PCR43 Reference & Maintenance Manual
Contents
1. Each PLG stage includes Forward and Reverse Limit sensors and a Home sensor Figure 7 4 shows the equivalent schematic for these switches 15 PC HA 3 N Reference amp Maintenance Manual 12 to 24V DC N Ki x Home R Forward Limit Switch K Reverse Limit Switch NW T Normally Closed jemo Temp Switch DCCOM Figure 7 4 Equivalent Limit Home and Temp circuit schematic 7 6 1 Home Options The Home switch is ordered in either the Normally Closed H1 or Normally Open H2 configuration H1 Switch is closed when carriage is between the negative reverse end of travel and the home transition point It is open from the transition point to forward end of travel H2 Switch is open when carriage is between the negative reverse end of travel and the home transition point It is closed from the transition point to forward end of travel 7 6 2 Limit Options 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 the2. PC R 4 9 f Reference amp Maintenance Manual primatics PCR43 Reference amp Maintenance Manual PC R 4 9 N Reference amp Maintenance Manual al primatics 32114 Mallard Ave PO Box 409 Tangent OR 97389 0409 U S A Phone 541 791 9678 Fax 541 791 9410 Toll Free 888 754 3111 Web www primatics com E mail info primatics com PCR43 Manual Revision Information Publication Date Notes March 2002 April 2005 Updated look amp formatting January 2007 Updated Ordering Information January 2008 Discontinued 40nm encoder option January 2015 Update Lubrication instructions January 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 PCR43 Datasheet available from our website at www primatics com Copyright 2008 2015 by Primatics Inc All Rights Reserved Primatics the Primatics logo PrimaFlex PrimaSeal amp SimpleMatch are trademarks of Primatics Inc PC HA 3 Reference amp Maintenance Manual PCR43 Manual Revision Information cccccccesseesesee
3. 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 Humidity should be less than 85 and there should be no condensation 6 3 Contamination Applications in contaminated environments require the electrical optical and mechanical components to be protected The PCR43 series is intended for clean environments free from particulate and fluids Additional protection must be designed for stages that are in dirty environments 6 4 Electrical Noise Electrical noise is the corruption of signals carried over low voltage wires Encoder signals can be corrupted resulting in spurious encoder counts thus causing the stage to drift Grounding shielding and spatial separation are all countermeasures to reduce the influences of electrical noise on performance You can minimize the potential for electrical noise by observing the following installation precautions o Physically separate low voltage conductors from those carrying high voltage o Ensure that all components are properly grounded o Ensure that all wiring is properly shielded 10 PC HA 3 Reference amp Maintenance Manual 7 Installing the PCR43 Positioning Stage 7 1 Tools you will need The PCR43 linear positioning stage uses M5x18mm minimum sockethead cap screws in the base plate mounting M5 and M3 tapped holes ar
4. R PCR 43 AL 0100 A D3 Hi D E7 BI Pi X0 M Model Series Cross Roller Deag PCR Table Height 43 mm 43 Base Material Bearings Standard Cross Hoer C Anti Cage Creep Cross Roller E Se A Drivetrain Linear Motor 1 Dk eben pl Home Sensor N C Current Sinking H1 N O Current Sinking H2 Travel Limits N C Current Sinking L1 N O Current Sinking L2 Encoder Linear Encoder 10 nanometer ee E6 Linear Encoder 20ranoreier E7 Pneumatic Counterbalance No Counterbalance B1 With Counterbalance B2 Protection Level Level 1 Class 10 000 Cleanroom Di Multi Axis Stacking Single axis no cable management x0 X axis with multi axis cable management X1 Y axis with multi axis cable management X2 Z axis with multi axis cable management X3 Options Error Mapping niii M No OPD E Leave Blank Allow Longer Delivery me Includes Z bracket Not all configurations are valid Consult factory for assistance 3 Model Configuration PC HA 3 N Reference amp Maintenance Manual A 4 Personal Safety A Please review before installing your positioning stage Observe common industrial safety practices when installing and operating automated equipment o Have power connections made by qualified personnel o Keep fingers and other items out of any opening in the stage while i
