PLG Reference & Maintenance Manual
Contents
1. 16 D LG Reference amp Maintenance Manual 7 6 Electrical Connections Electrical connections to the stages depend on the type of stage in use All PLG models with linear motors or frameless motors are terminated with a 450mm flexible cable with a 28 position circular connector on the end The pin out of this connector is shown with Table 7 1 This particular configuration is optimized for use with Primatics MDC drive chassis via an extension cable Connections to other drives and controls are also made through this connector PLG models with M1 M2 or M3 Motor Mount options provide all electrical connections through DSub connectors Models without internal encoders use a 9 position DSub described in Table 7 4 Models with internal encoders use a high density 15 position DSub described in either Table 7 3 internal brake option B2 or 7 4 no internal brake option B1 A popular option for applications not using the Primatics MDC drive chassis is the pigtailed extension cable This is similar to the extension cable used to connect a stage to the MDC drive chassis except the end that connects to the motor drive and controller is un terminated Section 7 6 1 shows the conductor assignments for this cable when ordered with a ballscrew drivetrain and without an encoder 17 PLG Heference amp Maintenance Manual Table 7 1 Axis Connector Motor encoder limits home temp for Linear motors and frameless motor options FCI cir2. D LG Reference amp Maintenance Manual PLG110 PLG160 amp PLG210 Manual Revision Information 2 2 Introduction About the PLG Family 5 3 MOGGIS i iscsseoss cose css Eos ees gu bca cas dao u NUN nai 5 A Personal Safely sssrin ep dev ee xU a Veo ue e due xv eva dee veu adea ENa cse Vues devra EN TUNE 6 5 COhVehllOliS iiis vixidave cect asx essa US ai Css Es Ela bras nba dees xL eB Sua Eris aa SUPE sa Ss cess 7 Syl Direc tom OF VIOUOM am D PT E 7 oe P WIS OF NIG as Ul Ou ederet cuc des vb eade UV aoo Peto e cf MU Lu Qu EDD Verve DAR de d oT RUE uU 7 6 Installation Preparations ee eere eere eee 8 OT IDC ar MOLDOES ierra b eaim fuvudi da fr RunDES DM ERE Ea FIR Nd oer Ditda ta coms CERE V 8 6 2 FISCAL ANCL nIBiQel E E devi e n 9 B23 Contamina TEE o ORE a e a 9 64 EIS CHIC AIINOIS Cite steasigace sane otia ule ues tuii domudiuse Disc Los su sd dotetd p etna D c CU eu Ense gLuu epe 10 6 5 Using the PLG in a Class 10 Cleanroom seeseeesseeseseeeeeeeeeennennnn nnn 10 6 6 Using the PLG in a VaCULDITTEs secs iuo oe Re Oe ta ere Ere oo D Ree ie m Ree esee oes 10 7 Installing the PLG Positioning Stage 11 res TOOLS VOURW IN NGC or 11 Ter alerte diae eR TP HP ET 11 7 3 Installing
3. Lift the stage by its base structure only Do not lift by the motor drive assembly Stage disassembly and alteration unless specified otherwise may void warranty J 4 7 3 Installing Motors on Ballscrew Stages If the stage was ordered without a Primatics supplied motor or coupling the motor and coupling will have to be installed by the user 7 3 1 In Line Motor Mounting The following procedure is used to mount a motor on PLG stages with the M1 Motor Mount Option 1 Install the flexible coupling on the motor shaft Note A Servo Motor with Encoder is shown but the procedure is similar for a step motor 2 Slip the coupling over the ballscrew shaft and seat the motor in the motor pilot The coupling clamp bolt should be visible If the clamp bolt is not visible or the ballscrew shaft does not extend past the clamping bolt repeat Step 1 and slide the coupling forward or back 12 D LG Reference amp Maintenance Manual 3 Mount the motor to the stage with 4 fasteners All stages typically use M5 x 12 SHCS 4 Fully tighten the coupling clamp screw 7 3 2 Parallel motor mounting The following steps describe the process to mount a motor on a Primatics PLG stage with the Parallel motor mount options M2 position 1 as seen in the following photos or M3 position 2 with the motor mounting in parallel on the other side of the stage Note The following photos are for a PLG110 with the M2 option
4. Common No internal connection 0 1 1 0 0 Encoder Ground S O Encoder Ground W Encoder Index 2Z L0 24 40 0 0 00 0 X Encoder Index J JJ Motor A Common No internal connection C DCCOM Temp Sensor Not Used Connected to DCCOM Not Used 19 PLG Heference amp Maintenance Manual Table 7 3 Signal Connector Internal encoder limits home and brake for Ballscrew motor with encoders and brake Hi Density Male Dsub 15P Pin Funcion 2 DOCOM O 3 Forward Limit Switch 4 Reverse Limit Switch 2 L0 Home 0000000000000 5 Home Brake release output 24VDC ea 3 4 L5 6 Brake return cam 9 EOE i Encoder 5V power for encoder Encoder OV Encoder OV 0 10 11 18 EncoderB ouput 13 Table 7 4 Signal Connector Internal encoder limits home no brake for Ballscrew motor with encoders and no brake Hi Density Male Dsub 15P Pin Funcion 39 3A 6 No connection m 8 Encoder 5V power for encoder gt Z 1 11 09 O EM Encoder OV EncoderOV 10 11 4 r 20 D LG Reference amp Maintenance Manual Table 7 5 Signal Connector Limits
