CHPS-Series Linear Stage User Manual

User Manual

CHPS-Series Linear Stage

Catalog Numbers CHPS-150, CHPS-200, CHPS-250

Important User Information

Read this document and the documents listed in the additional resources section about installation, configuration, and operation of this equipment before you install, configure, operate, or maintain this product. Users are required to familiarize themselves with installation and wiring instructions in addition to requirements of all applicable codes, laws, and standards.

Activities including installation, adjustments, putting into service, use, assembly, disassembly, and maintenance are required to be carried out by suitably trained personnel in accordance with applicable code of practice.

If this equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may be impaired.

In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment.

The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or liability for actual use based on the examples and diagrams.

No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or software described in this manual.

Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation,

Inc., is prohibited.

Throughout this manual, when necessary, we use notes to make you aware of safety considerations.

WARNING: Identifies information about practices or circumstances that can cause an explosion in a hazardous environment, which may lead to personal injury or death, property damage, or economic loss.

ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property damage, or economic loss. Attentions help you identify a hazard, avoid a hazard, and recognize the consequence.

IMPORTANT

Identifies information that is critical for successful application and understanding of the product.

Labels may also be on or inside the equipment to provide specific precautions.

SHOCK HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous voltage may be present.

BURN HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may reach dangerous temperatures.

ARC FLASH HAZARD: Labels may be on or inside the equipment, for example, a motor control center, to alert people to potential Arc Flash. Arc Flash will cause severe injury or death. Wear proper Personal Protective Equipment (PPE). Follow ALL

Regulatory requirements for safe work practices and for Personal Protective Equipment (PPE).

Allen-Bradley, Kinetix, Rockwell Software, Rockwell Automation, Ultra are trademarks of Rockwell Automation, Inc.

Trademarks not belonging to Rockwell Automation are property of their respective companies.

New and Updated

Information

Summary of Changes

This manual contains new and updated information. Changes throughout this revision are marked by change bars, as shown to the right of this paragraph.

This table contains the changes made to this revision.

Topic

Corrected catalog numbers

Added maximum velocity for Kinetix 6500 and Kinetix 300 Drives

Page

18, 29, 59, 60, 87

74

Rockwell Automation Publication CHPS-UM001D-EN-P - July 2014

3

Summary of Changes

Notes:

4


Table of Contents

Stage Safety

Understanding Your Stage

Planning the Stage Installation

Mounting the Stage

Connector Data

Preface

About This Publication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Who Should Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Chapter 1

Safety Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Clearances. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

General Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Vertical or Incline Payload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

End Cap Impacts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Air Freight Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Standards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Motor Model Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Chapter 2

Identifying the Components of Your Stage . . . . . . . . . . . . . . . . . . . . . . . . . 16

Component Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Recommended Maintenance Interval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Identifying Your Stage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Chapter 3

Stage Mounting Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

General Safety Standards for Stage Installations . . . . . . . . . . . . . . . . . 21

Mounting Restrictions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Clearance Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Chapter 4

Unpacking, Handling, and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Unpacking Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Store Packaging Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Stage Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Mounting the Stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Before You Begin the Mechanical Installation. . . . . . . . . . . . . . . . . . . 28

Mounting the Stage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Mount Your Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Chapter 5

Kinetix Servo Drive Compatible Connectors . . . . . . . . . . . . . . . . . . . . . . . 34

D-Type Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Flying Leads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Junction Box Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37


5

Table of Contents

6

Connecting the Stage

Operation Guidelines and Limit

Configuration

Troubleshooting

Maintenance

Removing and Replacing Stage

Components

Limit Sensor Flying Leads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Chapter 6

Connecting the Stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Attaching the Ground Strap and Interface Cables . . . . . . . . . . . . . . . 40

Thermal Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Optional Limit Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

TTL Differential Encoder Output Signal. . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Sine/Cos Encoder Output Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Hall Effect Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Motor and Hall Phasing and Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Stage Positive Direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Chapter 7

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Operational Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Travel Limits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Calculating the Stopping Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Overtravel Limit Sensor Position Adjustment . . . . . . . . . . . . . . . . . . . 51

Bumper Stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Chapter 8

Before You Begin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

PTC Thermal Signal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Hall Effect Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Hall to Back EMF Phasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Motor Coil Resistance Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Chapter 9

Before You Begin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Lubricate the Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Optical Encoder Scale Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Strip Seal Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Cover Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Chapter 10

Before You Begin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Cable Carrier Module Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Cable Carrier Module Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Strip Seal Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Stage Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Stage Side Cover Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Strip Seal Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Stage Cover Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Side Cover Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67



Specifications and Dimensions

Accessories

Stacking Stages

Appendix A

Static and Static Moment Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Performance Specifications for 325V CHPS-Series Stage . . . . . . . . 70

Performance Specifications for 325V or

650V CHPS-Series Stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

General Stage Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Accuracy Specification for the CHPS-Series Stage. . . . . . . . . . . . . . . 73

Commutation Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Limit Sensor Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

PTC Thermistor Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Encoder Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Maximum Velocity for Allen-Bradley Drives. . . . . . . . . . . . . . . . . . . . 74

Environmental Specifications for CHPS-Series Stages . . . . . . . . . . . 75

CHPS-Series Stage Travel versus Weight Specifications . . . . . . . . . 75

CHPS-Series Stage Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

CHPS-Series Stage Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . 83

Appendix B

Interconnect Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Power Cable Dimensions

(catalog number 2090-XXNPMF-16Sxx) . . . . . . . . . . . . . . . 85

Feedback Cable Dimensions

(catalog number 2090-XXNFMF-Sxx). . . . . . . . . . . . . . . . . . 86

Installation, Maintenance, and Replacement Kits . . . . . . . . . . . . . . . . . . . 87

Accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

Appendix C

Stage Stacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Specifications for Stacked Stages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

Start-up Guide for CHPS-Series Stage with Ultra3000 Drive and Ultraware

Software

Appendix D

Using This Appendix. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

Wiring the CHPS-Series Stage to the Ultra3000 Drive . . . . . . . . . . . . . . 91

Linear Motor File Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

Creating a CHPS-Series Stage Motor File . . . . . . . . . . . . . . . . . . . . . . . . . . 92

Recommended Start-up Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

CHPS-Series Stage and Ultra3000 Drive Troubleshooting Reference. 96

Positive Phasing Direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

Encoder Counting Polarity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

Oscilloscope Verification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

Oscilloscope Diagram for Ultra3000 Drive . . . . . . . . . . . . . . . . . . . . . 98

Reference Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

Commutation Diagnostics Utility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

Self-sensing Commutation and Startup. . . . . . . . . . . . . . . . . . . . . . . . 100

Main Screen Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102


7


Motor Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

Faults Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

Appendix E

Mounting Bolts and Torque Values

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

Index

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

8


Preface

Read this preface to familiarize yourself with the manual.

About This Publication

This manual provides detailed installation instructions for mounting, wiring, maintaining, and troubleshooting your CHPS-Series Linear Motor Driven

Stage.

Who Should Use This Manual

This manual is intended for engineers or technicians directly involved in the installation, wiring, and maintenance of stages. Any person that teaches, operates, maintains, or repairs these stages must be trained and demonstrate the competence to safely perform the assigned task.

If you do not understand the linear motor stages, contact your local Rockwell

Automation sales representative for information on training courses before using this product.

Read this entire manual before you attempt to install your stage into your motion system. This familiarizes you with the stage components, their relationship to each other and the system.

After installation, check the configuration of the system parameters to be sure they are properly set for the stage in your motion system.

Follow all instructions carefully and pay special attention to safety concerns.

Additional Resources

These documents contain additional information concerning related products from Rockwell Automation.

Resource Description

High Precision Linear Motor Driven Stages Selection Guide, publication CHPS-SG001

Kinetix® 2000 Multi-axis Servo Drive User Manual, publication 2093-UM001

Provides product specifications, ratings, certifications, system interface, and wiring diagrams to aid in product selection.

Describes how to configure and use Kinetix 2000 multi-axis servo drives.

Kinetix 6000 Multi-axis Servo Drive User Manual, publication

2094-UM001

Describes how to configure and use Kinetix 6000 multi-axis servo drives.

LZ Family of Linear Motors Brochure, publication PMC-BR001 Provides product specifications, outline drawing, ratings, and wiring information to aid in product selection.

LC Family of Linear Motors Brochure, publication PMC-BR002 Provides product specifications, outline drawing, ratings, and wiring information to aid in product selection.


9

Preface

Notes:

10


Chapter

1

Stage Safety

Topic

Safety Labels

Clearances

General Safety

Heat

Vertical or Incline Payload

End Cap Impacts

Air Freight Transportation

Standards

Motor Model Identification

13

14

13

13

14

14

13

13

Page

12

IMPORTANT

Any person that teaches, operates, maintains, or repairs these linear stages must be trained and demonstrate the competence to safely perform the assigned task.


11

Chapter 1

Stage Safety

Safety Labels

Location Title

A Danger-Pinch Points and Heavy Objects

Label

B Danger-Hazardous

Voltage

C Danger-Strong

Magnets

D Do Not Lift by

Junction Box

E Stay Clear

F Sharp Edges

To prevent injury and damage to the stage, review the safety labels and their warning details and location before using the stage.

Details

The linear stage presents a muscle strain hazard if one person attempts to lift it. When attempting to move the linear stage use a two-person-lift to prevent personal injury or damage to the linear stage.

To Installer - There exists a Crush and Cut hazard while installing the linear stage. The linear stage weighs from 13…63 kg (28…140 lb).

To User - The Pinch Point label identifies a moving object hazard, caused by the movement of the carriage on the linear stage. Never put fingers, hands, or limbs near the linear stage while running motion commands. Before executing any motion command, check that all maintenance tools have been removed from linear stage.

All types of linear stages, especially uncovered, present a pinch point hazard. This hazard may occur if fingers or hands come between the end cap and a moving carriage. Always lift the linear stage by the base and keep fingers and hands away from the opening and edges parallel to the carriage.

The Hazardous Voltage label identifies the junction box as a hazardous voltage area of the linear stage. To avoid injury be sure to follow Lockout-

Tagout procedures before attempting maintenance on these linear stages.

The Strong Magnets label identifies non-ionizing radiation found in the linear stage. Magnet channels inside the linear stage are constructed with strong magnets. Strong magnets can disrupt the functionality of automatic implantable cardioverter defibrillators (AICD); people with a pacemaker should not work near the linear stage. Maintenance personnel working on the linear stage should avoid the use of metallic tools and secure items such as badge clip and other personal effects that could be attracted by the strong magnets. Strong magnets can erase magnetic media. Never allow credit cards or floppy disks to contact or come near the linear stage.

Do not attempt to move the linear stage by grasping the cable junction box.

Moving the linear stage in this manner will damage the linear stage and create a pinch or crush hazard. The junction box is attached to the carriage, which is free to move. Lifting the linear stage in this manner will allow uncontrolled movement of the heavy base. Always use a two-person lift and grasp the linear stage by the base at the end caps. Always keep fingers clear of the carriage’s path of travel.

Do not put hands or objects on the linear stage cover. Doing so could deform the cover and damage the linear stage, causing excessive wear on the cover supports or scraping noises when the linear stage is in motion.

Always remove strip seals before removing the top or side covers. If it becomes necessary to remove the top or side covers or change the strip seal, exercise care when working near or on the strip seal. The edges of the strip seal are sharp and can cut if accidentally hit or if handled inappropriately.

12


Figure 1 - Warning Label Locations

A

PINCH P

OINTS

Moving pa rts inside

Lockout

/ Tagout

LIFT HA

ZARD

Two Pe rson Lift or carry r equired

Stage Safety

Chapter 1

E

F

AG

CA

Ca pac sen sitiv

NE

TED

ha ake

DANG

TIC FIE

IN

TH

LD rm rs a qu ful ipm

IS A

to

ot en

RE he

ER

DANGE

R

VOLTAG

E

OUS

LOCKO

TAGOU

UT AND

T POWE

R

SERVIC ING

BEFORE

C

F

D

See Safety Labels on page 12 to identify call out letters.

B

Clearances

General Safety

Install the stage to avoid interference with the building, structures, utilities, other machines and equipment that can create a trapping hazard of pinch points.

Dress cables by using the

Clearance Requirements

diagram on

page 23 as a guide.

Do not cross the path of motion or interfere with the cable carrier motion.

Stages are capable of sudden and fast motion. Always Lockout-Tagout stage systems before doing maintenance. Systems integrated with stages must contain interlock mechanisms that prevent motion while users are accessing the stage.

Rockwell Automation is not responsible for misuse, or improper implementation of their equipment.

Heat

When running the stage at its maximum rating, the temperature of the slide can reach 75

ºC (167 ºF).

Vertical or Incline Payload

A vertically or inclined mounted stage does not maintain position with the power removed. Under the influence of gravity, the slide and its payload falls to the low end of travel. Design engineers must design in controlled power down circuits or mechanical controls to prevent the stage and its payload from being damaged when the power fails.

End Cap Impacts

The internal bumpers of the stage are designed to absorb a large impact from

uncontrolled motion. The table on page 53 lists the energy that the bumpers can

absorb before risking damage to the stage. The payload must be secured to the slide such that it does not sheer off in the event of an impact in excess of the bumper ratings.

The bolts securing the end caps are not be able to sustain multiple impacts and can eventually sheer. Correct the cause of the uncontrolled motion that caused the impact before continuing the use of the stage.


13

Chapter 1

Stage Safety

Air Freight Transportation

When air freighting stages special preparations and precautions must be taken.

The following information outlines the basic requirements at the publication date of this document. However, regulations are subject to change and additional area or carrier restrictions can be imposed. Check with your carrier or logistics specialist regarding current local, regional, and national transportation requirements when shipping this product.

The 200 mm or a 250 mm stages contain magnetized material, as classified by

International Air Transport Association (IATA) Dangerous Goods Regulations.

An IATA trained individual must be involved when shipping this product via domestic or international air freight. Packing Instruction 902 provides information regarding the preparation of this product for air transportation.

Follow these regulations for general marking and labeling requirements, the application of Magnetized Material Handling Labels, and instructions for preparing the Shipper's Declaration for Dangerous Goods.

As a minimum, refer to the following IATA Dangerous Goods Regulations:

• Subsection 1.5: Training

• Subsection 3.9.2.2: Classification as Magnetized Material

• Subsection 4.2: Identification as UN 2807, Magnetized Material, Class 9,

Packing Instruction 902

• Subsection 7.1.5: Marking

• Subsection 7.2: Labeling

• Subsection 7.4.1: Magnetized Material Label

• Section 8: Shipper’s Declaration for Dangerous Goods

When shipped via ground in the United States, these products are not considered a U.S. D.O.T. Hazardous Material and standard shipping procedures apply.

Standards

Standards and requirements applicable to this product include, but are not limited to, the following:

• ANSI/RIA R15.06, Industrial Robots and Robot Systems Safety

Requirements - Teaching Multiple Robots

• ANSI/NFPA 79, Electrical Standard for Industrial Machinery

• CSA/CAN Z434, Industrial Robots and Robot Systems- General Safety

Requirements

• EN60204-1, Safety of Machinery. Electrical Equipment of Machines

Motor Model Identification

The nameplate lists the motor model for the stage.

14


Understanding Your Stage

Topic

Identifying the Components of Your Stage

Recommended Maintenance Interval

Identifying Your Stage

18

18

Page

16

Chapter

2


15

Chapter 2

Understanding Your Stage

Identifying the Components of Your Stage

Use the diagrams and descriptions to identify individual stage components.

Figure 2 - Components of Your Linear Stage

4

3

2 (4x)

1

6

7 (2x)

8

9 (2x)

10 (4x)

5 (4x)

15

6

14 (4x)

13

12

11

17

16 (2x)

21

20

18

19

16



Chapter 2

18

19

16

17

20

21

13

14

15

5

6

7

8

9

10

11

12

3

4

1

2

Component

Number

Component Description

Component Description

Ground Screw and Ground Label Use the labeled M5 x 0.8 - 6H ground screw to connect to the linear stage to a facility safety ground.

Bearing Lubrication Ports These capped ports provide access to the linear bearings without dismantling the stage. In addition these tapped holes

(M10 x 15. -6H) can be used to secure lifting hooks (not provided)

Stage Slide

Stage Cover

Your application hardware mounts to this slide by using provide mounting holes.

If the strip seals are used this protective cover the stage has magnetic edges to keep the upper edge of the strip seals in place.

Seal Guide

Cable Carrier Module

Stage Side Cover

Side Cover Support

Stainless Steel Strip Seal

These guides lets the strip seal to move smoothly around the stage slide.

