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CHPS-Series Linear Stage User Manual

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1. AppendixA Specifications and Dimensions CHPS x8xxxB C E F XLMxxx 4X M8 x 1 25 6H 12 0 0 47 4X 6 8 0 27 v 45 2 1 78 Thru 2X 5 5 0 22 Thru Pilot Hole 254 1 0 Slide 254 1 0 Mechanical Overtravel 339 Travel lt Mechanical Overtravel 28 0 54 E 254 1 10 1 0 5 15 4 09 1 0 JE E b I 215 7 8 49 216 7 166 6 8 53 6 56 L s 120 4 72 55 4 120 116 3 2 18 4 72 4 58 Square Nut Spacing 5 8 0 23 Thru See Detail A 4X M10 x 1 5 6H Thru 2 per end cap 03 7 0 38 Thru 112050 Access point for lubricating linear bearings Provision to use lifting hooks not provided 440 17 35 Travel Ground Screw M5 x 0 8 6H Detail A 52 206 r Ww L f 6 0 0 24 Depth max E Square Nut Mount to base using M6 x1 0 hardware Toe Clamp is standard for covered stages Mount to base Travel Length mm in Shortest 80 3 15 Increments 60 2 36 Longest 1580 62 2 80 Rockwell Automation Publication CHPS UM001D EN P July 2014
2. 4X 06 8 0 27 45 2 1 78 Thru 2X 05 5 0 22 Thru Pilot Hole 25 4 1 0 Slide 25 4 1 0 Mechanical Overtravel 239 Travel Mechanical Overtravel 28 0 54 __ DE m JJ 54 1 10 3 10 us 172 no b C Th m 215 2 8 49 216 2 166 6 q e 8 53 6 56 a o gt 120 4 72 55 4 120 56 H 1 Toe Clamp 2 18 4 72 2 20 Square Nut Spacing 5 8 0 23 Thru 09 7 0 38 Thru v 14 2 0 56 See Detail A 4X M10 x 1 5 6H Thru 2 per end cap 0 38 Thru 0 56 Access point for lubricating linear bearings Provision to use lifting hooks not provided 340 I 9 33 4 134 Travel Ground Screw e M5 x 0 8 6H 105 5 Detail A 52 0200 6 0 0 24 l ES f Hd H Square Nut Mount to base using M6 x1 0 hardware optional accessory Toe Clamp is standard for covered stages Mount to base using M6 x1 0 socket cap screw 4 15 Bracket located 51 2 0 from center of travel Travel Length Shortest 60 2 36 Increments 60 2 36 Longest 1680 66 14 Rockwell Automation Publication CHPS UM001D EN P July 2014 79
3. 30 5 1 20 Mechanical Slide E Overtravel 339 B 13 35 ji Travel Overtravel 250 165 250 0 98 B 0 98 6 50 3 42 z s 25 165 167 650 82 6 57 i E cal yi 9 1 4X 7 0 0 28 45 0 1 80 Thru 1 120 4 72 Pilot Hole aU aa Toe Clamp T Nut Spacing See Detail A 4X M10 x 1 5 6H Thru 2 per end cap Access point for lubricating linear bearings Provision to use lifting hooks not provided 238 6 108 939 181 5 7 15 Ground Screw 5 x 0 8 6H een Travel 123 8 4 88 Detail A j 0 30 9 3 0 37 Depth max H T Nut Mount to base using M6 x1 0 hardware optional accessory Toe Clamp is standard for covered stages Mount to base using M6 x1 0 socket cap screw Bracket located 51 2 0 from center of travel Travel Length mm in Shortest 60 2 36 Increments 60 2 36 Longest 1560 61 42 78 Rockwell Automation Publication CHPS UM001D EN P July 2014 Figure 23 CHPS x8xxxA D xLMxxx 4X 8 x 1 25 6H 12 0 0 47 Specifications and Dimensions Appendix A
4. Toe Clamp is standard for covered stages Mount to base using M6 x1 0 socket cap screw H T Nut Mount to base using M6 x 1 0 hardware optional accessory Travel Length mm in Shortest 80 3 15 Increments 60 2 36 Longest 1640 64 6 Rockwell Automation Publication CHPS UM001D EN P July 2014 81 AppendixA Specifications and Dimensions Figure 25 CHPS x9xxxH I K L xLMxxx 4X M8 x 1 25 6H y 12 0 0 47 4X 0 6 8 0 27 v 45 2 1 78 Thru 2X 5 5 0 22 Thru Pilot Hole 25 4 1 0 Slide 25 4 1 0 Mechanical Overtravel 339 Travel Mechanical Overtravel 13 35 280 254 130 8 104 254 1 10 1 0 5 15 4 09 1 0 i 5 oy 2647 E 10 42 265 7 208 6 10 46 8 21 I 5 W 9 120 4 72 554 Toe Clamp T Nut Spacin 018 120 116 p pcna 4 72 4 58 See Detail 05 8 0 23 Thru 4X 9 16 12 UNC Thru 2 per end cap Access point for lubricating linear bearings 03 7 0 38 Thru 7714 20 56 338 14 Provision to use lifting hooks not provided 46 8 13 31 1 84 ad 00 Travel Ground Screw 5 x 0 8 6H 4 ATO o e e 5 M om 4 15 0 172 30 0 6 78 1 18
5. Topic Page Unpacking Handling and Inspection 25 Unpacking Procedure 26 Store Packaging Material 28 Stage Storage 28 Mounting the Stage 28 Before You Begin the Mechanical Installation 28 Determine the Number of Fasteners Required 28 Determine the Type of Fastener to Use 29 Mounting the Stage 31 Mount Your Application 32 IMPORTANT Any person that teaches operates maintains or repairs these stages must be trained and demonstrate the competence to safely perform the assigned task Inspect packaging to make certain no damage occurred in shipment Document any damage or suspected damage Claims for damage due to shipment are usually made against the transportation company If you suspect damage contact Rockwell Automation immediately for further advice Be sure the information listed on the purchase order correlates to the information on the packing slip for your stage and its accessories Rockwell Automation Publication CHPS UM001D EN P July 2014 25 Chapter4 Mounting the Stage Inspect the assemblies and confirm if applicable the presence of specified options that require extreme caution during handling Do not disassemble the stage ATTENTION Linear motor driven stages contain powerful permanent magnets The forces generated by permanent magnets are very powerful and can cause bodily injury Persons with pacemakers or automatic implantable cardiac defibrillators AICD must maintain a minimum dist
6. 20 4 0 2 0 2 0 2 0 Table 11 Maximum Velocity for 200 and 250 mm frame size CHPS Series Linear Stages with Allen Bradley Drives Incremental Encoder Option Maximum Velocity Digital Sine Cosine Velocity Ulta3000 and Kinetix 2000 and Kinetix 6000 Kinetix 300 Resolution Period max Ultra5000 Drives Kinetix 6500 Drives Drive Drive pm count pm m s m s m s m s m s 1 5 0 40 40 1 5 2 0 0 5 3 0 2 0 2 0 0 7 0 1 0 7 0 5 0 50 20 40 2 0 20 2 0 1 LC motor option only Rockwell Automation Publication CHPS UM001D EN P July 2014 Specifications and Dimensions Appendix A Environmental Specifications for CHPS Series Stages Attribute Value Ambient temperature 0 40 C 32 104 F Storage temperature 30 70 C 22 158 F Relative humidity 5 95 non condensing Shock 20 g peak 6 ms duration Vibration 0 1 grms Hz 30 2000 Hz Cable carrier lifetime 10 000 000 cycles CHPS Series Stage Travel versus Weight Specifications CHPS Series Stage 150 mm frame size Unit Mass Mass kg I 2 030 1 240 X 17 0307 120 0 1 f LI M Travel Length Rockwell Automation Publication CHPS UM001D EN P July 2014 75 Specifications and Dimensions App
7. UNC UNF Plain Cadmium Plated Plain Cadmium Plated Bolt Size 1 2 Nem Ibf in Nem Ibf in Nem Ibf in Nem Ibf in 0 0 24 2 1 0 18 1 6 n 0 44 3 89 9 0 53 4 7 2 0 46 4 1 9 0 34 3 0 2 0 71 6 3 0 53 4 7 9 0 76 6 8 0 58 5 1 B 1 08 9 6 0 81 7 2 2 1 16 10 3 9 0 87 7 7 9 4 1 52 13 5 1 13 10 1 67 14 8 9 1 2 11 8 5 2 3 20 9 17 15 8 237 21 8 1 8 168 6 2 8 25 9 2 1 19 8 3 2 28 9 2 4 21 8 8 5 2 46 9 3 8 34 6 54 48 9 4 1 36 10 7 6 67 9 5 6 50 8 6 76 64 57 6 1 4 17 8 158 13 4 119 20 3 180 15 4 136 5 16 36 8 326 27 7 245 9 40 7 360 30 5 270 3 8 65 5 580 49 1 435 71 7 635 53 7 476 7 16 105 930 78 9 698 117 5 1 040 9 88 1 780 1 2 160 1 420 172 8 1 530 9 254 2 2 250 190 9 1 690 1 Mounting hardware is 1960 series socket head cap bolt that meets or exceeds ANSI B18 3 2 Torque is based on 80 000 psi bearing stress under the head of the bolt 3 Denotes torque based on 100 000 psi tensile stress with threads up to one inch in diameter Rockwell Automation Publication CHPS UM001D EN P July 2014 Mounting Bolts and Torque Values Appendix E Table 17 Recommended Seating Torque for Brass Rb 72 UNC UNF Plain Cadmium Plated Plain Cadmium Plated Bolt Size 2 Nem Ibf in Nem I
8. 105 5 4 15 Bracket located 51 2 0 from center of travel See Detail 338 14 46 8 13 31 1 84 281 11 06 8 5 0 33 38 3 1 51 249 9 8 Detail A Specifications and Dimensions Appendix A Figure 24 CHPS x9xxxG J xLMxxx 4X M8 x 1 25 6H 12 0 0 47 4X 6 8 0 27 vv 45 2 1 78 Thru 2X 5 5 0 22 Thru Pilot Hole 25 4 1 0 Slide 25 4 1 0 Mechanical Overtravel 279 Travel Mechanical Overtravel 10 98 28 0 254 130 8 44 pes 25 4 1 10 1 0 5 15 1 73 1 0 1 S b ls ea 2647 0042 265 7 j 10 46 8 21 1 7 1 120 4 72 55 4 e a Toe Clamp T Nut Spacing 2 18 56 2 2 22 5 8 0 23 Thru 4X 9 16 12 UNC Thru 2 per end cap 09 7 0 38 Thru 714 2 0 56 Access point for lubricating linear bearings Provision to use lifting hooks not provided 380 6 14 96 Travel Ground Screw M5 x 0 8 6H 105 4 4 15 O e e A JE w 1 18 Bracket located 51 2 0 5 6 from center of travel 022 65026 Depth max
9. Isink 10 mA Maximum Rp External pull up resistor Motor and Hall Ph asing and Consult drive manual or supplier for wiring instructions for your drive Motor Se quence wiring is phase and commutation sensitive Motor Phasing Diagram shows the standard phase and sequence relationship of the motor when phased in the positive direction The Hall signals are used by a compatible three phase brushless servo drive to perform electronic commutation Two types of servo drive Hall based commutation techniques are possible Trapezoidal Hall Mode and Encoder Software Mode with Hall startup For optimal commutation and force generation the selected servo drive must be compatible with the motor phasing and be wired correctly e Observe maximum applied voltage specification e Consult drive manual or supplier for drive wiring instructions Wiring is phase and commutation sensitive e Terminate per drive manual instructions e Hall Signals 120 Spacing Open Collector Transistor 24V maximum e Refer to CHPS Series Stage Connector Data starting on page 33 for termination options pin and wire designations ATTENTION Incorrect motor Hall or encoder wiring can cause runaway conditions 46 Rockwell Automation Publication CHPS UM001D EN P July 2014 Connecting the Stage Chapter 6 As shown in the Motor Phasing Diagram S1 in phase with W U Back EMF 52 in phase with Back EMF S3 in phase with V W Back EMF Phase sequence 51 le
10. illustrates correct system grounding techniques cutting drilling tapping and welding with it removed Be careful to keep any metal debris from falling into it Metal debris or other foreign matter can become lodged in the stage that can result in damage to components ATTENTION Plan the installation of your stage so that you can perform all wiring of the stage prior to applying power Once power is applied connector SHOCK HAZARD To avoid hazard of electrical shock perform all mounting and terminals can have voltage present even when not in use Rockwell Automation Publication CHPS UM001D EN P July 2014 39 Chapter6 Connecting the Stage Attaching the Ground Strap and Interface Cables The only electrical connections necessary between the stage and the drive system are the ground strap and the two cables 1 For electrical safety connect the ground screw on the chassis of the stage to the ground bus for your system To reduce the effects of electromagnetic interference EMI bond the stage with a braided ground strap 12 mm 0 5 in wide minimum to a grounded metal surface This creates a low impedance return path for high frequency energy 2 Torque the ground screw at the stage to 2 Nem 18 lbein M5 x 0 8 6H Ground Screw t Lug Braided Ground Wire 12 mm 0 5 in min 3 Form a drip loop in each cable at a point directly before it attaches to the stage Refer to the Connecting Kinetix Type M
11. Figure 17 Motor Phasing Schematic Lamination Frame Ram AAA Ru V ANN Motor Phases ANN B Motor Ground R Ram X 2 Compare the phase resistance readings to the cold resistance specification of the coil model See CHPS Series Stage Technical Specifications on page 83 If the three readings are balanced but vary from the specified reading the reason can be a special coil model Cable resistance can cause the result to be significantly higher 5 To rule out the cable resistance disconnect the stage cable and repeat the procedure this time at the stage motor power termination at the junction box 6 Measure and verify the phase to ground resistance for each phase is gt 100 MQ A lower reading indicates a potential electrical problem To rule out a field cable problem disconnect the stage cable and repeat the procedure this time at stage motor power termination If any reading with the cable disconnected is 100 MQ consult Rockwell Automation the stage can have an internal electrical problem IMPORTANT perform coil or insulation electrical stress tests Megger or Hi Pot test without consulting Rockwell Automation technical support 58 Rockwell Automation Publication CHPS UM001D EN P July 2014 Chapter 9 Maintenance Topic Page Before You Begin 59 Lubricate the Bearing 60 Optical Encoder Scale Maintenance 60 Strip Seal Cleaning 61 Cover Clean
12. For covered stages toe clamps are the easiest method for mounting On sides of the base secure a toe clamps every 120 mm 4 72 in by using M6 SHCS as shown in the Toe Clamps Mounting diagram Use slots formed into outside edge of the stage base 30 Rockwell Automation Publication CHPS UM001D EN P July 2014 Mounting the Stage Chapter 4 Tee nuts are used to mount the stage from underneath Insert the tee nuts every 120 mm 4 72 in in tee slots on the bottom of the unit Secure the tee nuts by using M6 SHCS as shown in Nut Mounting diagram Figure 8 Tee Nut Mounting Mounting the Stage Follow these steps to install a stage on its mounting surface 1 Be sure the mounting surface is clear of any and all foreign material IMPORTANT Donotuseabrasives to clean the surface If necessary stone the mounting surface acetone or methanol can be applied as cleaning agent 2 Verify that the flatness of the surface that the stage is to be mounted The total indicator reading TIR is 0 0254 mm 0 001 in per 300 mm 120 in TIR or runout correlates to an overall flatness of a surface 3 Lift the stage onto the prepared mounting surface box Moving the stage in this manner can damage the stage and create a pinch or crush hazard The junction box is attached to the carrier that is free to move Lifting the stage in this manner causes uncontrolled movement of the heavy base Always use a two person lift and gra
13. 63 kg 28 140 Ib or carry required To User The Pinch Point label identifies a moving object hazard caused by the movement of the carriage on the linear stage Never put fingers hands or limbs near the linear stage while running motion commands Before executing any motion command check that all maintenance tools have been removed from linear stage All types of linear stages especially uncovered present a pinch point hazard This hazard may occur if fingers or hands come between the end cap and a moving carriage Always lift the linear stage by the base and keep fingers and hands away from the opening and edges parallel to the carriage B Danger Hazardous DANGER The Hazardous Voltage label identifies the junction box as a hazardous Voltage HAZARDOUS VOLTAGE LOCKOUT AND TAGOUT POWER BEFORE SERVICING voltage area of the linear stage To avoid injury be sure to follow Lockout Tagout procedures before attempting maintenance on these linear stages Danger Strong Magnets DANGER MAGNETIC FIELDS LOCATED IN THIS AREA Can be harmful to pacemakers and other sensitive equipment The Strong Magnets label identifies non ionizing radiation found in the linear stage Magnet channels inside the linear stage are constructed with strong magnets Strong magnets can disrupt the functionality of automatic implantable cardioverter defibrillators AICD people with a pacemaker should not work near the linear stage Mai
14. 2 1 3 0 144 32 6 3 8 9 431 97 66 14836 270 199 620 457 270 199 1 Measured at 20 C 68 F ambient 2 For covered and sealed stages derate by 10 3 Values apply to bearing rating only Contact Applications Engineering for structural considerations Performance Specifications for 250 mm frame size CHPS Series Linear Stages Cat No Slide Mass Continuous 9 Peak Maximum Max Static Moment Loads Static Load Current Thrust Current Thrust Pitch Yaw Roll kg Ib Arms Ao pk N lbf rms Ao pk N lbf kN lbf kN lbf Nem ft lb Nem ft lb CHPS A9xxxG xLMxxx 8 58 18 9 1 9 2 7 109 25 5 8 8 2 328 74 93 6 21042 170 125 385 283 508 375 CHPS A9xxxH xLMxxx 9 62 21 2 3 8 5 4 219 49 11 5 16 3 656 147 93 6 21042 324 239 734 541 508 375 CHPS A9xxxl xLMxxx 9 62 21 2 1 9 2 7 219 49 5 8 8 2 656 147 93 6 21042 324 541 734 541 508 375 1 Measured at 20 C 68 F ambient 2 For covered and sealed stages derate by 10 3 Values apply to bearing rating only Contact Applications Engineering for structural considerations Performance Specifications for 325V or 650V CHPS Series Stage Maximum cable length 10 m 33 ft Please contact Applications Engineering concerning application requiring longer cables Rockwell Automation Publication CHPS UM001D EN P July 2014 71 AppendixA Specifications and Dimensions Tab
