PCL65 Reference & Maintenance Manual
Contents
1. Direciono Moleni ai a 7 2 UNS OF MEI U G conrra N 7 5 Installation Preparations ccooncocncconcconocenanennnconnnonanenancnnnrnnarennrenanrnanrnanrnnanenanos 8 DIREA and AMO curia 8 DA GOMAMIMAUOM dt E E a A a icicuias 8 Do IOCIICA NO Sunat 9 6 Installing the PCL65 Positioning Stage ooccconccccncncicnnoccnnanccnnnnncnnannnnannnnnannos 10 6 1 Tools YOU Will Need oc ooonnncccconcncococconoconcnnconononnnnnncononnnnnnnonnnrnnnnnnrnnrrnnnrnnnnnnrnnnnnnrnncnnanens 10 62 UNPACKINO arreir e a a 10 6 3 Installing Motors on Ballscrew Stages oocccccccconnconccononccononononncnnnnononnnnnononnonnnononanennnos 10 6 31 ME Me Motor Mou IA dd 10 6 4 Mounting surface preparation occccccoconccconnncoconcnnoconnnnnnnonnnnononcnnonnannnnonannnnonancnnennananess 13 BS Moumtind the Sad eds 13 5 5 Electical Sonne cu ec 14 6 6 1 Hall Effect Commutation SEQUENCE ccccccoccnncccconccnncncnoncnnnnnonanconnnnnnnnnnnnnnnnnnrnnnnnnnanennnnss 15 637 O SO a od ee ad 16 ELA MOS a aa 17 6 8 Recommended System TeSt ccccccseeccccsceseececccceseeeeecsceseeeeesecsseeeenssceeeeseesecesereesees 17 7 Preventive Maintenance mina 17 TA ALUIDIC ATION a di a 17 71 1 BallSCrew LUDICO ii 18 22122 Linear QuidecLUDniCQuOn asc aaa A a 18 8 SCIVO RP dE O O aai 19 8 1 TROUDIESMOGOUING Hd ed b 19 a 19 PCLS gt 1 Overview Reference amp Maintenance Manual This user guide is designed to help you install and maintain you2. tighten the bolts at one end of the stage first and move towards the other end 4 Replace top cover if needed 13 PC L65 Reference amp Maintenance Manual 6 6 Electrical Connections Electrical connections to the stage differ by model configuration Each configuration includes the connector for the internal limit sensors Table 6 1 describes these connections The failsafe brake option B uses a 2 pin connector described in Table 6 2 The M2 motor encoder option pinout is described in Table 6 3 Table 6 1 PCL65 Limit Connector DSub 9 pins Mates with DSub 9 sockets Limit power 5 24VDC Limit signal ground Forward Limit Reverse Limit Home Not used Not used Not used Table 6 2 PCL65 Brake Option B Molex Mini Fit 2 position with sockets Mates with Molex 39 01 2021 Table 6 3 PCL65 Servo Motor Encoder M2 Canon circular connector size 20 shell 28 pins panel mount Function o O 14 PC L65 Reference amp Maintenance Manual Forward Limit Switch Reverse Limit Switch Signal Shield b HallA Hall B d Notused ao Hall C 6 6 1 Hall Effect Commutation Sequence In the event that user amplifier and controls are being implemented use the following motor commutation timing charts Positive Direction of Motion Figure 6 1 Motor commutation chart Positive Direction of Motion Figure 6 2 Timing diagram for the encoder signals 15 PC L65 Reference
3. 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 6 3 Installing Motors on Ballscrew Stages If the stage was ordered without a Primatics supplied motor or coupling the motor and coupling will have to be installed by the user 6 3 1 In Line Motor Mounting The following procedure is used to mount a NEMA23 motor on PCL65 stages 10 PC L65 Reference amp Maintenance Manual 1 Install the flexible coupling on the motor shaft 2 Slip the coupling over the ballscrew shaft and seat the motor in the motor pilot The coupling clamp bolt should be visible If the clamp bolt is not visible or the ballscrew shaft does not extend past the clamping bolt repeat Step 1 and slide the coupling forward or back Make sure the coupling is not compressed axially against the shoulder on the ballscrew when the motor is seated 3 Mount the motor to the stage with four fasteners Fully tighten all four fasteners 11 PC L65 Reference amp Maintenance Manual 4 Make sure the coupling is not compressed axially against the shoulder on the ballscrew when the motor is seated then fully tighten the coupling clamp screw The coupling should be fully tightened when the coupling is in its relaxed state 12 PC L65 Refe
4. PC L65 Reference amp Maintenance Manual primatics PCL65 Reference Maintenance Manual PC L65 Reference amp Maintenance Manual 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 PCL65 Manual Revision Information Revision Date Notes 3 27 14 Original Release 1 19 14 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 PCL65 Datasheet available from our website at www primatics com Copyright 2014 2015 by Primatics Inc All Rights Reserved Primatics the Primatics logo PrimaFlex PrimaSeal amp SimpleMatch are trademarks of Primatics Inc PC L65 Reference amp Maintenance Manual PCL65 Manual Revision Informati0N ooocconccoconcnncnonononancnnnnonanonanennnnonanenanenanens 2 2 Introduction About the PCL G5 iia 5 A a E E a E a 5 3 Personal Safety sssaaa yeceesescoeszcesassneresuseteeasesaneeesveeneeesesasessseres 6 A CONVENIOS is 7 A
