
displayed on the screen. For more information, refer to the control box instruction manual
(technical).

„ Oiling

z LM guide

1. Feed grease by the grease pump from the grease

nipple.
2. Supply grease until the casing just overflows.
3. Wipe the excessive grease using a cloth, etc.

Grease nipple

„ Grease
* Supply grease from the grease nipple periodically (refer to “Lubrication Diagram”).
* Use lithium grease #1.

- 23 -
4. PARTS LIST
z CZ-1700
Code
Part Name Type Purpose Manufacturer Qty
No.
Traverse home position (L1)
Ascent end (L3)
TL-Q5MC1-C
Proximity switch Vertical home position (LHV) Star Seiki 4 193837
with connector
Crosswise home position
(LHW)
Posture return-end (L8)
Auto switch D-C73-C SMC 2 030389
Posture action-end (L9)
Posture action
Speed controller AS2201F-02-04S SMC 2 001266
Posture return
Filter regulator AW30-03BDE Air adjustment SMC 1
Vacuum generator
V51-100-3183 Suction TACO 2 210669
unit
Vacuum gauge PS30 Suction confirmation COPAL 2
IR3020-04BG-R-
Precision regulator Air adjustment SMC 1
X17

- 24 -
z CZ-1700s
Code
Part Name Type Purpose Manufacturer Qty
No.
Traverse home position (L1)
Product-side ascent end (L3)
Product-side vertical home
position (LHV)
Product-side crosswise home
TL-Q5MC1-C position (LHW)
Proximity switch Star Seiki 8 193837
with connector Runner-side ascent end (L3S)
Runner-side vertical home
position (LHVS)
Runner-side crosswise home
position (LHS)
Interference prevention (L33)
Posture return-end
D-C73-C SMC 2 030389
Posture action-end
Auto switch
D-97-90 Runner confirmation (L4S)
SMC 1 030119
with connector (sensor in chuck)
Posture action
Speed controller AS2201F-02-04S SMC 2 001266
Posture return
Filter regulator AW30-03DE Air adjustment SMC 1
Vacuum generator
V51-100-1283 Suction TACO 2 210669
unit
Vacuum gauge PS30 Suction confirmation COPAL 2
Runner chuck CHK-CM22II-C Runner chuck Star Seiki 1 021716
IR3020-04BG-R-
Precision regulator Air adjustment SMC 2
X17

- 25 -
5. EXPENDABLE PARTS LIST
z Product-side vertical unit (Posture unit)
Code Product Replacement
Type Manufacturer Qty Remarks
No. Name interval
SCM-00-63D-85
Posture unit
Packing set -T0HDZ-FL390 CKD 1SET 3000km
25Kg specification
425
030388 DU bush DUF1410-22 Daido 4SET 1year Posture unit
Miniature
6902ZZ NTN 2SET 1year Posture unit
ball bearing
SCM-U-00-50D- Balance cylinder
Packing set CKD 1SET 3000km
880ST-FL383944 1700 st
SCM-U-00-50D-
Balance cylinder
Packing set 1060ST-FL3839 CKD 1SET 3000km
2000 st
44
SCM-00-63B-85 Posture unit
Packing set CKD 1SET 3000km
-FL314819 35Kg specification
SCM-00-63B-85 Posture unit
Packing set CKD 1SET 3000km
T0HDFL326944 35Kg specification
Belt 400MTS8M760 MITSUBOSHI 1SET

z Valve unit
Code Product Replacement
Type Manufacturer Qty Remarks
No. Name interval
Product chuck (V31)
SZ3160K-5 20 million Runner chuck (For S
182171 Valve SMC 2(3)
MZ-C4 times model) (V3S)
Sprue chuck (V32)
SZ3260-5MZ 20million Posture action and
321735 Valve SMC 1
-C4 times return (V4R · V4P)
Silencer ANA1-C08 SMC 2 1year Manifold
Ejector
350283 92680 TACO 1SET 1year Vacuum generator
service kit
Single
solenoid 10 million Vacuum generator
350285 92682 TACO 1SET
2-way valve times (V3V)
service kit
001888 Filter AF30P-060S SMC 1 1year Air filter
Silencer AN402-04 SMC 2 1year Precision regulator
Silencer AN300-03 SMC 2 1year Balance cylinder
* Each value in the parentheses indicates the S model.