5. Never operate the motor in a location that could be splashed by water exposed to corrosive or flammable gases or is near combustible substances since this may cause an electric shock fire or malfunction Never touch the motor driver or peripheral devices when the power is on or immediately after the power is turned off The high temperature of these parts may cause burns D LG Reference amp Maintenance Manual 5 Conventions 5 1 Direction of Motion The positive direction of motion is defined as a motion away from the motor end of a stage A positive direction of motion also signifies the encoder count is increasing All cables and connectors are located at the motor end of the stage The reverse limit switch is located on the motor end and the forward limit switch is located on the opposite end of the stage Figure 5 2 illustrates this convention moving part of stage T Top Plate Carriage Pp Cj ae lt i Recirculating Belt Ps gt A NA Jj 19 p Se E A ut D 8 X Side Plate y E e 3 7X Base a Belt Cover Forward Limit Motor End E 3 end with cable for linear motor drives Reverse Limit Figure 5 1 Name Conventions Figure 5 2 Positive direction convention 5 2 Units of Measure Primatics uses the metric system for all specifications and dimensions All linear dimensions are specified in millimeters Accuracy repeatability resolution flatness and straightness for the PLG is spec
6. but the steps are the same for a PLG160 or PLG210 stage as well as the M3 options List of tools E Nur ee EC IN Wire Screw E e A Cover um n Cover PLG110 M3 1 4 Wrench M25 Varies M25 PLG160 1 4 Wrench PLG210 1 4 Wrench 13 D LG Reference amp Maintenance Manual 1 Remove the cover of the parallel mount 2 Locate the motor shaft coupling belt pulley and drive belt 3 Install the pulley and motor shaft coupling on the motor shaft Use a wrench for the coupling and band wrench or some other soft tool to secure the belt pulley Motor Shaft Socket Size Adjustment Screws 4 Mount motor to parallel mount as shown The motor pulley should be in the same plane as the drive pulley and spaced about 5mm from the surface of the housing Repeat Step 3 as necessary Loop the Belt around both pulleys 14 D LG Reference amp Maintenance Manual 5 Belt tension is adjusted by loosening the fasteners indicated in Step 4 and sliding the motor mount toward the motor Tighten the adjustment screws to secure the mount in place Use an M3 Hex Driver for the adjustment SCrews 6 Install the cover to the motor mount 15 PLG Reference amp Maintenance Manual 7 4 Mounting surface preparation The characteristics of the surface the positioning stage is mounted to will have a large effect on system performance An accurate and flat positioning stage will conform to the shape of its m
7. home brake no internal encoder for Ballscrew motor with no encoder Male DSub 9P Pin Funcion 6 Brake release output 24VDC for optional brake 8 No connection 420 LA 4 9 jNoconectin 21 D LG Reference amp Maintenance Manual 7 6 1 Color Codes for Pigtailed Cable Cable consists of 3 independent shielded pods One for motor signals one for encoder signals amp a 3 for sensors and brake Each of the pods is described below Cable 1 Motor R Red MotorS Motor T Shld Motor Shield soc Cable 2 Colr Function Red EncoderSVv j EHRE C EH Cable 3 Colo Function mg NS m M E Red HallA 22 PLG Heference amp Maintenance Manual 7 6 2 Hall Effect Commutation Sequence In the event that user amplifier and controls are being implemented use the following motor commutation timing charts Positive Direction of Motion Figure 7 3 Motor commutation chart Positive Direction of Motion Figure 7 4 Timing diagram for the encoder signals 7 7 Home and Limit Sensors Each PLG stage includes Forward and Reverse Limit sensors and a Home sensor Models ordered with internal motors also include a Motor Temperature Switch Figure 7 4 shows the equivalent schematic for
8. motion Can PLG stages be used with third party motors drives and controls What kinds of motors are these Yes in the simplest case the PLG with a ballscrew drivetrain can be ordered with no motor Any standard NEMA 23 size motor can be used with either the in line or parallel mount configurations in PLG110s and PLG160s Any standard NEMA 34 size motor can be used with either in line or parallel mount configurations in PLG210s A coupler can be ordered from Primatics or the user can provide their own coupler For PLGs being used without Primatics drives and controls there are a variety of pigtail assemblies that can be ordered to interface our stages to your drives Can PLG stages be used in gantry configurations Yes In a typical XY configuration two stages placed in parallel form the X motion and a third stage spanning the two create the Y motion An available accessory is a passive non motor driven stage but is dimensionally equivalent to a standard motor driven stage This can be used as one of the two stages placed in parallel 31 D LG Reference amp Maintenance Manual Can PLG stages be mounted vertically Yes For information on how load capacities change please see the PLG datasheets available on our website Can the PLG be used in clean rooms Yes The PLGs can be ordered for class 10 cleanroom Class 1000 cleanroom is standard Ordering options for cleanroom enabled stages are discussed in Section 6 4 C