5. ance Manual 7 5 1 Color Codes for Pigtailed Cable Cable consists of 3 independent shielded pods One for motor signals one for encoder signals amp a 3 for sensors Each of the pods is described below Cable 1 Color Function Black Motor A E Red Motor B White Motor C Shld Motor Shield Cable 2 Color Function i Red Encoder 5V White Encoder A output E Yellow Encoder A output E Green Encoder B output R Blue Encoder B output E Shld Encoder Shield E Black Encoder Common Orange Encoder Index Brown Encoder Index Cable 3 Color Function Green 12VDC E Blue DCCOM White Home BI Wht Red Not used JB Wht Black Not used a Shid Chassis g Black Hall V Brown Hall V Violet Forward Limit Switch H Gray Reverse Limit Switch E Red Hall A E Orange Hall B Tan Temperature Monitor Yellow Hall C PC R 4 9 Reference amp Maintenance Manual 7 5 2 Hall Effect Commutation Sequence The following diagram shows the motor signal timing for the Servo Motor option Positive Direction of Motion Figure 7 2 Motor commutation chart The following diagram shows the encoder signal timing for the Encoder option Positive Direction of Motion Figure 7 3 Timing diagram for the encoder signals 7 6 Home and Limit Sensors
6. carriage is moved away from the switch 16 PC R 4 9 N Reference amp Maintenance Manual 7 7 Limit amp Home Switch Adjustment The limit and home switch positions have been preset at the factory and cannot be adjusted The limit sensors and home sensors are offered as normally closed or normally open and they can only be adjusted at the factory prior to shipment Both limit switches are normally closed and moving from the reverse limit switch to the forward limit switch causes the home switch to transition from closed to open See Figure 7 2 for an illustration of this Limit Sensor Transition Region for Default Configuration Pi Encoder Index Transition Home Sensor Transistion Point 13 55 12 85 0 3 0 03 0 6 0 9 12 85 13 55 Reverse Limit Switch Center of Travel of Stage mm q Forward Limit Switch Figure 7 5 Limit amp Home Sensors 5V ar x gt g e F de Home Sensor Transition Point Home Sensor Transition Point H1 Option H2 Option Figure 7 6A Home Vane Figure 7 6B Home Vane Configuration H1 L1 Options Configuration H2 L2 Options Normally Closed Normally Open 7 8 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 in the positive direction and verify the encoder count is increasing Runaway conditions caused by miswired encoders can result in stage damage and personal injury Move the car
7. carriage up and down by hand noting the resistance and adjusting the pressure regulator slightly to iterate in on uniform resistance upwards and downwards 4 The counterbalancing can be optimized even more by cycling the z axis with the servo and adjusting the regulator until the torque requirements for constant velocity are the same for travel upward and downward 5 The pressure regulator should be located as close to the cylinder as possible to improve the response of the system 6 Due to the extremely low friction level of the air cylinder it is normal for there to be slight air leakage past the piston and end seals Adequate capacity of the air supply source should be ensured so that continuous counterbalancing can be maintained 18 PC HA 3 N Reference amp Maintenance Manual 8 Preventive Maintenance Performing preventive maintenance procedures on your stage will extend its life and improve its long term performance 8 1 Lubrication Use Nye Rheolube 737B low viscosity grease to lubricate the linear guide components For low duty cycle applications it is recommended that the linear guides be re greased every six months High duty cycle applications may require more frequent re lubrication Lubrication intervals depend on duty cycle load and ambient conditions Inspection of the elements may be required to determine the proper lubrication interval After power has been disconnected from the stage a light film of grease can b
8. dy to install and operate your stage Step 6 Review preventive maintenance section for proper lubrication schedule PC HA 3 Reference amp Maintenance Manual 2 Introduction About the PCR43 Each Primatics PCR43 positioning stage is designed for precision movement in one axis They feature a highly compact design and deliver exceptionally smooth travel by utilizing precision cross roller bearings The stages can be stacked to make X Y or X Y Z systems Many customers choose the Primatics Motion Drive Chassis MDC to power PCR43 stages The MDC is a modular system that packages motor drivers encoder interfaces power supplies and safety systems into a single chassis It acts as an intermediary between a Galil Optima National Instruments 7344 or Delta Tau PMAC II motion control cards and a Primatics positioning stage Pre wired high flex cables are available to allow a convenient connection from the stage to the MDC chassis The MDC drive chassis interfaces 3 party controllers via a removable interconnect module These interconnect modules conform to each manufacturers interconnect cable and internally route all the command and UO signals Optionally a Primatics positioning stage can be used with many third party controller and amplifier systems In this case a pigtailed cable is available to simplify the connection between the PCR43 stage and controls PC HA 3 Reference amp Maintenance Manual OPTIONS SAMPLE MODEL NUMBE
