ATS150 Series Stage User`s Manual
Contents
1. 29 Index NRI 31 Reader s Comments ooo oo 0 0 0 o ooo cece eee ec cece cece cence ccececcecececceceecececeeeeeees 32 www aerotech com lii Table of Contents ATS150 Series Stage User s Manual www aerotech com ATS150 Series Stage User s Manual List Of Figures List of Figures Figure 1 1 Typical ATS150 Series Linear Positioning 1 Figure 1 2 ATS150 with Cutaway View 2 Figure 1 3 Components of a Typical Motor Encoder and ATS150 Series Stage 3 Figure 2 1 Results of Coplanar Versus Non Coplanar 10 Figure 3 1 Load Capability and Travel Life of the 5150 17 Figure 3 2 Torque Required to ATS150 Series Ball screw with Various Loads and Leads 19 Figure 3 3 5150 Internal View Showing Optical Limit Switch 20 Figure 3 4 ATS150 Series Limit Switch Wiring 2 22 00 0 20 22 cece cece eee c eee e cece cece een 21 www aerotech com V List of Figures vi ATS150 Series Stage User s Manual www aerotech com ATS150 Series Stage User s Manual List of Tables List of Tables Table 1 1 Model Numbering2. 9 multiaxis combinations 25 www aerotech com N 10 Optical Limit Switch Assembly 20 P Preparing the Mounting Surface 10 S safety 6 Securing the Stage to the Mounting Surface 11 Standard 2 T Temperature 14 Travel Distance 1 Travel Life noe 2 U Unpacking and Handling the Stage 9 V Vacuum 22 608 6 31 Reader s Comments ATS150 Series Stage Manual P N EDA125 March 21 2011 Revision 1 01 00 Please answer the questions below and add any suggestions for improving this doc ument Is the manual Adequate to the subject 11555 Well organized o Clearly presented Well illustrated i How do you use this document in your job Does it meet your needs What improvements if any would you like to see Please be specific or cite examples C T SmwPeWbes Nam Weg seria erp Name
3. 2 222222 2 2 4 4 15 3 4 Life Expectancy and Load 17 3 5 Optical Limit Switch 22222222 2 2 2 2 4 2 2 2 20 3 5 1 Limit Switch 2 20 3 5 2 Limit 4 4 4 1 21 3 6 Vacuum 2 0 2 2 4 022 2 22 3 6 1 Special 2 4 22 Chapter 4 2 2 23 4 1 Lubrication 2 2 2 23 4 2 Lubrication and Cleaning 2 20 24 4 3 Important Notes on 2 2 1 25 4 4 Recommended Lubricants and Cleaning 25 Appendix A Warranty and Field 27 Appendix B Technical
4. 4 Table 3 1 Environmental 2 4 2 2 13 Table 3 2 ATS150 Series Positioning Stage 15 Table 3 3 4 2 2 2 16 Table 3 4 Applied Load 4 18 Table 3 5 Limit Interface Pin 40 000 02 21 Table B 1 Current Changes 1 01 00 0 0 0 0 70 72222 29 Table B 2 Archived Changes 2 cccecceececcccccceccccccccceecccccceeeecccccceeeeesecceeeeeeeeees 30 www aerotech com vii List of Tables ATS150 Series Stage User s Manual viii www aerotech com ATS150 Series Stage User s Manual Overview Chapter 1 Overview This manual describes Aerotech s ATS150 series of linear motor positioning stages Figure 1 1 shows a typ ical ATS150 positioning stage The ATS150 series are low profile linear positioning stages These stages provide highly accurate positioning with travel ranges from 100 mm to 250 mm 4 10 in They have a low profile compact design yet they are designed for high stiffness and stability The ATS150 series uses a long life linear motion guide LMG b
5. Aerotech Subsidiary Email Order Maiyourcommentsto Farto Aerotech Inc 412 967 6870 101 Zeta Drive Pittsburgh PA 15238 U S A service aerotech com
6. Manufactorer Aerotech Inc 101 Zeta Drive Pittsburgh PA 15238 USA AEROTECH xv herewith declares that the product Aerotech Inc ATS150 Stage is intended to be incorporated into machinery to constitute machinery covered by the Directive 2006 42 EC as amended does therefore not in every respect comply with the provisions of this directive and that the following harmonized European standards have been applied EN ISO 12100 1 2 2003 A1 2009 Safety of machinery Basic concepts general principles for design ISO 14121 1 2007 Safety of machinery Risk assessment Par 1 Principles EN 60204 1 2005 Safety of machinery Electrical equipment of machines Part 1 General requirements and further more declares that it is not allowed to put the equipment into service until the machinery into which it is to be incorporated or of which it is to be a component has been found and declared to be in conformity with the provisions of the Directive 2006 42 EC and with national implementing legislation i e as a whole including the equipment referred to in this Declaration Authorized Representative Manfred Besold Address Name Position Location Date AEROTECH GmbH S d West Park 90 D 90449 N mberg Alex Weibel bs Engineer Verifying Compliance Pittsburgh PA March 21 2011 Chapter 1 www aerotech com ATS150 Series Stage User s Manual Installation Chapter 2 Installation This chapter c
7. and ATS150 Series Stage NOTE Motor and limit wiring can be integral extending directly from the electrical housing as shown in Figure 1 3 or it can attach to a connector located on the motor itself depending on the model of motor hous ing ordered www aerotech com Chapter 1 3 Overview ATS150 Series Stage User s Manual 1 2 Model Numbers The table below lists the available options Aerotech continually improves its product offerings and listed options may be superseded at any time Refer to the most recent edition of the Aerotech Motion Control Prod uct Guide for the most current product information at www aerotech com Table 1 1 Model Numbering System ATS150 250 250 mm 10 in travel stage with limits NACE High Accuracy Linear Encoders LN10AS High accuracy linear encoder for ATS150 100 amplified sine output 1 Vpp 4 um sig nal period requires signal multiplier LN15AS High accuracy linear encoder for ATS150 150 amplified sine output 1 Vpp 4 um sig nal period requires signal multiplier U English dimension mounting pattern and holes 20 40 4 mm rev precision ground ball screw BMS Brushless servomotor with connectors and 1000 line encoder requires cable BMS60 A D25 E1000H Stepping motor with connector and home marker pulse one per rev requires cable 101SMB2 HM Limits Options _ 00000000000 FB BRK1 Fold back motor configuration with 24 VDC spring set motor brake for
