ASR1200 Rotary Stage User`s Manual
Contents
1. a 4 Dimensions senses 5 WRENCH 2 222 sme llllcli 4 drive motor options 4 controller 3 electronics 3 www aerotech com Index 35 ASR1200 Rotary Stage User s Manual Index mounting plate 222 eee eee 3 reat S alSiv 221 eo ee le 4 T NEA certo escnaeetsts tes oaosde rege 3 temperature and accuracy 22 17 Wrenches aaa 3 U i sess ened ee ALALA AA aa 1 Unpacking and Handling the Stage 9 P w performance temperature 17 WamningS oaaao naaa aoaaa oaaao ALA ang 6 piston seal replacement 23 wet eut LLL 2 position transducer options 2 4 wet cut fluid requirements 2 16 Preparing the Mounting Surface 10 wet cut rotary union removal 29 wet cut rotary union seal replacement 25 C HERREN workholding devices 2 22 22 22 13 wrenches i aaa 3 requirements AA SRI RON 16 ringseal o ring replacement 23 ringseals esses 3 rotary axis n ccs APAN 2 S safety procedures 0 02 00 022 02 22 6 seal replacement 0 22 22 222 200 23 Securing the Stage to the Mounting Surface 11 service schedule 21 specifications OVEIVIOW 17 temperature 0022 e eee eee eee eee eee 17 Specifications 022222. aaa 29 Wet Cut Rotary Union Installation 30 www aerotech com V List of Figures vi ASR1200 Rotary Stage User s Manual www aerotech com ASR1200 Rotary Stage User s Manual List of Tables List of Tables Table 1 1 Model Numbering System sse eR e Rr Rr he e ee eere 4 Table 3 1 Environmental Specifications aaa 17 Table 3 2 ASR1200 Series Specifications rss rssslI 18 Table 3 3 ASR1200 Motor Specifications a 19 Table 4 1 Recommended Lubricants aa 22 Table B 1 Current Changes 1 03 00 aa 33 Table B 2 Archived Changes 22 0 0 aaa 34 www aerotech com vii List of Tables ASR1200 Rotary Stage User s Manual viii www aerotech com ASR1200 Rotary Stage User s Manual Overview Chapter 1 Overview Aerotech s ASR1200 mechanical bearing rotary stage is a system that combines high precision rotary posi tioning with an integrated pneumatically controlled collet chuck for material handling The ASR1200 series util izes direct drive brushless motor technology to maximize positioning performance and virtually eliminate the need for maintenance The stage is also equipped with a rotary union attachment for wet cutting operations These features make the ASR1200 an ideal choice for applications where low maintenance high throughput and low total cost of ownership are essential The ASR 1200 has been desi
3. eee eeeeeeeeees 13 2 6 Electrical Installation 2 222 2 222 cece cece cece cece eee c eee c cece eeceeeeeceeeeeeeeees 16 2 7 Air Requirements 2 2 a aka a kakak 16 2 8 Wet Cut Fluid Requirements 2 2 0 0 222222 c cece eee ee cece cece eccccccecceececeeeeeeeees 16 Chapter 3 Operating Specifications ccc ccc cece cece cece ec eee eee eee 17 3 1 Environmental Specifications 22 2 2 220 222 a 17 3 2 Accuracy and Temperature Effects 00 2202 2 0 occ c cece cece e cece ccc c cece cece ec e Reese 17 3 3 Basic Specifications coe cece eee e eee c cece ccc ceeeeeceeececeeeeeeeeeees 18 3 4 Load Capability 2 2 2 0 e cece me oraora nannan 20 Chapter 4 Maintenance 21 4 1 Service and Inspection Schedule 2 2 0 22 eee 2 aaa 21 4 2 Cleaning and Lubrication 2 0 0 0 aa 22 4 2 1 Collet amp Collet Chuck Lubrication and Cleaning cccceeeceececceeeeeees 22 4 3 Seal Replacement 2 2 2 ccc cece a 23 4 3 1 Piston Seal Change Procedure 2 ccecceeccceceeccccccceecccccccceeeeecceeees 23 4 3 2 Ringseal O Ring Replacement 0 0 02 aa 23 4 3 3 Wet Cut Rotary Union Seal Replacement ueeeeeeeeee sees 25 4 4 Wet Cut Rotary Union Removal 2 2 2 0 sees ooo se eser esr herren erre 29 Appendix A Warranty and Field Service 31 Appendix B Technical
4. 20 00 22 22222 16 ACCUFACY ciu vecdcauddsaubecosveexcbuadextdscdasasie 10 Environmental Specifications 17 accuracy and temperature 17 l air inspection schedule 21 compressed cece cece ceeeeeeee 16 installation 9 Ae AA 16 Col eba a EC na sede 13 requirements eee ee ee 16 air leakage 2022 eee eee eee eee ee eee 16 L Attaching the Payload 222 5 12 leakage air 16 load capability 0 00000 002022222 eee 20 C lubrication Cable e eot ee ED LE EE 3 16 collet collet chuck 22 changing ASR workholding devices 13 OMNIS 2 22 0 Lg Lala eb BN hha LALA 22 cleaning piston seals 22 collet colletchuck a 22 L brication oclo Lise eene 22 malabis oe ne onc ae eue an daanan cies 22 Cleaning sese 22 M collet chuck option 4 maintenance sss ssssl 21 colletinstalltion a 13 model numbers aooaa oaoa a aoaaa aoan anaana naan 4 colletremoval eee eee eee 13 N collet collet chuck MOJEN RENE ERR PN 16 cleaning sse seeA 22 mog 7 1g e 11 0 1 AA AA 22 o compressed air sess 16 operating specifications 2 eee0ee 17 connector options 0 2 0 20 2 22 0222 4 te le eee ee ee ee 3 4 D 10 drive motor 4 MP mounting plate 4 Declaration of Incorporation 8 i NC colletchuck
