POF115 Reference & Maintenance Manual
Contents
1. POF 1 1 5 i Reference amp Maintenance Manual primatics POF115 Reference amp Maintenance Manual POF 1 15 f 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 POF115 Manual Revision Information Publication Date Notes July 2003 March 2003 Changed recommended grease from Lithium 2 to NSK Clean room grease April 2005 Updated look amp formatting January 2007 Updated Ordering Info January 2015 Updated 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 POF115 Datasheet available from our website at www primatics com Copyright 2007 2015 by Primatics Inc All Rights Reserved Primatics the Primatics logo PrimaFlex PrimaSeal amp SimpleMatch are trademarks of Primatics Inc POF 1 1 5 Reference amp Maintenance Manual POF115 Manual Revision Information c sccsssssessssseescenseessensen2. Heat and Humidity All positioning stages 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 Large thermal gradients in the interior of the stage can result from motor heat created by high acceleration moves Care must be taken to limit the duty cycle of the linear motor to maintain stage performance Airflow across the motor will help minimize thermal expansion effects and increase the allowable duty cycle 6 3 Contamination Applications in dirty or dusty environments require the electrical optical and mechanical components to be protected The POF115 series is intended for clean environments free from small particulates and fluids 6 4 Electrical Noise Electrical noise is the corruption of signals carried over low voltage wires Encoder signals can be corrupted resulting in spurious encoder counts thus causing the stage to drift Grounding shielding and spatial separation are all countermeasures to reduce the influences of electrical noise on performance You can minimize the potential for electrical noise by observing the following installation precautions o Physically separate low voltage conductors from those carrying high voltage o Ensure that all components are properly grounded o Ensure that all wiring is properly shielded 1
3. pods is described below Cable 1 Color Function E Black Motor A Red Motor B White Motor C H Shid Motor Shield Cable 2 Color Function Red Encoder 5V White Encoder A output Yellow Encoder A output H Green Encoder B output Blue Encoder B output E Shid Encoder Shield E Black Encoder Common Orange Encoder Index H Brown Encoder Index Cable 3 Color Function B Green 12VDC E Blue DCCOM White Home JB Wht Red_ Not used IE Wht Black Not used R Shid Chassis Black Hall V Brown Hall V R Violet Forward Limit Switch ii Gray Reverse Limit Switch R Red Hall A E Orange Hall B Tan Temperature Monitor a Yellow Hall C POF 1 1 5 f Reference amp Maintenance Manual 7 6 Hall Effect Commutation Sequence The following diagram shows the motor signal timing for the Servo Motor option Positive Direction of Motion Figure 7 2 Motor commutation chart The following diagram shows the encoder signal timing for the Encoder option Positive Direction of Motion Figure 7 3 Timing diagram for the encoder signals 7 7 Home and Limit Sensors Each POF115 stage includes Forward and Reverse Limit sensors and a Home sensor Figure 7 4 shows the equivalent schematic for these switches 15 POF 1 1 5 N Reference amp Maintena
4. stage verify the encoder and limit switches are working properly Move the stage carriage by hand in the positive direction and verify the encoder count is increasing Runaway conditions caused by miswired encoders can result in stage damage and personal injury Move the 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 8 Preventive Maintenance Performing preventive maintenance procedures on your stage will extend its life and improve its long term performance 8 1 Lubrication Use clean room grease to lubricate the linear guide components We recommend NSK grease part GRS LG2 For low duty cycle applications it is recommended that linear guides are re greased every six months High duty cycle applications may require more frequent re lubrication Lubrication intervals depend on duty cycle load and ambient conditions The linear motor is a non contact device and requires no lubrication Primatics offers a grease kit that has all the necessary hardware to re lubricate the linear bearings Grease ports are located on the ends of the linear guide blocks along the axis of the rails Use a grease gun with the appropriate fitting to connect to the grease port Figure 8 1 Bearing block lubri
