ALS1000 Series Stage User`s Manual
Contents
1. eeeeeeeee eene rere 25 Stage Orientations for LVC and LSC cece cece cece cee ecccceccececccceeeeeeeeceees 26 Normally Closed NC and Normally Open NO Limit Switch Wiring 27 www aerotech com V List of Figures vi ALS1000 Series Stage User s Manual www aerotech com ALS1000 Series Stage User s Manual List of Tables List of Tables Table 1 1 CW and CCW Home Marker Offset from Center of Travel 2 22ccceeeeeeeeeeeees 4 Table 1 2 Model Numbering System 0 2 cee e cece cece cece ccc ccc ccccccceeeeceeeeeeeeeeeeteeeeeeenees 5 Table 3 1 Environmental Specifications 2 2 2 2 22 22 cece cee cceccecccccccccccccecceccceeeeeeeeeees 21 Table 3 2 ALS1000 Series Specifications 2 2 0 02 cc cece cccccccececccccececeeececcecececeeeeerees 22 Table 3 3 ALS1000 Motor Specifications 22 2 0 022 e cece cccccceeececccccceceeceeccccececeesereees 24 Table 3 4 Feedback and Motor Connector Pin Assignments 22 ccccececeeccccccceccecccecees 28 Table 3 5 Limit Motor Wiring Pin Output Descriptions 2 2 0 2 2000 eecceececceccccccceeeecccceeees 29 Table B 1 Current Changes Revision 1 04 00 seueeeeeeeeeeeeeeee I RI mr rere 37 Table B 2 Archive of Changes 2 00 2 cece cece ccc ccccccccceccccccccceeeccccccceeececcceeteeececceeees 38 www aerotech com vii List of Tables ALS1000 Series Stage User s Manual viii www aero2. User s Manual 4 2 Cleaning and Lubrication 4 2 1 Recommended Cleaners and Lubricants For standard linear bearing guide rails NSK LGU 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 linear bearing trucks If acetone is required avoid the bearing seals For high speed applications i e near maximum speed at a duty cycle of 50 frequent maintenance with standard lubricants is required 4 2 2 Important Notes on Lubrication When cleaning and or lubricating components of the ALS 1000 series stages Be sure to use a clean dry soft and lint free cloth for cleaning 2 Take the opportunity during the lubrication procedure to inspect the linear motion guides for any damage or signs of wear 3 Inapplications that have multiple stages bolted together to form multi axis systems the orthogonality may be lost if the stage tables of the support stages are loosened Precision aligned stages should not be loosened or disassembled 32 Chapter 4 www aerotech com ALS1000 Series Stage User s Manual Maintenance 4 2 3 Lubrication and Cleaning Process The lubrication and cleaning process is outlined in the steps that follow Drive the stage table to one end of travel and remove power to the stage 2 Remove the screws on the edges of the hard cover as shown in Section 2 3 and sli
3. a single axis basis Repeatability and accuracy include linearity correction and minimum thermal change during measurement Vertical and axialloads subject to cantilever load restriction Selected motor and drive will limit performance specifications Consultfactory for XY and alternate mounting configurations 22 Chapter 3 www aerotech com ALS1000 Series Stage User s Manual Operating Specifications Table 3 2 ALS1000 Series Specifications continued Basic Model Maximum Linear Acceleration 2 g 20 m s2 787 in s2 no load LN mmn m Rm 5 RR Accuracy LT NEN EE T meram Repeatability LT EE mar oomen tuum Nominal Stage Weight All performance specifications are measured on a single axis basis Repeatability and accuracy include linearity correction and minimum thermal change during measurement Vertical and axialloads subject to cantilever load restriction Selected motor and drive will limit performance specifications Consultfactory for XY and alternate mounting configurations www aerotech com Chapter 3 23 Operating Specifications ALS1000 Series Stage User s Manual Table 3 3 ALS1000 Motor Specifications el BLMC 42 Winding Designation Eee Performance Specifications 1 5 Continuous Force 20 psi 1 4 bar 2 N 120 3 Continuous Force No Cooling 2 77 7 Peak Force 3 481 2 eS a 7 7 t E MEUM qe cup NN cop pU dHun E Motor Constant 2 4 N NW Ib NW
4. are completely internal to the stages How ever extemal CMS is available for three axis systems Custom configurations are common and readily avail able contact Aerotech for more details Figure 1 3 ALS1000 Option Example with a nickel finish www aerotech com Chapter 1 3 Overview ALS1000 Series Stage User s Manual 1 1 2 Home Markers The ALS1000 has three options for Home Marker location center of the stage CM counterclockwise end of the stage CCWM and clockwise end of the stage CWM These locations are defined with reference to the stage connectors The counterclockwise end is closest to the stage connectors and the clockwise end is furthest away from them Figure 1 4 shows the layout of a stage with a Home Marker in the center of the stage Stage Connector dorem Home uod Home Marker dorem Marker uod Center Home Marker Position Figure 1 4 Location of CW and CCW with Reference to Stage Connectors The Home Marker offset distance depends on the size of the stage Table 1 1 gives the offset distance for the ALS1000 series stages Table 1 1 CW and CCW Home Marker Offset from Center of Travel Stage Marker Offset from Center mm ALS10050 237 3 4 Chapter 1 www aerotech com ALS1000 Series Stage User s Manual Overview 1 1 3 Model Numbers The stage model number indicates the optional features on a particular stage To determine the options on your stage refer to Table 1