Facilitates quick and easy replacement. Replace the cable carrier module every 10 million cycles.

If the strip seals are used this protective cover the stage has magnetic edges to keep the lower edge of the strip seals in place.

These supports are used on long stages to stabilize the side cover.

Strip Seal Clamps

Index Mark

Optical Encoder Readhead

These replaceable, flexible stainless steel strips permit the stage to move while isolating the internal mechanism of the stage from environmental contaminants.

These clamps hold the strip seal in place. When replacing the strip seals, they are used to position it so it lays smooth against the top and side stage covers.

Part of the encoder system that provides a home location for the encoder.

This encoder readhead comes in various resolutions and requires little maintenance.

The TTL encoder option provides quadrature incremental position feedback with a differential signal on a RS-422.

Encoder Scale

Bearing

Motor Coil

Bearing Rail

Magnet Track

Limit Blade

Limit Sensor

Hall Sensor Module

Bumper Stop

The Sine/Cosine encoder option provides a 1 volt peak-to-peak sine and cosine output at a period of 20 μm. The Sine/Cosine encoder is also known as an analog encoder.

Part of the encoder system that provides an optical pattern to be read by the encoder readhead. It must be kept free of contamination for proper operation.

These support bearings guide the slide on the bearing rail, they require periodic lubrication.

This coil is part of the two piece linear motor. When excited by a linear drive, it generates magnetic forces that interact with the magnet track creating motion. LC linear motor option shown. LZ linear motors have a different configuration.

These rails provide the linear track that the slide assembly rides on, they must be kept free of debris.

This track of powerful static magnets is the other half of a linear motor. LC linear motor option shown. LZ linear motor option has a magnet channel.

Provides a mechanical trigger to the limit sensor.

These optional sensors output a signal when the limit blade passes in front of them. The position of these sensors can be

adjusted to suit your application, see Operation Guidelines and Limit Configuration section on page 49

.

Three Hall sensors in this module are provide for commutation startup and phase alignment. They can also be use for trapezoidal commutation of the motor.

These springs absorb slide and payload energy in the event the stage loses control. See page 53 for absorption limits.


17

Chapter 2


Recommended Maintenance

Interval

Under normal stage use, follow these lubrication guidelines.

IMPORTANT

You determine the frequency of re-lubrication that is best suited to your application as an application's environment, motion profile, and duty cycle can effect the re-lubrication time period required.

Lubricate the stage every 6 months or 2500 km (1550 mi) of travel, which ever comes first. Use the MPAS grease gun kit and grease cartridge (catalog numbers

MPAS-GPUMP and MPAS-CART respectively). See maintenance section for lubrication procedures.

Refer to Maintenance beginning on page 59 for lubrication procedures.

Identifying Your Stage

Use the following key to identify the options that your stage is equipped with. Be sure the information listed on the purchase order correlates to the information on the packing slip that accompanied your stage components. Inspect the assemblies and confirm, if applicable, the presence of specified options.

CHPS - A 6 054 A - F LM C 2 C

Bulletin Number

Voltage

A= 230V AC

Frame Size

6= 150 mm base

Stroke

Travel lengths start at 6 cm and are available in 6 cm increments.

For example: 006 for 6 cm travel or 054 for 54 cm travel.

Maximum travel = 120 cm.

Motor

A= LZ-030-T-120-D

B= LZ-030-T-240-D

C= LZ-030-T-240-E

Feedback

F= 1.0 micron incremental optical encoder, with integral index mark

G= 0.5 micron incremental optical encoder, with integral index mark

H= 0.1 micron incremental optical encoder, with integral index mark

I= 1V p-p sine/cosine encoder, 20 μm signal period, with integral index mark

Cable Management and Termination

A = No Cables or Cable Carrier (Slide Junction Box only)

B = Cables with Flying Leads and Cable Carrier

(1)

C = Cables with Kinetix MPF Connectors and Cable Carrier

(1)

D = Cables with D-Connectors and Cable Carrier

(1)

Limits

2 = No limits

5 = Two end of travel limits

Protection

S = Covered with strip seals (IP 30)

(2)(3)

C = Covered without strip seals

(2)

O = Open without any cover, without strip seals

LM Specifier

LM = Linear Motor

18



Chapter 2

CHPS - A 8 054 F - F LM C 2 C

Bulletin Number

Voltage

A= 230V AC

B= 460V AC (LC motors only)

Frame Size

8= 200 mm base

Stroke

For -100 and -120 motor coil lengths





For -200 or -240 motor coil lengths.



Motor

A= LZ-030-T-120-D

B= LZ-030-T-240-D

C = LZ-030-T-240-E

D= LC-050-100-D

E= LC-050-200-D

F= LC-050-200-E




(1)


(1)


(1)

Limits

2 = No limits


Protection

S = Covered, with strip seals (IP 30)

(2)(3)

C = Covered, without strip seals

(2)

O = Open, without cover, without strip seals

LM Specifier

LM = Linear Motor

Feedback

F = 1.0 micron incremental optical encoder, with integral index mark

G = 0.5 micron incremental optical encoder, with integral index mark

H = 0.1 micron incremental optical encoder, with integral index mark

I = 1V p-p sine/cosine encoder, 20 μm signal period, with integral

index mark

CHPS - A 9 054 G - F LM C 2 C

Bulletin Number

Voltage

A= 230V AC

B= 460V AC (LC motors only)

Frame Size

9= 250 mm base

Stroke




Motor

G = LZ-050-T-120-D

H = LZ-050-T-240-D

I = LZ-050-T-240-E

J = LC-075-100-D

K = LC-075-200-D

L = LC-075-200-E

(1) Not for upside down mounting.

(2) Contact Applications Engineering for upside down mounting.

(3) Strip seal and covers required for wall mount applications.




(1)


(1)


(1)

Limits

2 = No limits


Protection

S = Covered, with strip seals (IP 30)

(2)(3)

C = Covered, without strip seals

(2)

O = Open, without cover, without strip seals

LM Specifier

LM = Linear Motor

Feedback

F = 1.0 micron incremental optical encoder, with integral index mark

G = 0.5 micron incremental optical encoder, with integral index mark

H = 0.1 micron incremental optical encoder, with integral index mark

I = 1V p-p sine/cosine encoder, 20 μm signal period, with integral

index mark


19

Chapter 2


Notes:

20


Chapter

3

Planning the Stage Installation

Stage Mounting

Requirements

Topic

Stage Mounting Requirements

General Safety Standards for Stage Installations

Mounting Restrictions

Environmental Factors

Mounting Surface Restrictions

Clearance Requirements

22

22

23

21

21

Page

21

Requirements to be met when mounting your CHPS-Series stage include the following.

General Safety Standards for Stage Installations

General safety standards and requirements include, but are not limited to, the following:

• ANSI/RIA R15.06, Industrial Robots and Robot Systems Safety

Requirements - Teaching Multiple Robots

• ANSI/NFPA 79, Electrical Standard for Industrial Machinery

• CSA/CAN Z434, Industrial Robots and Robot Systems- General Safety

Requirements

• EN60204-1, Safety of Machinery. Electrical Equipment of Machines

Mounting Restrictions

When locating your CHPS-Series stage include the following.

• Environmental Factors

• Mounting Surface Restrictions

• Mounting Orientation

• Clearance Requirements


21

Chapter 3

Planning the Stage Installation

Environmental Factors

Factor Applicability

Temperature The stage does not require any special cooling considerations. Avoid mounting it near any heat generating objects, such as a heat register. Sustained average temperature must not be greater than 40 °C (104 °F), nor less than 0 °C (32 °F).

Humidity Avoid excessive humidity. Condensation on metal surfaces can cause stage corrosion. The maximum permissible humidity is 80% relative.

Access and Interference When possible, locate the system where sufficient working space is available to perform periodic maintenance.

Avoid installing where a trapping hazard or pinch point occurs as a result of interference with the building, structures, utilities, and other machines and equipment.

Dust and airborne contaminants

Avoid placing the stage in areas where excessive dust or other airborne contaminants are present. Chemical fumes or vapors can cause damage to internal components.

Vibration

Ambient Light

Install the stage in a location free of excessive vibration.

Have sufficient light readily available to enable inspection, testing and other functions to be performed on the stage.

Mounting Surface Restrictions

Mounting Orientation Restriction

Surface Stages are to be bolted or clamped to a flat, stable, and rigid surface along its entire length. Flatness deviation in the mounting surface must be less than or equal to

0.025 mm over a 300 x 300 mm (0.001 in. over a 12 x 12 in.) area.

Flatness must be maintained during operation of the stage.

Ceiling - inverted surface A ceiling mount (inverted on a horizontal surface) is not recommended. Stages mounted in this orientation are subject to premature cable carrier failure.

Wall - horizontal Horizontal wall mount stages must be installed with the cable carrier below the stage.

Stages mounted horizontally on a wall must have a travel of 1 m (3.28 ft) or less. Stages with a travel length greater than 1 m (3.28 ft) are subject to premature cable carrier failure.

Wall - vertical or incline Stages mounted vertically on a wall must have a travel of 1 m (3.28 ft) or less. Stages with a travel length greater than 1 m (3.28 ft) are subject to premature cable carrier failure.

22



Chapter 3

Clearance Requirements

The figures depict the minimum clearances for each stage type.

Power and feedback cables can impose additional clearance requirements. Refer to

Interconnect Cables on page 85

for connector and bend radius requirements.

Figure 3 - Minimum Clearance Requirements

Covered Stage: 419 mm (16.5 in.)

Clearance on Both Ends for Lubrication Access

Uncovered Stage: 3.2 mm (0.125 in.)

Clearance All Around

Cabling: 19 mm (0.75 in.) Clearance for Cable Routing


23

Chapter 3


Notes:

24


Chapter

4


Topic

Unpacking, Handling, and Inspection

Unpacking Procedure

Store Packaging Material

Stage Storage

Mounting the Stage

Before You Begin the Mechanical Installation

Determine the Number of Fasteners Required

Determine the Type of Fastener to Use

Mounting the Stage

Mount Your Application

29

31

32

28

28

28

28

26

28

Page

25

IMPORTANT

Any person that teaches, operates, maintains, or repairs these stages must be trained and demonstrate the competence to safely perform the assigned task.

Unpacking, Handling, and

Inspection

Inspect packaging to make certain no damage occurred in shipment. Document any damage or suspected damage. Claims for damage due to shipment are usually made against the transportation company. If you suspect damage, contact

Rockwell Automation immediately for further advice.

Be sure the information listed on the purchase order correlates to the information on the packing slip for your stage and its accessories.


25

Chapter 4

Mounting the Stage

Inspect the assemblies and confirm, if applicable, the presence of specified options.

ATTENTION: Linear motor driven stages contain powerful permanent magnets that require extreme caution during handling. Do not disassemble the stage.

The forces generated by permanent magnets are very powerful and can cause bodily injury.

Persons with pacemakers or automatic implantable cardiac defibrillators (AICD) must maintain a minimum distance of 0.3 m (12 in.) from magnet assemblies.

Additionally, unless absolutely unavoidable, a minimum distance of 1.5 m (5 ft) must be maintained between magnet assemblies and other magnetic or ferrous composite materials. Calipers, micrometers, laser equipment, and other types of instrumentation must be nonmetallic.

Unpacking Procedure

The following tools are recommended for unpacking the stage:

• Utility knife

• 2.5 mm, 5 mm, and 6 mm hex keys

• Packing tape

1. Place carton on flat stable surface with the tape seam side facing you.

2. Use a utility knife to score the packing tape on the edges of the carton.

3. Lift center cover to reveal the stage.

Users Manual

26

Desiccant

4. Remove the packing end caps.

Packing End Caps

ATTENTION: Never attempt a single-person lift. Personal injury and equipment damage can occur if the linear stage is handled improperly.


Mounting the Stage

Chapter 4

5. Remove the linear stage from the packaging supports.

• For stages shorter than 1 meter (39.3 in.), use two people and lift the linear stage by grasping the base near the end caps only.

• For stages 1 meter (39.3 in.) or longer, use support straps at the 1/4 and 3/4 length points to avoid distorting the base. Use this support system whenever the linear stage must be lifted.

1/4 1/4 1/4 1/4

End Cap Support Straps End Cap

6. Move the linear stage to a solid support surface before removing the shipping brace.

ATTENTION: The carriage is free to move once the shipping brace is removed.

Use additional care when handling the linear stage after the brace is removed.

Unexpected carriage movement can cause personal injury.

7. Remove the four socket head cap screws (SHCS) from the shipping brace.

8. Lift the shipping brace off the stage and set it aside.

M6 x 30 SHCS (2x) for

CHPS-x6xxxx-xLxxx (150 mm)


CHPS-x8xxxx-xLxxx (200 mm) and


Shipping Brace




CHPS-x8xxxx-xLxxx (200 mm) or


Shipping Clamp

M3 SHCS, washer, and nut (4x)

9. Remove the plastic wrap enclosing the stage and set it aside.

10. Remove the four SHCS that secure the shipping clamp.


27

Chapter 4

Mounting the Stage

Stage Storage


28

11. Remove the four square nuts loosened in the previous step, by sliding each nut to the end of channel.

Store Packaging Material

Keep the carton in case the unit needs to be returned for warranty service or stored for an extended period of time.

1. Tape screws and clamp hardware to the shipping brace.

2. Put end caps in their original positions on the center cover and place all packing material inside the carton.

3. Lightly tape carton closed and store in dry place.

Store the stage in area that is clean, dry, vibration free, and at a relatively constant temperature. Refer to Environmental Specifications for CHPS-Series Stage on

page 75

for more detailed information.

This section discusses mounting methods for your stage.

Before You Begin the Mechanical Installation

The machine designer is most qualified to determine the number and type of fasteners to use for mounting the stage. The following information is a guide for the decision-making process.

Determine the Number of Fasteners Required

The length of the stage determines the number of mounting fasteners that are required.

Use one of the following equations to calculate the required mounting hardware.

Figure 4 - Fasteners Required for Stages with 150 mm and 200 mm frame size (CHPS-x6xxxxxLMxxx and CHPS-x8xxx-xLMxxx)

fasteners =







 stroke (cm)

12

+ 26 (cm)



 round down + 1





×

2

Figure 5 - Fasteners Required for Stages 250 mm frame size (CHPS-x9xxx-xLMxxx)

fasteners =









-----------------------------------------------------------



 round down +1





×

2 or example, if you are mounting an CHPS-B8194F-ALM02C stage.


Fastener

Through Bolt

(1)

Order

–

Mounting the Stage

Chapter 4

1940 mm stroke length = 194.0 cm fasteners =

12

=

230

19.167

12

= fasteners = round down = 19

19 + 1 = 20

×

2 = 40 fasteners

Determine the Type of Fastener to Use

Three types of fasteners that can be used to mount the stage.

• Through bolts

• Toe clamps

• Tee nut or square nut

Toe clamps are supplied with the catalog number CHPS-

x6xxx stages, and covered types of the catalog number CHPS-

x8xxx and CHPS-x9xxx stages.

Refer to the Mounting Fastener Options table for an illustration of each fastener

type.

Table 1 - Mounting Fastener Options

Illustration User Supplies

(4)

M5 x 1.0 x 16 mm min

Recommended For

Uncovered stages

Torque

N•m (lbf•in)

2.3 (30)

Toe clamps MPAS-TOE M6 x 1.0 x 16 mm min Covered stages 5.5 (48)

Tee nuts

(2)

MPAS-x-TNUT

(3)

M6 x1.0

Securing a stage from beneath the mounting surface.

Tee Nut 6.7 (60)

Square Nut 2.3 (30)

(1) Through bolt mounting is not an option for catalog number CHPS-x6xxxx-xLMxxx (150 mm) stages.

(2) The tee nut mount for a catalog number CHPS-x8xxxx-xxxxx (200 mm) stage is a square nut in a tee slot.

(3) Where x is the frame size of a stage, 6 = CHPS-x6xxxx-xxxxx (150 mm), 8 = CHPS-x8xxxx-xxxxx (200 mm), 9 = CHPS-x9xxxx-xxxxx (250 mm).

(4) You supply the bolts.


29

Chapter 4

Mounting the Stage

Figure 6 - Through Bolt Mounting

IMPORTANT

Through bolt mounting is not available for the catalog number

CHPS-x6xxxx-xxxxx (150 mm) stages.

An uncovered stage is a good candidate for through bolt mounting.

