ATS125 Series Stage User`s Manual
Contents
1. 2 1 1 1 Optional 2 2 2 2 2 3 1 1 2 Model Numbers 4 1 2 Safety Procedures and Warnings 6 1 3 EC Declaration of Incorporation 8 Chapter 2 2 22222 0 22 9 2 1 Unpacking and Handling the Stage 9 2 2 Preparing the Mounting Surface 10 2 3 Securing the Stage to the Mounting 11 2 4 Attaching the Payload to the Stage 12 2 5 Electrical Installation _____ 13 2 5 1 Standard Aerotech Motor options 13 2 5 2 Motor Foldback Options 15 2 5 3 Optical Limit 4 8 15 Chapter 3 Ope2. 32 4 2 1 Recommended Lubricants and Cleaning Solvents 32 4 2 2 Important Notes on Lubrication 32 4 3 Lubrication and Cleaning Process 33 4 4 Belt Adjustment Foldback Motor Option 34 Appendix A Warranty and Field 35 Appendix B Technical 37 RENCONTRE RR or RR RERO RR EM 39 Reader s Comments 0 00000000000000 40 www aerotech com ill Table of Contents 5125 Series Stage User s Manual www aerotech com ATS125 Series Stage User s Manual List Of Figures List of Figures Figure 1 1 Figure 1 2 Figure 1 3 Figure 2 1 Figure 2 2 Figure 2 3 Figure 3 1 Figure 3 2 Figure 3 3 Figure 3 4 Figure 3 5 Figure 3 6 Figure 3 7 Figure 3 8 Figure 3 9 Figure 4 1 Figure 4 2 Typical ALS2500 Series Linear Positioning Stage 1 ATS125 with Cutaway View of Ballscrew 2 Two XZ and Three XYZ Axis Positioning Systems using ATS125 stages 3 Results of Flat V
3. Installation ATS125 Series Stage User s Manual 2 2 Preparing the Mounting Surface The mounting surface should be flat and have adequate stiffness in order to achieve the maximum per formance from the ATS125 When an ATS125 series stage is mounted to a non flat surface the stage can be distorted as the mounting screws are tightened This distortion will decrease the overall accuracy of the stage To maintain accuracy the mounting surface should be flat within per 50mm Adjustments to the mounting surface must be done before the stage is secured The effects of flatness on mounting are illus trated in Figure 2 1 Mounting to a flat surface Mounting to a curved surface exaggerated Figure 2 1 Results of Flat Versus Non Flat Mounting NOTE The stage base is precision machined and verified for flatness prior to stage assembly at the fac tory If machining is required to achieve the desired flatness it should be performed on the mounting 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 ATS125 Series Stage User s Manual Installation 2 3 Securing the Stage to the Mounting Surface If necessary manually move the stage table to access the 6 5 mm 0 28 in diameter mounting holes along the edges of the stage refer to Figure 2 2 Install the appropriately sized mounting screws M6 or
4. 1 4 through the mounting holes and secure the stage to the mounting surface Repeat this process for each set of mounting holes The stage must be mounted securely Improper mounting can result in injury and damage to the equipment WARNING NOTE The stage table may offer a considerable amount of resistance when it is moved manually This is especially true if the stage is fitted with a motor assembly NOTE If the stage is not connected to a power source and is not equipped with an optional brake it should be possible to move the stage table by hand with steady even pressure Do not attempt to manually move the stage if it is connected to a power source or includes an integrated brake Mounting Holes Stage Table Integral Motor Figure 2 2 view of an ATS125 Stage Showing Mounting Holes www aerotech com Chapter 2 11 Installation ATS125 Series Stage User s Manual 2 4 Attaching the Payload to the Stage To prevent damage to payloads test the operation of the stage before the payload is attached to the stage table Proceed with the electrical installation and test the motion control system in accordance with the sys tem documentation Document all results for future reference For information on electrical connections refer to Section 2 5 The payload should be flat rigid and comparable to the stage in quality NOTE For valid system performance the mounting interface should be flat within 1 um per 50 mm Re
5. 2 z z z z z Z Z z z z Z O O O O O O www aerotech com Chapter 1 7 Overview ATS125 Series Stage User s Manual 1 3 EC Declaration of Incorporation Manufactorer Aerotech Inc 101 Zeta Drive Pittsburgh PA 15238 USA AEROTECH herewith declares that the product Aerotech Inc ATS125 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 itis not allowed to put the equipment into service until the machinery into which it is to be incorporated or of which it is to be a component has been found and declared to be in conformity with the provisions of the Directive 2006 42 EC and with national implementing legislation i e as a whole including the equipment referred to in this Declaration Authorized Representative Manfred Besold Address Name Position Location Date AEROTECH GmbH S d West Park 90 D 90449 N mberg Alex Weibel bs Engineer Verifying Compl
6. belt power transfer system 2 5 3 Optical Limit Switches ATS125 stages are equipped with a pair of optical limit switches When the stage is ordered with an integral motor the limit switch wiring passes through the motor housing and is integrated into the motor wiring On models with the foldback option the limit switch wiring passes through the side of the stage and into a 9 pin D connector Referto Chapter 3 Operating Specifications for a description of limit switch operation and wir ing www aerotech com Chapter 2 15 Installation ATS125 Series Stage User s Manual 16 Chapter 2 www aerotech com ATS125 Series Stage User s Manual Operating Specifications Chapter 3 Operating Specifications The surrounding environment and operating conditions can affect the performance and service life of the stage This chapter provides information on ideal environmental and operating conditions Also included are instructions for estimating load and torque required to turn the ballscrew given various loadings 3 1 Environmental Specifications The environmental specifications for the ATS 125 are listed in the following table Table 3 1 Environmental Specifications Ambient Operating 10 to 35 C 50 to 95 F Temperature The optimal operating temperature is 20 C 2 C 68 F 4 F If at any time the operating tem perature deviates from 20 C degradation in performance could occur Contact Aerotech for information regarding you