8. 109 Travel Life Cunritilevered Load Capability of the ATS150 Series Loading vx Travel Life of the ATS150 Seriex Figure 3 1 Load Capability and Travel Life of the ATS150 Stages Load capacity and life expectancy are inversely related that is as loading increases life expectancy will decrease The ball screw is usually the critical component when determining life expectancy To determine the life expectancy in a given application refer to the loading vs travel life graph in Figure 3 1 Be sure to consider dynamic loading when using the ATS150 series stage for high speed applications Life expectancy is calculated using the following steps 1 Determine the loading percentage of the stage Use the following equation Applied Load 100 Max Load Specification Loading Percentage 2 Multiply the result by the proper factor from the Applied Load Coefficient Table Table 3 4 www aerotech com Chapter 3 17 Operating Specifications ATS150 Series Stage User s Manual 3 Refer to the loading vs travel life graph in Figure 3 1 Table 3 4 Applied Load Coeffcients Operating Conditions Smooth operation no shocks Normal operating conditions In applications using a cantilevered load the life expectancy is calculated as follows 1 18 Determine the equivalent direct acting loading force of the applied load Use the following equation Loading Force 2 Applied Load x Distance from Load CG to S
9. NEMA 23 motor 4 Chapter 1 www aerotech com ATS150 Series Stage User s Manual Overview Table 1 1 Model Numbering System continued LGR MTR COU 0 375 in coupling PLING HDZ2NAC6 VAC6 prepared English right angle L bracket for ATS150 100 and ATS150 150 stages only HDZ2M VAC6 VAC6 prepared metric right angle L bracket for ATS150 100 and ATS150 150 stages only Www aerotech com Chapter 1 5 Overview ATS150 Series Stage User s Manual 1 3 Safety Procedures and Warnings The following statements apply throughout this manual Failure to observe these precautions could result in serious injury to those performing the procedures and damage to the equipment This manual and any additional instructions included with the stage should be retained for the lifetime of the stage A DANGER gt DANGER gt DANGER gt DANGER WARNING WARNING WARNING To minimize the possibility of electrical shock and bodily injury or death disconnect all elec trical power prior to making any electrical connections To minimize the possibility of electrical shock and bodily injury or death when any electrical circuit is in use ensure that no person comes in contact with the circuitry when the stage is connected to a power source To minimize the possibility of bodily injury or death disconnect all electrical power prior to making any mechanical adjustments Moving parts of the stage can cause crushing
10. mm diameter on the stage table are aligned with any two of the mounting holes 0 28 in 6 5 mm diameter on the under side of the stage Install the appropriately sized screws though the access holes and secure the stage to the mounting surface Repeat this process for each set of mounting holes The stage must be mounted securely Improper mounting can result in injury and damage to the equipment WARNING NOTE The stage table may offer a considerable amount of resistance when it is moved manually This is especially true if the stage is fitted with a motor assembly NOTE Ifthe stage is not connected to a power source and is not equipped with an optional brake it should be possible to move the stage table by hand with steady even pressure Do not attempt to manually move the stage if it is connected to a power source or includes an integrated brake 2 4 Attaching the Payload to the Stage To prevent damage to payloads test the operation of the stage before the payload is attached to the stage table When attaching a payload to the stage table the mounting interface should be coplanar within 0 000010 in in for valid accuracies This can be achieved by scraping or shimming the mounting surface of the payload It is recommended that feet or pads be used on the payload surface to minimize the amount of surface area that needs to be coplanar www aerotech com Chapter 2 11 Installation ATS150 Series Stage User s Manual 2 5 Electri
