PFR225 Reference & Maintenance Manual
Contents
1. Encoder Index Forward Limit Switch Reverse Limit Switch Signal Shield Hall A Hall B Temperature monitor connect to DC Common for temperature OK Hall C o Q 0 o M IN lt lt S lt C Al n DI VIZIElH A C TIO m m v o w gt 13 P F R 2 2 5 N Reference amp Maintenance Manual 7 4 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 Color Function H Black Motor R E Red Motor S White Motor T Shld Motor Shield Cable 2 Color Function i Red Encoder 5V White Encoder A output H Yellow Encoder A output H Green Encoder B output E Blue Encoder B output H Shld Encoder Shield i Black Encoder Common H Orange Encoder Index al Brown Encoder Index Cable 3 Color Function H Green 12VDC i Blue DCCOM White Home H Wht Red Not used H Wht Black Not used H Shld Chassis E Black Hall V H Brown Hall V H Violet Forward Limit Switch H Gray Reverse Limit Switch E Red Hall A H Orange Hall B di Tan Temperature Monitor 8 Yellow Hall C 14 P F R 2 2 5 Reference amp2. P F R 2 2 5 Reference amp Maintenance Manual primatics PFR225 Reference amp Maintenance Manual P F R 2 2 5 N 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 PFR225 Manual Revision Information Publication Date Notes Dec 2000 May 2005 Updated look amp formatting 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 PFR Family Datasheet available from our website at www primatics com Copyright 2007 2015 by Primatics Inc All Rights Reserved Primatics the Primatics logo PrimaFlex PrimaSeal amp SimpleMatch are trademarks of Primatics Inc p F R 2 2 5 Reference amp Maintenance Manual PFR225 Manual Revision Information ccccccssseeesseeeeeeeeeeeeeeeeeeseeeeeeeeeeeenees 2 KM EENEG EEGEN 4 2 Introduction About the PFR Series seen 5 3 Model CGopfguratlon svekvuuseNeEE
3. 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 P F R 2 2 5 N Reference amp Maintenance Manual 5 Stage amp Manual Conventions 5 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 Positive Direction Figure 5 1 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 Angular displacement is specified in degrees Accuracy error and repeatability for the PFR 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 some common conversions into English units Metric
4. If additional holes are necessary contact your local distributor 3 Lift the stage by its base structure only 4 Stage disassembly and alteration unless specified otherwise may void warranty 11 p F R 2 2 5 Reference amp Maintenance Manual 7 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 and flat positioning stage will conform to the shape of its mounting 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 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 grad
5. N O L2 Absent N O L4 Encoder Type 2 1 Arc Sec RESONON ad gen 8 NN NEISTER ENN E1 0 41 Arc Sec ResolutioM E2 Protection Level Level 1 Covers w High Pressure Purge P1 Level 2 High Flow Air Purge P2 Level 3 Class 10 Cleanroom P3 P F R 2 2 5 N Reference amp Maintenance Manual A 4 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 workcell o Note the places in the workcell where pinch points occur
6. 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 Ibs 1 Kg has a weight of 2 205 Ib when g 9 8 m s P F R 2 2 5 N 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 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 stage 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 cleaning can be performed without difficulty 0000 6 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 temperature should be maintained at 20 C Deviatio
7. second repeatability and fast settling times making the PFR ideal for point to point indexing assembly and optical applications Many customers choose the Primatics Motion Drive Chassis MDC to power PFR 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 UO 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 simplify the connection between the PFR and controls PFR225 3 Model Configuration Table Diameter Reference amp Maintenance Manual SAMPLE MODEL NUMBER PER 225 AL P HE It E Model Series Full ROGHON aus SCENE TEE PFR 5 KANN 22 Base Material lee kreeg tee Cl Aluminum AL Grade Precision ve cre om EE P Home Sensors Present N C Hi Present N O H2 Limit Sensors Present N C LI Absent N C L3 Present