7. cables Aero tech recommends that customers bake out vacuum systems when first installing them in the vacuum chamber Chapter 3 www aerotech com ATS125 Series Stage User s Manual Maintenance Chapter 4 Maintenance This chapter will cover information about intervals between lubrications detail the lubrication and inspection process and cover which lubricants are recommended for use Also included is a section on belt tension and adjustment on stages with the foldback option N OTE The bearing area must be kept free of foreign matter and moisture otherwise the performance and life expectancy of the stage will be reduced Always operate the stage with the hard cover and side seals in place to help keep dirt out To minimize the possibility of bodily injury confirm that all electrical power is disconnected prior to making any mechanical adjustments DANGER 4 1 Service and Inspection Schedule Lubricant inspection and replenishment in ATS125 series stages depends on conditions such as duty cycle speed and the environment An inspection interval of once per month is recommended until a trend develops for the application Longer or shorter intervals may be required to maintain the film of lubricant on the bearing surfaces In general it is recommended that stages operating in a clean environment be lubricated annually For stages operating under conditions involving excessive debris lubrication every six months is rec ommended
8. per revolution Typically used for home reference cycle MKR N Incremental encoder output either the compliment of Marker with a line driven TTL type encoder or 2 5 V DC bias level with amplified sine wave type encoder Sine Incremental encoder output either TTL line driven or amplified sign wave type signal SIN N Incremental encoder output Complement of sin MTR A Motor Phase A MTR B Motor Phase B MTR C Motor Phase C BRAKE Brake 24 VDC 250 mA BRAKE Brake 24 VDC Common www aerotech com Chapter 3 29 Operating Specifications ATS125 Series Stage User s Manual 3 7 Vacuum Operation Aerotech will prepare the ATS125 series stage for operation in vacuum environments Aerotech offers two vacuum preparation options one for low vacuum for use in atmospheric pressures to 10 3 torr and one for high vacuum preparation for environments from 10 3 to 10 6 torr As part of this preparation attention to detail during modification cleaning and assembly results in stages with optimal performance in vacuum applications This chapter will outline preparation techniques for stages that will operate in a vacuum Some techniques covered are Lubrication with vacuum compatible lubricants Use of materials fasteners and coatings with vacuum outgas performance compatible with the level of vacuum specified For high vacuum stages elimination of situations that may allow gases to become temporarily trapped during pump down Extensiv
9. ATS125 Series Stage User s Manual P N EDS101 Revision 1 02 00 Dedicated to the Science of Motion Aerotech Inc 101 Zeta Drive Pittsburgh PA 15238 Phone 412 963 7470 Fax 412 963 7459 www aerotech com Product Registration Technical Support Revision History Register online at http www aerotech com prodreg cfm United States Headquarters Phone 412 967 6440 Fax 412 967 6870 Email service aerotech com United Kingdom Phone 44 118 940 9400 Fax 44 118 940 9401 Email service aerotech co uk Germany Phone 49 911 967 9370 Fax 49 911 967 93720 Email service aerotechgmbh de Japan Phone 81 0 47 489 1741 Sales Phone 81 0 47 489 1742 Service Fax 81 0 47 489 1743 Email service aerotechkk com jp China Phone 852 3793 3488 Email saleschina aerotech com Revision 1 02 00 November 19 2010 Revision 1 01 00 February 11 2008 Revision 1 00 00 February 10 2008 Product names mentioned herein are used for identification purposes only and may be trademarks of their respective companies Aerotech Inc 2010 ATS125 Series Stage User s Manual Table of Contents Table of Contents Tableor Contents lt luu iii LiStiOf FIQUIOS ERR EE V Eist or Tables LRL vii Chapter 1 22 2 2 2 2 1 1 1 Standard Features
10. CW refer to the direction of motor rotation while looking into the shaft of the motor For ATS125 series stages a clockwise CW rotation of the motor causes the stage table to move away from the motor Counterclockwise CCW rotation of the motor causes the stage table to move toward the motor The exception is if an optional fold back option is used in which case the directions are reversed Www aerotech com Chapter 3 23 Operating Specifications ATS125 Series Stage User s Manual 3 5 2 Limit Switch Wiring Limit switches are open collector TTL compatible electro optical devices powered by 5 Volts that change output states when the stage approaches its maximum travel distance and breaks the light beam Since they are open collector devices they may be interfaced to 24V logic inputs Each limit switch is mounted ona small printed circuit board Standard ATS125 Stages include limit switch wiring integrated into one of the two main connectors but stages with the foldback option include a separate 9 pin limit switch connector detailed in Figure 3 5 24 VIO 5 25mA 24 GRN Common 24 WHT 24 ORN CW Limit Home Limit 24 GRY 24 BLU CCW Limit 9 Pin Male D DE 9P ECK137 Backshell 17 1724 2 ECK1021 Jacksockets ECK128 Figure 3 5 ATS125 Series 9 pin Limit Switch Wiring Foldback Equipped Stages Only Assuming a NC limit configuration the input to the controller is seen as a logic 0 typical 0 4