5. ASR1200 Rotary Stage User s Manual Operating Specifications Table 3 3 ASR1200 Motor Specifications Performance Specifications 1 3 Stall Torque Continuous 2 3 Peak Torque 9 Electrical Specifications 9 NmbeoPdes P8 o 8 1 Performance is dependent upon heat sink configuration system cooling conditions and ambient temperature 2 Values shown 130 C rise above a 25 C ambient temperature with motor mounted to a 250 mm x 250 mm x6 mm aluminum heat sink 3 Peaktorque assumes correct rms current consult Aerotech 4 Torque Constant and Motor Constant specified at stall 5 All performance and electrical specifications 10 percent 6 Maximum winding temperature is 155 C 7 Ambient operating temperature range 0 C 25 C consult Aerotech for performance in elevated ambient temperatures 8 De rate continuous torque and continuous current by 10 percent when using an encoder 9 All Aerotech amplifiers are rated Apk use torque constant in N m Apk when sizing www aerotech com Chapter 3 19 Operating Specifications ASR1200 Rotary Stage User s Manual 3 4 Load Capability The ASR1200 is designed for tubular manufacturing applications With this in mind the tubes loaded into the collet chuck of the rotary axis must fall within the max load parameters outlined in Table 3 2 NOTE Maximum loads are mutually exclusive loading limits are due to the collet chuck mechanism Contact Aerotech dir
6. and replacement process of various components It is recommended that rotary seals be replaced at a minimum of every 1000 hours of serv ice or until a definitive trend develops Refer to Section 4 3 3 for more details WARNING 4 1 Service and Inspection Schedule Seal inspection and replacement in ASR1200 series stages depends on conditions such as duty cycle speed and the environment A frequent inspection interval is recommended until a trend develops for the application As part of this inspection interval the seals should be examined for excessive air or water leak age The application will determine the required replacement interval for the seals The bearings motor and encoder require no lubrication or maintenance www aerotech com Chapter 4 21 Maintenance ASR1200 Rotary Stage User s Manual 4 2 Cleaning and Lubrication O rings and collet piston seals should be lubricated with with Parker O Lube lubricant or an equivalent o ring lubricant See Section 4 3 3 for details regarding lubrication of the wet cut rotary union seals Any metal parts may be cleaned with either acetone or isopropyl alcohol Seals and o rings may be wiped with a small amount of isopropyl alcohol if necessary Acetone should never be used to clean the o rings or seals WARNING 4 2 1 Collet amp Collet Chuck Lubrication and Cleaning Forthe collet chuck and collet to operate properly preventative maintenance and regular cleaning is re
7. 4 5 5 bar 60 80 psig depending on the collet size Higher pressures will not cause damage to the rotary union but high flow rates will result Because of the non contact rotary union design on collet equipped stages a small amount of leakage will occur Approximate leakage rates of between 10 Lpm 0 5 CFM and 40 Lpm 1 4 CFM depending on pressure will be observed when the collet is open NOTE When operating the ASR1200 it is recommended that 5 psi be supplied to the collet at all times This will act as an air purge and help prevent contaminants from entering rotary union 2 8 Wet Cut Fluid Requirements Water or cutting fluid used during wet cut operations must be conditioned to meet certain requirements ensur ing seal functionality and service life of the wet cut rotary union e Water or cutting fluid must be filtered to 5 microns or better e Fluid filter must be installed upstream of the rotary union between pump outlet and rotary union inlet 16 Chapter 2 www aerotech com ASR1200 Rotary 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 contains general technical information about the ASR 1200 on ideal environmental oper ating and basic product specifications 3 1 Environmental Specifications The environmental specifications for the ASR1200 are listed in the follo
8. c eee eee 18 stage distortion 10 standard features juge pM 2 Standard Features 2 22222 2222 2 2 36 Index www aerotech com Reader s Comments ASR1200 Series Stage Manual P N EDS132 February 21 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 D fi Well organized Ba Clearly presented Cl Well illustrated dq 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 ae O Meg I me seria erp Name PU Bmeshpped O Aem O Guomeroded Aerotech Subsidiary Email Order Maiyourcommentsto Faxto Aerotech Inc 412 967 6870 101 Zeta Drive Pittsburgh PA 15238 U S A service aerotech com
9. the stage Aerotech stages are designed for and built in a 20 C 68 F environment www aerotech com Chapter 3 17 Operating Specifications 3 3 Basic Specifications ASR1200 Rotary Stage User s Manual ASR1200 stage specifications are shown in Table 3 2 Motor specifications are given in tab Table 3 2 ASR1200 Series Specifications E Maximum Load 9 Continuous Current APK ARMS Stage Mass Minimum System Air Pressure 4 Finish Stage Body Collet Chuck degrees rpm n a mm arc sec arc sec kg m microns k k N m amps 9 g amps kg psig n a n a ASR1200 360 continuous ER16 15 x 1075 0 014 oz in s 8 5 0 1 100 Electroless Nickel plated Al Hardened 440C stainless steel NiCoTef 5 s2 3 2 3 1 T 5 1 ASR1100 collet chuck accepts Rego Fix ER collets manufactured to DIN6499 specifications only 2 Measured TIR of precision gage pin chucked with an ultra precision ER collet DIN6499 10 mm away from collet face 3 Maximum loads are mutually exclusive Loading limits are due to the collet chuck mechanism Contact Aerotech directly if part load requirement exceeds specifications 4 Collet chuck mechanism is normally closed Collet mechanism requires air to open collet chuck Air supply must be dry 0 F dew point oil less air OR 99 99 pure Nitrogen Air or nitrogen must be filtered to 0 25 micron particle size or better 18 Chapter 3 www aerotech com