- 26 -
6. LIST OF DRIVE COMPONENTS FOR EACH AXIS

Replace-
Axis Code Manufac-
name No. No. Name Type ture Qty ment
interval
Remarks

1 AC servo motor TS4614N1035E200 Tamagawa 1

750W seiki
2 Reduction gear VRSF-15D-750-S-
M5
NIDEC-S
HIMPO 1
Traverse

LM guide SHS35LV2UUE+31 THK 2 sets 2500TR

60L-II
3
LM guide SHS35LV2UUE+37 THK 2 sets 3000TR
20L-II
Iron rubber AT belt 050-AT10-0362E-L NOK 1 2500TR
4
Iron rubber AT belt 050-AT10-0418E-L NOK 1 3000TR
Product-side
1 AC servo motor TS4609N1035E200 Tamagawa 1 (2) crosswise
400W seiki Runner-side
Crosswise

crosswise
2 Reduction gear VRKF-S9C-400-M5 NIDEC-S
HIMPO 1 (2)
3 LM guide SSR20XV4UUC1 THK 2 sets
＋1720L-II
4 Iron rubber AT belt 020-AT10-0402E-L NOK 1 (2)
* The figures in parenthesis in the [Quantity] and [Remarks] columns represent the S model.

- 27 -
 Replace-
Axis Code Manufac-
name No. No. Name Type ture Qty ment
interval
Remarks

1 AC servo motor TS4815N6902E235 Tamagawa 1

seiki
2 Reduction gear VRSF-S9E-1500-C
S1
NIDEC-
SHIMPO 1

LM guide SSR25XW2SSC1+ THK 2 sets The first stage

1180L 1700st
3
LM guide SSR25XW2SSC1 THK 2 sets The first stage
Product-side vertical

+1360L 2000st
SSR25XW2SSC1+ The second stage
LM guide 1200L THK 1 set 1700st
4 (G=30)
LM guide SSR25XW2SSC1 THK 1 set The second stage
+1380L 2000st
The first stage
Iron rubber AT belt 040-AT10-0245E-L NOK 1 1700st
5
The first stage
Iron rubber AT belt 040-AT10-0281E-L NOK 1 2000st
The second stage
Iron rubber AT belt 075-AT10-0140E-L NOK 1 1700st
6
The second stage
Iron rubber AT belt 075-AT10-0162E-L NOK 1 2000st
7 Belt 400MTS8M760 MITSUBOSHI 1

- 28 -
 Axis Code Manufac- Replacement
name No. No. Name Type ture Qty interval
Remarks

1 AC servo motor TS4614N6020E200 Tamagawa 1

seiki
2 Reduction gear VRKF-S9D-750 NIDEC- 1
SHIMPO
SSR25XW2SSC1+ The first stage
LM guide 1200L THK 1 1750st
(G=30)
3
SSR25XW2SSC1+ The first stage
LM guide 1380L THK 1 2050st
Runner-side vertical

(G=30)
SSR20XW2SSC1+ The second stage
LM guide 1200L THK 1 1750st
(G=30)
4
SSR20XW2SSC1+ The second stage
LM guide 1380L THK 1 2050st
(G=30)
Iron rubber AT 020-AT10-0250E-L NOK 1 The first stage
belt 1750st
5
Iron rubber AT 020-AT10-0286E-L NOK 1 The first stage
belt 2050st
Iron rubber AT 050-AT10-0143E-L NOK 1 The second stage
belt 1750st
6
Iron rubber AT 050-AT10-0161E-L NOK 1 The second stage
belt 2050st

7 Belt 400MTS8M760 MITSUBOSHI 1

* The replacement intervals indicated above are based on information provided by the manu-
facturer. Actual replacement intervals may vary according to the unloader's usage frequency
and the operating environment. This is particularly true with respect to the drive components
listed here. (The replacement intervals are given as a guide only, and do mot refer to a war-
ranty period.)
* The above listing indicates parts used under the standard configuration (standard specifica-
tion). Part types may differ in cases where the stroke has been lengthened or other such
change has been made.
* Parts used in the unloader are subject to change without prior notice.