15. Air Freight Transportation ses ok ete ENTRE te Ieee Leere 14 5 ay whch eat cats de See tek 14 Motor Model Identification sese eee 14 Chapter 2 Identifying the Components of Your 16 Component 88 uev alpin 16 Recommended Maintenance Interval seesuee sues 18 Identifying Your Stage gr ur 18 Chapter 3 Stage Mounting 21 General Safety Standards for Stage Installations 21 Mounting 21 Clearance Requirements ed edades 23 Chapter 4 Unpacking Handling and Inspection 8 8 25 Wapacking Proctedute rrt EE C E COS Nem DARET 26 Store Packaging Material a4 usa ade cA EN 28 s ed dado udo Pate EE Sue 28 Mo u nting theStag MEER 28 Before You Begin the Mechanical Installation 28 Mounting the Stages a tour e EE 31 Mount Your Application euro ER EORR EUH D BAI PP ees 32 Chapter 5 Kinetix Servo Drive Compatible 34 D Type x cs os sida da e RENI tae 35 Flying Leads pP Bn 36 Junction Box Connectors 0c ccc 3
16. Follow ALL Regulatory requirements for safe work practices and for Personal Protective Equipment PPE psp Allen Bradley Kinetix Rockwell Software Rockwell Automation Ultra are trademarks of Rockwell Automation Inc Trademarks not belonging to Rockwell Automation are property of their respective companies Summary of Changes This manual contains new and updated information Changes throughout this revision are marked by change bars as shown to the right of this paragraph New and Updated This table contains the changes made to this revision Information Corrected catalog numbers 18 29 59 60 87 Added maximum velocity for Kinetix 6500 and Kinetix 300 Drives 74 Rockwell Automation Publication CHPS UM001D EN P July 2014 3 Summary of Changes Notes 4 Rockwell Automation Publication CHPS UM001D EN P July 2014 Stage Safety Understanding Your Stage Planning the Stage Installation Mounting the Stage Connector Data Table of Contents Preface About This Publication 0 0 ccc 9 Who Should Use This Manual een 9 Additional Resources lees 9 Chapter 1 Satety Label utes Rura DEM d IM UE 12 Clearances venere eiue ute emer ir RW ERES 13 General ree NEED M IDE EI ED 13 Pleat scusa 13 Vertical or Incline Payload ee te 13 End Cap Impacts co cesse odes Seu hun dut 13
17. Output Signal The incremental encoder typically have the following quadrature edge separation Encoder Typical Edge Separation Maximum velocity um ns m s 1 100 5 0 5 90 3 0 1 90 0 7 1 Speeds based on 3 m maximum cable length and a minimum readhead input of 5V To calculate the minimum recommended counter frequency for 1 um and 0 5 um encoders use the following formula encoder velocity m s x Counter clock frequency MHz 4 safety factor resolution Um The minimum recommend counter frequency for the 0 1 encoder is 12 MHz Figure 11 TTL Differential Encoder Timing Diagram Incremental 2 channels A and B in quadrature 90 phase shifted ENC A Pte Quadrature edge separation Index Mark pulse in synchronised to one position count Repeatability of position uni directional is maintained if temperature Index is 15 35 59 95 F and ie li Speed is 250 mm s 9 8 in s Reference Figure 12 TTL Differential Encoder Termination Readhead ENCA ENC B j Drive or amp Index Mark Controller gt gt Square wave differential line driver to EIA RS422A ENCA Standard 94224 ENCB line receive circuit amp Index Mark 1 Total termination resistance in ohms 44 Rockwell Automation Publication CHPS UM001D EN P July 2014 Sine Cos Encoder Output Signals Connecting the Sta
18. Sequence 94 W s 9C Calculate Energy absorption Cth tm Rth where tm is the motor s thermal time constant in seconds Leave the value as found if a valid LC or LZ file is used If necessary use the following tm values based on the heat sink size and cooling method LC motors tm 1800 seconds LZ motors tm 1200 seconds Follow these steps for optimal motor commutation performance overcurrent and overtemperature protection 1 Set General Axis Parameters udb file extension a Auto Motor Iden disabled for linear motors b Motor Model select as needed c Total Moving Mass in kg coil mass or magnet mass moving structure mass moving cable assembly mass customer load d Current Limits in Amperes peak set as needed for the application The drive uses the lowest value between the drive rating and the motor rating e Display Precision Set to 2 decimal places User Current Fault in Amperes peak this is the continuous current Set as needed for the application The drive uses the lowest value between drive rating and the motor rating To avoid nuisance tripping of the fast acting protection it can need to be set slightly higher 2 Follow instructions from the standard drive manual and other applicable documentation Pay special attention to electrical noise control by using cable shielding shield termination grounding and bonding 3 Wiring must match the CHPS Series sta
19. Trapezoidal Hall 53 TIL Trapezoidal Hall Case Shield Shield Shield 1 PTC Temp is connected to Common 34 Intercontec P N AKUA034NN00100035000 Mating Cable Allen Bradley 2090 XXNFMF Sxx Rockwell Automation Publication CHPS UM001D EN P July 2014 Connector Data Chapter 5 D Type Connectors The following tables identify the power and feedback pinouts for D shell connectors that enable custom cables to be used Pin Color Signal eee M 1 Red U A phase 8 99 o i White V B phase Positronic P N CBD9W4M20000 1702 0 Black W C phase Mating Connector M Green Yellow Ground Positronic P N CBD9W4F20000 1701 0 Case Shield Cable Shield With Incremental Encoder With Analog Encoder 1 Yellow TIL Differential Sin Analog Differential 1V p p 2 Brown B TIL Differential Cos Analog Differential 1V p p 3 Violet Index Mark TIL Differential Index Differential Pulse 1V p p 4 White Red 5V DC Encoder and Hall Sensor Power 5V DC Encoder and Hall Sensor Power 5 Reserved 6 7 8 9 White Green 51 TTL Trapezoidal Hall 51 TTL Trapezoidal Hall 10 Green 7 PTC Thermistor PTC Temp PTC Thermistor 11 Reserved 12 White Blue 53 TIL Trapezoidal Hall 53 TTL Trapezoidal Hall 13 Green Yellow Shield Shield 14 White Yellow A TIL Differential Sin A
20. box cover Rockwell Automation Publication CHPS UM001D EN P July 2014 63 Chapter 10 Removing and Replacing Stage Components 3 Remove junction box cover assembly ATTENTION Never pull on wires when disconnecting power and feedback connectors Damage to the connector can occur 4 Separate motor power connector by squeezing the side tabs and pulling on the housing Do not pull on the wires Figure 18 Cable Carrier Module Replacement M3 0 5 X8 LG Phillips Pan Head Screws 4x Cable Carrier Module M4X 0 7 X 10 LG SHCS 2x Motor Power Connector Feedback Connector 5 Separate the feedback connector from the circuit board by pushing on the center tab and pulling up on the connector housing Do not pull on wires 6 Remove the two 2 SHCS from the angle bracket 7 Lay the cable carrier out flat and mark the location of the end bracket on the base 8 Loosen but do not remove the two 2 SHCS that secure the end bracket to the stage base 9 Remove cable carrier Cable Carrier Module Align the cable carrier module with the marks made before removing and follow Installation cable carrier removal procedure in reverse 64 Rockwell Automation Publication CHPS UM001D EN P July 2014 Removing and Replacing Stage Components Chapter 10 Strip Seal Removal Figure 19 Stage Seal Components Strip Seal Clamp 4x Seal Guide 4x 3M SHCS 2x per guide 3M SHCS 8x Stainless
21. in this orientation are subject to premature cable carrier failure Wall horizontal Horizontal wall mount stages must be installed with the cable carrier below the stage Stages mounted horizontally on a wall must have a travel of 1 m 3 28 ft or less Stages with a travel length greater than 1 m 3 28 ft are subject to premature cable carrier failure Wall vertical or incline Stages mounted vertically on a wall must have a travel of 1 m 3 28 ft or less Stages with a travel length greater than 1 m 3 28 ft are subject to premature cable carrier failure Rockwell Automation Publication CHPS UM001D EN P July 2014 Planning the Stage Installation Chapter 3 Clearance Requirements The figures depict the minimum clearances for each stage type Power and feedback cables can impose additional clearance requirements Refer to Interconnect Cables on page 85 for connector and bend radius requirements Figure 3 Minimum Clearance Requirements Covered Stage 419 mm 16 5 in Clearance on Both Ends for Lubrication Access Uncovered Stage 3 2mm 0 125 in Clearance All Around Cabling 19 mm 0 75 in Clearance for Cable Routing Rockwell Automation Publication CHPS UM001D EN P July 2014 23 Chapter3 Planning the Stage Installation Notes 24 Rockwell Automation Publication CHPS UM001D EN P July 2014 Unpacking Handling and Inspection Chapter 4 Mounting the Stage
22. 38 3 1 51 249 9 8 Detail Bracket located 51 2 0 5 6 from center of travel 0 22 65 0 26 Depth max T Nut Mount to base using M6 x 1 0 hardware optional accessory Toe Clamp is standard for covered stages Mount to base using M6 x1 0 socket cap screw Travel Length mm in Shortest 80 3 15 Increments 60 2 36 Longest 1580 62 2 82 Rockwell Automation Publication CHPS UM001D EN P July 2014 CHPS Series Stage Technical Specifications and Dimensions Appendix A Use this specification to make stage dependent calculations Specifications Cat No Total Moving Coil Resistance p p Force Constant Tet 25 77 F 100 212 F kg Ib Ohms Ohms N A Ibf A o peak CHPS A6xxxA xLMxxx 5 39 11 85 7 2 9 3 24 1 5 42 CHPS A6xxxB xLMxxx 7 09 15 6 3 6 4 6 24 1 5 42 7 09 15 6 14 3 18 6 48 2 10 83 CHPS A8xxxA xLMxxx 6 70 14 73 7 2 9 3 24 1 5 42 CHPS A8xxxB xLMxxx 8 87 19 52 3 6 46 24 1 5 42 CHPS A8xxxC XLMXxx 8 87 19 52 143 18 6 48 2 10 83 CHPS x8xxxD xLMxxx 7 57 16 65 3 8 4 9 30 3 6 81 CHPS x8xxxE xLMxxx 10 23 22 5 1 9 24 30 3 6 81 CHPS x8xxxF xLMxxx 10 23 22 5 75 9 8 60 7 13 64 CHPS A9XxxG xLMxxx 8 56 18 84 94 122 40 2 9 04 CHPS A9xxxH xLMxxx 10 70 23 53 4 7 6 1 40 2 9 04 CHPS A9xxxl xLMxxx 10 70 23 53 18 8 24 5 80 4 18 07 C
23. 96 Positive Phasing Direction 96 Encoder Counting 96 Oscilloscope Verification 1 Sad ao 97 Oscilloscope Diagram for Ultra3000 98 Reference Information Elea 99 Commutation Diagnostics Utility 99 Self sensing Commutation and 100 Main Screen E ERE PO eps one 102 Rockwell Automation Publication CHPS UM001D EN P July 2014 7 Table of Contents Motor Screen ed cR aidan Add RU seg dda Aa 103 ES IS 104 Appendix Mounting Bolts and Torque Values 105 lid soseisivater itd Nan UAI A females beat 109 8 Rockwell Automation Publication CHPS UM001D EN P July 2014 About This Publication Who Should Use This Manual Additional Resources Resource Preface Read this preface to familiarize yourself with the manual This manual provides detailed installation instructions for mounting wiring maintaining and troubleshooting your CHPS Series Linear Motor Driven Stage This manual is intended for engineers or technicians directly involved in the installation wiring and maintenance of stages Any person that teaches operates maintains or repairs these stages must be trained and demonstrate the compet
24. A TTL Differential Sin Analog Differential 1V p p White Yellow A TIL Differential Sin Analog Differential 1V p p Brown B TIL Differential Cos Analog Differential 1V p p White Brown B TIL Differential Cos Analog Differential 1V p p Violet Index Mark TIL Differential Index Differential Pulse 1V p p White Violet Index Mark TIL Differential Index Differential Pulse 1V p p Red 5V Encoder and Hall Sensor Power 5V Encoder and Hall Sensor Power White Red 5V Encoder and Hall Sensor Power 5V Encoder and Hall Sensor Power Black Common Common White Black Common Common Green PTCTemp PTC Thermistor 7 PTC Thermistor White Green 51 Trapezoidal Hall 51 TTL Trapezoidal Hall Blue 52 Trapezoidal Hall 52 Trapezoidal Hall White Blue 53 TTL Trapezoidal Hall 53 TIL Trapezoidal Hall Green Yellow Shield Shield 1 PTC Temp is connected to Common Rockwell Automation Publication CHPS UM001D EN P July 2014 Connector Data Chapter 5 Junction Box Connectors The following diagram and tables identify the power and feedback pinouts of the junction box connector use this information to make custom cables Item Description A J1 Feedback connector output to flex cable Mating connector is a Molex P N 43025 1600 B J2 Thermistor signal connector the input from side
25. Brochure publication 2 Provides product specifications outline drawing ratings and wiring information to aid in product selection Rockwell Automation Publication CHPS UM001D EN P July 2014 9 Preface Notes 10 Rockwell Automation Publication CHPS UM001D EN P July 2014 Chapter 1 Stage Safety Topic Page Safety Labels 12 Clearances 13 General Safety 13 Heat 13 Vertical or Incline Payload 13 End Cap Impacts 13 Air Freight Transportation 14 Standards 14 Motor Model Identification 14 IMPORTANT Any person that teaches operates maintains or repairs these linear stages must be trained and demonstrate the competence to safely perform the assigned task Rockwell Automation Publication CHPS UM001D EN P July 2014 11 Chapter 1 Stage Safety Safety Labels To prevent injury and damage to the stage review the safety labels and their warning details and location before using the stage Location Title Label Details A Danger Pinch Points DANGER The linear stage presents a muscle strain hazard if one person attempts to and Heavy Objects PINCH POINTS lift it When attempting to move the linear stage use a two person lift to Moving parts inside prevent personal injury or damage to the linear stage Lockout Tagout LIFT HAZARD To Installer There exists Crush and Cut hazard while installing the linear Two Person Lift stage The linear stage weighs from 13
26. E Support Straps j End Cap 4 6 Move the linear stage solid support surface before removing the shipping brace Use additional care when handling the linear stage after the brace is removed ATTENTION The carriage is free to move once the shipping brace is removed Unexpected carriage movement can cause personal injury 7 Remove the four socket head cap screws SHCS from the shipping brace 8 Lift the shipping brace off the stage and set it aside M6 x 30 SHCS 2x for CHPS x6xxxx xLxxx 150 mm P M8 x 30 SHCS 2x for CHPS x8xxxx xLxxx 200 mm and CHPS x9xxxx xLxxx 250 mm M6 x 75 SHCS 2x for CHPS x6xxxx xLxxx 150 mm M6 x 75 SHCS 2x for CHPS x8xxxx xLxxx 200 mm or CHPS x9xxxx xLxxx 250 mm Shipping Brace Shipping Clamp M3 SHCS washer and nut 4x 9 Remove the plastic wrap enclosing the stage and set it aside 10 Remove the four SHCS that secure the shipping clamp Rockwell Automation Publication CHPS UM001D EN P July 2014 27 Chapter4 Mounting the Stage Stage Storage Mounting the Stage 28 11 Remove the four square nuts loosened in the previous step by sliding each nut to the end of channel Store Packaging Material Keep the carton in case the unit needs to be returned for warranty service or stored for an extended period of time 1 Tape screws and clamp hardware to the shipping brace 2 Put end caps in their original pos
27. Material Handling Labels and instructions for preparing the Shipper s Declaration for Dangerous Goods Asa minimum refer to the following IATA Dangerous Goods Regulations e Subsection 1 5 Training Subsection 3 9 2 2 Classification as Magnetized Material e Subsection 4 2 Identification as UN 2807 Magnetized Material Class 9 Packing Instruction 902 e Subsection 7 1 5 Marking e Subsection 7 2 Labeling Subsection 7 4 1 Magnetized Material Label e Section 8 Shipper s Declaration for Dangerous Goods When shipped via ground in the United States these products are not considered a US D O T Hazardous Material and standard shipping procedures apply Standards and requirements applicable to this product include but are not limited to the following e ANSI RIA R15 06 Industrial Robots and Robot Systems Safety Requirements Teaching Multiple Robots ANSI NFPA 79 Electrical Standard for Industrial Machinery e CSA CAN 7434 Industrial Robots and Robot Systems General Safety Requirements e EN60204 1 Safety of Machinery Electrical Equipment of Machines The nameplate lists the motor model for the stage Rockwell Automation Publication CHPS UM001D EN P July 2014 Chapter 2 Understanding Your Stage Topic Page Identifying the Components of Your Stage 16 Recommended Maintenance Interval 18 Identifying Your Stage 18 Rockwell Automation Publication CHPS UM001D EN P July 2014 15 Chapter2 Un
28. Stee Strip Seal 2x IMPORTANT Handle strip seal material with care The strip seal has sharp edges that can cut if mishandled 1 Loosen the strip seal clamps at each end of the stage 2 Carefully grasp the end of the strip seal and slide it out of the stage Stage Cover Removal 1 Remove strip seals following strip seal removal procedure 2 Remove the 4 M4 screws securing the stage cover to the end caps 3 Remove cover Figure 20 Cover Removal eS Stage Side Cover Removal 1 Remove strip seals following strip seal removal procedure 2 Remove the 2 M4 x 07 screws securing the side cover to the end caps 3 Remove side cover by dropping it down so the lower lip clears the channel Rockwell Automation Publication CHPS UM001D EN P July 2014 65 Chapter 10 Removing and Replacing Stage Components Strip Seal Replacement ATTENTION Handle strip seal material with care Strip seal has sharp edges 1 2 that can cause personal injury if mishandled Remove power from unit and Lockout Tagout the power source Follow the instructions below on how to measure mark and cut new strip seals 1 Mark needed strip length 3 Make two 45 marks to centerline din NE 2 Mark strip width centerline 4 Use tin snips to cut along 45 marks E TA 3 Position slide at middle of travel 10 11 66 Loosen end clamps and screws on one
