PZA25 Reference & Maintenance Manual
Contents
1. s PZ A25 Reference amp Maintenance Manual 5 Installation Preparations This section outlines installation environments Unfavorable installation conditions may cause electric shock fire or breakdown Certain breakdown situations or malfunctions in particular may lead to serious injury or other consequences Assure that the unit is used under the following installation conditions Indoors free from being splashed by water No corrosive or inflammable gases present Well ventilated place minimum level of dust or waste An environmental temperature range between 0 40 C and humidity between 20 80 RH location with no condensation Note These values show the range in which operation can be carried out safely but not the environmental range in which stages accuracy can be guaranteed Stage accuracy can be guaranteed at 20 C 1 C o Location should not be affected by electrical noise o Location should be where inspection and cleaning can be performed without difficulty SHOTS TO 5 1 Heat and Humidity All positioning stages are assembled and tested at 20 C Any stage calibrations are also performed at 20 C For optimum accuracy the ambient temperature should be maintained at 20 C Deviations from this nominal temperature may result in degraded accuracy performance Ballscrew driven stages are also susceptible to thermal expansion effects The ballscrew nut can create a localized thermal gradient if driven at hi2. Do not lift by the motor drive assembly 4 Stage disassembly and alteration unless specified otherwise may void warranty 6 3 Mounting surface preparation The characteristics of the surface the positioning stage is mounted to will have a large effect on system performance An accurate and flat positioning stage will conform to the shape of its mounting surface therefore a flat mounting surface is required For best results in maintaining stage specifications we suggest the following 1 Use a laboratory Grade AA granite surface plate 2 Before mounting stage inspect for burrs or dings on the stage mounting surfaces 3 Clean all mounting surfaces with acetone In the absence of a granite surface plate we recommend a base plate made of the same material as the base of the stage A mounting surface constructed out of a material different from the stage base material can introduce warping in the stage in the presence of a thermal gradient The surface flatness should match the requirements of the application a good starting point is to have the mounting surface flat to less than 5 8um 10 PZ A 25 Reference amp Maintenance Manual 6 4 Mounting the PZA25 The following text and illustrations give instructions to accessing the PZA25 Mounting Holes 1 Remove the fasteners in Rear Top Cover area in red with M2 Hex Wrench and slide forward 2 Remove the fasteners in Rear Lower Cover area in red with M2 Hex Wrench and slide
3. forward Mounting Holes are circled in white and outlined in red Use the Manual Adjust Knob to raise the tabletop for access to these holes After the PZA25 is mounted replace both Rear Top and Rear Lower covers by reversing steps 1 and 2 11 PZ A25 Reference amp Maintenance Manual 6 5 Electrical Connections Electrical connections to the stages depend on the type of stage in use All PZA25 models are terminated with a 450mm flexible cable with a 28 position circular connector on the end The pin out of this connector is shown with Table 6 1 Primatics offers a variety of cable assemblies compatible with the PZA25 Table 6 1 Connector Cannon 192926 0480 with 28 pins and size 20 backshell Function A MotorA o O OMR E Encoder 5V powerforencoder _ _ gt o gt oZ o o o F Encoder A output G _ Encoder A output o H Encoder B output S J Encoder B output S K Encoder Shield S L 12 24VDC for limit home and temp sensor DCCOM M DCCOM N Not used Sensors Shield Hall Ve o O Hall V Hall V Encoder Common S Encoder Common NC N C Hall A C Hall B Temperature monitor U V W A Hall C Pin A SE C EDA E EE G EN y ice L M Ni eS OR ES EU Ww X EEE _b aml d BCE 12 PZ A25 Reference amp Maintenance Manual 6 5 2 Hall Effect Commutation Sequence The following diagram shows the motor signal timing for the
4. name phone email address o Unit Serial Number see Figure 8 1 o Symptom of problem o History of troubleshooting steps already taken Figure 8 1 Unit Serial Number Location 17
