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ALS20000 / ALS25000 Series Stage User`s Manual

1. sssssssssssssssssssssememIm IIR cece aora aa aora oranana naraon 1 1 1 Standard Features oooissssssssssssssssssslssssslls lll s ss cece ee eee aaao aaraa rnrn 2 11 1 Optional Features gt 2 2 2 eee ilie ec ec p e te bcemsoedo iteiui s elc oes 222s 2 1 1 2 Model Numbers 2 2 22222 22 cece cece cece cece cee ecccccececeeeeeeeeeeeceeeeeeeees 3 UE Ee D ARRIERE 5 1 3 Safety Procedures and Warnings 2 22 0 ooo eee 6 1 4 EC Declaration of Incorporation 2 2 2 222222 c cece eee c cece ccc eeecccceeeccceeeeeeeeeees 8 Chapter 2 Installation 2 2 000 000 coco ccc oc ccc ccc ec ec eee ce ccc ececece cece ceeeesecesecesees 9 2 1 Unpacking and Handling the Stage 2000222 c ccc ccc ccc cece cece ee essen 9 2 2 Preparing the Mounting Surface 2 2 e cece iaire oraraa rroan 10 2 3 Securing the Stage to the Mounting Surface 2 222200 e eee cece ceeeeceeeeees 11 2 4 Attaching the Payload to the Stage 22 2 0 c ccc ccc ccc ccc ccc ccc cece cece cece esses sse 13 2 5 Electrical Installation 22 20 0000 222 cc eee c cece cc anaa anaoa oaoaraa 13 Chapter 3 Operating Specifications 2 0 0 0 o cee ec cece cece ec ece eect 15 3 1 Environmental Specifications 2 2 2 2 2222 eee cece cece cece eee cccccccccceeeeeeeees 15 3 2 Basic Specifications 2 2 2 0 coe cece cece eee e r eoa eta earte
2. Table 3 1 Environmental Specifications Ambient Operating 10 to 35 C 50 to 95 F Temperature The optimal operating temperature is 20 C 2 C 68 F 4 F If at any time the operating tem perature deviates from 20 C degradation in performance could occur Contact Aerotech for information regarding your specific application and environment Storage 0 to 40 C 32 to 104 F in original shipping packaging Humidity Operating 40 percent to 60 percent RH The optimal operating humidity is 50 percent RH Storage 30 percent to 60 percent RH non condensing in original packaging Altitude Operating 0 to 2 000 m 0 to 6 562 ft above sea level dE Contact Aerotech if your specific application involves use above 2 000 m or below sea level Vibration Use the system in a low vibration environment Excessive floor or acoustical vibration can affect stage and system performance Contact Aerotech for information regarding your specific appli cation Dust Expo The ALS25000 stages have limited protection against dust but not water This equates to an sure ingress protection rating of IP50 Due to their side openings the ALS20000 stages have an ingress protection rating of IP10 Indoor use only Do not expose the stage to environments or conditions outside the specified range of oper ating environments Operation in conditions other than those specified can cause damage to the equipment WARNING www aerotech com Chapt
3. speed and the environment An inspection interval of once per month is recommended until a trend develops for the application Longer or shorter intervals may be required to maintain the film of lubricant on the bearing surfaces In general it is recommended that stages operating in a clean environment be lubri cated annually For stages operating under conditions involving excessive debris lubrication every six months is recommended The motor is completely non contact and requires no lubrication 4 2 Cleaning and Lubrication 4 2 1 Recommended Lubricants and Cleaning Solvents For standard linear bearing guide rails NSK LGU grease is recommended If a solvent is necessary for cleaning the stage it is recommended that isopropyl rubbing alcohol be used Harsher solvents such as acetone may damage the plastic and rubber seals on the linear bearing trucks For high speed applications i e near maximum speed at a duty cycle of 5096 frequent maintenance with standard lubricants is required 4 2 2 Important Notes on Lubrication When cleaning and or lubricating components of the ALS25000 series stages Be sure to use a clean dry soft and lint free cloth for cleaning 2 Take the opportunity during the lubrication procedure to inspect the linear motion guides for any damage or signs of wear 3 Inapplications that have multiple stages bolted together to form multi axis systems the orthogonality may be lost if the stage tables of t
4. 71 7 Ib Meets a Black Anodize Hard Coating 62 Rockwell Hardness Teflon Impregnated 1 Maximum speed based on stage capability maximum application velocity may be limited by system data rate and system res olution 2 Maximum load based on bearing capability maximum application load may be limited by acceleration requirements 3 Thermal limitations of positioning stage with respect to performance may limit continuous force output 4 Force may be limited by amplifier output 5 Available with Aerotech controllers 16 Chapter 3 www aerotech com ALS20000 ALS25000 Series Stage User s Manual Operating Specifications Table 3 3 ALS20000 ALS25000 Series Resolution Information Signal Period Travel Step Multiplier Maximum Speed Signal Type LTAS 0 02 um to 1 0 um Requires External System Data Rate LNAS 0 004 um to 0 2 um Requires External System Data Rate Table 3 4 ALS20000 ALS25000 Motor Specifications Winding Designation ee 00 0 1 Performance Specifications 1 9 Continuous Force 20 psi 1 4 bar 2 134 2 30 2 Continuous Force No Cooling 2 85 6 19 3 Peak Force 3 537 0 120 7 Electrical Specifications 5 BEMF Constant line to line max V m sec 31 75 V in sec 0 81 ep oinbeve Current 20 psi 1 4 bar A pk 4 86 A rms 3 44 Continuous Current No Cooling 2 A pk 3 10 A rms 2 19 Force Constant Sinusoidal Drive 48 27 62 Ib A rms 8 78 Motor Constant 2 4 N NW 8 16 1 Performa