- 29 -
8.AIR CIRCUIT DIAGRAM

Product-side vertical Posture cylinder

16 balance cylinder

(Product) chuck Sprue chuck

7 7

4 4 6 6 4 4

4 6 5

3
14

17

15 18 Unit SMC 1
12 KQ2H10-12
17 Silencer ANA1-C08 SMC 1
16 Silencer AN300-03 SMC 1
12 10 8 AN402-04 SMC 1
15 Silencer
8
2 14 Precision regulator IR3020-04BG-R-X17 SMC 1
18 9 12
8 13 Unit T KQ2T06-00 SMC 1
6 12 Unit T KQ2T06-08 SMC 1
11 Vacuum pressure PS30 COPAL 1
6 10 Unit KQ2H06-M5 SMC 1
9 Unit T KQ2T08-10 1
SMC
8 Joint KQ2Y12-03S SMC 1
7 Speed controller AS2201F-02-04S SMC 2
Vacuum
switch 6 Solenoid valve SZ3260-5MZ-C6 SMC 1
13 11
5 Solenoid valve SZ3160K-5MZ-C4 SMC 1
6
4 Solenoid valve SZ3260-5MZ-C4 SMC 1

10 3 Solenoid valve unit SS5Z3-60-04U-7 SMC 1

6
1 2 Vacuum generator V51-100-3183 TACO 1
1 Filter regulator AW30-03BDE-6 SMC 1
No. Name Type Manufacturer Qty

This diagram shows a type without S side vertical unit

op.
Gate cut CZ-1700
Posture unit with MAX.load:25kg

-30-
8.AIR CIRCUIT DIAGRAM

Product-side vertical Posture cylinder Posture cylinder (S)chuck

16 balance cylinder S-side vertical
16 balance cylinder

(Product) chuck Sprue chuck

7 7

6 6 6 6 6 6
4 4

4 5 4 6

14 14

17

15
15 18 Unit KQ2H10-12 SMC 1
12 12 17 Silencer ANA1-C08 SMC 1
16 Silencer AN300-03 SMC 2
15 Silencer AN402-04 SMC 2
12 10 8
8 14 Precision regulator IR3020-04BG-R-X17 SMC 2
2 Unit T 1
18 9 13 KQ2T06-00 SMC
12
8 12 Unit T 1
KQ2T06-08 SMC
6
12 11 Vacuum pressure PS30 COPAL 1
Unit KQ2H06-M5 SMC 1
10
6 Unit T
9 KQ2T08-10 SMC 1
8 Joint KQ2Y12-03S SMC 1
7 Speed controller AS2301F-02-06S SMC 2
Vacuum 6 Solenoid valve SZ3160K-5MZ-C6 SMC 1
switch 5 Solenoid valve SZ3160K-5MZ-C4 SMC
11
1
13 4 Solenoid valve SZ3260-5MZ-C6 SMC
6 2
3 Solenoid valve unit SS5Z3-60-04U-7 SMC 1
6
10
2 Vacuum generator V51-100-3183 TACO 1
1 1 Filter regulator AW30-03BDE-6 SMC 1
No. Name Type Manufacturer Qty

This diagram shows a type with S side vertical unit

op.
Gate cut CZ-1700S
Posture unit with MAX.load:35kg

-31-
8.AIR CIRCUIT DIAGRAM

Posture cylinder Posture cylinder

Product-side vertical
16 balance cylinder

(Product) chuck Sprue chuck

7 7

6 6 6 6 6
6

4 5 5

3
14

17 Unit KQ2H10-12 SMC 1

16 Silencer AN300-03 SMC 1
15 12 AN402-04 SMC 1
15 Silencer
14 Precision regulator IR3020-04BG-R-X17 SMC 1
12 10 13 Unit T KQ2T06-00 SMC 1
8
8 12 Unit T KQ2T06-08 SMC 1
2
17 9 12 11 Vacuum pressure PS30 COPAL 1
8
6 10 Unit KQ2H06-M5 SMC 1
12
9 Unit T KQ2T08-10 1
SMC
8 Joint KQ2Y12-03S SMC 1
6
7 Speed controller AS2301F-02-06S SMC 2
6 Silencer ANA1-C08 SMC 1
5 Solenoid valve SZ3160K-5MZ-C6 SMC 1
Vacuum 4 Solenoid valve SZ3260-5MZ-C6 SMC 2
switch
11 3 Solenoid valve unit SS5Z3-60-04U-7 SMC 1
13
6 2 Vacuum generator V51-100-3183 TACO 1
1 Filter regulator AW30-03BDE-6 SMC 1
10
6 No. Name Type Manufacturer Qty
1