8. ESEKEERSKKEKREENEEAEEEENEKESKEKUSEAEEREEEEERERKNKEESNEANEEEEERENENENER 6 A 4 Personal Safety vvvcsssseccicssineecenseseesnrceeeecensneeneasecesuawasveasnecanatawasauniaedsie 7 5 Stage amp Manual Conventions ccccccccrcceccccccccceenenannncccceenn nn 8 8 1 Dir ction ot Monon ssenarini EEN Eed E 8 5 2 Units OP Measure vise nav ceed EEN EE E 8 6 Installation Preparations eeeceeeeeeseeeeeeeeeeeeeeeeeeeeeeseeeeneeeeeeeeesseeeeeeneeeeees 9 6 17 Heat Tele le H uulle TTT 9 6 2 Environment TTT 10 6 3 Electrical NOSE uie oae ea ERRAR RR AEEA AAAA SARAS a ARRA isan RAE DOR ARRA RXRA RA 10 7 Installation Eroceeduresg decke Eege 11 Z U TOUS you wi DEE 11 422 IN PACKING EE 11 7 3 Mounting surface preparation ccceecceeeeeeeeeeeeeeneeeeeeeeeeeeeaaeeeeteaeeeeteaaeeeeeeeeeeeneaaeeees 12 7 4 Electrical Connection ceeccceeeceeeteeeeeneeeeeeeeseaeeeeeaeeceaeeseeeeesaeeseeaeeseaeeseaeeeeeaeeeeeneeseaeetas 12 7 4 1 Color Codes for Pigtailed Cable ciii csiinens 14 7 4 2 Hall Effect Commutation Geouence 15 7 5 Home and Limit Gensors 15 5 1 Home elle 16 7 6 Limit and Home Switch Adjustment 0 ccceceeceeeeeeeseeeeeeeeeeeaeeeeaeeeseaeeseaeeeeaeeseneeeseeeeteas 17 7 7 Recommended System Test 18 8 Preventive Maintenance cccccccesssssseeeeeeeeeeeeeeseeeeeeeeeeeeeeeeeseeseeseeeeeees 19 8 1 Belt TENSION EE 19 8 2 Belt Tension Adjustment cceecceeeeesec
9. Maintenance Manual 7 4 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 1 Motor commutation chart Positive Direction of Motion Figure 7 2 Timing diagram for the encoder signals 7 5 Home and Limit Sensors Each PFR model includes a Home Sensor used for homing the state Forward and Reverse Limit Sensors are optional and may or may not be included in a specific model The internal motors include an over temperature switch Figure 7 3 shows the equivalent schematic for these sensors and switches 15 P F R 2 2 5 N Reference amp Maintenance Manual 12 to 24 V DC Ki gt Home geet Forward Limit Switch Reverse Limit BA Switch i u T Normally Closed Temp Temp Switch DCCOM D D Figure 7 3 Equivalent Limit Home and Temp circuit schematic 7 5 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 5 2 L
10. ceeeeseceeeeeseneeeeaneeeenaneesssaneeesaaseeesneeneenensaneenees 20 8 3 Belt Lubrication s ccic02 stevens Gua ae od el eee eel 21 9 Troubleshooting amp Service iviceccceesccccccnsceceesesetsccenscecesanssassennacteeesedeneceanasnence 22 9 19 Troubleshooting Help cietesvsctehcesbeas cee egethee ds leteleneieheetieai res dedeee delateleie endo eee aes 22 GERT 22 p F R 2 2 5 Reference amp Maintenance Manual 1 Overview This user guide is designed to help you install and maintain your PFR Series rotary 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 Step3 Familiarize yourself with the conventions summary Step 4 Review installation procedures For best results 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 P F R 2 2 5 N Reference amp Maintenance Manual 2 Introduction About the PFR Series Each Primatics PFR positioning stage is designed for precision rotary movement An innovative drive system creates arc
11. ch Top Covers 20 P F R 2 2 5 N Reference amp Maintenance Manual 8 3 Belt Lubrication The drive belt operates most smoothly if it has a light coat of grease on its teeth This should not be done in harsh environments Not more often than yearly apply a small amount of 2 grease to the middle of the toothed side of the belt The engagement of the belt on the pulley will spread the grease to the edges 21 P F R 2 2 5 N Reference amp Maintenance Manual 9 Troubleshooting amp Service 9 1 Troubleshooting Help For further assistance contact the factory M F 8AM to 5PM Pacific Time Phone 541 791 9678 Fax 541 791 9410 Toll Free 888 754 3111 Web www primatics com E mail service primatics com 9 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 see Figure 9 1 o Symptom of problem o History of troubleshooting steps already taken Figure 9 1 Unit Serial Number Location 22
12. d in 6 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 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 10 P F R 2 2 5 N Reference amp Maintenance Manual 7 Installation Procedures 7 1 Tools you will need To install the PFR stage you will need the hex wrenches listed below Cover Base Plate Rotary Platen PFR100 M2 M4 M4 PFR225 M2 5 1 4 or M M5 amp M6 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 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
13. f Travel of Stage mm Forward Limit Switch Figure 7 5 Limit and Home Sensor Transition Ranges for PFR225 The home and limit signals are each produced by separate reflective sensors mounted to the base next to the platen A white reflective strip the home vane mounted on the platen 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 amp L3 Figure 7 6B shows the tape configuration for the normally open sensor options H2 L2 amp L4 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 17 P F R 2 2 5 N Reference amp Maintenance Manual P Home Sensor On Region Home Sensor On Region E IECH e Home Sensor Transition Point Home Sensor Transition Point Limits Limits Figure 7 6A Home Vane Figure 7 6B Home Vane Configuration H1 L1 amp L3 Options Configuration H2 L2 amp L4 Options Normally Closed Normally Open 7 7 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 platen by hand in the positive direct