5. amp Maintenance Manual 6 7 Limit Sensors Each PCL65 stage includes Forward and Reverse Limit sensors The limit sensors are optical slot switches which are more repeatable than magnetic or inductive versions Figure 6 3 shows the equivalent schematic for these switches 5 to 24 V DC Forward Limit Switch Reverse Limit Switch DECOM Figure 6 3 Equivalent Limit circuit schematic The forward and reverse limit sensors are factory set to give full advertised travel That is a PCL65 with 100mm of travel will travel at least 50mm in either direction from the center of travel before activating a limit sensor Each sensor is active from its activation point through the end of travel at the hard stop Figure 6 4 illustrates the limit sensor factory nominal default positions 100 200 300 400 600 hardstop contact trips 26mm 51mm 101mm 151mm 201mm 301mm Nominal travel Center of travel trips 2 mm 52mm 102mm 152mm 202mm 302mm contact hardstop Figure 6 4 Typical Limit Sensor Transition Ranges 16 PC L65 Reference amp Maintenance Manual 6 7 1 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 th
6. are assembled and tested at 20 C Any stage calibrations are also performed at 20 C For optimum accuracy the ambient temperature should be maintained at 20 C Deviations from this nominal temperature may result in degraded accuracy performance due to thermal expansion Humidity should be less than 85 and there should be no condensation in the environment in which the stage is used Ballscrew driven stages are susceptible to thermal expansion effects The ballscrew nut can create a localized thermal gradient if driven at high speeds amp duty cycles Care must be taken to limit the duty cycle of the motor to maintain highest stage performance 5 2 Contamination The PCL65 series is intended for clean environments free from small particulates and fluids Applications in dirty or dusty environments require the electrical optical and mechanical components to be protected Additional protection must also be used for stages that will be splashed with fluids Contact your local distributor or the factory for more information on this topic PC L65 Reference amp Maintenance Manual 5 3 Electrical Noise Electrical noise is the corruption of signals carried over low voltage wires Encoder signals can be corrupted resulting in sourious encoder counts thus causing the stage to drift Grounding shielding and spatial separation are all countermeasures to reduce the influences of electrical noise on performance You can minimize the potential for
7. bricate the ballscrew and linear bearings For low duty cycle applications it is recommended that the ballscrew and linear guides are re greased every 4 6 months or 500km of travel whichever comes first High duty cycle applications may require more frequent re lubrication Lubrication intervals depend on duty cycle load and ambient conditions Inspection of the drive train elements may be required to determine the proper lubrication interval ALWAYS DISCONNECT MOTOR POWER BEFORE RE LUBRICATING THE STAGE 17 PC L65 Reference amp Maintenance Manual 7 1 1 Ballscrew Lubrication The ballscrew should be re greased with NSK grease part GRS PS2 To gain access to the component to grease remove the stage top cover after power has been disconnected from the stage Push out the plastic plug from rear endplate and move the carriage towards the rear endplate The grease fitting for the ballscrew can now be accessed through the hole in the rear endplate Typical grease volume is up to 1 cm or until grease is seen extruding from the ballnut Cycle the stage back and forth to distribute the grease and then wipe off any excess Reinstall plastic plug and top cover 7 1 2 Linear Guide Lubrication The linear bearings should be re greased with Dynalube 520 To gain access to the linear guides remove the stage top cover after power has been disconnected from the stage On the end of each bearing block are two small grease holes where grease is