This diagram shows a type without S side vertical unit

op.
Gate cut
CZ-1700
Posture unit with MAX.load:35kg

-32-
9.OVERALL DIAGRAM

445 C D I J

G 110

F
R

M N
L S

P stands for product side arm Posture unit with MAX.load:25kg

R stands for runner side arm
CZ-1700 Forward operation
-33-
9.OVERALL DIAGRAM

D C 445 I J

110
G

R
F

M N
L S

P stands for product side arm Posture unit with MAX.load:25kg

R stands for runner side arm
CZ-1700 Reverse operation
-34-
9.OVERALL DIAGRAM
B

B
I J
445 C D

G 110 K

F
R

O P Q
M N
L S

P
Posture unit with MAX.load:25kg
stands for product side arm
R stands for runner side arm
CZ-1700S Forward operation
-35-
9.OVERALL DIAGRAM

B
D C 445 I J

110 K
G

F R

O P Q
M N
L S

P stands for product side arm Posture unit with MAX.load:25kg

R stands for runner side arm
CZ-1700S Reverse operation
-36-
9.OVERALL DIAGRAM

445 C D I J

125
G

F
R

M N
L S

P stands for product side arm

R stands for runner side arm
Posture unit with MAX.load:35kg
CZ-1700 Forward operation
-37-
9.OVERALL DIAGRAM
B

B
I J
445 C D

125
G K

F R

O P Q

M N
L S

P stands for product side arm Posture unit with MAX.load:35kg

R stands for runner side arm
CZ-1700S Forward operation
-39-
-38-
9.OVERALL DIAGRAM

B
D C 445 I J

125 K
G

F R

L Q
O P
M N S

Posture unit with MAX.load:35kg

P stands for product side arm
R stands for runner side arm
CZ-1700S Reverse operation
-40-
-39-
 134-058
Modular Vacuum Generation Unit
－ TACOVAM －
Model No. V51-100-8283

◇ SPECIFICATIONS
Operating fluid Compressed air filtered with filter element rated under
74μm
Operating pressure 0.35～0.50MPa
Generated vacuum pressure －0.079MPa (at 0.4MPa of supply pressure)
Suction flow 18±1.5dm3/min (ANR) (at 0.4MPa of supply pressure)
Air consumption 30～40 dm3/min (ANR) (at 0.4MPa of supply pressure)
Ambient temperature 5～50℃
Mass 1.0 kg (about)
Referred technical drawing H-8924＊

◇ SPECIFICATIONS for Solenoid Valve Section for ON/OFF of supply air

Type of solenoid valve 2-position double solenoid 2-port valve
Rated voltage DC24V
Power consumption 1.8W (0.075A for DC24V supply)
Response time 0.05sec max.
Voltage allowance Within ±10% of rated voltage
Insulation classification Class B (by JIS C4003)

◇ SPECIFICATIONS for Vacuum Switch Section

Type and model number PG-30-102R-N (by COPAL)
Operating fluid Air which is containing no moisture and no oily material
Supply voltage DC10.8～30V±10%,（with ripple）
Electric current 35mA max. (at DC24V)
IP degree IP 65 (Connector part is excepted)
Setting of operation pressure －53.3 kPa
Differential pressure 13.3 kPa
Output operation Output transistor is turned ON when vacuum degree is
increased beyond the set operation pressure.
Output type 1 NPN open collector type: 30V 100mA max.
Residual voltage: 1.2V max. (at 100mA load current)
Output type 2 Linear output of 1～5VDC

TACO CO.,LTD. http://www.taco-ltd.com/

27－9, Takashimadaira 9-chome, Itabashi-ku, Tokyo 175-0082, JAPAN
Tokyo Engineering Service: Tel 03-3936-2311 Nagoya Engineering Service: Tel 052-322-1631
Tohoku Engineering Service: Tel 0244-36-8962 Osaka-Shiga Engineering Service: Tel 077-553-0611
Kita-Kanto Engineering Service: Tel 048-556-9511 Hiroshima Engineering Service: Tel 082-875-4041
Ebina Engineering Service: Tel 046-233-6741 Kyushu Engineering Service: Tel 093-651-4955
Tokai Engineering Service: Tel 0538-43-0451 Shanghai contacts office (China): +86-13681636278