5. DANGER Hardcover Mounting Screws Figure 4 1 Top view of ALS20000 ALS25000 Stage Showing Hardcover Mounting Screws 26 Chapter 4 www aerotech com Warranty and Field Serv ALS20000 ALS25000 Series Stage User s Manual ice Appendix A Warranty and Field Service Aerotech Inc warrants its products to be free from defects caused by faulty mate rials or poor workmanship for a minimum period of one year from date of shipment from Aerotech Aerotech s liability is limited to replacing repairing or issuing credit at its option for any products that are returned by the original purchaser during the warranty period Aerotech makes no warranty that its products are fit for the use or purpose to which they may be put by the buyer where or not such use or purpose has been disclosed to Aerotech in specifications or drawings previously or sub sequently provided or whether or not Aerotech s products are specifically designed and or manufactured for buyer s use or purpose Aerotech s liability or any claim for loss or damage arising out of the sale resale or use of any of its prod ucts shall in no event exceed the selling price of the unit Aerotech Inc warrants its laser products to the original purchaser for a minimum Laser Products period of one year from date of shipment This warranty covers defects in work manship and material and is voided for all laser power supplies plasma tubes and laser systems subject to electrical or physic
6. additional installation and operation information In some cases if the system is uniquely configured a drawing showing system interconnects is supplied An integral linear motor comes mounted to all ALS20000 ALS25000 stages The electrical wiring from the motor encoder and limit switches are integrated into two main connectors at the factory Refer to Section 3 5 for standard motor wiring and connector pin outputs Never connect or disconnect any electrical component or connecting cable while power is applied or serious damage may result WARNING The stage and motor s protective ground is located on pin A4 of the motor connector If you are using cables other than those provided by Aerotech to connect the motor to the drive you must connect pin A4 to a ground connection WARNING www aerotech com Chapter 2 13 Installation ALS20000 ALS25000 Series Stage User s Manual 14 Chapter 2 www aerotech com ALS20000 ALS25000 Series Stage User s Manual Operating Specifications Chapter 3 Operating Specifications The surrounding environment and operating conditions can affect the performance and service life of the stage This chapter provides information on ideal environmental and operating conditions Also included are instructions for estimating load capability given various loading situations 3 1 Environmental Specifications The environmental specifications for the ALS20000 ALS25000 are listed in the following table
7. disconnect all electrical power prior to making any mechanical adjustments Moving parts of the stage can cause crushing or shearing injuries All personnel must remain clear of any moving parts Improper use of the stage can cause damage shock injury or death Read and understand this manual before operating the stage If the stage is used in a manner not specified by the manufacturer the protection provided by the stage can be impaired Stage cables can pose a tripping hazard Securely mount and position all stage cables to avoid potential hazards Chapter 1 www aerotech com ALS20000 ALS25000 Series Stage User s Manual Overview Do not expose the stage to environments or conditions outside the specified range of oper ating environments Operation in conditions other than those specified can cause damage to the equipment The stage must be mounted securely Improper mounting can result in injury and damage to the equipment Use care when moving the stage Manually lifting or transporting stages can result in injury Only trained personnel should operate inspect and maintain the stage This stage is intended for light industrial manufacturing or laboratory use Use of the stage for unintended applications can result in injury and damage to the equipment Before using this stage perform an operator risk assessment to determine the needed safety requirements A A A A A A z Z Z Z Z Z Z Z Z z z Z Q Q Q Q Q Q
8. purchase order to Aerotech cov ering all transportation and subsistence costs For warranty field repairs the cus tomer will not be charged for the cost of labor and material If service is rendered at times other than normal work periods then special service rates apply If during the on site repair it is determined the problem is not warranty related then the terms and conditions stated in the following On Site Non Warranty Repair section apply If any Aerotech product cannot be made functional by telephone assistance or pur chased replacement parts and cannot be returned to the Aerotech service center for repair then the following field service policy applies Aerotech will provide an on site field service representative in a reasonable amount of time provided that the customer issues a valid purchase order to Aerotech cov ering all transportation and subsistence costs and the prevailing labor cost includ ing travel time necessary to complete the repair Aerotech Inc Phone 412 963 7470 101 Zeta Drive Pittsburgh PA Fax 412 963 7459 15238 2897 Appendix A www aerotech com ALS20000 ALS25000 Series Stage User s Manual Technical Changes Appendix B Technical Changes Table B 1 Current Changes 1 03 00 Section s Affected General Information Section 3 5 Changed pin 8 to reserved www aerotech com Appendix B 29 Technical Changes ALS20000 ALS25000 Series Stage User s Manual Table B 2 Archived Change