10. verified for flatness If the mounting plate is not selected a custom mounting option can be attached using the Qty 4 M6 tapped holes in the bottom of the stage 1 2 2 Wrenches This option is selected when spanner wrenches for removing the collet nut are desired 1 2 3 Electronics Controller The ASR1200 stage is part of a complete Aerotech motion control system which is adjusted at the factory for optimum performance Setup involves connecting a stage to the appropriate drives with the cables pro vided Refer to your electrical documentation package for further information 1 2 4 Ringseals Replaceable O Ring seals are required to perform wet cut operations using the ASR 1200 These ringseals are sized for specific tube diameters in sizes up to 5 8 mm Consult Aerotech for supported sizes Www aerotech com Chapter 1 3 Overview ASR1200 Rotary Stage User s Manual 1 3 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 Example ASR 1200 10 HPD NC RE2048AS MP WRENCH RINGSEAL 1 08MM Table 1 1 Model Numbering System 10 5 N m peak 1 95 N m continuous direct drive brushless motor M Collet Chuck Rear Seal s S MP Mounting plate WRENCH Spanner wrenches for changing ER16 collets RINGSEAL O ring seal assembly for wet cutting Consult factory for supported sizes 4 Chapte
11. ASR1200 Rotary Stage User s Manual P N EDS132 Revision 1 03 00 Dedicated to the Science of Motion Aerotech Inc 101 Zeta Drive 7 Pittsburgh PA 15238 ABRCITECH 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 49911 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 February 21 2011 Revision 1 02 00 August 16 2010 Revision 1 01 00 December 2 2008 Revision 1 00 00 October 14 2008 Product names mentioned herein are used for identification purposes only and may be trademarks of their respective companies Aerotech Inc 2011 ASR1200 Rotary Stage User s Manual Table of Contents Table of Contents Tableor Contents 6 256222 es oti eee dah sates tue LU e NAY PA ERU RUE iii LiStiOf FIQUIOS ERR EE V Eist or Tables e ari e ose et eh D I LRL E ED p a LEE vii Chapter 1 Overview III IIIIIIII aora ranon oranana naraon 1 1 1 S
12. Changes 33 re lt banna an la ta AA a GG An 35 Reader s Comments o oo o oo sese se sese s ele aaan 37 www aerotech com lil Table of Contents ASR1200 Rotary Stage User s Manual iV www aerotech com ASR1200 Rotary Stage User s Manual List Of Figures List of Figures Figure 1 1 Figure 1 2 Figure 2 1 Figure 2 2 Figure 2 3 Figure 2 4 Figure 3 1 Figure 4 1 Figure 4 2 Figure 4 3 Figure 4 4 Figure 4 5 Figure 4 6 Figure 4 7 Figure 4 8 Figure 4 9 Figure 4 10 ASR1200 Rotary Stage e eese sese sees esee eere stesse seen el 1 ASR1200 Dirmensloris aaa aa Bar AUN nG Pa GAGA ED kenn c uA Kha kda BE HUA Nana 5 ASR1200 Stage Showing Mounting Plate Top View 2 eee eee e eee e eee 11 ASR1200 Stage Without Mounting Plate Bottom View sese 11 Installation of Collet into Collet Nut RR nnns 14 Installation Procedure for Collet Collet Nut 15 ASR1200 Wet Cut Rotary Union Location 20 Ringseal Removal and Replacement esee serra 23 Typical Ringseal 22 ll aa 24 Cross Section View of Ringseal Showing O Ring aaa 24 Cross Section View of Wet Cut Rotary Union Assembly 25 Rotary Union Hardware Removal 2 2 2 0 aaa 26 Seal Installation 2 20 0 aaan cece cc ccccc cece aa 26 Seal Retainer Assembly aaa 27 Wet Cut Rotary Union Shaft Inspection 27 Wet Cut Rotary Union
13. If the rotary union shaft becomes scratched or damaged it will be necessary for the rotary union to be replaced in order to properly seal the system Figure 4 9 shows a view of the rotary union assembly The pro cedure for replacement is as follows DANGER Figure 4 9 Wet Cut Rotary Union 1 Remove power and disconnect water from the stage 2 Remove waterinlet fitting and rotary union cover see Section 4 3 3 for the removal procedure Www aerotech com Chapter 4 29 Maintenance ASR1200 Rotary Stage User s Manual 3 Remove shoulder bolt and bushing see Figure 4 10 4 Using two 19 mm wrenches one on rotary union shaft nut the other on ASR 1200 shaft flats coming in from the top of the carriage unscrew the rotary union from ASR 1200 shaft see Figure 4 10 KO Wrench on Rotary Union Nut Figure 4 10 Wet Cut Rotary Union Installation Install a new rotary union assembly by attaching to rear of ASR1200 Tighten to 10 ft Ibs Tighten shoulder bolt and bushing Attach the rotary union cover and water fitting Dx NDA Restore powerto the stage 30 Chapter 4 www aerotech com ASR1200 Rotary Stage User s Manual Warranty and Field Service Appendix A Warranty and Field Service Aerotech Inc warrants its products to be free from defects caused by faulty mate rials or poor workmanship for a minimum period of one year from date of shipment from Aerotech Aerotech s liability is limited to replacing repair