For covered stages, toe clamps are the easiest method for mounting. On sides of the base secure a toe clamps every 120 mm (4.72 in) by using M6 SHCS as shown in the

Toe Clamps Mounting

diagram. Use slots formed into outside edge of the stage base.

Figure 7 - Toe Clamps Mounting

120 mm

(4.72 in.)

30


Mounting the Stage

Chapter 4

Tee nuts are used to mount the stage from underneath. Insert the tee nuts every

120 mm (4.72 in.) in tee slots on the bottom of the unit. Secure the tee nuts by using M6 SHCS as shown in

Tee Nut Mounting

diagram.

Figure 8 - Tee Nut Mounting

T-Slots


Follow these steps to install a stage on its mounting surface.

1. Be sure the mounting surface is clear of any and all foreign material.

IMPORTANT

Do not use abrasives to clean the surface.

If necessary, stone the mounting surface (acetone or methanol can be applied as cleaning agent).

2. Verify that the flatness of the surface that the stage is to be mounted.

The total indicator reading (TIR) is 0.0254 mm (0.001 in.) per 300 mm

(120 in.). TIR or runout, correlates to an overall flatness of a surface.

3. Lift the stage onto the prepared mounting surface

ATTENTION: Do not attempt to move the stage by grasping the cable junction box. Moving the stage in this manner can damage the stage and create a pinch or crush hazard. The junction box is attached to the carrier that is free to move.

Lifting the stage in this manner causes uncontrolled movement of the heavy base. Always use a two person lift and grasp the stage by the base at the end caps keeping fingers clear of the carrier’s path of travel.

The two lubrication ports on each end cap (four total) are M10 x1.5 tapped through holes and can be used to install lifting hooks supplied by the customer.

Personal injury and equipment damage can occur if stage is handled improperly.


31

Chapter 4

Mounting the Stage

4. Align the stage on the mounting surface, and insert the correct number of mounting bolts. Refer to CHPS-Series Stage Dimensions beginning on

page 77 for detailed mounting dimensions.

5. Secure the stage by using all mounting holes. Torque bolts to the values

shown in the Mounting Fastener Options table on page 29

.

Mount Your Application

Mount your application to the slide by using the following bolts and torque values:

Cat. No.

CHPS-x6xxxx-xLMxxx

CHPS-x8xxxx-xLMxxx

CHPS-x9xxxx-xLMxxx

Bolt

M6

M8

M8

Torque

N•m (lb•in)

3.2 (48)

10.1 (90)

10.1 (90)

32


Connector Data

Topic

Kinetix Servo Drive Compatible Connectors

D-Type Connectors

Flying Leads

Junction Box Connectors

Limit Sensor Flying Leads

Chapter

5

37

38

35

36

Page

34


33

Chapter 5

Connector Data

Kinetix Servo Drive

Compatible Connectors

The following tables identify the power and feedback pinouts for the Intercontec circular connectors for use with standard Allen Bradley connectors.

Pin Color Wire

7

8

5

6

3

4

1

2

15

16

13

14

11

12

9

10

Yellow

White/yellow

Brown

White/Brown

Violet

White/Violet

Reserved

Reserved

White/Red

Black

Reserved

Green

White/Black

White/Green

Blue

17 White/Blue

Case Shield

(1) PTC Temp- is connected to Common.

PTC Temp+

(1)

Common

S1

S2

S3

Shield

A+

A-

B+

B-

B

C

Pin

A

Color

Red

White

Black

Signal

U (A) Phase

V (B) Phase

W (C) Phase

D Green/Yellow Ground

Case Shield Cable

With Incremental Encoder

Signal

Designations

Signal Description

Index Mark+

Index Mark-

—

—

+5V DC

Common

—

TTL - Differential

TTL - Differential

TTL - Differential

TTL - Differential

TTL - Differential

TTL - Differential

—

—

Encoder and Hall Sensor Power

—

—

A

L

B C

G

F

H

E

D

Index+

Index-

Reserved

Reserved

+5V DC

Common

Reserved

Sin+

Sin-

Cos+

Cos-

Intercontec P/N BKUA090NN000550003500

Mating Cable: Allen-Bradley 2090-XXNPMF-16Sxx

With Analog Encoder

Signal

Designations


Analog Differential 1V p-p




Differential Pulse 1V p-p


—

—


—

—

PTC Thermistor

—

TTL - Trapezoidal Hall



—

PTC Temp+

Common

S1

S2

S3

Shield

(1)

PTC Thermistor

—




—

34

10

11 12

9

16

1

13

8

15

7

17

6

5

14

4

2

3

Intercontec P/N AKUA034NN00100035000

Mating Cable: Allen-Bradley 2090-XXNFMF-Sxx


Connector Data

Chapter 5

D-Type Connectors

The following tables identify the power and feedback pinouts for D-shell connectors that enable custom cables to be used.

Pin

A1

A2

A3

A4

Case

Color

Red

White

Black

Green/Yellow

Signal

U (A) phase

V (B) phase

W (C) phase

Ground

M

A1 A2 A3

A4

Positronic P/N CBD9W4M20000-1702.0

Mating Connector:

Positronic P/N CBD9W4F20000-1701.0

Pin

13

14

15

16

17

9

10

11

12

7

8

5

6

3

4

1

2

Color Wire

Yellow

Brown

Violet

White/Red

Reserved


Signal

Designations


A+

B+

Index Mark +

+5V DC

—

White/Green

Green

Reserved

White Blue

Green/Yellow

White/Yellow

White/Brown

White/Violet

Black,

White/Black

Reserved

22

23

24

25

18

19

20

21

Blue

Reserved

—

S2

—


S1

PTC Temp+

(1)

—

S3

Shield

A-

B-

Index Mark-

Common

TTL - Differential

TTL - Differential

TTL - Differential


—


PTC Thermistor

—


—

TTL - Differential

TTL - Differential

TTL - Differential

—

—


—


Signal Designations

Sin+

Cos+

Index+

+5V DC

—

S1

PTC Temp+*

—

S3

Shield

Sin-

Cos-

Index-

Common

—

S2

—






—


PTC Thermistor

—





—

—


—

1

1

14

25

13

M

Connector Part Number AMP P/N 207464-2

Mating Connector Part Number AMP P/N 5205207-1


35

Chapter 5

Connector Data

Flying Leads

The following tables identify the power and feedback pinouts for flying lead this option lest you to use your own connectors.

ATTENTION: Disconnect input power supply before installing or servicing stage

Stage lead connections can short and cause damage or injury if not well secured and insulated.

Insulate the connections, equal to or better than the insulation on the supply conductors.

Properly ground the stage as described in the drive manual.

Color

Red

White

Black

Green/Yellow

Signal

U (A) phase

V (B) phase

W (C) phase

Ground

Yellow

White/Yellow

Brown

White/Brown

Violet

White/Violet

Red

White/Red

Black

White/Black

Green

White/Green

Blue

White/Blue

Green/Yellow

Color Wire


Signal

Designations

A+


TTL - Differential

A-

B+

B-

Index Mark+

TTL - Differential

TTL - Differential

TTL - Differential

TTL - Differential

Index Mark-

+5V

+5V

Common

Common

PTC Temp+

S1

S2

S3

Shield

(1)

TTL - Differential



—

—

PTC Thermistor




—



Signal

Designations

Sin+


Analog - Differential 1V p-p

Sin-

Cos+

Cos-

Index+





Index-

+5V

+5V

Common

Common

PTC Temp+

S1

S2

S3

Shield

(1)




—

—

PTC Thermistor




—

36


Junction Box Connectors

Connector Data

Chapter 5

The following diagram and tables identify the power and feedback pinouts of the junction box connector, use this information to make custom cables

A

B

Pin 1

9

D C

12

6

8

16

7

Pin 1

E

4

Pin 1

D

E

B

C

Item Description

A J1 Feedback connector, output to flex cable, Mating connector is a Molex P/N 43025-1600

J2 Thermistor signal connector, the input from side

J3 Hall signal connector, input from side

J4 Encoder signal connector, input from side

Mating power connector AMP 359780-1

Signals from slide

Header 2X6 Right Angle

J4

8

9

10

11

12

6

7

4

5

1

2

3

ENCA+

ENCB+

INDEX+

POSLIM

GND

SHIELD

ENCA-

ENCB-

INDEX-

NEGLIM

5V

Header 2X3, Right Angle

J3

6

5

4

3

2

1

HALLS1

HALLS3

5V

SHIELD

HALLS2

GND

Header 2, Right Angle

J2

2

1

TEMP+

GND

SHIELD

HALLS3

ENCA+

ENCB+

INDEX+

POSLIM

GND

HALLS1

HALLS2

ENCA-

ENCB-

INDEX-

NEGLIM

5V

TEMP+

Header 2x8, Vertical

To flexible feedback cable

14

15

16

10

11

12

13

7

8

5

6

9

3

4

1

2

J1

TP1

Shield terminates to mounting hole


37

Chapter 5

Connector Data

Table 2 - Junction Box Power Connector

2

3

Pin

1

4

Color

Red

White

Black

Green/Yellow

Table 3 - Junction Box J1 Connector

Signal

U (A) phase

V (B) phase

W (C) phase

Ground

Pin

9

10

5

8

3

4

1

2

13

15

11

12

16


Shield

S3

A+

B+

S1

S2

Index Mark+

Common

A-

B-

Index Mark-

+5V

PTC Temp+

(1)


Signal Designation Signal Description

—


TTL - Differential

TTL - Differential

TTL - Differential

—



TTL - Differential

TTL - Differential

TTL - Differential


PTC Thermistor


Signal

Designation

Shield

S3 -

Sin+

Cos+

S1

S2

Index+

Common

Sin-

Cos-

Index-

+5V

PTC Temp+

(1)


—





—







PTC Thermistor

Limit Sensor Flying Leads

The limit sensor option comes with flying leads, regardless of the power and feedback termination option ordered.

Color

Brown

Black

Blue

(1) Load- is connected to 0V.


+V

Load+

0V

(1)

38


Chapter

6



Topic

Connecting the Stage

Attaching the Ground Strap and Interface Cables

Thermal Protection

Optional Limit Sensors

TTL Differential Encoder Output Signal

Sine/Cos Encoder Output Signals

Hall Effect Circuit

Motor and Hall Phasing and Sequence

Stage Positive Direction

43

44

45

46

46

48

40

42

Page

39

The installation procedure assumes you prepared your system for correct electrical bonding and understand the importance of electrical bonding for correct operation of the system. If you are unfamiliar with electrical bonding, the

section Attaching the Ground Strap and Interface Cables briefly describes and

illustrates correct system grounding techniques.

ATTENTION: Plan the installation of your stage so that you can perform all cutting, drilling, tapping, and welding with it removed. Be careful to keep any metal debris from falling into it. Metal debris or other foreign matter can become lodged in the stage, that can result in damage to components.

SHOCK HAZARD: To avoid hazard of electrical shock, perform all mounting and wiring of the stage prior to applying power. Once power is applied, connector terminals can have voltage present even when not in use.


39

Chapter 6


Attaching the Ground Strap and Interface Cables

The only electrical connections necessary between the stage and the drive system are the ground strap and the two cables.

1. For electrical safety, connect the ground screw on the chassis of the stage to the ground bus for your system.

To reduce the effects of electromagnetic interference (EMI), bond the stage with a braided ground strap, 12 mm (0.5 in.) wide minimum, to a grounded metal surface. This creates a low-impedance return path for high-frequency energy.

2. Torque the ground screw at the stage to 2 N•m (18 lb•in)

40

M5 x 0.8 -6H

Ground Screw

Lug

Braided Ground Wire 12 mm (0.5 in) min.

3. Form a drip loop in each cable at a point directly before it attaches to the

stage. Refer to the Connecting Kinetix Type Motor and Feedback Cables

diagram for a visual example.

ATTENTION: Be sure that cables are installed and restrained to prevent uneven tension or flexing at the cable connectors.

Excessive and uneven lateral force at the cable connectors can result in the connector’s environmental seal opening and closing as the cable flexes.

Failure to observe these safety procedures could result in damage to the motor and its components.



Chapter 6

4. Attach the feedback cable, and the power cable to the stage.

ATTENTION: Do not connect or disconnect the stage feedback cable, or the power cable while power is applied to them.

Inadvertent pin connections can result in unexpected motion or result in irreversible damage to the components.

For Kinetix type connectors. a. Carefully align each cable connector with the respective motor connector as shown in Figure 1. b. Do not apply excessive force when mating the cable and stage connectors. If the connectors do not go together with light hand force, realign and try again.

ATTENTION: Be sure that cables are installed and restrained to prevent uneven tension or flexing at the cable connectors. Excessive and uneven lateral force at the cable connectors can result in the connector’s environmental seal opening and closing as the cable flexes. Failure to observe these safety procedures could result in damage to the motor and its components.

c. Hand tighten the knurled collar five to six turns to fully seat each connector.

ATTENTION: Keyed connectors must be properly aligned and handtightened the recommended number of turns.

Improper alignment is indicated by the need for excessive force, such as the use of tools, to fully seat connectors.

Connectors must be fully tightened for connector seals to be effective.

Failure to observe these safety procedures could result in damage to the motor, cables, and connector components.

Figure 9 - Connecting Kinetix Type Motor and Feedback Cables

Align flat surfaces.

Align flat surfaces.

Feedback

Connector

Power Connector

Cable

Drip Loop


41

Chapter 6


Thermal Protection

Connect the stage PTC thermistor signal to the drive or control system to create a thermal protection system.

PTC Thermistor Signal Characteristics

Temperature °C (°F)

Up to 100 (212)

Up to 105 (221)

Up to 110 (221)

Resistance in Ohms

≤

750

≤

7500

≥

10,000

ATTENTION: PTC thermistor supplies a signal that indicates the stage temperature limit condition. Connect this signal to control system or drive system so it shuts down the stage power upon reaching a limit condition.

Multiple levels of stage thermal protection are strongly recommend.

The following thermal protection methods are also recommended.

• Typically digital drives use RMS current protection and or estimated temperature vs. time (I

2

T) software protection schemes. Activated and set these available features according to the stage model ratings for your application.

• Set the maximum value of ± peak-current-magnitude limits of your drive to the stage’s peak-current rating.

• For drives without stage protection features, install stage fuses (current rating not to exceed stage continuous RMS) according to local and

National Electrical Code. Uses time-delay type fuses that are rated for the drive PWM output voltage.

42


Optional Limit Sensors


Chapter 6

Two limit sensors, positive overtravel (OT) and negative OT, provide electrical

protection for stage overtravel. Their physical location is shown in Component

Description diagram on page 16 they and can be adjusted up to 30 mm (1.2 in.)

toward the center of travel. The electric characteristics are shown here.

• Input Power: 12

…

28V DC, 15 mA circuit draw + 50 mA maximum sourcing = 65 mA total.

• Output: PNP, Open collector Normally Closed, 50 mA maximum sourcing.

Brown

+ V

Main

Circuit

Black

Limit

Blue

+V com

Figure 10 - Limit Sensor Orientation

Adjustable

Negative OT Limit on this side

Limit Sensor cables exit here

Adjustable

Positive OT Limit on this side


43

Chapter 6


TTL Differential Encoder

Output Signal

44

Use the following information to connect a stage with a TTL Differential Encoder.

The incremental encoder typically have the following quadrature edge separation.

Encoder

μm

Typical Edge Separation

ns

1 100

0.5

@ Maximum Velocity

m/s

5

(1)

90 3

0.1

90 0.7

(1) Speeds based on 3 m maximum cable length and a minimum readhead input of 5V.

To calculate the minimum recommended counter frequency for 1

μ m and

0.5

μ m encoders, use the following formula.

Counter clock frequency (MHz) = resolution

( μ

( m

)

)

×

4 (safety factor)

The minimum recommend counter frequency for the 0.1

μ m encoder is 12 MHz.

Figure 11 - TTL Differential Encoder Timing Diagram

Incremental 2 channels A and B in quadrature (90° phase shifted)

Quadrature edge separation

ENC A+

ENC B+

Reference

Index

Mark +

Figure 12 - TTL Differential Encoder Termination

Readhead

ENC A +,

ENC B +,

& Index Mark +

Index Mark pulse in synchronised to one position count. Repeatability of position

(uni-directional) is maintained if temperature is 15…35 °C (59…95 °F) and speed is <250 mm/s (9.8 in./s).

Drive or

Controller

Square wave differential line driver to EIA RS422A

120 Ω

(1)

Standard RS422A line receive circuit

(1) Total termination resistance in ohms.