5. third party controller and amplifier systems In this case a pigtailed cable is available to simplify the connection between the POF stage and controls POF 1 1 5 Reference amp Maintenance Manual 3 Model Configuration MODEL NUMBER CONFIGURATION OPTIONS SAMPLE MODEL NUMBER POF 115 AL 0300 P DS His bis Gh 5 E2 PF M Model Series Linear Guide Open Frame ssesessesscceseeneentens POF Table Height FO RAARO 115 Base Material RHEIN eegener AL Table Travel SOOT BOO E 0300 Grade SE d EE P Drivetrain Ditert Mee ncaa aaee ee eE a a aeee aa D5 Dual Linear Mili iisisssisrsisssisssiviiisriitisisronansisssasiiaas D8 Home Sensor N C Current Sinking H1 N O Current Sinking H2 Travel Limits N C Current Sinking L1 N O Current Sinking L2 Motor Coupling NO Cupi ienis C1 Motor Type Kgl TEE 5 Encoder Linear Encoder ToT asasina E2 Linear Encoder 0 5 micron Linear Encoder 0 1 micron Linear Encoder 0 2 mircon Protection Level Standard Protechon Pi Options ENOT Mapping saiscarsananncnannnanaimmnnnt M NY ODIOS Zossen Leave Blank Allow Longer Delivery Trime Includes Z bracket Not all configurations are valid Consult factory for assistance POF1 1 5 N Reference amp Maintenance Manual A 4 Personal Safety A Please review before installing your positioning stage Observe common industrial safety practices when installing and operating automated equipment o Have
6. 0 POF1 1 5 N Reference amp Maintenance Manual 7 Installation Procedures 7 1 Tools you will need The POF linear positioning stage uses M8x16mm sockethead cap screws for the base plate mounting The carriage plate has M6 tapped holes for customer mounting 7 2 Unpacking Carefully remove the stage from its shipping crate and inspect it for evidence of shipping damage Report any damage immediately to your authorized dealer If so equipped remove the red shipping clamp from the stage Improper handling of the stage may degrade its performance Follow these guidelines when handling and mounting your stage 1 Do not drop the stage onto its mounting surface Place the stage gently on the mounting surface Impact loads can cause high spots on mounting surfaces misalignment of drive components and warping of the base 2 Do not drill holes into the stage If additional holes are necessary contact your local distributor 3 Lift the stage by its base structure only Do not lift by the motor drive assembly 4 Stage disassembly and alteration unless specified otherwise may void warranty 7 3 Mounting surface preparation The characteristics of the surface the positioning stage is mounted to will have a large effect on system performance An accurate and flat positioning stage will conform to the shape of its mounting surface therefore a flat mounting surface is required The flatness and straightness specifications can be affected
7. OF 1 1 5 Reference amp Maintenance Manual 2 Introduction About the POF115 The POF 115 is a dual axis large aperture positioning stage that provides accurate flat motion It provides high stiffness and load capacity The open frame design gives the flexibility for access to the payload from both above and below There are two drive configurations for the POF115 Each is briefly described in the table below POF115 Single Drive POF115 Dual Drive Basic Width x Height mm 336 x 115 Travel Lengths mm 300 x 300 Drive Types Single Linear Motor Dual Linear Motor Encoder Option Linear Payload kg 50 75 Each can be configured with options listed in Section 3 Many customers choose the Primatics Motion Drive Chassis MDC to power POF 115 stages The MDC is a modular system that packages motor drivers encoder interfaces power supplies and safety systems into a single chassis It acts as an intermediary between a Galil Optima National Instruments 7344 or Delta Tau PMAC II motion control cards and a Primatics positioning stage Pre wired high flex cables are available to allow a convenient connection from the stage to the MDC chassis The MDC drive chassis interfaces 3 party controllers via a removable interconnect module These interconnect modules conform to each manufacturers interconnect cable and internally route all the command and UO signals Optionally a Primatics positioning stage can be used with many
8. cation fitting 18 POF 1 1 5 N Reference amp Maintenance Manual 8 2 Cables The flat cables inside the stage are designed for millions of cycles of use The pigtail cables exiting the stage are strain relieved but excessive force or repetitive cycling forces should not be applied to the pigtail cables 9 Troubleshooting amp Service 9 1 Troubleshooting Help For further assistance contact the factory M F 8AM to 5PM Pacific Time Phone 541 791 9678 Fax 541 791 9410 Toll Free 888 754 3111 Web www primatics com E mail service primatics com 9 2 Service Should your device require factory service contact the factory for a Return Materials Authorization RMA When inquiring about an RMA please have the following information available o Your contact information name phone email address o Unit Serial Number see Figure 9 1 o Symptom of problem o History of troubleshooting steps already taken Figure 9 1 POF115 Serial Number Location s 19