14. a collet first clean the collet housing collet nut threads collet nut and new collet Ace tone or isopropyl alcohol may be used to clean the metal components A small amount of any general pur pose high viscosity grease can be applied to collet taper to help reduce friction and decrease wear 5 Noting the orientation of the spot drill on the back side of the collet nut refer to the instructions in Figure 2 3to install the collet 6 Guide the collet using the nut into the stage Figure 2 4 making sure that the collet seats properly in its taper Be sure that air pressure is still being supplied to the stage so the collet chuck is in the open posi tion 7 Tighten the collet nut Tightening by hand is sufficient as the clamping force is not determined by the torque of the nut but by the force of intemal springs Spanner wrenches may be used if desired Restore powerto the stage Forremoval of a collet from the collet nut apply pressure to the front of the collet while tilting it towards the spot drill www aerotech com Chapter 2 13 Installation ASR1200 Rotary Stage User s Manual Spot Drill Collet Collet Nut 3 When engaged in the groove tilt the collet away from the spot drill while applying pressure in the direction indicated The collet will snap into place Figure 2 3 Installation of Collet into Collet Nut 14 Chapter 2 www aerotech com ASR1200 Rotary Stage User s Manual Installation Collet Hous
15. al 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 examination the buyer shall be notified of the repair cost At such Returned Product time the buyer must issue a valid purchase order to cover the cost of the repair and Non warranty Deter freight or authorize the product s to be shipped back as is at the buyer s mination expense Failure to obtain a purchase order number or approval within 30 days of notification will result in the product s being returned as is at the buyer s expense Repair work is warranted for 90 days from date of shipment Rep
16. bers contain information necessary for maintaining or updating system hardware and software Locate this label and record the infor mation for later reference Improper stage handling could adversely affect the stage s performance Use care when moving the stage Manually lifting or transporting the stage can result in injury WARNING Do not allow the stage to drop onto any surface WARNING www aerotech com Chapter 2 9 Installation ASR1200 Rotary 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 ASR1200 stage When a stage is mounted to a non flat surface the stage can be dis torted as the mounting screws are tightened This distortion will decrease the overall accuracy of the stage Adjustments to the mounting surface must be done before the stage is secured NOTE To maintain accuracy the mounting surface should be flat within 1 um per 50 mm 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 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 ASR1200 Rotary Stage User s Manual Installation 2 3 Secur
17. correct material size is clamped the accuracy of the collet could be com promised Never clamp material or tools that are larger than the specified range It is also important to have the material or tool inserted at least 2 3 the length of the collet bore Any less than this could cause per manent deformation of the collet and reduce accuracy see Section 2 5 1 for collet installation 12 Chapter 2 www aerotech com ASR1200 Rotary Stage User s Manual Installation 2 5 Changing ASR Workholding Devices ASR1200 stages are equipped with an ER 16 style collet It is important that only the collets designed for a particular collet holder are used Aerotech collet chucks are designed for use with ER collets manufactured to DIN6499 specifications Aerotech recommends the use of ultra precision electroplated collets only Contact the factory for more details NOTE Various grip diameters are commonly available and can be interchanged following the collet removal and installation procedure detailed in Section 2 5 1 2 5 1 Collet Installation and Removal Procedure To minimize the possibility of bodily injury confirm that all electrical power is disconnected prior to making any mechanical adjustments DANGER 1 2 3 4 Before any collet change operation remove power to the stage Apply air pressure to loosen the collet chuck Unscrew the collet nut If necessary use a spanner wrench available from Aerotech For installation of
18. coupled with smooth motion There are no brushes to wear no belts to tension and no gears to wear resulting in a completely maintenance free motor The ASR1200 is designed with an ER16 style collet chuck The maximum tube diameter supported by the ER16 collet chuck is 5 8 mm The collet is retained with a threaded collet nut enabling quick changeover It is configured in a fail safe normally closed mode where full clamping force is applied when no air pressure is present NOTE Aerotech recommends using electro polished collets manufactured to DIN6499 specs 1 1 2 Wet Cut The ASR1200 rotary stage has a standard wet cut rotary union that is used for fluid delivery 100 psi max pressure in wet laser cutting applications A 1 4 NPT tapped hole is supplied on the rear of the rotary to allow for connections of different length pressure vessels depending on the tube length being cut See Sec tion 3 4 Section 4 3 3 and Section 4 4 for details regarding use and maintenance of the wet cut rotary union NOTE The purchase of a ringseal will also be required based on the tube diameter used in the cutting application Consult Aerotech for more information 2 Chapter 1 www aerotech com ASR1200 Rotary Stage User s Manual Overview 1 2 Optional Features 1 2 1 Mounting Plate ASR1200 stages can be configured to include a mounting plate that can use either M6 or 1 4 20 bolts The bot tom of this mounting plate is precision machined and
