Aerotech ASR1200 User manual

ASR1200 Rotary Stage
User’s Manual
P/N: EDS132 (Revision 1.03.00)
Dedicated to the Science of Motion
Aerotech, Inc.
101 Zeta Drive,
Pittsburgh, PA, 15238
Phone: [phone]
Fax: [phone]
www.aerotech.com

Product Registration Register online at: http://www.-
aerotech.com/prodreg.cfm
Technical Support United States Headquarters:
Phone: [phone]
Fax: [phone]
Email: [e-mail]
United Kingdom:
Phone: [phone]
Fax: [phone]
Email: [e-mail]
Germany:
Phone: [phone]
Fax: [phone]
Email: [e-mail]
Japan:
Phone: [phone] (Sales)
Phone: [phone] (Service)
Fax: [phone]
Email: [e-mail]
China:
Phone: [phone]
Email: [e-mail]
Revision History Revision 1.03.00 February 21, 2011
Revision 1.02.00 August 16, 2010
Revision 1.01.00 December 2, 2008
Revision 1.00.00 October 14, 2008
Product names mentioned herein are used for identification purposes only and may be trademarks of
their respective companies.
© Aerotech, Inc. 2011

ASR1200 Rotary Stage User's Manual Table of Contents
Table of Contents
Table of Contents iii
List of Figures v
List of Tables vii
Chapter 1: Overview 1
1.1. Standard Features 2
1.1.1. Rotary Axis 2
1.1.2. Wet Cut 2
1.2. Optional Features 3
1.2.1. Mounting Plate 3
1.2.2. Wrenches 3
1.2.3. Electronics Controller 3
1.2.4. Ringseals 3
1.3. Model Numbers 4
1.4. Dimensions 5
1.5. Safety Procedures and Warnings 6
1.6. EC Declaration of Incorporation 8
Chapter 2: Installation 9
2.1. Unpacking and Handling the Stage 9
2.2. Preparing the Mounting Surface 10
2.3. Securing the Stage to the Mounting Surface 11
2.4. Attaching the Payload to the Stage 12
2.5. Changing ASR Workholding Devices 13
2.5.1. Collet Installation and Removal Procedure 13
2.6. Electrical Installation 16
2.7. Air Requirements 16
2.8. Wet Cut Fluid Requirements 16
Chapter 3: Operating Specifications 17
3.1. Environmental Specifications 17
3.2. Accuracy and Temperature Effects 17
3.3. Basic Specifications 18
3.4. Load Capability 20
Chapter 4: Maintenance 21
4.1. Service and Inspection Schedule 21
4.2. Cleaning and Lubrication 22
4.2.1. Collet & Collet Chuck Lubrication and Cleaning 22
4.3. Seal Replacement 23
4.3.1. Piston Seal Change Procedure 23
4.3.2. Ringseal O-Ring Replacement 23
4.3.3. Wet Cut Rotary Union Seal Replacement 25
4.4. Wet Cut Rotary Union Removal 29
Appendix A: Warranty and Field Service 31
Appendix B: Technical Changes 33
Index 35
Reader's Comments 37
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Table of Contents ASR1200 Rotary Stage User's Manual
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ASR1200 Rotary Stage User's Manual List Of Figures
List of Figures
Figure 1-1: ASR1200 Rotary Stage 1
Figure 1-2: ASR1200 Dimensions 5
Figure 2-1: ASR1200 Stage Showing Mounting Plate (Top View) 11
Figure 2-2: ASR1200 Stage Without Mounting Plate (Bottom View) 11
Figure 2-3: Installation of Collet into Collet Nut 14
Figure 2-4: Installation Procedure for Collet/Collet Nut 15
Figure 3-1: ASR1200 Wet Cut Rotary Union Location 20
Figure 4-1: Ringseal Removal and Replacement 23
Figure 4-2: Typical Ringseal 24
Figure 4-3: Cross-Section View of Ringseal Showing O-Ring 24
Figure 4-4: Cross-Section View of Wet Cut Rotary Union Assembly 25
Figure 4-5: Rotary Union Hardware Removal 26
Figure 4-6: Seal Installation 26
Figure 4-7: Seal Retainer Assembly 27
Figure 4-8: Wet Cut Rotary Union Shaft Inspection 27
Figure 4-9: Wet Cut Rotary Union 29
Figure 4-10: Wet Cut Rotary Union Installation 30
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List of Figures ASR1200 Rotary Stage User's Manual
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ASR1200 Rotary Stage User's Manual List of Tables
List of Tables
Table 1-1: Model Numbering System 4
Table 3-1: Environmental Specifications 17
Table 3-2: ASR1200 Series Specifications 18
Table 3-3: ASR1200 Motor Specifications 19
Table 4-1: Recommended Lubricants 22
Table B-1: Current Changes (1.03.00) 33
Table B-2: Archived Changes 34
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List of Tables ASR1200 Rotary Stage User's Manual
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ASR1200 Rotary Stage User's Manual Overview
Chapter 1: Overview
Aerotech’s ASR1200 mechanical-bearing rotary stage is a system that combines high precision rotary posi-
tioning with an integrated pneumatically controlled collet chuck for material handling. The ASR1200 series util-
izes direct-drive brushless motor technology to maximize positioning performance and virtually eliminate the
need for maintenance. The stage is also equipped with a rotary union attachment for wet cutting operations.