5. PZ A25 Reference amp Maintenance Manual PZA25 Manual Revision INfOrmatiOn ccccccssccesseeeseeseeeeeeeseoeseeeneeenseoeseeeaeess 2 A OVErVIE W iniinis Nna a EAEE 4 2 Introduction About the PZA25 ccccsccescceneceeecnsecnseenseenseenesensonssenssenesens 5 A 3 PEFSORA LS ATOS Re teens 6 4 CONVENTIONS EE ee ER nn mn dan non a ete elec oc nant tit 7 Aol Direction OF MONO Ns 7 42 INS OF Mea UE 7 5 Installation Preparations ccooncocncconcnonoconanenannonnnonanenanrnnnrnnanennrenannnanrnanrnnanenanas 8 e ETS UE Ca te RUTUY D ai utaninat 8 E 8 919 IOCIICAl MIN OSC RS ne des inde tatin Literie tenir en 9 5 INStallatiGN Procedures cummins 10 021 TOOTS YOU WI N e EE a rr AN den du 10 02 Nel Ue ono Mo ue aie ana be ee Duo don toes 10 6 3 Mounting surface preparation iii 10 OA Mounting the PLAZO Res acre diel na tata dont a aR 11 6 5 Elecmical Connections is 12 6 5 2 Hall Effect Commutation SEQUENCE cccccccocccccccnnnccnncocnnnconnnnononcnnnononancnnnnnnnnnrnnnnnnnanennnnss 13 626 MEINE SWIC ING S ren ni nu sn sd saa hl Nu se A 14 6 7 Recommended System Testi eae ee ee ee 15 7 Preventive MAINeNaANnCe mira 16 TA UDA CATON SRE SR AR RE tre Rte ete tente MON ieee 16 8 Troubleshooting amp Service ccccccseecssseecsseeceenseseeseeseesseeeeseesenseesonseesonnees 17 8 1 FROUDIESHOO UNG FIC Distri cd 17 A Po 17 PZA25 gt 1 Overview Reference amp Maintenance Manual This user guide is design
6. PZ A25 Reference amp Maintenance Manual primatics G PZA25 Reference amp Maintenance Manual PZ A 2 D Reference amp Maintenance Manual Drimatics 32114 Mallard Ave PO Box 409 Tangent OR 97389 0409 U S A Phone 541 791 9678 Fax 541 791 9410 Toll Free 888 754 3111 Web www primatics com E mail info primatics com PZA25 Manual Revision Information Publication Date Notes Oct 2003 March 2003 Changed recommended grease from Lithium 2 to NSK Clean room grease April 2005 Updated look amp formatting November 2006 Added pitch roll amp yaw graphic January 2007 Updated Ordering Info June 2007 Updated Table 7 1 Aug 2010 Removed references to linear encoder Mar 2014 New photos Jan 2015 New Logo Notice The descriptions drawings and specifications contained herein are subject to change Primatics is not responsible for errors or omissions herein or for incidental damages in connection with the furnishing or use of this information This document shall not be reproduced photocopied or duplicated in whole or in part without prior written approval of Primatics Corporation For Specifications Dimensioned Drawings and additional information refer to the PZA25 Datasheet available from our website at www primatics com Copyright 2007 2014 by Primatics Inc All Rights Reserved Primatics the Primatics logo PrimaFlex PrimaSeal amp SimpleMatch are trademarks of Primatics Inc
7. Servo Motor option Positive Direction of Motion Figure 6 1 Motor commutation chart The following diagram shows the encoder signal timing for the Encoder option Positive Direction of Motion Figure 6 2 Timing diagram for the encoder signals 13 PZ A25 Reference amp Maintenance Manual 6 6 Limit Switches A home sensor is not present because the PZA25 was designed with the idea of finding a home position near the reverse limit of travel This facilitates moving downward normally out of harms way in the homing process There is an encoder index transition every 0 8 mm of vertical travel So the anticipated homing procedure would be to search for the reverse limit sensor transition and then move up to the first encoder index transition in order to establish a repeatable home position The Limit switches are ordered in either the Normally Closed L1 or Normally Open L2 configuration L1 When the carriage is in the normal operating range of travel both limit switches are closed When the carriage encounters a limit the switch opens The switch will close again when the carriage is moved away from the switch L2 When the carriage is in the normal operating range of travel both limit switches are open When the carriage encounters a limit the switch closes The switch will open again when the carriage is moved away from the switch The limit switch positions have been preset at the factory and cannot be adjuste
8. d Figure 6 3 shows the relative placement of the limit transitions Both limit switches can be ordered normally open or normally closed Range for Forward Sensor Transition Height of Carriage mm ty 12 6 90 12 5 11 5 0 0 65 a Lo Range for Reverse Sensor Transition Figure 6 3 PZA25 Limit Sensors 14 PZ A25 Reference amp Maintenance Manual 6 7 Recommended System Test Before attaching a load or applying power to your stage verify the encoder and limit switches are working properly Move the stage carriage by hand using the manual adjust knob at the end of the stage Runaway conditions caused by miswired encoders can result in stage damage and personal injury When closing the position loop for the first time set the torque limit of your controller to a low value and use conservative tuning gains Once the control loop is working properly payloads can be added to the stage carriage 15 PZ A25 Reference amp Maintenance Manual 7 Preventive Maintenance Performing preventive maintenance procedures on your stage will extend its life and improve its long term performance 7 1 Lubrication Use clean room grease to lubricate the ballscrew and linear guide components We recommend NSK grease part GRS LG2 For low duty cycle applications it is recommended that the ballscrew and linear guides are re greased every six months High duty cycle applications may require more frequent re lubrication Lubrication intervals