9. simplify the connection between the PLG stage and controls 3 Models Refer to the PLG Datasheets available from www primatics com for current model options Some options and configurations referenced in this manual have been discontinued The information remains here for reference only PLG Heference amp Maintenance Manual 4 Personal Safety Please review before installing your positioning stage Observe common industrial safety practices when installing and operating automated equipment O Have power connections made by qualified personnel Keep fingers and other items out of any opening in the stage while it is in operation since injury or damage may result Provide a safe access route and adequate room for servicing Perform the recommended periodic maintenance described in this document Verify that the work envelope is free of obstructions before the positioning stage is powered Insure that you have the feedback wired properly to the controller before applying power to the positioning stage Improper feedback connections can cause a motor run away condition that has the potential to damage the stage and injure an operator Only trained operators of the positioning stage should be allowed near the work environment If so equipped identify emergency stop circuits and actuators in the workcell Note the places in the workcell where pinch points occur and provide adequate safety clearance or safety curtain
10. these switches 23 PLG Heference amp Maintenance Manual 12 to 24 V DC Home Forward Limit Switch Reverse Limit Switch T Normally Closed Temp Temp Switch DCCOM Figure 7 4 Equivalent Limit Home and Temp circuit schematic 7 7 1 Home Options The Home switch is ordered in either the Normally Closed H1 or Normally Open H2 configuration H1 Switch is closed when carriage is between the negative reverse end of travel and the home transition point It is open from the transition point to forward end of travel H2 Switch is open when carriage is between the negative reverse end of travel and the home transition point It is closed from the transition point to forward end of travel 7 7 2 Limit Options The Limit switches are ordered in either the Normally Closed L1 or Normally Open L2 configuration L1 When the carriage is in the normal operating range of travel both limit switches are closed When the carriage encounters a limit the switch opens The switch will close again when the carriage is moved away from the switch L2 When the carriage is in the normal operating range of travel both limit switches are open When the carriage encounters a limit the switch closes The switch will open again when the carriage is moved away from the switch 24 PLG Reference amp Maintenance Manual 7 8 Limit and Home Switch Adjustment The limit and home switch positions are preset at the factor
11. LG Heference amp Maintenance Manual 7 Installing the PLG Positioning Stage 7 1 Tools you will need To install the PLG stage you will need the hex wrenches and fasteners listed below M sizes refer to Metric sizes and fractions refer to English sizes In reference to screw sizes the second dimension given refers to the length of the screw in mm For example M4 x 16 would require an M4 screw that is 16 mm long The term BHSC refers to Button Head Stainless Screws Hex Wrench Sizes Base Plate Carriage Top amp Side Coupling Plate Plates PLG210 5 32 Screw Sizes tose Pie corps Pe EGS HO rom Ores em icis Zinc Pau Mess Sonde 7 2 Unpacking Carefully remove the stage from its shipping crate and inspect it for evidence of shipping damage Report any damage immediately to your authorized dealer If so equipped remove the red shipping clamp from the stage PLG110 PLG160 PLG210 Figure 7 1 PLG210 Shipping Clamp Improper handling of the stage may degrade its performance Follow these guidelines when handling and mounting your stage 11 PLG Reference amp Maintenance Manual 1 Do not drop the stage onto its mounting surface Place the stage gently on the mounting surface Impact loads can cause high spots on mounting surfaces misalignment of drive components and warping of the base 2 Do not drill holes into the stage If additional holes are necessary contact your local distributor