These features make the ASR1200 an ideal choice for applications where low maintenance, high throughput,
and low total cost of ownership are essential.
The ASR1200 has been designed with a collet chuck that can support ER16 collets (manufactured to
DIN6499 specs) to allow for a wide range of materials and applications. This product is intended for light
industrial manufacturing or laboratory use.
This chapter introduces standard and optional features of the ASR1200, explains the model numbering sys-
tem, and gives general safety precautions. Figure 1-1 shows a typical ASR1200.
Figure 1-1: ASR1200 Rotary Stage
N O T E : Aerotech continually improves its product offerings, and listed options may be superseded at any
time. Refer to the most recent edition of the Aerotech Motion Control Product Guide for the most current
product information at www.aerotech.com.
N O T E : This manual should be read in its entirety before operating the ASR1200 system.
Failure to follow the maintenance procedures outlined in Section 4.3.3. will result in voiding of
warranty.
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Overview ASR1200 Rotary Stage User's Manual
1.1. Standard Features
1.1.1. Rotary Axis
ASR1200 stages come standard with a direct drive brushless motor with a non-contacting integral rotary
union. These features combine to create a low friction, low maintenance rotary stage capable of high accel-
erations and low positioning error. With a non-contact rotary union, there are no seals to be replaced or lubri-
cated allowing for a lifetime of maintenance free performance. The brushless, slotless motor design allows
for extremely high torque coupled with smooth motion. There are no brushes to wear, no belts to tension, and
no gears to wear resulting in a completely maintenance-free motor.
The ASR1200 is designed with an ER16 style collet chuck. The maximum tube diameter supported by the
ER16 collet chuck is 5.8 mm. The collet is retained with a threaded collet nut enabling quick changeover. It
is configured in a “fail-safe” normally-closed mode where full clamping force is applied when no air pressure
is present.
N O T E : Aerotech recommends using electro-polished collets manufactured to DIN6499 specs.
1.1.2. Wet Cut
The ASR1200 rotary stage has a standard wet cut rotary union that is used for fluid delivery (@ 100 psi max
pressure) in wet laser cutting applications. A 1/4" NPT tapped hole is supplied on the rear of the rotary to
allow for connections of different length pressure vessels depending on the tube length being cut. See Sec-
tion 3.4. , Section 4.3.3. , and Section 4.4. for details regarding use and maintenance of the wet cut rotary
union.
N O T E : The purchase of a ringseal will also be required based on the tube diameter used in the cutting
application. Consult Aerotech for more information.
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ASR1200 Rotary Stage User's Manual Overview
1.2. Optional Features
1.2.1. Mounting Plate
ASR1200 stages can be configured to include a mounting plate that can use either M6 or 1/4-20 bolts. The bot-
tom of this mounting plate is precision machined and verified for flatness. If the mounting plate is not
selected, a custom mounting option can be attached using the (Qty-4) M6 tapped holes in the bottom of the
stage.
1.2.2. Wrenches
This option is selected when spanner wrenches for removing the collet nut are desired.
1.2.3. Electronics Controller
The ASR1200 stage is part of a complete Aerotech motion control system, which is adjusted at the factory
for optimum performance. Setup involves connecting a stage to the appropriate drives with the cables pro-
vided. Refer to your electrical documentation package for further information.
