PDR Series Reference & Maintenance Manual
Contents
1. ASUIE seepe re ne Ea rt RESE ERAS EAE E 7 5 Installation Preparation esch ht eco efeei gebei Eed ebas 8 5 1 Heat and Humidity sise 8 5 32 nde tte sant en nn nate ci ta aa eed ete seine a AR eee 8 5 89 Electrical NOiS tx sist 2 te ne nn ee ee ane nel Mt Eege 9 6 Installing the PDR Positioning Stage 10 6 1 T00lS You Will Deler ege ien eege gg ees eege eege 10 6 2 UMPACKING RE 10 6 3 Mounting surface preparation issu 10 6 4 Electrical Connechons siens 11 6 4 1 Hall Effect Commutation Geouence 12 6 4 2 Encoder Timing Diagram issu 12 6 5 HOME SWIC Hissar scare esac enke eege eege ee 13 6 6 Recommended System Test 14 7 Preventive Maintenance seen 15 8 Troubleshooting amp Service snnnsnnnnnnes 16 8 1 Troubleshooting Help ses rss unes eed begets ne entente tar eyed ee 16 EE Ee 16 PD R Reference amp Maintenance Manual 1 Overview This user guide is designed to help you install and maintain your positioning stage application Follow these steps to ensure correct stage installation and maximum stage life Step 1 Review this entire user manual Become familiar with all installation procedures prior to integrating your system Step 2 Review the safety summary to develop an understanding of standard safety practices when installing and operating automated equipment Step 3 Familiarize yourself with the conventions summary Step 4 Review installation procedures For best result2. P D R Reference amp Maintenance Manual primatics PDR Series Reference amp Maintenance Manual PDR Reference amp Maintenance Manual al primatics 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 PDR Manual Revision Information Publication Date Notes Jan 2015 New Version New Logo Aug 2015 Corrected section 6 4 to include home sensor 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 Copyright 2015 by Primatics Inc All Rights Reserved Primatics the Primatics logo PrimaFlex PrimaSeal amp SimpleMatch are trademarks of Primatics Inc PD R Reference amp Maintenance Manual PDR Manual Revision Information sssssssssssnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn 2 AY OVER EEN 4 2 Introduction About the PDR family ss 5 3 Personal Safety 7 uesesetseeeuNKENeESNEEENEEHKEKNEECNEENNEEEERERNEENKEESNEENEEENEEENEKENE 6 4 Stage amp Manual Conventions ms sssssnnnnnsnnnnnee 7 RRE UC ele Ree 7 4 2 UNIS OF MO
3. and flat positioning stage will conform to the shape of its mounting surface therefore a flat mounting surface is required For best results in maintaining stage specifications we suggest the following 1 Use a laboratory 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 10 PDR Reference amp Maintenance Manual 6 4 Electrical Connections All PDR models 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 6 1 No other connections are necessary for the PDR Table 6 1 Axis Electrical Connector FCI circular connector 28 pins size 20 shell D 5 Function Motor A Motor B Motor C Motor Shield Encoder 5V power for encoder Encoder A output Encoder A output Encoder B output Encoder B output Encoder Shield Sensor power 12 24VDC Sensor common Home sensor Not used Not used Signal S
4. cautions 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 PD R Reference amp Maintenance Manual 6 Installing the PDR Positioning Stage 6 1 Tools you will need The PDR Series uses the following fasteners Base Rotating Platen PDR110 M4 SHCS M4 SHCS PDR160 M5 SHCS M5 SHCS PDR201 M6 SHCS M5 SHCS 6 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 Improper handling of the stage may degrade its performance Follow these guidelines when handling and mounting your stage 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 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 Remove the red shipping brackets prior to use AES 6 3 Mounting surface preparation The characteristics of the surface the positioning stage is mounted to will have a large effect on system performance An accurate
5. ctory and cannot be adjusted 12 to 24 V DC lt lt Home Sak Forward Limit L1 Closed Signal L2 Open Reverse Limit L1 Closed Signal nN L2 Open Temp T Normally Closed Temp Switch DCCOM 2 Pi Figure 6 3 Equivalent Limit Home and Temp circuit schematic The home sensor transition occurs relative to the encoder index according to the diagrams below Home Transition Home Transition Home Transitoin Nominal deg Min deg Max deg PDR110 13 5 20 PDR160 4 2 6 PDR201 4 2 6 Table 6 2 Home Sensor Transitions for each PDR Series Open Open Closed Closed 2 l ep z e Encoder Index X Encoder Index X H1 Option H2 Option Figure 6 4 Home Transitions Chart X represents Nominal Home Transition 13 PD R Reference amp Maintenance Manual Ki P Y RON HAL ENCODE INDEX F D K jf TRAR SETICH WHEN WITNESS d HARK QUE SCREW 45 SHOWN NOMINAL HOME TRANSITION WHEN WITNESS MARK E 13 PDR 10 4 PDR160 amp PORZ10 FROM SCREW AS SHOWN Figure 6 5 Encoder Index and Home Transitions 6 6 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 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 ensur
6. e 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 lbs 1 Newton equals 0 2248 lbs 1 Kg has a weight of 2 205 Ib when g 9 8 m s PD R Reference amp Maintenance Manual 5 Installation Preparation 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 80 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 1 C o Location should not be affected by electrical noise o Location should be where inspection and cleaning can be performed without difficulty E 5 1 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 t
