Cartesius-SD Series Cartesian Robot User`s Manual
Contents
1. 00002022 eee eee eee 20 Inspection Schedule 29 Stage table terete 3 14 Standard Features 0 00 2 L Limit Switch Operation 21 T limit switches 2 temperature effects 19 Limit Switches 0000 17 21 www aerotech com Index 39 Cartesius SD Series Stage User s Manual 40 U Unpacking and Handling the System 11 Vv vacuum applications e 3 Vacuum Operation 27 Vacuum Preperation e 27 W MELA AN RA 8 WIRING cc chs baa cms ALENA kal ina 17 Wiring iii iii iii 22 Index Index www aerotech com Reader s Comments Cartesius SD Series Stage Manual PIN EDS141 November 29 2010 Revision 1 01 00 Please answer the questions below and add any suggestions for improving this doc ument AEROTECH Is the manual Adequate to the subject fi Well organized Ba i Clearly presented a al sl Well illustrated BS 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 Seolo TT Na SSC S eee Re O A Come bets O ae O Gusoneroaeg o Aerotech Subsidiary Email Order DO Mailyour comments to Faxto Aerotech Inc 412 967 6870 101 Zeta Drive Pittsburgh PA2. 68 F The greater the temperature dif ference the greater the error The temperature of the ballscrew depends on the speed and duty cycle of the axis The faster the movement and higher the duty cycle the more the stage accuracy will be affected by heat The thermal expansion coefficient of the ballscrew is 11 7 ppm C www aerotech com Chapter 3 19 Operating Specifications Cartesius SD Series Stage User s Manual 3 3 Basic Specifications Specifications forthe Cartesius SD series positioning system are not included in this manual For more detailed information see the individual axis PRO165 or PRO115 manuals 3 4 Load Capability The Cartesius SD s load capability will vary widely depending on the number of axes the individual axes lengths leads the payload s size location and the move profile Each case should be confirmed with Aero tech as acceptable For reference all Cartesius SD configurations can handle a centered non offset 5 kg load Systems with shorter travel axes or XY assemblies will have a greater load capability 20 Chapter 3 www aerotech com Cartesius SD Series Stage User s Manual Operating Specifications 3 5 Optical Limit Switch Each Cartesius SD axis is provided with a pair of optical limit switch assemblies mounted to the base of the stage The limit switches signal when the axis has reached its maximum useable travel distance in both direc tions 3 5 1 Limit Switch Operation Each limit sw
3. 15238 U S A service aerotech com
4. Cartesius SD e Besure to use a clean dry soft lint free cloth for cleaning e Take the opportunity during the lubrication procedure to inspect the linear motion guides for any damage or signs of wear e The orthogonality may be lost if the inter axis bolts are loosened Precision aligned stages should not be loosened or disassembled e Further disassembly of the system is not recommended because proper assembly and calibration can only be done at the factory In addition a laser interferometer is required for post assembly verification to maintain warranties 4 2 3 Lubrication and Cleaning Process The lubrication and cleaning process is outlined in the steps that follow Follow the procedure for each individ ual axis Before beginning lubrication see Section 4 2 1 for recommended lubricants Follow the steps below for each axis individually For Cartesius SD Y axes the motor cover will have to be removed to gain access to the hardcover mounting screws Remove the motor cover as shown in Figure 4 1 and Figure 4 2 For Cartesius SD Z axes depending on customer assembly configuration it may not be pos sible to remove the hardcover by sliding it out of the side opposite the motor as the work area may be in the way In this case the hardcover can be removed from the motor end although the cover must be angled above the front end plate to be removed Do not remove the stage tabletop Drive the stage carriage to the far end of travel
5. Step 3 cece cc cee cece cece cece cece ee eeeeeeees 33 www aerotech com V List of Figures vi Cartesius SD Series Stage User s Manual www aerotech com Cartesius SD Series Stage User s Manual List of Tables List of Tables Table 1 1 Table 2 1 Table 3 1 Table 3 2 Table 3 3 Table 3 4 Table B 1 Table B 2 Model Numbering System iii iiiiiiiiias 5 Stage Mounting Surface Flatness Requirement 00 00000000 12 Environmental Specifications 0 19 Limit Brake and Encoder Wiring Pinout Descriptions 2c cece cece ee ee 24 Motor Wiring Pinout Descriptions o occ c ccc cece ccc ccc cece cece eee eeeeees 25 Connectorized USER IO Cable Pin Assignments 200000 ee ceeeeeeeeeeeeeee 26 Current Changes 1 01 00 0 0000 37 Archived Changes 0 cece cece cece cece cece ee ivi 38 www aerotech com vii List of Tables Cartesius SD Series Stage User s Manual viii www aerotech com Cartesius SD Series Stage User s Manual Overview Chapter 1 Overview The Cartesius SD series Cartesian robot is an industrial strength multi axis system that is built on the Aero tech Producer Series linear ballscrew stages It is ideal for many automation applications including pick and place assembly test and inspection dispensing stations and many more Chapter 1 shows a typical Cartesius SD positi