19. ectly if part load requirement exceeds specifications ASR1200 stages will contain a rotary union attached to the end of the rotary shaft as pictured below in Fig ure 3 1 A 1 4 NPT tapped hole is provided on the end of the rotary union shaft to allow for connecting a pres sure vessel or extension tube To prevent damage or performance degradation of the stage the unsupported length and weight of the attached pressure vessel is limited NOTE Aerotech recommends the following limitations on the size and weight of an unsupported pressure vessel Length past end of rotary union L z250 mm Moment about end of rotary union M 1 0 N m If these limits are exceeded it is recommended that an external steady rest or support be implemented Figure 3 1 ASR1200 Wet Cut Rotary Union Location 20 Chapter 3 www aerotech com ASR1200 Rotary Stage User s Manual Maintenance Chapter 4 Maintenance This chapter will cover information about component replacement intervals between lubrications detail the lubrication and inspection process and cover which lubricants are recommended for use To minimize the possibility of bodily injury confirm that all electrical power is disconnected prior to making any mechanical adjustments DANGER Although the ASR1200 is designed to be low maintenance there are a few items that may require pre ventative maintenance during the lifetime of the stage This chapter will detail the lubrication inspection
20. gned with a collet chuck that can support ER 16 collets manufactured to DIN6499 specs to allow for a wide range of materials and applications This product is intended for light industrial manufacturing or laboratory use This chapter introduces standard and optional features of the ASR1200 explains the model numbering sys tem and gives general safety precautions Figure 1 1 shows atypical ASR1200 Figure 1 1 ASR1200 Rotary Stage NOTE Aerotech continually improves its product offerings and listed options may be superseded at any time Refer to the most recent edition of the Aerotech Motion Control Product Guide for the most current product information at www aerotech com NOTE This manual should be read in its entirety before operating the ASR 1200 system Failure to follow the maintenance procedures outlined in Section 4 3 3 will result in voiding of warranty www aerotech com Chapter 1 1 Overview ASR1200 Rotary Stage User s Manual 1 1 Standard Features 1 1 1 Rotary Axis ASR1200 stages come standard with a direct drive brushless motor with a non contacting integral rotary union These features combine to create a low friction low maintenance rotary stage capable of high accel erations and low positioning error With a non contact rotary union there are no seals to be replaced or lubri cated allowing for a lifetime of maintenance free performance The brushless slotless motor design allows for extremely high torque
21. housing using care not to damage the sealing surfaces see Figure 4 7 Inspect the shaft and seal surface for scratches or nicks see Figure 4 8 Small wear marks are normal If the shaft and sealing surface are undamaged clean both the shaft and seal assembly surfaces with a lint free rag and isopropyl alcohol If the shaft sealing surface is scratched you can feel it with your fingernail contact Aerotech customer service If advised to remove the rotary union see Section 4 4 for instructions Seal Retainer Sealing Surface O Ring Figure 4 7 Seal Retainer Assembly Inspect the Shaft Sealing Surface for scratches Apply Parker O Lube before reattaching the seal Figure 4 8 Wet Cut Rotary Union Shaft Inspection www aerotech com Chapter 4 27 Maintenance ASR1200 Rotary Stage User s Manual Lubricate the new seal with a generous amount of Parker O Lube and press it uniformly into its housing Reattach the seal retainer to the end cap and tighten all screws in a cross pattern 9 Apply Parker O Lube to the exposed end of the rotary union shaft shown in Figure 4 8 10 Press the seal assembly back over the rotary union shaft Use care so that damage does not occur to the newly installed seal 11 Tighten the seal assembly screws and reattach the cover and fitting 12 Restore power to the stage 28 Chapter 4 www aerotech com ASR1200 Rotary Stage User s Manual Maintenance 4 4 Wet Cut Rotary Union Removal