5. c ec ec cece cece ceceeeeeeeeeeeeeeseseenenseseeneaees 1 1 1 Standard Features 22 00 oon ccc ccc eee e cece ccc e cece cece ee ceceeeeeeeeeeeeseees 2 1 1 1 Optional Features 2 2 2 2 2 02 e a e E a e cece cece ccc cceeeeceeeeceeeeeeees 3 1 1 2 Home Markers 2 2 2 22222 c cc ee ee cece ccc cece cece ccc ccceeeeeeeeeeeeeeeeeeeeeees 4 4153 Model N rnmbers 2222 sects deen ee Seca eels ca ek roche Ser E ba tes dee da dade ceSaclncts 5 UESTRE 7 1 3 Safety Procedures and Wamings 2222220000 9 1 4 EC Declaration of Incorporation 2 222 2002 2 cee eee ccc cece cece cece ccceeeeccceecceeeeeeeees 11 Chapter 2 Installation 0 2 2 0 0 0 0 o ooo occ cece cece eee cc cecececece cece ececececeseceseees 13 2 1 Unpacking and Handling the Stage 0 0 00222 c cece ccc ccc ccc cece ccc cece eee esee sen 13 2 2 Preparing the Mounting Surface 22 2 2 ccc cece cece cece cece Renee ese 14 2 3 Securing the Stage to the Mounting Surface 22 2 2 0c eee cece cece cece ceeeeeeeeeees 16 2 4 Attaching the Payload to the Stage 02 0 2 0 coco ccc cece sess 18 2 5 Electrical Installation 22 22 0022 222 eee cece cece cc ccc eee c cece cc ceeeeeceeeeeceeeeeeeeees 19 Chapter 3 Operating Specifications 0 2 000 00 ooo eee ec cececec cece cec eee ec eee ece eee 21 3 1 Environmental Specifications 22 22 2002 22 e eee c eee e cece cc ccee cece cccc
6. 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 ALS1000 Series Stage User s Manual Technical Changes Appendix B Technical Changes Table B 1 Current Changes Revision 1 04 00 Section 1 4 Added section Section 3 1 Added section Chapter 2 Installation Section 2 1 Section 2 3 Changed base width to 5 95 from 6 00 Section 2 5 and Section 1 3 Section 3 2 Added motor specifications Section 3 5 Added note about motor wire current and voltage require ments www aerotech com Appendix B 37 Technical Changes ALS1000 Series Stage User s Manual Table B 2 Archive of Changes Version Section Change O OC O 1 02 00 Section 1 1 2 Added Home Marker section 1 02 00 Section 1 1 3 Added Home Marker option to Model Numbering 1 03 00 Section 1 2 Changed base width to 5 95 from 6 00 38 Appendix B www aerotech com Index ALS1000 Series Stage User s Manual Index S A safety pro
7. 1 Performance is dependent upon heat sink configuration system cooling conditions and ambient temperature 2 Values shown 100 C rise above a 25 C ambient temperature with motor mounted to the specified aluminum heat sink 3 Peakforce assumes correct rms current consult Aerotech 4 Force Constant and Motor Constant specified at stall 5 All performance and electrical specifications 10 6 Maximum winding temperature is 125 C 7 Ambient operating temperature range 0 C 25 C consult Aerotech for performance in elevated ambient temperatures 8 All Aerotech amplifiers are rated Apk use torque constant in N m Apk when sizing 24 Chapter 3 www aerotech com ALS1000 Series Stage User s Manual Operating Specifications 3 3 Load Capability It is recommended that application loads be symmetrically distributed whenever possible i e the payload should be centered on the stage table and the entire stage should be centered on the support structure With the stage lying flat horizontal and the application load vertically applied and symmetrically distributed the maximum vertical load carrying capacity of ALS1000 stages is 50 0 kg If cantilevered loads are applied refer to Figure 3 1 to find the maximum allowable load In Figure 3 1 two curves are shown for different loading conditions The Lvc or vertical cantilever curve is for situations where the stage is mounted in a vertical orientation and the payload is mounte
8. 10001400 250 0 10 00 400 0 16 00 550 012200 681012681 16 Figure 1 5 ALS1000 Dimensions www aerotech com Chapter 1 7 Overview ALS1000 Series Stage User s Manual 42 5 1 67 100 0 mm M option 4 00 in U option Sq j NHN Envelope of Z or Theta Axis 231 2 9 10 Cable Management Option M6 1 0 Thd x 8 0 Dp 1 4 20 Thd x 0 32 Dp 25 Holes 25 0 mm M option 1 00 in U option Typ Optional Z or Theta Axis Connector Bracket 55 9 2 20 190 5 7 50 17781009 pL 100 0 4 00 151 1 5 95 d Stage Mounting 97 0 20 28 Thru F Holes Upper Axis Connections Base Total T i Dimensions Millimeters Inches Model otal Trave ALS10010 100 0 4 00 100 0 4 00 250 0 10 00 sonso 8 7410293 i ALS10015 150 0 16 00 100 0 14 00 2500 000 _ 381 0 15 00 8 T 10 1 9 395 200 0 8 00 100 0 4 00 250 0 1000 431011698 8 10 1 0 306 300 0 12 00 100 0 4 00 250 0 10 00 4000 1609 531012090 12 10 1 0 306 450 0 18 00 Figure 1 6 ALS1000 XY Dimensions 8 Chapter 1 www aerotech com ALS1000 Series Stage User s Manual Overview 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