6. opposite the motor before performing this procedure Once the hardcovers for the Cartesius SDY and Z axes have been removed clean and lubricate as described below Step1 Drive the stage table to one end of travel Figure 4 3 and remove power to the stage Step2 Remove the screws on the edges of the hard cover Figure 4 4 and slide it out from the side oppo site of the motor Figure 4 5 This can be done without removing the table Step 3 Remove any accumulated dust or debris from the inside of the assembly Step4 Remove any dirty or dried lubricant from the ballscrew Use a clean lint free cloth with a side to side motion Manually turn the ballscrew to clean its entire circumference A swab soaked in Iso propyl Alcohol may be used to remove stubborn debris Step5 Clean the end of the ballscrew nut and wiper with a clean lint free cloth or swab Step 6 Clean the linear bearing guides using a similar technique 30 Chapter 4 www aerotech com Cartesius SD Series Stage User s Manual Maintenance Step 7 Apply a thin continuous film of lubricant to the ballscrew threads and linear bearing guides A good quality natural bristle artist s brush makes an excellent applicator Step 8 For stages without an optional brake manually move the stage to the opposite end of travel This will work the grease into the ballscrew and linear bearing guides If the stage has an optional brake the stage cannot be moved by hand In this case
7. 449 N rnberg Alex Weibel My Neho tb Engineer Verifying Compliance Pittsburgh PA November 29 2010 Chapter 1 www aerotech com Cartesius SD Series Stage User s Manual Installation Chapter 2 Installation This chapter describes the installation procedure for the Cartesius SD stage including handling the stage properly preparing the mounting surface securing the stage to the mounting surface attaching the payload and making the electrical connections 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 System Carefully remove the system from the protective shipping container Use the provided eyebolt to lift the assembly The lifting eyebolt should be removed before operating the system Set the system on a smooth flat and clean surface This is a simple yet very important step in maintaining the integrity of the system A leveling foot is attached to the Y axis bracket for support during shipping The leveling foot must be removed before operating the system If any damage has occurred during shipping report it immediately 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 infor mation for later reference If any damage has occurr
8. 5MM 600 600 mm 24 in travel 5mm lead ballscrew stage Y 20MM 200 Y 20MM 250 500 mm 20 in travel 5mm lead ballscrew stage www aerotech com Chapter 1 5 Overview Cartesius SD Series Stage User s Manual Table 1 1 Model Numbering System continued XZONMSIOXCNS Y 05MM 250 YCMS 250 mm 10 in travel 5mm lead ballscrew stage and cable management NOZ Tuz USER IO DSUB 2 6mm airlines and 1 customer I O cable provided with mated 25 pin D connector at the stage carriage USER IO FLY 2 6mm airlines and 1 customer I O cable provided with flying leads at the stage car riage 6 Chapter 1 www aerotech com Cartesius SD Series Stage User s Manual 1 2 Dimensions Yy STAGE PRO165 05MM 250 PRO165 20MM 150 STAGE rel Overview stase eTo PRO115 05MM 050 PRO165 05MM 300 PRO165 20MM 200 o Prosoma PRO115 05MM 250 PRO115 20MM 150 737 5 PRO115 05MM 100 336 195 FRO115 0sMM 180 386 220 PRO165 05MM 400 PRO165 20MM 300 636 484 PRO165 05MM 500 PRO165 20MM 400 736 534 9 PRO115 05MM 200 436 245 PRO115 05MM 250 486 270 PRO115 05MM 300 536 295 RIGHT HAND RH CONFIGURATION STAGE BULKHEAD 1 CUSTOMER VO CABLE 25 PIN CONN amp 2 CUSTOMER AIRLINES 6MM OD PROVIDED X AXIS PRO165 SEE STANDARD PRO165 DATA SHEET FOR MOUNTING HOLE DETAIL X AXIS SHIPPING BRACKETS 65 7 3 Y AXIS SHIPPING BRACKETS 20MM LEAD STAGES O
9. Cartesius SD Series Cartesian Robot User s Manual P N EDS141 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 Technical Support Revision History Register online at http www aerotech com prodreg cfm 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 1 01 00 November 29 2010 Revision 1 00 00 February 13 2009 Product names mentioned herein are used for identification purposes only and may be trademarks of their respective companies Aerotech Inc 2010 Cartesius SD Series Stage User s Manual Table of Contents Table of Contents Chapter 1 Overview iii linia malal iii iaia ales 1 1 1 Standard Features 0 2 1 1 1 Optional Features c eee e eee iii aooo aoaaa annan 3 1 1 2 Model Numbers 222222 cccce cece cece cece ee ccce cece ceceeceeeeee
10. NLY QTY 2 bad Y NOMINAL TRAVEL i w Y AXIS PRO115 3 a H 1 2 Z AXIS ba NOMINAL TRAVEL LI E Y AXIS ite gr m 6 it i 100 101 6 SO 75 76 2 SQ LEFT HAND LH CONFIGURATION Y AXIS TABLETOP FOR XYCONFIG 12 THK AN TTM LTTUJ 25 25 4 SQ 137 SQ 50 50 8 SQ M6X1 0 1 4 20 A F10 10 8 FOR XYZ CONFIG SEE 16 PLACES STANDARD PRO115 FOR Z TABLETOP DIMENSIONS Z AXIS PRO115 W BMS60 amp BRAKE lt 2 a SHIPPING FOOT 168 B DIMENSIONS MILLIMETERS Figure 1 5 www aerotech com Chapter 1 Cartesius SD Dimensions Overview Cartesius SD 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
