Aerotech ABL1500Z, Hardware Manual

Page 1: ...Revision 1 03 00 ABL1500Z Hardware Manual ...

Page 2: ...rvice aerotech com 101 Zeta Drive Pittsburgh PA 15238 2811 www aerotech com United Kingdom Japan Phone 44 0 1256 855055 Fax 44 0 1256 855649 Email service aerotech co uk Phone 81 0 50 5830 6814 Fax 81 0 43 306 3773 Email service aerotechkk co jp Germany China Phone 49 0 911 967 9370 Fax 49 0 911 967 93720 Email service aerotechgmbh de Phone 86 21 5508 6731 Email service aerotech com France Taiwan ...

Page 3: ...2 3 Securing the Stage to the Mounting Surface 20 2 4 Attaching the Payload to the Stage 22 Load Capability 22 2 5 Setting Up the Pneumatic Counterbalance 24 Chapter 3 Electrical Specifications and Installation 29 3 1 Motor and Feedback Connectors 30 3 2 Motor and Feedback Wiring 33 3 3 Motor and Feedback Specifications 34 3 4 Limits Marker and Machine Direction 36 3 5 Motor and Feedback Phasing 3...

Page 4: ...Load Capability Yaw for Various Peak Applications 23 Figure 2 6 Cantilever and Offset Loading Diagram 23 Figure 2 7 Counterbalance Pressure vs External Payload 24 Figure 2 8 Connections for Air Bearing and Counterbalance 25 Figure 2 9 Shipping Bracket 26 Figure 3 1 Connector Locations 29 Figure 3 2 Motor and Feedback Wiring 33 Figure 3 3 Machine Direction 36 Figure 3 4 Hall Phasing 37 Figure 3 5 A...

Page 5: ...ations 12 Table 1 3 ABL1500Z Series Specifications 13 Table 1 4 Air Specifications 14 Table 3 1 Motor Connector Pinouts 31 Table 3 2 Feedback Connector Pinouts 32 Table 3 3 Feedback Specifications 34 Table 3 4 Encoder Specifications 35 Table 3 5 BLMC 192 Motor Specifications 35 Table 4 1 Recommended Cleaning Solvents 39 www aerotech com 5 ...

Page 6: ...Table of Contents ABL1500Z Hardware Manual 6 www aerotech com This page intentionally left blank ...

Page 7: ...he product 6 PINCH POINT Keep Hands Clear while the stage is in motion W A R N I N G To minimize the possibility of electrical shock bodily injury or death the following precautions must be followed 1 Moving parts can cause crushing or shearing injuries Access to all stage and motor parts must be restricted while connected to a power source 2 Cables can pose a tripping hazard Securely mount and po...

Page 8: ...Safety ABL1500Z Hardware Manual 8 www aerotech com This page intentionally left blank ...

Page 9: ...r more declares that it is not allowed to put the equipment into service until the machinery into which it is to be incorporated or of which it is to be a component has been found and declared to be in con formity 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 This is to certify that ...

Page 10: ...Declaration of Conformity ABL1500Z Hardware Manual 10 www aerotech com This page intentionally left blank ...

Page 11: ...sine output E2 Incremental linear encoder 0 1 µm TTL line driver output E3 High accuracy incremental linear encoder 1 Vpp amplified sine output Cable Management Required CMS1 Single axis cable management system CMS2 Cable management system for ZT assembly Metrology Required PL1 Metrology uncalibrated with performance plots PL2 Metrology calibrated HALAR with performance plots Accessories to be ord...

Page 12: ...affect system performance Contact Aerotech for information regarding your specific application Protection Rating ABL1500Z stages are not suited for dusty or wet environments This equates to an ingress protection rating of IP00 Use Indoor use only 1 2 Accuracy and Temperature Effects Due to the small clearances in the air bearing design extreme temperature environments could cause a decrease in per...

Page 13: ...on 2 g no load Maximum Force Continuous 93 6 N Load Capacity 2 15 0 kg Operating Pressure 3 80 psi 5 psig Air Consumption 4 Stage 24 30 SLPM 551 kPa Counterbalance 60 SLPM max Moving Mass no load 5 9 kg Stage Mass 23 8 kg 26 6 kg 28 5 kg 30 5 kg Material Aluminum Mean Time Between Failure 20 000 Hours 1 Certified with each stage 2 Axis orientation for on axis loading is listed refer to Section 2 4...

Page 14: ...quirement is to prevent particles from clogging the air bearing openings 3 Aerotech recommends using a polyurethane air hose Aerotech also recommends that you install a pressure switch P N MCA03094 tied to the motion controller s emergency stop ESTOP that will remove power to the air bearing if pressure drops below 40 psi a drop in pressure could result in contact between bearing surfaces which co...

Page 15: ...ABL1500Z Hardware Manual Overview Figure 1 1 Air Fitting Locations for Air Bearing Figure 1 2 Counterbalance Air Flow vs Counterbalance Pressure www aerotech com Chapter 1 15 ...