11. or shearing injuries All personnel must remain clear of any moving parts Improper use of the stage can cause damage shock injury or death Read and understand this manual before operating the stage If the stage is used in a manner not specified by the manufacturer the protection provided by the stage can be impaired Stage cables can pose a tripping hazard Securely mount and position all stage cables to avoid potential hazards Chapter 1 www aerotech com ATS150 Series Stage User s Manual Overview Do not expose the stage to environments or conditions outside the specified range of oper ating environments Operation in conditions other than those specified can cause damage to the equipment The stage must be mounted securely Improper mounting can result in injury and damage to the equipment Use care when moving the stage Manually lifting or transporting stages can result in injury Only trained personnel should operate inspect and maintain the stage This stage is intended for light industrial manufacturing or laboratory use Use of the stage for unintended applications can result in injury and damage to the equipment Before using this stage perform an operator risk assessment to determine the needed safety requirements A A A A A A 2 2 2 2 2 2 Z Z 2 2 2 Z www aerotech com Chapter 1 7 Overview ATS150 Series Stage User s Manual 1 4 EC Declaration of Incorporation
12. upon heat sink configuration system cooling conditions and ambient temperature 2 Values shown 75 C rise above a 25 C ambient temperature with housed motor mounted to a 250 mm x 250 mm x6 mm alu minum heat sink 3 Peak torque assumes correct rms current consult Aerotech 4 Torque Constant and Motor Constant specified at stall 5 All performance and electrical specifications 10 percent 7 Ambient operating temperature range 0 C 25 C consult Aerotech for performance in elevated ambient temperatures 6 Maximum winding temperature is 100 C Thermistor trips at 100 C 8 All Aerotech amplifiers are rated Apk use torque constant in N m Apk when sizing 16 Chapter 3 www aerotech com ATS150 Series Stage User s Manual Operating Specifications 3 4 Life Expectancy and Load Capability The accuracy specification of ATS150 series stages is measured at the center of travel with no load located 1 75 inches above the table with the stage in a horizontal position It is recommended the load be symmetrically distributed the payload should be centered on the stage table and the entire stage should be centered on the support structure For cantilever loading refer to Figure 3 1 for a graph of the maximum allowable load versus the distance of the load s center of gravity to the center of the stage table Loading Percentage Along Longitudinal Axis 1000 E 107 108 109 1010 PT m 105 10 108
13. with Cutaway View of Ballscrew Additional features of the ATS150 series stages include Optical limit switches and cushioned end stops Aluminum alloy standard or steel construction for severe temperature environments English or Metric mounting holes on the stage table 1 4 20 on a 1 square grid pattern or M6 on a 25 mm grid pattern Micro stepping DC servo motors or brushless servo motors Vacuum preparation for operation to 10 torr High accuracy HAL stage option providing positioning accuracy of 1 micron over full travel and 25 micron bi directional repeatability Precision multi axis configurations such as XY and XYZ having orthogonality within 5 arc seconds Motors are mounted to a plate on one end of ATS150 series stages A motor housing and encoder are optional on most models A cable or set of cables carries motor power encoder feedback as well as limit switch signals to the appropriate hardware devices such as axis controllers and amplifiers Chapter 1 www aerotech com ATS150 Series Stage User s Manual Overview Optiona Encoder Cutaway View of Marker Wheel on Motor Shaft ATS150 Series Stage Electrical Housing Can Kit Limit Switch Airing Connects to Electrica Housing Cornects to an Appropriate Limits Connector Axis Cortroller Device e g U11 U14 DR S00 etc Integral Motor Motor Connector and Limits Wiring Figure 1 3 Components ofa Typical Motor Encoder
14. 200 2 1 2 Model Nu tribers z prec E E De shane 4 1 3 Safety Procedures and 2222222222 2 1 70 2020 22 6 1 4 EC Declaration 21 1 2 2 8 Chapter 2 Installation 2 222222 2 2 9 2 1 Unpacking and Handling the 222222222 2 2 2 2 4 4 9 2 2 Preparing the Mounting 10 2 3 Securing the Stage to the Mounting 11 2 4 Attaching the Payload to the 22222222222 2 2 2 1 42 11 2 5 Electrical 2 2 2 4 12 2 5 1 DC Servo 424 425 0 2 12 Chapter 3 Operating Specifications 13 3 1 Environmental 4 4 13 3 2 Accuracy and Temperature 2 24 14 3 3 Basic
15. ATS150 Series Stage User s Manual P N EDA125 Revision 1 01 00 Dedicated to the Science of Motion Aerotech Inc 101 Zeta Drive Pittsburgh PA 15238 Phone 412 963 7470 Fax 412 963 7459 www aerotech com AEROTECH Product Registration Register online at http www aerotech com prodreg cfm Technical Support United States Headquarters Phone 412 967 6440 Fax 412 967 6870 Email service aerotech com United Kingdom Phone 44 118 940 9400 Fax 44 118 940 9401 Email service aerotech co uk Germany Phone 49 911 967 9370 Fax 49 911 967 93720 Email service aerotechgmbh de Japan Phone 81 0 47 489 1741 Sales Phone 81 0 47 489 1742 Service Fax 81 0 47 489 1743 Email service aerotechkk com jp China Phone 852 3793 3488 Email saleschina aerotech com Revision History Revision 1 01 00 March 21 2011 Revision 1 00 00 March 10 2006 Product names mentioned herein are used for identification purposes only and may be trademarks of their respective companies Aerotech Inc 2011 ATS150 Series Stage User s Manual Table of Contents Table of Contents Table of 22 iii LiStiOf FIQUIOS ERR EE V Eist or Tables ea DA E ED p dre AR Er vii Chapter 1 2 2 2 4 1 022 1 1 1 Standard 242