ENC A -,

ENC B -,

& Index Mark -


Sine/Cos Encoder Output

Signals


Chapter 6

Use the following information to connect a stage with a Sine/Cosine Encoder option to a drive or controller that processes sine/cosine position feedback.

The sine/cos encoder amplitude is 0.90V p-p minimum up to 2 meters per second. 0.60V p-p up to 4 meters per second.

Figure 13 - Sine/Cos Encoder Timing

Incremental 2 channels V1 and V2 differential sinusoids in quadrature (90° phase shifted)

20 μm

Sine = (V1+)-(V1-)

90°

0.6 …1.2V p-p with green

LED indication and

120 Ω termination

Cosine = (V2+)-(V2-)

Reference

(V0+)-(V0-)

-18º

0º

108º

0.8…1.2V p-p

Differential pulse V0 - 18°…108°

Duration 126° (electrical) Repeatability of position (uni-directional) is maintained if temperature is 15…35 °C and speed is <250 mm/s

Recommended termination = 120 Ω resistors, V0, V1, V2.

Figure 14 - Sine/Cos Encoder Termination

Readhead

ENC A +,

ENC B +,

& Index Mark +

Drive or

Controller

120 Ω

(1)

ENC A -,

ENC B -,

& Index Mark -

(1) Total termination resistance in ohms.


45

Chapter 6


Hall Effect Circuit

Use the following information to connect the Hall Effect circuit to your servo drive.

• Input power: 5

…

24 V DC, 10 mA maximum

• Output: NPN, Open Collector, 10 mA maximum

V+

Hall Signal

Rp

Isink

Hall S1

Hall S2

Hall S3

Drive

Isink = 10 mA Maximum

Rp = External pull-up resistor

Motor and Hall Phasing and

Sequence

Consult drive manual or supplier for wiring instructions for your drive. Motor wiring is phase and commutation sensitive. Motor Phasing Diagram shows the standard phase and sequence relationship of the motor when phased in the positive direction. The Hall signals are used by a compatible three-phasebrushless servo drive to perform electronic commutation. Two types of servo drive Hall-based commutation techniques are possible, Trapezoidal Hall Mode and Encoder Software Mode with Hall startup. For optimal commutation and force generation, the selected servo drive must be compatible with the motor phasing and be wired correctly.

• Observe maximum applied voltage specification.

• Consult drive manual or supplier for drive wiring instructions. Wiring is phase and commutation sensitive.

• Terminate per drive manual instructions.

• Hall Signals, 120 o

Spacing, Open Collector Transistor 24V maximum.

• Refer to CHPS-Series Stage Connector Data starting on

page 33 for

termination options, pin, and wire designations.

ATTENTION: Incorrect motor, Hall, or encoder wiring can cause runaway conditions.

46


As shown in the Motor Phasing Diagram:

S1 in phase with W-U Back EMF

S2 in phase with U-V Back EMF

S3 in phase with V-W Back EMF

Phase sequence = S1 leads S2 leads S3. Spacing is 120°.

Figure 15 - Motor Phasing Diagram

Back EMF Voltage vs. Hall Signals


Chapter 6

W-U

Back

EMF

Voltage

U-V

V-W

S1

Digital

Hall

Signals

S2

S3

Linear Travel mm (in.)

0° 60° 120° 180° 240° 300° 360°

Motor Type

50 (1.97)

LC

60 (2.36) LZ

Phasing direction = Slide toward positive end block,

IMPORTANT Phasing direction = Positive stage direction.


47

Chapter 6


Stage Positive Direction

Stage positive direction is defined by a location of a Slide End Cap.

Slide End Cap + Slide = Slide Assembly

(+)

Positive Direction

(-)

48


Chapter

7

Operation Guidelines and Limit Configuration

Introduction

Operational Guidelines

This chapter gives you operational guidelines and limit sensor position adjustment procedures.

Topic

Operational Guidelines

Travel Limits

Calculating the Stopping Distance

Overtravel Limit Sensor Position Adjustment

Bumper Stops

51

53

50

50

Page

49

Please read the following notices about using your stage.

ATTENTION: A runway condition is caused by incorrect motor, Hall, or encoder wiring. It results in uncontrolled speeding of the stage. Keep away from the line of travel while commissioning the stage.

IMPORTANT

The customer is responsible for ensuring the servo control system safely controls the stage with regards to maximum force, acceleration, speed, and preventing runaway conditions.

ATTENTION: Stages are capable of very high forces, accelerations and speeds.

Moving parts can cause personnel injury. Before running the stage, make sure all components are secure.

Check that the stage travel and air gap is clear of foreign matter and tools.

Objects hit by the moving stage can cause personnel injury or damage to the equipment.

ATTENTION: Do not operate the stage with protective covers removed. Do not go near electrically live parts. High voltages can cause personal injury or death.


49

Chapter 7

Operation Guidelines and Limit Configuration

Travel Limits

CHPS-Series stages offer three methods for containing slide travel: software travel limits, optional overtravel limit sensors, and standard bumpers stops. For safest operation use all three.

Set software travel limits and overtravel limit sensors according to the maximum speed of the servo drive system and the payload of the application. You can determine the Deceleration Distance between the slide and the end-of-travel bumpers based on the combination of the Deceleration Rate of the load, and the available peak force from the stage-drive. Do a calculation similar to the one in

Calculating the Stopping Distance for your application.

Bumper Stop on the stage can stop the slide up to the ratings listed in the table on

page 53.

IMPORTANT

Bumper stops are not intended as range of motion stops, but they can stop the moving slide up to the ratings listed in

Bumper Stops on page 53 .

Calculating the Stopping Distance

In the following example we calculate the stopping distance for a 10 kg payload on a CHPS-x8xE-xLMxxxx stage driven by a Kinetix 6000 drive (2094-xxxxx) by using the specification found in

Appendix A . Substitute values for your system as

necessary.

Known Values:

Slide Moving Mass = 10.32 kg

Payload = 10 kg

Maximum Programmable Velocity

(1)

, Vmax = 2 m/s

Available Peak Force

(2)

= 600 N @ 23.2 A o-pk

Start with:

Total Moving Mass = m = Payload + Stage Moving Mass

= 10 kg + 10.23 kg = 22.23 kg

50

So the maximum deceleration rate, Dmax is 26.99 m/s

2

.

(1) Velocity and kinetic energy can be much higher due to a uncontrolled worst-case motion constrained by the stroke and power capacity of the motor drive paring only.

(2) Approximation only; actual peak force typically decreases as speed increases.


Calculate the deceleration time, T d

.


Chapter 7

Use T d

to calculate the deceleration distance.

Therefore, you set the software travel limits to 74 mm.

IMPORTANT

Velocity and deceleration distance can be much higher due to an uncontrolled worst-case motion constrained by the stroke and power capacity of the motordrive paring only.

Drive Current Limitation

Your available peak force can be limited by your drive’s peak current.

For example a drive with a peak rating of 15 A o-pk has available peak force 386 N.

Here is the calculation:

Overtravel Limit Sensor Position Adjustment

Maximum stage travel is defined as the distance the slide can travel between end caps such that the bumper stop can touch the end cap but not be compress. You can shorten the slide travel up to 30 mm (1.18 in.) by adjusting the overtravel limit sensor.


51

Chapter 7


To adjust overtravel limit sensor:

1. Measure location from end block to the inside tip of the overtravel limit sensor.

Bumper Stop

End Block

Slide

Limit Blade

Overtravel Limit Sensor

2. Loosen screw and slide the overtravel limit sensor toward center of stage. It can be adjusted up to 30 mm.

Correct

Make adjustments without compressing the bumper.

Bumper Stop

Slide

End Block

Limit Blade


Original position

Can cause programming anomaly.

Slide

39 mm adjust

up to 30 mm

End Block

Limit Blade


IMPORTANT

Do not adjust the switch more than 30 mm. Doing so can cause a programming anomaly.

3. Redress the limit sensor cables with the cable clips. Make sure wires are neatly against the base and do not interfere with the motion of the limit blade.

52



Chapter 7

Bumper Stops

In addition to software overtravel limits and limit sensors the end of travel bumper stops can stop the slide up to the ratings listed. Bumper stops are not intended to be used as range of motion stops.

Table 4 - Bumper Stop Energy Limits for Stage End of Travel

Cat. No.

CHPS-x6xxxx-xLMxxx

CHPS-x8xxxx-xLMxxx

CHPS-x9xxxx-xLMxxx

Bumper Stop Energy Limit

37.3 J (330 in•lb)

45.5 J (403 in•lb)

35.2 J (312 in•lb)

ATTENTION: If energy greater than the bumper capacity is anticipated in the application, provide additional mechanical means for safely stopping the slide.

To calculate kinetic energy of the slide with your payload use the formula

J in jules

M = moving mass in kg (slide + payload)

V = maximum velocity of stage in your application in m/s

(1)

(1) Velocity and kinetic energy can be much higher due to a uncontrolled worst-case motion constrained by the stroke and power capacity of the motor drive pairing only.

(1)


53

Chapter 7


Notes:

54


Chapter

8

Troubleshooting

Before You Begin

PTC Thermal Signal

Hall Effect Module

Topic

Before You Begin

PTC Thermal Signal

Hall Effect Module

Hall to Back EMF Phasing

Motor Coil Resistance Measurements

57

58

55

55

Page

55

The following test equipment is required:

• Ohm meter

• Two-channel storage oscilloscope

At ambient room temperature, approximately 25 ° C (77 °F), check that the resistance measurement between PTC Temp+ and Common (pins 13 and 14, respectively) on the feedback connector is

≤

750

Ω

.

The table lists increase in resistance at higher temperatures outside the normal operating temperature envelope.

Table 5 - PTC Thermistor Signal Characteristics

Temperature °C (°F)

Up to 100 (212)

Up to 105 (221)

Up to 110 (230)

Resistance in Ohms

≤

750

≤

7500

≥

10,000

Use this procedure to verify the Hall Effect module is operating properly.

1. With drive power OFF, verify the Hall circuit is properly connected to the drive by using stage and drive interface wiring specifications.

2. Disconnect stage power leads from the drive.

3. Apply power to the Hall device by setting the drive control power to ON.

4. Use an oscilloscope to check waveforms at S1, S2 and S3 at the feedback connector.


55

Chapter 8

Troubleshooting

Move the slide slowly and steadily by hand in the specified phasing direction to generate the Hall waveform.

5. Check for proper logic levels (approximately 0V = low, V+= high) and correct signal sequence (S1 leads S2, and S2 leads S3) with approximately

120° electrical spacing between signal transitions.

Hall Effect Leads

Color

White/Green

Blue

White/Blue

Name

S1

S2

S3


Trapezoidal Hall, TTL-Single



Figure 16 - Hall Signals Waveforms

S1

S2

S3

0° 60° 120° 180°

240° 300°

360°

TIP

Connect the common probe from the scope to the Hall signal common.

To determine the location of the signal common, refer to the Stage Power and

Feedback Connections beginning on page 40 .

6. Before assuming a Hall module fault check Hall field wiring or drive Hall circuit interface.

56


Hall to Back EMF Phasing

Troubleshooting

Chapter 8

Verify the Hall to Back EMF Phasing with this procedure.

1. With drive power OFF.

2. Verify the Hall circuit is connected to the drive as describe in the CHPS-

Series Connector Data beginning on

page 33 .

3. Disconnect the stage motor power leads from the drive.

EXAMPLE

To observe W-U Back EMF phase polarity, connect oscilloscope probe tip to the W phase and the common probe to the U phase.

4. Apply power to the Hall device by setting the drive control power to ON.

5. Slowly and steadily move the stage by hand to perform the Hall signal test, except this time check the motor phases are in-phase with the Hall signal as

shown in the Motor Phasing Schematic on page 58

.

Make sure the phase error between Hall signal and in-phase Back EMF does not exceed ± 5 electrical degrees.

6. If poor results were obtained in step 5 repeat the test at the stage power terminations to check field wiring

ATTENTION: Dangerous voltages, forces and energy levels exist in servo controlled systems. Extreme care must be exercised when operating, maintaining or servicing the stage to prevent harm to personnel or equipment.


57

Chapter 8

Troubleshooting

Motor Coil Resistance

Measurements

If a motor coil electrical problem is suspected perform this check.

1. Let the coil attain ambient room temperature, approximately 25 °C

(77 °F).

2. Verify the drive power is OFF.

3. Disconnect all stage leads (phases and ground) from the drive.

4. Measure the phase-to-phase (ptp) resistance of the phase combinations (U to V, V to W, and W to U) and record the values.

Verify these three readings are approximately equal to each other.

Figure 17 - Motor Phasing Schematic

R ptn

Shield

R ptp

U

V

W

Motor Phases

Lamination

Frame

Motor Ground

R ptp

= R ptn

X 2

Compare the phase resistance readings to the cold resistance specification of the coil model. See

CHPS-Series Stage Technical Specifications

on

page 83 .

If the three readings are balanced but vary from the specified reading, the reason can be a special coil model. Cable resistance can cause the result to be significantly higher.

5. To rule out the cable resistance, disconnect the stage cable and repeat the procedure this time at the stage motor power termination at the junction box.

6. Measure and verify the phase-to-ground resistance for each phase is

>100 MΩ. A lower reading indicates a potential electrical problem.

To rule out a field cable problem disconnect the stage cable and repeat the procedure this time at stage motor power termination.

If any reading with the cable disconnected is

≤

100 MΩ, consult Rockwell

Automation; the stage can have an internal electrical problem

IMPORTANT

Do not perform coil or insulation electrical stress tests (Megger or Hi-Pot test) without consulting Rockwell Automation technical support.

58



Chapter

9

Maintenance

Topic Page

Before You Begin 59

Lubricate the Bearing

Optical Encoder Scale Maintenance

60

60

Strip Seal Cleaning

Cover Cleaning

61

61

IMPORTANT

Any person that teaches, operates, maintains, or repairs these stages must be trained and demonstrate the competence to safely perform the assigned task.

The following tools are required to lubricate and clean your stage.

ATTENTION: Lockout tagout power before servicing.

• 0.5 m (14 in.) or larger clamp with soft jaws.

• Grease (catalog number MPAS-CART).

• Grease gun kit (catalog number MPAS-GPUMP) with tip type installed and primed.

• Air line with maximum pressure of 10 psi.

• Lint free cloth.

• A few drops of isopropyl alcohol if necessary for cleaning encoder scale.


59

Chapter 9

Maintenance

Lubricate the Bearing

Your stage requires lubrication every 6 months or 2500 km (1550 mi) of travel, which ever comes first. Use the MPAS grease gun kit and grease cartridge, catalog numbers MPAS-GPUMP and MPAS-CART respectively.

Optical Encoder Scale

Maintenance

60

Bearing Lubrication Ports (2x per end cap)

1. Position slide at end of travel and clamp it to hold the stage against end cap.

ATTENTION: Do not use clamp across the side panels. This can deform and damage the side panels.

2. Remove the lubrication port protective caps.

3. Insert the tip of grease gun in the lubrication port. Push in until contact with bearing grease nipple is felt.

4. Pump handle until back pressure is felt or two strokes are completed.

5. Repeat steps 3 and 4 to the second bearing on this side.

6. Move slide to opposite end of travel and repeat steps 1

…

5.

7. Remove clamp.

8. Reinstall the protective caps on all the lubrication ports.

1. If installed remove strip seal and side cover on the side opposite the cable carrier.

2. Clear any coarse or abrasive particles with a clean air line with maximum pressure of 10 psi.

3. Clean scale with a clean dry cloth. Avoid the use of solvents.

4. If necessary use isopropyl alcohol sparingly, apply with a wetted cloth by using a gentle wiping action.

5. Reinstall side cover and strip seal, if used.


Strip Seal Cleaning

Cover Cleaning

Maintenance

Chapter 9

Clean the strip seals, if installed, by using a lint free cloth lightly saturated with isopropyl alcohol

IMPORTANT

Replace the strip seal if it cannot be cleaned, or if an uneven or scored surface is detected during cleaning.

A buildup of foreign material on the strip seal degrades the performance of the linear stage. This buildup coupled with rapid movement of the slide and the resulting friction can score the surface and create a burnished appearance on the strip seal

Elements contributing to a typical buildup on the strip seals are dust, grease, and other contaminates normally encountered in any operating environment that is not strictly controlled.

Refer to the Strip Seal Removal procedure on page 65

and Strip Seal

Replacement procedure on page 66 when performing this task.