07-06 (1st Ed, K-Yamamoto) 1

◇ OPERATION
During SUCTION
＝V17 side solenoid pilot is in energized
condition.
• Pressure air that is supplied by 2-port
solenoid valve passes through ejector
section (24) with high speed. At this time,
ejector sucks air in circuit of VACUUM
port to generate vacuum condition.
• When vacuum degree is increased up to set
operation pressure (－53.3 kPa) for the
vacuum switch, electrical signal is issued.
• Pressure air from the 2-port valve is also
given to tank (49) through vacuum destruct
valve (61).
• Generated vacuum adjusting screw (34) can adjust suction flow amount by the ejector. This
screw can make the change degree of vacuum generated bigger, so as to distinct the
judgments between complete sucking and incomplete sucking at sucker pad.
• An element (27) installed in suction line in order to prevent the entrance of dust and
contaminants, which comes form VACUUM port and may deteriorate the performance of the
ejector, into the ejector and the generated vacuum adjusting screw.
• Silencer element (32) decreases exhaust noise generated by pressure air flowed from the
ejector.
• Put a wrench on the metal part, and do removing and installing of the pressure switch.
clamp torque : 10 N･m max.
Caution: Don't apply force to the plastic part.

At RELEASING =V3V side solenoid pilot is in energized condition.

• Air supply is stopped by shift of solenoid valve. The vacuum destruct valve (61) is shifted and
releases air pressure in the tank to VACUUM port side, as the air pressure against vacuum
destruct valve is decreased. Therefore vacuum condition in VACUUM port is destructed.
• Output signal of the vacuum switch (70) is also turned off. Moreover as bigger hysterisis
(differential) is given to the vacuum switch that intends not to issue “OFF” signal
momentarily during suction operation of the work object, even when momentary lowering of
supply pressure that may lower the vacuum degree.

◇ CHARCTERISTIC CURVE

TACO .CO.,LTD. 2
◇ HANDLING
INSTALLATION
• Install the TACOVAM vacuum generation unit
with vertical position.
• Enough space for maintenance and inspection
should be considered.
• Piping connected to the unit should be flushed
with compressed air before installation.
• Sealing material and seal tape should be used
at a minimum in order to avoid entering them
into inside of the unit.
• Supply clean compressed air, which is 0.35 to
0.50 MPa, to AIR IN port.
• Supply air should be cleaned and regulated by general filter unit and regulator unit. Don’t
use lubricator upstream the vacuum generating unit.

ATTENTION of PIPING PROCEDURE

TO AIR SUPPLY SIDE PIPING
• Piping for air supply side should be large enough in order to avoid pressure drop. Take care
not to use some connectors that are throttled inside.
• Pressure decrease of supply air may cause lowering vacuum degree. Maintain the pressure
drop as small as possible.
TO VACUUM SIDE PIPING
• Large sized piping is also recommended for the vacuum side. If the small sized piping is used,
the troubles with incomplete suction by weak vacuum or with time delay by small amount
suction flow may happen due to flow restriction of piping.
• Piping length should be as short as possible. Spiral piping and long winding piping should be
avoided.
• In case of plastic tubing, using rigid tubing is required to avoid crushing easily by
atmospheric pressure when vacuum degree builds up inside tubing.

ELECTRICAL WIRING
• Rated supply voltage is DC24V for both the 2-port solenoid valve and the vacuum switch.
2-Port Solenoid Valve
• V51-100-8283 unit is assembled with a 2-position double solenoid valve. Energizing V3V side
solenoid stops air supplying to the ejector and to the tank. Energizing V17 side solenoid
supplies air to ejector and charges air pressure in the tank. Take care not to confuse wiring
for V3V and for V17.
• Consider the control circuit that both V3V and V17 solenoid are not activated at the same
time. Also keep the valve shift in V3V side (=supplying no air) until just before the suction
operation (in order to save air consumption and to extend element life).