9. www aerotech com Chapter 1 7 Overview ALS20000 ALS25000 Series Stage User s Manual 1 4 EC Declaration of Incorporation Manufactorer Aerotech Inc 101 Zeta Drive Pittsburgh PA 15238 USA AEROTECH Nx herewith declares that the product Aerotech Inc ALS20000 ALS25000 Stage is intended to be incorporated into machinery to constitute machinery covered by the Directive 2006 42 EC as amended does therefore not in every respect comply with the provisions of this directive and that the following harmonized European standards have been applied EN ISO 12100 1 2 2003 A1 2009 Safety of machinery Basic concepts general principles for design ISO 14121 1 2007 Safety of machinery Risk assessment Par 1 Principles EN 60204 1 2005 Safety of machinery Electrical equipment of machines Part 1 General requirements and further more declares that it is not allowed to put the equipment into service until the machinery into which it is to be incorporated or of which it is to be a component has been found and declared to be in conformity with the provisions of the Directive 2006 42 EC and with national implementing legislation i e as a whole including the equipment referred to in this Declaration Authorized Representative Manfred Besold Address Name Position Location Date AEROTECH GmbH S d West Park 90 D 90449 N mberg Alex Weibel Cb Neho tb Engineer Verifying Compliance Pitts
10. 16 3 3 Load Capability 2 2 00 sese IR RII rrr rer 18 3 4 Optical Limit Switch 2 2 2 0 2 022 2 e eee c cece cccceeeecceeeecseeees 20 3 4 1 Limit Switch Operation 22 00 2222 o ccc cece ccc cee eee ce cece cceecececccecceeees 20 3 4 2 Limit Switch Wiring 0000 0000000 o coco ce eee cece eeeeeeeeeeeeeeees 20 3 5 Standard Motor Wiring 0 00 00 occ eee eee cece cece eee eeeeeeeeeeeeeeeeeeeeeees 21 3 6 Vacuum Operation 22 2 2 occ cece cece eee ce cece cece eee e cece cece eeeeeeeeceeeeeeeeeeeeees 24 Chapter 4 Maintenance 0 2 2 0 0 e ccc ec nce c ccc ee cc aLa aa a r211 25 4 1 Service and Inspection Schedule 2 2 2 e cece ce eee ccccceceeccccccceeecccccceeeeeeccceeeeeeeees 25 4 2 Cleaning and Lubrication 2 2 0 0 00 ce ccc e cece eee eeeeeeeeeeeecceececcccccececccscceeeceees 25 4 2 1 Recommended Lubricants and Cleaning Solvents ceceeeeeeeeeeeees 25 4 2 2 Important Notes on Lubrication 0 00 00 ccc cccececeecccceeeeececccccceececcceeees 25 4 2 3 Lubrication and Cleaning Process 00 c cece eee e cece cece cece cece ee eeeeeees 26 Appendix A Warranty and Field Service 2 0 0 0 0 ooo cece cece cece eee eee ec eee 27 Appendix B Technical Changes 2 2 2 0 0 0 o cece eee ec ec cee eee ec eee ececeececeeceees 29 Index uod eh ete eee re DL EA ae LUE 31 Reader s Comments o oo o oo o occ cence c
11. ALS20000 ALS25000 Series Stage User s Manual P N EDS100 Revision 1 03 00 Dedicated to the Science of Motion Aerotech Inc 101 Zeta Drive n Pittsburgh PA 15238 AEROTECH Phone 412 963 7470 Fax 412 963 7459 www aerotech com Product Registration Technical Support Revision History Register online at http www aerotech com prodreg cfm United States Headquarters Phone 412 967 6440 Fax 412 967 6870 Email service aerotech com United Kingdom Phone 44 118 940 9400 Fax 44 118 940 9401 Email service aerotech co uk Germany Phone 49 911 967 9370 Fax 49 911 967 93720 Email service aerotechgmbh de Japan Phone 81 0 47 489 1741 Sales Phone 81 0 47 489 1742 Service Fax 81 0 47 489 1743 Email service aerotechkk com jp China Phone 852 3793 3488 Email saleschina aerotech com Revision 1 03 00 April 5 2011 Revision 1 02 00 February 28 2011 Revision 1 01 00 August 26 2009 Revision 1 00 00 February 10 2006 Product names mentioned herein are used for identification purposes only and may be trademarks of their respective companies Aerotech Inc 2011 ALS20000 ALS25000 Series Stage User s Manual Table of Contents Table of Contents Table of COnteris e o ouest naL sec ia ce ee ce A a A EU LLL eC iii LiStiOf FIJUG Sza E V Eist or Tables e riu E EEEE ER 2a DA I LRL E ED p E ote es vii Chapter 1 Overview
12. LS25000 Series Stage User s Manual www aerotech com ALS20000 ALS25000 Series Stage User s Manual List of Tables List of Tables Table 1 1 Model Numbering System sssesssssssssssssssse esses ees se heres serrer reris 3 Table 3 1 Environmental Specifications 022 cecee ccc cccccecccccccecccceecceceeeceeeeeeerees 15 Table 3 2 ALS20000 ALS25000 Series Specifications 2 000 c cece ecccccceeeceecceeeeeeeees 16 Table 3 3 ALS20000 ALS25000 Series Resolution Information cc cceeeeccceeeeeeees 17 Table 3 4 ALS20000 ALS25000 Motor Specifications 2 2 2 2 2 ccc ccc ee cece cccceceeecececeeceees 17 Table 3 5 Feedback and Motor Connectors for Stages with LT Square Wave Encoders 21 Table 3 6 Feedback and Motor Connectors for Stages with LT Amplified Sine Encoders 22 Table 3 7 Feedback and Motor Connectors for Stages with LN High Accuracy Encoders 23 Table 3 8 Motor Wiring Pinout Descriptions 2 2 0 0 2 ec cece cee cece ccc ceecccccccececcccceceeeeccucees 24 Table B 1 Current Changes 1 03 00 2 0 occ e eee c cece cece I RR RR RR rr rr erret rrr 29 Table B 2 Archived Changes sssssssssessssssssse ee ee e e eene eee eres erre reser terri 30 www aerotech com vii List of Tables ALS20000 ALS25000 Series Stage User s Manual viii www aerotech com ALS20000 ALS25000 Series Stage User s Manual Overvie