Clean the covers at the same time you clean the strip seals. Use pressurized air and a lint free cloth lightly saturated with isopropyl alcohol to remove any dirt or grease.


61

Chapter 9

Maintenance

Notes:

62


Chapter

10

Removing and Replacing Stage Components


Cable Carrier Module

Removal

Topic

Before You Begin

Cable Carrier Module Removal

Cable Carrier Module Installation

Strip Seal Removal

Stage Cover Removal

Stage Side Cover Removal

Strip Seal Replacement

Stage Cover Installation

Side Cover Installation

The following tools are required before you begin removal and replacement procedures.

• Torque wrench

• Phillips head screw driver

• 2.5 mm hex wrench

• 3 mm hex wrench

• 4 mm hex wrench

• Fine-point permanent marker

• Tin snips

• Loctite 222

Use this procedure to remove the cable carrier module assembly.

TIP

Mark the location of the end bracket before removing the cable carrier, this makes it easier to align the carrier when re-installing.

1. Remove the four (4) pan head screws from junction box side cover.

2. Remove the two (2) button head cap screws (BHCS) from the junction box cover.

65

66

65

65

67

67

63

64

Page

63


63

Chapter 10

Removing and Replacing Stage Components

3. Remove junction box cover assembly.

ATTENTION: Never pull on wires when disconnecting power and feedback connectors. Damage to the connector can occur.

4. Separate motor power connector by squeezing the side tabs and pulling on the housing. Do not pull on the wires

Figure 18 - Cable Carrier Module Replacement

Junction Box Cover

M3 0.5 X8 LG Phillips Pan Head Screws (4x)

Junction Box Side Cover

M4 X 0.7 X 8 LG BHCS (2x)

Cable Carrier Module

M4 X 0.7 X 10 LG SHCS (2x)

Cable Carrier Module

Installation

M3 X 0.5 X 8 LG SHCS (2x)

End Bracket

Angle Bracket

Motor Power Connector

Feedback Connector

5. Separate the feedback connector from the circuit board by pushing on the center tab and pulling up on the connector housing. Do not pull on wires.

6. Remove the two (2) SHCS from the angle bracket.

7. Lay the cable carrier out flat and mark the location of the end bracket on the base.

8. Loosen but do not remove the two (2) SHCS that secure the end bracket to the stage base.

9. Remove cable carrier.

Align the cable carrier module with the marks made before removing and follow cable carrier removal procedure in reverse.

64


Strip Seal Removal

Figure 19 - Stage Seal Components .

Seal Guide (4x)


Chapter 10

Strip Seal Clamp (4x)

Stage Cover Removal

3M SHCS (2x per guide)

3M SHCS (8x)

Stainless Steel

Strip Seal (2x)

IMPORTANT

Handle strip seal material with care. The strip seal has sharp edges that can cut if mishandled

1. Loosen the strip seal clamps at each end of the stage.

2. Carefully grasp the end of the strip seal and slide it out of the stage.

1. Remove strip seals following strip seal removal procedure.

2. Remove the (4) M4 screws securing the stage cover to the end caps.

3. Remove cover.

Figure 20 - Cover Removal

Stage Side Cover Removal

1. Remove strip seals following strip seal removal procedure.

2. Remove the (2) M4 x.07 screws securing the side cover to the end caps.

3. Remove side cover by dropping it down so the lower lip clears the channel.


65

Chapter 10


Strip Seal Replacement

ATTENTION: Handle strip seal material with care. Strip seal has sharp edges that can cause personal injury if mishandled.

1. Remove power from unit and Lockout-Tagout the power source.

2. Follow the instructions below on how to measure, mark, and cut new strip seals.

1) Mark needed strip length.

3) Make two 45° marks to centerline.

2) Mark strip width centerline.

4) Use tin snips to cut along 45° marks.

3. Position slide at middle of travel.

4. Loosen end clamps and screws on one seal guide enough to expose center metal section of guide.

5. Thread new strip seal, point end first, through the seal guides, slide and end clamps.

6. Center and smooth strip seal against top cover and side panel magnetic strips.

7. With very light pressure hold the seal guide against the strip seal and tighten the seal guide.

8. Tighten only one end clamp.

9. Move the slide by hand through travel and make sure the strip seal seats smoothly against the cover and side panel magnet strips. Pulling against the tightened end clamp to help smooth the seal.

10. Once the seal lays flat and smooth against the top cover and side panel, tighten the second end clamp.

11. With the outside edge of the end clamps as a guide, use tin snips to cut and remove excess strip seal material.

66



Chapter 10

12. Position slide at the far ends of travel and re-adjust seal guide by inserting a

0.8 mm (0.015 in.) shim between seal guide and strip seal.

Strip Seal

Stage Cover Installation

Side Cover Installation

Seal Guide

13. Return stage to service.

0.8 mm (0.015 in.) Shim

1. Starting at the end cap with the magnetic warning label. Install (2)

M3 x 25 SHCS and torque to 4 N•m (35 lbf•in). Make sure the cover makes contact with the end cap.

2. On the opposite end install (2) M3 x 30 SHCS and bottom out the screw.

The cover does not contact the end cap on this side it floats on the screw.

1. Insert side cover into the stage base by holding it with the top slightly tilted outward and hooking bottom in the channel near bottom of the base.

2. Starting at the end cap with the magnetic warning label or the MP motor.

Install (1) M4 x 0.7 x 30 LG SHCS and torque to 4 N•m (35 lb•in). Make sure the side cover makes contact with the end cap.

3. On the opposite end install (1) M4 x 0.7 x 30 LG SHCS and torque

2.26 N•m (20 lb•in). The side cover does not contact the end cap on this side.


67

Chapter 10


Notes:

68


Appendix

A

Specifications and Dimensions

This appendix is a supplement to this document. Associated Kinetix publications listed in

Additional Resources on page 9 and information in product

specifications can supersede the information in this appendix.

Topic

Static and Static Moment Loads

Performance Specifications for 325V CHPS-Series Stage

Performance Specifications for 325V or 650V CHPS-Series Stage

Accuracy Specification for the CHPS-Series Stage

General Stage Specifications

Commutation Sensor

Limit Sensor Specification

PTC Thermistor Specifications

Encoder Specifications

Maximum Velocity for Allen-Bradley Drives

Environmental Specifications for CHPS-Series Stages

CHPS-Series Stage Travel versus Weight Specifications

CHPS-Series Stage Dimensions

CHPS-Series Stage Technical Specifications

75

77

83

74

75

73

74

73

73

73

73

70

71

Page

70


69

Appendix A Specifications and Dimensions

Static and Static Moment

Loads

The figure depicts the Static and Static Moment Loads in the tables that follow.

Table 6 - Static and Static Moment Loads on Linear Stages

Pitch Moment Load

Reverse

Radial Force Load Radial Force Load

Yaw Moment Load

70

Lateral Force Load

Roll Moment Load

The static moment and force ratings shown in the tables are the maximum permissible values possible before permanent damage to the linear stage can occur. To determine the estimated L10 bearing and ball screw life of CHPS-Series

Integrated Linear Stages, use Motion Analyzer software version 4.4 or later.

Performance Specifications for 325V CHPS-Series Stage

Maximum cable length 10 m (33 ft). Please contact Applications Engineering concerning application requiring longer cables.


Specifications and Dimensions Appendix A

Table 7 - Performance Specifications for 150 mm frame size CHPS-Series Linear Stages

Cat. No.

CHPS-A6xxxA-xLMxxx

CHPS-A6xxxB-xLMxxx

CHPS-A6xxxC-xLMxxx

Slide Mass

kg (lb)

4.64 (10.23)

6.48 (14.28)

6.48 (14.28)

Continuous

(1)

A rms (Ao-pk)

2.3 (3.3)

4.7 (6.6)

2.3 (3.3)

(2)

N (lbf)

80 (18)

160 (36)

Peak Maximum

Static Load

(3)

Max Static Moment Loads

(3)

A rms (Ao-pk)

7.0 (9.9)

160 (36) 14.0 (19.9)

7.0 (9.9)

(1) Measured at 20 °C (68 °F) ambient.

(2) For covered and sealed stages derate by 10%

(3) Values apply to bearing rating only. Contact Applications Engineering for structural considerations.

Thrust

N (lbf)

239 (54)

479 (108) kN (lbf)

38.0 (8722)

38.0 (8722)

479 (108) 38.0 (8722)

Pitch Yaw

kN (lbf) N•m (ft•lb)

71 (52)

128 (94)

183 (134)

327 (241)

128 (94) 327 (241)

Roll

N•m (ft•lb)

97 (71)

97 (71)

97 (71)


Cat. No.

CHPS-A8xxxA-xLMxxx

CHPS-A8xxxB-xLMxxx

CHPS-A8xxxC-xLMxxx

Slide Mass

kg (lb)

6.58 (14.5)

Continuous

A rms (Ao-pk) N (lbf)

4.59 (10.1) 2.1 (3.0)

4.2 (6.0)

6.58 (14.5) 2.1 (3.0)

(1) (2)

72 (16)

144 (32)

144 (32)

Peak Maximum

Static Load

(3)


(3)

A rms (Ao-pk)

6.3 (8.9)

12.6 (17.9)

6.3 (8.9)


(2) For covered and sealed stages derate by 10%.

(3) Values apply to bearing rating only, Contact Applications Engineering for structural considerations.

Thrust Pitch

N (lbf)

215 (48)

431 (97) kN (lb)

66 (14836)

66 (14836)

431 (97) 66 (14836) kN (lbf)

171 9126)

270 (199)

270 (199)

Yaw

N•m (ft•lb)

412 (304)

620 (457)

620 (457)

Roll

N•m (ft•lb)

270 (199)

270 (199)

270 (199)

Performance Specifications for 250 mm frame size CHPS-Series Linear Stages

Cat. No.

CHPS-A9xxxG-xLMxxx

CHPS-A9xxxH-xLMxxx

CHPS-A9xxxI-xLMxxx

Slide Mass

kg (lb)

Continuous

(1)(2)

A rms (Ao-pk) N (lbf)

8.58 (18.9) 1.9 (2.7)

9.62 (21.2) 3.8 (5.4)

9.62 (21.2) 1.9 (2.7)

109 (25)

219 (49)

219 (49)

Peak Maximum

Static Load

(3)


(3)

Thrust

A rms (Ao-pk) N (lbf) kN (lbf)

Pitch

kN (lbf)

Yaw

N•m (ft•lb)

Roll

N•m (ft•lb)

5.8 (8.2)

11.5 (16.3)

5.8 (8.2)




328 (74)

656 (147)

656 (147)

93.6 (21042)

93.6 (21042)

93.6 (21042)

170 (125)

324 (239)

324 (541)

385 (283)

734 (541)

734 (541)

508 (375)

508 (375)

508 (375)

Performance Specifications for 325V or 650V CHPS-Series Stage

Maximum cable length 10 m (33 ft). Please contact Applications Engineering concerning application requiring longer cables.


71



Cat. No.

CHPS-x8xxxD-xLMxxx

CHPS-x8xxxE-xLMxxx

CHPS-x8xxxF-xLMxxx

Slide Mass

kg (lb)

5.64 (12.4)

8.34 (18.4)

8.34 (18.4)

Continuous

(1)(2)

A rms (Ao-pk)

3.1 (4.3)

6.2 (8.7)

3.1 (4.3)


(3)

Static

Load

(3)

N (lbf) A rms (Ao-pk)

132 (30) 8.3 (11.7)

Thrust

N (lbf)

302 (68) kN (lbf)

66 (14836)

Pitch

kN (lbf)

171 9126)

Yaw

N•m (ft•lb)

412 (304)

265 (60) 16.5 (23.3)

265 (60) 8.2 (11.6)

600 (135)

600 (135)

66 (14836)

66 (14836)

270 (199)

270 (199)

620 (457)

620 (457)

Roll

N•m (ft•lb)

270 (199)

270 (199)

270 (199)




Performance Specifications for 250 mm frame size CHPS-Series Linear Stages

Cat. No.

CHPS-x9xxxJ-xLMxxx

CHPS-x9xxxK-xLMxxx

CHPS-x9xxxL-xLMxxx

Slide Mass Continuous

(1)(2)

Peak Maximum

Static Load

(3)


(3)

kg (lb) A rms (Ao-pk) N (lbf)

11.54 (25.4) 3.0 (4.2) 385 (87)

A rms (Ao-pk)

8.1 (11.5)

Thrust

N (lbf)

882 (198) kN (lbf)

93.6 (21042)

Pitch

kN (lbf)

170 (125)

Yaw

N•m (ft•lb)

385 (283)

9.69 (21.4) 3.0 (4.2)

11.54 (25.4) 6.0 (8.5)

193 (43)

385 (87)

8.1 (11.5)

16.2 (22.9)

441 (99)

882 (198)

93.6 (21042)

93.6 (21042)

324 (239)

324 (541)

734 (541)

734 (541)

Roll

N•m (ft•lb)

508 (375)

508 (375)

508 (375)




72



General Stage Specifications

The following sections contain general specifications.

Accuracy Specification for the CHPS-Series Stage

Cat. No

CHPS-xxxxxx-FLMxxx

CHPS-xxxxxx-GLMxxx

CHPS-xxxxxx-HLMxxx

CHPS-xxxxxx-ILMxxx

Repeatability

μm (in.)

±1.0

±1.5

±2.0

Interpolation

Dependent

Accuracy

μm (in.)

(1)(2)(3)

±3 μm/25 mm NTE ±10 μm/300 mm

(±0.0001 in./1 in. NTE ±0.0004 in./12 in.)

Straightness and Flatness

μm (in.)

(3)

±3 μm/25 mm NTE ±8 μm/300 mm

(±0.0001 in./1 in. NTE ±0.0003 in./12 in.)

(1) Non-cumulative. For higher performance or software error mapping, please contact Applications Engineering.

(2) Accuracy specification is based upon a 5 kg test load, measured 35 mm above the center of the slide, fully supported on a granite surface.

(3) Based upon a fully supported and clamped in place unit, mounted on a rigid surface with flatness of 0.012/300 x 300 mm, NTE 0.025 mm overall (0.0004/12 x 12 in., NTE

0.001 in. overall)

Commutation Sensor

Description

Input Power

Output

Specifications

5…24V DC, 10 mA max.

NPN, open collector, 10 mA max.

Limit Sensor Specification

Description

Input Power

Output

Specifications

12…28V DC, 15 mA max.

PNP, open collector, normally closed 50 mA max.sourcing

PTC Thermistor Specifications

Temp °C (°F)

Up To 100 (212)

Up To 105 (221)

Up To 110 (230)

Resistance (Ohm)

Less than 750

Less than 7500

Greater than 10,000


73


Encoder Specifications

Type

Digital

Analog

Signal

Power Supply

A/B/Index

Sine/Cosine

Integral Index Mark

Specification

5V DC ±5%

RS422 Differential Line Driver

0.6…1.2V p-p Differential Analog

Differential Pulse 0.8…1.3V p-p

IMPORTANT

Contact Application Engineering for third party drives and controllers. The controls need to meet a minimum recommended counter clock frequency that varies with encoder type and resolution and required peak speed.

Maximum Velocity for Allen-Bradley Drives

Table 10 - Maximum Velocity for 150 mm frame size CHPS-Series Linear Stages with Allen-Bradley

Drives

Incremental Encoder Option

Digital

Resolution

Sine/Cosine

Period

μm/count

1

0.5

0.1

—

μm

—

—

—

20

3.0

0.7

4.0

Velocity, max

m/s

5.0

Maximum Velocity

Ultra™ 3000 and

Ultra5000 Drives

Kinetix 2000 and

Kinetix 6500 Drives

m/s

4.0

2.0

0.5

2.0

m/s

4.0

2.0

—

2.0

0.7

—

2.0

Kinetix 6000

Drive

m/s

1.5

—

—

—

Kinetix 300

Drive

m/s

2.0

Table 11 - Maximum Velocity for 200 and 250 mm frame size CHPS-Series Linear Stages with

Allen-Bradley Drives

Incremental Encoder Option

Digital

Resolution

Sine/Cosine

Period

μm/count

1

0.5

0.1

—

μm

—

—

—

20

(1) LC motor option only.