29. bumpers can absorb before risking damage to the stage The payload must be secured to the slide such that it does not sheer off in the event of an impact in excess of the bumper ratings The bolts securing the end caps are not be able to sustain multiple impacts and can eventually sheer Correct the cause of the uncontrolled motion that caused the impact before continuing the use of the stage Rockwell Automation Publication CHPS UM001D EN P July 2014 13 Chapter1 Stage Safety Air Freight Transportation Standards Motor Model Identification When air freighting stages special preparations and precautions must be taken The following information outlines the basic requirements at the publication date of this document However regulations are subject to change and additional area or carrier restrictions can be imposed Check with your carrier or logistics specialist regarding current local regional and national transportation requirements when shipping this product The 200 mm or a 250 mm stages contain magnetized material as classified by International Air Transport Association LATA Dangerous Goods Regulations An IATA trained individual must be involved when shipping this product via domestic or international air freight Packing Instruction 902 provides information regarding the preparation of this product for air transportation Follow these regulations for general marking and labeling requirements the application of Magnetized
30. circuits equipment or software described in this manual Reproduction of the contents of this manual in whole or in part without written permission of Rockwell Automation Inc is prohibited Throughout this manual when necessary we use notes to make you aware of safety considerations WARNING Identifies information about practices or circumstances that can cause an explosion in a hazardous environment which may lead to personal injury or death property damage or economic loss ATTENTION Identifies information about practices or circumstances that can lead to personal injury or death property damage or economic loss Attentions help you identify a hazard avoid a hazard and recognize the consequence P IMPORTANT Identifies information that is critical for successful application and understanding of the product Labels may also be on or inside the equipment to provide specific precautions SHOCK HAZARD Labels may be on or inside the equipment for example a drive or motor to alert people that dangerous voltage may be present BURN HAZARD Labels may be on or inside the equipment for example a drive or motor to alert people that surfaces may reach dangerous temperatures ARCFLASH HAZARD Labels may be on or inside the equipment for example a motor control center to alert people to potential Arc Flash Arc Flash will cause severe injury or death Wear proper Personal Protective Equipment PPE
31. max Output NPN open collector 10 mA max Limit Sensor Specification Description Specifications Input Power 12 28V DC 15 mA max Output PNP open collector normally closed 50 mA max sourcing PTC Thermistor Specifications Temp C F Resistance Ohm Up To 100 212 Less than 750 Up To 105 221 Less than 7500 Up To 110 230 Greater than 10 000 Rockwell Automation Publication CHPS UM001D EN P July 2014 73 Appendix 74 Specifications and Dimensions Encoder Specifications Type Signal Specification Power Supply 5V DC 5 Digital A B Index RS422 Differential Line Driver Analog Sine Cosine 0 6 1 2V Differential Analog Integral Index Mark Differential Pulse 0 8 1 3V p p IMPORTANT Contact Application Engineering for third party drives and controllers The controls need to meet a minimum recommended counter clock frequency that varies with encoder type and resolution and required peak speed Maximum Velocity for Allen Bradley Drives Table 10 Maximum Velocity for 150 mm frame size CHPS Series Linear Stages with Allen Bradley Drives Incremental Encoder Option Maximum Velocity Digital Sine Cosine Velocity Ultra 3000 and Kinetix 2000 and Kinetix 6000 Kinetix 300 Resolution Period max Ultra5000 Drives Kinetix 6500 Drives Drive Drive um count pm m s m s m s m s m s 1 5 0 40 40 1 5 2 0 0 5 3 0 2 0 2 0 0 7 0 1 0 7 0 5
32. signals sent to the Ultra Drive are ignored during self sensing start up 100 Rockwell Automation Publication CHPS UM001D EN P July 2014 Start up Guide for CHPS Series Stage with Ultra3000 Drive and Ultraware Software Appendix D The following in an example of a CHPS Series stage custom motor file created in Ultraware Motor Database utility Motor Database Encoder Type Incremental Standard Motor Commutation Type Sinusoidal Force Constant 241 N A Startup Type Hallinputs Mass 074 Offset 0 Eleciical Cycle Length 0 06 meters Lines Per Meter 250000 ae x Integral Limits Resistance 715 LS Inductance 134 mH Integral Thermostat v Rated Voltage 230 Vols Software Protection V Ec TEE S npe 157 CA Cth w a 764 W s C For linear stages with a size 200 frame LZ 030 T 120 D linear motor 1 um encoder cover seals and no integral limits Rockwell Automation Publication CHPS UM001D EN P July 2014 101 AppendixD Start up Guide for CHPS Series Stage with Ultra3000 Drive and Ultraware Software Main Screen Setup On this screen enter CHPS Series stage motor file Current Limits not to exceed motor file Display Precision and access the Current Control Panel Ultraware LM stage axis 02821 sme xi og ss Test application udb 101 LM stage axis i Mad
33. the end cap on this side it floats on the screw Insert side cover into the stage base by holding it with the top slightly tilted outward and hooking bottom in the channel near bottom of the base Starting at the end cap with the magnetic warning label or the MP motor Install 1 4 0 7 x 30 LG SHCS and torque to 4 Nem 35 lbein Make sure the side cover makes contact with the end cap On the opposite end install 1 M4 x 0 7 x 30 LG SHCS and torque 2 26 Nem 20 lbein The side cover does not contact the end cap on this side Rockwell Automation Publication CHPS UM001D EN P July 2014 67 Chapter 10 Removing and Replacing Stage Components Notes 68 Rockwell Automation Publication CHPS UM001D EN P July 2014 Appendix A Specifications and Dimensions This appendix is a supplement to this document Associated Kinetix publications listed in Additional Resources on page 9 and information in product specifications can supersede the information in this appendix Topic Page Static and Static Moment Loads 70 Performance Specifications for 325V CHPS Series Stage 70 Performance Specifications for 325V or 650V CHPS Series Stage 71 Accuracy Specification for the CHPS Series Stage 73 General Stage Specifications 73 Commutation Sensor 73 Limit Sensor Specification 73 PTC Thermistor Specifications 73 Encoder Specifications 74 Maximum Velocity for Allen Bradley Drives 74 Environ
34. 0 036 042 054 066 078 090 102 or 114 MPAS 8xxxE SIDE Xxx cm stroke 014 020 026 032 038 044 056 068 080 092 104 128 152 176 or 194 MPAS 9xxxK SIDE Xxx cm stroke 014 020 026 032 038 044 056 068 080 092 104 128 152 176 or 194 Top Cover Replacement Kit MPAS 6xxxB TOP Xxx cm stroke 012 018 024 030 036 042 054 066 078 090 102 or 114 MPAS 8xxxE TOP cm stroke 014 020 026 032 038 044 056 068 080 092 104 128 152 176 or 194 9 cm stroke 014 020 026 032 038 044 056 068 080 092 104 128 152 176 194 Rockwell Automation Publication CHPS UM001D EN P July 2014 87 AppendixB Accessories Notes 88 Rockwell Automation Publication CHPS UM001D EN P July 2014 Stacking Stages Appendix This appendix provides information about center stacked stage configurations Topic Page Stage Stacking 89 Specifications for Stacked Stages 90 Stage Stacking Certain combinations of MPAS linear stages are designed to be stacked on top of one another Stacking forms an X Y axis arrangement A center stack arrangement mounts the top axis in the middle of the bottom axis The top stage is centered on the bottom stage Table 12 Stacking Stages The MPAS x6xxxx is capable of mounting to the top of another MPAS x6xxxx by bolting through toe clamps to the slide on th
35. 050 100 D 1V p p sine cosine encoder 20 um signal period with integral index mark CHPS A9054G FLMC2C Bulletin Number MEET HE Cable Management and Termination Voltage A No Cables or Cable Carrier Slide Junction Box only 230 AC B Cables with Flying Leads and Cable Carrier B 460V AC LC motors only C Cables with Kinetix MPF Connectors and Cable Carrier Frame Size D Cables with D Connectors and Cable Carrier 9 250 mm base Limits Stroke 2 No limits Travel lengths start at 8 cm and are available in 6 cm increments 5 Two end of travel limits For example 008 for 8 cm travel or 020 for 20 cm travel Protection Maximum travel 122 cm S Covered with strip seals IP 3029 Motor Covered without strip seals G LZ 050 T 120 D 0 Open without cover without strip seals LZ 050 T 240 D LM Specifier 17 050 7 240 LM Linear Motor J LC 075 100 D Feedback LC 075 200 D F 1 0 micron incremental optical encoder with integral index mark L LC 075 200 E G 0 5 micron incremental optical encoder with integral index mark 1 Not for upside down mounting H 0 1 micron incremental optical encoder with integral index mark 2 Contact Applications Engineering for upside down mounting 1V p p sine cosine encoder 20 signal period with integral 3 Strip seal and covers required for wall mount applications index mark Rockwell Automation Publication CHPS UM001D EN P July 2014 19
36. 2 2 1 16 10 3 9 0 87 7 7 9 4 1 52 13 5 9 1 1 10 8 1 67 14 8 9 124 11 9 5 23 20 9 17058 237 21 9 1 8 16 6 2 8 25 2 1 19 8 3 2 28 2 37 21 9 8 5 2 46 9 3 8 34 8 3 2 48 9 4 1 36 10 7 6 67 5 6 50 8 6 76 64 57 1 4 12 8 113 9 6 85 12 8 113 9 6 85 5 16 21 5 190 16 1 143 21 5 190 16 1 143 3 8 44 8 397 33 6 298 44 8 397 33 7 298 7 16 64 4 570 48 0 425 64 4 570 48 0 425 1 2 159 3 1 410 119 8 1 060 159 3 1 410 119 8 1 060 1 Mounting hardware is 1960 series socket head cap bolt that meets or exceeds ANSI B18 3 2 Torque is based on 50 000 psi bearing stress under the head of the bolt 3 Denotes torques based on 100 000 psi tensile stress with threads up to one inch in diameter 108 Rockwell Automation Publication CHPS UM001D EN P July 2014 accessibility 22 accessories feedback interconnect cable 86 power interconnect cable 85 accuracy specifications 73 ambient temperature defined 75 analog differential encoder 45 ANSI NFPA 79 electrical for industrial machines 21 ANSI RIA R15 06 industrial robot multiple teaching 21 bearing 17 lubrication ports 17 bearing lubrication 60 bearing rail 17 bolt through 29 C cable carrier module about 17 installation 64 lifetime 75 replacement 63 center stacked stage 89 damps 17 deaning 18 cover 61 strip seal 61 dearance 23 coil resistance 83 commutat
37. 3 thermal protection 42 through bolt 30 toe clamp 29 30 spacing 30 torque cover 67 ground screw 40 side cover 67 values for different metals 105 total moving mass 83 trapezoidal Hall mode 46 travel vs weight specifications 150 mm frame 75 200 mm frame 76 250 mm frame 76 troubleshooting Hall effect module 55 Hall to back EMF phasing 57 motor coil resistance measurements 58 PTC thermal signal 55 TIL differential encoder 44 TTL encoder 17 U Ultra3000 drive 91 set up 91 111 Index Ultraware mbd file 93 commutation diagnostics utility 99 self sensing commutation and start up 100 start up 94 verification 97 V vertical payload 13 vibration 22 75 W wiring Hall effect 46 limit sensor 43 sin cos encoder 45 TIL differential encoder 44 Ultra3000 drive 91 Y yaw 70 112 Rockwell Automation Publication CHPS UM001D EN P July 2014 Index Notes Rockwell Automation Publication CHPS UM001D EN P July 2014 113 Rockwell Automation Support Rockwell Automation provides technical information on the Web to assist you in using its products At http www rockwellautomation com support you can find technical and application notes sample code and links to software service packs You can also visit our Support Center at https rockwellautomation custhelp com for software updates support chats and forums technical information FAQs and to sign up for product notification updates In addition we of
38. 61 PTCthermal signal 55 PTC thermistor resistance values 42 readhead 17 reference documents standards 21 CSA CAN 2434 industrial robot safety 21 repeatability specifications 73 requirements 22 23 restrictions 22 clearance 23 mounting 23 roll 70 safety bolts 12 cover 12 end caps 13 hazardous voltage 12 heat 12 impacts 13 junction box 12 labels 12 pinch points 12 sharp edges 12 strong magnets 12 sudden motion 13 seal guide 17 shearing bolts 13 shipping brace 28 clamp 28 container storage 28 dangerous goods declaration 14 form 902 instructions 14 shock 75 side cover 17 installation 67 removal 65 torque 67 side cover support 17 sin cos encoder 17 slide 17 specifications commutation sensor 73 flatness 73 humidity range 75 limit sensor 73 repeatability 73 shock and vibration 75 storage and operating temperature 75 straightness 73 technical 83 travel vs weight 150 mm frame 75 200 mm frame 76 Rockwell Automation Publication CHPS UM001D EN P July 2014 Index 250 mm frame 76 square nut 29 30 31 spacing 31 stacking of stages 89 stage cover 17 side cover 17 slide 17 storage 28 standards EN60204 1 safety of electrical machines 21 static load rotational movement definitions 70 stoping distance 50 storage 28 storage temperature 75 straightness specifications 73 strip seal about 17 clamps 17 cleaning 61 guide 17 installation 66 T temperature 22 42 temperature max 1
39. 660 4 0 kg 8 8 Ib MPAS x8xxxx on MPAS x8xxxx 320 14 0 kg 30 8 Ib Direct Drive 560 6 5 kg 14 3 Ib 800 3 0 kg 6 6 Ib MPAS x8xxxx on MPAS x9xxxx 320 14 0 kg 30 8 Ib Direct Drive 560 6 5 kg 14 3 Ib 800 3 0 kg 6 6 Ib MPAS x8xxxx on MPAS x8xxxx 300 14 0 kg 30 8 Ib Ball Screw 540 6 5 kg 14 3 Ib 780 3 0 kg 6 6 Ib MPAS x8xxxx on MPAS x9xxxx 300 14 0 kg 30 8 Ib Ball Screw 540 6 5 kg 14 3 Ib 780 3 0 kg 6 6 Ib 1 Payload is based solely on bearing and structure limitations For other stacking arrangements please contact Rockwell Automation Application Engineering 90 Rockwell Automation Publication CHPS UM001D EN P July 2014 Using This Appendix Wiring the CHPS Series Stage to the Ultra3000 Drive Appendix D Start up Guide for CHPS Series Stage with Ultra3000 Drive and Ultraware Software This appendix is a supplement to CHPS Series stage and Kinetix drive manuals The information in the current product manuals supersedes this appendix Topic Page Using This Appendix 91 Wiring the CHPS Series Stage to the Ultra3000 Drive 91 Linear Motor File Parameters 92 Creating a CHPS Series Stage Motor File 92 Recommended Start up Sequence 94 CHPS Series Stage and Ultra3000 Drive Troubleshooting Reference 96 Reference Information 99 This appendix is for use with CHPS Series stages This document addresses CHPS Series stage motor file parameter values and commutation wiring Basic start up
40. 7 Rockwell Automation Publication CHPS UM001D EN P July 2014 5 Table of Contents Connecting the Stage Operation Guidelines and Limit Configuration Troubleshooting Maintenance Removing and Replacing Stage Components Limit Sensor Flying Leads n ree esses 38 Chapter 6 Connecting the Stages eost dn des ads EE 39 Attaching the Ground Strap and Interface Cables 40 Thermal Protection eseeeee RR 42 Optional Limit Sensors coccz rper E RISE o UE REIR ERIS 43 TTL Differential Encoder Output Signal 5 5 S otros ch Renee 44 Sinc Gos Encoder Output evea e VERE ES 45 Hall Effect I 46 Motor and Hall Phasing and Sequence wi vere sca ua titan eve tnn 46 Stage Positive Direct Otten vere a e ee EUER tases 48 Chapter 7 Titroduction ecu Pee MAR ee er EL e le ator dates 49 Operational Guidelines er es es eee YR 49 Travel oe vc estre dote prac ERE Regd 50 Calculating the Stopping 50 Overtravel Limit Sensor Position Adjustment POE a sat 51 Bumper Stops aS n REC oe wd oa SERT eee 53 Chapter 8 Before You 55 PTC Thermal Signal quies dese ne ia a EEE be 55 Hall Effect Module onon eee cece e RII 55 Hall to Back EMF Phasing et ay ai ie et tee 57 Motor Coil Resis