7. e 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 conservative tuning gains Once the control loop is working properly payloads can be added to the stage carriage 14 PD R Reference amp Maintenance Manual 7 Preventive Maintenance The PDR series rotary stage does not require periodic maintenance The motor and encoder are non contact devices and the bearing element is pre packed with grease and does not need relubrication The stage should be kept clean and a soft cloth should be used wipe down the stage Do not use compressed air to spray away dust since this may force dust into crevices 15 PD R Reference amp Maintenance Manual 8 Troubleshooting amp Service 8 1 Troubleshooting Help For further assistance contact the factory M F 8AM to 5PM Pacific Time Phone 541 791 9678 Fax 541 791 9410 Web www primatics com E mail service primatics com 8 2 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 located as shown below o Symptom of problem o History of troubleshooting steps already taken Figure 8 1 Unit Serial Number Location 16
8. emperature should be maintained at 20 C Deviations from this nominal temperature may result in degraded accuracy performance Humidity should be less than 85 and there should be no condensation 5 2 Environment The PDR series is intended for clean environments free from particulate and fluids Additional protection must be designed for stages that are in dirty environments The PDR Series stages have an optional high pressure low flow air system Remove thescrew shown in Figure 5 1 and replace with an M5 air fitting Figure 5 1 High Pressure Low flow port PD R Reference amp Maintenance Manual Airflow through a stage must be filtered and dry The filtration system should reject particles larger than 2 microns Air pressures between 30 50 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 85 and there should be no condensation in the environment the stage is used in 5 3 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 pre
9. hield Hall V Hall V Encoder common Encoder Index Encoder Index Forward Limit see Note Reverse Limit see Note Key Hall A Hall B Not used Hall C ojala o N lt x S lt C Al wm D uIZzZr xle To mM o o w gt Note The PDR series does not include limit sensors The Limit Signal options are provided for compatibility with motion controller requirements 11 PDR Reference amp Maintenance Manual 6 4 1 Hall Effect Commutation Sequence The following diagram shows the motor signal timing for the Servo Motor option Positive Direction of Motion Figure 6 1 Motor Phase and Hall Sensor Timing 6 4 2 Encoder Timing Diagram The following diagrams show the signal timing for the Encoder options A ei I U I B l i La 4 I I I I z i Pk Figure 6 2 Timing diagram for digital encoder signals 12 PD R Reference amp Maintenance Manual 6 5 Home Switch The home switch uses a reflective sensor located in the base of the stage A white reflective strip runs the circumference of the stage and is viewed with this reflective sensor 180 of this strip is covered with a black mask When the sensor is over the white area the output signal conducts current and closes the home switch When the sensor is over the black the switch is open The home switch is fixed at the fa
10. les conform to each manufacturers interconnect cable and internally route all the command and I O signals The PDR can also be used with user supplied drives and controls Electrical interface to the PDR is through a single robust industrial connector at the end of a short flexible cable This configuration allows the PDR to be fit into small spaces PD R Reference amp Maintenance Manual A 3 Personal Safety A 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 o Keep fingers and other items out of any opening in the stage while it is in operation since injury or damage may result o Provide a safe access route and adequate room for servicing o Perform the recommended periodic maintenance described in this document o Verify that the work envelope is free of obstructions before the positioning stage is powered o 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 o Only trained operators of the positioning stage should be allowed near the work environment o If so equipped identify emergency stop circuits and actuators in the workcell o Note the places in the workcell where pi
11. nch points occur and provide adequate safety clearance or safety curtain o 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 o 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 PD R Reference amp Maintenance Manual 4 Stage amp Manual Conventions 4 1 Direction of Motion The positive direction of motion is defined as a rotation in the counter clockwise direction as one is looking down on the stage platen The encoder is wired so that the encoder count increases as the stage rotates in the positive direction Figure 5 1 illustrates this convention Figure 4 1 illustrates this convention Positive Direction Figure 4 1 Positive direction convention 4 2 Units of Measure Primatics uses the metric system for all specifications and dimensions All linear dimensions are specified in millimeters Angular displacement is specified in degrees Accuracy error and repeatability for the PDR is expressed in arc seconds 1 degree 3600 arc seconds 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 som
12. s follow these procedures carefully Step 5 Once you successfully complete all the installation procedures you will be ready to install and operate your stage Step 6 Review preventive maintenance section for proper lubrication schedule PD R Reference amp Maintenance Manual 2 Introduction About the PDR family The PDR Series is a precision continuous travel rotary stage It incorporates a direct drive brushless servo motor and high resolution encoder in a small package It comes in three sizes the base of the stage is square with dimension 110 160 and 210 mm The corresponding diameters of the platen the part that rotates are 110 155 and 210 mm respectively A high precision glass scale rotary encoder is directly coupled to the rotating platen A home switch and index pulse on the encoder are used for determining a repeatable home position Many customers choose the Primatics Motion Drive Chassis MDC to power PDR 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 and 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 modu
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