3.0

0.7

4.0

Velocity, max

m/s

5.0

m/s

4.0

2.0

0.5

2.0

Maximum Velocity

Ulta3000 and

Ultra5000 Drives

Kinetix 2000 and

Kinetix 6500 Drives

m/s

4.0

2.0

0.5

2.0

(1)

0.7

—

2.0

Kinetix 6000

Drive

m/s

1.5

—

—

—

Kinetix 300

Drive

m/s

2.0

74



Environmental Specifications for CHPS-Series Stages

Attribute Value

Ambient temperature 0...40 °C (32...104 °F)

Storage temperature

Relative humidity

-30...70 °C (-22...158 °F)

5…95% non-condensing

Shock

Vibration

Cable carrier lifetime

20 g peak, 6 ms duration

0.1 grms @ Hz, 30…2000 Hz

10,000,000 cycles

CHPS-Series Stage Travel versus Weight Specifications

CHPS-Series Stage (150 mm frame size)

Unit Mass

35

30

25

20

45

40

15

10

5

0

LZ-030-T-240-X

LZ-030-T-120-D

Travel Length


75


76


Unit Mass

35

30

25

20

15

10

Travel Length

LC-050-100-D

LZ-030-T-120-D

Unit Mass

30

25

40

35

20

15

Travel Length


Unit Mass

70

60

50

40

30

20

10

0

Travel Length


LC-050-200-X

LZ-030-T-240-X

LZ-050-T-240-X

LZ-050-T-120-D

LC-075-200-X

LC-075-100-D


CHPS-Series Stage

Dimensions

(4X) M6 x 1.0-6H 12.0 (0.47)

30.5 (1.20)

Mechanical

Overtravel

25.0

(0.98)

Stage are designed to metric dimensions. Inch dimensions are conversions from millimeters. Dimensions without tolerances are for reference.

Figure 21 - CHPS-A6xxxA-xLMxxx

Slide

239

(9.41)

165

(6.50)

30

(1.18)

Travel

30.5 (1.20)

Mechanical

Overtravel

25.0

(0.98)

165

(6.50)

167

(6.57)

8.5

(0.33)

32.0

(1.26)

See Detail A

46.8

(1.84)

181.5

(7.15)

238.6

(9.39)

92.0

(3.62)

150

(5.9)

(4X) Ø 7.0 (0.28) Thru

Pilot Hole

115

(4.53)

(4X) M10 x 1.5-6H Thru (2 per end cap)

Access point for lubricating linear bearings.

Provision to use lifting hooks (not provided).

Ground Screw

M5 x 0.8-6H

123.8

(4.88)

30.0

(1.18)

Detail A 7.6

(0.30)

9.3 (0.37)

Depth, max

Toe Clamp is standard for covered stages. Mount to base using M6 x1.0 socket cap screw.

62

(2.44)

350.0

(13.87)

+ Travel

T-Nut Mount to base using

M6 x1.0 hardware

(optional accessory).

Travel Length mm (in.)

Increments 60 (2.36)

Bracket located ±51 (2.0) from center of travel.

120 (4.72)

Toe Clamp/T-Nut Spacing


77


(4X) M6 x 1.0-6H 12.0 (0.47)

30.5 (1.20)

Mechanical

Overtravel

25.0

(0.98)

165

(6.50)

Figure 22 - CHPS-A6xxxB/C-xLMxxx

Slide

339

(13.35)

165

(6.50)

87

(3.42)

Travel

See Detail A

46.8

(1.84)

181.5

(7.15)

238.6

(9.39)

8.5

(0.33)

32.0

(1.26)

92.0

(3.62)

150

(5.9)

(4X) Ø 7.0 (0.28) Thru

Pilot Hole

130

(5.12)




Ground Screw

M5 x 0.8-6H

123.8

(4.88)

30.0

(1.18)

Detail A 7.6

(0.30)

9.3 (0.37)

Depth, max


104.5

(4.11)

450.0

(17.71)

+ Travel

T-Nut Mount to base using

M6 x1.0 hardware


Travel Length mm (in.)



30.5 (1.20)

Mechanical

Overtravel

25.0

(0.98)

167

(6.57)

120 (4.72)


78



Figure 23 - CHPS-x8xxxA/D-xLMxxx

(4X) M8 x 1.25-6H

(4X) Ø 6.8 (0.27)

12.0 (0.47)

45.2 (1.78) Thru

25.4 (1.0)

Mechanical Overtravel

28.0

(1.10)

25.4

(1.0)

Slide

239

(9.41)

130.8

(5.15)

215.7

(8.49)

166.6

(6.56)

(2X) Ø 5.5 (0.22) Thru

Pilot Hole

44

(1.72)

Travel

25.4 (1.0)


25.4

(1.0)

216.7

(8.53)

See Detail A

46.8

(1.84)

232

(9.13)

288.9

(11.38)

8.5

(0.33)

37.8

(1.49)

130.8

(5.15)

200

(7.9)

Detail A

55.4

(2.18)

120

(4.72)




56

(2.20)

Ø 5.8 (0.23) Thru

Ø 9.7 (0.38) Thru

340

(13.4)

+ Travel

14.2 (0.56)

120 (4.72)

Toe Clamp/

Square Nut Spacing

Ground Screw

M5 x 0.8-6H

105.5

(4.15)

30.0

(1.38)


5.2

(0.206)

6.0 (0.24)

Depth, max


Square Nut

Mount to base using M6 x1.0 hardware


Travel

Increments

Length mm (in.)

60 (2.36)


79


CHPS-x8xxxB/C/E/F-xLMxxx

(4X) M8 x 1.25-6H

(4X) Ø 6.8 (0.27)

12.0 (0.47)

45.2 (1.78) Thru

25.4 (1.0)


28.0

(1.10)

25.4

(1.0)

215.7

(8.49)

166.6

(6.56)

Slide

339

(13.35)

130.8

(5.15)

(2X) Ø 5.5 (0.22) Thru

Pilot Hole

104

(4.09)

Travel

25.4 (1.0)


25.4

(1.0)

216.7

(8.53)

See Detail A

46.8

(1.84)

232

(9.13)

288.9

(11.38)

8.5

(0.33)

37.8

(1.49)

130.8

(5.15)

200

(7.9)

Detail A

55.4

(2.18)

120

(4.72)




116.3

(4.58)

Ø 5.8 (0.23) Thru

Ø 9.7 (0.38) Thru

440

(17.35)

+ Travel

14.2 (0.56)

120 (4.72)

Toe Clamp/

Square Nut Spacing

Ground Screw

M5 x 0.8-6H

105.5

(4.15)

30.0

(1.38)


5.2

(0.206)

6.0 (0.24)

Depth, max

Toe Clamp is standard for covered stages. Mount to base

Travel

Square Nut

Mount to base using M6 x1.0 hardware

Length mm (in.)


80



Figure 24 - CHPS-x9xxxG/J-xLMxxx

(4X) M8 x 1.25-6H

(4X) Ø 6.8 (0.27)

12.0 (0.47)

45.2 (1.78) Thru

25.4 (1.0)


28.0

(1.10)

25.4

(1.0)

Slide

279

(10.98)

130.8

(5.15)

264.7

(10.42)

208.6

(8.21)

(2X) Ø 5.5 (0.22) Thru

Pilot Hole

Travel

44

(1.73)

25.4 (1.0)


25.4

(1.0)

265.7

(10.46)

See Detail A

46.8

(1.84)

281

(11.06)

338.14

(13.31)

8.5

(0.33)

38.3

(1.51)

172.2

(6.78)

249

(9.8)

Detail A

55.4

(2.18)

(4X) 9/16-12 UNC Thru (2 per end cap)



120

(4.72)

Ground Screw

M5 x 0.8-6H

30.0

(1.18)

56.2

(2.22)

Ø 5.8 (0.23) Thru

Ø 9.7 (0.38) Thru 14.2 (0.56)

120 (4.72)


380.6

(14.96)

+ Travel

105.4

(4.15)


5.6

(0.22)

6.5 (0.26)

Depth, max


Travel

Increments

T-Nut

Mount to base using M6 x 1.0 hardware


Length mm (in.)

60 (2.36)


81


Figure 25 - CHPS-x9xxxH/I/K/L-xLMxxx

(4X) M8 x 1.25-6H

(4X) Ø 6.8 (0.27)

12.0 (0.47)

45.2 (1.78) Thru

25.4 (1.0)


28.0

(1.10)

25.4

(1.0)

Slide

339

(13.35)

130.8

(5.15)

264.7

(10.42)

208.6

(8.21)

(2X) Ø 5.5 (0.22) Thru

Pilot Hole

Travel

104

(4.09)

25.4 (1.0)


25.4

(1.0)

265.7

(10.46)

See Detail A

46.8

(1.84)

281

(11.06)

338.14

(13.31)

8.5

(0.33)

38.3

(1.51)

172.2

(6.78)

249

(9.8)

Detail A

55.4

(2.18)

(4X) 9/16-12 UNC Thru (2 per end cap)



120

(4.72)

Ground Screw

M5 x 0.8-6H

30.0

(1.18)

116

(4.58)

Ø 5.8 (0.23) Thru

Ø 9.7 (0.38) Thru 14.2 (0.56)

120 (4.72)


440.6

(17.35)

+ Travel

105.4

(4.15)


5.6

(0.22)

6.5 (0.26)

Depth, max


Travel

Increments

T-Nut

Mount to base using M6 x 1.0 hardware


Length mm (in.)

60 (2.36)

82



CHPS-Series Stage Technical

Specifications

Use this specification to make stage dependent calculations.

Cat. No.

CHPS-A6xxxA-xLMxxx

CHPS-A6xxxB-xLMxxx

CHPS-A6xxxC-xLMxxx

CHPS-A8xxxA-xLMxxx

CHPS-A8xxxB-xLMxxx

CHPS-A8xxxC-xLMxxx

CHPS-x8xxxD-xLMxxx

CHPS-x8xxxE-xLMxxx

CHPS-x8xxxF-xLMxxx

CHPS-A9xxxG-xLMxxx

CHPS-A9xxxH-xLMxxx

CHPS-A9xxxI-xLMxxx

CHPS-x9xxxJ-xLMxxx

CHPS-x9xxxK-xLMxxx

CHPS-x9xxxL-xLMxxx

Total Moving

Mass kg (lb)

5.39 (11.85)

7.09 (15.6)

7.09 (15.6)

6.70 (14.73)

8.87 (19.52)

8.87 (19.52)

7.57 (16.65)

10.23 (22.5)

10.23 (22.5)

8.56 (18.84)

10.70 (23.53)

10.70 (23.53)

10.02 (22.04)

13.16 (28.95)

13.16 (28.95)

9.4

4.7

18.8

4.9

14.3

3.8

1.9

7.5

2.5

9.9

3.6

14.3

7.2

3.6

Coil Resistance (p - p)

@25 °C (77 °F) @100 °C (212 °F)

Ohms

7.2

Ohms

9.3

4.6

18.6

9.3

4.6

18.6

4.9

2.4

9.8

12.2

6.1

24.5

6.4

3.2

12.8

Force Constant

30.3 (6.81)

60.7 (13.64)

40.2 (9.04)

40.2 (9.04)

80.4 (18.07)

45.5 (10.29)

45.5 (10.29)

91.0 (20.46)

N/A

0 - peak

(lbf/A

0 - peak

)

24.1 (5.42)

24.1 (5.42)

48.2 (10.83)

24.1 (5.42)

24.1 (5.42)

48.2 (10.83)

30.3 (6.81)


83


Notes:

84


Appendix

B

Accessories

Topic

Interconnect Cables

Installation, Maintenance, and Replacement Kits

Page

85

87

Interconnect Cables

75 (2.9)

75 (2.9)

Start of Bend Radius

142 (5.59)

Power Cable Dimensions (catalog number 2090-XXNPMF-16Sxx)

The maximum cable length of 10 m (32.8 ft).

Dimensions are in mm (in.)

Cable Shield

(overall)

Brown

Black

Blue

Green/Yellow

BR+

BR-

Bend Radius1

Cable Shield

(for brake wires, not used for linear motor stages)

28.0 (1.1)

14.0 (0.55)

Connector

Diameter

Cable

Diameter

E

H F G

L

A

C

B

L

E

H

F

G

A

B

C

16 AWG BROWN

16 AWG BLACK

16 AWG BLUE

16 AWG GRN/YEL

18 AWG WHITE

18 AWG BLACK

18 AWG WHITE

18 AWG RED

SHIELD

U

V

W

1

2

BR+

BR -

1 Bend radius (BR) is the specified minimum bend radius for cable assemblies. For standard cable, BR is a one-time flex application. Flex cables have a much higher BR to withstand flex applications. BR can vary on user-fabricated cables.

B

C

Pin

A

GND

Gauge

16

16

16

16

Color

Brown

Black

Blue

Green/Yellow

Signal Designation

U

V

W

GND

Pin

F

G

E

H

L

SHIELD

18

18

N/A

Gauge

18

18

Color

White

Black

White

Red

N/A

1

2


BR+

BR-

Not used for CHPS

Stages

N/A

Feedback Cable Dimensions (catalog number 2090-XXNFMF-Sxx)

The maximum cable length of 10 m (32.8 ft).

Dimensions are in mm (in.)

54

(2.1)

Start of

Bend Radius

57

(2.2)

26

(1.0)

99

(3.9)

10

(0.4)

Bend Radius

1

Connector

Diameter

Cable

Diameter

2

3

1

13

12

4

14 1715

5

6

11

16

10

9

7

8

10

11

13

5

6

9

3

4

1

2

14

15

16

17

7

8

12

I -

+5V

COM

+9V

TS+

TS -

A+

A -

B+

B -

I+

S1

S2

S3

MTR RRAME

ABS

COM

28 AWG BLACK

28 AWG WHITE/BLACK

28 AWG RED

28 AWG WHITE/RED

28 AWG GREEN

28 AWG WHITE/GREEN

16 AWG GRAY

16 AWG WHITE/GRAY

22 AWG ORANGE

22 AWG WHITE/ORANGE

28 AWG BLUE

28 AWG WHITE /BLUE

28 AWG YELLOW

28 AWG WHITE/YELLOW

28 AWG BROWN

28 AWG WHITE/BROWN

DRAIN

1 Bend radius (BR) is the specified minimum bend radius for cable assemblies. For standard cable, BR is a one-time flex application. Flex cables have a much higher BR to withstand flex applications. BR can vary on user-fabricated cables.

Installation, Maintenance, and

Replacement Kits

Accessories available for installing stages, replacing items, and performing maintenance at regular intervals are listed in the tables that follow.

Description

Grease Pump Maintenance Kit

Grease Cartridge

Toe Clamp Installation Kit

Tee Nut Installation Kit

Cable Carrier Modules

Strip Seal Replacement Kits

Side Covers Replacement Kit

Top Cover Replacement Kit

Accessories

Cat. No

MPAS-GPUMP

MPAS-CART

MPAS-TOE

MPAS-6-TNUT

MPAS-8-TNUT

MPAS-9-TNUT

MPAS-6xxxB-CABLE

MPAS-8xxxE-CABLE

MPAS-9xxxK-CABLE

MPAS-6xxxB-SEAL

MPAS-8xxxE-SEAL

MPAS-9xxxK-SEAL

MPAS-6xxxB-SIDE

MPAS-8xxxE-SIDE

MPAS-9xxxK-SIDE

MPAS-6xxxB-TOP

MPAS-8xxxE-TOP

MPAS-9xxxK-TOP

Comments

Includes grease pump, one grease cartridge, and all necessary tips.

Refill cartridge for grease pump.

10 toe clamps per package

10 Tee nuts per package xxx = cm stroke:

012, 018, 024, 030, 036, 042, 054, 066, 078, 090, 102, or 114 xxx = cm stroke:

014, 020, 026, 032, 038, 044, 056, 068, 080, 092, 104, 128, 152, 176, or 194 xxx = cm stroke:

014, 020, 026, 032, 038, 044, 056, 068, 080, 092, 104, 128, 152, 176, or 194 xxx = cm stroke:

012, 018, 024, 030, 036, 042, 054, 066, 078, 090, 102, or 114 xxx = cm stroke:

014, 020, 026, 032, 038, 044, 056, 068, 080, 092, 104, 128, 152, 176, or 194 xxx = cm stroke:

014, 020, 026, 032, 038, 044, 056, 068, 080, 092, 104, 128, 152, 176, or 194 xxx = cm stroke:

012, 018, 024, 030, 036, 042, 054, 066, 078, 090, 102, or 114 xxx = cm stroke:

014, 020, 026, 032, 038, 044, 056, 068, 080, 092, 104, 128, 152, 176, or 194 xxx = cm stroke:

014, 020, 026, 032, 038, 044, 056, 068, 080, 092, 104, 128, 152, 176, or 194 xxx = cm stroke:

012, 018, 024, 030, 036, 042, 054, 066, 078, 090, 102, or 114 xxx = cm stroke:

014, 020, 026, 032, 038, 044, 056, 068, 080, 092, 104, 128, 152, 176, or 194 xxx = cm stroke:

014, 020, 026, 032, 038, 044, 056, 068, 080, 092, 104, 128, 152, 176, or 194

Notes:

Stage Stacking

Appendix

C

Stacking Stages

This appendix provides information about center-stacked stage configurations.