9. depend on duty cycle load and ambient conditions Inspection of the drivetrain elements may be required to determine the proper lubrication interval Primatics offers a grease kit that has all the necessary hardware to re lubricate the ballscrew and linear bearings To gain access to component grease ports remove the Front Top Cover Front Lower Cover and Rear Top Cover On the end of each bearing block is a small hole where grease is injected using a syringe A light film can also be applied the linear bearings when the stage Is at one extreme end of travel After power has been disconnected from the stage a light film of grease can be smeared along the length of the ballscrew Cycle the stage back and forth to distribute the grease and wipe off any excess The stage should be kept clean and a soft cloth should be used wipe down the stage Do not use compressed air to spray away dust since this may force dust into crevices Figure 7 1 Bearing block lubrication port 16 PZ A25 b Reference amp Maintenance Manual 8 Troubleshooting amp Service 8 1 Troubleshooting Help For further assistance contact the factory M F 8AM to 5PM Pacific Time 541 791 9678 541 791 9410 Toll Free 888 754 3111 8 2 Service Should your device require factory service contact the factory for a Return Materials Authorization RMA When inquiring about an RMA please have the following information available o Your contact information
10. ed to help you install and maintain your PZA25 Series vertical positioning stage application Follow these steps to ensure correct stage installation and maximum stage life Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Review this entire user manual Become familiar with all installation procedures prior to integrating your system Review the safety summary to develop an understanding of standard safety practices when installing and operating automated equipment Familiarize yourself with the conventions summary Review installation procedures For best results follow these procedures carefully Once you successfully complete all the installation procedures you will be ready to install and operate your stage Review preventive maintenance section for proper lubrication schedule PZ A25 Reference amp Maintenance Manual 2 Introduction About the PZA25 The PZA Series is a general purpose ballscrew driven elevator stage with an integrated brushless servo motor It utilizes a moving wedge design that converts horizontal movement from a ballscrew to vertical elevation The design and components ensure sub micron resolution in a compact profile and make the PZA ideal for semiconductor inspection fiber optics assembly and machine vision applications requiring smooth motion exceptional stiffness and high resolution From a control standpoint the PZA25 appears as a brushless servo motor with incremental encoder and fo
11. gh speeds Airflow through the stage can help minimize ballnut heating 5 2 Contamination Applications in dirty or dusty environments require the electrical optical and mechanical components to be protected The PZA25 series is intended for clean environments free from small particulates and fluids The air the PZA25 is operated in should be clean and dry The cover protection and high pressure 60 120psi low flow air purge system is sufficient for environments generating moderate quantities of 0 5 mm and larger particles However for dusty wet or harsh environments or applications with continuous exposure to smaller contaminants additional protection must be designed Airflow through a stage must be filtered and dry The filtration system should reject particles larger than 2 microns Air pressures between 60 100 psi are sufficient for convection cooling A typical air source can be made suitable with the addition of an inline desiccant dryer and filter regulator assembly Humidity should be less than 85 and there should be no condensation in the environment in which the stage is used PZ A25 Reference amp Maintenance Manual 5 3 Electrical Noise Electrical noise is the corruption of signals carried over low voltage wires Encoder signals can be corrupted resulting in sourious encoder counts thus causing the stage to drift Grounding shielding and spatial separation are all countermeasures to reduce the influences of electrical n