11. Limit Switch ATS125 series stages are provided with a pair of optical limit switch assemblies mounted to the bottom of the stage table The limit switches signal when the stage table has reached its maximum useable travel dis tance in both directions 3 5 1 Limit Switch Operation Each limit switch has a light source and detector mounted to a small printed circuit board Each limit switch board is mounted at the ends of the stage with their emitter detector axes perpendicular to the direction of table motion On a standard stage the clockwise CW switch is located at the end opposite the motor When movement of the stage table causes the blade mounted to the stage carriage to break the light beam from the emitter to the detector a CW or counterclockwise CCW limit signal is generated The limit switch itself can be configured as normally closed NC or normally open NO If the stage is driven approximately 2 0 revolutions 10mm beyond the electrical limit it will encounter a mechanical stop Although the operating speed of the stage may be relatively slow damage to the stage could result WARNING Mounting Holes LMG Guide Rails m 7v 2 0 5 2 2 2 gt unam m im t Ballscrew INC O o u O 7 Optical Limit Switch Stage Table Optical Limit Switch CCW Limit CW Limit Figure 3 4 Internal View of a Typical Stage Showing Limit Switches NOTE Theterms clockwise CW and counterclockwise C
12. Remove the four mounting screws for the foldback cover Check the tension in the belt described above to determine if adjustment is necessary If adjustment is required loosen but do not remove the four motor mounting screws as shown below by small angled arrows 5 As shown below the motor mounting holes are slotted to allow for belt adjustment With all four screws loose pull the motor away from the stage by hand until desirable belt tension is achieved 6 Tighten motor mounting screws and re check the tension in the belt Belt tension may change after the mounting screws are tightened so if necessary repeat step 5 until desired tension is reached 7 While adjusting tension it is advisable to verify that the pulleys are tight on their respective shafts Each pulley is held in position with two set screws If a pulley is loose it may be necessary to tighten one or both of these screws 8 Once tension adjustment is complete replace the foldback cover and mounting screws Restore power to the stage NOTE If the stage has been calibrated HALAR note the orientation of the two pulleys within regard to each other or recalibration might be required Figure 4 2 Belt Access and Adjustment on Foldback Models 34 Chapter 4 www aerotech com ATS125 Series 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 fault
13. The ballscrew end bearings and motor bearings are sealed and should not need to be relu bricated under normal use www aerotech com Chapter 4 31 Maintenance ATS125 Series Stage User s Manual 4 2 Cleaning and Lubrication 4 2 1 Recommended Lubricants and Cleaning Solvents For standard ballscrew assemblies and LMG guide rails NSK LGU grease is recommended If a solvent is necessary for cleaning the stage it is recommended that isopropyl rubbing alcohol be used Harsher solvents such as acetone may damage the plastic and rubber seals on the ballscrew or LMG trucks For high speed applications i e near maximum speed at a duty cycle of 5096 frequent ballscrew main tenance with standard lubricants is required 4 2 2 Important Notes on Lubrication When cleaning and or lubricating components of the ATS125 series stages Be sure to use a clean dry soft and lint free cloth for cleaning 2 Take the opportunity during the lubrication procedure to inspect the linear motion guides for any damage or signs of wear 3 Inapplications that have multiple stages bolted together to form multiaxis systems the orthogonality may be lost if the stage tables of the support stages are loosened Precision aligned stages should not be loosened or disassembled 4 Further disassembly of the stage is not recommended because proper assembly and calibration can only be done at the factory In addition a laser interferometer is required for post a
14. 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 ATS125 Series Stage User s Manual Overview Do not expose the stage to environments or conditions outside the specified range of oper ating environments Operation in conditions other than those specified can cause damage to the equipment The stage must be mounted securely Improper mounting can result in injury and damage to the equipment Use care when moving the stage Manually lifting or transporting stages can result in injury Only trained personnel should operate inspect and maintain the stage This stage is intended for light industrial manufacturing or laboratory use Use of the stage for unintended applications can result in injury and damage to the equipment Before using this stage perform an operator risk assessment to determine the needed safety requirements A A A A A A
15. V 12 8mA when no limit condition is present When the limit switch is activated a 5V source through a pull up resistor causes a logic 1 typically 4 8 5V to be seen by the controller input The limit switch operation for a NO limit configuration is the exact opposite as described above See Figure 3 6Figure 3 6 for a diagram of limit switch wiring NC 5V NO 5V Pull up resistor Pull up resistor Limit Input Limit Input to Controller to Controller NC Limit NO Limit Switch Swlten Figure 3 6 Normally Closed NC and Normally Open NO Limit Switch Wiring 24 Chapter 3 www aerotech com ATS125 Series Stage User s Manual Operating Specifications 3 6 Standard Motor Wiring Stages fitted with standard motors and encoders come from the factory completely wired and assembled For reference connector pin outputs and general wiring information is given in the following figures Pin outputs are defined in Table 3 5 NOTE Refertothe other documentation accompanying your Aerotech equipment Call your Aerotech rep resentative if there are any questions on system configuration NOTE If you are using your own cables to connect the stage ensure that the motor and ground wires can handle current higher than the continuous current listed in Table 3 4 The voltage rating of the wire insulation must be greater than the maximum bus voltage listed in Table 3 4 www aerotech com Chapter 3 25 Operating Specifications ATS125 Series Sta