9. e preset at the factory The limits are nominally set to yield slightly more travel than specified in the model configuration The nominal home switch transition point is about 2mm to the positive side of the center of travel Limit Sensor Transition Region for Default Configuration Home Sensor Transistion Point wl gil SS 151 5 150 5 150 ek 0 1 1327 150 150 5 151 5 Reverse Limit Switch d Range for Encoder Index Transition S Forward Limit Switch Figure 7 5 Limit and Home Sensor Transition Ranges The home and limit signals are each produced by separate reflective sensors mounted to the underside of the carriage A white reflective strip the home vane mounted to the base runs the length of the stage and is viewed by each sensor A special non reflective black tape is applied to the home vane Each switch is closed when viewing the white area and is open when viewing the non reflective tape Figure 7 6A shows the tape configuration for the normally closed sensor options H1 L1 Figure 7 6B shows the tape configuration for the normally open sensor options H2 L2 Limited adjustments can be made to the limit transition signals by adding or removing black tape Figure 7 6A Home Vane Figure 7 6B Home Vane Configuration H1 L1 Options Configuration H2 L2 Options Normally Closed Normally Open 17 POF 1 1 5 N Reference amp Maintenance Manual 7 9 Recommended System Test Before attaching a load or applying power to your
10. n for both axes is defined as shown in Figure 5 1 A positive direction of motion also signifies the encoder count is increasing The forward limit switches are encountered just before the end of travel in the forward direction The reverse limit operates similarly in the reverse direction Carriage iia X Axis Forward Limit Forward fl Limit Reverse X Axis Limit Reverse Limit Figure 5 1 Positive direction convention 5 2 Units of Measure Primatics uses the metric system for all specifications and dimensions All linear dimensions are specified in millimeters Accuracy repeatability resolution flatness and straightness for the POF is specified in microns Load capacity is specified in kilograms and moment capacity is given in Newton meters All torque specifications are given in Newton meters Thrust specifications are given in Newtons The following table gives some common conversions into English units Metric Unit English Unit 1 Kilogram equals 0 0685 slug 1 micron equals 0 0000394 inch 1 millimeter equals 0 0394 inch 1 Newton meter equals 8 85 in lbs 1 Newton equals 0 2248 Ibs 1 Kg has a weight of 2 205 Ib when g 9 8 m s POF 1 1 5 Reference amp Maintenance Manual 6 Installation Preparations This section outlines installation environments Unfavorable installation conditions may cause electric shock fire or breakdown Certain breakdown situations or malfunctions in particular may lead to seri
11. nce Manual 12 to 24 V DC S S Home H Forward Limit Switch S Reverse Limit a Switch T Normally Closed Temp IT Temp Switch DCCOM 2 4 4 Figure 7 4 Equivalent Limit Home and Temp circuit schematic 7 7 1 Home Options The Home switch is ordered in either the Normally Closed H1 or Normally Open H2 configuration H1 Switch is closed when carriage is between the negative reverse end of travel and the home transition point It is open from the transition point to forward end of travel H2 Switch is open when carriage is between the negative reverse end of travel and the home transition point It is closed from the transition point to forward end of travel 7 7 2 Limit Options The Limit switches are ordered in either the Normally Closed L1 or Normally Open L2 configuration L1 When the carriage is in the normal operating range of travel both limit switches are closed When the carriage encounters a limit the switch opens The switch will close again when the carriage is moved away from the switch L2 When the carriage is in the normal operating range of travel both limit switches are open When the carriage encounters a limit the switch closes The switch will open again when the carriage is moved away from the switch 16 POF 1 1 5 N Reference amp Maintenance Manual 7 8 Limit and Home Switch Adjustment The limit and home switch positions ar
12. ous 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 stages accuracy can be guaranteed Stage accuracy can be guaranteed at 20 C 1 C o Location should not be affected by electrical noise o Location should be where inspection and cleaning can be performed without difficulty e ke Mee Mer 6 1 Linear Motors Linear motors have large magnetic flux that can draw ferrous metals inside them from large distances destroy magnetic media and disrupt some electronic circuits Materials attracted to the magnets can pinch fingers and cause injury Great care must be taken when operating less than 25mm from the surface of the motor In addition braking is difficult for linear motors making them inappropriate for many vertical applications Make sure no load is attached to the linear motor stage when stage is first connected to the electronics Linear motors can generate large accelerations and improper wiring to the control system can result in a high speed crash POF 1 1 5 Reference amp Maintenance Manual 6 2