13. al abuse tampering such as opening the housing or removal of the serial tag or improper operation as determined by Aerotech This warranty is also voided for failure to comply with Aerotech s return procedures Claims for shipment damage evident or concealed must be filed with the carrier Return Procedure by the buyer Aerotech must be notified within 30 days of shipment of incorrect materials No product may be returned whether in warranty or out of warranty with out first obtaining approval from Aerotech No credit will be given nor repairs made for products returned without such approval Any returned product s must be accompanied by a return authorization number The return authorization number may be obtained by calling an Aerotech service center Products must be returned prepaid to an Aerotech service center no C O D or Collect Freight accepted The status of any product returned later than 30 days after the issuance of a return authorization number will be subject to review After Aerotech s examination warranty or out of warranty status will be deter Returned Product War mined If upon Aerotech s examination a warranted defect exists then the prod ranty Determination uct s will be repaired at no charge and shipped prepaid back to the buyer If the buyer desires an airfreight return the product s will be shipped collect Warranty repairs do not extend the original warranty period After Aerotech s exami
14. burgh PA April 5 2011 Chapter 1 www aerotech com ALS20000 ALS25000 Series Stage User s Manual Installation Chapter 2 Installation This chapter describes the installation procedure for the ALS20000 ALS25000 stage including handling the stage properly preparing the mounting surface to accept the stage securing the stage to the mounting sur face attaching the payload and making the electrical connections Installation must follow the instructions in this chapter Failure to follow these instructions could result in injury and damage to the equipment WARNING 2 1 Unpacking and Handling the Stage Carefully remove the stage from the protective shipping container Before operating the stage it is important tolet the stage to stabilize at reom temperature for at least 12 hours It is also important to clean the stage by blowing it off with pressurized nitrogen or clean oil less air All ALS20000 ALS25000 series stages are packaged with shipping clamps installed to prevent stage table movement These are red anodized brackets the only red anodized pieces Aerotech uses that bolt the stage table to the base These must be removed before the stage table can be moved Each stage has a label listing the system part number and serial number These numbers contain information necessary for maintaining or updating system hardware and software Locate this label and record the infor mation for later reference If any damage has oc
15. ches Basic Model Total Travel Arr Coe Pome 71 i281 THRU 10001400 39120540 sofa 4 4051412 C BORE ALS25020 200 0 8 00 492 8 19 40 2150 846 4 E STAGE MTG HOLES ALS25030 300 0 12 00 594 4 23 40 215 0 8 46 500 0 19 68 EB ALS25045 450 0 18 00 746 8 29 40 215 0 8 46 5000 1968 ALS25060 600 0 24 00 899 2 35 40 215 0 8 46 500 0 19 68 es Figure 1 3 ALS20000 ALS25000 Dimensions www aerotech com Chapter 1 5 Overview ALS20000 ALS25000 Series Stage User s Manual 1 3 Safety Procedures and Warnings The following statements apply throughout this manual Failure to observe these precautions could result in serious injury to those performing the procedures and damage to the equipment This manual and any additional instructions included with the stage should be retained for the lifetime of the stage A DANGER gt DANGER gt DANGER gt DANGER WARNING WARNING WARNING To minimize the possibility of electrical shock and bodily injury or death disconnect all elec trical power prior to making any electrical connections To minimize the possibility of electrical shock and bodily injury or death when any electrical circuit is in use ensure that no person comes in contact with the circuitry when the stage is connected to a power source To minimize the possibility of bodily injury or death
16. curred during shipping report it immediately Improper stage handling could adversely affect the stage s performance Use care when moving the stage Manually lifting or transporting stages can result in injury WARNING Do not allow the stage to drop onto the mounting surface WARNING Lift the stage only by the base Do not use the stage table as a lifting point WARNING www aerotech com Chapter 2 9 Installation ALS20000 ALS25000 Series Stage User s Manual 2 2 Preparing the Mounting Surface The mounting surface should be flat and have adequate stiffness in order to achieve the maximum per formance from the ALS20000 ALS25000 When an ALS20000 ALS25000 series stage is mounted to a non flat surface the stage can be distorted as the mounting screws are tightened This distortion will decrease the overall accuracy of the stage To maintain accuracy the mounting surface should be flat within Tum per 50mm Adjustments to the mounting surface must be done before the stage is secured The effects of flatness on mounting are illustrated in Figure 2 1 I I I I I I I I t t Flat Mounting Surface Non flat Mounting Surface Figure 2 1 Results of Flat Versus Non Flat Mounting NOTE The stage base is precision machined and verified for flatness prior to stage assembly at the fac tory If machining is required to achieve the desired flatness it should be performed on the mounting