9. 2 for an explanation of the numbering system Table 1 2 Model Numbering System E M CMS For lower axis 09 of ae LZ axis type and middle axis Y ee YXZ axis type U English dimension mounting pattem andholes Brushless linear motor BLMC 142 A Magnet Track Linear Encoders www aerotech com Chapter 1 5 Overview ALS1000 Series Stage User s Manual Table 1 2 Model Numbering System continued P Opi C PIN Accessories to be ordered as separate line item ALIGNMENT NPA ALIGNMENT PA10 ALIGNMENT PA15 HALAR MXH5 D mm External 20 times multiplier 33 MHz maximum data rate 1 0 um resolution LTAS MXH10 D mm External 40 times multiplier 33 MHz maximum data rate 0 5 um resolution LTAS MXH25 D mm External 100 times multiplier 33 MHz maximum data rate 0 2 um resolution LTAS MXH50 D mm External 200 times multiplier 32 MHz maximum data rate 0 1 um resolution LTAS MXH100 D mm External 400 times multiplier 32 MHz maximum data rate 0 05 um resolution LTAS MXH200 D mm External 800 times multiplier 32 MHz maximum data rate 0 025 um resolution LTAS MXH250 D mm External 1000 times multiplier 33 MHz maximum data rate 0 02 um resolution LTAS MXH500 D mm External 2000 times multiplier 33 MHz maximum data rate 0 01 um resolution LTAS MXC nn Multiplier to controller cable specify length nn in feet Specify data rate mm 2M 2MHz 4M 4MHz 8M 8MHz 16M 16MHz 32M 3
10. 2MHz Non precision XY assembly XY assembly 10 arc sec orthogonal XY assembly 5 arc sec orthogonal High accuracy system linear error correction for accuracy and repeatability NOTE Internal signal multipliers available with A3200 amplifier products 6 Chapter 1 www aerotech com ALS1000 Series Stage User s Manual Overview 1 2 Dimensions i 25 mm M option 100 mm M option 1 in U option 4 in U option Typ Sq al Envelope of External Cable Management Option 231 2 9 10 M6 1 0 Thd x 8 0 Dp 742 2 92 1 4 20 Thd x 0 32 Dp 82 5 3 25 Without Tabletop 25 Holes With Tabletop Applicable Only for Lower Required for Single Axis Axis in X Y Configuration ps 190 5 7 50 k or Y Axis Configuration Il 177 8 7 00 1 Optional Air Purge z4 20 0 0 79 be 1 H nw 100 0 4 00 B 151 1 5 95 C Stage Mounting D 97 0 20 28 Thru E rows Upper Axis Connections Applicable Only for X Y Configurations Base Total T Dimensions Millimeters Inches woe Tm a 8 t Tt ALS10010 10001400 100 01400 2500 m0 00 33100303 8 ALStOO15 150 0 6 00 100 0 4 00 250011000 onson 8 ALS10020 200 0 8 00 10001400 250011000 j4310 1696 8 ALStO030 3000 1200 100 0 4 00 250011000 400 0 1600 531 0 20 90 12 ALS10045 450 0 18 00
11. ALS1000 Series Stage User s Manual P N EDS125 Revision 1 04 00 Dedicated to the Science of Motion Aerotech Inc 101 Zeta Drive n Pittsburgh PA 15238 AEROTECH Phone 412 963 7470 Fax 412 963 7459 www aerotech com 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 04 00 February 28 2011 Revision 1 03 00 March 30 2010 Revision 1 02 00 May 19 2009 Revision 1 01 00 October 10 2007 Revision 1 00 00 April 10 2007 Product names mentioned herein are used for identification purposes only and may be trademarks of their respective companies Aerotech Inc 2011 ALS1000 Series Stage User s Manual Table of Contents Table of Contents Table of COnteris e ouo es acne eee eL sect eae eee NU a ee ee iii LiStiOf FIQUIOS ERR EE V Eist or Tables e riu E EEEE EA eh D IDA E ee een oes s UE Er vii Chapter 1 Overview 0 000 0c ccc c cece ccc
12. cables other than those provided by Aerotech to connect the motor to the drive you must connect pin A4 to a ground connection WARNING www aerotech com Chapter 2 19 Installation 20 ALS1000 Series Stage User s Manual Chapter 2 www aerotech com ALS1000 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 stage This chapter provides information on ideal environmental and operating conditions Also included are instructions for estimating load capability given various loading situations 3 1 Environmental Specifications The environmental specifications for the ALS1000 are listed in the following table Table 3 1 Environmental Specifications Ambient Operating 10 to 35 C 50 to 95 F Temperature The optimal operating temperature is 20 C 2 C 68 F 4 F If at any time the operating tem perature deviates from 20 C degradation in performance could occur Contact Aerotech for information regarding your specific application and environment Storage 0 to 40 C 32 to 104 F in original shipping packaging Humidity Operating 40 percent to 60 percent RH The optimal operating humidity is 50 percent RH Storage 30 percent to 60 percent RH non condensing in original packaging Altitude Operating 0 to 2 000 m 0 to 6 562 ft above sea level dE Contact Aerotech if yo
13. cations detail the lubrication and inspection process and cover which lubricants are recommended for use Also included is a section on belt tension and adjustment on stages with the foldback option N OTE The bearing area must be kept free of foreign matter and moisture otherwise the performance and life expectancy of the stage will be reduced 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 ALS1000 series stages depends on conditions such as duty cycle speed and the environment An inspection interval of once per month is recommended until a trend develops for the application Longer or shorter intervals may be required to maintain the film of lubricant on the bearing surfaces In general it is recommended that stages operating in a clean environment be lubricated annually or 500 km whichever comes first For stages operating under conditions involving excessive debris lubri cation 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 redis tribute the lubrication in the bearings The motor is completely non contact and requires no lubrication www aerotech com Chapter 4 31 Maintenance ALS1000 Series Stage