1.2.4. Ringseals
Replaceable O-Ring seals are required to perform wet cut operations using the ASR1200. These ringseals
are sized for specific tube diameters in sizes up to 5.8 mm. Consult Aerotech for supported sizes.
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Overview ASR1200 Rotary Stage User's Manual
1.3. Model Numbers
The stage model number indicates the optional features on a particular stage. To determine the options on
your stage, refer to Table 1-1 for an explanation of the numbering system.
Example: ASR1200-10-HPD-NC-RE2048AS-MP-WRENCH-RINGSEAL-1.08MM
Table 1-1: Model Numbering System
ASR1200, Direct Drive Rotary Stage
ASR1200 Direct drive rotary stage with integral ER-style collet chuck
Drive Motor
-10 5 N-m peak, 1.95 N-m continuous direct-drive brushless motor
Connector
-HPD High power D connector for motor power and 25-pin D for feedback
-25D Dual 25-pin D connectors with bridged pins for motor power
-MS MS-style connectors for motor power and feedback
Collet Chuck
-NC Normally Closed Collet Chuck for ER16 Collet
Position Transducer
-RE2048AS Incremental encoder with 2048 cycles per rev sinusoidal output signal
-RE5000AS Incremental encoder with 5000 cycles per rev sinusoidal output signal
Rear Seal
-S Rear shaft seal
-NS No shaft seal
Options
-MP Mounting plate
-WRENCH Spanner wrenches for changing ER16 collets
-RINGSEAL O-ring seal assembly for wet cutting. Consult factory for supported sizes.
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ASR1200 Rotary Stage User's Manual Overview
1.4. Dimensions
Figure 1-2: ASR1200 Dimensions
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Overview ASR1200 Rotary Stage User's Manual
1.5. Safety Procedures and Warnings
The following statements apply throughout this manual. Failure to observe these precautions could result in
serious injury to those performing the procedures and damage to the equipment.
This manual and any additional instructions included with the stage should be retained for the lifetime of the
stage.
To minimize the possibility of electrical shock and bodily injury or death, disconnect all elec-
trical power prior to making any electrical connections.
To minimize the possibility of electrical shock and bodily injury or death when any electrical
circuit is in use, ensure that no person comes in contact with the circuitry when the stage is
connected to a power source.
To minimize the possibility of bodily injury or death, disconnect all electrical power prior to
making any mechanical adjustments.
Moving parts of the stage can cause crushing or shearing injuries. All personnel must
remain clear of any moving parts.
Improper use of the stage can cause damage, shock, injury, or death. Read and understand
this manual before operating the stage.
If the stage is used in a manner not specified by the manufacturer, the protection provided
by the stage can be impaired.
Stage cables can pose a tripping hazard. Securely mount and position all stage cables to
avoid potential hazards.
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ASR1200 Rotary Stage User's Manual Overview
Do not expose the stage to environments or conditions outside the specified range of oper-
ating environments. Operation in conditions other than those specified can cause damage to
the equipment.
The stage must be mounted securely. Improper mounting can result in injury and damage to
the equipment.
Use care when moving the stage. Manually lifting or transporting stages can result in injury.
Only trained personnel should operate, inspect, and maintain the stage.
This stage is intended for light industrial manufacturing or laboratory use. Use of the stage
for unintended applications can result in injury and damage to the equipment.
Before using this stage, perform an operator risk assessment to determine the needed
safety requirements.
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Overview ASR1200 Rotary Stage User's Manual
1.6. EC Declaration of Incorporation
Manufactorer: Aerotech, Inc.
101 Zeta Drive
Pittsburgh, PA 15238
USA
herewith declares that the product:
Aerotech, Inc. ASR1200 Stage
is intended to be incorporated into machinery to constitute machinery covered by the Directive
2006/42/EC as amended;
does therefore not in every respect comply with the provisions of this directive;
and that the following harmonized European standards have been applied:
EN ISO 12100-1,-2:2003+A1:2009
Safety of machinery - Basic concepts, general principles for design
ISO 14121-1:2007
Safety of machinery - Risk assessment - Par 1: Principles
EN 60204-1:2005
Safety of machinery - Electrical equipment of machines - Part 1: General requirements
and further more declares that
it is not allowed to put the equipment into service until the machinery into which it
is to be incorporated or of which it is to be a component has been found and
declared to be in conformity with the provisions of the Directive 2006/42/EC and
with national implementing legislation, i.e. as a whole, including the equipment
referred to in this Declaration.