9. e applied along the length of the crossed roller bearings when the stage is at either extreme end of travel Cycle the stage back and forth to distribute the grease and wipe off any excess The motor and linear encoder is a non contact device and does not need lubrication 8 2 Bearing Cage Creep The bearing elements cross roller bearings in the PCR43 offer extremely smooth and precise motion which is required to obtain repeatability of less than 50nm but unfortunately there is a tradeoff for such low friction Cage creep is the slow migration of the bearing roller elements which will cause the effective travel to be decreased This phenomenon may occur over time especially if accelerations and decelerations are not the same and if a stage is in a vertical orientation If the stage no longer gets full travel the roller elements need to be re centered This is done by moving the carriage to one end of travel and pushing the carriage by hand until you feel the cages slide Move the carriage to the opposite end and repeat the procedure It should take a moderate amount of force 88N 20Ibs to get the cages to slide If there is metal to metal sound and feel at the end of travel then the cages need to slide If there is a soft compressive rubber feeling at the end of travel then the cages are properly aligned and the carriage is compressing the end of travel bumpers If the stage was ordered with the ACS option cage creep is eliminated and
10. e available for customer use for mounting payloads to the carriage 7 2 Unpacking Carefully remove the stage from its shipping crate and inspect it for evidence of shipping damage Report any damage immediately to your authorized dealer If so equipped remove the red shipping clamp from the stage see Figure 5 1 Improper handling of the stage may degrade its performance Follow these guidelines when handling and mounting your stage 1 Do not drop the stage onto its mounting surface Place the stage gently on the mounting surface Impact loads can cause high spots on mounting surfaces misalignment of drive components and warping of the base 2 Do not drill holes into the stage If additional holes are necessary contact your local distributor 3 Lift the stage by its base structure only Do not lift by the motor drive assembly 4 Stage disassembly and alteration unless specified otherwise may void warranty 7 3 Mounting surface preparation The characteristics of the surface the positioning stage is mounted to will have a large effect on system performance An accurate and flat positioning stage will conform to the shape of its mounting surface therefore a flat mounting surface is required In the absence of a sufficiently flat surface a three point mounting scheme can be utilized to rely on the inherent flatness of the stage This technique can introduce negative dynamic effects in moment load applications because a large porti
11. eeeeeeeeeeeeeeeeeeeeeeeeeeeeees 2 Re TEE 4 2 Introduction About the PCHA seen 5 3 Model Configuration sisisscccsinsiceracesSsaescestcaicnesScesssesSaeisesstannaceneeussen tens snavaansuedss 6 AN 4 Personal Safety 5 envcensiannansusisnsitutilaainietblusheasicusinladiiesinuadeaabeuddnainuatinse din 7 5 Stage amp Manual Conventions cccccccsesesseeeeeeeeeeeeeeeeeeeeneeeeeeeeeeeeeeneeeeneeeees 8 5 1 Direction Of Molom erreren one e o a a ao 8 5 2 Units Of Meaeure o oo eee eeeseceeeeseeceeeeeneeeeeeneeeeaaeeeeessaneesesaaneesesaaneesesaneeseseanenseneanenseneees 8 6 Installation Preparations wwicicccsescectecicccseeesecnscescsnsssetecasennretenncriecnennaenedecenn 9 Gel Eimear MOONS aces eee eta eee eege Zeg ee EE Eege ee EE 9 6 2 el nee Halle TE EE E 10 6 3 CONTAMINATION ar a ar cas Eege enee Eege EES Ee shdges datas 10 6 4 Electrical NoiSe Aere Eege eer Eege EE ee ESA Eed 10 7 Installing the PCR43 Positioning Stage cccccccsssessseeeeeeeeeeeseeeseeeeeeeees 11 fA Tools von will Needse eiriaa ee ee ced eect 11 1 2 UN Packing BEEN 11 7 3 Mounting surface preparation ccceecceeeeeeseeeeeeeneeeeeeeneeeeeeeaeeeeeteaeeeeeseaaeeeeeeaaeeeeneaeeeee 11 7 4 Mounting the PORES oc ceecccceceeceseeeceee cece eeeaeeeeaeeeseaeeseaeeeeeaeeseaeeesaeeseaeeseeeeseaeeseeneeseas 12 7 5 Electrical CONNECTIONS c ccccecececeeeceeeeeeeeeeteaeeeeeaeeceaeeceeeeeseaeeseaeeseaeeseaeesseaeeseeeeetsaeetaas 12 7 5 1 C