14. ccceeeeeeeees 21 3 2 Basic Specifications 2 2 2 0 coe cece ce eee eee ence cece cece ceeeeeceeecceceeeeeeeeees 22 3 3 Load Capabilly asserens eski eeren E Erer eee 25 3 4 Magnetic Actuator Limit 00000000000000000000000000000 ccc cc ccc cece aa e esses esses sn 27 3 4 1 Actuator Limit Operation 2 2 2 0 202 e cece cece cece cece ccc cceeecececcccceeteees 27 3 4 2 Limit Switch Wiring 00 00000000 c cece eee ce cece uaau eeeeeeeeeeeeeees 27 3 5 Standard Motor Wiring 0 00000 c eee ccc cee eee cece cece eee eeeeeeeeeeeceeeeeeeeeees 28 3 6 Vacuum Operation 2 2 2 22 occ cece cece cece cece cece eee e ec ceeeeeeceeeeeceeeeeeeeeeeeees 29 Chapter 4 Maintenance oo 2 2 2 2 ce ccc aaa ADAL aL a a raan 31 4 1 Service and Inspection Schedule 22 2 2 cece cece ccccccecceccccccececcccccceeeeeeccceeeees 31 4 2 Cleaning and Lubrication 0 00 00 e cece cece cece eeeeeeneeceeeeececcuccuccccceceeaeeeeeee 32 4 2 1 Recommended Cleaners and Lubricants 2 00 0 cc ccecceceeeccccceeeeeeccceees 32 4 2 2 Important Notes on Lubrication 2 0 0 0 2c cc ccecceeeeccccceceecccccccceeeeccceeees 32 4 2 3 Lubrication and Cleaning Process 00 0 2 ccc ce eee ee cece e cece cece cece eeeee ees 33 Appendix A Warranty and Field Service sees 35 Appendix B Technical Changes ssussussssssssssssssssesee sees een
15. cedures 2 20 020022 222 e eee 9 Attaching the Payload 2 2 2ceceeeeeeees 18 Service schedule ee 31 stage table Luuuuuuleueeeeeeeseeeeeeee 16 s Standard Features 222 22222 2222222 2 cable P P 19 U x Unpacking and Handling the Stage 13 Declaration of Incorporation 2 11 Dimensions 20222 e cece eee eee e cece es 7 w WarningS 022 222 2e eee eee eee eee eens 9 WIFING 2 2 eee eee ee eee 19 27 Electrical Installation 22 2222 22 19 encoders 22 222 22222 cece eee eee eee 19 28 Environmental Specifications 21 l Inspection schedule 22 22222222 31 L limit switches 2 22 00 0 2 e eee ence ee eee 27 lubricants recomended 222 2222 2 222 eee eee 32 Lubrication and Cleaning 33 Lubrication schedule 22 2222 22 31 M model numbers 222 2 2 6 13 Lo MM 19 multiaxis combinations 222 22 32 0 Operating Specifications 2 020 21 P Preparing the Mounting Surface 14 www aerotech com Index 39 ALS1000 Series Stage User s Manual Index 40 Index www aerotech com Reader s Comments ALS1000 Series Stage Manual P N EDS125 February 28 2011 Revision 1 04 00 Please answer the q
16. d to the table top with its center of gravity extended outward The Lsc or side cantilever curve assumes a horizontal stage orientation If a cantilevered load situation is used first determine if it is a vertical cantilever or side cantilever system based on Figure 3 2 Measure the cantilever length then find the corresponding load value from Fig ure 3 1 Load kg 0 50 100 150 200 250 300 Distance of Load C G from Tabletop mm Figure 3 1 Load Capability of ALS1000 Series Stages www aerotech com Chapter 3 25 Operating Specifications ALS1000 Series Stage User s Manual Figure 3 2 Stage Orientations for L vc and Loo 26 Chapter 3 www aerotech com ALS1000 Series Stage User s Manual Operating Specifications 3 4 Magnetic Actuator Limit 3 4 1 Actuator Limit Operation Each actuator limit has a magnet which is detected by the encoder read head Each actuator is mounted at the ends of the stage table perpendicular to the direction of table motion When movement of the stage table detects the magnet a limit signal is generated The actuator limit output is active high If the stage is driven 8 mm beyond the electrical limit it will encounter the mechanical stop Although the operating speed of the stage may be relatively slow damage to the stage could result WARNING 3 4 2 Limit Switch Wiring Limit switches are open collector TTL compatible devices powered by 5 Volts that change output states when the stag
17. de it out from under the stage 3 Remove any accumulated dust or debris from the inside of the assembly Remove any dirty or dried lubricant from the linear bearing rails Use a clean lint free cloth with a side to side motion A swab soaked in Isopropyl Alcohol may be used to remove stubborn debris 5 Apply athin continuous film of lubricant to the linear bearing guides A good quality natural bristle art ist s brush makes an excellent applicator 6 Manually move the stage to the opposite end of travel This will work the grease into the linear bearing guides The stage table should move freely with little resistance Repeat steps 3 through 5 for any areas covered by the original table position Refasten the hardcover Restore power to the stage and drive the stage table back to its original position to redistribute lubricants To minimize the possibility of bodily injury confirm that all electrical power is disconnected prior to making any mechanical adjustments DANGER www aerotech com Chapter 4 33 Maintenance ALS1000 Series Stage User s Manual 34 Chapter 4 www aerotech com ALS1000 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 caused by faulty mate rials or poor workmanship for a minimum period of one year from date of shipment from Aerotech Aerotech s liability is limited to replacing repairing or issu