11. Specifications Cartesius SD Series Stage User s Manual 3 6 Limit Switch Wiring Limit switches are open collector TTL compatible electro optical devices powered by 5 Volts that change output states when the stage approaches its maximum travel distance and breaks the light beam Since they are open collector devices they may be interfaced to 24 Volt logic inputs Each limit switch is mounted on a small printed circuit board Standard stages include wiring in a separate 9 pin limit switch connector detailed in Figure 3 2 5 25MA 24 VIO 24 GRN Common CW Limit 24 WHT Home Limit CCW Limit lt __ 24GRY 9 Pin Male D DE 9P ECK137 Backshell 17 1724 2 ECK1021 Jacksockets ECK128 Figure 3 2 Series 9 pin Limit Switch Wiring Assuming a NC limit configuration the input to the controller is seen as a logic O typical 0 4V 12 8 mA when no limit condition is present When the limit switch is activated a 5V source through a pull up resistor on the controller causes a logic 1 typically 4 8 5 V to be seen by the controller input The limit switch oper ation for a NO limit configuration is the exact opposite as described above See Figure 3 3 for a diagram of limit switch wiring 5V Controller 5V Controller o Pull Up Limit Input Resistor Limit Input Resistor To Controller To Controller NC Limit 4 NO Limit Switch Switch Pull Up g Normally Closed NC Normally Open NO Figure 3 3 Normally Closed NC
12. and Normally Open NO Limit Switch Wiring 22 Chapter 3 www aerotech com Cartesius SD Series Stage User s Manual Operating Specifications 3 7 Standard Motor Wiring Stages fitted with standard motors and encoders come from the factory completely wired and assembled For reference connector pin outputs and general wiring information is given in the following figures and tables Pin outputs are defined in 3 7 and 3 7 NOTE Referto the other documentation accompanying your Aerotech equipment Call your Aerotech rep resentative if there are any questions on system configuration NOTE If you are using your own cables to connect the stage ensure that motor and ground wires can handle current higher than the continuous motor current listed in the individual axis PRO165 or PRO115 manuals The voltage rating of the wire insulation must be higher than the maximum drive output voltage listed in the individual axis PRO165 or PRO115 manuals o GY Y a pa 08 A o j gt g so 7 OS 7 O 7 o h a gt BRAKE 1 02 wo BRAKE 92 gt UA 7 oz LIMIT 5V 4 O UT LIMIT COM Y f ENC 5V A ENC COM 1 cos 4 COS N G DB25P ECKD01 01 sina Haman 4 I 26 orN 4 CONTACT SIDE man e 26 winor Z n __ zecrn _W Cinch DB 255 ECK300 HA azsen Ng HA TTT seen YA 7 7 7 Figure 3 4 Limit Brake and Encoder Wiring for Standard Stages SIG SHLD www aerotech com Chapter 3 23 Operating Specifica
13. ard X axis 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 Table 2 1 Stage Mounting Surface Flatness Requirement X Axis Stage Travel Flatness Requiement 12 Chapter 2 www aerotech com Cartesius SD Series Stage User s Manual Installation 2 3 Shipping Brackets Cartesius SD s X axis comes equipped with shipping brackets There are also shipping brackets on the Y axis if it has a 20mm lead ballscrew Both sets are shown in Figure 2 2 Remove the shipping brackets once the stage has been placed on the mounting surface The X axis shipping bracket is composed of three pieces Remove the vertical block at the opposite end of the X axis motor first It is secured by two M5x0 8 socket head cap screws SHCS Then manually translate the X axis table away from the motor to access and remove the second vertical shipping block which is also secured by two M5x0 8 SHCS The shipping bracket base can then be removed by removing the four M4x0 7 SHCS The Y axis brackets are mounted in place with two M4x0 7 socket head cap screws Retain all shipping brackets for future use Figure 2 2 Shipping Bracket Locations www a
14. 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 retum authorization number The return authorization number may be obtained by calling an Aerotech service center Products must be retumed prepaid to an Aerotech service center no C O D or Collect Freight accepted The status of any product returned later than 30 days afterthe 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 mination expense Failure to obtain a purchase order number or approval within 30
15. ceeeeeeeees 5 1 2 Dimensions c eee e La cee e eee e cece eee e cece cece ceeeeeeeeeeeseeees 7 1 3 Safety Procedures and Wamings c cece cece cece cc ccc cece cece eee ceeeeeeeeeeees 8 1 4 EC Declaration of Incorporation 10 Chapter 2 Installation 11 2 1 Unpacking and Handling the System iii 11 2 2 Preparing the Mounting Surface 000000000 12 2 3 Shipping Brackets iii iii iii veci 13 2 4 Securing the System to the Mounting Surface ce cece e cece ee ceceecceeeeeees 14 2 5 Attaching the Payload to the System iii 15 2 6 Electrical Installation 222 2 2225 slice trae Na ka Salari sea 16 2 6 1 Standard Aerotech Motor Options 00 17 2 6 2 Optical Limit Switches ce cece cece ccceeeeeeeeeeee 17 Chapter 3 Operating Specifications c cece cece ec ece eee eee 19 3 1 Environmental Specifications 22 0 2 2 002222 cece ccc cece eee cece cece ccc cecccceeeeeeeeees 19 3 2 Accuracy and Temperature Effects cece cece cece cece ccc cece ccc ceeeeeeeeeees 19 3 3 Basic Specifications e ee eaaa aaraa anran nrnna 20 3d Load Capability ston tse Sooo bh et PEPE cetera tates ake sie seine See tes Ba 20 3 5 Optical Limit Switch 21 3 5 1 Limit Switch Operation 0 li iiiiiiiii i