12. ifies the encoder count is increasing All cables and connectors are located at the motor end of the stage The reverse limit switch is located on the motor end and the forward limit switch is located on the opposite end of the positioner Figure 5 1 illustrates this convention Forward Limit Carriage Reverse Limit Figure 5 1 Positive direction convention 5 2 Units of Measure Primatics uses the metric system for all specifications and dimensions All linear dimensions are specified in millimeters Accuracy repeatability resolution flatness and straightness for the PCR 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 Ibs 1 Kg has a weight of 2 205 Ib when g 9 8 m s PC HA 3 Reference amp Maintenance Manual 6 Installation Preparations This section outlines installation environments Unfavorable installation conditions may cause electric shock fire or breakdown Certain breakdown situations or malfunctions in particular may lead to serious injury or other consequences Assure that the unit is used under the fol
13. lowing 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 e ke Mee Mer 6 1 Linear Motors Linear motors have large magnetic flux that can draw ferrous metals inside them from large distances destroy magnetic media and disrupt some electronic circuits Materials attracted to the magnets can pinch fingers and cause injury Great care must be taken when operating less than 25mm from the surface of the motor In addition braking is difficult for linear motors making them inappropriate for many vertical applications Make sure no load is attached to the linear motor stage when stage is first connected to the electronics Linear motors can generate large accelerations and improper wiring to the control system can result in a high speed crash PC HA 3 N Reference amp Maintenance Manual 6 2 Heat and Humidity All positioning stages are assembled and tested at 20 C
14. olor Codes for Pigtailed Cable 14 7 5 2 Hall Effect Commutation Geouence 15 7 6 Home and Limit Gensors ne 15 7 61 Home Options een cect eege SEdeEEe EEN ee 16 7 7 Limit amp Home Switch AGjUStMeNt ccccecceeeeeeeeeeeeceeeeeeeeeeeeaeeesaeeseaeeseaeeeseaeeseeeeeeeaeetaas 17 7 8 Recommended System Test 17 7 8 1 Pneumatic Counterbalance for Z axis Operation 18 8 Preventive Maintenance cccccccesseeeeeeeeeeeeeeeeesseeeeeeeeeeeeeeeesseeseeeeneeeaees 19 BE Beete EE 19 8 2 Bearing Gage Gree EE 19 9 Troubleshooting amp Service ccccccccessseseeeeeeeeeeeeeseeseeeeeeeeeeeeeeseseseseeneneeees 20 9 1 Troubleshooting Help ANEREN 20 9 2 SCIV EE 20 PC HA 3 Reference amp Maintenance Manual 1 Overview This user guide is designed to help you install and maintain your PCR43 Series linear positioning stage application Follow these steps to ensure correct stage installation and maximum stage life Step 1 Review this entire user manual Become familiar with all installation procedures prior to integrating your system Step 2 Review the safety summary to develop an understanding of standard safety practices when installing and operating automated equipment Step3 Familiarize yourself with the conventions summary Step A Review installation procedures For best results follow these procedures carefully Step 5 Once you successfully complete all the installation procedures you will be rea
15. on of the stage base is not in contact with the mounting surface The flatness and straightness specifications can be affected under large loads For best results in maintaining stage specifications we suggest the following 1 Use a laboratory Grade AA granite surface plate 2 Before mounting stage inspect for burrs or dings on the stage mounting surfaces 3 Clean all mounting surfaces with acetone In the absence of a granite surface plate we recommend a base plate made of the same material as the base of the stage A mounting surface constructed out of a material different from the stage base material can introduce warping in the stage in the presence of a thermal 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 11 PC R 4 9 N Reference amp Maintenance Manual 7 4 Mounting the PCR43 The PCR43 has four mounting holes that can be accessed by moving the carriage to its forward and reverse limits Figure 7 1 shows the location of these mounting holes Figure 7 1 Mounting Hole Locations 7 5 Electrical Connections All PCR43 models are terminated with a 450mm flexible cable with a 28 position circular connector on the end The pin out of this connector is shown with Table 7 1 This particular configuration is optimized for use with Primatics MDC drive chassis via an extension cable Connections to other drives and controls a