16. ature of the ballscrew depends on the speed and duty cycle of the stage The faster the movement and higher the duty cycle the more the stage accuracy will be affected by heat www aerotech com Chapter 3 17 Operating Specifications ATS125 Series Stage User s Manual 3 3 Basic Specifications Basic ATS125 series positioning stage specifications are shown in Table 3 2 Resolution is dependent on ballscrew pitch encoder resolution and controller interpolation For all ATS125 series stages the ballscrew pitch is 5 mm per revolution To increase resolution with the amplified sine AS encoder the use of a con troller multiplier is required Table 1 2 shows resolutions available assuming a x4 controller multiplication Motor specifications are given in Table 3 4 Table 3 2 ATS125 Series Specifications S ERN MEE MEI mm EE M a Horizontal Load 45 5 kg 100 Ib Axialload Load 18 2 kg 40 Ib EI 4 2 kg 9 2 46kg 10 1 49kg 108 52kg 114 55kg 12 1 Ib Ib Ib Ib Ib Max Screw Speed 60 Bidirectional Repeat 0 um x 0 um m 0 um I 0 um apy Horizontal Load 45 5 kg 100 Ib Axial Load 18 2 kg 40 Ib Stage Weight 5 8kg 128 65kg 143 7 2kg 15 9 7 8 kg 17 2 Ib Ib Ib Ib All performance specifications based on precision mounting surface flat to within 002mm 300mm and are measured on a single axis basis Repeatability and accuracy include linearity correction and minimum thermal cha
17. crew by hand rather than simply push the stage manually This can be done by turning the motor coupling If the stage has an optional brake the stage cannot be moved by hand In this case restore power to the stage drive it to the desired position then remove power and con tinue to step 9 Be sure to use extreme caution while operating the stage temporarily without the hard cover installed Repeat steps 3 through 7 for any areas covered by the original table position Refasten the hardcover Restore power to the stage drive the stage table back to its original position to redistribute lubricants To minimize the possibility of bodily injury confirm that all electrical power is disconnected prior to making any mechanical adjustments DANGER Figure 4 1 Hardcover Removal Procedure www aerotech com Chapter 4 33 Maintenance ATS125 Series Stage User s Manual 4 4 Belt Adjustment Foldback Motor Option On foldback stages the motor torque is transferred to the ballscrew via a timing belt Belt tension is critical to stage performance and accuracy When lubricating and cleaning the stage it is recommended that belt tension be checked Deflection in the belt should be less than 5 mm when applying a downward force directly between the pulleys as shown by the large arrow of approximately 5 N If deflection exceeds this range the belt tension should be adjusted The method of adjustment is outlined below Remove power to the stage
18. del Numbers Stage model number example ATS125 050 TTM 5MM NC IM2500H 3 PLOTS The table below lists the available options in the order they appear in the example above Aerotech con tinually 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 4 Chapter 1 www aerotech com ATS125 Series Stage User s Manual Overview Table 1 1 Model Numbering System 3 8125147 8125 www aerotech com Chapter 1 5 Overview ATS125 Series Stage User s Manual 1 2 Safety Procedures and Warnings The following statements apply throughout this manual Failure to observe these precautions could result in serious injury to those performing the procedures and damage to the equipment This manual and any additional instructions included with the stage should be retained for the lifetime of the stage A DANGER gt DANGER gt DANGER gt DANGER WARNING WARNING WARNING To minimize the possibility of electrical shock and bodily injury or death disconnect all elec trical power prior to making any electrical connections To minimize the possibility of electrical shock and bodily injury or death when any electrical circuit is in use ensure that no person comes in contact with the circuitry when the stage is connected to a power source
19. e cleaning prior to assembly in a clean environment and packaging in a special polyethylene bag 3 7 1 Special Guidelines To ensure that the stage will continue to perform well in the vacuum environment follow the guidelines listed below in addition to standard handling installation and lubrication guidelines outlined earlier in this manual 30 Do not remove the stage from the sealed bag until it is ready for use Always handle the stage in a clean environment and use powder free polyethylene gloves to prevent any contaminants from adhering to the surface of the stage During installation use cleaned vented stainless steel fasteners when securing the stage Reduced air pressure eliminates significant convective heat transfer This coupled with the viscous vac uum compatible lubricants could result in excessive motor operating temperatures Because of this consider all continuous torque ratings to be 40 to 60 lower than the value specified for operation in nor mal atmospheric environment Reduce motor usage accordingly For vacuum applications the recommended lubricant is a small quantity of BraycoteW 602EF grease or a substitute of equal quality Aerotech does not bake out vacuum components Baking vacuum components between 100 and 125 C for 24 to 48 hours significantly reduces outgassing at initial pump down to vacuum pressure and evap orates water vapor that impregnates porous surfaces on the aluminum surfaces and Teflon
20. ech com Index ATS125 Series Stage User s Manual Index Multi axis combinations 3 multiaxis 5 32 A Attaching the 12 o AXIS LLL 3 operating conditions 17 Optical Limit Switch U 23 B Optical limit 2 ball screw Optional Features 3 temperature of 17 P C Preparing the Mounting Surface 10 cable uu RT 13 Cleaning 32 s clockwise CW switch 23 safety 6 counterclockwise CCW switch 23 Securing the Stage to the Mounting Surface 11 CW and CCWterminology 23 u 18 stage table 3 11 D Standard Features 2 Declaration 8 T E temperature 17 Electrical Installation 13 travel distance 1 Te ce eben te ede de 13 25 Environmental 17 U Unpacking and Handling