16. ATS150 series stages are equipped with optical limit switch assemblies 690B1371 which are used to indicate maximum travel condition 3 5 1 Limit Switch Operation Limit switches are mounted perpendicularly to table travel at each end of the stage and have an emitting light source and detector When the carriage interrupts the light path from the emitter to the detector a clock wise CW or counter clockwise CCW limit signal active low will indicate an over travel condition Mechanical Stops for Mounting Mounting Holes Motor Mounting Plate Limit Switch Wiring Optical Limit Detector Optical Limit Dete ctor CW Limit Optic al Limit Blades C Cw Limit Figure 3 3 ATS150 Internal View Showing Optical Limit Switch Assembly If the stage is driven approximately 1 5 mm beyond the electrical limit it will encounter the mechanical stop Although the operating speed of the stage might be relatively slow dam age to the stage could result WARNING Unless specifically modified the CW limit is activated when the stage table is at the end of travel opposite the motor end 20 Chapter 3 www aerotech com ATS150 Series Stage User s Manual Operating Specifications 3 5 2 Limit Interface six pin printed circuit board connector is provided to facilitate wiring of the limit interface The mating con nector is AMP part number 640234 6 Table 3 5 Limit Interface Pin Assignments J1 1 5V input 5V at 25mA source 1mA a
17. Less Motor Weight 7 2kg 15 9 8 6kg 19 0 9 0 19 8 9 5 kg 20 9 Aluminum Body Stage and Table Clear Anodize Finish 1 Excessive duty cycle may impact accuracy 2 Payload specifications are for single axis system and based on ball screw and bearing life of 2500 km 100 million inches of travel 3 Available with Aerotech controllers 4 Specifications are for single axis systems measured 50 mm above the tabletop Performance of multi axis systems is payload and workpoint dependent Consult factory for multi axis or non standard applications Drive System Resolution www aerotech com Chapter 3 15 Operating Specifications Table 3 3 Motor Specifications Model Winding Designation Performance Specifications 1 5 Stall Torque Continuous 2 N m oz in Peak Torque 9 N m oz in ATS150 Series Stage User s Manual 0 33 46 2 1 31 184 9 Rated Power Output Continuous 112 0 Electrical Specifications BEMF Constant line to line max Volts pk krpom 3 Continuous Current Stall 2 Amp pk Amp rms Peak Current Stall 3 Amp pk Amp rms N m Amp pk oz in Amp pk Amp rms oz in Amp rms Motor Constant 2 4 N m VW oz in NW Resistance 25 C line to line ohms Inductance line to line mH Maximum Bus Voltage VDC Thermal Resistance Number of Poles Torque Constant 4 8 2 1 6 9 2 6 5 0 14 20 1 0 20 28 4 0 050 7 02 8 4 1 30 340 1 Performance is dependent
18. S150 Series Stage User s Manual 2 2 Preparing the Mounting Surface In order for the ATS150 series stage to maintain accuracy the mounting surface should be coplanar within 0 000010 in in For example if the longest distance between the rectangular base hole pattern is 8 inches then the mounting surface should be coplanar within 0 000080 inches Adjustments to the mounting surface must be done before the stage is secured Adjustments to the mounting surface must be done before the stage is secured The effects of flatness on mounting are illustrated in Figure 2 1 Coplanar Mounting Surface Non coplanar Mounting Surface Figure 2 1 Results of Coplanar Versus Non Coplanar Mounting When an ATS150 series stage is mounted onto a non coplanar surface the stage can be distorted as the mounting screws are tightened This distortion can decrease the overall accuracy of the stage NOTE The stage base is precision machined and verified for flatness prior to stage assembly at the fac tory If machining is required to achieve the desired flatness it should be performed on the mounting sur face rather than the stage base Shimming should be avoided if possible If shimming is required it should be minimized to improve the rigidity of the system 10 Chapter 2 www aerotech com ATS150 Series Stage User s Manual Installation 2 3 Securing the Stage to the Mounting Surface Manually position the stage table so that the access holes 0 5 in 75 0
19. This equates to an sure ingress protection rating of IP50 Indoor use only Do not expose the stage to environments or conditions outside the specified range of oper ating environments Operation in conditions other than those specified can cause damage to the equipment WARNING www aerotech com Chapter 3 13 Operating Specifications ATS150 Series Stage User s Manual 3 2 Accuracy and Temperature Effects The ATS150 series stages are designed to have maximum accuracy at 68 F The accuracy of the stages ball screw is a key element in the overall positioning accuracy An offset error can be expected if the temperature of the ball screw differs from 68 F As the temperature of the ball screw increases the actual position from the motor will be greater by a factor of 7x10 inches be 113x10 5mm inches of travel x deg F mm of travel x deg C Similarly as the temperature of the ball screw decreases the actual positioning will be less by the same fac tor The value specified in the inches of travel and mm of travel represent the distance from the center of the stage to the bearing on the motor end of the stage NOTE Ball screw temperature is dependent on the speed of the stage and duty cycle Higher speeds and duty cycles produce greater ball screw heating 14 Chapter 3 www aerotech com ATS150 Series Stage User s Manual Operating Specifications 3 3 Basic Specifications The ATS150 series positioning stage and mot