16. re also made through this connector A popular option for applications not using the Primatics MDC drive chassis is the pigtailed extension cable This is similar to the extension cable used to connect a stage to the MDC drive chassis except the end that connects to the motor drive and controller is un terminated Section 7 5 1 shows the conductor assignments for this cable when ordered with a ballscrew drivetrain and without an encoder 12 PC R 4 9 N Reference amp Maintenance Manual Table 7 1 Axis Connector Motor encoder limits home temp FCI circular connector 28 pins size 20 shell 8 5 Function Motor A Motor B Motor C Motor Shield Encoder 5V power for encoder Encoder A output Encoder A output Encoder B output Encoder B output Encoder Shield 12VDC for limit home and temp sensor DCCOM Home Switch to DOCOM when on forward side of home position Not used Not used Chassis Hall V Hall V Encoder Common Encoder Index Encoder Index Forward Limit Switch switch to DCCOM in normal operation Reverse Limit Switch switch to DCCOM in normal operation Signal Shield Hall A Hall B Temperature monitor connect to DC Common for temperature OK Hall C 0 Q 0 o M IN lt lt S lt C Al n DI VIZIElH A C TIO m m vjo w gt 13 PC R 4 9 N Reference amp Mainten
17. riage to each end of travel to ensure limit switches are working properly 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 17 PC HA 3 N Reference amp Maintenance Manual 7 8 1 Pneumatic Counterbalance for Z axis Operation A pneumatic counterbalance and Z bracket option is available for vertical operation of the PCR43 Counterbalancing is achieved using a glass lined air cylinder aircraft cable and pulley assembly and a precision pressure regulator Counterbalance operation is as follows 1 Remove any shipping brackets and protective shipping items on the counterbalance assembly 2 With the servo off the payload should be mounted to the Z axis carriage and the carriage should be resting at the end of travel under gravity Max allowable payload for counterbalance is 4 5kg 10lbs including the weight of the carriage 3 Clean dry filtered air should enter the inlet side see marking on regulator of the pressure regulator 690kPa 100psi max and should exit the regulator and enter into the air cylinder via polyurethane tubing Starting with the regulator valve closed no air passing through slowly open the valve until the cylinder pressurizes and the stage carriage slowly rises upwards Slightly close the valve until the carriage stops rising Move the
18. t is in operation since injury or damage may result o Provide a safe access route and adequate room for servicing o Perform the recommended periodic maintenance described in this document o Verify that the work envelope is free of obstructions before the positioning stage is powered o Insure that you have the feedback wired properly to the controller before applying power to the positioning stage Improper feedback connections can cause a motor run away condition that has the potential to damage the stage and injure an operator o Only trained operators of the positioning stage should be allowed near the work environment o If So equipped identify emergency stop circuits and actuators in the workcell o Note the places in the workcell where pinch points occur and provide adequate safety clearance or safety curtain o Never operate the motor in a location that could be splashed by water exposed to corrosive or flammable gases or is near combustible substances since this may cause an electric shock fire or malfunction o Never touch the motor driver or peripheral devices when the power is on or immediately after the power is turned off The high temperature of these parts may cause burns PC R 4 9 N Reference amp Maintenance Manual 5 Stage amp Manual Conventions 5 1 Direction of Motion The positive direction of motion is defined as a motion away from the motor end of a stage A positive direction of motion also sign
19. this section can be ignored 19 PC R 4 9 N Reference amp Maintenance Manual 9 Troubleshooting amp Service 9 1 Troubleshooting Help For further assistance contact the factory M F 8AM to 5PM Pacific Time Phone 541 791 9678 Fax 541 791 9410 Toll Free 888 754 3111 Web www primatics com E mail service primatics com 9 2 Service Should your device require factory service contact the factory for a Return Materials Authorization RMA When inquiring about an RMA please have the following information available o Your contact information name phone email address o Unit Serial Number located shown below o Symptom of problem o History of troubleshooting steps already taken Figure 9 1 Unit Serial Number Location 20
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