18. e approaches its maximum travel distance Since they are open collector devices they may be interfaced to 24V logic inputs Each limit is glued to the stage base near the scale Standard ALS 1000 stages include limit wiring integrated into one of the two main connectors With a NC limit configuration the input to the controller is seen as a logic 0 typical 0 4 V 12 8 mA when no limit condition is present When the limit is activated a 5 V source through a pull up resistor causes a logic 1 typically 4 8 5 V to be seen by the controller input See Figure 3 3 for a diagram of limit switch wiring 5V 5V Pull Up Pull Up Resistor Resistor Limit Input To Controller Limit Input To Controller NC Limit NO Limit Switch E dis Normally Closed NC 7 Normally Open NO Figure 3 3 Normally Closed NC and Normally Open NO Limit Switch Wiring www aerotech com Chapter 3 27 Operating Specifications ALS1000 Series Stage User s Manual 3 5 Standard Motor Wiring Stages fitted with standard motors and encoders come from the factory completely wired and assembled For reference connector pin assignments and general wiring information is given in the following figures Pin assignements are defined in Table 3 5 N OTE Refer to the other documentation accompanying your Aerotech equipment Call your Aerotech rep resentative if there are any questions on system configuration N OTE If you are using your own cables to con
19. equipment This manual and any additional instructions included with the stage should be retained for the lifetime of the stage gt DANGER gt DANGER gt DANGER A DANGER 2 D D Z Z Z Z Z Z O O O To minimize the possibility of electrical shock and bodily injury or death disconnect all elec trical power prior to making any electrical connections To minimize the possibility of electrical shock and bodily injury or death when any electrical circuit is in use ensure that no person comes in contact with the circuitry when the stage is connected to a power source To minimize the possibility of bodily injury or death disconnect all electrical power prior to making any mechanical adjustments Moving parts of the stage can cause crushing 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 www aerotech com Chapter 1 9 Overview A A A A A A z Z Z Z Z Z Z Z Z z z Z Q Q Q Q Q Q 10 ALS1000 Series Stage User s Manual Do not expose the stage to environments or conditions outside the specified range o
20. f oper ating environments Operation in conditions other than those specified can cause damage to the equipment The stage must be mounted securely Improper mounting can result in injury and damage to the equipment Use care when moving the stage Manually lifting or transporting stages can result in injury Only trained personnel should operate inspect and maintain the stage This stage is intended for light industrial manufacturing or laboratory use Use of the stage for unintended applications can result in injury and damage to the equipment Before using this stage perform an operator risk assessment to determine the needed safety requirements Chapter 1 www aerotech com ALS1000 Series Stage User s Manual Overview 1 4 EC Declaration of Incorporation Manufactorer Aerotech Inc 101 Zeta Drive Pittsburgh PA 15238 USA AEROTECH xv herewith declares that the product Aerotech Inc ALS1000 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 mac
21. hines Part 1 General requirements and further more declares that it is not allowed to put the equipment into service until the machinery into which it is to be incorporated or of which it is to be a component has been found and declared to be in conformity with the provisions of the Directive 2006 42 EC and with national implementing legislation i e as a whole including the equipment referred to in this Declaration Authorized Representative Manfred Besold Address Name Position Location Date AEROTECH GmbH S d West Park 90 D 90449 N mberg Alex Weibel by Neho tb Engineer Verifying Compliance Pittsburgh PA February 28 2011 www aerotech com Chapter 1 11 Overview ALS1000 Series Stage User s Manual 12 Chapter 1 www aerotech com ALS1000 Series Stage User s Manual Installation Chapter 2 Installation This chapter describes the installation procedure for the ALS1000 stage including handling the stage prop erly preparing the mounting surface to accept the stage securing the stage to the mounting surface attach ing 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 Stage Carefully remove the stage from the protective shipping container Set the stage on a smooth flat and clean surface Before operating