20. al performance in high vacuum applications 10 6 torr This preparation includes Lubrication with vacuum compatible lubricants see Section 4 4 for lubricants Exclusive use of materials with excellent vacuum outgas performance Elimination of situations that may allow gases to become temporarily trapped during pump down Extensive cleaning and bake out prior to special assembly in a clean environment and packing in a nitrogen filled bag 3 6 1 Special Guidelines To ensure that the stage will continue to perform well in the vacuum environment follow the guidelines listed below in addition to standard handling installation and lubrication guidelines outlined earlier in this manual 1 22 Do not remove the stage from the sealed bag until it is ready for use Use Teflon gloves in a clean envi ronment to prevent any contaminants from adhering to the surface of the stage During the installation process use cleaned vented stainless steel fasteners when securing the stage A motor cover and cable connector might be supplied with the stage motor These should be removed before the stage is used in vacuum applications In a vacuum environment the lack of convective heat transfer could result in excessive motor operating temperatures This coupled with the viscous nature of vacuum compatible greases might make it nec essary to de rate performance specifications To reduce the amount of heat generated Aerotech offers special controll
21. ation expense Failure to obtain a purchase order number or approval within 30 days of notification will result in the product s being returned as is at the buyer s expense Repair work is warranted for 90 days from date of shipment Replacement com ponents are warranted for one year from date of shipment At times the buyer may desire to expedite a repair Regardless of warranty orout Rush Service of warranty status the buyer must issue a valid purchase order to cover the added rush service cost Rush service is subject to Aerotech s approval www aerotech com Appendix A 27 Warranty and Field Service On site Warranty Repair On site Non warranty 28 Repair Company Address ATS150 Series Stage User s Manual If an Aerotech product cannot be made functional by telephone assistance or by sending and having the customer install replacement parts and cannot be returned to the Aerotech service center for repair and if Aerotech determines the problem could be warranty related then the following policy applies Aerotech will provide an on site field service representative in a reasonable amount of time provided that the customer issues a valid purchase order to Aerotech cov ering all transportation and subsistence costs For warranty field repairs the cus tomer will not be charged for the cost of labor and material If service is rendered at times other than normal work periods then special service rates apply If d
22. cal Installation Electrical installation requirements will vary depending on stage options Installation instructions in this sec tion are for stages equipped with standard Aerotech motors intended for use with an Aerotech motion control system Contact Aerotech for further information regarding stages that are otherwise configured Aerotech motion control systems are adjusted at the factory for optimum performance When the ATS 150 series stage is part of a complete Aerotech motion control system setup involves connecting a stage and motor combination to the appropriate drive chassis with the cables provided Connect the provided cables to the motor and feedback connectors on the stage Labels on the drive indicate the appropriate connections Refer to your drive manuals and documentation for additional installation and operation information In some cases if the system is uniquely configured a drawing showing system interconnects is supplied Never connect or disconnect any electrical component or connecting cable while power is applied or serious damage may result WARNING 2 5 1 DC Servo Motor Wiring When stages are equipped with standard Aerotech DC motor and encoder combinations refer to the appro priate motor manuals and documentation for additional installation and operation information 12 Chapter 2 www aerotech com ATS150 Series Stage User s Manual Operating Specifications Chapter 3 Operating Specifications The surro
23. d must be filed with the carrier Return Procedure by the buyer Aerotech must be notified within 30 days of shipment of incorrect materials No product may be returned whether in warranty or out of warranty with out first obtaining approval from Aerotech No credit will be given nor repairs made for products returned without such approval Any returned product s must be accompanied by a return authorization number The return authorization number may be obtained by calling an Aerotech service center Products must be returned prepaid to an Aerotech service center no C O D or Collect Freight accepted The status of any product returned later than 30 days after the issuance of a return authorization number will be subject to review After Aerotech s examination warranty or out of warranty status will be deter Returned Product War mined If upon Aerotech s examination a warranted defect exists then the prod ranty Determination uct s will be repaired at no charge and shipped prepaid back to the buyer If the buyer desires an airfreight return the product s will be shipped collect Warranty repairs do not extend the original warranty period After Aerotech s examination the buyer shall be notified of the repair cost At such Returned Product time the buyer must issue a valid purchase order to cover the cost of the repair and Non warranty Deter freight or authorize the product s to be shipped back as is at the buyer s min