13. power connections made by qualified personnel o Keep fingers and other items out of any opening in the stage while it is in operation since injury or damage may result o Provide a safe access route and adequate room for servicing o Perform the recommended periodic maintenance described in this document o Verify that the work envelope is free of obstructions before the positioning stage is powered o Insure that you have the feedback wired properly to the controller before applying power to the positioning stage Improper feedback connections can cause a motor run away condition that has the potential to damage the stage and injure an operator o Only trained operators of the positioning stage should be allowed near the work environment o If So equipped identify emergency stop circuits and actuators in the workcell o Note the places in the workcell where pinch points occur and provide adequate safety clearance or safety curtain o Never operate the motor in a location that could be splashed by water exposed to corrosive or flammable gases or is near combustible substances since this may cause an electric shock fire or malfunction o Never touch the motor driver or peripheral devices when the power is on or immediately after the power is turned off The high temperature of these parts may cause burns POF 1 1 5 N Reference amp Maintenance Manual 5 Conventions 5 1 Direction of Motion The positive direction of motio
14. r applications not using the Primatics MDC drive chassis is the pigtailed extension cable This is similar to the extension cable used to connect a stage to the MDC drive chassis except the end that connects to the motor drive and controller is un terminated Section 7 7 1 shows the conductor assignments for this cable 12 POF 1 1 5 N Reference amp Maintenance Manual Table 7 1 Axis Connector Motor encoder limits home temp FCI circular connector 28 pins size 20 shell Pin Function A Motor A Motor B Motor C Motor Shield Encoder 5V power for encoder Encoder A output Encoder A output Encoder B output Encoder B output Encoder Shield 12VDC for limit home and temp sensor DCCOM Home Switch to DOCOM when on forward side of home position Not used Not used Chassis Hall V Hall V Encoder Common Encoder Index Encoder Index Forward Limit Switch switch to DCCOM in normal operation Reverse Limit Switch switch to DCCOM in normal operation Signal Shield Hall A Hall B Temperature monitor connect to DC Common for temperature OK Hall C olJ SNI lt x E lt col z Zm AeA mnm 13 POF 1 1 5 N Reference amp Maintenance Manual 7 5 1 Color Codes for Pigtailed Cable Cable consists of 3 independent shielded pods One for motor signals one for encoder signals amp a 3 for sensors Each of the
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16. tgletlysechase seeders ebeecutel naet aae aaaea apra etie ghee 16 7 8 Limit and Home Switch Adjustment cccceceeeeseeeseeeeeeeeeeeeeeteeeeeseeeeseaeeseaeeseeeeseneeseas 17 7 9 Recommended System Test 18 8 Preventive Maintenance cccccccesseseseeeeeeeeeeeeesseeeeeeeeeeeeeeeesseeeeeseneeeeees 18 Bil FEUD CATON EE 18 82 CADIS 2 026 eege ascites eset eee Seas etna eeh Shara tte ae ate 19 9 Troubleshooting amp Service ccccccceseseeeseeeeeeeeeeeeeseeeeeeneeeeeeeesseeeeeeeeeeeeees 19 9 1 Troubleshooting Help EE 19 LEE ee EE EE 19 POF 1 1 5 Reference amp Maintenance Manual 1 Overview This user guide is designed to help you install and maintain your POF 115 Series linear positioning stage application Follow these steps to ensure correct stage installation and maximum stage life Step 1 Review this entire user manual Become familiar with all installation procedures prior to integrating your system Step 2 Review the safety summary to develop an understanding of standard safety practices when installing and operating automated equipment Step3 Familiarize yourself with the conventions summary Step A Review installation procedures For best results follow these procedures carefully Step 5 Once you successfully complete all the installation procedures you will be ready to install and operate your stage Step 6 Review preventive maintenance section for proper lubrication schedule P
17. under large loads For best results in maintaining stage specifications we suggest the following 1 Use a laboratory Grade AA granite surface plate 2 Before mounting stage inspect for burrs or dings on the stage mounting surfaces 3 Clean all mounting surfaces with acetone In the absence of a granite surface plate we recommend a base plate made of the same material as the base of the stage A mounting surface constructed out of a material different from the stage base material can introduce warping in the stage in the presence of a thermal gradient The surface flatness should match the requirements of the application a good starting point is to have the mounting surface flat to less than 5 8um 11 POF 1 1 5 N Reference amp Maintenance Manual 7 4 Mounting the POF115 The POF115 has four mounting holes that can be accessed by moving the X Axis to its forward and reverse limits Figure 7 1 shows the location of these mounting holes Figure 7 1 Mounting Hole Locations 7 5 Electrical Connections Electrical connections to the stages depend on the type of stage in use All POF115s are terminated with a 450mm flexible cable with a 28 position circular connector on the end The pin out of this connector is shown with Table 7 1 This particular configuration is optimized for use with Primatics MDC drive chassis via an extension cable Connections to other drives and controls are also made through this connector A popular option fo
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