17. e before the payload is attached to the stage table Proceed with the electrical installation and test the motion control system in accordance with the sys tem documentation Document all results for future reference For information on electrical connections refer toSection 2 5 The payload should be flat rigid and comparable to the stage in quality NOTE For valid system performance the mounting interface should be flat within 1 um per 25 mm Refer to Chapter 3 Operating Specifications for information on cantilevered loads and load positioning 2 5 Electrical Installation Electrical installation requirements will vary depending on stage options Installation instructions in this sec tion are for stages equipped with standard Aerotech motors intended for use with an Aerotech motion control system Contact Aerotech for further information regarding stages that are otherwise configured See Section 3 5 for wiring diagrams connector pin labels and pin descriptions Aerotech motion control systems are adjusted at the factory for optimum performance When the ALS20000 ALS25000 series stage is part of a complete Aerotech motion control system setup involves connecting a stage and motor combination to the appropriate drive chassis with the cables provided Connect the provided cables to the motor and feedback connectors on the stage Labels on the drive indicate the appropriate con nections Refer to your drive manuals and documentation for
18. ece cece cee c cc eceecececcececeecececceceseeceeees 33 www aerotech com lii Table of Contents ALS20000 ALS25000 Series Stage User s Manual iV www aerotech com ALS20000 ALS25000 Series Stage User s Manual List Of Figures List of Figures Figure 1 1 Typical ALS2500 Series Linear Positioning Stage eese esee esee 1 Figure 1 2 Typical ALS25000 Stage cssssssssssseesssslsess ess sn Reese slm rer r iler 2 Figure 1 3 ALS20000 ALS25000 Dimensions 2 2 0 0 c cece eee e eee e een e ren nnne nne 5 Figure 2 1 Results of Flat Versus Non Flat Mounting 2 0 20 cccceeeeeeeeeec cece eene 10 Figure 2 2 Top View of ALS20000 ALS25000 Stage Showing Hardcover Mounting Screws 11 Figure 2 3 Internal View of ALS20000 ALS25000 Stage Showing Mounting Holes 12 Figure 3 1 Load Capability of ALS20000 ALS25000 Series Stages 2 2 0 0 2 ec cceeeeeeeeeeceeeees 18 Figure 3 2 Finding LSC for Side Mounted Stages 2 2 2 20 22 ccc cece cece cece cece eee ceceeeceeeseeeeeees 18 Figure 3 3 Acceleration vs Mass for ALS20000 ALS25000 Series Stages usLssuu 19 Figure 3 4 Normally Closed NC and Normally Open NO Limit Switch Wiring 20 Figure 4 1 Top view of ALS20000 ALS25000 Stage Showing Hardcover Mounting Screws 26 www aerotech com V List of Figures vi ALS20000 A
19. ed circuit board Each limit switch board is mounted at the ends of the stage table with their emitter detector axes perpendicular to the direction of table motion When movement of the stage table causes the blade mounted to the stage base to break the light beam from the emitter to the detector a limit signal is generated The limit switch itself can be con figured as normally closed NC or normally open NO If the stage is driven approximately 8 mm beyond the electrical limit it will encounter a mechanical stop Although the operating speed of the stage may be relatively slow damage to the stage could result WARNING 3 4 2 Limit Switch Wiring Limit switches are open collector TTL compatible electro optical devices powered by 5 Volts that change output states when the stage approaches its maximum travel distance and breaks the light beam Since they are open collector devices they may be interfaced to 24V logic inputs Each limit switch is mounted on a small printed circuit board Standard ALS20000 ALS25000 Stages include limit switch wiring integrated into one of the two main connectors Assuming a NC limit configuration the input to the controller is seen as a logic 0 typical 0 4V 12 8mA when no limit condition is present When the limit switch is activated a 5V source through a pull up resistor causes a logic 1 typically 4 8 5V to be seen by the controller input The limit switch operation for a NO limit configuration
20. eled with LMT with Standard Jumper or LMT Optional Jumper limit Typ ically not used SETUP Analog output that represents quality of encoder signal used for troubleshooting and setup LT encoders only MTR SHLD Shield for motor connector wiring FRM GND Motor common ground ERROR Active high TTL output that represents encoder failure or misalignment LT encoders only 3 6 Vacuum Operation Please contact Aerotech for information regarding operation in a vacuum environment 24 Chapter 3 www aerotech com ALS20000 ALS25000 Series Stage User s Manual Maintenance Chapter 4 Maintenance It is necessary to keep the linear bearing rails properly lubricated Without proper lubrication excessive wear will cause premature failure of the bearings This will seriously degrade overall performance of the stage This chapter will cover information about intervals between lubrications detail the lubrication and inspection process and cover which lubricants are recommended for use NOTE The bearing area must be kept free of foreign matter and moisture otherwise the performance and life expectancy of the stage will be reduced To minimize the possibility of bodily injury confirm that all electrical power is disconnected prior to making any mechanical adjustments DANGER 4 1 Service and Inspection Schedule Lubricant inspection and replenishment in ALS20000 ALS25000 series stages depends on conditions such as duty cycle