16. cote 602EF grease or a substitute of equal quality Baking vacuum components between 100 and 125 C for 24 to 48 hours significantly reduces outgassing at initial pump down to vacuum pressure and evaporates water vapor that impregnates porous surfaces on the aluminum surfaces and Teflon cables Aerotech recommends that customers bake out vacuum systems when first installing them in the vacuum chamber www aerotech com Chapter 3 27 Operating Specifications Cartesius SD Series Stage User s Manual 28 Chapter 3 www aerotech com Cartesius SD 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 NOTE The bearing area must be kept free of foreign matter and moisture otherwise the performance and life expectancy of the system will be reduced Always operate the system with all hard covers 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 Service and Inspection Schedule Lubricant inspection and replenishment in the Cartesius SD series systems 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 applicatio
17. d high flex cables ensure that Cartesius SD provides millions of cycles of maintenance free operation In the unlikely event of a failure a modular design ensures that part replacement is fast and easy Other standard design features include integral hardcovers and side seals to keep contamination out of the interior of the stages and integral wipers on the ballscrew nut and bearing trucks to further reduce con tamination Optical limit switches and mechanical end stops which protect the machine from over travel are also standard Figure 1 2 A single axis of the Cartesius SD with Cutaway View of Ballscrew 2 Chapter 1 www aerotech com Cartesius SD Series Stage User s Manual Overview 1 1 1 Optional Features Available assembly options allow Cartesius SD to be configured for a variety of applications Cartesius SD can be configured in either a right hand RH or left hand LH orientation The Z axis is optional so Cartesius SD can be made as an XY or XYZ system The travels of each axis can be matched in any combination The X and Y axes can use either a 5mm or 20mm lead ballscrew The axes can also be pre cision aligned to either 10 or 5 arc sec orthogonality if needed See Figure 1 3 and Figure 1 4 for examples of different arrangements available The stage table of the Y axis or Z axis if ordered is available with the mounting holes and grid pattern in either English TTU or Metric TTM dimensions Cartesius SD systems ca
18. 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 or out 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 JO Warranty and Field Service Cartesius SD Series Stage User s Manual On site Warranty Repair On site Non warranty 36 Repair Company Address 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 during the on site repair it is determined the problem is not warranty related
19. dicate 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 The stage s protective ground is located on pin A4 of the motor connector If you are using cables other than those provided by Aerotech you must connect pin A4 to a ground con nection WARNING Figure 2 4 Components of a Typical Stage 16 Chapter 2 www aerotech com Cartesius SD Series Stage User s Manual Installation 2 6 1 Standard Aerotech Motor Options Aerotech s high performance brushless rotary motors are the standard motors for all axes of Cartesius SD The BM130 and BMS 100 are standard for the X axis PRO165 The BM75 and BMS60 are the standard motors for the Y and Z axes PRO115 with the Z axis motor always supplied with a brake The electrical wir ing from the motor and encoder to the connectorized ports on the motor can is contained within the rear motor housing and has been completed at the factory The motor cables and limit cable convey motor power encoder feedback and limit switch signals to an appropriate hardware device e g axis controller or ampli fier Refer to Section 3 7 for standard motor wiring and connector pin output
20. e table Proceed with the electrical installation and test the motion control system in accordance with the sys tem documentation Document all results for future reference For information on electrical connections refer to Section 2 6 Electrical Installation The payload should be flat rigid and comparable to the system in quality NOTE For valid accuracies the mounting interface should be flat within 1 um per 50 mm Do not attach a payload to the stage table with screws that are too long A screw passing through the stage table can come into contact with the hardcover affecting travel and pos sibly damaging the stage WARNING www aerotech com Chapter 2 15 Installation Cartesius SD Series Stage User s Manual 2 6 Electrical Installation Electrical installation requirements will vary depending on system options Installation instructions in this section are for systems equipped with standard Aerotech motors intended for use with an Aerotech motion control system Contact Aerotech for further information regarding systems that are otherwise configured Aerotech motion control systems are adjusted at the factory for optimum performance When the Cartesius SD series system is part of a complete Aerotech motion control system setup involves connecting the sys tem to the appropriate drive chassis with the cables provided Connect the provided cables to the motor and feedback connectors on the Cartesius SD Labels on the drive in