41. C J3 Hall signal connector input from side D Encoder signal connector input from side E Mating power connector AMP 359780 1 Signals from slide Header 2x8 Vertical Header 2X6 Right Angle To flexible feedback cable eae 1 SHIELD 1 2 HALLS3 2 3 ENCB ENCA 3 4 INDEX ENCB 4 5 POSLIM INDEX 5 yy 6 GND POSLIM 6 i SHIELD 7 8 ENG GND 8 9 ENCB HALLS1 9 10 INDEX HALLS2 10 11 NEGLIM ENCA 11 12 5V ENCB 12 INDEX 13 4 T NEGLIM 14 eader 2X3 Right Angle ee LN 6 TMP 16 5 a N H 3 SHIELD 2 HALLS2 1 GND Header 2 Right Angle m 2 TEMP Shield terminates to mounting hole TP1 e Rockwell Automation Publication CHPS UM001D EN P July 2014 37 Chapter5 Connector Data Table 2 Junction Box Power Connector Pin Color Signal 1 Red U A phase 2 White V B phase 3 Black W C phase 4 Green Yellow Ground Table 3 Junction Box J1 Connector Pin With Incremental Encoder With Analog Encoder Signal Designation Signal Description Signal Signal Description Designation 1 Shield Shield 2 S3 TIL Trapezoidal Hall 3 Trapezoidal Hall 3 A TIL Differential Sin Analog Differential 1V p p 4 B TIL Differential Cos Analog Differential 1V p p 5 Index Mark TIL Differential Index Differential Pulse 1V p p Common Common 9 51 TTL Trapezoidal Hall 51
42. Chapter2 Understanding Your Stage Notes 20 Rockwell Automation Publication CHPS UM001D EN P July 2014 Chapter 3 Planning the Stage Installation Topic Page Stage Mounting Requirements 21 General Safety Standards for Stage Installations 21 Mounting Restrictions 21 Environmental Factors 22 Mounting Surface Restrictions 22 Clearance Requirements 23 Stage Mounting be met when mounting your CHPS Series stage include the Requirements General Safety Standards for Stage Installations General safety standards and requirements include but are not limited to the following e ANSI RIA R15 06 Industrial Robots and Robot Systems Safety Requirements Teaching Multiple Robots ANSI NFPA 79 Electrical Standard for Industrial Machinery e CSA CAN 7434 Industrial Robots and Robot Systems General Safety Requirements e EN60204 1 Safety of Machinery Electrical Equipment of Machines Mounting Restrictions When locating your CHPS Series stage include the following e Environmental Factors e Mounting Surface Restrictions e Mounting Orientation e Clearance Requirements Rockwell Automation Publication CHPS UM001D EN P July 2014 21 Chapter 3 22 Planning the Stage Installation Environmental Factors Factor Temperature Applicability The stage does not require any special cooling considerations Avoid mounting it near any heat generating objects such as a heat register Sustained av
43. Drive 3 vs V W 98 Rockwell Automation Publication CHPS UM001D EN P July 2014 360 Start up Guide for CHPS Series Stage with Ultra3000 Drive and Ultraware Software Appendix D Reference Information Refer to these sections for information about the following Commutation Diagnostics Utility Self sensing Commutation and Startup Main Screen Setup Motor Screen Motor Screen Faults Screen Commutation Diagnostics Utility This test utility is intended for custom motors that do not have verified optimal phasing information It can be used instead of the Ultraware oscilloscope based phasing method given in the Ultra3000 Drive Manual 1 The test utility can make false recommendations if the test set up current level is too low or an obstruction is encountered during the test motion The CHPS Series stage wiring must not deviate from the standard wiring Do not use the utility if the free travel distance of the application is less than the required test motion These are the pre test requirements 1 2 3 Check for mechanical problems with the stage assembly Use a test current value high enough to overcome non acceleration forces of stiction and friction cable drag magnetic attraction A typical value used is 15 20 But values as high as 40 can be necessary Verify the free travel range from motor starting position is at least two magnet pitches or 1 electrical cycle in the negative direction and f
44. HPS x9xxxJ XxLMxxx 10 02 22 04 4 9 6 4 45 5 10 29 CHPS x9xxxK XLMXxxx 13 16 28 95 2 5 3 2 45 5 10 29 CHPS x9xxxL xLMxxx 13 16 28 95 9 9 12 8 91 0 20 46 Rockwell Automation Publication CHPS UM001D EN P July 2014 83 AppendixA Specifications and Dimensions Notes 84 Rockwell Automation Publication CHPS UM001D EN P July 2014 Interconnect Cables 2 T Appendix B Accessories Interconnect Cables Installation Maintenance and Replacement Kits 87 Power Cable Dimensions catalog number 2090 XXNPMF 76Sxx The maximum cable length of 10 m 32 8 ft Dimensions are in mm in E 3 Start of Bend Radius 28 0 1 1 142 5 59 Ld 14 0 0 55 Y Brown Black Cable Shield B overall ue J Green Yellow DS Sun i Cable Shield V for brake wires not used for linear motor stages 16 AWG BROWN Connector Diameter sj Cable Diameter lt c 55 n SHIELD 1 Bend radius BR is the specified minimum bend radius for cable assemblies For standard cable BR is a one time flex application Flex cables have a much higher BR to withstand flex applications BR can vary on user fabricated cables Pin Gauge Color Signal Designation 16 Brown U B 16 Black C 16 Blue W GND 16 Green Yello
45. MPORTANT Velocity and deceleration distance can be much higher due to an uncontrolled worst case motion constrained by the stroke and power capacity of the motor drive paring only Drive Current Limitation Your available peak force can be limited by your drive s peak current For example drive with a peak rating of 15 Ao pk has available peak force 386 N Here is the calculation Fp 600N x 15A 386N 23 3 Overtravel Limit Sensor Position Adjustment Maximum stage travel is defined as the distance the slide can travel between end caps such that the bumper stop can touch the end cap but not be compress You can shorten the slide travel up to 30 mm 1 18 in by adjusting the overtravel limit sensor Rockwell Automation Publication CHPS UM001D EN P July 2014 51 Chapter 7 52 Operation Guidelines and Limit Configuration To adjust overtravel limit sensor 1 Measure location from end block to the inside tip of the overtravel limit sensor Bumper Stop End Block Slide Limit Blade WW FRIES Overtravel Limit Sensor 2 Loosen screw and slide the overtravel limit sensor toward center of stage It can be adjusted up to 30 mm Correct Make adjustments without compressing the bumper Bumper Stop Slide End Block ENS Limit Blade e ate a a ae t i 39 mm Overtravel Limit Sensor Original position a
46. Mxxx 11 54 25 4 6 0 8 5 385 87 16 2 22 9 882 198 93 6 21042 324 541 734 541 508 375 1 Measured at 20 C 68 F ambient 2 For covered and sealed stages derate by 10 3 Values apply to bearing rating only Contact Applications Engineering for structural considerations 72 Rockwell Automation Publication CHPS UM001D EN P July 2014 Specifications and Dimensions Appendix A General Stage Specifications The following sections contain general specifications Accuracy Specification for the CHPS Series Stage Cat No Repeatability Accuracy 128 Straightness and Flatness in um in pm in CHPS xxxxxx FLMxxx 1 0 3 25 mm NTE 10 um 300 mm 3 25 mm NTE 8 300 mm 0 0001 in 1 NTE 0 0004 in 12 in 0 0001 in 1 NTE 0 0003 in 12 in CHPS xxXxxX GLMXXx 15 CHPS xxxxxx HLMXXX 20 CHPS xxxxxx ILMxxx Interpolation Dependent 1 Non cumulative For higher performance or software error mapping please contact Applications Engineering 2 Accuracy specification is based upon a 5 kg test load measured 35 mm above the center of the slide fully supported on a granite surface 3 Based upon a fully supported and clamped in place unit mounted on a rigid surface with flatness of 0 012 300 x 300 mm NTE 0 025 mm overall 0 0004 12 x 12 in NTE 0 001 in overall Commutation Sensor Description Specifications Input Power 5 24V DC 10 mA
47. PS UM001D EN P July 2014 Installation Maintenance and Accessories available for installing stages replacing items and performing Accessories Appendix B maintenance at regular intervals are listed in the tables that follow Replacement Kits 5 Accessories Description Cat No Comments Grease Pump Maintenance Kit MPAS GPUMP Includes grease pump one grease cartridge and all necessary tips Grease Cartridge MPAS CART Refill cartridge for grease pump Toe Clamp Installation Kit MPAS TOE 10 toe clamps per package Tee Nut Installation Kit MPAS 6 TNUT 10 Tee nuts per package MPAS 8 TNUT MPAS 9 TNUT Cable Carrier Modules MPAS 6xxxB CABLE Xxx cm stroke 012 018 024 030 036 042 054 066 078 090 102 or 114 MPAS 8xxxE CABLE cm stroke 014 020 026 032 038 044 056 068 080 092 104 128 152 176 or 194 MPAS 9xxxK CABLE cm stroke 014 020 026 032 038 044 056 068 080 092 104 128 152 176 or 194 Strip Seal Replacement Kits MPAS 6xxxB SEAL Xxx cm stroke 012 018 024 030 036 042 054 066 078 090 102 or 114 MPAS 8xxxE SEAL Xxx cm stroke 014 020 026 032 038 044 056 068 080 092 104 128 152 176 or 194 MPAS 9xxxK SEAL Xxx cm stroke 014 020 026 032 038 044 056 068 080 092 104 128 152 176 or 194 Side Covers Replacement Kit MPAS 6xxxB SIDE Xxx cm stroke 012 018 024 03
48. TIL Trapezoidal Hall 10 S2 TIL Trapezoidal Hall 52 TIL Trapezoidal Hall 11 A TIL Differential Sin Analog Differential 1V p p 12 B TIL Differential Cos Analog Differential 1V p p 13 Index Mark TIL Differential Index Differential Pulse 1V p p 15 5V Encoder and Hall Sensor Power 45V Encoder and Hall Sensor Power 16 Thermistor PTC Temp PTC Thermistor 1 PTC Temp is connected to Common Limit Sensor Flying Leads 38 feedback termination option ordered Rockwell Automation Publication CHPS UM001D EN P July 2014 The limit sensor option comes with flying leads regardless of the power and 1 Color Signal Description Brown TV Black Load Blue oy Load is connected to OV Chapter 6 Connecting the Stage Topic Page Connecting the Stage 39 Attaching the Ground Strap and Interface Cables 40 Thermal Protection 42 Optional Limit Sensors 43 TTL Differential Encoder Output Signal 44 Sine Cos Encoder Output Signals 45 Hall Effect Circuit 46 Motor and Hall Phasing and Sequence 46 Stage Positive Direction 48 Connecting the Stage The installation procedure assumes you prepared your system for correct electrical bonding and understand the importance of electrical bonding for correct operation of the system If you are unfamiliar with electrical bonding the section Attaching the Ground Strap and Interface Cables briefly describes and
49. User Manual Allen Bradley CHPS Series Linear Stage Catalog Numbers CHPS 150 CHPS 200 CHPS 250 Allen Bradley Rockwell Software Automation Important User Information Read this document and the documents listed in the additional resources section about installation configuration and operation of this equipment before you install configure operate or maintain this product Users are required to familiarize themselves with installation and wiring instructions in addition to requirements of all applicable codes laws and standards Activities including installation adjustments putting into service use assembly disassembly and maintenance are required to be carried out by suitably trained personnel in accordance with applicable code of practice If this equipment is used in a manner not specified by the manufacturer the protection provided by the equipment may be impaired In no event will Rockwell Automation Inc be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment The examples and diagrams in this manual are included solely for illustrative purposes Because of the many variables and requirements associated with any particular installation Rockwell Automation Inc cannot assume responsibility or liability for actual use based on the examples and diagrams No patent liability is assumed by Rockwell Automation Inc with respect to use of information
50. ads 52 leads 53 Spacing is 120 Figure 15 Motor Phasing Diagram Back EMF Voltage vs Hall Signals wu Back ZEN T Mw Voltage ese d Digital Hall Signals 0 60 120 180 240 300 360 Motor Type Linear Travel mm in 50 1 97 LC 60 2 36 LZ Phasing direction Slide toward positive end block IMPORTANT Phasing direction Positive stage direction Rockwell Automation Publication CHPS UM001D EN P July 2014 47 Chapter6 Connecting the Stage Stage Positive Direction Stage positive direction is defined by a location of a Slide End Cap Slide End Cap Slide Slide Assembly Positive Direction 48 Rockwell Automation Publication CHPS UM001D EN P July 2014 Introduction Operational Guidelines Chapter 7 Operation Guidelines and Limit Configuration This chapter gives you operational guidelines and limit sensor position adjustment procedures Topic Page Operational Guidelines 49 Travel Limits 50 Calculating the Stopping Distance 50 Overtravel Limit Sensor Position Adjustment 51 Bumper Stops 53 Please read the following notices about using your stage wiring It results in uncontrolled speeding of the stage Keep away from the line ATTENTION A runway condition is caused by incorrect motor Hall or encoder of travel while commissioning the stage IMPORTANT The customer is responsible for ensu
51. agnet pitches or one electrical cycle in the positive direction Drive disables ready for normal operation During this startup the drive evaluates the test motion A fault indicates that the motor motion was not as expected Possible reasons include the following Mechanical problem with the stage such as excessive stiction friction or cable drag Obstruction during test motion Incorrect coil or encoder wiring Encoder or signal problems device fault wiring problem noise During startup the drive uses a fixed 1 6 of the peak motor or drive current whichever is lower Ultraware software version 1 3 with firmware revision 1 16 or greater has improved functionality with proper alignment under any single obstruction If during the positive test move after detent an obstruction is encountered a test move is done in the opposite direction after re initializing the new detent If an obstruction prevents the motor from going to the real detent for example detent past negative hard stop the Ultra drive senses false detent during the test move due to false alignment After re initializing of the new detent a second test move is done in the positive direction The self sensing routine can take 2x longer because of obstructions Ifa second obstruction is detected during whole routine such as low test current or too high friction the test faults The new versions lets a user programmable test current value Limit
52. ance of 0 3 m 12 in from magnet assemblies Additionally unless absolutely unavoidable a minimum distance of 1 5 m 5 ft must be maintained between magnet assemblies and other magnetic or ferrous composite materials Calipers micrometers laser equipment and other types of instrumentation must be nonmetallic Unpacking Procedure The following tools are recommended for unpacking the stage 1 Users Manual Utility knife 2 5 mm 5 mm and 6 mm hex keys Packing tape Place carton on flat stable surface with the tape seam side facing you Usea utility knife to score the packing tape on the edges of the carton Liftcenter cover to reveal the stage Desiccant Packing End Caps Remove the packing end caps damage can occur if the linear stage is handled improperly m Never attempt a single person lift Personal injury and equipment 26 Rockwell Automation Publication CHPS UM001D EN P July 2014 Mounting the Stage Chapter 4 5 Remove the linear stage from the packaging supports For stages shorter than 1 meter 39 3 in use two people and lift the linear stage by grasping the base near the end caps only For stages 1 meter 39 3 in or longer use support straps at the 1 4 and 3 4 length points to avoid distorting the base Use this support system whenever the linear stage must be lifted 1 4 1 4 1 4 1 4 l l l n Cap
53. atible Connectors Pin Color Wire The following tables identify the power and feedback pinouts for the Intercontec circular connectors for use with standard Allen Bradley connectors Pin Color Signal Red U A Phase B White V B Phase C Black W C Phase D Green Yellow Ground Case Shield Cable Shield Intercontec P N BKUAO90NN000550003500 Mating Cable Allen Bradley 2090 165 With Analog Encoder Signal Designations Signal Description 1 Yellow A TIL Differential Sin Analog Differential 1V p p 2 White yellow A TIL Differential Sin Analog Differential 1V p p 3 Brown B TIL Differential 05 Analog Differential 1V 4 White Brown B TIL Differential Cos Analog Differential 1V p p 5 Violet Index Mark TIL Differential Index Differential Pulse 1V p p 6 White Violet Index Mark TIL Differential Index Differential Pulse 1V p p 7 Reserved Reserved 8 Reserved Reserved 9 White Red 5V DC Encoder and Hall Sensor Power 5V DC Encoder and Hall Sensor Power 10 Black Common Common 11 Reserved Reserved 12 13 Green PIC PTC Thermistor PTC 7 PTC Thermistor 14 White Black Common Common 15 White Green S1 TTL Trapezoidal Hall 51 TTL Trapezoidal Hall 16 Blue 52 Trapezoidal Hall 52 TTL Trapezoidal Hall 17 White Blue 53 TTL