Topic

Stage Stacking

Specifications for Stacked Stages

Page

89

90

Certain combinations of MPAS linear stages are designed to be stacked on top of one another. Stacking forms an X-Y axis arrangement. A center-stack arrangement mounts the top axis in the middle of the bottom axis. The top stage is centered on the bottom stage.

Table 12 - Stacking Stages

The MPAS-x6xxxx is capable of mounting to the top of another MPAS-x6xxxx by bolting through toe-clamps to the slide on the bottom stage.

The MPAS-x8xxxx is capable of mounting to the top of either a MPAS-x8xxxx or a MPAS-x9xxxx by bolting through the slide on the bottom stage and into T-nut slots on the top stage.


89

Appendix C Stacking Stages

Specifications for Stacked

Stages

Linear stage specifications are based on mounting the stage to a precision base along the entire length of the stage, and MPAS stage specifications follow this convention. In the case of stacked stages, the top axis is no longer supported along its entire length, and this alters both the precision and the load carrying capability of that stage. Furthermore, linear stage specifications are based on a specified test payload with a low center of gravity that is centered on the carriage. Deviations from the test payload condition can impact the performance of both the top and bottom linear stages.

The following table provides information about the payload that the top stage, or axis, can carry without derating the life of its bearings from those specified for the same stage mounted as a single-axis stage on a precision base.

Table 13 - Centered Stack Combinations Not Requiring Derating

Y-axis Travel Mass of Payload

(1)

Catalog Numbers of

Centered Stack Linear Stages

MPAS-x6xxxx on MPAS-x6xxxx

Ball Screw or Direct Drive


Direct Drive


Direct Drive


Ball Screw


Ball Screw

(1) Payload is based solely on bearing and structure limitations.

For other stacking arrangements, please contact Rockwell Automation

Application Engineering.

90


Appendix

D

Start-up Guide for CHPS-Series Stage with Ultra3000

Drive and Ultraware Software

Using This Appendix

This appendix is a supplement to CHPS-Series stage and Kinetix drive manuals.

The information in the current product manuals supersedes this appendix.

Topic

Using This Appendix

Wiring the CHPS-Series Stage to the Ultra3000 Drive

Linear Motor File Parameters

Creating a CHPS-Series Stage Motor File

Recommended Start-up Sequence

CHPS-Series Stage and Ultra3000 Drive Troubleshooting Reference

Reference Information

96

99

92

94

91

92

Page

91

This appendix is for use with CHPS-Series stages. This document addresses

CHPS-Series stage-motor file parameter values and commutation wiring. Basic start-up test procedures and troubleshooting information is also given.

IMPORTANT

Motor, commutation, feedback parameters, and wiring affect commutation, and must be correct for proper motor-drive operation. Improper setup can cause stage control problems including erratic behavior, bad spots, runaway, and thermal failure.

Wiring the CHPS-Series Stage to the Ultra3000 Drive

The CHPS-Series stage has four termination options. The Kinetix/MPF option is recommended for plug & play to Kinetix and Ultra family servo drives.

Kinetix MPF interconnect cable makes it easy to wire the stage and set-up commutation with the Ultra3000 Drive. The wiring for non-Logix Ultra3000 drives and Logix® version Ultra3000 drives are the same.

If you are not using Kinetix/MPF termination option, properly wire the stage to the Ultra drive by using the following connectivity information. Refer to the

CHPS-Series Stage Connector Data for additional information.


91

Appendix D Start-up Guide for CHPS-Series Stage with Ultra3000 Drive and Ultraware Software

Connector Data Summary

CHPS-Series Stage Signal Designation

Motor phase U

Motor phase V

Motor phase W

Encoder A+ (digital) or Sin+ (analog)

Encoder A - (digital) or Sin - (analog)

Encoder B+ (digital) or Cos+ (analog)

Encoder B - (digital) or Cos - (analog)

Hall S1

Hall S2

Hall S3

U

V

Ultra3000 Drive

Terminal or Pin

W

CN2-1

CN2-2

CN2-3

CN2-4

CN2-12

CN2-13

CN2-8


Motor phase U

Motor phase V

Motor phase W

Encoder A+ (digital) or Sin+ (analog)

Encoder A - (digital) or Sin - (analog)

Encoder B+ (digital) or Cos+ (analog)

Encoder B - (digital) or Cos - (analog)

Hall S1

Hall S2

Hall S3

Linear Motor File Parameters

The following guide supplements the information found in the Ultra3000 drive manuals. Some of the motor parameters are critical for commutation and motor protection. Incorrect entry of theses motor parameters can cause motor problems,

Ultraware assumes a linear motor is functionally equivalent to a rotary motor.

However, the functional equivalent to a rotary motor is a complete linear motor driven stage. To account for the difference, the parameters highlighted in bold in

the Linear Motor Parameter File (.mdb extension)

table shown below must be adjusted to stage level specifications.

Creating a CHPS-Series Stage

Motor File

Complete CHPS-Series stage motor specifications are in the linear motor specifications information contained in this manual or the motor’s data sheet.

Identify the stage motor option for your CHPS-Series stage and use the corresponding data.

Conversion Factors:

• Ultra3000 drive ampere units are measured at the peak of the sine wave, not RMS. Standard CHPS-Series stage motors are rated both ways. Be sure to select the correct value. If necessary, use the following conversion.

ampere peak = 1.4 x RMS

92


Start-up Guide for CHPS-Series Stage with Ultra3000 Drive and Ultraware Software Appendix D

• All Ultra drive electrical parameters are defined phase-to-phase. Standard

CHPS-Series stage motors are specified phase-to-phase. If necessary, use the following conversion.

phase-to-phase = 2 x phase-to-neutral

Table 14 - Linear Motor Parameter File (.mdb extension)

Parameter

Force Constant

Mass

Electrical Cycle Length

Resistance

Inductance

Rated Voltage

Flux Saturation table

Maximum Speed

Intermittent Current:

Continuous Current

Max Current Boost

Encoder Type

Commutation Type

Startup Type

Hall Input Offset

Lines/Meter

Integral Limits

Integral Thermostat kg m

Units

N/A

0-peak

Ohms mH

V AC

— m/s

A

0-peak

A

0-peak

—

—

—

— degrees

— lines/m

—

—

Enter

Motor’s linear region force constant

Motor model coil mass

0.05 for LC motors or

0.06 for LZ motors

Motor’s cold resistance

Motor’s inductance

Drive’s input AC voltage.

—

Lowest maximum velocity

Motor’s peak current rating

Comment

Convert if necessary. Standard CHPS-Series stage motors specify the correct unit value.

Standard CHPS-Series stages are intended for moving coil (slide) use.

Standard CHPS-Series stage motors specify the electrical cycle length in mm.

Electrical cycle equals 2 x magnet pitch.

Motor’s continuous current rating Use the motor rating in the CHPS-Series Stage Selection Guide. Do not use the values from the Motor Product Profile. For CHPS-Series stages with cover and seals option, derate the base value by 10%.

0%

Select applicable type per CHPS-

Series stage option code

Sinusoidal

Desired commutation mode

0

For standard CHPS-Series stages without forced cooling.

Use Incremental for digital encoder or Sine/Cosine for analog encoder. Sine/Cosine requires additional set up per the Ultra3000 Drive manual.

The recommended and default setting Hall Inputs and has no motion on startup.

For self-sensing, refer to the section on Self-Sensing Commutation and Startup.

For standard CHPS-Series stage motor models.

250,000

500,000

2,500,000

12,500

Unchecked

Check

Phase-to-phase directly from motor specifications.

Phase-to-phase directly from motor specifications.

LC motors are rated up to 460V AC.

LZ motors are rated up to 230V AC.

For stages with 0.1 um encoder option, the maximum drive input is 115V AC.

Leave default values.

Choose the lowest maximum velocity between the encoder or the application restriction. The encoder maximum velocity for the Ultra3000 drive is found in the

CHPS-Series stage specifications.

Use the motor rating in the CHPS-Series Stage Selection Guide. Do not use the values from the Motor Product Profile. The CHPS-Series LZ motors are restricted to

3x continuous current. Consult with an application engineer if you are considering increasing this value.

Enter the encoder lines per meter of travel. Lines are pre-quadrature resolution.

Alternatively, for incremental encoders, calculate the counts/meter and divide by

4 to get lines/meter.

Following are the values for the standard CHPS-Series stage encoders:

1 μm/count incremental

0.5 μm/count incremental

0.1 μm/count incremental

Analog sin/cos, 20 μm period

For the standard CHPS-Series stage limits option. The standard limits option is not compatible with the CN2 input circuit that expects an NPN open collector limit signal.

For the standard CHPS-Series stage motor options. The PTC thermistor signal is compatible with the Ultra3000 drive thermal input circuit.

Except for very earliest Ultra Drives.


93


Table 14 - Linear Motor Parameter File (.mdb extension)

Parameter

Software Protection

Thermal Protection

Rth(w-a)

Units

—

º

C /W

Enter

—

Calculate

Thermal Protection

Cth(w-a)

W/s/

º

C Calculate

Comment

—

The thermal resistance with the winding at ambient temperature:

For LC motors, enter the rated thermal resistance value, multiply by 1.1 for covered and sealed stages.

For 150 frame stage that use only LZ motor, enter the rated thermal resistance value.

For 200 and 250 frame stages:

LZ motors, enter 1.1x the rated thermal resistance value.

In addition for all stages with LZ motors, multiply this value again by 1.1 for a covered and sealed stage.

Energy absorption: Cth = tm/Rth where tm is the motor's thermal time constant in seconds. Leave the value as found if a valid LC or LZ file is used.

If necessary, use the following tm values based on the heat sink size and cooling method:

LC motors: tm = 1800 (seconds)

LZ motors: tm = 1200 (seconds)

Recommended Start-up

Sequence

Follow these steps for optimal motor commutation, performance, overcurrent, and overtemperature protection.

1. Set General Axis Parameters (.udb file extension) a. Auto Motor Iden = disabled for linear motors.

b. Motor Model: select as needed.

c. Total Moving Mass in kg = coil mass or magnet mass + moving structure mass+ moving cable assembly mass + customer load.

d. Current Limits in Amperes peak - set as needed for the application. The drive uses the lowest value between the drive rating and the motor rating.

e. Display Precision - Set to 2 decimal places.

f. User Current Fault in Amperes peak - this is the continuous current. Set as needed for the application. The drive uses the lowest value between drive rating and the motor rating. To avoid nuisance tripping of the fastacting protection, it can need to be set slightly higher.

2. Follow instructions from the standard drive manual and other applicable documentation. Pay special attention to electrical noise control by using cable shielding, shield termination, grounding, and bonding.

3. Wiring must match the CHPS-Series stage and Ultra drive connectivity table provided on

page 92 . Incorrect wiring or Hall offset combinations

can result in motor motion that has excessive force ripple and increased current, temperature, or reduced force per unit of current.

4. Verify that the correct motor file is selected or correct custom motor parameter values are entered.

5. User Current Fault parameter - this value must not exceed the CHPS-

Series stage motor’s continuous current rating.

94



6. Current Limit parameters - the positive and negative current limit, must not exceed the CHPS-Series stage motor’s intermittent current rating. Set per the application requirements.

7. Verify correct encoder polarity and test distance count. Encoder must count in positive direction when CHPS-Series stage is moving in the

positive stage direction as shown in Stage Positive Direction on page 48

.

Also see

CHPS-Series Stage and Ultra3000 Drive Troubleshooting

Reference

on

page 96 . Incorrect encoder sequencing can cause a runaway

motor condition or incorrect commutation.

8. Perform Commutation Diagnostics only if enough free +/- travel distance is available. You can guarantee optimal commutation only by doing oscilloscope verification.

You can use the following checks for non-optimal commutation verification. These tests cannot detect bad spots and other anomalies.

• Use Current Control Panel mode to give a small positive current command. Verify the stage moves in the positive direction.

• Check for consistent force resistance over whole travel by pushing the slide to multiple locations.

• Check that the amount of current to move the load and overcome friction forces at a low steady speed are correct.

• The motor’s force constant (Kf ) can also be verified with a force gauge.

The Ultraware software command units for current scaling are in

A

0-peak

/V.

9. When current mode tests successfully, perform auto velocity or manual velocity tuning with the Ultraware oscilloscope function, do this even if you are using current mode to control your application. This further evaluates commutation and check for a good step response.


95


CHPS-Series Stage and

Ultra3000 Drive

Troubleshooting Reference

The section contains troubleshooting reference for the CHPS-Series stage and

Ultra3000 drive combination.

Positive Phasing Direction

Positive stage direction = slide moving towards junction box or cable exit end as shown here.

Slide End Cap + Slide = Slide Assembly

(-)

(+)

Positive Direction

Encoder Counting Polarity

Encoder must count in positive direction when moving in the positive direction.

IMPORTANT

Incorrect encoder sequencing can cause a runaway motor condition or incorrect commutation.

96



Oscilloscope Verification

Correct stage and Ultra3000 drive wiring yields the phase relationship shown in

Hall Oscilloscope Diagram.

Figure 26 - Hall Oscilloscope Diagram

S1

S2

S3

0° 60° 120° 180° 240° 300° 360°

• Data capture direction - stage positive phasing direction as shown in

Positive Phasing Direction on page 96.

• S1 leads S2 leads S3, 120° electrical spacing.

• For standard stages have following phase relationship:

S1 in phase with W-U

S2 in phase with U-V

S3 in phase with V-W

• Hall probe GND to Hall common and, for W-U for example, coil probe tip = W and probe GND = U

• If wiring is correct the causes for incorrect phasing are:

– non-standard coil or Hall assembly

– coil electrical problem

– Hall module electrical or mechanical problem


97


Oscilloscope Diagram for Ultra3000 Drive

Motor with Hall offset = 0°

While moving slide in positive direction.

BEMF

Hall

0° 60° 120° 180° 240° 300° 360°

Ultra Drive phasing pairs:

S1 vs. W-U

S2 vs. U-V

S3 vs. V-W

Ultra3000 Drive

98


Reference Information


Refer to these sections for information about the following:

•

Commutation Diagnostics Utility

•

Self-sensing Commutation and Startup

•

Main Screen Setup

•

Motor Screen

•

Motor Screen

•

Faults Screen

Commutation Diagnostics Utility

This test utility is intended for custom motors that do not have verified optimal phasing information. It can be used instead of the Ultraware oscilloscope based phasing method given in the Ultra3000 Drive Manual

(1)

. The test utility can make false recommendations if the test set-up current level is too low, or an obstruction is encountered during the test motion. The CHPS-Series stage wiring must not deviate from the standard wiring. Do not use the utility if the free travel distance of the application is less than the required ± test motion.

These are the pre-test requirements.

1. Check for mechanical problems with the stage assembly.

2. Use a test current value high enough to overcome non-acceleration forces of stiction and friction, cable drag, magnetic attraction. A typical value used is 15…20%. But values as high as 40% can be necessary.

3. Verify the free travel range from motor starting position is at least two magnet pitches or 1 electrical cycle, in the negative direction, and four magnet pitches or 2 electrical cycles, in the positive direction.

(1) The phasing diagram in the drive manual is for phase-to-neutral measurements. This requires use of a balanced resistor Y network to create a virtual neutral. Alternatively, the phase-to-phase diagrams and procedures in the Ultra 100/200 can be used because they are equivalent to each other after the phase shift correction is made.


99


100

Self-sensing Commutation and Startup

This type of commutation does not use the Hall effect sensor. Motors with a Hall effect sensor connection can be set to self-sensing commutation, the Hall effect signals are ignored. Self-sensing start-up is not commutation diagnostics. You can perform commutation diagnostics at any time on Hall effect or self-sensing motors. Self-sensing start-up refers to the motor motion initialization that is executed automatically after every power-up and enabling of the system. It synchronizes the arbitrary encoder position or count to the drive’s initial commutation angle.

This is the self-sensing start-up sequence:

• Enable is activated.