21. ed within 30 days of shipment of incorrect materials No product may be returned whether in warranty or out of warranty with out first obtaining approval from Aerotech No credit will be given nor repairs made for products returned without such approval Any returned product s must be accompanied by a return authorization number The return authorization number may be obtained by calling an Aerotech service center Products must be returned prepaid to an Aerotech service center no C O D or Collect Freight accepted The status of any product returned later than 30 days after the issuance of a return authorization number will be subject to review After Aerotech s examination warranty or out of warranty status will be deter Returned Product War mined If upon Aerotech s examination a warranted defect exists then the prod ranty Determination uct s will be repaired at no charge and shipped prepaid back to the buyer If the buyer desires an airfreight return the product s will be shipped collect Warranty repairs do not extend the original warranty period After Aerotech s 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 o
22. ersus Non Flat Mounting 10 Top view of an ATS125 Stage Showing Mounting Holes 11 Components of a Typical ATS125 14 Load Capability of ATS125 Series Stages 20 Stage Orientations for LVC and LSC 21 Torque Required to ATS125 Ballscrew with Various Loads 22 Internal View of a Typical Stage Showing Limit Switches 23 ATS125 Series 9 pin Limit Switch Wiring Foldback Equipped Stages Only 24 Normally Closed NC and Normally Open NO Limit Switch Wiring 24 Feedback Wiring for Standard ATS125 Stages with Integral 26 Motor Wiring Connector for all ATS125 Stages 27 Brake and Encoder Connector for Stages with Foldback 28 Hardcover Removal Procedure 33 Belt Access and Adjustment on Foldback Models 34 www aerotech com V List of Figures vi ATS125 Series Stage User s Manual www aerotech com ATS125 Series Stage User s Manual List o
23. es other than those provided by Aerotech you must connect pin A4 to a ground con nection WARNING 2 5 1 Standard Aerotech Motor options An integral motor BMS60 comes mounted to one end of the ATS125 stage Refer to Figure 2 3 Motor en coder combinations offered as standard with ATS 125 series have rear housings with integral cables These connecting ports convey motor power encoder feedback and limit switch signals to an appropriate hardware device e g axis controller or amplifier The electrical wiring from the motor encoder and limit switches to these connecting ports is contained within the rear motor housing and has been completed at the factory Refer to Chapter 3 Operating Specifications for standard motor wiring and connector pin outputs www aerotech com Chapter 2 13 Installation ATS125 Series Stage User s Manual ATS125 Series Stage Motor Limit Encoder Wiring y Integral BMS60 Motor Figure 2 3 Components of a Typical ATS125 Stage 14 Chapter 2 www aerotech com ATS125 Series Stage User s Manual Installation 2 5 2 Motor Foldback Options When the foldback option is chosen a motor with a standard NEMA 23 frame size may be used Either a 6 35mm 1 4 shaft or a 9 53mm 3 8 shaft size can be specified when ordering the stage The belt pulleys are attached to the motor shaft with two set screws See Figure 4 2 for an illustration showing the location of the set screws as well as the entire pulley and
24. f notification will result in the product s being returned as is at the buyer s expense Repair work is warranted for 90 days from date of shipment Replacement com ponents are warranted for one year from date of shipment At times the buyer may desire to expedite a repair Regardless of warranty orout Rush Service of warranty status the buyer must issue a valid purchase order to cover the added rush service cost Rush service is subject to Aerotech s approval www aerotech com Appendix A 35 Warranty and Field Service On site Warranty Repair On site Non warranty 36 Repair Company Address ATS125 Series Stage User s Manual If an Aerotech product cannot be made functional by telephone assistance or by sending and having the customer install replacement parts and cannot be returned to the Aerotech service center for repair and if Aerotech determines the problem could be warranty related then the following policy applies Aerotech will provide an on site field service representative in a reasonable amount of time provided that the customer issues a valid 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
25. f Tables List of Tables Table 1 1 Model Numbering System 5 Table 3 1 Environmental Specifications 17 Table 3 2 ATS125 Series Specifications 18 Table 3 3 ATS125 Series Resolution Information 18 Table 3 4 ATS125 Motor Specifications 19 Table 3 5 Motor Wiring Pinout Descriptions 29 Table B 1 Current Changes 1 02 00 37 Table B 2 Archived Changes 38 www aerotech com vii List of Tables ATS125 Series Stage User s Manual viii www aerotech com ATS125 Series Stage User s Manual Overview Chapter 1 Overview This manual describes Aerotech s ATS125 series of linear motor positioning stages Figure 1 1 shows a typ ical ATS125 positioning stage The ATS125 series stages have travel distances ranging from 50 to 600 mm The ATS 125 is Aerotech s smallest hard cover side sealed stage design The brushless integral motor option reduces the overall foot print of the stage enabling its use in space const