Page 16: ...Overview ABL1500Z Hardware Manual 16 Chapter 1 www aerotech com This page intentionally left blank ...

Page 17: ...Z on a smooth flat and clean surface Before operating the ABL1500Z it is important to let it stabilize at room temperature for at least 12 hours Allowing it to stabilize to room temperature will ensure that all of the alignments preloads and tolerances are the same as they were when tested at Aerotech Use compressed nitrogen or clean dry oil less air to remove any dust or debris that has collected...

Page 18: ...al Figure 2 1 Lifting Features and Shipping Clamps N OTE After removing the lifting features or shipping brackets retain them for future use Do not transport or ship the ABL1500Z without the lifting features or shipping brackets attached 18 Chapter 2 www aerotech com ...

Page 19: ...ABL1500Z Hardware Manual Mechanical Specifications and Installation 2 2 Dimensions Figure 2 2 ABL1500Z Dimensions www aerotech com Chapter 2 19 ...

Page 20: ...ket is precision machined and verified for flatness prior to stage assembly at the factory If machining is required to achieve the desired flatness it should be performed on the mounting surface 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 Procedure for ABL1500Z mounting W A R N I N G Do not a...

Page 21: ...ABL1500Z Hardware Manual Mechanical Specifications and Installation Figure 2 3 Surface Mounting Screws www aerotech com Chapter 2 21 ...

Page 22: ...ith a representative payload based on the information provided at the time of order If the ABL1500Z is started up without a payload the servo gains provided by Aerotech with the shipment may not be appropriate and servo instability can occur Refer to the controller help file for tuning assistance The payload must be flat rigid and comparable to the stage in quality to maintain optimum performance ...

Page 23: ...0Z Hardware Manual Mechanical Specifications and Installation Figure 2 5 Offset Load Capability Yaw for Various Peak Applications Figure 2 6 Cantilever and Offset Loading Diagram www aerotech com Chapter 2 23 ...

Page 24: ...her axes attached the counterbalance is set for the mass of the carriage plus the additional mass If there is an adjustment to the mass that is carried by the counterbalance cylinders either adding or subtracting payload there also needs to be an adjustment to the counterbalance pressure supplied to the pneumatic cylinders Standard ABL1500Z stages have two counterbalance cylinders with a combined ...

Page 25: ...upply meets specifications before you continue Figure 2 8 Connections for Air Bearing and Counterbalance 2 Turn on the air supply to both the air bearing stage and the pneumatic counterbalance The pressure supply to the counterbalance fitting must exceed the pressure determined by Figure 2 7 3 Loosen but do not remove the two M5 0 8x25mm socket head cap screws mounting the shipping bracket to the ...

Page 26: ...ting the factory setting of the regulator Increase the supply pressure to the fitting until the pressure gauge on the back of the stage does not show a corresponding increase in pressure Check the counterbalance of the carriage again b To adjust the pressure to the cylinders place one hand on the carriage with the shipping brackets still loose and slowly turn the regulator knob Clockwise rotation ...

Page 27: ...ly To change the payload on the stage add or remove mass 1 Follow the steps above to turn off the air to the stage 2 Turn the regulator knob counterclockwise until it bottoms out prevents any pressure from reaching the cylinders 3 Change the payload as required See Section 2 4 for payload flatness requirement and for loading charts 4 Estimate the pressure required to lift the payload using Figure ...

Page 28: ...Mechanical Specifications and Installation ABL1500Z Hardware Manual 28 Chapter 2 www aerotech com This page intentionally left blank ...

Page 29: ...t follow for standard motor wiring and connector pinouts The stage and its carriage are protected from dangerous faults by an integral safety ground through the stage s motor power cable In addition a spot faced safety ground connection point shown in Figure 3 1 is provided on the stage endplate for customer use W A R N I N G Applications requiring access to the stage while it is energized will re...

Page 30: ...r or qualified installer is responsible for determining and meeting all safety and compliance requirements necessary for the integration of this stage into the final application D A N G E R Remove power before connecting or disconnecting electrical components or cables Failure to do so may cause electric shock or damage to the equipment W A R N I N G The protective ground connection must be proper...

Page 31: ... Phase A A2 Motor Phase B A3 Motor Phase C 1 Reserved 2 Reserved 3 Reserved 4 Reserved 5 Reserved A4 Frame ground motor protective ground Mating Connector Aerotech P N Third Party P N Backshell ECK00656 Amphenol 17E 1726 2 Sockets QTY 4 ECK00659 ITT Cannon DM53744 6 Connector ECK00657 ITT Cannon DBM9W4SA197 www aerotech com Chapter 3 31 ...

Page 32: ...t sensor phase C 12 Signal indicating maximum travel produced by positive CW stage direction 13 Reserved 14 Cosine 15 Cosine N 16 5 V power supply 17 Sine 18 Sine N 19 Reserved 20 Limit Common 21 Encoder Common 22 Reserved 23 Reserved 24 Signal indicating maximum travel produced by negative CCW stage direction 25 Reserved Case Signal shield connection to case Mating Connector Aerotech P N Third Pa...