21. er 3 15 Operating Specifications ALS20000 ALS25000 Series Stage User s Manual 3 2 Basic Specifications Basic ALS20000 ALS25000 series positioning stage specifications are shown in Table 3 2 General res olution information is given in Table 3 3 for each type of encoder Motor specifications are given in Table 3 4 Table 3 2 ALS20000 ALS25000 Series Specifications ascMod Atszspro Atsesezo ALsesbsb ALSasbes Atszsoeo Basic Model ALS25010 ALS25020 ALS25030 ALS25045 ALS25060 4in Bin 12in 18in 24in Resolution 0 001 um 0 2 um 0 04 uin 8 pin 0 005 um 1 0 um 0 2 uin 40 pin Maximum Linear Acceleration 3 g 30 m s2 1152 in s2 no load Maximum 70 0 kg 154315 Load Side 35 0 kg 77 2 Ib Continuous Air C 20 psi 168 0 N 37 9 Ib Stall Peak Force 673 0 N 151 0 Ib Accuracy LN 1 0 um 40 yin Standard 5 0 um 200 yin HALAR HALAR 1 0 um 40 uin Brace ca 160 pin 320 pin 480 pin em pin 960 pin Fu Fu 10 5 um 20 inj Straight Dif HALSF 1 um 25 mm 40 yin in ies and ferential Standard 2 um 25 mm 80 pin in amgss Maximum HALSF 1 0 um 1 5 um 2 0 um 2 5 um 3 0 um Deviation 40 yin 60 yin 80 yin 100 pin 120 pin Standard 2 0 um 4 0 um 6 0 um 9 0 um 9 0 um 80 yin 160 uin 240 pin 360 Un 360 yin Nominal Stage Weight 13 5 kg 17 5 kg 21 0 kg 27 0 kg 32 5 kg 29 8 Ib 38 6 Ib Si 3 Ib 59 5 Ib
22. evered load sit uation is used measure the cantilever length then find the corresponding load value from Figure 3 1 18 Distance of Load C G from Tabletop mm Figure 3 1 Load Capability of ALS20000 ALS25000 Series Stages Stage Table Lsc Figure 3 2 Finding L SC for Side Mounted Stages Chapter 3 www aerotech com ALS20000 ALS25000 Series Stage User s Manual Operating Specifications The acceleration capability of the ALS20000 ALS25000 stage will depend on the mass that is mounted to the stage table Figure 3 3 gives both peak acceleration and continuous acceleration capabilities of the ALS20000 ALS25000 series stages Peak accelerations can be reached for small amounts of time but can not be sustained Continuous acceleration specifications should be used when calculating accelerations for processes that require high duty cycles Figure 3 3 Acceleration vs Mass for ALS20000 ALS25000 Series Stages Www aerotech com Chapter 3 19 Operating Specifications ALS20000 ALS25000 Series Stage User s Manual 3 4 Optical Limit Switch ALS20000 ALS25000 series stages are provided with a pair of optical limit switch assemblies mounted to the bottom of the stage table The limit switches signal when the stage table has reached its maximum use able travel distance in both directions 3 4 1 Limit Switch Operation Each limit switch has a light source and detector mounted to a small print
23. he support stages are loosened Precision aligned stages should not be loosened or disassembled www aerotech com Chapter 4 25 Maintenance ALS20000 ALS25000 Series Stage User s Manual 4 2 3 Lubrication and Cleaning Process The lubrication and cleaning process is outlined in the steps that follow Drive the stage table to one end of travel and remove power to the stage 2 Remove the screws on the edges of the hard cover as shown in Figure 4 1 and slide it out from under the stage 3 Remove any accumulated dust or debris from the inside of the assembly Remove any dirty or dried lubricant from the linear bearing rails Use a clean lint free cloth with a side to side motion A swab soaked in Isopropyl Alcohol may be used to remove stubborn debris 5 Apply athin continuous film of lubricant to the linear bearing guides A good quality natural bristle art ist s brush makes an excellent applicator 6 Manually move the stage to the opposite end of travel This will work the grease into the linear bearing guides The stage table should move freely with little resistance Repeat steps 3 through 5 for any areas covered by the original table position Refasten the hardcover Restore power to the stage and drive the stage table back to its original position to redistribute lubri cants To minimize the possibility of bodily injury confirm that all electrical power is disconnected prior to making any mechanical adjustments
24. is the exact opposite as described above See Figure 3 4 for a diagram of limit switch wiring NC 5V NO 5V Pull up resistor Pull up resistor Limit Input Limit Input to Controller to Controller NO Limit Switch Figure 3 4 Normally Closed NC and Normally Open NO Limit Switch Wiring 20 Chapter 3 www aerotech com ALS20000 ALS25000 Series Stage User s Manual Operating Specifications 3 5 Standard Motor Wiring Stages come from the factory completely wired and assembled For reference connector pin outputs pin outs and general wiring information is given in the following figures Pinouts are defined in Table 3 8 NOTE Refer to the other documentation accompanying your Aerotech equipment Call your Aerotech rep resentative if there are any questions on system configuration NOTE If you are using your own cables to connect the stage ensure that motor and ground wires can handle current higher than the continuous current listed in Table 3 4 The voltage rating of the wire insulation must be greater than the bus voltage listed in Table 3 4 Table 3 5 Feedback and Motor Connectors for Stages with LT Square Wave Encoders 1 5 9 13 y ideae vitii elg o o o 9g o o o o 14 18 22 25 HA HC wo 2 7 10 fA D 12 M 1 mesmwp www aerotech com Chapter 3 21 Operating Specifications ALS20000 ALS25000 Series Stage User s Manual Table 3 6 Feedback and Mo