26. fer to Chapter 3 Operating Specifications for information on cantilevered loads and load positioning 12 Chapter 2 www aerotech com ATS125 Series Stage User s Manual Installation 2 5 Electrical Installation Electrical installation requirements will vary depending on stage options Installation instructions in this sec tion are for stages equipped with standard Aerotech motors intended for use with an Aerotech motion control system Contact Aerotech for further information regarding stages that are otherwise configured Aerotech motion control systems are adjusted at the factory for optimum performance When the ATS 125 series stage is part of a complete Aerotech motion control system setup involves connecting a stage and motor combination to the appropriate drive chassis with the cables provided Connect the provided cables to the motor and feedback connectors on the stage Labels on the drive indicate the appropriate connections Refer to your drive manuals and documentation for additional installation and operation information In some cases if the system is uniquely configured a drawing showing system interconnects is supplied Refer to Section 3 6 for standard motor wiring and connector pin outputs Never connect or disconnect any electrical component or connecting cable while power is applied or serious damage may result WARNING The stage s protective ground is located on pin A4 of the motor connector If you are using cabl
27. ge User s Manual ip FDBK CCW LMT CwWr LHT HOME LMT NO CONN BRAKE 3 13 22 EXT SD THERMISTOR 3 e e e Dog 19 LIMIT COM ENC COM LIMIT 5V ENG t5V 25 PIN MALE ECKDO101 BACKSHELL ECKDO6b8 JAGKSOCKET ECKQO120 Figure 3 7 Feedback Wiring for Standard ATS125 Stages with Integral Motor 26 Chapter 3 www aerotech com ATS125 Series Stage User s Manual Operating Specifications mom A 7 7 MTR amp C 7 7 7 7 MTR Ae HE f 7 MTR 9 BLK Z J 7 Figure 3 8 Motor Wiring Connector for all ATS125 Stages www aerotech com Chapter 3 27 Operating Specifications ATS125 Series Stage User s Manual SEE DETAIL A 25 PIN MALE D WIRE SIGNAL 21 2 2 GRY COM WHITE BROWN BLACK AND GRAY ORANGE WHT ORN WHT BLU GREEN BLUE RED AND MOLET WHT YEL YELLOW ro wn ro ro e gt gt 4 I1 2 fF S 9 8 6 OT IT aT PIN 1 DRAIN 15 WHT YEL COS N 5 He FOIL SHIELD DETAIL A SIGNAL Figure 3 9 Brake and Encoder Connector for Stages with Foldback Option 28 Chapter 3 www aerotech com ATS125 Series Stage User s Manual Operating Specifications Table 3 5 Motor Wiring Pinout Descriptions Pin Output Description 727 Clockwise Active high si
28. gnal indicating maximum travel produced by CW motor rotation Normally not CW Limit used on ATS125 stage with standard limit switch wiring CW Limit N Active low signal indicating stage maximum travel produced by CW motor rotation Cosine Incremental encoder output either TTL line driven or amplified sine wave type sig nal COS N Incremental encoder output Complement of cos Active high signal indicating stage maximum travel produced by negative stage direction Counter Active high signal indicating stage maximum travel produced by CCW motor rotation clockwise CCW Limit CCW Limit N Active low signal indicating stage maximum travel produced by CCW motor rotation HOME LMT Home Limit Paralleled with CCW with Standard Jumper or CW Optional Jumper limit Typically not used ENC 5V 5 V supply input for optical encoders Typical requirement is 250 mA ENC COM 5 V return for optical encoders ground H Hall Effect A Brushless motor commutation track output TTL line driven signal with rotary motor H Hall Effect B Brushless motor commutation track output TTL line driven signal with rotary motor H Hall Effect C Brushless motor commutation track output TTL line driven signal with rotary motor M LMT 5v 5 V supply input for optical limit switch boards Typical requirement is 50 mA LMT COM 5 V return for optical limit switch boards ground A B C KR Marker Incremental encoder output pulse given once
29. iance Pittsburgh PA November 19 2010 Chapter 1 www aerotech com ATS125 Series Stage User s Manual Installation Chapter 2 Installation This chapter describes the installation procedure for the ATS 125 stage including handling the stage properly preparing the mounting surface to accept the stage securing the stage to the mounting surface attaching the payload and making the electrical connections Installation must follow the instructions in this chapter Failure to follow these instructions could result in injury and damage to the equipment WARNING 2 1 Unpacking and Handling the Stage Carefully remove the stage from the protective shipping container Set the stage on a smooth flat and clean surface This is a simple yet very important step in maintaining the integrity of the stage Each stage has a label listing the system part number and serial number These numbers contain information necessary for maintaining or updating system hardware and software Locate this label and record the information for later reference If any damage has occurred during shipping report it immediately Improper stage handling could adversely affect the stage s performance Therefore use care when moving the stage Manually lifting or transporting the stage can result in injury WARNING Lift the stage only by the base WARNING Do not use the ballscrew or motor as lifting points WARNING www aerotech com Chapter 2 9
30. levered load situation is used first determine if it is a vertical cantilever or side can tilever system based on 3 4 Measure the cantilever length then find the corresponding load value from Fig ure 3 1 100 Load Ib 8 8 8 0 50 100 150 200 250 300 0 2 4 6 B 10 12 in Cantilever Length Figure 3 1 Load Capability of ATS125 Series Stages 20 Chapter 3 www aerotech com ATS125 Series Stage User s Manual Operating Specifications Stage Table Stage Table Lye Log C G C G e e REN Figure 3 2 Stage Orientations for Le L SC The approximate amount of torque required to turn the ballscrew of an ATS125 series stage can be found from Figure 3 3 orthe following equation Torque Axial Load x Lead of Screw JUE 2 x x Efficiency For ATS125 series stages the ballscrew efficiency is rated at 90 0 90 Refer to Figure 3 3 The maximum axial load carrying capacity of ATS125 stages is 18 2 kg 405 www aerotech com Chapter 3 21 Operating Specifications ATS125 Series Stage User s Manual 0 2000 0 1800 0 1600 0 1400 0 1200 0 1000 0 0800 0 0600 0 0400 0 0200 0 0000 Torque Required Nm 0 0 4 0 8 0 12 0 16 0 20 0 Axial Load kg Figure 3 3 Torque Required to Turn ATS125 Ballscrew with Various Loads 22 Chapter 3 www aerotech com ATS125 Series Stage User s Manual Operating Specifications 3 5 Optical