54. ation Sensor cesses 73 Limit Sensor Specification Ae oua eet 73 PTC Thermistor 73 Encoder n oT Mee penne dde ens 74 Maximum Velocity for Allen Bradley 74 Environmental Specifications for CHPS Series Stages 75 CHPS Series Stage Travel versus Weight Specifications 75 CHPS Series Stage Dimensions ccs satis ene er XR Ce rini 77 CHPS Sednes Stage Technical 83 Appendix B Interconnect eaa DU cr eau desta 85 Power Cable Dimensions catalog number 2090 XXNPMF 16Sxx 85 Feedback Cable Dimensions catalog number 2090 86 Installation Maintenance and Replacement 87 INCCESSOLIES TNS Mesh UU ETE S 87 Appendix Stage Stacking ouch Re lutum 89 Specifications for Stacked Stages sid ro ee ve erp e es 90 Appendix D Using ThisAppendit sens Cet iq ch equat co e eit RM on 91 Wiring the CHPS Series Stage to the Ultra3000 Drive 91 Linear Motor File 92 Creating a CHPS Series Stage Motor 92 Recommended Start up Sequence 94 CHPS Series Stage and Ultra3000 Drive Troubleshooting Reference
55. bf in Nem Ibf in Nem Ibf in 0 0 24 2 1 0 18 1 6 1 0 43 3 8 0 33 2 9 0 46 4 1 0 34 3 0 2 0 71 6 3 0 53 4 7 0 77 6 8 0 58 5 1 B 1 08 9 6 9 0 81 7 2 2 1 16 10 3 0 87 7 7 4 1 52 13 5 9 1 1 10 8 1 67 14 8 9 124 11 9 5 2 2 20 6 17 15 8 2419 1 8 16 8 6 2 8 25 6 24 19 8 3208 2 4 21 8 8 5 2 46 8 3 8 34 5 4 48 9 4 1 36 10 7 6 67 5 6 50 8 6 76 9 64 57 8 1 4 15 3 136 11 5 102 15 4 136 11 5 102 5 16 25 8 228 193 171 25 8 228 19 3 171 3 8 53 7 476 40 3 357 53 7 476 40 3 357 7 16 76 8 680 57 6 510 76 8 680 57 6 510 1 Mounting hardware is 1960 series socket head cap bolt that meets or exceeds ANSI B18 3 2 Torque is based on 60 000 psi bearing stress under the head of the bolt 3 Denotes torques based on 100 000 psi tensile stress with threads up to one inch in diameter Rockwell Automation Publication CHPS UM001D EN P July 2014 107 AppendixE Mounting Bolts and Torque Values Table 18 Recommended Seating Torque for Aluminum Rb 72 2024 T UNC UNF Plain Cadmium Plated Plain Cadmium Plated Bolt Size 7 0 Nem Nem Ibf in Nem Ibf in Nem Ibf in 0 024 Q 1 0 18 1 6 1 0 44 3 8 9 0 33 2 9 0 46 4 1 9 0 343 0v 2 0 71 6 3 9 0 53 4 7 0 77 6 8 0 58 5 1 B 1 08 9 6 0 81 7
56. can stop the slide up to the ratings listed in the table on page 53 IMPORTANT Bumper stops are not intended as range of motion stops but they can stop the moving slide up to the ratings listed in Bumper Stops on page 53 Calculating the Stopping Distance In the following example we calculate the stopping distance for a 10 kg payload ona CHPS x8xE xLMxxxx stage driven by a Kinetix 6000 drive 2094 xxxxx by using the specification found in Appendix A Substitute values for your system as necessary Known Values Slide Moving Mass 10 32 kg Payload 10 kg Maximum Programmable Velocity Vmax 2 m s Available Peak Force 600 2232 Ao pk Start with F ma gt a F m Total Moving Mass m Payload Stage Moving Mass 10 kg 10 23 kg 22 23 kg So the maximum deceleration rate Dmax is 26 99 m 52 1 Velocity and kinetic energy can be much higher due to a uncontrolled worst case motion constrained by the stroke and power capacity of the motor drive paring only 2 Approximation only actual peak force typically decreases as speed increases Rockwell Automation Publication CHPS UM001D EN P July 2014 Operation Guidelines and Limit Configuration Chapter 7 Calculate the deceleration time Ty Vmax 2m s 0 0745 Dmax 26 99 m s Use Ty to calculate the deceleration distance Distance Vmax x T 2m s 0 0745 0 074m 74mm 2 2 Therefore you set the software travel limits to 74 mm I
57. d and restrained to prevent c Hand tighten the knurled collar five to six turns to fully seat each connector ATTENTION Keyed connectors must be properly aligned and hand N tightened the recommended number of turns Improper alignment is indicated by the need for excessive force such as the use of tools to fully seat connectors Connectors must be fully tightened for connector seals to be effective Failure to observe these safety procedures could result in damage to the motor cables and connector components Figure 9 Connecting Kinetix Type Motor and Feedback Cables Feedback Align flat surfaces Connector Rockwell Automation Publication CHPS UM001D EN P July 2014 41 Chapter6 Connecting the Stage Thermal Protection Connect the stage PTC thermistor signal to the drive or control system to create a thermal protection system PTC Thermistor Signal Characteristics Temperature C F Resistance in Ohms Up to 100 212 lt 750 Up to 105 221 lt 7500 Up to 110 221 10 000 temperature limit condition Connect this signal to control system or drive system so it shuts down the stage power upon reaching a limit condition Multiple levels of stage thermal protection are strongly recommend ATTENTION PTC thermistor supplies a signal that indicates the stage The following thermal protection methods are also recommended Typically digital drives use RMS current protection and or estimated
58. derstanding Your Stage Identifying the Components Use the diagrams and descriptions to identify individual stage components of Your Stage Figure 2 Components of Your Linear Stage 16 Rockwell Automation Publication CHPS UM001D EN P July 2014 Understanding Your Stage Chapter 2 Component Description Component Component Description Number 1 Ground Screw and Ground Label Use the labeled M5 x 0 8 6H ground screw to connect to the linear stage to a facility safety ground 2 Bearing Lubrication Ports These capped ports provide access to the linear bearings without dismantling the stage In addition these tapped holes M10 x 15 6H can be used to secure lifting hooks not provided 3 Stage Slide Your application hardware mounts to this slide by using provide mounting holes 4 Stage Cover If the strip seals are used this protective cover the stage has magnetic edges to keep the upper edge of the strip seals in place 5 Seal Guide These guides lets the strip seal to move smoothly around the stage slide 6 Cable Carrier Module Facilitates quick and easy replacement Replace the cable carrier module every 10 million cycles 7 Stage Side Cover If the strip seals are used this protective cover the stage has magnetic edges to keep the lower edge of the strip seals in place 8 Side Cover Support These supports are used on long stages to stabilize the side cover 9 Stainles
59. djust up to 30 mm Can cause programming anomaly Slide End Block TA Y T Limit Blade Overtravel Limit Sensor IMPORTANT Do not adjust the switch more than 30 mm Doing so can cause a programming anomaly 3 Redress the limit sensor cables with the cable clips Make sure wires are neatly against the base and do not interfere with the motion of the limit blade Rockwell Automation Publication CHPS UM001D EN P July 2014 Operation Guidelines and Limit Configuration Chapter 7 Bumper Stops In addition to software overtravel limits and limit sensors the end of travel bumper stops can stop the slide up to the ratings listed Bumper stops are not intended to be used as range of motion stops Table 4 Bumper Stop Energy Limits for Stage End of Travel Cat No Bumper Stop Energy Limit 5 37 3 J 330 inelb CHPS x8xxxx xLMxxx 45 5 J 403 inelb CHPS x9xxxx xLMxxx 35 2 J 312 inelb ATTENTION If energy greater than the bumper capacity is anticipated in the application provide additional mechanical means for safely stopping the slide To calculate kinetic energy of the slide with your payload use the formula J 1xMxV 2 J in jules M moving mass in kg slide payload V maximum velocity of stage in your application in m SO 1 Velocity and kinetic energy can be much higher due to a uncontrolled worst case motion constrained by the
60. e Configuration E Motor ET Tuning Encoders Digital Inputs 1 Digital Outputs EZ Analog Outputs a4 Service Info 102 Rockwell Automation Publication CHPS UM001D EN P July 2014 Start up Guide for CHPS Series Stage with Ultra3000 Drive and Ultraware Software Appendix D Motor Screen On this screen enter Total Moving Mass check for correct Motor Model and parameters and access the Motor Feedback Diagnostics Utility Ultraware LM stage axis Motor amp Eile p queo Insert Program Tools Commands Window Help Da ASA S Mex MA lO om Workspace Ew On Line Drives gg Off line Test application udb f 701 LM stage axis A EAA lt Mode Configuration Total Moving Massi 10 000 K Kg Motor 30 Tuning 4 Encoders 39 Digital Inputs Digital Outputs Analog Outputs Monitor Oscilloscope A Faults Service Info Show Status Show Commands LM stage axis LM stage asi Rockwell Automation Publication CHPS UM001D EN P July 2014 103 AppendixD Start up Guide for CHPS Series Stage with Ultra3000 Drive and Ultraware Software Faults Screen On this screen enter the continuous current in User Current Fault field not to exceed the motor file continuous current value Faults Cel a x 5 Ultraware LM stage axis File Edit View Insert Program Tools Commands Window Hel
61. e bottom stage The MPAS x8xxxx is capable of mounting to the top of either a MPAS x8xxxx or a MPAS x9xxxx by bolting through the slide on the bottom stage and into T nut slots on the top stage Rockwell Automation Publication CHPS UM001D EN P July 2014 89 AppendixC Stacking Stages Specifications for Stacked Linear stage specifications are based on mounting the stage to a precision base Sta ges along the entire length of the stage and MPAS stage specifications follow this convention In the case of stacked stages the top axis is no longer supported along its entire length and this alters both the precision and the load carrying capability of that stage Furthermore linear stage specifications are based on a specified test payload with a low center of gravity that is centered on the carriage Deviations from the test payload condition can impact the performance of both the top and bottom linear stages The following table provides information about the payload that the top stage or axis can carry without derating the life of its bearings from those specified for the same stage mounted as a single axis stage on a precision base Table 13 Centered Stack Combinations Not Requiring Derating Catalog Numbers of Y axis Travel Mass of Payload Centered Stack Linear Stages MPAS x6xxxx on MPAS x6xxxx 300 10 0 kg 22 Ib Ball Screw or Direct Drive 420 8 0 kg 17 6 Ib 540 5 0 kg 11 Ib
62. e cosine encoder 20 um signal period with integral index mark Rockwell Automation Publication CHPS UM001D EN P July 2014 Understanding Your Stage Chapter 2 A 8 054F FLMC2C Bulletin Number LI E Cable Management and Termination Voltage A No Cables or Cable Carrier Slide Junction Box only A 230V AC B Cables with Flying Leads and Cable Carrier B 460V AC LC motors only Cables with Kinetix MPF Connectors and Cable Carrier Frame Size D Cables with D Connectors and Cable Carrier 8 200 mm base Limits Stroke 2 No limits For 100 and 120 motor coil lengths 5 Two end of travel limits Travel lengths start at 6 cm and are available in 6 cm increments Protection For example 006 for 6 cm travel or 054 for 54 cm travel S Covered with strip seals IP 3020 Maximum travel 126 cm 2 0 Travel lengths start at 8 and are available in 6 cm increments C Covered without strip seals For 200 or 240 motor coil lengths 0 Open without cover without strip seals For example 008 for 8 cm travel or 020 for 20 cm travel LM Specifier Maximum travel 122 LM Linear Motor Motor Feedback A 12 030 7 120 0 E LC 050 200 D F 1 0 micron incremental optical encoder with integral index mark B LZ 030 T 240 D F LC 050 200 E G 0 5 micron incremental optical encoder with integral index mark 12 030 7 240 0 1 micron incremental optical encoder with integral index mark D 1C
63. ect bad spots and other anomalies Use Current Control Panel mode to give a small positive current command Verify the stage moves in the positive direction e Check for consistent force resistance over whole travel by pushing the slide to multiple locations e Check that the amount of current to move the load and overcome friction forces at a low steady speed are correct The motor s force constant Kf can also be verified with a force gauge The Ultraware software command units for current scaling are in AQ peak V 9 When current mode tests successfully perform auto velocity or manual velocity tuning with the Ultraware oscilloscope function do this even if you are using current mode to control your application This further evaluates commutation and check for a good step response Rockwell Automation Publication CHPS UM001D EN P July 2014 95 AppendixD Start up Guide for CHPS Series Stage with Ultra3000 Drive and Ultraware Software CHPS Series Stage and Ultra3000 Drive Troubleshooting Reference 96 The section contains troubleshooting reference for the CHPS Series stage and Ultra3000 drive combination Positive Phasing Direction Positive stage direction slide moving towards junction box or cable exit end as shown here Slide End Cap Slide Slide Assembly Positive Direction Encoder Counting Polarity Encoder must count in positive direction when moving in the positive direction IMPORTANT Incor
64. ence to safely perform the assigned task If you do not understand the linear motor stages contact your local Rockwell Automation sales representative for information on training courses before using this product Read this entire manual before you attempt to install your stage into your motion system This familiarizes you with the stage components their relationship to each other and the system After installation check the configuration of the system parameters to be sure they are properly set for the stage in your motion system Follow all instructions carefully and pay special attention to safety concerns These documents contain additional information concerning related products from Rockwell Automation Description High Precision Linear Motor Driven Stages Selection Guide Provides product specifications ratings certifications system interface and wiring publication CHPS SG001 diagrams to aid in product selection Kinetix 2000 Multi axis Servo Drive User Manual Describes how to configure and use Kinetix 2000 multi axis servo drives publication 2093 UM001 Kinetix 6000 Multi axis Servo Drive User Manual publication Describes how to configure and use Kinetix 6000 multi axis servo drives 2094 UM001 LZ Family of Linear Motors Brochure publication PMC BROO1 Provides product specifications outline drawing ratings and wiring information to aid in product selection LC Family of Linear Motors
65. endix A CHPS Series Stage 200 mm frame size je ne uar o V sa NEUE SEE Ium Me 28 Hw EN ees 28 F 860 5 5565 n na nni 1 N N ace t 720 ee E ow mcn prete 4 60 n 5 gt a i gt E E 4 4 40 8 5 muc cx Eso 8 SEEN 5 B S duc 300 ee ee 8 Y 1 p 240 20 5 2 MEUM p j EX MES on I EP eee eM MY 5 E l 4 Ww K 5 de a o wo n by sse By ssew atl 6 ssew a m Rockwell Automation Publication CHPS UM001D EN P July 2014 76 Specifications and Dimensions Appendix A CHPS Series Stage Stage are designed to metric dimensions Inch dimensions are conversions from millimeters Dimensions without tolerances are for reference Dimensions Figure 21 CHPS A6xxxA xLMxxx 4X M6 x 1 0 6H Y 12 0 0 47 30 5 1 20 Slide 30 5 1 20 Mechanical 239 Mechanical Overtravel 9 41 T Travel Overtravel 25 0 165
66. erage temperature must not be greater than 40 C 104 F nor less than 0 C 32 F Humidity Avoid excessive humidity Condensation on metal surfaces can cause stage corrosion The maximum permissible humidity is 80 relative Access and Interference When possible locate the system where sufficient working space is available to perform periodic maintenance Avoid installing where a trapping hazard or pinch point occurs as a result of interference with the building structures utilities and other machines and equipment Dust and airborne contaminants Avoid placing the stage in areas where excessive dust or other airborne contaminants are present Chemical fumes or vapors can cause damage to internal components Vibration Install the stage in location free of excessive vibration Ambient Light Have sufficient light readily available to enable inspection testing and other functions to be performed on the stage Mounting Surface Restrictions Mounting Orientation Surface Restriction Stages are to be bolted or clamped to a flat stable and rigid surface along its entire length Flatness deviation in the mounting surface must be less than or equal to 0 025 mm over a 300 x 300 mm 0 001 in over a 12 x 12 in area Flatness must be maintained during operation of the stage Ceiling inverted surface A ceiling mount inverted on a horizontal surface is not recommended Stages mounted
67. ermine the Type of Fastener to Use Three types of fasteners that can be used to mount the stage e Through bolts Toe clamps e Tee nut or square nut Toe clamps are supplied with the catalog number CHPS x6xxx stages and covered types of the catalog number CHPS x8xxx and CHPS x9xxx stages Refer to the Mounting Fastener Options table for an illustration of each fastener type Table 1 Mounting Fastener Options Torque Fastener Order Illustration User Supplies Recommended For Nem Ibf in Through Bolt M5x1 0x 16 mm min Uncovered stages 2 3 30 Toe clamps MPAS TOE M6 x 1 0x 16 mm min Covered stages 5 5 48 Tee nuts MPAS x TNUT M6 x1 0 Securing a stage from Tee Nut 6 7 60 beneath the mounting Square Nut 2 3 30 SSS surface Through bolt mounting is not an option for catalog number CHPS x6xxxx xLMxxx 150 mm stages 2 The tee nut mount for a catalog number CHPS x8xxxx xxxxx 200 mm stage is a square nut in a tee slot Where xis the frame size of a stage 6 CHPS x6xxxx xxxxx 150 mm 8 CHPS x8xxxx xxxxx 200 mm 9 CHPS x9xxxx xxxxx 250 mm You supply the bolts Rockwell Automation Publication CHPS UM001D EN P July 2014 29 Chapter4 Mounting the Stage Figure 6 Through Bolt Mounting IMPORTANT Through bolt mounting is not available for the catalog number CHPS x6xxxx xxxxx 150 mm stages An uncovered stage is a good candidate for through bolt mounting