12. Motors on Ballscrew Stages cccccscccceccceseeeeeeeeaeeeeeeeeseeeeeeeeesaeeeeeeesseeeeeeaas 12 7 3 1 In Line Motor Mounting ssseesesssessseeeeennneenn nnne nnns 12 7 3 2 Parallel motor mounting cccseecceceeeeeeceeeeeeeeeeeeeeseeseeeceeeeeeseaueeesaeeeeesseeseeeseueeeesseneeseas 13 7 4 Mounting surface preparation eesssesesssseesseeeeee enne nennen nnne nnn 16 7 5 MoOBhg a4 H6 SLAG Ciacci uae cries due Duces A 16 720 EleC iCal GOMNCCIOMNS t D rc 17 7 6 1 Color Codes for Pigtailed Cabole ccccccccccssssceeeceeeseceeeeaeeeeeeeeeseaseeeeessageeseeesaaeseeeseas 22 7 6 2 Hall Effect Commutation Sequence cccccseeeccecceeeseeeeeceesseceeceeeaseceeseseaseeeeeeaaaeeeeeeaas 23 7 7 HOME and Limit SCMS ONS i coe techo ande ita exi eat oacceben ete tat Umen ua dues ed a oca Haden 23 AT Coan aCe f ODIOSd dosis or Ree Pe EM cuidar Meme aec c ciiin nen eet eee ern E 24 7 8 Limit and Home Switch Adjustment ccccccseeeeceecceeseeeeeeeeeeeceeeseeeeeeeesseaeeeeeesseeeeeeeeas 25 7 9 Recommended System Testa tees eee e b e tes ese tubeu i 26 8 Preventive Maintenance eee eere eere eren eene nena 27 s BEBUeqeiog wake ices Ce 27 9 2 Protection Belts scs berb Stud ber Rr ove cu tinier Peu bv etd PEVP UE Vr bov d ua d CuS ade MP Va ci 27 8 2 1 Replacing Belts at the End Opposite of the Cable Exit
13. PLG Heference amp Maintenance Manual primatics PLG Reference amp Maintenance Manual PLG Heference amp Maintenance Manual Drimatics 32114 Mallard Ave PO Box 409 Tangent OR 97389 0409 U S A Phone 541 791 9678 Fax 541 791 9410 Toll Free 888 754 3111 Web www primatics com E mail info primatics com PLG110 PLG160 amp PLG210 Manual Revision Information Revision Date Notes Oct 2003 March 2003 Changed recommended grease from Lithium 2 to NSK Clean room grease April 2005 Updated formatting amp content June 2006 Added table 7 2 November 2006 Updated PLG options images January 2007 Updated Ordering Info January 2008 Deleted P4 option September 2014 Deleted model configurations Jan 2015 New Logo Notice The descriptions drawings and specifications contained herein are subject to change Primatics is not responsible for errors or omissions herein or for incidental damages in connection with the furnishing or use of this information This document shall not be reproduced photocopied or duplicated in whole or in part without prior written approval of Primatics Corporation For Specifications Dimensioned Drawings and additional information refer to the PLG Datasheet available from our website at www primatics com Copyright 2008 2015 by Primatics Inc All Rights Reserved Primatics the Primatics logo PrimaFlex PrimaSeal amp SimpleMatch are trademarks of Primatics Inc
14. an the PLG be used in vacuum Yes The PLGs can be ordered for operation in vacuum Ordering options for vacuum enabled stages are discussed in Section 6 4 Can the PLG be used in dirty environments Yes The PLGs offer several levels of protection for applications in dirty environment The first level of protection includes a hard cover shell over the length of travel The second level of protection includes our proprietary recirculating belt system All stages with these belts come with a high pressure air purge as well as an optional high flow air purge s there a brake option for the Linear Motor drivetrain No Where should mount the stage for optimal performance For optimal performance at high encoder resolutions the PLG stage should be mounted on a smooth granite surface Can the home and limit sensor locations be changed Unless ordered otherwise the home and limit sensors are set in a standard way at the factory Custom home and limit sensor locations can be ordered and they can also be set by the user as demonstrated in Section 8 5 Do you have problems with noise coupling between the power and feedback flex cables As in all cable management systems care must be taken to isolate high and low level signals to prevent cross coupling of noise Primatics has taken steps to electrically isolate the flex cables from each other to minimize noise problems Are the flexible flat cables susceptible to me
15. ction must be used for stages that will be splashed with fluids Airflow through a stage must be filtered and dry The filtration system should reject particles larger than 2 microns Air pressures between 60 100 psi are sufficient for convection cooling A typical air source can be made suitable with the addition of an inline desiccant dryer and filter regulator assembly Humidity should be less than 8596 and there should be no condensation in the environment in which the stage is used D LG Reference amp Maintenance Manual 6 4 Electrical Noise Electrical noise is the corruption of signals carried over low voltage wires Encoder signals can be corrupted resulting in spurious encoder counts thus causing the stage to drift Grounding shielding and spatial separation are all countermeasures to reduce the influences of electrical noise on performance You can minimize the potential for electrical noise by observing the following installation precautions o Physically separate low voltage conductors from those carrying high voltage o Ensure that all components are properly grounded o Ensure that all wiring is properly shielded 6 5 Using the PLG in a Class 10 Cleanroom For operation in a Class 10 Cleanroom the PLG stages must be configured with the P4 or P5 Protection options 6 6 Using the PLG in a Vacuum Many configurations of the PLG Family are compatible with operation in a vacuum Contact us for more information 10 P