14. ient 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 7 4 Electrical Connection All PFR 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 7 1 This particular configuration is optimized for use with Primatics MDC drive chassis via an extension cable Extension cables compatible with this circular connector are available from Primatics No other connections are necessary for the PFR 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 drive is un terminated for easy connection to a user supplied motion controller Section 7 4 1 shows the conductor assignments for this cable 12 P F R 2 2 5 N Reference amp Maintenance Manual Table 7 1 Axis Connector Motor encoder limits home temp FCI circular connector 28 pins size 20 shell 8 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 12 24VDC for limit home and temp sensor DCCOM Home Not used Not used Chassis Hall V Hall V Encoder Common Encoder Index
15. imit Options The Limit switches are ordered in either the Normally Closed L1 L3 or Normally Open L2 L4 configuration If the PFR is specified with either the L3 or L4 options the switches are replaced with a permanently Closed L3 or Open L4 circuit This feature offers compatibility with other positioning stages and controls 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 16 P F R 2 2 5 N Reference amp Maintenance Manual 7 6 Limit and Home Switch Adjustment The limit and home switch positions are preset at the factory The limits are nominally set to yield slightly more travel than specified in the model configuration The nominal home switch transition point is about 2 to the positive side of the center of travel Figure 7 4 shows the default signal transition points Figure 7 4 Limit amp Home Switch PCB and Home amp Limit Switch Ring Limit Sensor Transition Region for Default Configuration P Home Sensor Transistion Point N 171 7 170 2 170 0 13 27 170 170 2 171 7 S Reverse Limit Switch Center o
16. ion counterclockwise see Figure 5 1 Runaway conditions caused by miswired encoders can result in stage damage and personal injury 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 platen 18 P F R 2 2 5 N Reference amp Maintenance Manual 8 Preventive Maintenance 8 1 Belt Tension The PFR will operate through a fairly broad range of belt tension However too much or too little tension will manifest itself in notchiness of rotation control problems and premature belt wear When the belt is tensioned correctly the motion should feel smooth when the platen is rotated by hand Figure 8 1 illustrates that when the belt is tensioned correctly a 10 Ib side load will deflect the belt 3mm at the motor housing een Figure 8 1 Testing Belt Tension 19 P F R 2 2 5 N Reference amp Maintenance Manual 8 2 Belt Tension Adjustment 1 Remove Top Covers 2 Loosen the 4 ea M5 SHCS that secure the motor housing to the base with a M4 Hex Driver They should be barely loose enough to allow the housing to slide in the slot it is captured in 3 With an M3 Hex Wrench turn the tensioning screw on the opposite side of the stage clockwise to tension counterclockwise to loosen 4 Retighten the Motor Housing Screws 5 Reatta
17. ns from this nominal temperature may result in degraded accuracy performance Ballscrew driven stages are also susceptible to thermal expansion effects The ballscrew nut can create a localized thermal gradient if driven at high speeds Air flow through the stage can help minimize ballnut heating p F R 2 2 5 Reference amp Maintenance Manual 6 2 Environment Applications in dusty or dirty environments require the electrical optical and mechanical components to be protected The PFR series is intended for clean environments free from small particulates and fluids The cover protection and high pressure 60 100psi low flow air purge system P1 options is sufficient for environments generating moderate quantities of 0 25 mm and larger particles However for dusty wet or harsh environments or applications with continuous exposure to smaller contaminants additional protection must be designed If P2 High Flow Air Purge is in use 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 Air should be routed into the stage through the 4mm OD pneumatic hose located next to the power cable 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 use
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