24. d Cleaning Process The lubrication and cleaning process is outlined in the steps that follow Before beginning lubrication please see Section 4 4 for recommended lubricants Drive the stage table to one end of travel and remove power to the stage Remove the socket head screws on the edges of the stage table and pull the bellows way covers back toward the edge of the stage to reveal the inside of the stage Remove any accumulated dust or debris from the inside of the assembly Remove any dirty or dried lubricant from the lead screw ball screw Use a clean cloth with a side to side motion to clean the thread roots Manually turn the ball screw to clean its entire circumference A cotton swab soaked in solvent may be used to remove stubborn debris Clean the end of the ball screw nut and wiper with a clean cloth or cotton swab These areas can be accessed from the underside of the stage Clean the linear bearing guides using a similar technique 7 After the solvent has evaporated if solvent is used apply a thin continuous film of lubricant to the lead 10 screw ball screw threads and linear bearing guides A good quality natural bristle artist s brush makes an excellent applicator Refasten the bellows way covers and screws to the stage table Restore power to the stage drive the stage table to the opposite end of travel and remove power Repeat steps 2 through 7 To minimize the possibility of bodily injury confirm tha
25. ear ing system that provides ultra fine positioning resolution up to 0 1 micron with an average accuracy better than 0 7 micron 25 mm 0 00003 in in This chapter introduces standard and optional features of the ATS150 stages explains the model numbering system and gives general safety precautions Figure 1 1 Typical ATS150 Series Linear Positioning Stage N OTE Aerotech continually improves its product offerings and listed options may be superseded at any time Refer to the most recent edition of the Aerotech Motion Control Product Guide for the most current product information at www aerotech com www aerotech com Chapter 1 1 Overview ATS150 Series Stage User s Manual 1 1 Standard Features ATS150 series stages use a precision ground ball screw see cutaway view in Figure 1 2 that is preloaded to eliminate backlash High quality duplex bearings are used to eliminate axial play while the LMG bearing system provides high load capability stiffness and continuous carriage support over the entire travel dis tance Internal contamination is prevented with integral bellows way covers The connecting nut on the ball screw has wipers that prevent internal contamination of the drive and bearing system thereby ensuring high accuracy over the expected travel life in excess of 100 000 000 inches Ballscrew Cutaway View Stage Base clear anodized finish Motion Axis Direction of Travel Figure 1 2 ATS150
26. eld Service Aerotech Inc warrants its products to be free from defects caused by faulty mate rials or poor workmanship for a minimum period of one year from date of shipment from Aerotech Aerotech s liability is limited to replacing repairing or issuing credit at its option for any products that are returned by the original purchaser during the warranty period Aerotech makes no warranty that its products are fit for the use or purpose to which they may be put by the buyer where or not such use or purpose has been disclosed to Aerotech in specifications or drawings previously or sub sequently provided or whether or not Aerotech s products are specifically designed and or manufactured for buyer s use or purpose Aerotech s liability or any claim for loss or damage arising out of the sale resale or use of any of its prod ucts shall in no event exceed the selling price of the unit Aerotech Inc warrants its laser products to the original purchaser for a minimum Laser Products period of one year from date of shipment This warranty covers defects in work manship and material and is voided for all laser power supplies plasma tubes and laser systems subject to electrical or physical abuse tampering such as opening the housing or removal of the serial tag or improper operation as determined by Aerotech This warranty is also voided for failure to comply with Aerotech s return procedures Claims for shipment damage evident or conceale
27. ers that reduce the current sup plied to the motor when it is in an idle state Contact Aerotech for assistance Chapter 3 www aerotech com ATS150 Series Stage User s Manual Maintenance Chapter 4 Maintenance This chapter will cover information about intervals between lubrications detail the lubrication and inspection process and cover which lubricants are recommended for use N OTE The bearing area must be kept free of foreign matter and moisture otherwise the performance and life expectancy of the stage will be reduced Always operate the stage with the hard cover and side seals in place to help keep dirt out To minimize the possibility of bodily injury confirm that all electrical power is disconnected prior to making any mechanical adjustments DANGER 4 1 Lubrication Schedule Lubricant inspection and replenishment in ATS150 series stages depends on conditions such as duty cycle speed and the environment An inspection interval of once per month is recommended until a trend develops for the application Longer or shorter intervals may be required to maintain the film of lubricant on the bearing surfaces In general ball screws and linear bearings require lubricant after 20 million inches of travel The ball screw end bearings and motor bearings are shielded and should not need to be re lubricated under normal use www aerotech com Chapter 4 23 Maintenance ATS150 Series Stage User s Manual 4 2 Lubrication an