31. mm x 250 mm x6 mm alu minum 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 6 Maximum winding temperature is 100 C Thermistor trips at 100 C 7 Ambient operating temperature range 0 C 25 C consult Aerotech for performance in elevated ambient temperatures 8 All Aerotech amplifiers are rated Apk use torque constant in N m Apk when sizing www aerotech com Chapter 3 19 Operating Specifications ATS125 Series Stage User s Manual 3 4 Load Capability It is recommended that application loads be symmetrically distributed whenever possible i e the payload should be centered on the stage table and the entire stage should be centered on the support structure With the stage lying flat horizontal and the application load vertically applied and symmetrically distributed the maximum vertical load carrying capacity of ATS125 stages is 45 5 kg If cantilevered loads are applied refer to Figure 3 1 to find the maximum allowable load In Figure 3 1 two curves are shown for different loading conditions The Lvc or vertical cantilever curve is for situations where the stage is mounted in a vertical orientation and the payload is mounted to the table top with its center of gravity extended outward The Lsc or side cantilever curve assumes a horizontal stage orientation If a canti
32. nge during measurement Vertical and axial loads subject to cantilever load restriction Selected motor and drive will limit performance specifications Consult factory for XY and alternate mounting configurations Table 3 3 ATS125 Series Resolution Information Encoder Option Travel Step Steps Revolution 1000 amplified sine 1 25 um 4000 1 Assumes times 4 interpolation by controller 18 Chapter 3 www aerotech com ATS125 Series Stage User s Manual Table 3 4 ATS125 Motor Specifications Model Winding Designation Performance Specifications 1 9 Stall Torque Continous 2 N m oz in Peak Torque 9 N m oz in Operating Specifications 0 33 46 2 1 31 184 9 Rated Power Output Continuous 112 0 Electrical Specifications 9 BEMF Constant line to line max Volts pk krpom 3 Continuous Current Stall 2 Amp pk Amp rms Peak Current Stall 3 Amp pk Amp rms N m Amp pk oz in Amp pk Amp rms oz in Amp rms Motor Constant 2 4 N m VW oz in VW Resistance 25 C line to line ohms Inductance line to line mH Maximum Bus Voltage VDC Thermal Resistance Number of Poles Torque Constant 4 8 2 1 6 9 2 6 5 0 14 20 1 0 20 28 4 0 050 7 02 8 4 1 30 340 1 Performance is dependent upon heat sink configuration system cooling conditions and ambient temperature 2 Values shown 75 C rise above 25 C ambient temperature with housed motor mounted to a 250
33. r specific application and environment Storage 0 to 40 C 32 to 104 F in original shipping packaging Humidity Operating 40 percent to 50 percent RH The optimal operating humidity is 50 percent RH Storage 30 percent to 60 percent RH non condensing in original packaging Altitude Operating 0 to 2 000 m 0 to 6 562 ft above sea level dE Contact Aerotech if your specific application involves use above 2 000 m or below sea level Vibration Use the system in a low vibration environment Excessive floor or acoustical vibration can affect stage and system performance Contact Aerotech for information regarding your specific appli cation Dust Expo The ATS125 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 The accuracy specification of ATS125 series stages is measured at the center of travel 45mm above the table with the stage in a horizontal position The accuracy of the ballscrew is a key element in the overall positioning accuracy A scale error can be expected if temperature of the ballscrew differs from 20 C 68 F The greater the temperature difference the greater the error The temper
34. rained applications This chapter introduces standard and optional features of the ATS 125 stages explains the model numbering System and gives general safety precautions Figure 1 1 Typical ALS2500 Series Linear Positioning Stage NOTE Aerotech continually improves its product offerings and listed options may be superseded at any time Refer to the most recent edition of the Aerotech Motion Control Product Guide for the most current product information at www aerotech com Www aerotech com Chapter 1 1 Overview ATS125 Series Stage User s Manual 1 1 Standard Features The 5 mm lead ballscrew and Linear Motion Guide LMG are standard features on all stages see Figure 1 2 The precision ground preloaded ballscrew ensures superior positioning resolution and accuracy while the LMG bearing system provides stiffness good load carrying capabilities and continuous load support over the entire range of travel Other standard design features include an integral hardcover and side seals to keep contamination out of the internal mechanism and integral wipers on the ballscrew nut and bearing trucks to further reduce contamination Optical limit switches and mechanical end stops to protect the stage table from over travel are also standard Hardcover Stage Table Carriage Truck Guide Rail Stage Base Integrated Motor Figure 1 2 ATS125 with Cutaway View of Ballscrew 2 Chapter 1 www aerotech com ATS125 Series S
35. rating 17 3 1 Environmental Specifications 17 3 2 Accuracy and Temperature Effects 17 3 3 Basic Specifications 18 3 4 Load Capability 20 3 5 Optical Limit 2 2244 4 1 22 2 23 3 5 1 Limit Switch Operation 23 3 5 2 Limit Switch Wiring 24 3 6 Standard Motor Wiring 25 3 7 Vacuum Operation 30 3 7 1 Special 4 24 4 9 22020202 30 Chapter 4 31 4 1 Service and Inspection Schedule 31 4 2 Cleaning and Lubrication