68. essure is felt or two strokes are completed Repeat steps 3 and 4 to the second bearing on this side Move slide to opposite end of travel and repeat steps 1 5 Remove clamp Reinstall the protective caps on all the lubrication ports I finstalled remove strip seal and side cover on the side opposite the cable carrier Clear any coarse or abrasive particles with a clean air line with maximum pressure of 10 psi 3 Clean scale with a clean dry cloth Avoid the use of solvents If necessary use isopropyl alcohol sparingly apply with a wetted cloth by using a gentle wiping action Reinstall side cover and strip seal if used Rockwell Automation Publication CHPS UM001D EN P July 2014 Maintenance 9 Strip Seal Cleaning Clean the strip seals if installed by using lint free cloth lightly saturated with isopropyl alcohol IMPORTANT Replace the strip seal if it cannot be cleaned or if an uneven or scored surface is detected during cleaning A buildup of foreign material on the strip seal degrades the performance of the linear stage This buildup coupled with rapid movement of the slide and the resulting friction can score the surface and create a burnished appearance on the strip seal Elements contributing to a typical buildup on the strip seals are dust grease and other contaminates normally encountered in any operating environment that is not strictly controlled Refer to the St
69. fer multiple support programs for installation configuration and troubleshooting For more information contact your local distributor or Rockwell Automation representative or visit http www rockwellautomation com services online phone Installation Assistance If you experience a problem within the first 24 hours of installation review the information that is contained in this manual You can contact Customer Support for initial help in getting your product up and running United States or Canada 1 440 646 3434 Outside United States or Canada Use the Worldwide Locator at http www rockwellautomation com rockwellautomation support overview page or contact your local Rockwell Automation representative New Product Satisfaction Return Rockwell Automation tests all of its products to help ensure that they are fully operational when shipped from the manufacturing facility However if your product is not functioning and needs to be returned follow these procedures United States Contact your distributor You must provide a Customer Support case number call the phone number above to obtain one to your distributor to complete the return process Outside United States Please contact your local Rockwell Automation representative for the return procedure Documentation Feedback Your comments will help us serve your documentation needs better If you have any suggestions on how to improve this document complete this for
70. fications for 150 mm frame size CHPS Series Linear Stages Cat No Slide Mass Continuous 1 2 Max Static Moment Loads Static Load Current Thrust Current Thrust Pitch Yaw Roll kg Ib A rms Ao pk N Ibf A rms Ao pk N Ibf kN Ibf kN Ibf Nem ft lb Nem ft lb CHPS A6xxxA xLMxxx 4 64 10 23 2 3 3 3 80 18 7 0 9 9 239 54 38 0 8722 71 52 183 134 97 71 CHPS A6xxxB xLMxxx 6 48 14 28 4 7 6 6 160 36 14 0 19 9 479 108 38 0 8722 128 94 327 241 97 71 CHPS A6xxxC xLMxxx 6 48 14 28 2 3 3 3 160 36 7 0 9 9 479 108 38 0 8722 128 94 327 241 97 71 1 Measured at 20 C 68 F ambient 2 For covered and sealed stages derate by 10 3 Values apply to bearing rating only Contact Applications Engineering for structural considerations Table 8 Performance Specifications for 200 mm frame size CHPS Series Linear Stages Cat No Slide Mass Continuous Peak Maximum Max Static Moment Loads Static Load Current Thrust Current Thrust Pitch Yaw Roll kg Ib Arms Ao pk N Ibf Arms Ao pk N lbf KN Ib kN Ibf Nem ft lb Nem ft lb CHPS A8xxxA xLMxxx 4 59 10 1 2 1 3 0 72 16 6 3 8 9 215 48 66 14836 1719126 412 304 270 199 CHPS A8xxxB xLMxxx 6 58 14 5 4 2 6 0 144 32 12 6 17 9 431 97 66 14836 270 199 620 457 270 199 CHPS A8xxxC xLMxxx 6 58 14 5
71. ge Chapter 6 Use the following information to connect a stage with a Sine Cosine Encoder option to a drive or controller that processes sine cosine position feedback The sine cos encoder amplitude is 0 90V p p minimum up to 2 meters per second 0 60V p p up to 4 meters per second Figure 13 Sine Cos Encoder Timing Incremental 2 channels V1 and V differential sinusoids in quadrature 90 phase shifted 20 um Sine V14 V1 Cosine V2 V2 0 6 1 2V p p with green m NIA LED indication and 120 0 termination Reference Vo Vo Differential pulse V9 18 108 Duration 126 electrical Repeatability of position uni directional is maintained if temperature is 15 35 C and speed is 250 mm s Recommended termination 120 Q resistors VO V1 V2 Figure 14 Sine Cos Encoder Termination Readhead ENCA ENCB amp Index Mark Drive or i Controller gt 7 120007 ENCA ENCB amp Index Mark 1 Total termination resistance in ohms Rockwell Automation Publication CHPS UM001D EN P July 2014 45 Chapter6 Connecting the Stage Hall Effect Circuit Use the following information to connect the Hall Effect circuit to your servo drive Input power 5 24 V DC 10 mA maximum e Output NPN Open Collector 10 mA maximum Hall Signal gt Rp j isin Hall 1 Hall 2 Drive Hall 3
72. ge and Ultra drive connectivity table provided on page 92 Incorrect wiring or Hall offset combinations can result in motor motion that has excessive force ripple and increased current temperature Or reduced force per unit of current 4 Verify that the correct motor file is selected or correct custom motor parameter values are entered 5 User Current Fault parameter this value must not exceed the CHPS Series stage motor s continuous current rating Rockwell Automation Publication CHPS UM001D EN P July 2014 Start up Guide for CHPS Series Stage with Ultra3000 Drive and Ultraware Software Appendix D 6 Current Limit parameters the positive and negative current limit must not exceed the CHPS Series stage motor s intermittent current rating Set per the application requirements 7 Verify correct encoder polarity and test distance count Encoder must count in positive direction when CHPS Series stage is moving in the positive stage direction as shown in Stage Positive Direction on page 48 Also see CHPS Series Stage and Ultra3000 Drive Troubleshooting Reference on page 96 Incorrect encoder sequencing can cause a runaway motor condition or incorrect commutation 8 Perform Commutation Diagnostics only if enough free travel distance is available You can guarantee optimal commutation only by doing oscilloscope verification You can use the following checks for non optimal commutation verification These tests cannot det
73. he Ultra3000 drive is found in the CHPS Series stage specifications Intermittent Current Ap peak Motor s peak current rating Use the motor rating in the CHPS Series Stage Selection Guide Do not use the values from the Motor Product Profile The CHPS Series 17 motors are restricted to 3x continuous current Consult with an application engineer if you are considering increasing this value Continuous Current A peak Motor continuous current rating Use the motor rating in the CHPS Series Stage Selection Guide Do not use the values from the Motor Product Profile For CHPS Series stages with cover and seals option derate the base value by 10 Max Current Boost 0 For standard CHPS Series stages without forced cooling Encoder Type Select applicable type per CHPS Use Incremental for digital encoder Sine Cosine for analog encoder Sine Cosine Series stage option code requires additional set up per the Ultra3000 Drive manual Commutation Type Sinusoidal Startup Type Desired commutation mode The recommended and default setting Hall Inputs and has no motion on startup For self sensing refer to the section on Self Sensing Commutation and Startup Hall Input Offset degrees 0 For standard CHPS Series stage motor models Lines Meter Enter the encoder lines per meter of travel Lines are pre quadrature resolution Alternatively for incremental encoders calculate the counts meter and divide by 4 to get lines meter Following a
74. ing 61 IMPORTANT person that teaches operates maintains or repairs these stages must be trained and demonstrate the competence to safely perform the assigned task Before You Begin The following tools are required to lubricate and clean your stage N ATTENTION Lockout tagout power before servicing 0 5 m 14 in or larger clamp with soft jaws e Grease catalog number MPAS CART Grease gun kit catalog number MPAS GPUMP with tip type installed and primed Air line with maximum pressure of 10 psi e Lint free cloth few drops of isopropyl alcohol if necessary for cleaning encoder scale Rockwell Automation Publication CHPS UM001D EN P July 2014 59 Chapter9 Maintenance Lubricate the Bearing Optical Encoder Scale Maintenance 60 Your stage requires lubrication every 6 months or 2500 km 1550 mi of travel which ever comes first Use the MPAS grease gun kit and grease cartridge catalog numbers MPAS GPUMP and MPAS CART respectively QJ d amp Bearing Lubrication Ports 2x per end cap Position slide at end of travel and clamp it to hold the stage against end cap ATTENTION Do not use clamp across the side panels This can deform and damage the side panels Remove the lubrication port protective caps Insert the tip of grease gun in the lubrication port Push in until contact with bearing grease nipple is felt Pump handle until back pr
75. ion 46 commutation sensor specifications 73 component description bearing 17 lubrication ports 17 bearing rail 17 cable carrier module 17 cover 17 index mark 17 limit blade 17 optical encoder readhead 17 optical encoder scale 17 side cover 17 side cover support 17 slide 17 strip seal 17 strip seal damp 17 strip seal guide 17 components 18 connector pinout d type Rockwell Automation Publication CHPS UM001D EN P July 2014 Index feedback 35 power 35 Kinetix feedback 34 power 34 connectors flying lead termination 36 counter clock frequency 44 cover 17 cleaning 61 installation 67 removal 65 torque 67 D dimensions 150 mm 77 78 200 mm 79 80 250 mm 81 82 direction 47 48 drip loop 40 dust 22 edge separation 44 EMI 40 encoder analog differential 45 maintenance 60 TIL differential 44 encoder scale maintenance 60 optical encoder scale 17 example fastener calculation 28 stopping distance calculation 50 Ultraware custom motor file 101 extension cables 85 fastener quanity calculation 28 square nut 31 tee nut 31 through bolt 30 toe clamp 30 feedback interconnect cable 86 flatness specifications 73 flying lead termination 36 force constant 83 109 Index 110 G ground screw 40 torque 40 strap 40 grounding 40 Hall effect circuit 46 Hall effect module 55 Hall phasing 46 heat 13 high frequency energy 40 humidity 22 humidity range 75 incline payload 13 index mark 17 insta
76. is 39 25 0 0 98 F 6 50 1 18 0 98 o oo a M i 165 167 6 50 657 i 55 5 To lel 9 ah d L 1 120 4 72 43 07 0 028 Y 45 0 1 80 Thu He 18 amp Toe Clamp T Nut Spacing Pilot Hole 453 2 44 See Detail A 4X M10 x 1 5 6H Thru 2 per end cap 238 6 Access point for lubricating linear bearings 46 8 0 39 Provision to use lifting hooks not provided 1 84 5 350 0 715 Ground Screw Travel 5 x 0 8 6H amp ex ut 123 8 4 88 150 DUET Detail A 7 6 Bracket located 51 2 0 5 9 0 30 from center of travel 9 3 0 37 c Depth max Toe Clamp is standard for T Nut Mount to base using covered stages Mount to base 6 x1 0 hardware using M6 x1 0 socket cap screw optional accessory Travel Length mm in Shortest 60 2 36 Increments 60 2 36 Longest 1620 63 78 Rockwell Automation Publication CHPS UM001D EN P July 2014 77 Appendix Specifications and Dimensions Figure 22 CHPS A6xxxB C xLMxxx 4X M6 x 1 0 6H V 12 0 0 47
77. itions on the center cover and place all packing material inside the carton 3 Lightly tape carton closed and store in dry place Store the stage in area that is clean dry vibration free and at a relatively constant temperature Refer to Environmental Specifications for CHPS Series Stage on page 75 for more detailed information This section discusses mounting methods for your stage Before You Begin the Mechanical Installation The machine designer is most qualified to determine the number and type of fasteners to use for mounting the stage The following information is a guide for the decision making process Determine the Number of Fasteners Required The length of the stage determines the number of mounting fasteners that are required Use one of the following equations to calculate the required mounting hardware Figure 4 Fasteners Required for Stages with 150 mm and 200 mm frame size CHPS x6xxxx xLMxxx and CHPS x8xxx xLMxxx fasteners Ge em v 26 e round down 4 1 x2 Figure 5 Fasteners Required for Stages 250 mm frame size CHPS x9xxx xLMxxx fasteners cs cm 2 E round down 1 x2 or example if you are mounting an CHPS B8194F ALMO2C stage Rockwell Automation Publication CHPS UM001D EN P July 2014 Mounting the Stage Chapter 4 1940 mm stroke length 194 0 cm 194 cm 36 _ 230 12 Em 19 167 fasteners round down 19 fasteners 1941 20 2 40 fasteners Det
78. k waveforms at S1 S2 and S3 at the feedback connector Rockwell Automation Publication CHPS UM001D EN P July 2014 55 Chapter 8 56 Troubleshooting Move the slide slowly and steadily by hand in the specified phasing direction to generate the Hall waveform 5 Check for proper logic levels approximately low V high and correct signal sequence 51 leads 52 and 52 leads 3 with approximately 120 electrical spacing between signal transitions Hall Effect Leads Color Name Signal Description White Green 51 Trapezoidal Hall TTL Single Blue 57 Trapezoidal Hall TTL Single White Blue 53 Trapezoidal Hall TTL Single Figure 16 Hall Signals Waveforms LLL LLLI of 0 60 120 180 240 300 360 TIP Connect the common probe from the scope to the Hall signal common To determine the location of the signal common refer to the Stage Power and Feedback Connections beginning on page 40 6 Before assuming a Hall module fault check Hall field wiring or drive Hall circuit interface Rockwell Automation Publication CHPS UM001D EN P July 2014 Troubleshooting Chapter 8 Hall to Back EMF Phasing Verify the Hall to Back EMF Phasing with this procedure 1 2 With drive power OFF Verify the Hall circuit is connected to the drive as describe in the CHPS Series Connector Data beginning on page 33 Disconnect the stage mot
79. le 9 Performance Specifications for 200 mm frame size CHPS Series Linear Stages Cat No Slide Mass Continuous 12 Peak Maximum Max Static Moment Loads Static Load Current Thrust Current Thrust Pitch Yaw Roll kg Ib Arms Ao pk N Ibf Arms Ao pk N Ibf kN Ibf kN Ibf Nem ft lb Nem ft lb CHPS x8xxxD xLMxxx 5 64 12 4 3 1 4 3 132 30 8 3 11 7 302 68 66 14836 1719126 412 304 270 199 CHPS x8xxxE xLMxxx 8 34 18 4 6 2 8 7 265 60 16 5 23 3 600 135 66 14836 270 199 620 457 270 199 CHPS x8xxxF xLMXXX 8 34 18 4 3 1 4 3 265 60 8 2 11 6 600 135 66 14836 270 199 620 457 270 199 1 Measured at 20 C 68 F ambient 2 For covered and sealed stages derate by 10 3 Values apply to bearing rating only Contact Applications Engineering for structural considerations Performance Specifications for 250 mm frame size CHPS Series Linear Stages Cat No Slide Mass Continuous 2 Peak Maximum Max Static Moment Loads Static Load Current Thrust Current Thrust Pitch Yaw Roll kg Ib Arms Ao pk N Ibf Arms Ao pk N Ibf kN Ibf kN Ibf Nem ft lb Nem ft lb CHPS x9xxxJ xLMXXx 11 54 25 4 3 0 4 2 385 87 8 1 11 5 882 198 93 6 21042 170 125 385 283 508 375 CHPS x9xxxK xLMxxx 9 69 21 4 3 0 4 2 193 43 8 1 11 5 441 99 93 6 21042 324 239 734 541 508 375 CHPS x9xxxL xL
80. llation clearance requirements 22 K Kinetix connector 34 interconnect cables 85 Ultra3000 drive set up 91 L lighting 22 limit blade 17 limit sensor setting 50 signals wires 38 specification 73 wiring 43 lubrication 17 18 60 M maintenance 18 bearing lubrication 60 cable carrier installation 64 cable carrier module removal 63 cover installation 67 removal 65 torque 67 optical encoder scale 60 replacement kits 87 side cover installation 67 removal 65 torque 67 strip seal Rockwell Automation Publication CHPS UM001D EN P July 2014 installation 66 removal 65 maitenance 59 metric bolts torque 105 motor file creating 92 motor phasing 46 mounting 22 before mounting 23 28 bolt through 29 ceiling 22 indine 22 inverted 22 square nut 31 square nuts 29 surface 22 surface restrictions 23 tee nut 31 through bolt 30 toe clamp 29 30 vertical 13 22 wall 22 0 operating temperature 75 operational guidelines 49 optical encoder readhead sin cos encoder 17 TTL encoder 17 options 18 orientation 48 overtravel 43 P packaging material storage 28 packing air transportion restrictions 14 unpacking 26 pitch 70 polarity encoder counting 96 positive direction 47 48 power interconnect cables 85 procdeure cover cleaning 61 lubrication 60 procedure connecting stage 40 drip loop 40 EMI bonding 40 grounding 40 number of fasteners 28 stage storage 28 store packing material 28 strip seal cleaning