• Motor locks into detent or zero force position > up to ± one magnet pitch

(½ electrical cycle) of motion jerk.

• After jerk motion settles out in 1 or 2 seconds, motor executes a slow speed test move of approximately two magnet pitches or one electrical cycle in the positive direction.

• Drive disables, ready for normal operation.

During this startup, the drive evaluates the test motion. A fault indicates that the motor motion was not as expected. Possible reasons include the following:

• Mechanical problem with the stage such as excessive stiction, friction, or cable drag.

• Obstruction during test motion.

• Incorrect coil or encoder wiring.

• Encoder or signal problems, device fault, wiring problem, noise.

• During startup, the drive uses a fixed 1/6 of the peak motor or drive current, whichever is lower.

Ultraware software version 1.3 with firmware revision 1.16 (or greater) has improved functionality with proper alignment under any single obstruction:

• If during the positive test move, after detent, an obstruction is encountered, a test move is done in the opposite direction after reinitializing the new detent.

• If an obstruction prevents the motor from going to the real detent, for example, detent past negative hard stop, the Ultra drive senses a false detent during the test move due to false alignment. After re-initializing of the new detent a second test move is done in the positive direction.

• The self-sensing routine can take 2x longer because of obstructions.

• If a second obstruction is detected during whole routine, such as low test current or too high friction, the test faults.

• The new versions lets a user programmable test current value.

• Limit signals sent to the Ultra Drive are ignored during self-sensing startup.



The following in an example of a CHPS-Series stage custom motor file created in

Ultraware Motor Database utility.

For linear stages with a size 200 frame, LZ-030-T-120-D linear motor, 1 μm encoder, cover/seals, and no integral limits.


101


Main Screen Setup

On this screen, enter CHPS-Series stage motor file, Current Limits not-toexceed motor file, Display Precision, and access the Current Control Panel.

102



Motor Screen

On this screen, enter Total Moving Mass, check for correct Motor Model and parameters, and access the Motor Feedback Diagnostics Utility.


103


Faults Screen

On this screen, enter the continuous current in User Current Fault field, not to exceed the motor file continuous current value.

104


Appendix

E

Mounting Bolts and Torque Values

M3

M4

M5

M6

M8

M10

Bolt Size (Metric)

(1)

M1.6

(2)

M2

(2)

M2.5

(2)

Table 15 - Recommended Seating Torque for Metric Bolts

0.5

0.7

0.8

1.0

Pitch

0.35

0.40

0.45

1.25

1.5

Plain

N•m (lbf•in)

0.29 (2.6)

0.60 (5.3)

1.24 (11)

2.15 (19)

4.6 (41)

9.6 (85)

15.8 (140)

39.5 (350)

76.8 (680)

Cadmium Plated

N•m (lbf•in)

0.22 (1.95)

0.45 (3.98)

0.93 (8.25)

1.61 (14.25)

3.47 (30.75)

7.20 (63.75)

11.9 (105)

29.7 (262.5)

57.6 (510)

Zinc

N•m (lbf•in)

0.41(3.64)

0.84 (7.42)

1.74 (15.4)

3.00 (26.6)

6.48 (57.4)

13.4 (119)

22.1 (196)

55.4 (490)

115.2 (1020)

(1) Mounting hardware is ISO 898/1 socket head cap bolt that meets or exceeds ANSI B113M, ISO 261, ISO 262 (coarse series only).

(2) Microsize bolt.


105

Appendix E Mounting Bolts and Torque Values

Table 16 - Recommended Seating Torque for Mild Steel Rb 87 or Cast Iron Rb 83

#10

1/4

5/16

3/8

7/16

1/2

#4

#5

#6

#8

Bolt Size

(1), (2)

#0

#1

#2

#3

Plain

N•m (lbf•in)

—

0.44 (3.89)

(3)

0.71 (6.3)

(3)

1.08 (9.6)

(3)

1.52 (13.5)

(3)

2.3 (20)

(3)

2.8 (25)

(3)

5.2 (46)

(3)

7.6 (67)

(3)

17.8 (158)

(3)

36.8 (326)

(3)

65.5 (580)

(3)

105 (930)

(3)

160 (1,420)

(3)

UNC

Cadmium Plated

N•m (lbf•in)

—

0.53 (4.7)

(3)

0.53 (4.7)

(3)

0.81 (7.2)

(3)

1.13 (10)

(3)

1.7 (15)

(3)

2.1 (19)

(3)

3.8 (34)

(3)

5.6 (50)

(3)

13.4 (119)

(3)

27.7 (245)

(3)

49.1 (435)

78.9 (698)

(3)

172.8 (1,530)

(3)

Plain

N•m (lbf•in)

0.24 (2.1)

(3)

0.46 (4.1)

(3)

0.76 (6.8)

(3)

1.16 (10.3)

(3)

1.67 (14.8)

(3)

2.37 (21)

(3)

3.2 (28)

(3)

5.4 (48)

(3)

8.6 (76)

(3)

20.3 (180)

(3)

40.7 (360)

(3)

71.7 (635)

117.5 (1,040)

(3)

254.2 (2,250)

UNF

Cadmium Plated

N•m (lbf•in)

0.18 (1.6)

(3)

0.34 (3.0)

(3)

0.58 (5.1)

(3)

0.87 (7.7)

(3)

1.2 (11)

(3)

1.8 (16)

(3)

2.4 (21)

(3)

4.1 (36)

(3)

6.4 (57)

(3)

15.4 (136)

(3)

30.5 (270)

(3)

53.7 (476)

88.1 (780)

(3)

190.9 (1,690))

(3)

(1) Mounting hardware is 1960-series socket head cap bolt that meets or exceeds ANSI B18.3.

(2) Torque is based on 80,000 psi bearing stress under the head of the bolt.

(3) Denotes torque based on 100,000 psi tensile stress, with threads up to one inch in diameter.

106


Mounting Bolts and Torque Values Appendix E

Table 17 - Recommended Seating Torque for Brass Rb 72

#3

#4

#5

#6

#8

Bolt Size

(1), (2)

#0

#1

#2

#10

1/4

5/16

3/8

7/16

Plain

N•m (lbf•in)

—

0.43(3.8)

(3)

0.71 (6.3)

(3)

1.08 (9.6)

(3)

1.52 (13.5)

(3)

2.2 (20)

(3)

2.8 (25)

(3)

5.2 (46)

(3)

7.6 (67)

(3)

15.3 (136)

25.8 (228)

53.7 (476)

76.8 (680)

UNC

Cadmium Plated

N•m (lbf•in)

—

0.33 (2.9)

(3)

0.53 (4.7)

(3)

0.81 (7.2)

(3)

1.1 (10)

(3)

1.7 (15)

(3)

2.1 (19)

(3)

3.8 (34)

5.6 (50)

(3)

11.5 (102)

19.3 (171)

40.3 (357)

57.6 (510)

Plain

N•m (lbf•in)

0.24 (2.1)

(3)

0.46 (4.1)

0.77 (6.8)

(3)

1.16 (10.3)

(3)

1.67 (14.8)

(3)

2.4 (21)

(3)

3.2 (28)

(3)

5.4 (48)

(3)

8.6 (76)

(3)

15.4 (136)

25.8 (228)

53.7 (476)

76.8 (680)

UNF

Cadmium Plated

N•m (lbf•in)

0.18 (1.6)

(3)

0.34 (3.0)

(3)

0.58 (5.1)

(3)

0.87 (7.7)

(3)

1.24 (11)

(3)

1.8 (16)

(3)

2.4 (21)

(3)

4.1 (36)

(3)

6.4 (57)

(3)

11.5 (102)

19.3 (171)

40.3 (357)

57.6 (510)



(3) Denotes torques based on 100,000 psi tensile stress with threads up to one inch in diameter.


107

Appendix E Mounting Bolts and Torque Values

Table 18 - Recommended Seating Torque for Aluminum Rb 72 (2024-T

4

)

#6

#8

#10

1/4

5/16

3/8

7/16

1/2

#2

#3

#4

#5

Bolt Size

(1), (2)

#0

#1

Plain

N•m (lbf•in)

—

0.44 (3.8)

(3)

0.71 (6.3)

(3)

1.08 (9.6)

(3)

1.52 (13.5)

(3)

2.3 (20)

(3)

2.8 (25)

(3)

5.2 (46)

(3)

7.6 (67)

(3)

12.8 (113)

21.5 (190)

44.8 (397)

64.4 (570)

159.3 (1,410)

UNC

Cadmium Plated

N•m (lbf•in)

—

0.33 (2.9)

(3)

0.53 (4.7)

(3)

0.81 (7.2)

(3)

1.1 (10)

(3)

1.7 (15)

(3)

2.1 (19)

(3)

3.8 (34)

(3)

5.6 (50)

(3)

9.6 (85)

16.1 (143)

33.6 (298)

48.0 (425)

119.8 (1,060)

Plain

N•m (lbf•in)

0.24 (2.1)

(3)

0.46 (4.1)

(3)

0.77 (6.8)

(3)

1.16 (10.3)

(3)

1.67 (14.8)

(3)

2.37 (21)

(3)

3.2 (28)

(3)

3.2 (48)

(3)

8. 6 (76)

(3)

12.8 (113)

21.5 (190)

44.8 (397)

64.4 (570)

159.3 (1,410)

UNF

Cadmium Plated

N•m (lbf•in)

0.18 (1.6)

(3)

0.34 3.0v

0.58 (5.1)

(3)

0.87 (7.7)

(3)

1.24 (11)

(3)

1.8 (16)

(3)

2.37 (21)

(3)

4.1 (36)

(3)

6.4 (57)

(3)

9.6 (85)

16.1 (143)

33.7 (298)

48.0 (425)

119.8 (1,060)



(3) Denotes torques based on 100,000 psi tensile stress with threads up to one inch in diameter.

108


Index

A

accessibility

22

accessories

feedback interconnect cable

86

power interconnect cable

85

accuracy specifications

73

ambient temperature

defined

75

analog differential encoder

45

ANSI/NFPA 79 - electrical for industrial machines

21

ANSI/RIA R15.06 - industrial robot, multiple teaching

21

B

bearing

17

lubrication ports

17

bearing lubrication

60

bearing rail

17

bolt through

29

C

cable carrier module

about

17

installation

64

lifetime

75

replacement

63

center-stacked stage

89

clamps

17

cleaning

18

cover

61

strip seal

61

clearance

23

coil resistance

83

commutation

46

commutation sensor specifications

73

component description

bearing

17

lubrication ports

17

bearing rail

17

cable carrier module

17

cover

17

index mark

17

limit blade

17

optical encoder readhead

17

optical encoder scale

17

side cover

17

side cover support

17

slide

17

strip seal

17

strip seal clamp

17

strip seal guide

17

components

18

connector pinout

d-type


Kinetix feedback

34

power

34

connectors

feedback

35

power

35

flying lead termination

36

counter clock frequency

44

cover

17

cleaning

61

installation

67

removal

65

torque

67

D

dimensions

150 mm

77

,

78

200 mm

79

,

80

250 mm

81

,

82

direction

47

,

48

drip loop

40

dust

22

E

edge separation

44

EMI

40

encoder

analog differential

45

maintenance

60

TTL differential

44

encoder scale

maintenance

60


17

example

fastener calculation

28

stopping distance calculation

50

Ultraware custom motor file

101

extension cables

85

F

fastener

quanity calculation

28

square nut

31

tee nut

31

through bolt

30

toe clamp

30

feedback interconnect cable

86

flatness specifications

73

flying lead termination

36

force constant

83

109

Index

110

G

ground

screw

40

torque

40

strap

40

grounding

40

H

Hall effect circuit

46

Hall effect module

55

Hall phasing

46

heat

13

high-frequency energy

40

humidity

22

humidity range

75

I

incline payload

13

index mark

17

installation clearance requirements

22

K

Kinetix

connector

34

interconnect cables

85

Ultra3000 drive set-up

91

L

lighting

22

limit blade

17

limit sensor

setting

50

signals wires

38

specification

73

wiring

43

lubrication

17

,

18

,

60

M

maintenance

18

bearing lubrication

60

cable carrier installation

64

cable carrier module removal

63

cover installation

67

removal

65

torque

67


60

replacement kits

87

side cover installation

67

removal

65

torque

67

strip seal

Rockwell Automation Publication CHPS-UM001D-EN-P - July 2014 installation

66

removal

65

maitenance

59

metric bolts

torque

105

motor file

creating

92

motor phasing

46

mounting

22

before mounting

23

,

28

bolt through

29

ceiling

22

incline

22

inverted

22

square nut

31

square nuts

29

surface

22

surface restrictions

23

tee nut

31

through bolt

30

toe clamp

29

,

30

vertical

13

,

22

wall

22

O

operating temperature

75

operational guidelines

49

optical encoder readhead

sin/cos encoder

17

TTL encoder

17

options

18

orientation

48

overtravel

43

P

packaging material

storage

28

packing

air transportion restrictions

14

unpacking

26

pitch

70

polarity

encoder counting

96

positive direction

47

,

48

power interconnect cables

85

procdeure

cover cleaning

61

lubrication

60

procedure

connecting stage

40

drip loop

40

EMI bonding

40

grounding

40

number of fasteners

28

stage storage

28

store packing material

28

strip seal cleaning

61

PTC thermal signal

55

Index

PTC thermistor

resistance values

42

R

readhead

17

reference documents

standards

21

CSA/CAN Z434 - industrial robot safety

21

repeatability specifications

73

requirements

22

,

23

restrictions

22

roll

70

clearance

23

mounting

23

S

safety

bolts

12

cover

12

end caps

13

hazardous voltage

12

heat

12

impacts

13

junction box

12

labels

12

pinch points

12

sharp edges

12

strong magnets

12

sudden motion

13

seal guide

17

shearing bolts

13

shipping

brace

28

clamp

28

container storage

28

dangerous goods declaration

14

form 902 instructions

14

shock

75

side cover

17

installation

67

removal

65

torque

67

side cover support

17

sin/cos encoder

17

slide

17

specifications

commutation sensor

73

flatness

73

humidity range

75

limit sensor

73

repeatability

73

shock and vibration

75

storage and operating temperature

75

straightness

73

technical

83

travel vs. weight

150 mm frame

75

200 mm frame

76

250 mm frame

76

square nut

29

,

30

,

31

spacing

31

stacking of stages

89

stage

cover

17

side cover

17

slide

17

storage

28

standards

EN60204-1 safety of electrical machines

21

static load, rotational movement definitions

70

stoping distance

50

storage

28

storage temperature

75

straightness specifications

73

strip seal

about

17

clamps

17

cleaning

61

guide

17

installation

66

T

temperature

22

,

42

temperature max.

13

thermal protection

42

through bolt

30

toe clamp

29

,

30

spacing

30

torque

cover

67

ground screw

40

side cover

67

values for different metals

105

total moving mass

83

trapezoidal Hall mode

46

travel vs. weight specifications

150 mm frame

75

200 mm frame

76

250 mm frame

76

troubleshooting

Hall effect module

55

Hall to back EMF phasing

57

motor coil resistance measurements

58

PTC thermal signal

55

TTL differential encoder

44

TTL encoder

17

U

Ultra3000 drive

91

set-up

91


111

Index

Ultraware

.mbd file

93

commutation diagnostics utility

99

self-sensing commutation and start-up

100

start-up

94

verification

97

V

vertical payload

13

vibration

22

,

75

W

wiring

Hall effect

46

limit sensor

43

sin/cos encoder

45

TTL differential encoder

44

Ultra3000 drive

91

yaw

70

Y

112


Notes:

Index


113

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At http://www.rockwellautomation.com/support you can find technical and application notes, sample code, and links to software service packs. You can also visit our Support Center at https://rockwellautomation.custhelp.com/ for software updates, support chats and forums, technical information, FAQs, and to sign up for product notification updates.

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Installation Assistance

If you experience a problem within the first 24 hours of installation, review the information that is contained in this manual. You can contact Customer Support for initial help in getting your product up and running.

United States or Canada 1.440.646.3434

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, or contact your local

Rockwell Automation representative.

New Product Satisfaction Return

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Contact your distributor. You must provide a Customer Support case number (call the phone number above to obtain one) to your distributor to complete the return process.

Please contact your local Rockwell Automation representative for the return procedure.

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Publication CHPS-UM001D-EN-P - July 2014

Supersedes Publication CHPS-UM001C-EN-P - November 2010 Copyright © 2014 Rockwell Automation, Inc. All rights reserved. Printed in the U.S.A.

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