22. htened see Figure 2 1 and Figure 2 2 Mounting to a Flat Surface Mounting screws would not be visible mounting screws can be accessed by removing the hardcover Mounting Surface Figure 2 1 Mounting to a Flat Surface NOTE To maintain accuracy the mounting surface should be flat within 1um per 50mm Any distortion will decrease the overall accuracy of the stage Adjustments to the mounting surface must be done before the stage is secured see Figure 2 2 14 Chapter 2 www aerotech com ALS1000 Series Stage User s Manual Installation Mounting screws would not be visible mounting screws can be accessed by removing the hardcover Figure 2 2 Mounting to a Curve Surface N OTE Thestage housing is precision machined and verified for flatness prior to stage assembly at the factory If necessary machining should be performed on the mounting surface rather than the stage hous ing to achieve a required flatness Shimming should be avoided if possible Shimming decreases the rigidity of the system www aerotech com Chapter 2 15 Installation ALS1000 Series Stage User s Manual 2 3 Securing the Stage to the Mounting Surface To access the mounting holes of the stage the hardcover must be removed Four screws two at each end of the stage retain the hardcover see Figure 2 3 Remove the screws and slide the hardcover out from under the table If necessary manually move the stage table to access the counter bored moun
23. ie 37 rie hs eects HRK 39 Reader s Comments o oo ooo o eco ccc cc cece cece cece cence ecececcececeecececcececeeceeees 41 www aerotech com lii Table of Contents ALS1000 Series Stage User s Manual iV www aerotech com ALS1000 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 1 6 Figure 2 1 Figure 2 2 Figure 2 3 Figure 2 4 Figure 3 1 Figure 3 2 Figure 3 3 ALS 1000 Series Linear Positioning Stage in an XY Configuration 1 Typical ALS1000 Stage with Callouts Luuuuuueussseeseseee mene 2 ALS 1000 Option Example with a nickel finish LLsuuuuuuuuuuuseeeeee enn 3 Location of CW and CCW with Reference to Stage Connectors 0 cece eee eee 4 ALS 1000 Dimensions 00 cece cece cece cece eee eeeeeeeeeeeeteeeeeeneeeeeeeneeeeceeeees 7 ALS1000 XY Dimensions 2 22 0 0 0 c eee cec cece eccccceceecccccceceeeccccceeeeeeeecceeeees 8 Mounting to a Flat Surface 00 00 cece cece ccc cccceecccccceeeecccccceececeececeeeeeeees 14 Mounting to a Curve Surface oo eee cece cece cece eceecceccccccecceccecceceeeeeeeees 15 Mounting Hole Locations 0 2 0 ccccce ee cccccccecccccccecececccceceeeccccceeeeeeeecceeeees 16 Reattaching the Hardcover o oo cece cece cece cece e e Re RR Rr rrr rrr rrr 17 Load Capability of ALS1000 Series Stages
24. ing credit at its option for any products that are returned by the original purchaser during the warranty period Aerotech makes no warranty that its products are fit for the use or purpose to which they may be put by the buyer where or not such use or purpose has been disclosed to Aerotech in specifications or drawings previously or sub sequently provided or whether or not Aerotech s products are specifically designed and or manufactured for buyer s use or purpose Aerotech s liability or any claim for loss or damage arising out of the sale resale or use of any of its prod ucts shall in no event exceed the selling price of the unit Aerotech Inc warrants its laser products to the original purchaser for a minimum Laser Products period of one year from date of shipment This warranty covers defects in work manship and material and is voided for all laser power supplies plasma tubes and laser systems subject to electrical or physical abuse tampering such as opening the housing or removal of the serial tag or improper operation as determined by Aerotech This warranty is also voided for failure to comply with Aerotech s return procedures Claims for shipment damage evident or concealed must be filed with the carrier Return Procedure by the buyer Aerotech must be notified within 30 days of shipment of incorrect materials No product may be returned whether in warranty or out of warranty with out first obtaining approval from Aer
25. m ponents are warranted for one year from date of shipment At times the buyer may desire to expedite a repair Regardless of warranty orout Rush Service of warranty status the buyer must issue a valid purchase order to cover the added rush service cost Rush service is subject to Aerotech s approval www aerotech com Appendix A 35 Warranty and Field Service On site Warranty Repair On site Non warranty 36 Repair Company Address ALS1000 Series Stage User s Manual If an Aerotech product cannot be made functional by telephone assistance or by sending and having the customer install replacement parts and cannot be returned to the Aerotech service center for repair and if Aerotech determines the problem could be warranty related then the following policy applies Aerotech will provide an on site field service representative in a reasonable amount of time provided that the customer issues a valid purchase order to Aerotech cov ering all transportation and subsistence costs For warranty field repairs the cus tomer will not be charged for the cost of labor and material If service is rendered at times other than normal work periods then special service rates apply If during the on site repair it is determined the problem is not warranty related then the terms and conditions stated in the following On Site Non Warranty Repair section apply If any Aerotech product cannot be made functional by telephone assistance or