21. ed during shipping report it immediately Improper system handling could adversely affect the stage s performance Use care when moving the system Manually lifting or transporting the system can result in injury WARNING Do not use the ballscrew or motor as lifting points WARNING www aerotech com Chapter 2 11 Installation Cartesius SD Series Stage User s Manual 2 2 Preparing the Mounting Surface The mounting surface should be flat and have adequate stiffness in order to achieve the maximum per formance from the Cartesius SD When a stage is mounted to a non flat surface the stage can be distorted as the mounting screws are tightened See Figure 2 1 NG 4 TT TT Mounting to a flat surface Mounting to a curved surface exaggerated Figure 2 1 Results of Flat Versus Non Flat Mounting NOTE To maintain accuracy the mounting surface should be flat as specified in Table 2 1 Any distortion will decrease the overall accuracy of the system Aerotech recommends stoning the mounting surface and the X axis stage base with precision flat stones prior to mounting the system to the mounting sur face to remove any local high spots or imperfections in the surfaces Adjustments to the mounting surface must be done before the system is secured If Aerotech HDR165 risers have been ordered as part of the Car tesius system in order to achieve desired accuracy the flatness requirement must be observed as it would for a stand
22. erotech com Chapter 2 13 Installation Cartesius SD Series Stage User s Manual 2 4 Securing the System to the Mounting Surface If necessary manually move the X axis stage table to access the 6 5 mm 0 28 in diameter mounting holes along the edges of the X axis stage refer to Figure 2 3 This stage is designed to use socket head cap screws SHCS to secure the base to the mounting surface Use M6 x 22 mm or 1 4 x 7 8 long SHCS to achieve 1 5x diameter thread engagement Torque the mounting screws to 8 1 N m 6 ft Ib 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 If the stage is not connected to a power source and 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 The system must be mounted securely Improper mounting can result in injury and damage to the equipment WARNING 0 Carefully slide the stage table to expose the mounting holes Figure 2 3 Mounting Hole Locations on X Axis 14 Chapter 2 www aerotech com Cartesius SD Series Stage User s Manual Installation 2 5 Attaching the Payload to the System To prevent damage to delicate payloads test the operation of the system before attaching the payload to th
23. ii ieLaa 21 3 6 Limit Switch Wiring iii aaran aroaro naonana 22 3 7 Standard Motor Wiring e cece cece eeeeeeeeeeeeeeeeeeeeeeees 23 3 8 Vacuum Operation 2 222222 ii 27 3 8 1 Special Guidelines 22 2 2 2 coe cee cece cece aride iiSi 27 Chapter 4 Maintenance 29 4 1 Service and Inspection Schedule 2 2 2 0 a 29 4 2 Cleaning and Lubrication a 30 4 2 1 Recommended Lubricants and Cleaning Solvents 0 30 4 2 2 Important Notes on Lubrication 0 00 00 aaa 30 4 2 3 Lubrication and Cleaning Process ccecce eee e cece e cece eee eeeeeeeeeeees 30 Appendix A Warranty and Field Service c cece e eee eee 35 Appendix B Technical Changes 2 2 0 0 0 0 ooo occ ccc cece cece cec eee ececeececeececee 37 UN SERRARA RO e TO III ATI tee ee et 39 Reader s Comments iii e KALONG aller li 41 www aerotech com lil Table of Contents Cartesius SD Series Stage User s Manual IV www aerotech com Cartesius SD Series Stage User s Manual List Of Figures List of Figures Figure 1 1 Figure 1 2 Figure 1 3 Figure 1 4 Figure 1 5 Figure 2 1 Figure 2 2 Figure 2 3 Figure 2 4 Figure 3 1 Figure 3 2 Figure 3 3 Figure 3 4 Figure 3 5 Figure 4 1 Figure 4 2 Figure 4 3 Figure 4 4 Figure 4 5 Typical Cartesius SD Series Cartesian Robot_ _ 1 A s
24. ingle axis of the Cartesius SD with Cutaway View of Ballscrevv 2 Right Hand XYZ with Cable Management System top and XY bottom Assemblies 3 Left Hand XYZ top and XY bottom Assemblies 0000 0000000000 4 Cartesius SD Dimensions iii ceeeeeeeeees 7 Results of Flat Versus Non Flat Mounting 00000000 12 Shipping Bracket Locations iii ii cece eee eee eeeeeeeeeeeeeeees 13 Mounting Hole Locations on X AXis c cece cece cece ccc cece cece cece ee anann 14 Components of a Typical Stage e cece cece cece ccccceceeceeees 16 Internal View of a Typical Stage Showing Limit Switches 220000 222222000 21 Series 9 pin Limit Switch Wiring 00 22 Normally Closed NC and Normally Open NO Limit Switch VViring 22 Limit Brake and Encoder Wiring for Standard Stages o o o 23 Motor Wiring Connector for all Stages c ccc e cece cece cece eeeeeee 25 Y axis Motor Cover eee eee 31 Y axis Motor Cover Removal Procedure 0 00 2 c cece cece cece ccc cece eee ii ii iii 32 Hardcover Removal Procedure Step T cece cece ccc cece cece cece cece eeees 32 Hardcover Removal Procedure Step 2 cece ccc cece cece cece ceeeeeees 33 Hardcover Removal Procedure