22. il a trend devel ops for the application Longer or shorter intervals might be required to maintain a film of lubricant on the collet taper Every time you remove a collet you should clean inspect and grease the collet and chuck inter face surfaces 22 Chapter 4 www aerotech com ASR1200 Rotary Stage User s Manual Maintenance 4 3 Seal Replacement 4 3 1 Piston Seal Change Procedure The collet chuck on the ASR1200 is equipped with o ring piston seals that are designed to last many collet chuck open close cycles However due to regular wear the seals may require replacement during the life time of the product If trouble with the piston seals is suspected it is recommended that you contact Aero tech customer service The seals should only be replaced by a qualified Aerotech technician 4 3 2 Ringseal O Ring Replacement During the lifetime of the stage it may be necessary to change the ringseal o rings A typical ringseal insert is shown in Figure 4 2 Depending on the size the ringseal may be one or two pieces The ringseal screws into the center of the shaft from the front of the stage and is replaced by the following steps To minimize the possibility of bodily injury confirm that all electrical power is disconnected prior to making any mechanical adjustments DANGER Figure 4 1 Ringseal Removal and Replacement Www aerotech com Chapter 4 23 Maintenance ASR1200 Rotary Stage User s Manual Figure 4 2 Ty
23. ing vet vat EM es B ioie Figure 2 4 Installation Procedure for Collet Collet Nut WARNING Www aerotech com Chapter 2 15 Installation ASR1200 Rotary Stage User s Manual 2 6 Electrical Installation Aerotech motion control systems are adjusted at the factory for optimum performance The ASR 1200 series stage is part of a complete Aerotech motion control system Setup involves connecting the stage and motor combination to the appropriate drive chassis with the cables provided Connect the provided cables to the feedback and motor connectors on the stage Labels on the drive indicate the appropriate connections Refer to your drive manuals and documentation for additional installation and operation information In some cases if the system is uniquely configured a draw ing showing system interconnects is supplied Never connect or disconnect any electrical component or connecting cable while power is applied or serious damage may result WARNING Use only the cables provided by Aerotech as part of the complete motion control system WARNING 2 7 Air Requirements The air pressure supplied to the collet chuck is important in ensuring that the material or tool is released prop erly e If compressed air is used it must be filtered to 0 25 microns dry to 0 F dew point and oil free e If nitrogen is used it must be 99 99 pure and filtered to 0 25 microns The chuck becomes fully open at approximately
24. ing 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 physical abuse tampering such as opening the housing or removal of the serial tag or improper operation as determined by Aerotech This warranty is also voided for failure to comply with Aerotech s return procedures Claims for shipment damage evident or concealed must be filed with the carrier Return Procedure by the buyer Aerotech must be notified within 30 days of shipment of incorrect materials No product may be returned whether in warranty or out of warranty with out first obtaining approv
25. ing the Stage to the Mounting Surface If a mounting plate is included on the stage mount using Qty 4 M6 or 1 4 20 bolts refer to Figure 2 1 If the stage is configured without a mounting plate use the Qty 4 M6 tapped holes on the bottom of the stage to attach an alternative means of mounting see Figure 2 2 The stage must be mounted securely Improper mounting can result in injury and damage to the equipment WARNING MP STET Mounting Plate BE alang Mounting Holes O O Figure 2 1 ASR1200 Stage Showing Mounting Plate Top View Qty 4 M6 Tapped Holes No MP Moutning Plate Option Figure 2 2 ASR1200 Stage Without Mounting Plate Bottom View www aerotech com Chapter 2 11 Installation ASR1200 Rotary Stage User s Manual 2 4 Attaching the Payload to the Stage To prevent damage to the stage or parts test the operation of the stage before any material is held in the col let Proceed with the electrical installation and test the motion control system To operate the collet clean compressed air or nitrogen must be supplied to the stage see Section 2 7 The one touch air inlet fitting accepts 4 mm or 5 32 OD plastic air line Once air is supplied material of the appropriate size can be placed in the collet All collets supplied by Aero tech are clearly labeled with their clamping size range and collet style Be sure to use only the correct size material in the collet If an in
26. l shock and bodily injury or death when any electrical circuit is in use ensure that no person comes in contact with the circuitry when the stage is connected to a power source To minimize the possibility of bodily injury or death disconnect all electrical power prior to making any mechanical adjustments Moving parts of the stage can cause crushing or shearing injuries All personnel must remain clear of any moving parts Improper use of the stage can cause damage shock injury or death Read and understand this manual before operating the stage If the stage is used in a manner not specified by the manufacturer the protection provided by the stage can be impaired Stage cables can pose a tripping hazard Securely mount and position all stage cables to avoid potential hazards Chapter 1 www aerotech com ASR1200 Rotary 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 app