Page 33: ...Wiring All motor and controller manufacturers have their own designations for motor phases A B C and Hall signals A B C refer to Section 3 5 for motor phasing Shielded cables are required for the motor and feedback connections Figure 3 2 Motor and Feedback Wiring www aerotech com Chapter 3 33 ...

Page 34: ...ecifications Supply Voltage 5 V 5 Supply Current 250 mA typical Output Signals Sinusoidal Type Incremental Encoder 1 Vpk pk into 120 Ω Load differential signals SIN SIN COS COS are 5 V pk pk relative to ground Digital Output Incremental Encoder RS422 485 compatible Limit Switch Specifications Supply Voltage 5 V from encoder Supply Current 250 mA typical Output Type Open Collector Output Voltage 24...

Page 35: ...line line max V m s V in s 30 66 0 78 Continuous Current Apk Arms 4 00 2 83 Peak Current Stall 3 Apk Arms 23 20 16 40 Force Constant Sine Drive 4 5 N Apk lb Apk 26 67 6 00 N Arms lb Arms 37 72 8 48 Motor Constant 4 6 N W lb W 10 29 2 31 Resistance 25 C line line Ω 6 4 Inductance line line mH 1 90 Thermal Resistance No Forced Cooling C W 0 93 Maximum Bus Voltage VDC 80 7 Magnetic Pole Pitch mm in 2...

Page 36: ...back and motor signals and is dictated by the stage wiring refer to Section 3 5 for Motor and Feedback phasing information Programming direction of a stage is set by the controller that is used to move the stage Programming direction is typically selectable in the controller while machine direction is hardwired in the stage Figure 3 3 shows the machine direction of ABL1500Z stages Figure 3 3 Machi...

Page 37: ...dware Manual Electrical Specifications and Installation 3 5 Motor and Feedback Phasing Motor phase voltage is measured relative to the virtual wye common point Figure 3 4 Hall Phasing www aerotech com Chapter 3 37 ...

Page 38: ...lectrical Specifications and Installation ABL1500Z Hardware Manual Figure 3 5 Analog Encoder Phasing Reference Diagram Figure 3 6 Encoder Phasing Reference Diagram Standard 38 Chapter 3 www aerotech com ...

Page 39: ...ct the stage and cables l Re tighten loose connectors l Replace or repair damaged cables l Clean the ABL1500Z and any components and cables as needed l Repair any damage before operating the ABL1500Z l Inspect and perform an operational check on all safeguards and protective devices 4 2 Cleaning and Lubrication There are no elements on ABL1500Z stages that require lubrication Clean all air bearing...

Page 40: ...e stage Move the stage to one end of travel and remove power D A N G E R To minimize the possibility of bodily injury or death disconnect all electrical power prior to performing any maintenance or making adjustments to the equipment 2 Clean all of the surfaces that you can access Make sure to use the correct solvent on each surface refer to Section 4 2 When the surface is fully dry move the stage...

Page 41: ...ABL1500Z Hardware Manual Maintenance Figure 4 1 Air Bearing Surfaces and Encoder Scales Require Periodic Cleaning www aerotech com Chapter 4 41 ...

Page 42: ...ure safety switch and either the air pressure is too low or the switch is not present Check the air supply and the switch Air pressure switches are typically configured to trip if the supply pressure to the bearing drops below 40 psi l Counterbalance supply pressure is not correct Follow the counterbalance set up procedure in Section 2 5 Stage moves uncontrollably l Encoder sine and cosine signal ...

Page 43: ... such approval A Return Materials Authorization RMA number must accompany any returned product s The RMA number may be obtained by calling an Aerotech service center or by submitting the appropriate request available on our website www aerotech com 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 thir...

Page 44: ...ms and conditions stated in the following On Site Non Warranty Repair section apply On site Non Warranty Repair If any Aerotech product cannot be made functional by telephone assistance or purchased 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 rea...

Page 45: ...dded 1 01 00 l Declaration of Incorporation section added l Environmental Specifications section added l Updated ordering information l Added safety information and warnings l Updated stage specifications l Added motor specifications l Added note about motor wire current and voltage requirements l Corrected mechanical stop warning 1 00 00 New manual www aerotech com Appendix B 45 ...

Page 46: ...Revision History ABL1500Z Hardware Manual 46 Appendix B www aerotech com This page intentionally left blank ...

Page 47: ...G Global Technical Support 2 H Hall Effect Sensors Specifications 34 hose air 14 Humidity 12 I Inspection Schedule 39 Isopropyl Alcohol 39 L label 17 lifting bars 17 Lifting Hardware 17 Limit Switch Specifications 34 lubrication 39 Lubrication 39 M MCA03094 14 mounting surface securing stage 20 P part number 17 pressure switch 14 Protection Rating 12 protective ground connection 30 S Securing the ...

Page 48: ...Index ABL1500Z Hardware Manual testing stage operation 22 Thermistor Specifications 34 V Vibration 12 W Warranty and Field Service 43 48 Index www aerotech com ...