16. cular connector 28 pins size 20 shell Function A A MotorA 3 2 O C MotorC vs Jo 0 O E Encoder5V powerforencoder 1 1 1 o F Encoder A output 1 0 0 0 0 G _ Encoder A output H Encoder B output 0 0 0 0 0 0 0 J Encoder B output O K EncoderShield A 7L0 A L 12 24VDC for limit amp home M DCCOM Home Home 0000000000000 HalA Hall A C Hall B Temperature monitor connect to DC Common for temperature OK T U V W X Hall C 18 PLG Heference amp Maintenance Manual Table 7 2 Stepper Axis Connector Motor encoder limits home temp FCI circular connector 28 pins size 20 shell Encoder signals pins E K W and X are available only when encoder option is specified in model Motor B C Motor B J J 000 0000 E Encoder 5V 4 F Encoder A 2J 7 G0 0 0 G EncoderA J J Encoder B 1 1 0 0 0 0 0 0 K Encoder Shield J 0 40 0 L Limit Sensor Power 12VDC 0 000000 M DCCOM DOCOM 0000000000000 O N Home Reserved N C Function 0 1 42 SO A Motor B 0000000000000 O zE T Motor A o O U Motor B
17. essary 3 Follow instructions provided in 8 2 1 30 D LG Reference amp Maintenance Manual 9 Troubleshooting amp Service 9 1 Troubleshooting FAQ s What are typical applications for the PLG PLG stages are typically used in applications such as material handling electronic assembly inspection metrology and process automation with high levels of required precision Do all the positioning stages in a family have the same dimensions The PLG110 PLG160 and PLG210 are considered separate stage families The in line frameless parallel and linear motor versions of each family of stages have identical height and width dimensions but the total length varies slightly depending on the model Although the body of the parallel mount stage has identical dimensions to the others the motor mount itself is wider than the rest of the stage Can PLG stages be used in multi axis configurations Yes PLG stages can be stacked or mounted using brackets PLG110s can be mounted directly to PLG110s PLG160s can be mounted directly to PLG160s and PLG210s can be mounted directly to PLG210s Additionally PLG160s can be mounted directly to PLG210s All other configurations require mounting brackets Mounting bracket drawings are available from our website Can PLG stages be used with other Primatics stages and motion controls Yes PLG stages can be mounted in multi axis configurations with other Primatics stages for a greater range in
18. ified in microns Load capacity is specified in kilograms and moment capacity is given in Newton meters All torque specifications are given in Newton meters Thrust specifications are given in Newtons The following table gives some common conversions into English units Metric Unit English Unit 1 Kilogram equals 0 0685 slug 1 micron equals 0 0000394 inch 1 millimeter equals 0 0394 inch 1 Newton meter equals 8 85 in Ibs 1 Newton equals 0 2248 lbs 1 Kg has a weight of 2 205 Ib when g 9 8 m s D LG Reference amp Maintenance Manual 6 Installation Preparations This section outlines installation environments Unfavorable installation conditions may cause electric shock fire or breakdown Certain breakdown situations or malfunctions in particular may lead to serious injury or other consequences Assure that the unit is used under the following installation conditions Indoors free from being splashed by water No corrosive or inflammable gases present Well ventilated place minimum level of dust or waste An environmental temperature range between 0 40 C and humidity between 20 8096 RH location with no condensation Note These values show the range in which operation can be carried out safely but not the environmental range in which stages accuracy can be guaranteed Stage accuracy can be guaranteed at 20 C 1 C o Location should not be affected by electrical noise o Location should be where inspection and clea
19. iguration H2 L2 Options Normally Closed Normally Open 20 D LG Reference amp Maintenance Manual Adjustment of the limit and home positions can be achieved easily The white metal strip on the interior of the stage has three pieces of black tape affixed to it The bottom half of the strip contains two narrow pieces of tape that correspond to the limit switch positions The limits transition points can be moved by adding additional black tape to the white strip No adjustment of cables is necessary The home transition point can be moved as well or converted to a momentary switch in a similar fashion A 3 inch length of tape is supplied with each stage for this purpose Longer pieces are available upon request The Top Cover must be removed to gain access to the Home Vain Figure 7 7 shows the Top Cover fastener locations Top Plate Fasteners A gei Figure 7 7 Top Cover fastener locations 7 9 Recommended System Test Before attaching a load or applying power to your stage verify the encoder and limit switches are working properly Move the stage carriage by hand in the positive direction and verify the encoder count is increasing Runaway conditions caused by miswired encoders can result in stage damage and personal injury Move the carriage to each end of travel to ensure limit switches are working properly When closing the position loop for the first time set the torque limit of your controller to a low value and use con