12. oise on performance You can minimize the potential for electrical noise by observing the following installation precautions o Physically separate low voltage conductors from those carrying high voltage o Ensure that all components are properly grounded o Ensure that all wiring is properly shielded PZ A25 Reference amp Maintenance Manual 6 Installation Procedures 6 1 Tools you will need The PZA25 positioning stage has mounting holes for M5 SHCS in the base and M4 and M5 tapped holes in the tabletop M3 BHCS s are used to attach the hard covers The lower rear cover must be secured with M3 x 5mm long fasteners Longer fasteners will result in damage to the stage A 2mm hex tool will remove all the hard cover screws 3mm and 4mm hex tools are required for the stage mounting hardware 6 2 Unpacking Carefully remove the stage from its shipping crate and inspect it for evidence of shipping damage Report any damage immediately to your authorized dealer Improper handling of the stage may degrade its performance Follow these guidelines when handling and mounting your stage 1 Do not drop the stage onto its mounting surface Place the stage gently on the mounting surface Impact loads can cause high spots on mounting surfaces misalignment of drive components and warping of the base 2 Do nat drill holes into the stage If additional holes are necessary contact your local distributor Lift the stage by its base structure only
13. rward and reverse limits sensors The PZA can be controlled by a wide variety of servo drives and controls PZA25 gt A 3 Personal Safety Reference amp Maintenance Manual A Please review before installing your positioning stage Observe common industrial safety practices when installing and operating automated equipment O Have power connections made by qualified personnel Keep fingers and other items out of any opening in the stage while it is in operation since injury or damage may result Provide a safe access route and adequate room for servicing Perform the recommended periodic maintenance described in this document Verify that the work envelope is free of obstructions before the positioning stage is powered Insure that you have the feedback wired properly to the controller before applying power to the positioning stage Improper feedback connections can cause a motor run away condition that has the potential to damage the stage and injure an operator Only trained operators of the positioning stage should be allowed near the work environment If so equipped identify emergency stop circuits and actuators in the workcell Note the places in the workcell where pinch points occur and provide adequate safety clearance or safety curtain Never operate the motor in a location that could be splashed by water exposed to corrosive or flammable gases or is near combustible substances since this may cause an elec
14. tric shock fire or malfunction Never touch the motor driver or peripheral devices when the power is on or immediately after the power is turned off The high temperature of these parts may cause burns PZ A25 b Reference amp Maintenance Manual 4 Conventions 4 1 Direction of Motion The positive direction of motion is defined as when the carriage elevates upward overall height of stage increases The encoder count increases as the stage travels in the in the positive direction Figure 4 1 illustrates this convention Yaw Axis Positive Direction Roll Axis y Tabletop Pitch Axis Rear Top Cover Front Lower Cover Front Top Cover Manual Adjust Knob Figure 4 1 PZA25 Conventions 4 2 Units of Measure Primatics uses the metric system for all specifications and dimensions All linear dimensions are specified in millimeters Accuracy repeatability resolution flatness and straightness for the PZA is specified in microns Load capacity is specified in kilograms and moment capacity is given in Newton meters All torque specifications are given in Newton meters Thrust specifications are given in Newtons The following table gives some common conversions into English units Metric Unit English Unit 1 Kilogram equals 0 0685 slug 1 micron equals 0 0000394 inch 1 millimeter equals 0 0394 inch 1 Newton meter equals 8 85 in lbs 1 Newton equals 0 2248 lbs 1 Kg has a weight of 2 205 Ib when g 9 8 m
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