8. cifications are given in Newton meters Thrust specifications are given in Newtons The following table gives some common conversions into English units Metric Unit English Unit 1 Kilogram equals 0 0685 slug 1 micron equals 0 0000394 inch 1 millimeter equals 0 0394 inch 1 Newton meter equals 8 85 in lbs 1 Newton equals 0 2248 lbs 1 Kg has a weight of 2 205 lb when g 9 8 m s PC L65 Reference amp Maintenance Manual 5 Installation Preparations This section outlines installation environments Unfavorable installation conditions may cause electric shock fire or breakdown Certain breakdown situations or malfunctions in particular may lead to serious injury or other consequences Assure that the unit is used under the following installation conditions Indoors free from being splashed by water No corrosive or inflammable gases present Well ventilated place minimum level of dust or waste An environmental temperature range between 0 40 C and humidity between 20 80 RH location with no condensation Note These values show the range in which operation can be carried out safely but not the environmental range in which stage accuracy can be guaranteed Stage accuracy can only be guaranteed at 20 C 1 o Location should not be affected by electrical noise o Location should be where inspection and cleaning can be performed without difficulty SHOTS TO 5 1 Heat and Humidity All positioning stages
9. e carriage is in the normal operating range of travel both limit switches are open When the carriage encounters a limit the switch closes The switch will open again when the carriage is moved away from the switch 6 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 mis wired encoders can result in stage damage and personal injury Move the carriage 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 7 Preventive Maintenance Performing preventive maintenance procedures on your stage will extend its life and improve its long term performance The stage should be kept clean and a soft lint free cloth should be used wipe down the stage Do not use compressed air to spray away dust since this may force dust into crevices 7 1 Lubrication It is recommended to use only the following greases for lubricating the ballscrew and linear bearings Do not mix different greases as a chemical incompatibility may occur Primatics offers a grease kit that has all the necessary hardware to re lu
10. 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 PC L65 Reference amp Maintenance Manual 6 Installing the PCL65 Positioning Stage 6 1 Tools you will need The hex wrenches and fasteners listed below are required to install the PCL65 M sizes refer to Metric sizes and fractions refer to English sizes In reference to screw sizes the second dimension given refers to the length of the screw thread in mm For example M4 x 16 would require an M4 screw that is 16 mm long The term BHSC refers to Button Head Socket Screws Hex Wrench Sizes Stage Base Coupling Top Cover gs 4mm 2 5mm Screw Sizes M5 M5 x 18 SHCS length is M3 x 6 M5 x 12 SHCS minimum payload BHCS dependant 6 2 Unpacking Carefully remove the stage from its shipping crate and inspect it for evidence of shipping damage Report any damage immediately to your authorized dealer Improper handling of the stage may degrade its performance Follow these guidelines when handling and mounting your stage 1 Do not drop the stage onto its mounting surface Place the stage gently on the mounting surface Impact loads can cause high spots on mounting surfaces misalignment of drive components and warping of the base 2 Do nat drill holes into the stage
11. he places in the workcell where pinch points occur and provide adequate safety clearance or safety curtain Never operate the motor in a location that could be splashed by water exposed to corrosive or flammable gases or is near combustible substances since this may cause an electric shock fire or malfunction Never touch the motor driver or peripheral devices when the power is on or immediately after the power is turned off The high temperature of these parts may cause burns PC L65 Reference amp Maintenance Manual 4 Conventions 4 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 signifies 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 stage Figure 4 1 illustrates this convention DIRECTION DIRECTION OF INCREASING ENCODER COUNTS FORWARD LIMIT REVERSE LIMIT Figure 4 1 Positive direction convention 4 2 Units of Measure Primatics uses the metric system for all specifications and dimensions All linear dimensions are specified in millimeters Accuracy repeatability resolution flatness and straightness for the PCL65 are specified in microns Load capacity is specified in kilograms and moment capacity is given in Newton meters All torque spe