26. nect the stage ensure that motor and ground wires can handle current higher than the continuous current listed in Table 3 3 The voltage rating of the wire insulation must be greater than the bus voltage listed in Table 3 3 Table 3 4 Feedback and Motor Connector Pin Assignments 1 5 9 13 tn oe Cece o Olgooo Qiogoooo 14 18 22 25 seso 34 feo 2 NGC 1 60N 3 eos 6 WWrsV 6 MRN 9 REERED pe E ume 8 amp N Encoder Common RESERVED Description i Description MTR A RESERVED MTR B RESERVED MTR C RESERVED MTR SHLD FRMGND RESERVED 28 Chapter 3 www aerotech com ALS1000 Series Stage User s Manual Operating Specifications Table 3 5 Limit Motor Wiring Pin Output Descriptions PinOutput Descripion MKR Marker MKR N Incremental encoder output either the complement of Marker with a line driven TTL type encoder or 2 5 VDC bias level with amplified sine wave type encoder MTR Shield for motor connector wiring SHLD FRM GND Motor common ground 3 6 Vacuum Operation Contact the factory for information regarding operation in a vacuum environment www aerotech com Chapter 3 29 Operating Specifications ALS1000 Series Stage User s Manual 30 Chapter 3 www aerotech com ALS1000 Series Stage User s Manual Maintenance Chapter 4 Maintenance This chapter will cover information about intervals between lubri
27. otech No credit will be given nor repairs made for products returned without such approval Any returned product s must be accompanied by a return authorization number The return authorization number may be obtained by calling an Aerotech service center Products must be returned prepaid to an Aerotech service center no C O D or Collect Freight accepted The status of any product returned later than 30 days after the issuance of a return authorization number will be subject to review After Aerotech s examination warranty or out of warranty status will be deter Returned Product War mined If upon Aerotech s examination a warranted defect exists then the prod ranty Determination uct s will be repaired at no charge and shipped prepaid back to the buyer If the buyer desires an airfreight return the product s will be shipped collect Warranty repairs do not extend the original warranty period After Aerotech s examination the buyer shall be notified of the repair cost At such Returned Product time the buyer must issue a valid purchase order to cover the cost of the repair and Non warranty Deter freight or authorize the product s to be shipped back as is at the buyer s mination expense Failure to obtain a purchase order number or approval within 30 days of notification will result in the product s being returned as is at the buyer s expense Repair work is warranted for 90 days from date of shipment Replacement co
28. r the hardcover Repeat as necessary until the stage runs smoothly through travel Ensure that the hardcover is centered properly to prevent contact between the hardcover and tableto p e e e VIEW FROM TOP Contact between the TABLETOP hardcover and tabletop Ec can damage the stage and degrade performance wow St 527 Bee VIEW FROM FRONT gt HARDCOVER EGE Figure 2 4 Reattaching the Hardcover www aerotech com Chapter 2 17 Installation ALS1000 Series Stage User s Manual 2 4 Attaching the Payload to the Stage To prevent damage to delicate payloads test the operation of the stage before attaching the payload to the stage table Proceed with the electrical installation and test the motion control system in accordance with the system documentation Document all results for future reference For information on electrical con nections refer to Section 2 5 Electrical Installation The payload should be flat rigid and comparable to the stage in quality N OTE For valid accuracies the mounting interface should be flat within 10 um Refer to Section 3 3 for information on cantilevered loads and load positioning NOTE 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 possibly damaging the stage 18 Chapter 2 www aerotech com ALS1000 Series Stage User
29. s Manual Installation 2 5 Electrical Installation Electrical installation requirements will vary depending on stage options Installation instructions in this sec tion are for stages equipped with standard Aerotech motors intended for use with an Aerotech motion control system Contact Aerotech for further information regarding stages that are otherwise configured Aerotech motion control systems are adjusted at the factory for optimum performance When the ALS1000 series stage is part of acomplete Aerotech motion control system setup involves connecting a stage and motor combination to the appropriate drive chassis with the cables provided Connect the provided cables to the motor and feedback connectors on the stage Labels on the drive indicate the appropriate connections Refer to your drive manuals and documentation for additional installation and operation information In some cases if the system is uniquely configured a drawing showing system interconnects is supplied An integral linear motor comes mounted to all ALS1000 stages The electrical wiring from the motor and encoder are integrated into two main connectors at the factory Refer to Section 3 5 for standard motor wiring and connector pin outputs 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