36. ssembly verification to maintain warranties 32 Chapter 4 www aerotech com ATS125 Series Stage User s Manual Maintenance 4 3 Lubrication and Cleaning Process The lubrication and cleaning process is outlined in the steps that follow Before beginning lubrication please see Section 4 2 1 for recommended lubricants Drive the stage table to one end of travel and remove power to the stage Remove the screws on the edges of the hard cover Figure 4 1 and slide it out from the side opposite of the motor This can be done without removing the table Remove any accumulated dust or debris from the inside of the assembly Remove any dirty or dried lubricant from the ballscrew Use a clean lint free cloth with a side to side motion Manually turn the ballscrew to clean its entire circumference A swab soaked in Isopropyl Alco hol may be used to remove stubborn debris Clean the end of the ballscrew nut and wiper with a clean lint free cloth or swab Clean the linear bearing guides using a similar technique 7 Apply athin continuous film of lubricant to the ballscrew threads and linear bearing guides A good qual 10 11 ity natural bristle artist s brush makes an excellent applicator For stages without an optional brake manually move the stage to the opposite end of travel This will work the grease into the ballscrew and linear bearing guides Depending on the pitch of the ballscrew it may be necessary to turn the balls
37. tage User s Manual Overview 1 1 1 Optional Features Available assembly options allow the ATS125 series stages to be configured for a variety of applications A foldback option is available for use in space constrained applications In addition any motor with a NEMA 23 frame size and 6 35mm 1 4 or 9 53mm 3 8 shaft can be mounted to the stage when using the foldback option The stage table is available with the mounting holes and grid pattern in either English or metric dimensions ATS125 stages can be easily assembled in XY axis arrangements Available L bracket accessories allow the stages to be mated to form XZ or XYZ axis arrangements Multi axis combinations can be optionally aligned to either 10 or 5 arc sec orthogonality Optional wipers can be installed to the stage table to prevent accumu lation of debris on the hard cover which could potentially become lodged between the cover and table There are two rotary encoder options for stages equipped with integral motors The two options are a 1000 line amplified sine encoder and a 2500 line driver encoder For vacuum applications two vacuum preparation options are available upon request one compatible with low vacuum environments down to 1073 torr and the other for high vacuum 10 3 to 10 6 torr applications Figure 1 3 Two XZ and Three XYZ Axis Positioning Systems using ATS125 stages www aerotech com Chapter 1 3 Overview ATS125 Series Stage User s Manual 1 1 2 Mo
38. terms and conditions stated in the following On Site Non Warranty Repair section apply If any Aerotech product cannot be made functional by telephone assistance or pur chased replacement parts and cannot be returned to the Aerotech service center for repair then the following field service policy applies Aerotech will provide an on site field service representative in a reasonable amount of time provided that the customer issues a valid purchase order to Aerotech cov ering all transportation and subsistence costs and the prevailing labor cost includ ing travel time necessary to complete the repair Aerotech Inc Phone 412 963 7470 101 Zeta Drive Pittsburgh PA Fax 412 963 7459 15238 2897 Appendix A www aerotech com ATS125 Series Stage User s Manual Technical Changes Appendix B Technical Changes Table B 1 Current Changes 1 02 00 Section s Affected General Information Section 1 3 Added section Section 3 3 Added section Chapter 2 Installation Section 2 1 Section Added safety information and warnings 2 3 Section 2 5 and Section 1 2 Section 3 3 Added motor specifications Section 3 6 Added note about current requirements of motor and ground wires www aerotech com Appendix B 37 Technical Changes 5125 Series Stage User s Manual Table B 2 Archived Changes Section s Affected General Information 1 01 00 Section 3 6 Encoder wiring graphic updated 38 Appendix B www aerot
39. the Stage 9 L limit 2 V lubricants vacuum 30 recommended 32 w Lubrication 32 Warniligs urnu eee lasers 6 lubrication and cleaning 33 WINING stow 13 24 lubrication 31 M model numbers 9 oot eee 13 www aerotech com Index 39 Reader s Comments ATS125 Series Stage Manual P N EDS101 November 19 2010 Revision 1 02 00 Please answer the questions below and add any suggestions for improving this doc ument Is the manual Adequate to the subject Well organized Clearly presented Well illustrated H 1 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 Nam A Aerotech Subsidiary Email Order Maiyourcommentsto Farto Aerotech Inc 412 967 6870 101 Zeta Drive Pittsburgh PA 15238 U S A service aerotech com
40. y mate rials or poor workmanship for a minimum period of one year from date of shipment from Aerotech Aerotech s liability is limited to replacing repairing or issuing credit at its option for any products that are returned by the original purchaser during the warranty period Aerotech makes no warranty that its products are fit for the use or purpose to which they may be put by the buyer where or not such use or purpose has been disclosed to Aerotech in specifications or drawings previously or sub sequently provided or whether or not Aerotech s products are specifically designed and or manufactured for buyer s use or purpose Aerotech s liability or any claim for loss or damage arising out of the sale resale or use of any of its prod ucts shall in no event exceed the selling price of the unit Aerotech Inc warrants its laser products to the original purchaser for a minimum Laser Products period of one year from date of shipment This warranty covers defects in work manship and material and is voided for all laser power supplies plasma tubes and laser systems subject to electrical or 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 notifi
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