25. ion 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 CES Contact Aerotech if your specific application involves use above 2 000 m or below sea level Vibration 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 Cartesius SD has limited protection against dust but not water This equates to an ingress sure 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 3 2 Accuracy and Temperature Effects The accuracy specification of Cartesius SD series robot is measured at the center of travel 25 mm above the table The system is assumed to be fully supported by a mounting surface meeting or exceeding the spec ification in Table 2 1 The accuracy of the ballscrew is a key element in the overall positioning accuracy A scale error on each axis can be expected if temperature of the ballscrew differs from 20 C
26. itch has a light source and detector mounted to a small printed circuit board Each limit switch board is mounted at an end of the stage with its emitter detector axes perpendicular to the direction of table motion On a standard stage the clockwise CW switch is located at the end opposite the motor When movement of the stage table causes the blade mounted to the stage carriage to break the light beam from the emitter to the detector a CW or counterclockwise CCW limit signal is generated The limit switch itself can be configured as normally closed NC or normally open NO If the stage is driven past the electrical limit it will encounter the hard stop Where the hard limit occurs is dependent on stage travel Although the operating speed of the stage may be relatively slow and the stage s shocks will provide some protection damage to the stage could result WARNING o Guide Rails dl Stage Table NU 5 a ro _ gt _ C AEROTECH a OOO Optical Limit Switch Optical Limit CCW Limit Switch CW Limit Figure 3 1 Internal View of a Typical Stage Showing Limit Switches NOTE Clockwise CW and counterclockwise CCW refer to the direction of motor rotation while looking into the shaft of the motor CW rotation of the motor causes the stage table to move away from the motor CCW rotation of the motor causes the stage table to move toward the motor www aerotech com Chapter 3 21 Operating
27. n Longer or shorter intervals may be required to maintain the film of lubricant on the bearing surfaces In general it is recommended that stages operating in a clean environment be lubri cated annually or every 500 km whichever comes first For stages operating under conditions involving excessive debris lubrication every six months is recommended If the application process uses only a small portion of travel for most of the duty cycle it is recommended that the stage be periodically driven through full travel to redistribute the lubrication in the bearings and ballscrew The ballscrew end bearings and motor bear ings are sealed and should not need to be relubricated under normal use www aerotech com Chapter 4 29 Maintenance Cartesius SD Series Stage User s Manual 4 2 Cleaning and Lubrication 4 2 1 Recommended Lubricants and Cleaning Solvents For standard ballscrew assemblies and LMG guide rails THK AFE CA grease is recommended If a solvent is necessary for cleaning the stage it is recommended that isopropyl alcohol be used Harsher solvents such as acetone may damage the plastic and rubber seals on the ballscrew nuts or LMG trucks If acetone is required avoid the screw and bearing seals For high speed applications i e near maximum speed at a duty cycle of 5096 frequent ballscrew main tenance with standard lubricants is required 4 2 2 Important Notes on Lubrication When cleaning and or lubricating components of the
28. n be ordered with a USER IO option where Aerotech supplies 2 6mm airlines and 1 25 conductor signal cable through the stage cable management to the stage tabletop for easy integration The signal cable can be supplied connectorized or with flying leads For vacuum applications two vacuum preparation options are available upon request one compatible with low vacuum environments down to 103 torr and the other for high vacuum 1073 to 10 9 torr applications Figure 1 3 Right Hand XYZ with Cable Management System top and XY bottom Assemblies www aerotech com Chapter 1 3 Overview Cartesius SD Series Stage User s Manual Figure 1 4 Left Hand XYZ top and XY bottom Assemblies 4 Chapter 1 www aerotech com Cartesius SD Series Stage User s Manual Overview 1 1 2 Model Numbers System model number example CARTESIUS SD RH X 20MM 300 Y 20MM 300 YCMS Z 05MM 050 ZCMS TTMZ USER IO SUBD The table below lists the available options in the order they appear in the example above Aerotech con tinually 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 Table 1 1 Model Numbering System X 20MW 300 XC20MM 400 X 20MM 500 500 mm 20 in travel 20mm lead ballscrew stage XCO5MM 250 ICOSMM 300 X 05MM 500 500 mm 20 in travel 5mm lead ballscrew stage X 0