TACO .CO.,LTD. 3
Vacuum Switch
• Take care not to apply unreasonable tension force to the leads of vacuum switch.
• A connector is connected to the lead wire at factory. Number of connector pin and lead wire
are as follow.

Pin Signal Color of

no. lead wire
1 0V Blue
2 ON/OFF Output White
3 Linear Output Gray
4 +V (12～24VDC) Brown

ADJUSTMENT
Vacuum degree adjusting screw: can adjust suction flow amount through VACUUM port.
Turn anticlockwise ⇒ increases suction flow ⇒ increases vacuum degree
Turn clockwise ⇒ decreases suction flow ⇒ decreases vacuum degree

Vacuum destruct flow adjusting screw: can adjust flow amount for vacuum destruct that is
performed by discharging air pressure in the tank when
solenoid pilot is shifted to V3V side.
Turn anticlockwise ⇒ increases flow amount for vacuum destruct pressure
Turn clockwise ⇒ decreases flow amount for vacuum destruct pressure
NOTE: Lock each adjusting screw with lock nut after adjustment is completed.

MAINTENANCE
• Filter element (27):
The dust and contaminants, which adhere to the work object and exist in surroundings, are
gradually accumulated at this filter element by suction operation. Periodical replacement is
required as the clogged filter element causes decrease of suction efficiency.
• Inspect the piping, tubing and sucker pad for the system. Inferiors and damaged should be
replaced.
• Disassembling and reassembling should be done with preparation of the assembly drawing.
CAUTION: Power supply and air supply should be removed before disassembling.

TACO .CO.,LTD. 4
◇ TROBLE SHOOTING
MALFUNCTION CAUSES
【1】 1-1: No supply pressure, or lower supply pressure.
Impossible to generate 1-2: 2-port sol. valve is not shifted. ⇒Refer to 【5】
vacuum pressure. 1-3: Improper adjustments of the generated vacuum adjusting
screw. (It may be excessively screwed.)
1-4: Failure of vacuum destruct valve leaks pressure air toward
VACUUM port side.
【2】 2-1: There is a leak in vacuum circuit by failure of piping/tubing,
Vacuum degree is in or failure of sucker pad. ⇒To be replaced.
low. And suction flow 2-2: Improper adjustments of the generated vacuum adjusting
becomes a little screw.
amount. 2-3: There happens failure of vacuum destruct valve.
2-4: Element or silencer clogs. ⇒To be replaced.
2-5: Ejector clogs up, or O-ring on ejector is damaged.
⇒To be replaced.
【3】 3-1: Valve packing swelled, or jammed foreign matter, or was
Vacuum destruct valve reassembled inversely after disassembling.
does not work. 3-2: Vacuum destruct flow adjusting screw is screwed excessively.
3-3: Supply air pressure is low.
【4】 4-1: Generated vacuum degree is too low for the switch to
Vacuum switch does function.
not work. 4-2: Electrical wiring or supply voltage is incorrect.
4-3: Vacuum switch malfunctions. ⇒To be replaced.
【5】 5-1: Pilot solenoid is not activated. Or the other pilot solenoid
2-port solenoid valve remains energized.
does not work. 5-2: There is no supply pressure.
5-3: Solenoid coil is in breaking. ⇒To be replaced.
5-4: Foreign matter prevents working of valve.
● According to the causes of troubles, perform adjustment, modification, inspection with
disassembling, and replacement of parts.

◇ PARTS & SERVICE KIT (SK) NO.

Name of Service Kit Service Kit No.
Vacuum destruct valve SK 92246
Ejector SK 92680
Vacuum Switch SK 95555-01
2-Port Valve SK 92682
Magnet SK 92683
Piston SK 92684
Spool SK 92685
Element SK 92686

TACO .CO.,LTD. 5
◇ V51-100-8283 Main Parts Assembly Drawing

TACO .CO.,LTD. 6
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 All stated here is subject to change without advance notice.

STAR SEIKI( HONG KONG) COMPANYLIMITED

Head Office 12th Floor CCT Telecom №.11 Wo Shing Street, Fo Tan,Shatin,
New Territories Hong Kong (852) 2687-6745

China Factory The First Industrial Zone, Bogang Village, Shajing Town,
Baoan Country, Shenzhen City, Guangdong, P.R.C
(755) 2962-2537

0911-02-CZE-M