25. nation the buyer shall be notified of the repair cost At such Returned Product time the buyer must issue a valid purchase order to cover the cost of the repair and Non warranty Deter freight or authorize the product s to be shipped back as is at the buyer s mination expense Failure to obtain a purchase order number or approval within 30 days of notification will result in the product s being returned as is at the buyer s expense Repair work is warranted for 90 days from date of shipment Replacement com ponents are warranted for one year from date of shipment At times the buyer may desire to expedite a repair Regardless of warranty orout Rush Service of warranty status the buyer must issue a valid purchase order to cover the added rush service cost Rush service is subject to Aerotech s approval www aerotech com Appendix A 27 Warranty and Field Serv Ice On site Warranty Repair On site Non warranty 28 Repair Company Address ALS20000 ALS25000 Series Stage User s Manual If an Aerotech product cannot be made functional by telephone assistance or by sending and having the customer install replacement parts and cannot be returned to the Aerotech service center for repair and if Aerotech determines the problem could be warranty related then the following policy applies Aerotech will provide an on site field service representative in a reasonable amount of time provided that the customer issues a valid
26. nce is dependent upon heat sink configuration system cooling conditions and ambient temperature 2 Values shown 100 C rise above a 25 C ambient temperature with motor mounted to the specified aluminum heat sink 3 Peakforce assumes correct rms current consult Aerotech 4 Force Constant and Motor Constant specified at stall 5 All performance and electrical specifications 10 6 Maximum winding temperature is 125 C 7 Ambient operating temperature range 0 C 25 C consult Aerotech for performance in elevated ambient temperatures 8 All Aerotech amplifiers are rated Apk use torque constant in N m Apk when sizing www aerotech com Chapter 3 17 Operating Specifications ALS20000 ALS25000 Series Stage User s Manual 3 3 Load Capability It is recommended that application loads be symmetrically distributed whenever possible i e the payload should be centered on the stage table and the entire stage should be centered on the support structure With the stage lying flat horizontal and the application load vertically applied and symmetrically distributed the maximum vertical load carrying capacity of ALS20000 ALS25000 stages is 70 0 kg If cantilevered loads are applied refer to Figure 3 1 to find the maximum allowable load In Figure 3 1 a curve is shown for cantilevered loading conditions The Lsc or side cantilever curve assumes a horizontal stage orientation with the load extended above the table If a cantil
27. nded Lubricants and Cleaning Sol 25 Venlo zaoii ra inp LOL lip pete dde Del S safety procedures 2 2 0 22 2222222002 6 www aerotech com Index 31 ALS20000 ALS25000 Series Stage User s Manual Index 32 Index www aerotech com Reader s Comments ALS20000 ALS25000 Series Stage Manual P N EDS100 April 5 2011 Revision 1 03 00 Please answer the questions below and add any suggestions for improving this doc ument AEROTECH Is the manual Adequate to the subject ln ia Well organized o Clearly presented Well illustrated i How do you use this document in your job Does it meet your needs What improvements if any would you like to see Please be specific or cite examples C T SmwPeWbes Nam Weg 0 I me seria erp Name Bmeshpped Aem Guomeroded Aerotech Subsidiary Email Order Maiyourcommentsto Farto Aerotech Inc 412 967 6870 101 Zeta Drive Pittsburgh PA 15238 U S A service aerotech com
28. quirements for cables that must run to the stage table Custom configurations are common and readily available contact Aerotech for more details Hardcover Cable Management System ALS25000 Base Figure 1 2 Typical ALS25000 Stage 2 Chapter 1 www aerotech com ALS20000 ALS25000 Series Stage User s Manual Overview 1 1 2 Model Numbers The stage model number indicates the optional features on a particular stage To determine the options on your stage referto Table 1 1 for an explanation of the numbering system Table 1 1 Model Numbering System 10 S Brushless linear motor with standard magnet track BLM 142 A www aerotech com Chapter 1 3 Overview ALS20000 ALS25000 Series Stage User s Manual Table 1 1 Model Numbering System continued X CMS Cable management system for single axis assembly 1 Only available on the ALS20000 2 Only available on the ALS25000 4 Chapter 1 www aerotech com ALS20000 ALS25000 Series Stage User s Manual Overview 1 2 Dimensions nom us lt ig Lai j X Y Cable Management Option Shipping Brackets 175 0 x 175 0 6 89 x 6 89 1 4 20 Thru 1 4 20 Thru Hole Pattern 4 Holes 215 0 x 140 0 8 46 x 5 51 25 0 x 25 0 1 00 x 1 00 Hole Pattern 4 Holes 4 Hole Pattern 13 Holes Hin iE a ae Se ae LU EL 4 o a fo 140 0 5 51 H 205 0 8 07 98 0 3 e Dimensions Millimeters In