29. oning system For this manual X axis will refer to the base axis Y axis will refer to the cross axis and Z axis will refer the vertical axis The X Y and Z axes are com prised of the PRO165 PRO115 and PRO115 respectively The X and Y axes travel ranges from 150 to 600 mm and the Z axis from 50 mm to 300 mm This chapter introduces standard and optional features of the Cartesius SD series explains the model num bering system and gives general safety precautions Figure 1 1 Typical Cartesius SD Series Cartesian Robot NOTE 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 Cartesius SD Series Stage User s Manual 1 1 Standard Features A precision ground ballscrew and Linear Motion Guide LMG are standard features in all the axes of Car tesius SD The precision ground preloaded ballscrews ensure superior positioning resolution and accuracy while the LMG bearing systems provide stiffness good load carrying capabilities and continuous load sup port over the entire range of travel Cartesius SD also includes a complete cable management system CMS Extensive R amp D has resulted in an optimized CMS that has been field proven as the industry s most reliable design Large bend radii an
30. restore power to the stage drive it to the desired posi tion then remove power and continue to Step 9 Be sure to use extreme caution while operating the stage temporarily without the hardcover installed Step 9 Repeat steps 3 through 7 for any areas covered by the original table position Step 10 Refasten the hardcover Step 11 Restore power to the stage drive the stage table back to its original position to redistribute lubri cants To minimize the possibility of bodily injury confirm that all electrical power is disconnected prior to making any mechanical adjustments DANGER Figure 4 1 Y axis Motor Cover www aerotech com Chapter 4 31 Maintenance Cartesius SD Series Stage User s Manual 4 Remove Motor Cover Mounting Screws Figure 4 2 Y axis Motor Cover Removal Procedure Figure 4 3 Hardcover Removal Procedure Step 1 32 Chapter 4 www aerotech com Cartesius SD Series Stage User s Manual Maintenance Remove hard MIN cover screws ge je ate mi ak Figure 4 4 Hardcover Removal Procedure Step 2 Slide hard cover out away from the motor ta Figure 4 5 Hardcover Removal Procedure Step 3 www aerotech com Chapter 4 Maintenance Cartesius SD Series Stage User s Manual 34 Chapter 4 www aerotech com Cartesius SD Series Stage User s Manual Warranty and Field Service Appendix A Warranty and Field Service Aerotech Inc warrants its products to be free from defects cau
31. s 2 6 2 Optical Limit Switches Each axis of Cartesius SD is equipped with a pair of optical limit switches one at each end of nominal travel The limit switches can be configured as normally closed NC or normally open NO On the X axis stage the limit cable exits the stage on the same side as the motor and is bundled with the other system cables For the Y and Z axis stages the limit cable is wired into the feedback cable Refer to Section 3 6 for a descrip tion of limit switch operation and wiring www aerotech com Chapter 2 17 Installation Cartesius SD Series Stage User s Manual 18 Chapter 2 www aerotech com Cartesius SD Series Stage User s Manual Operating Specifications Chapter 3 Operating Specifications The surrounding environment and operating conditions can affect the performance and service life of the sys tem This chapter provides information on ideal environmental and operating conditions Also included are instructions for estimating load capability 3 1 Environmental Specifications The environmental specifications for the Cartesius SD 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 applicat
32. sed 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 retumed 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 concealed must be filed with the carrier Return Procedure by the buyer Aerotech must
33. 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 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 Cartesius SD 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
34. t Descriptions Description FRM GND Ground to stage base MTR SHLD Shield for motor wiring connector MTR A Motor Phase A MTR B Motor Phase B MTR QC Motor Phase C www aerotech com Chapter 3 25 Operating Specifications Cartesius SD Series Stage User s Manual Table 3 4 Connectorized USER IO Cable Pin Assignments Cable Shield User connection 1 1 amp maximum current 50 volts maximum User connection 2 1 amp maximum current 50 volts maximum User connection 3 1 amp maximum current 50 volts maximum User connection 4 1 amp maximum current 50 volts maximum 7 User connection 6 1 amp maximum current 50 volts maximum 10 i 12 13 14 15 16 7 18 19 20 21 Pin 16 ESE 8 9 EA tt 12 3 EE ES 16 18 119 20 21 26 Chapter 3 www aerotech com Cartesius SD Series Stage User s Manual Operating Specifications 3 8 Vacuum Operation Aerotech can specially prepare the Cartesius SD system for operation in vacuum environments Aerotech offers two vacuum preparation options one for low vacuum for use in atmospheric pressures to 103 torr and one for high vacuum preparation for environments from 1073 to 10 9 torr As part of this preparation attention to detail during modification cleaning and assembly results in stages with optimal performance in vacuum applications This section will outline preparation techniques for stages that will operate in a vacu