27. lacement 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 31 Warranty and Field Service On site Warranty Repair On site Non warranty 32 Repair Company Address ASR1200 Rotary Stage User s Manual If an Aerotech product cannot be made functional by telephone assistance or by sending and having the customer install replacement parts and cannot be returned to the Aerotech service center for repair and if Aerotech determines the problem could be warranty related then the following policy applies Aerotech will provide an on site field service representative in a reasonable amount of time provided that the customer issues a valid purchase order to Aerotech cov ering all transportation and subsistence costs For warranty field repairs the cus tomer will not be charged for the cost of labor and material If service is rendered at times other than normal work periods then special service rates apply If during the on site repair it is determined the problem is not warranty related then the terms and conditions stated in the following On Site Non Warranty Repair section apply If any Aerotech product cannot be made functional by telephone as
28. lications 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 www aerotech com Chapter 1 7 Overview ASR1200 Rotary Stage User s Manual 1 6 EC Declaration of Incorporation Manufactorer Aerotech Inc 101 Zeta Drive Pittsburgh PA 15238 USA AEROTECH xv herewith declares that the product Aerotech Inc ASR1200 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 Rep
29. ower is disconnected prior to making any mechanical adjustments DANGER The wet cut rotary union seal should be replaced and relubricated at a minimum of every 1000 hours of stage operation For heavy use or three shift operation this cor responds to replacement every month For lighter use or single shift operation this corresponds to replacement every three months Failure to do so will void the stage DANGER warranty Rotary Housing Rotary Union Shaft Figure 4 4 Cross Section View of Wet Cut Rotary Union Assembly www aerotech com Chapter 4 25 Maintenance ASR1200 Rotary Stage User s Manual 1 Remove power and disconnect water from the stage 2 Toaccess the rotary union seal assembly first remove the water inlet fitting see Figure 4 5 Rotary Union Cover Mounting Hardware Qty 4 Water Inlet Fitting Rotary Union Cover Seal Assembly Mounting Hardware Qty 6 Figure 4 5 Rotary Union Hardware Removal 3 Removethe six seal assembly screws from the rear end of the rotary union see Figure 4 5 4 Carefully pull the seal assembly off of the stage Figure 4 6 shows an exploded view of the seal assembly Seal Retainer Mounting Screws Qty 4 m Figure 4 6 Seal Installation 26 Chapter 4 www aerotech com ASR1200 Rotary Stage User s Manual Maintenance 5 Removethe four seal retainer screws and remove the seal retainer The seal will now be exposed 6 Pry the rotary seal from its
30. pical Ringseal Remove power to the stage 2 Openthe collet chuck Since the collet holder is in the normally closed position this will require air pres sure supplied to the air inlet 3 Once the collet has been released unscrew the collet nut as shown in Figure 4 1 If necessary use a spanner wrench available from Aerotech 4 With the collet and collet nut removed the ringseal will now be exposed Unscrew the ringseal from the shaft 5 Remove the damaged or worn o ring and replace it with a properly sized and lubricated new o ring as shown in Figure 4 3 A long pick or thin screwdriver will be necessary to remove the o ring and replace it Contact Aerotech for the appropriate o ring size and type Re insert the ringseal into the inner collet housing and tighten it into position 7 Replace collet and collet nut Seal Retainer Figure 4 3 Cross Section View of Ringseal Showing O Ring 24 Chapter 4 www aerotech com ASR1200 Rotary Stage User s Manual Maintenance 4 3 3 Wet Cut Rotary Union Seal Replacement There is a rotary seal in the wet cut rotary union that requires periodic replacement Aerotech recommends replacing this seal before 1000 hours of stage run time Contact Aerotech for obtaining appropriate replace ment seals Figure 4 4 shows a cross section of the rotary union assembly The procedure for seal replace ment is as follows To minimize the possibility of bodily injury confirm that all electrical p
31. quired Failure to lubricate and clean the collet interface surfaces will cause premature failure and wear that can void the warranty WARNING Before inserting any collet into the chuck clean the chuck taper and the collet with acetone or isopropyl alco hol with a lint free cloth a rag If necessary you can use compressed airto clean out the collet grooves Inspect the collet and the chuck interface surfaces to confirm that no marks are present If wear or fret marks copper colored oxide marks are present you can lightly polish the taper with a fine grit crocus cloth You should clean the surface without removing an excessive amount of material If the wear marks are large or excessive polishing is required to remove these marks the taper and the collet might need to be replaced Contact Aerotech customer service for more information After inspection and cleaning grease the chuck taper and collet taper with a small amount of lubricant and insert the collet Table 4 1 shows the lubricants recommended by Aerotech Table 4 1 Recommended Lubricants Vender Product items Description Henkel Technologies 80209 Silver Grade Anti Seize Henkel Technologies 51168 Food Grade Anti Seize Jet Lube White Knight 16404 Food Grade Anti Seize Lubricant inspection and replenishment depends on conditions such as collet chuck duty cycle and the sur rounding environment An inspection interval of once every eight hours is recommended unt