30. tech com ALS1000 Series Stage User s Manual Overview Chapter 1 Overview This manual describes Aerotech s ALS1000 series of linear motor positioning stages Figure 1 1 shows a typ ical ALS1000 positioning stage This chapter introduces standard and optional features of the ALS1000 stages explains the model numbering system and gives general safety precautions Figure 1 1 ALS1000 Series Linear Positioning Stage in an XY Configuration 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 ALS1000 Series Stage User s Manual 1 1 Standard Features The ALS1000 is a compact high performance stage for use in applications where a small footprint and envi ronmental protection are required The linear motor is completely cog free allowing for extremely tight veloc ity control Also the magnetic field is completely self contained within the U channel design Hardcover Screws Side Seals f pc c j Em M x aien Hardcover i T ALS1000 Base Figure 1 2 Typical ALS1000 Stage with Callouts 2 Chapter 1 www aerotech com ALS1000 Series Stage User s Manual Overview 1 1 1 Optional Features In single and two axis systems the Cable Management Systems
31. the stage it is important to let the stage stabilize at room temperature All ALS1000 series stages are packaged with shipping clamps installed to prevent stage table movement These are red anodized brackets the only red anodized pieces Aerotech uses that bolt the stage table to the base These must be removed before the stage table can be moved For the ALS 1000 series these shipping clamps are internal to the stage The hardcover must be removed to access the shipping clamps see Section 2 3 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 occurred during shipping report it immediately Improper stage handling could adversely affect the stage s performance Use care when moving the stage Manually lifting or transporting stages can result in injury WARNING Lift the stage only by the base WARNING Do not use the stage table as a lifting point WARNING www aerotech com Chapter 2 13 Installation ALS1000 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 stage When an ALS1000 series stage is mounted to a non flat surface the stage can be distorted as the mounting screws are tig
32. ting holes along the edges of the stage The stage is designed to use socket head cap screws SHCS to secure the base to the mounting surface Use M6 x 18 mm or 74 x 7 8 long SHCS with flat washers to 1 5x diameter thread engagement Torque the mounting screws to 8 1 N m 6 ft Ib The stage must be mounted securely Improper mounting can result in injury and damage to the equipment WARNING za mmm Remove hardcover ee nounting screws a1 aan OR E Ne A Remove the hard cover to expose the stage mounting screw locations Remove the shipping brackets qty 2 before attempting to move the tabletop EAIA Stage mounting hole locations Stage mounting LS 9 hole locations ao Cable Management System CMS Figure 2 3 Mounting Hole Locations 16 Chapter 2 www aerotech com ALS1000 Series Stage User s Manual Installation Once the stage has been secured to the mounting surface the hardcover must be reattached Take special care to reattach the hardcover in the same orientation as it was removed align the adhesive strip on the under side of the hardcover with the blue ribbon cable within the stage Furthermore before tightening the screws center the hardcover on the stage Once the hardcover is tightened down manually run the stage through travel Check to make sure there is no increased friction or noise If either of these occur loosen the screws and re cente
33. uestions below and add any suggestions for improving this doc ument AEROTECH Is the manual Adequate to the subject ln ia Well organized o Clearly presented Well illustrated i How do you use this document in your job Does it meet your needs What improvements if any would you like to see Please be specific or cite examples C T SmwPeWbes Nam Weg 0 I me seria erp Name Bmeshpped Aem Guomeroded Aerotech Subsidiary Email Order Maiyourcommentsto Farto Aerotech Inc 412 967 6870 101 Zeta Drive Pittsburgh PA 15238 U S A service aerotech com
34. ur specific application involves use above 2 000 m or below sea level Use the system in a low vibration environment Excessive floor or acoustical vibration can affect stage and system performance Contact Aerotech for information regarding your specific appli cation Dust Expo The ALS1000 stages have limited protection against dust but not water This equates to an sure ingress protection rating of IP50 Indoor use only Do not expose the stage to environments or conditions outside the specified range of oper ating environments Operation in conditions other than those specified can cause damage to the equipment WARNING www aerotech com Chapter 3 21 Operating Specifications ALS1000 Series Stage User s Manual 3 2 Basic Specifications Basic ALS1000 series positioning stage specifications are shown in Table 3 2 Motor specifications are listed in Table 3 3 Table 3 2 ALS1000 Series Specifications Basic Model Drive System Linear Brushless Servomotor BLMC 142 A Maximum Linear Acceleration Maximum Load Standard 24 0 um 160 6 0 um 240 8 0 um 320 yin yin uin Repeatability LT 1 0 um 40 yin 3 0 um 25 mm 120 uin in Straightness and Flat ness Maximum Devi 2 4 um 96 yin 3 6 um 144 4 8 um 192 ation pin pin Nominal Stage Weight 8 4 kg 18 4 Ib 10 0 kg 22 0 Ib 11 0 kg 24 2 Ib Aluminum Body Black Anodize Finish Hardcoat All performance specifications are measured on
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