Authorized Representative: Manfred Besold
Address: AEROTECH GmbH
Süd-West-Park 90
D-90449 Nürnberg
Name:
Alex Weibel /
Position: Engineer Verifying Compliance
Location: Pittsburgh, PA
Date: February 21, 2011
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This is to certify that the aforementioned product is in accordance with the applicable
requirements of the following Directive(s):
2011/65/EU RoHS 2 Directive

ASR1200 Rotary Stage User's Manual Installation
Chapter 2: Installation
This chapter describes the installation procedure for the ASR1200 stage, including handling the stage prop-
erly, preparing the mounting surface to accept the stage, securing the stage to the mounting surface, attach-
ing the payload, and making the electrical connections.
Installation must follow the instructions in this chapter.Failure to follow these instructions
could result in injury and damage to the equipment.
2.1. Unpacking and Handling the Stage
Carefully remove the stage from the protective shipping container. Use compressed nitrogen or clean, dry air
to remove any dust or debris that has collected during shipping. If any damage has occurred during shipping,
report it immediately.
Before operating the stage, it is important to let the stage stabilize at room temperature for at least 12 hours.
Allowing the stage to stabilize to room temperature will ensure that all of the alignments, preloads, and tol-
erances are the same as they were when tested at Aerotech. Set the stage on a smooth, flat, and clean sur-
face.
Each stage has a label listing the system part number and serial number. These numbers contain information
necessary for maintaining or updating system hardware and software. Locate this label and record the infor-
mation for later reference.
Improper stage handling could adversely affect the stage’s performance. Use care when
moving the stage. Manually lifting or transporting the stage can result in injury
Do not allow the stage to drop onto any surface.
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Installation ASR1200 Rotary Stage User's Manual
2.2. Preparing the Mounting Surface
The mounting surface should be flat and have adequate stiffness in order to achieve the maximum per-
formance from the ASR1200 stage. When a stage is mounted to a non-flat surface, the stage can be dis-
torted as the mounting screws are tightened. This distortion will decrease the overall accuracy of the stage.
Adjustments to the mounting surface must be done before the stage is secured.
N O T E : To maintain accuracy, the mounting surface should be flat within 1 µm per 50 mm.
N O T E : The stage base is precision machined and verified for flatness prior to stage assembly at the fac-
tory. If machining is required to achieve the desired flatness, it should be performed on the mounting sur-
face rather than the stage base. Shimming should be avoided if possible. If shimming is required, it should
be minimized to improve the rigidity of the system.
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ASR1200 Rotary Stage User's Manual Installation
2.3. Securing the Stage to the Mounting Surface
If a mounting plate is included on the stage, mount using (Qty-4) M6 or 1/4-20 bolts (refer to Figure 2-1). If the
stage is configured without a mounting plate, use the (Qty-4) M6 tapped holes on the bottom of the stage to
attach an alternative means of mounting (see Figure 2-2).
The stage must be mounted securely. Improper mounting can result in injury and damage to
the equipment.
Figure 2-1: ASR1200 Stage Showing Mounting Plate (Top View)
Figure 2-2: ASR1200 Stage Without Mounting Plate (Bottom View)
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Installation ASR1200 Rotary Stage User's Manual
2.4. Attaching the Payload to the Stage
To prevent damage to the stage or parts, test the operation of the stage before any material is held in the col-
let. Proceed with the electrical installation and test the motion control system.
To operate the collet, clean compressed air or nitrogen must be supplied to the stage (see Section 2.7. ). The
one-touch air inlet fitting accepts 4 mm or 5/32” OD plastic air line.
Once air is supplied, material of the appropriate size can be placed in the collet. All collets supplied by Aero-
tech are clearly labeled with their clamping size range and collet style. Be sure to use only the correct size
material in the collet. If an incorrect material size is clamped, the accuracy of the collet could be com-
promised. Never clamp material or tools that are larger than the specified range. It is also important to have
the material or tool inserted at least 2/3 the length of the collet bore. Any less than this could cause per-
manent deformation of the collet and reduce accuracy (see Section 2.5.1. for collet installation).
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