28. nd sink 2 6 mA or 12V at 25mA source 3mA and sink 19mA DJO For 12V 25mA remove wire jumper 1 2 Reed 02 Signateommon OO a Reewd 36 Pigtail with P c Shrink Cover 240 45V 824 GRN tali 824 GRN Common 824 GRY CCW Limit N 824WHT CW Limit N Figure 3 4 ATS150 Series Limit Switch Wiring The CCW Limit N output equals a logical 1 when the limit is not active Typically this is a value of 2 4 V at 0 8 mA The CCW limit N output equals a logical 0 when the limit is active Typically this is a value of 0 4 V at 12 8 mA The CW Limit N output behaves similarly NOTE Theterms clockwise CW and counter clockwise CCW refer to the rotation direction of the motor while looking into the shaft of the motor For ATS150 series stages a clockwise CW rotation of the motor causes the stage table to move away from the motor Conversely a counter clockwise CCW rota tion of the motor causes the stage table to move toward the motor The exception is if an optional foldback motor is used in which case the directions are reversed www aerotech com Chapter 3 21 Operating Specifications ATS150 Series Stage User s Manual 3 6 Vacuum Operation As an option Aerotech will prepare the ATS150 series stage for operation in a vacuum environment As part of this preparation meticulous attention to detail during modification cleaning and assembly results in a stage with optim
29. or specifications are provided in Table 3 2 and Table 3 3 Table 3 2 5150 Series Positioning Stage Specifications Basic Model ATS150 100 ATS150 150 ATS150 200 ATS150 250 Total Travel 100 mm 4 150 mm 6 200 mm 8 250 mm 10 in in in in Super Precision Ground Ball Screw Brushless Servomotor BMS60 A D25 E1000H Bus Voltage Up to 160 VDC Up to 2 3 Continuous Current Upto 16A Feedback Noncontact Rotary Encoder 1000 line 2 mm rev lead 0 5 um 20 uin 4000 steps rev Motor Resolution 4 mm rev lead 1 0 um 40 pin 4000 steps rev Motor Resolution LN Linear Encoder 0 001 pm 2 pins N A N A Maximum Travel 2 mm rev lead 115 mm s 4 5 in s Speed 4 mm rev lead 230 mmis 9 0 in s 450 9921 a 25019 6511 Side 25 0 kg 55 1 Ib HALAR 1 0 um 40 uin Ball Screw 2 4 um 2 5 um 2 8 um 2 10 um Standard 80 160 80 200 80 320 80 400 Accuracy uin uin uin uin HALARG 10 pm 240 pin HALAR 0 5 um 20 pin Repeatability Ball Screw ALARA zu l Bidirectional Standard 1 0 40 yin LN 0 5 um 20 pin N A HALSF 1 um 25 mm 40 yin in Differential HALSF E Standard 2 um 25 mm 80 yin in Straightness HALSF 1 0 40 1 5 um 2 0 um 3 0 um and Flatness Maximum pin 60 pin 80 pin 120 pin Deviation 2 0 um 3 0 um 4 0 um 5 0 um Sandara 80 pin 120 pin 160 pin 200 pin 6 1 kg 13 4 7 5kg 16 5 7 9kg 17 4 8 4 kg 18 5
30. overs the mechanical aspects of setting up the stage including proper stage handling tech niques how to prepare the mounting surface to accept the stage how to secure the stage to the mounting sur face and how to attach a payload Also covered are the electrical aspects of setting of the stage including motor wiring information the optical limit switch assembly and limit home wiring options Installation must follow the instructions in this chapter Failure to follow these instructions could result in injury and damage to the equipment WARNING 2 1 Unpacking and Handling the Stage Carefully remove the stage from the protective shipping container Set the stage on a smooth flat and clean surface This is asimple yet very important step in maintaining the integrity of the stage Each stage has a label listing the system part number and serial number These numbers contain information necessary for maintaining or updating system hardware and software Locate this label and record the information for later reference If any damage has occurred during shipping report it immediately Improper stage handling could adversely affect the stage s performance Therefore use care when moving the stage Manually lifting or transporting the stage can result in injury WARNING Lift the stage only by the base WARNING Do not use the ballscrew or motor as lifting points WARNING www aerotech com Chapter 2 9 Installation AT
31. t all electrical power is disconnected prior to making any mechanical adjustments DANGER 24 Chapter 4 www aerotech com ATS150 Series Stage User s Manual Maintenance 4 3 Important Notes on Lubrication When cleaning and lubricating components of the ATS150 series stages 1 Be sure to use a clean dry soft and lint free cloth for cleaning 2 Take the opportunity during the lubrication procedure to inspect the linear motion guides for any damage or signs of wear 3 Inapplications that have multiple stages bolted together to form multiaxis systems the orthogonality can be altered upon loosening the stage tables of the support stages In this case lubricant should be applied with a hypodermic needle through the aperture hole in the base of the stage or the optional aperture in the stage table Otherwise a master square must be used to realign the XY or YZ orthogonality 4 Further disassembly of the stage is not recommended because proper assembly and calibration can only be done at the factory 4 4 Recommended Lubricants and Cleaning Solvents For standard environments use Dow Corning BR2 on the ball screw and the linear bearings For vacuum environments use Castrol Braycote 602 EF on the ballscrew and linear bearings www aerotech com Chapter 4 25 Maintenance 26 ATS150 Series Stage User s Manual Chapter 4 www aerotech com ATS150 Series Stage User s Manual Warranty and Field Service Appendix A Warranty and Fi