20. itioning stage is designed for precision movement in one axis The individual PLG stage can be ordered in a variety of configurations from the differing cross sectional sizes and lengths to the numerous motor options to the various protection levels The stages can be stacked to make X Y or X Y Z systems There are three model Series in the PLG Family PLG110 PLG160 amp PLG210 Each is briefly described in the table below PLG110 PLG160 PLG210 Basic Width x Height mm Travel Lengths mm Drive Types Encoder Option Payload kg 25 100 Each can be configured with options listed in Section 3 Many customers choose the Primatics Motion Drive Chassis MDC to power PLG stages The MDC is a modular system that packages motor drivers encoder interfaces power supplies and safety systems into a single chassis It acts as an intermediary between a Galil Optima National Instruments 7344 or Delta Tau PMAC II motion control cards and a Primatics positioning stage Pre wired high flex cables are available to allow a convenient connection from the stage to the MDC chassis The MDC drive chassis interfaces 3 party controllers via a removable interconnect module These interconnect modules conform to each manufacturers interconnect cable and internally route all the command and I O signals Optionally a Primatics positioning stage can be used with many third party controller and amplifier systems In this case a pigtailed cable is available to
21. lting in peak current conditions All cables follow a simple rule the maximum current a conductor can carry before failure is proportional to the cross section of the copper in the conductor Flexible flat cables are no 32 PLG Heference amp Maintenance Manual different We have designed our flex cables to be able to withstand the maximum current draw of the motor without damage How does a frameless motor work A frameless motor works exactly the same as a brushless servomotor The only difference is that the rotor magnets are placed directly on the ballscrew shaft The ballscrew acts as the motor s rotor This improves the dynamic response of the stage since a compliant coupler is no longer in the system In addition the stage is shortened by several inches Motor Housing Hall Effect Sensor Board Thrust Bearing Ballscrew Shaft Attached screw Shaft Motor Stator Winding Figure 9 1 Frameless Motor Cutaway Where can get more information about the PLG For downloadable brochures datasheets and CAD models go to our website at www primatics com You may also contact your distributor or the factory at 888 754 3111 or 541 791 9678 or email info primatics com 33 D LG Reference amp Maintenance Manual 9 2 Troubleshooting Help For further assistance contact the factory M F 8AM to 5PM Pacific Time 541 791 9678 541 791 9410 Toll Free 888 754 3111 www primatics com E
22. mail service primatics com 9 3 Service Should your device require factory service contact the factory for a Return Materials Authorization RMA When inquiring about an RMA please have the following information available o Your contact information name phone email address o Unit Serial Number o Symptom of problem o History of troubleshooting steps already taken 45 5 y n H 2 y e 3 T D A Pa gt Figure 9 1 Unit Serial Number Location 34
23. ning can be performed without difficulty O O The PLG features built in protection to counteract some negative environmental effects Please see section 3 the PLG datasheet or refer to Table 6 1 below to confirm your selected protection P level Table 6 1 Protection Level Options Protection Hardcover Belts Clean High Pressure High Flow Class 10 Level Level 1 6 1 Linear Motors Linear motors have large magnetic flux that can draw ferrous metals inside them from large distances destroy magnetic media and disrupt some electronic circuits Materials attracted to the magnets can pinch fingers and cause injury Great care must be taken when operating less than 25mm from the surface of the motor In addition braking is difficult for linear motors making them inappropriate for many vertical applications Make sure no load is attached to the linear motor stage when stage is first connected to the electronics Linear motors can generate large accelerations and improper wiring to the control system can result in a high speed crash D LG Reference amp Maintenance Manual 6 2 Heat and Humidity All positioning stages are assembled and tested at 20 C Any stage calibrations are also performed at 20 C For optimum accuracy the ambient temperature should be maintained at 20 C Deviations from this nominal temperature may result in degraded accuracy performance Large thermal gradients in the interior of the stage can result from mot