81. log CN2 3 Encoder B digital or Cos analog Encoder B digital or Cos analog CN2 4 Encoder B digital or Cos analog Hall 51 CN2 12 Hall 51 Hall 52 CN2 13 Hall 52 Hall 53 CN2 8 Hall 53 Linear Motor File Parameters The following guide supplements the information found in the Ultra3000 drive manuals Some of the motor parameters are critical for commutation and motor protection Incorrect entry of theses motor parameters can cause motor problems Ultraware assumes a linear motor is functionally equivalent to a rotary motor However the functional equivalent to a rotary motor is a complete linear motor driven stage To account for the difference the parameters highlighted in bold in the Linear Motor Parameter File mdb extension table shown below must be adjusted to stage level specifications Creating a CHPS Series Stage Complete CHPS Series stage motor specifications are in the linear motor Motor File specifications information contained in this manual or the motor data sheet Identify the stage motor option for your CHPS Series stage and use the corresponding data Conversion Factors e Ultra3000 drive ampere units are measured at the peak of the sine wave not RMS Standard CHPS Series stage motors are rated both ways Be sure to select the correct value If necessary use the following conversion ampere peak 1 4x RMS 92 Rockwell Automation Publication CHPS UM001D EN P July 2014 Start up Guide fo
82. m publication RA DU002 available at http www rockwellautomation com literature Rockwell Otomasyon Ticaret A S Kar Plaza Is Merkezi E Blok Kat 6 34752 erenk y stanbul Tel 90 216 5698400 www rockwellautomation com Power Control and Information Solutions Headquarters Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 2496 USA Tel 1 414 382 2000 Fax 1 414 382 4444 Europe Middle East Africa Rockwell Automation NV Pegasus Park De Kleetlaan 12a 1831 Diegem Belgium Tel 32 2 663 0600 Fax 32 2 663 0640 Asia Pacific Rockwell Automation Level 14 Core F Cyberport 3 100 Cyberport Road Hong Kong Tel 852 2887 4788 Fax 852 2508 1846 Publication CHPS UMO001D EN P July 2014 Supersedes Publication CHPS UM001C EN P November 2010 Copyright 2014 Rockwell Automation Inc All rights reserved Printed in the U S A
83. mental Specifications for CHPS Series Stages 75 CHPS Series Stage Travel versus Weight Specifications 75 CHPS Series Stage Dimensions 77 CHPS Series Stage Technical Specifications 83 Rockwell Automation Publication CHPS UM001D EN P July 2014 69 AppendixA Specifications and Dimensions Static and Static Moment The figure depicts the Static and Static Moment Loads in the tables that follow Loads Table 6 Staticand Static Moment Loads on Linear Stages Pitch Moment Load Reverse Radial Force Load Radial Force Load Yaw Moment Load Roll Moment Load KO N Lateral Force Load at 9 The static moment and force ratings shown in the tables are the maximum permissible values possible before permanent damage to the linear stage can occur To determine the estimated L10 bearing and ball screw life of CHPS Series Integrated Linear Stages use Motion Analyzer software version 4 4 or later Performance Specifications for 325V CHPS Series Stage Maximum cable length 10 m 33 ft Please contact Applications Engineering concerning application requiring longer cables 70 Rockwell Automation Publication CHPS UM001D EN P July 2014 Specifications and Dimensions Appendix A Table 7 Performance Speci
84. nalog Differential 1V p p 15 White Brown TIL Differential Cos Analog Differential 1V p p 16 White Violet Index Mark TIL Differential Index Differential Pulse 1V p p 17 Black Common Common White Black 18 Reserved 19 20 21 22 Blue 82 TTL Trapezoidal Hall 82 TIL Trapezoidal Hall 23 Reserved 24 25 1 PTC Temp is connected to Common 1f i Connector Part Number AMP P N 207464 2 Mating Connector Part Number AMP P N 5205207 1 Rockwell Automation Publication CHPS UM001D EN P July 2014 35 Chapter5 Connector Data The following tables identify the power and feedback pinouts for flying lead this option lest you to use your own connectors AN Flying Leads ATTENTION Disconnect input power supply before installing or servicing stage Stage lead connections can short and cause damage or injury if not well secured and insulated Insulate the connections equal to or better than the insulation on the supply conductors Properly ground the stage as described in the drive manual 36 Color Signal Red U A phase White V B phase Black W C phase Green Yellow Ground Shield Cable Shield With Incremental Encoder With Analog Encoder Solor Wire ations Signal Description ations Signal Description Yellow
85. ntenance personnel working on the linear stage should avoid the use of metallic tools and secure items such as badge clip and other personal effects that could be attracted by the strong magnets Strong magnets can erase magnetic media Never allow credit cards or floppy disks to contact or come near the linear stage Do Not Lift by Junction Box Do not attempt to move the linear stage by grasping the cable junction box Moving the linear stage in this manner will damage the linear stage and create a pinch or crush hazard The junction box is attached to the carriage which 15 free to move Lifting the linear stage in this manner will allow uncontrolled movement of the heavy base Always use a two person lift and grasp the linear stage by the base at the end caps Always keep fingers clear of the carriage s path of travel Stay Clear Do not put hands or objects on the linear stage cover Doing so could deform the cover and damage the linear stage causing excessive wear on the cover supports or scraping noises when the linear stage is in motion 12 Sharp Edges Always remove strip seals before removing the top or side covers If it becomes necessary to remove the top or side covers or change the strip seal exercise care when working near or on the strip seal The edges of the strip seal are sharp and can cut if accidentally hit or if handled inappropriately Rockwell Automation Publication CHPS UM001D EN P J
86. or power leads from the drive EXAMPLE To observe W U Back EMF phase polarity connect oscilloscope probe tip to the W phase and the common probe to the U phase Apply power to the Hall device by setting the drive control power to ON Slowly and steadily move the stage by hand to perform the Hall signal test except this time check the motor phases are in phase with the Hall signal as shown in the Motor Phasing Schematic on page 58 Make sure the phase error between Hall signal and in phase Back EMF does not exceed 5 electrical degrees Ifpoor results were obtained in step 5 repeat the test at the stage power terminations to check field wiring ATTENTION Dangerous voltages forces and energy levels exist in servo controlled systems Extreme care must be exercised when operating maintaining or servicing the stage to prevent harm to personnel or equipment Rockwell Automation Publication CHPS UM001D EN P July 2014 57 Chapter8 Troubleshooting Motor Coil Resistance Ifa motor coil electrical problem is suspected perform this check Measurements 77 F 1 Let the coil attain ambient room temperature approximately 25 C 2 Verify the drive power is OFF 3 Disconnect all stage leads phases and ground from the drive 4 Measure the phase to phase ptp resistance of the phase combinations U to V V to W and W to U and record the values Verify these three readings are approximately equal to each other
87. otor and Feedback Cables diagram for a visual example ATTENTION Be sure that cables are installed and restrained to prevent uneven tension or flexing at the cable connectors Excessive and uneven lateral force at the cable connectors can result in the connector s environmental seal opening and closing as the cable flexes Failure to observe these safety procedures could result in damage to the motor and its components 40 Rockwell Automation Publication CHPS UM001D EN P July 2014 Connecting the Stage Chapter 6 4 Attach the feedback cable and the power cable to the stage the power cable while power is applied to them Inadvertent pin connections can result in unexpected motion or result in irreversible damage to the components ATTENTION Do not connect or disconnect the stage feedback cable For Kinetix type connectors a Carefully align each cable connector with the respective motor connector as shown in Figure 1 b Do not apply excessive force when mating the cable and stage connectors If the connectors do not go together with light hand force realign and try again uneven tension or flexing at the cable connectors Excessive and uneven lateral force at the cable connectors can result in the connector s environmental seal opening and closing as the cable flexes Failure to observe these safety procedures could result in damage to the motor and its components ATTENTION Be sure that cables are installe
88. our magnet pitches or 2 electrical cycles in the positive direction 1 The phasing diagram in the drive manual is for phase to neutral measurements This requires use of a balanced resistor Y network to create a virtual neutral Alternatively the phase to phase diagrams and procedures in the Ultra 100 200 can be used because they are equivalent to each other after the phase shift correction is made Rockwell Automation Publication CHPS UM001D EN P July 2014 99 AppendixD Start up Guide for CHPS Series Stage with Ultra3000 Drive and Ultraware Software Self sensing Commutation and Startup This type of commutation does not use the Hall effect sensor Motors with a Hall effect sensor connection can be set to self sensing commutation the Hall effect signals are ignored Self sensing start up is not commutation diagnostics You can perform commutation diagnostics at any time on Hall effect or self sensing motors Self sensing start up refers to the motor motion initialization that is executed automatically after every power up and enabling of the system It synchronizes the arbitrary encoder position or count to the drive s initial commutation angle This is the self sensing start up sequence Enable is activated Motor locks into detent or zero force position gt up to one magnet pitch electrical cycle of motion jerk After jerk motion settles out in 1 or 2 seconds motor executes a slow speed test move of approximately two m
89. p Dc uet jxxmex as ocl 9 Workspace 26 On Line Drives 1 08 Offline Test application udb 161 LM stage axis amp 9 Mode Configuration Analog Preset a Follower Motor QUT Tuning AD Encoders Digital Inputs 2 Digital Outputs EZ Analog Outputs Monitor m Oscilloscope A Service Info 104 Rockwell Automation Publication CHPS UM001D EN P July 2014 Mounting Bolts and Torque Values Table 15 Recommended Seating Torque for Metric Bolts Appendix Plain Cadmium Plated Zinc Bolt Size Metric Pitch Nem Ibf in Nem Ibf in Nem Ibf in 16 0 35 0 29 2 6 0 22 1 95 0 41 3 64 2 0 40 0 60 5 3 0 45 3 98 0 84 7 42 2 5 9 0 45 1 24 11 0 93 8 25 14 15 4 M3 0 5 2 15 19 1 61 14 25 3 00 26 6 M4 07 46 41 3 47 30 75 6 48 57 4 5 0 8 9 6 85 7 20 63 75 13 4 119 M6 1 0 15 8 140 11 9 105 22 1 196 M8 125 39 5 350 29 7 262 5 55 4 490 M10 15 76 8 680 57 6 510 115 2 1020 1 Mounting hardware is 150 898 1 socket head cap bolt that meets or exceeds ANSI B113M ISO 261 150 262 coarse series only 2 Microsize bolt Rockwell Automation Publication CHPS UM001D EN P July 2014 105 Appendix E 106 Mounting Bolts and Torque Values Table 16 Recommended Seating Torque for Mild Steel Rb 87 or Cast Iron Rb 83
90. pt free of debris 17 Magnet Track This track of powerful static magnets is the other half of a linear motor LC linear motor option shown LZ linear motor option has a magnet channel 18 Limit Blade Provides a mechanical trigger to the limit sensor 19 Limit Sensor These optional sensors output a signal when the limit blade passes in front of them The position of these sensors can be adjusted to suit your application see Operation Guidelines and Limit Configuration section on page 49 20 Hall Sensor Module Three Hall sensors in this module are provide for commutation startup and phase alignment They can also be use for trapezoidal commutation of the motor 21 Bumper Stop These springs absorb slide and payload energy in the event the stage loses control See page 53 for absorption limits Rockwell Automation Publication CHPS UM001D EN P July 2014 17 Chapter2 Understanding Your Stage Recommended Maintenance Interval Identifying Your Stage Under normal stage use follow these lubrication guidelines IMPORTANT You determine the frequency of re lubrication that is best suited to your application as an application s environment motion profile and duty cycle can effect the re lubrication time period required Lubricate the stage every 6 months or 2500 km 1550 mi of travel which ever comes first Use the MPAS grease gun kit and grease cartridge catalog numbers MPAS GPUMP and MPAS CART respectively See maintenance sec
91. r CHPS Series Stage with Ultra3000 Drive and Ultraware Software Appendix D All Ultra drive electrical parameters are defined phase to phase Standard CHPS Series stage motors are specified phase to phase If necessary use the following conversion phase to phase 2 x phase to neutral Table 14 Linear Motor Parameter File mdb extension Parameter Units Enter Comment Force Constant N Ap peak Motor linear region force Convert if necessary Standard CHPS Series stage motors specify the correct unit constant value Mass kg Motor model coil mass Standard CHPS Series stages are intended for moving coil slide use Electrical Cycle Length m 0 05 for LC motors Standard CHPS Series stage motors specify the electrical cycle length in mm or Electrical cycle equals 2 x magnet pitch 0 06 for LZ motors Resistance Ohms Motor s cold resistance Phase to phase directly from motor specifications Inductance mH Motor s inductance Phase to phase directly from motor specifications Rated Voltage VAC Drive s input AC voltage LC motors are rated up to 460V AC LZ motors are rated up to 230V AC For stages with 0 1 um encoder option the maximum drive input is 115V AC Flux Saturation table Leave default values Maximum Speed m s Lowest maximum velocity Choose the lowest maximum velocity between the encoder or the application restriction The encoder maximum velocity for t
92. re the values for the standard CHPS Series stage encoders lines m 250 000 1 ym count incremental 500 000 0 5 um count incremental 2 500 000 0 1 um count incremental 12 500 Analog sin cos 20 um period Integral Limits Unchecked For the standard CHPS Series stage limits option The standard limits option is not compatible with the CN2 input circuit that expects an NPN open collector limit signal Integral Thermostat Check For the standard CHPS Series stage motor options The PTC thermistor signal is compatible with the Ultra3000 drive thermal input circuit Except for very earliest Ultra Drives Rockwell Automation Publication CHPS UM001D EN P July 2014 93 Appendix 0 Start up Guide for CHPS Series Stage with Ultra3000 Drive and Ultraware Software Table 14 Linear Motor Parameter File mdb extension Parameter Software Protection Units Enter Comment Thermal Protection Rth w a 9C W Calculate The thermal resistance with the winding at ambient temperature For LC motors enter the rated thermal resistance value multiply by 1 1 for covered and sealed stages For 150 frame stage that use only LZ motor enter the rated thermal resistance value For 200 and 250 frame stages LZ motors enter 1 1x the rated thermal resistance value In addition for all stages with LZ motors multiply this value again by 1 1 for a covered and sealed stage Thermal Protection Cth w a Recommended Start up
93. rect encoder sequencing can cause a runaway motor condition or incorrect commutation Rockwell Automation Publication CHPS UM001D EN P July 2014 Start up Guide for CHPS Series Stage with Ultra3000 Drive and Ultraware Software Appendix D Oscilloscope Verification Correct stage and Ultra3000 drive wiring yields the phase relationship shown in Hall Oscilloscope Diagram Figure 26 Hall Oscilloscope Diagram 51 52 53 0 60 120 180 240 300 360 Data capture direction stage positive phasing direction as shown Positive Phasing Direction on page 96 51 leads 52 leads S3 120 electrical spacing For standard stages have following phase relationship S1 in phase with W U S2 in phase with U V S3 in phase with V W e Hall probe GND to Hall common and for W U for example coil probe tip W and probe GND U If wiring is correct the causes for incorrect phasing are non standard coil or Hall assembly coil electrical problem Hall module electrical or mechanical problem Rockwell Automation Publication CHPS UM001D EN P July 2014 97 AppendixD Start up Guide for CHPS Series Stage with Ultra3000 Drive and Ultraware Software Oscilloscope Diagram for Ultra3000 Drive Motor with Hall offset 0 While moving slide in positive direction BEMF 0 60 120 180 240 300 Ultra Drive phasing pairs 51 vs W U S2 vs U V Ultra3000