32. tage Table Center Use the cantilever load chart see Figure 3 1 to determine the maximum direct loading force using the following equation Max Loading Force Max Cantilevered Load x Dis tan ce from Load CG to Stage Table Center Calculate the loading percentage using the calculated loading forces Loading Force Loading Percentage x 100 Max Loading Force Multiply the result by the proper factor from the Applied Load Coefficient Table Table 3 4 Refer to the loading vs travel life graph in Figure 3 1 Chapter 3 www aerotech com ATS150 Series Stage User s Manual Operating Specifications The following conversions can be used during load calculations 1 kg 2 2 pounds 2 54 cm 1 in 1 kg cm 13 9 oz in 16 oz in sec2 1 Ib in sec2 1 revolution approximately equals 6 28 radians The approximate amount of torque required to turn the ball screw of an ATS150 series stage can be found from Figure 3 2 Axial Load x Lead of Screw T 2x 7x Efficiency For ATS150 series stages the efficiency is rated at 90 percent 0 90 Maximum load is 100 pounds WARNING Axial Load bs 2mmLead 01001 400 300 200 100 D 0 10 20 30 40 50 60 70 Torque Required oz im Figure 3 2 Torque Required to Turn ATS150 Series Ball screw with Various Loads and Leads Www aerotech com Chapter 3 19 Operating Specifications ATS150 Series Stage User s Manual 3 5 Optical Limit Switch Assembly
33. tion 3 5 1 Changed warning to specify distance in millimeters Section 4 4 Changed recommended lubricants www aerotech com Appendix B 29 Technical Changes 5150 Series Stage User s Manual Table B 2 Archived Changes Section s Affected General Information 30 Appendix B www aerotech com Index ATS150 Series Stage User s Manual Index A ri cadence 14 Attaching the Payload 11 B Basic 15 ae 12 10 D DC Servo Motor 12 Declaration of Incorporation 8 E Electrical 12 Environmental Specifications 13 L Life 17 Limit 21 Limit Switch Assembly 20 Limit Switch 20 Load 1 17 Lubricants 25 Lubrication and Cleaning 24 Lubrication 23 M Model 9 model
34. unding environment and operating conditions can affect the performance and service life of the stage This chapter provides information on ideal environmental and operating conditions Also included are instructions for estimating load and torque required to turn the ballscrew given various loadings 3 1 Environmental Specifications The environmental specifications for the ATS 150 are listed in the following table Table 3 1 Environmental Specifications Ambient Operating 10 to 35 C 50 to 95 F Temperature The optimal operating temperature is 20 C 2 C 68 F 4 F If at any time the operating tem perature deviates from 20 C degradation in performance could occur Contact Aerotech for information regarding your specific application and environment Storage 0 to 40 C 32 to 104 F in original shipping packaging Humidity Operating 40 percent to 60 percent RH The optimal operating humidity is 50 percent RH Storage 30 percent to 60 percent RH non condensing in original packaging Altitude Operating 0 to 2 000 m 0 to 6 562 ft above sea level dE Contact Aerotech if your specific application involves use above 2 000 m or below sea level Use the system in a low vibration environment Excessive floor or acoustical vibration can affect stage and system performance Contact Aerotech for information regarding your specific appli cation Dust Expo The ATS150 stages have limited protection against dust but not water
35. uring the on site repair it is determined the problem is not warranty related then the terms and conditions stated in the following On Site Non Warranty Repair section apply If any Aerotech product cannot be made functional by telephone assistance or pur chased replacement parts and cannot be returned to the Aerotech service center for repair then the following field service policy applies Aerotech will provide an on site field service representative in a reasonable amount of time provided that the customer issues a valid purchase order to Aerotech cov ering all transportation and subsistence costs and the prevailing labor cost includ ing travel time necessary to complete the repair Aerotech Inc Phone 412 963 7470 101 Zeta Drive Pittsburgh PA Fax 412 963 7459 15238 2897 Appendix A www aerotech com ATS150 Series Stage User s Manual Technical Changes Appendix B Technical Changes Table B 1 Current Changes 1 01 00 Section s Affected General Information All Complete revision of style and formatting Some sections were moved or com bined with other sections No technical information was altered as part of this change Section 1 2 Updated model numbers Section 1 4 Added section Section 3 1 Added section Chapter 2 Installation Added safety information and warnings Section 2 1 Section 2 3 Section 2 5 and Sec tion 1 3 Section 0 1 Revised specifications added motor specifications Sec
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