24. or heat created by high acceleration moves Care must be taken to limit the duty cycle of the linear motor to maintain stage performance Airflow across the motor will help minimize thermal expansion effects and increase the allowable duty cycle Ballscrew driven stages are also susceptible to thermal expansion effects The ballscrew nut can create a localized thermal gradient if driven at high speeds Both high pressure air purge and high flow air purge through the stage can help minimize ballnut heating the latter being most effective 6 3 Contamination Applications in dirty or dusty environments require the electrical optical and mechanical components to be protected The standard belt protection and high pressure 60 90psi high flow air purge system P2 is sufficient for environments generating moderate quantities of 0 5 mm and larger particles It is important to be aware of the amount of airflow going into the stage air flowing into a stage can push the belts against the slots that they run in and cause an increase in the amount of drag created by the belts This can affect the performance of the stage Adverse effects may include increased settling times or decreased repeatability of the stage For dusty environments or applications with continuous exposure to smaller contaminants an optional low pressure high flow purge system is necessary P5 It allows movement of 5 15 cfm of low pressure air through each stage Additional prote
25. ounting surface therefore a flat mounting surface is required In the absence of a sufficiently flat surface a three point mounting scheme can be utilized to rely on the inherent flatness of the stage This technique can introduce negative dynamic effects in moment load applications because a large portion of the stage base is not in contact with the mounting surface The flatness and straightness specifications can be affected under large loads For best results in maintaining stage specifications we suggest the following 1 Usealaboratory Grade AA granite surface plate 2 Before mounting stage inspect for burrs or dings on the stage mounting surfaces 3 Clean all mounting surfaces with acetone In the absence of a granite surface plate we recommend a base plate made of the same material as the base of the stage A mounting surface constructed out of a material different from the stage base material can introduce warping in the stage in the presence of a thermal gradient The surface flatness should match the requirements of the application a good starting point is to have the mounting surface flat to less than 5 8um Figure 7 2 Mounting Hole locations 7 5 Mounting the Stage 1 Remove Side Covers Insert Mounting Screws 3 Tighten Screws Access holes are provided for hex tool When mounting the base down to the surface plate tighten the bolts at one end of the stage first and move towards the other end 4 Replace Side Covers
26. screw lubrication port port If the stage has re circulating belts upon reinstalling the side covers make sure the belts engage both the top and side cover containment grooves In the event that the top cover has been removed replace the top cover first and insert the belts into the containment grooves before replacing the side covers When replacing the side covers insert the belts into the containment grooves before attempting to tighten down the mounting hex screws Failure to seat the belts properly will compromise the sealing system and reduce belt life 8 2 Protection Belts 2 D LG Reference amp Maintenance Manual Protective belts can be ordered with the PLG stages under the P2 or P5 options The belts are made of a polymer with a polyurethane coating that will provide millions of cycles of use In a dirty environment particles deposited on the belts may collect into a small area in the endplates Removal of the belt end plate covers see Figure 8 3 gains access to this area Periodic cleaning of this area is necessary Belt Belt Pulley Set Screws Pulley shaft access holes Belt Endplate Cover Particle Collection Area Figure 8 3 Protection Belt anatomy 8 2 1 Replacing Belts at the End Opposite of the Cable Exit To replace the belts on the end opposite of the cable exit use the following procedure 1 Remove belt covers outlined in white 28 D LG Reference amp Maintenance Manual 2 Remove bel