35. the needed safety requirements A A A A A A z Z Z Z Z Z Z Z Z Z Z Z Q Q Q Q Q Q www aerotech com Chapter 1 9 Overview Cartesius SD Series Stage User s Manual 1 4 EC Declaration of Incorporation Manufactorer Aerotech Inc 101 Zeta Drive Pittsburgh PA 15238 USA AEROTECH NG herewith declares that the product Aerotech Inc Cartesius SD 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 10 AEROTECH GmbH S d West Park 90 D 90
36. 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 Cartesius SD Series Stage User s Manual Technical Changes Appendix B Technical Changes Table B 1 Current Changes 1 01 00 Section s Affected General Information Section 1 4 Section added Section 3 1 Section added Chapter 2 Installation Section 2 1 Section 2 4 Added safety information and warnings Section 2 6 and Section 1 3 Section 3 7 Added note about wire current and voltage requirements www aerotech com Appendix B 37 Technical Changes Cartesius SD Series Stage User s Manual Table B 2 Archived Changes Section s Affected General Information 38 Appendix B www aerotech com Index Cartesius SD Series Stage User s Manual Index linear motion guide l
37. tions Cartesius SD Series Stage User s Manual Table 3 2 Limit Brake and Encoder Wiring Pinout Descriptions PinOutput Description CW LMT CENT HA Hall Effect A Brushless motor commutation track output TTL line driven signal with rotary motor HB Hall Effect B Brushless motor commutation track output TTL line driven signal with rotary motor HC Hall Effect C Brushless motor commutation track output TTL line driven signal with rotary motor HOME LMT Homing cycle reference limit optional LMT 5v 5 V supply input for optical limit switch boards Typical requirement is 50 mA LMT COM Common ground for limit switch MKR Marker Incremental encoder output pulse given once per revolution Typically used for home reference cycle Incremental encoder output either the compliment of Marker with a line driven TTL type encoder or 2 5 V DC bias level with amplified sine wave type encoder SIN Sine Incremental encoder output either TTL line driven or amplified sign wave type signal SIN N Incremental encoder output Complement of sin 24 Chapter 3 www aerotech com Cartesius SD Series Stage User s Manual Operating Specifications MTR MTR SHLD eee Set BENTAHE 1 18 GIYEL I MTR B A2 i8RED _ KZ DEMMOWAP ECK658 a VIEW CONNECTOR MTR A 18 BLK k CONTACT SIDE 5 MATING CONNECTOR 4 ECK657 CONNECTOR ECK659 CONTACTS QTY 4 Figure 3 5 Motor Wiring Connector for all Stages Table 3 3 Motor Wiring Pinou
38. ubrication 30 A Load Capability 0 20 Attaching the Payload to the System 15 9 y y Lubricants B Recommended eee eee eee 30 b lls rew Lubrication 0 00 00 002 c eee eee eee eee ee 30 temperature of 19 Lubrication Schedule 29 c M per 16 model numbers eee eee 11 cable management system 2 USA cece cece eter teeeeees Li Cleaning iii 30 o Cleaning Solvents i DE operating conditions 19 Recommended 30 L La Optical Limit Switch 000 21 clockwise CW switch 21 PE et Soh a 2 optical limit switches 2 counterclockwise CCW switch 21 I dia Optical Limit Switches 17 CW and CCW terminology 2 21 9y Optional Features 3 D P Declaration of Incorporation 10 kakaba Preparing the Mounting Surface 12 Dimensions iii 7 S E safety procedures 00 8 Electrical Installation 16 Securing the System to the Mounting Surface 14 encode Seenen AA 17 23 Service Schedule 29 Environmental Specifications 19 NG Shipping Brackets 13 I Specifications
39. um Some techniques covered are e Lubrication with vacuum compatible lubricants e Useof materials fasteners and coatings with vacuum outgas performance compatible with the level of vacuum specified e Forhigh vacuum stages elimination of situations that may allow gases to become temporarily trapped during pump down e Extensive cleaning prior to assembly in a clean environment and packaging in a special polyethylene bag 3 8 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 Do not remove the stage from the sealed bag until it is ready for use 2 Always handle the stage in a clean environment and use powder free polyethylene gloves to prevent any contaminants from adhering to the surface of the stage 3 During installation use cleaned vented stainless steel fasteners when securing the stage Reduced air pressure eliminates significant convective heat transfer This coupled with the viscous vac uum compatible lubricants could result in excessive motor operating temperatures Because of this consider all continuous torque ratings to be 40 to 60 lower than the value specified for operation in nor mal atmospheric environment Reduce motor usage accordingly 5 Forvacuum applications the recommended lubricant is a small quantity of Bray
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