29. s 100 NeMame Chapter 2 Installation Sec Added safety information and warnings tion 2 1 Section 2 3 Sec tion 2 5 and Section 1 3 1 02 00 Section 3 2 Added motor specifications 1 02 00 Section 3 5 Added note about motor wire current and voltage require ments 30 Appendix B www aerotech com Index ALS20000 ALS25000 Series Stage User s Manual Index Securing the Stage to the Mounting Surface 11 Specifications 0 2222 22 2222 eee ee eee 16 A Standard Features 00 22 202200022 2 Attaching the Payload LL 13 Standard Motor Wiring 22 22 2 21 C U po m sie 13 i Unpacking and Handling the Stage 9 Cleaning Luiuuuuuuuluellleeeleesss eee eee 25 Ww D WarningS sse rreren cece cece cee nemen 6 Declaration of Incorporation 8 Dimensions _ 2222 2222 2222 2 5 E Electrical Installation 00 00 22 02 22 13 Environmental Specifications 15 l Important Notes on Lubrication L 25 Inspection Schedule 222 22222 25 L Lubrication 2occ ccecebedeestatdecucssuceege decease 25 Lubrication and Cleaning Process 26 Oo Optical Limit Switch 22222222222 22222222 20 P Preparing the Mounting Surface 10 R Recomme
30. sur face rather than the stage base Shimming should be avoided if possible If shimming is required it should be minimized to improve the rigidity of the system 10 Chapter 2 www aerotech com ALS20000 ALS25000 Series Stage User s Manual Installation 2 3 Securing the Stage to the Mounting Surface To access the mounting holes of the stage the hardcover must be removed Four screws two at each end of the stage retain the hardcover see Figure 2 2 Remove the screws and slide the hardcover out from under the table If necessary manually move the stage table to access the counter bored mounting holes along the edges of the stage refer to Figure 2 3 Install the appropriately sized socket head cap screws M6 or 1 4 through the mounting holes and secure the stage to the mounting surface The stage must be mounted securely Improper mounting can result in injury and damage to the equipment WARNING Hardcover Mounting Screws Figure 2 2 Top View of ALS20000 ALS25000 Stage Showing Hardcover Mounting Screws www aerotech com Chapter 2 11 Installation ALS20000 ALS25000 Series Stage User s Manual Stage Table Stage Mounting Holes Figure 2 3 Internal View of ALS20000 ALS25000 Stage Showing Mounting Holes 12 Chapter 2 www aerotech com ALS20000 ALS25000 Series Stage User s Manual Installation 2 4 Attaching the Payload to the Stage To prevent damage to payloads test the operation of the stag
31. tor Connectors for Stages with LT Amplified Sine Encoders 1 5 9 13 E A te vti eGlg o e o 9g o o o o9 14 18 22 25 SIG SHLD THERM SW HB M pu RUE 22 Chapter 3 www aerotech com ALS20000 ALS25000 Series Stage User s Manual Operating Specifications Table 3 7 Feedback and Motor Connectors for Stages with LN High Accuracy Encoders 1 5 9 13 d eGlg o e o 9g o o o o9 14 18 22 25 1 SIG SHLD 4 THERM SW ENC 5V MKR N MKR RESERVED 0 1 3 2 2 PRESERVED 22 2 2 4 M pu www aerotech com Chapter 3 23 Operating Specifications ALS20000 ALS25000 Series Stage User s Manual Table 3 8 Motor Wiring Pinout Descriptions PinOuput Descipion 1 HA Hall Effect A Brushless motor commutation track output TTL line driven signal with rotary motor HB Hall Effect B Brushless motor commutation track output TTL line driven signal with rotary motor Hall Effect C Brushless motor commutation track output TTL line driven signal with rotary motor LMT 5v 5 V supply input for optical limit switch boards Typical requirement is 50 mA MKR Marker Incremental encoder output pulse given once per revolution Typically used for home reference cycle Incremental encoder output either the compliment of Marker with a line driven TTL type encoder or 2 5 V DC bias level with amplified sine wave type encoder HMLMT N Home Limit Parall
32. w Chapter 1 Overview This manual describes Aerotech s ALS20000 ALS25000 series of linear motor positioning stages Figure 1 1 shows a typical ALS25000 positioning stage This chapter introduces standard and optional features of the ALS20000 ALS25000 stages explains the model numbering system and gives general safety precautions Figure 1 1 Typical ALS2500 Series Linear Positioning Stage NOTE Aerotech continually improves its product offerings and listed options may be superseded at any time Referto the most recent edition of the Aerotech Motion Control Product Guide for the most current product information at www aerotech com Www aerotech com Chapter 1 1 Overview ALS20000 ALS25000 Series Stage User s Manual 1 1 Standard Features The ALS20000 ALS25000 stages are low profile high accuracy stages for use in production environments where space and contamination are concerns The ironless linear motor is completely cog free allowing for extremely tight velocity control Due to the ironless forcer and U channel magnet design the magnetic field is self contained The ALS20000 stages have a metal waycover to protect the stage from vertically falling debris The ALS25000 stages have the added protection of side belts to prevent particle ingress in harsher envi ronments 1 1 1 Optional Features Cable management systems are available in various configurations depending on the number of axes involved and customer re

ALS20000 / ALS25000 Series Stage User`s Manual

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