12. injected using a syringe see Figure 8 1 Typical grease volume is up to 0 03 cm per hole 0 06 per bearing block or until grease is seen extruding from the sides of the bearing block Cycle the stage back and forth to distribute the grease and then wipe off any excess Reinstall the top cover Figure 7 1 Bearing block lubrication ports 18 PCL6S gt Reference amp Maintenance Manual 8 Service 8 1 Troubleshooting Help For further assistance contact the factory M F 8AM to 5PM Pacific Time 541 791 9678 541 791 9410 Toll Free 888 754 3111 E mail service primatics com 8 2 Service Should your device require factory service contact the factory for a Return Materials Authorization RMA When inquiring about an RMA please have the following information available O O O O Your contact information name phone email address Unit Serial Number Symptom of problem History of troubleshooting steps already taken at ane Figure 8 1 Unit Serial Number Location 19
13. or this purpose Feature Summary Travels of 50 100 200 300 400 and 600mm Low profile XY stack is only 130mm tall Precision ground ballscrew drive train with 5mm lead or optional 10mm lead Quiet operation NEMA 23 in line mount Optional 1 4 or 3 8 bore couplings available Optional NEMA 23 brushless motor w 4000 line encoder available Precision performance for a low price PCL65_ gt Reference amp Maintenance Manual 3 Personal Safety Please review before installing your positioning stage Observe common industrial safety practices when installing and operating automated equipment O Have power connections made by qualified personnel Keep fingers and other items out of any opening in the stage while it is in operation since injury or damage may result Provide a safe access route and adequate room for servicing Perform the recommended periodic maintenance described in this document Verify that the work envelope is free of obstructions before the positioning stage is powered Insure that you have the feedback wired properly to the controller before applying power to the positioning stage Improper feedback connections can cause a motor run away condition that has the potential to damage the stage and injure an operator Only trained operators of the positioning stage should be allowed near the work environment If so equipped identify emergency stop circuits and actuators in the workcell Note t
14. r PCL65 Series linear positioning stage application Follow these steps to ensure correct stage installation and maximum stage life Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Review this entire user manual Become familiar with all installation procedures prior to integrating your system Review the safety summary to develop an understanding of standard safety practices when installing and operating automated equipment Familiarize yourself with the conventions summary Review installation procedures For best results follow these procedures carefully Once you successfully complete all the installation procedures you will be ready to install and operate your stage Review preventive maintenance section for proper lubrication schedule PC L65 Reference amp Maintenance Manual 2 Introduction About the PCL65 The PCL65 is a low profile linear positioning stage with a precision ground ballscrew drive train The overall height is 65mm at the carriage Two PCL65 s can be directly XY stacked for an overall height of just 130mm It is offered with travels of 50 100 200 300 400 and 600mm and can be ordered with or without a NEMA 23 servo motor The PCL65 includes fixed forward and reverse limit sensors for end of travel High stiffness and rigidity at low weight are achieved using an AL6061 T6 aluminum base The PCL65 can also be used with 3 party drives and controls Several cable assemblies are available f
15. rence amp Maintenance Manual 6 4 Mounting surface preparation The characteristics of the surface to which the positioning stage is mounted will have a large effect on system performance An accurate and flat positioning stage will conform to the shape of the mounting surface therefore a flat mounting surface is required The flatness and straightness specifications can be affected under large loads For best results in maintaining stage specifications we suggest the following guidelines 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 6 5 Mounting the Stage 1 Remove top cover if needed 2 Insert mounting screws in counterbores circled below Move the carriage by hand to gain access to all the counterbores gt AAA oe O 0 3 Tighten Screws When mounting the base down to the surface plate
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