27. servative tuning gains Once the control loop is working properly payloads can be added to the stage carriage 26 PLG Reference amp Maintenance Manual 8 Preventive Maintenance Performing preventive maintenance procedures on your stage will extend its life and improve its long term performance 8 1 Lubrication Use clean room grease to lubricate the ballscrew and linear guide components We recommend NSK grease part GRS LG2 For low duty cycle applications it is recommended that the ballscrew and linear guides are re greased every six months High duty cycle applications may require more frequent re lubrication Lubrication intervals depend on duty cycle load and ambient conditions Inspection of the drivetrain elements may be required to determine the proper lubrication interval Primatics offers a grease kit that has all the necessary hardware to re lubricate the ballscrew and linear bearings To gain access to component grease ports remove the stage side plates On the end of each bearing block is a small hole where grease is injected using a syringe see Figure 8 1 The ballnut in ballscrew drive models must be lubricated Beneath the carriage a grease tube with a 3mm nipple is located between the bearing blocks on the side opposite the home limit strip see Figure 8 2 It supplies the ball nut with grease Use a grease gun with a mating coupler La UE AE tics Figure 8 1 Bearing block lubrication Figure 8 2 Ball
28. sussssse 28 8 2 2 Replacing Belts at the End of the Cable Exit eeeeeeseseeseeeseesess 30 9 Troubleshooting amp Service 1 eee eeee ee eeee eene eene ennt 31 91 Troubleshooting FAQS u octekueribaxoss o Dtm twr Put citu vlbtdespd S actu ucs Eae 31 9 2 Troubleshoolhng bIelpsss son ote eva E deu Rod unt UR nius 34 SDS VIG Casta sade uaa en ad iota asc ELM M MI LA Mes I MMIM ELA EI MIS A ME 34 PLG 1 Overview Reference amp Maintenance Manual This user guide is designed to help you install and maintain your PLG Series linear positioning stage application Follow these steps to ensure correct stage installation and maximum stage life Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Review this entire user manual Become familiar with all installation procedures prior to integrating your system Review the safety summary to develop an understanding of standard safety practices when installing and operating automated equipment Familiarize yourself with the conventions summary Review installation procedures For best results follow these procedures carefully Once you successfully complete all the installation procedures you will be ready to install and operate your stage Review preventive maintenance section for proper lubrication schedule D LG Reference amp Maintenance Manual 2 Introduction About the PLG Family Each Primatics PLG pos
29. t from carriage plate pins This may require a small regular screwdriver to pop off the belts 3 Turn seal pulley set Pulley Set Screw screw 1 4 turn be Ee counterclockwise Insert 1 5mm hex screwdriver into q gt the pulley access hole and pop out the pulley shaft 4 Loosen top cover to give enough clearance for the belt Remove the belt 29 Heference amp Maintenance Manual Follow this procedure for the other 3 belts Follow the reverse procedures to install new belts Make sure you attach the spring before attempting to attach the belts to the carriage belt pins 8 2 2 Replacing Belts at the End of the Cable Exit To replace the belts on the motor end of the stage requires additional steps depending on the motor mount Follow these additional steps when replacing the belts 8 2 2 1 Parallel Mount Motor Stages 1 Remove parallel motor housing outer cover 2 Remove the two hex screws that attach motor housing to the endplate with M2 5 hex tool 3 Remove motor housing 4 Follow instructions provided in 8 2 1 8 2 2 2 Nema 23 In Line amp Frameless Motor Stages 1 Remove the two hex screws on the cable exit box with a M2 5 hex tool 2 Remove cable exit box 3 Follow instructions provided in 8 2 1 8 2 2 3 Linear Motor Stages 1 Remove the two hex screws that attach the cable exit housing to the endplate with a M3 hex tool Remove cable exit housing Disconnecting the cable should not be nec
30. y The limits are nominally set to yield slightly more travel than specified in the model configuration The nominal home switch transition point is about 2mm to the positive side of the center of travel Figure 7 5 shows the default signal transition points for a 200mm travel stage Limit Sensor Transition Region for Default Configuration P d Home Sensor Transition Range N 101 7 100 2 100 0 13 27 100 100 2 101 7 N Reverse Limit Switch Transition Range Center of Travel of Stage mm 4 Forward Limit Switch Transition Range Figure 7 5 Limit and Home Sensor Transition Ranges The home and limit signals are each produced by separate reflective sensors mounted to the underside of the carriage A white reflective strip the home vane mounted on the inside of the stage runs the length of the stage and is viewed by each sensor A special non reflective black tape is applied to the home vane Each switch is closed when viewing the white area and is open when viewing the non reflective tape Figure 7 6A shows the tape configuration for the normally closed sensor options H1 L1 Figure 7 6B shows the tape configuration for the normally open sensor options H2 L2 The point at which each signal transition occurs can be adjusted by adding or removing the non reflective tape The home sensor can also be reconfigured to a momentary switch by adding or removing tape Figure 7 6A Home Vane Figure 7 6B Home Vane Configuration H1 L1 Options Conf
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