32. r 1 www aerotech com ASR1200 Rotary Stage User s Manual Overview 1 4 Dimensions 5 Max Stroke Collet Chuck Interchangeable Ringseal Insert P5 8 Max Tube Size Wrench Flats 7 1 Thru Slot Stage Mounting Holes For M6 OR 1 4 20 SHCS Motor and Feedback Pigtails 406 0 Long otor Feedback Fittings ER 16 Collet Chuck 14 0 55 Shaft Thru Hole Extra Height Required for Cable Bend Radius 6MM One Touch Water Connection One Touch Air Inlet For 4MM or 5 32 Tube 241 1 4 NPT For Extension Tube or Cap 4X M6 X 10 Deep Mtg 54 Holes Used when mtg With Mtg Without Mtg plate is removed Plate Option Plate Option DIMENSIONS MILLIMETERS Figure 1 2 ASR1200 Dimensions Www aerotech com Chapter 1 5 Overview ASR1200 Rotary Stage User s Manual 1 5 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 electrica
33. resentative Manfred Besold Address Name Position Location Date AEROTECH GmbH S d West Park 90 D 90449 N mberg Alex Weibel by Neho tb Engineer Verifying Compliance Pittsburgh PA February 21 2011 Chapter 1 www aerotech com ASR1200 Rotary Stage User s Manual Installation Chapter 2 Installation This chapter describes the installation procedure for the ASR 1200 stage including handling the stage prop erly preparing the mounting surface to accept the stage securing the stage to the mounting surface attach ing the payload and making the electrical connections Installation must follow the instructions in this chapter Failure to follow these instructions could result in injury and damage to the equipment WARNING 2 1 Unpacking and Handling the Stage Carefully remove the stage from the protective shipping container Use compressed nitrogen or clean dry air to remove any dust or debris that has collected during shipping f any damage has occurred during shipping report it immediately Before operating the stage it is important to let the stage stabilize at room temperature for at least 12 hours Allowing the stage to stabilize to room temperature will ensure that all of the alignments preloads and tol erances are the same as they were when tested at Aerotech Set the stage on a smooth flat and clean sur face Each stage has a label listing the system part number and serial number These num
34. sistance 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 ASR1200 Rotary Stage User s Manual Technical Changes Appendix B Technical Changes Table B 1 Current Changes 1 03 00 Section s Affected General Information Section 1 6 Section added Section 3 1 Section added Chapter 2 Installation Section 2 1 Section 2 3 Sec Safety information and warnings added tion 2 6 and Section 1 5 Section 3 3 Motor specifications added www aerotech com Appendix B 33 Technical Changes ASR1200 Rotary Stage User s Manual Table B 2 Archived Changes Section s Revision Affected General Information 1 01 00 Section 2 8 Wet Cut Fluid Requirements section added 1 01 00 Section 1 4 Dimensions section added 1 02 00 Section 4 2 1 Collet cleaning and lubrication procedure updated 34 Appendix B www aerotech com Index ASR1200 Rotary Stage User s Manual Index E A Electrical Installation
35. tandard Features e e eR RR RR RR RR RR ere e elei 2 1 1 4 Rotary AXIS napana ama daka toI bol Bada iier Deen AL pad lec DU mapa 2 1 1 2 Wet QUE c une 5 4 naaa Ibn ANAL ALY e a a a ai ra ROEL ADRIAN 2 1 2 Optional Features 222 0 0 c cece ccccccceccecececeececeeeeeceeeeeceeeeeeeeeeeees 3 1 2 1 Mounting Plate esI RR essem rl lisse nelli 3 122 WIEC RERO 3 1 2 3 Electronics Controller 0020000000 0000000000000000 cece oaaao aidaa aa aaan 3 ABA II 4E 3 1 3 Model Numbers 2 222 s IIIIIIllllllllLLLmllll222222LLmll l22222 4 1 4 Dimensions aan den eel lel le erm ote na Ph Dat Glande ee I Pcdei Dok ene NYA 5 1 5 Safety Procedures and Warnings 2 22 00 lessen nlll 6 1 6 EC Declaration of Incorporation 2 2 2 0 22222 c cece eee c cece cece eeeccceeccceeeeeeeeeees 8 Chapter 2 Installation 9 2 1 Unpacking and Handling the Stage c cece cece eee cece eeeeeseeeeeeees 9 2 2 Preparing the Mounting Surface 2222 20 00 sss ss sess n eli 10 2 3 Securing the Stage to the Mounting Surface 22 22 0 eee eee cece eee cece ceececeeeeeee 11 2 4 Attaching the Payload to the Stage cece cece eee c cece cece eeceeeeeeeeeees 12 2 5 Changing ASR Workholding Devices 22 000 ccc cece cece cece cece cece e Reese meer 13 2 5 1 Collet Installation and Removal Procedure
36. wing table Table 3 1 Environmental Specifications Ambient Operating 16 to 25 C 61 to 77 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 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 The ASR1200 stages have limited protection against dust but not water This equates to an sure ingress protection rating of IP50 Indoor use only Do not expose the stage to environments or conditions outside the specified range of oper ating environments Operation in conditions other than those specified can cause damage to the equipment WARNING 3 2 Accuracy and Temperature Effects Extreme temperature changes could cause a decrease in performance or permanent damage to
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