94. ring the servo control system safely controls the stage with regards to maximum force acceleration speed and preventing runaway conditions ATTENTION Stages are capable of very high forces accelerations and speeds N Moving parts can cause personnel injury Before running the stage make sure all components are secure Check that the stage travel and air gap is clear of foreign matter and tools Objects hit by the moving stage can cause personnel injury or damage to the equipment ATTENTION Do not operate the stage with protective covers removed Do not go near electrically live parts High voltages can cause personal injury or death Rockwell Automation Publication CHPS UM001D EN P July 2014 49 Chapter7 Operation Guidelines and Limit Configuration Travel Limits 50 CHPS Series stages offer three methods for containing slide travel software travel limits optional overtravel limit sensors and standard bumpers stops For safest operation use all three Set software travel limits and overtravel limit sensors according to the maximum speed of the servo drive system and the payload of the application You can determine the Deceleration Distance between the slide and the end of travel bumpers based on the combination of the Deceleration Rate of the load and the available peak force from the stage drive Do a calculation similar to the one in Calculating the Stopping Distance for your application Bumper Stop on the stage
95. rip Seal Removal procedure on page 65 and Strip Seal Replacement procedure on page 66 when performing this task Cover Cleaning Clean the covers at the same time you clean the strip seals Use pressurized air and lint free cloth lightly saturated with isopropyl alcohol to remove any dirt or grease Rockwell Automation Publication CHPS UM001D EN P July 2014 61 Chapter9 Maintenance Notes 62 Rockwell Automation Publication CHPS UM001D EN P July 2014 Chapter 10 Removing and Replacing Stage Components Topic Page Before You Begin 63 Cable Carrier Module Removal 63 Cable Carrier Module Installation 64 Strip Seal Removal 65 Stage Cover Removal 65 Stage Side Cover Removal 65 Strip Seal Replacement 66 Stage Cover Installation 67 Side Cover Installation 67 Before You Begin The following tools are required before you begin removal and replacement procedures e Torque wrench e Phillips head screw driver 2 5 mm hex wrench 3mm hex wrench 4mm hex wrench e Fine point permanent marker e Tin snips e Loctite 222 Cable Ca rrier Module Use this procedure to remove the cable carrier module assembly Removal TIP Mark the location of the end bracket before removing the cable carrier this makes it easier to align the carrier when re installing 1 Remove the four 4 pan head screws from junction box side cover 2 Remove the two 2 button head cap screws BHCS from the junction
96. s Steel Strip Seal These replaceable flexible stainless steel strips permit the stage to move while isolating the internal mechanism of the stage from environmental contaminants 10 Strip Seal Clamps These clamps hold the strip seal in place When replacing the strip seals they are used to position it so it lays smooth against the top and side stage covers 11 Index Mark Part of the encoder system that provides a home location for the encoder 12 Optical Encoder Readhead This encoder readhead comes in various resolutions and requires little maintenance The TTL encoder option provides quadrature incremental position feedback with a differential signal on a RS 422 The Sine Cosine encoder option provides a 1 volt peak to peak sine and cosine output at a period of 20 um The Sine Cosine encoder is also known as an analog encoder 13 Encoder Scale Part of the encoder system that provides an optical pattern to be read by the encoder readhead It must be kept free of contamination for proper operation 14 Bearing These support bearings guide the slide on the bearing rail they require periodic lubrication 15 Motor Coil This coil is part of the two piece linear motor When excited by a linear drive it generates magnetic forces that interact with the magnet track creating motion LC linear motor option shown LZ linear motors have a different configuration 16 Bearing Rail These rails provide the linear track that the slide assembly rides on they must be ke
97. seal guide enough to expose center metal section of guide Thread new strip seal point end first through the seal guides slide and end clamps Center and smooth strip seal against top cover and side panel magnetic strips With very light pressure hold the seal guide against the strip seal and tighten the seal guide Tighten only one end clamp Move the slide by hand through travel and make sure the strip seal seats smoothly against the cover and side panel magnet strips Pulling against the tightened end damp to help smooth the seal Once the seal lays flat and smooth against the top cover and side panel tighten the second end clamp With the outside edge of the end clamps as a guide use tin snips to cut and remove excess strip seal material Rockwell Automation Publication CHPS UM001D EN P July 2014 Stage Cover Installation Side Cover Installation 12 13 Removing and Replacing Stage Components Chapter 10 Position slide at the far ends of travel and re adjust seal guide by inserting a 0 8 mm 0 015 in shim between seal guide and strip seal Strip Seal Seal Guide 0 8 mm 0 015 in Shim Return stage to service Starting at the end cap with the magnetic warning label Install 2 M3 x 25 SHCS and torque to 4 Nem 35 Ibfein Make sure the cover makes contact with the end cap On the opposite end install 2 M3 x 30 SHCS and bottom out the screw The cover does not contact
98. sp the stage by the base at the end caps keeping fingers clear of the carrier s path of travel ATTENTION Do not attempt to move the stage by grasping the cable junction Thetwo lubrication ports on each end cap fourtotal are M10 x1 5 tapped through holes and can be used to install lifting hooks supplied by the customer Personal injury and equipment damage can occur if stage is handled improperly Rockwell Automation Publication CHPS UM001D EN P July 2014 31 Chapter4 Mounting the Stage Align the stage on the mounting surface and insert the correct number of mounting bolts Refer to CHPS Series Stage Dimensions beginning on page 77 for detailed mounting dimensions 5 Secure the stage by using all mounting holes Torque bolts to the values shown in the Mounting Fastener Options table on page 29 Mount Your Application Mount your application to the slide by using the following bolts and torque values Cat No Bolt Torque Nem Ib in CHPS x6xxxx XLMxxx M6 3 2 48 CHPS x8xxxx xXLMxxx M8 10 1 90 CHPS x9xxxx XLMxxx M8 10 1 90 32 Rockwell Automation Publication CHPS UM001D EN P July 2014 Chapter 5 Connector Data Topic Page Kinetix Servo Drive Compatible Connectors 34 D Type Connectors 35 Flying Leads 36 Junction Box Connectors 37 Limit Sensor Flying Leads 38 Rockwell Automation Publication CHPS UM001D EN P July 2014 33 Chapter5 Connector Data Kinetix Servo Drive Comp
99. stroke and power capacity of the motor drive pairing only Rockwell Automation Publication CHPS UM001D EN P July 2014 53 Chapter7 Operation Guidelines and Limit Configuration Notes 54 Rockwell Automation Publication CHPS UM001D EN P July 2014 Chapter 8 Troubleshooting Tre sss Before You Begin o PTC Thermal Signal 55 Hall Effect Module 55 Hall to Back EMF Phasing 57 Motor Coil Resistance Measurements 58 Before You Begin The following test equipment is required e Ohm meter e Two channel storage oscilloscope PTC Thermal Signal At ambient room temperature approximately 25 C 77 F check that the resistance measurement between PTC Temp and Common pins 13 and 14 respectively on the feedback connector is lt 750 The table lists increase in resistance at higher temperatures outside the normal operating temperature envelope Table 5 PTC Thermistor Signal Characteristics Temperature C F Resistance in Ohms Up to 100 212 750 Up to 105 221 7500 Up to 110 230 gt 10 000 Hall Effect Module Use this procedure to verify the Hall Effect module is operating properly 1 With drive power OFF verify the Hall circuit is properly connected to the drive by using stage and drive interface wiring specifications 2 Disconnect stage power leads from the drive 3 Apply power to the Hall device by setting the drive control power to ON Usean oscilloscope to chec
100. tance Measurements sene 58 Chapter 9 Before Yon BEI niet ais au iua iuret PCR oodd ae 59 Lubricate the Beating sss oda eS D 60 Optical Encoder Scale Maintenance or epe 60 Strip Seal Cleanings n ci eed tg nel ek ER Le ue eel lh eta 61 e X9 i EP 61 Chapter 10 Before dees date e vile ee eee ol ela 63 Cable Carrier Module Removal esee eese 63 Cable Carrier Module Installation 0 0 cee eee eee eee 64 Strip Seal Removal i52 cedro E e edu HIE ISP ate 65 Stace Cover Removal cce ate colera eee e dee e e en die 65 Stage Side Cover o ice sues RE Ree E LH 65 Strip Seal Replacemielitz issveen outer reni c eer lee e Fede 66 Stage Cover Installation vi ater e ue en da 67 Side Cover Installation esee 67 Rockwell Automation Publication CHPS UM001D EN P July 2014 Specifications and Dimensions Accessories Stacking Stages Start up Guide for CHPS Series Stage with Ultra3000 Drive and Ultraware Software Table of Contents Appendix A Static and Static Moment 70 Performance Specifications for 325V CHPS Series Stage 70 Performance Specifications for 325V or 650V CHPS Series Stage teer enr Rh ern 71 General Stage Specifications s cook ka ewe a Ge gro e MEA ba UA 73 Accuracy Specification for the CHPS Series 73 Commut
101. temperature vs time PT software protection schemes Activated and set these available features according to the stage model ratings for your application Set the maximum value of peak current magnitude limits of your drive to the stage s peak current rating For drives without stage protection features install stage fuses current rating not to exceed stage continuous RMS according to local and National Electrical Code Uses time delay type fuses that are rated for the drive PWM output voltage 42 Rockwell Automation Publication CHPS UM001D EN P July 2014 Connecting the Stage Chapter 6 Optional Limit Sensors Two limit sensors positive overtravel OT and negative OT provide electrical protection for stage overtravel Their physical location is shown in Component Description diagram on page 16 they and can be adjusted up to 30 mm 1 2 in toward the center of travel The electric characteristics are shown here Input Power 12 28V DC 15 mA circuit draw 50 mA maximum sourcing 65 mA total Output PNP Open collector Normally Closed 50 mA maximum sourcing Limit V com Adjustable Negative OT Limit on this side Adjustable Limit Sensor Positive OT Limit cables exit here on this side Rockwell Automation Publication CHPS UM001D EN P July 2014 43 Chapter6 Connecting the Stage TIL Differential Encoder Use the following information to connect a stage with a TTL Differential Encoder
102. test procedures and troubleshooting information is also given IMPORTANT Motor commutation feedback parameters and wiring affect commutation and must be correct for proper motor drive operation Improper setup can cause stage control problems including erratic behavior bad spots runaway and thermal failure The CHPS Series stage has four termination options The Kinetix MPF option is recommended for plug amp play to Kinetix and Ultra family servo drives Kinetix MPF interconnect cable makes it easy to wire the stage and set up commutation with the Ultra3000 Drive The wiring for non Logix Ultra3000 drives and Logix version Ultra3000 drives are the same If you are not using Kinetix MPF termination option properly wire the stage to the Ultra drive by using the following connectivity information Refer to the CHPS Series Stage Connector Data for additional information Rockwell Automation Publication CHPS UM001D EN P July 2014 91 AppendixD Start up Guide for CHPS Series Stage with Ultra3000 Drive and Ultraware Software Connector Data Summary CHPS Series Stage Signal Designation Ultra3000 Drive Signal Designation Motor phase U U Motor phase U Motor phase V Motor phase V Motor phase W W Motor phase W Encoder A digital or Sin analog CN2 1 Encoder A digital or Sin analog Encoder A digital or Sin analog CN2 2 Encoder A digital or Sin analog Encoder B digital or Cos ana
103. tion for lubrication procedures Refer to Maintenance beginning on page 59 for lubrication procedures Use the following key to identify the options that your stage is equipped with Be sure the information listed on the purchase order correlates to the information on the packing slip that accompanied your stage components Inspect the assemblies and confirm if applicable the presence of specified options CHPS A6054 A FLMC2C Bulletin Number r _ Cable Management and Termination Voltage A No Cables or Cable Carrier Slide Junction Box only A 230 AC Frame Size Stroke Motor Feedback 18 6 150 mm base Cables with Flying Leads and Cable Carrier C Cables with Kinetix MPF Connectors and Cable Carrier D Cables with D Connectors and Cable Carrier Limits Travel lengths start at 6 cm and are available in 6 cm increments 2 No limits For example 006 for 6 cm travel or 054 for 54 cm travel Maximum travel 120 cm A LZ 030 T 120 D B L7 030 T 240 D C 17 030 240 5 Two end of travel limits Protection S Covered with strip seals IP 30 29 Covered without strip seals 0 Open without any cover without strip seals LM Specifier LM Linear Motor F 1 0 micron incremental optical encoder with integral index mark G 0 5 micron incremental optical encoder with integral index mark H 0 1 micron incremental optical encoder with integral index mark I 1V p p sin
104. uly 2014 Clearances General Safety Heat Vertical or Incline Payload End Cap Impacts Stage Safety Chapter 1 Figure 1 Warning Label Locations See Safety Labels on page 12 to identify call out letters Install the stage to avoid interference with the building structures utilities other machines and equipment that can create a trapping hazard of pinch points Dress cables by using the Clearance Requirements diagram on page 23 as a guide Do not cross the path of motion or interfere with the cable carrier motion Stages are capable of sudden and fast motion Always Lockout Tagout stage systems before doing maintenance Systems integrated with stages must contain interlock mechanisms that prevent motion while users are accessing the stage Rockwell Automation is not responsible for misuse or improper implementation of their equipment When running the stage at its maximum rating the temperature of the slide can reach 75 C 167 F A vertically or inclined mounted stage does not maintain position with the power removed Under the influence of gravity the slide and its payload falls to the low end of travel Design engineers must design in controlled power down circuits or mechanical controls to prevent the stage and its payload from being damaged when the power fails The internal bumpers of the stage are designed to absorb a large impact from uncontrolled motion The table on page 53 lists the energy that the
105. w GND Rockwell Automation Publication CHPS UM001D EN P July 2014 85 AppendixB Accessories Pin Gauge Color Signal Designation F 18 White BR G 18 Black BR 18 White 1 used for 5 tages H 18 Red 2 L N A N A N A SHIELD Feedback Cable Dimensions catalog number 2090 XXNFMF Sxx The maximum cable length of 10 m 32 8 ft 54 2 1 Dimensions are in mm in amp 7 36 start of 57 l Bend Radius 2 2 99 LJ Bend Radius 3 9 26 1 0 10 04 Y 1 Cable X Connector Diameter cL Diameter 28 AWG BLACK Li V V 289AWGWHTEBACK B 5 28 AWG RED B Bb 28 AWG GREEN a ooo o X AWG WHITENGREEN Y 5V 18 AWG GRAY s ISAWGWHTEGRAY X 22 AWG ORANG b 4 N 8 I co z E 2 5 S 22 55 B doch 28 AWG BLUE 28 AWG WHITE BLUE ew MTR RRAME X 28awe WHITevELLOW MTR RRAME 28 AWG BROWN 28AWGWHTEBROWN 1 2 3 4 5 6 9 0 1 3 4 5 6 7 7 8 2 1 Bend radius BR is the specified minimum bend radius for cable assemblies For standard cable BR is a one time flex application Flex cables have a much higher BR to withstand flex applications BR can vary on user fabricated cables 86 Rockwell Automation Publication CH

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