Aerotech ABL2000 Series User manual

ABL2000 Series Stage
User’s Manual
P/N: EDS105 (Revision 1.02.00)
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 1.02.00 March 2, 2011
Revision 1.01.00 January 5, 2009
Revision 1.00.00 February 2, 2006
Product names mentioned herein are used for identification purposes only and may be trademarks of
their respective companies.
© Aerotech, Inc. 2011

ABL2000 Series 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 1
1.1.1. Optional Features 2
1.1.2. Cable Management Systems 3
1.2. Dimensions 4
1.3. Safety Procedures and Warnings 5
1.4. EC Declaration of Incorporation 7
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 14
2.5. Electrical Installation 14
2.6. Air Requirements 14
Chapter 3: Operating Specifications 15
3.1. Environmental Specifications 15
3.2. Basic Specifications 16
3.3. Load Capability 22
3.4. Optical Limit Switch 24
3.4.1. Limit Operation 24
3.4.2. Limit Switch Wiring 24
3.5. Standard Stage Wiring 25
3.6. Vacuum Operation 27
Chapter 4: Maintenance 29
4.1. Service and Inspection Schedule 29
4.2. Cleaning and Lubrication 29
4.2.1. Recommended Cleaning Solvents 29
4.2.2. Cleaning Process 30
Appendix A: Warranty and Field Service 31
Appendix B: Technical Changes 33
Index 35
Reader's Comments 37
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ABL2000 Series Stage User's Manual List Of Figures
List of Figures
Figure 1-1: ABL2000 Series Stage 1
Figure 1-2: ABL2000 Dimensions 4
Figure 2-1: Results of Flat Versus Non-Flat Mounting 10
Figure 2-2: Hardcover and End Plate Mounting Screws 12
Figure 2-3: Magnet Track Mounting Hardware 13
Figure 2-4: With Magnet Tracks Removed, Stage Mounting Holes are Accessible 13
Figure 3-1: Velocity vs. resolution as a function of system data rate (ABL2000 with LTAS or LNAS
encoder)
20
Figure 3-2: Load capability of ABL2000 Series Stages 22
Figure 3-3: Cantilever Length Diagram 22
Figure 3-4: Maximum Accelerations Possible Based on Mass 23
Figure 3-5: Normally Closed (NC) and Normally Open (NO) Limit Switch Wiring 24
Figure 4-1: Air Bearing Surfaces and Encoder Scales Require Periodic Cleaning 30
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ABL2000 Series Stage User's Manual List of Tables
List of Tables
Table 1-1: Ordering Example (ABL20100-10-RIBBON-LN100AS-NC-XY-CMS) 2
Table 1-2: Model Numbers and Ordering Options 2
Table 3-1: Environmental Specifications 15
Table 3-2: ABL2000 Series Specifications 16
Table 3-3: ABL2000 Series Resolution Information 20
Table 3-4: ABL2000 Motor Specifications 21
Table 3-5: Motor Connector Pinouts for all ABL2000 Stages 25
Table 3-6: Connector Pinouts for LNAS Encoder Option 25
Table 3-7: Connector Pinouts for all LT Encoders, Including Squarewave and Amplified Sine Models 26
Table 3-8: Wiring Connector Pinouts for Stages with LZR (Laser) Feedback 26
Table 3-9: Motor Wiring Pinout Descriptions 27
Table 4-1: Recommended Cleaning Solvents 29
Table B-1: Current Changes (1.02.00) 33
Table B-2: Archived Changes 34
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ABL2000 Series Stage User's Manual Overview
Chapter 1: Overview
This manual describes Aerotech’s ABL2000 series of air bearing positioning stages.
The ABL2000 series supports travel distances ranging from 100 mm to 1200 mm (4 in to 48 in). The ABL2000
combines excellent pitch/yaw characteristics with the unsurpassed velocity control that is necessary for print-
ing, imaging, and fiber-optic applications.
This chapter introduces standard and optional features of the ABL2000 stages and gives general safety pre-
cautions.
1.1. Standard Features
The ABL2000 series stages all incorporate completely non-contact air bearing surfaces, linear motors, and
feedback devices to provide a maintenance free stage. There is no mechanical contact to wear or require lubri-
cation, making these stages ideal for clean room and medical applications.
The ABL2000 incorporates an active preload on both vertical and horizontal surfaces. The opposing thin-film
pressure maintains the bearing nominal gap tolerance. This design, in addition to the large air-bearing surface
that distributes the load over a large surface area, results in a stage with outstanding stiffness that is ideal for
heavy or offset loading.
The brushless linear motor uses an ironless forcer, which means there is zero cogging and no attractive
forces – resulting in unsurpassed smoothness of motion. This is especially useful in applications where veloc-
ity control is important.
Figure 1-1: ABL2000 Series 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.
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Overview ABL2000 Series Stage User's Manual
1.1.1. Optional Features
The ABL2000 can be readily customized to meet the needs of individual applications. Common examples
include cable management for stage-mounted payloads, custom tabletops, and granite bases. Contact the
Aerotech factory for more details.
Table 1-1: Ordering Example (ABL20100-10-RIBBON-LN100AS-NC-XY-CMS)
Series Travel (mm) Motor Cabling Linear Encoder Limits Options
ABL20 100 -10 -RIBBON -LN100AS -NC -XY-CMS
Table 1-2: Model Numbers and Ordering Options
ABL2000 Series Linear Air-Bearing Stage
ABL20010 100 mm (4 in) travel linear air-bearing stage with linear motor and limits
ABL20020 200 mm (8 in) travel linear air-bearing stage with linear motor and limits
ABL20030 300 mm (12 in) travel linear air-bearing stage with linear motor and limits
ABL20040 400 mm (16 in) travel linear air-bearing stage with linear motor and limits
ABL20050 500 mm (20 in) travel linear air-bearing stage with linear motor and limits
ABL20075 750 mm (30 in) travel linear air-bearing stage with linear motor and limits
ABL20100 1000 mm (40 in) travel linear air-bearing stage with linear motor and limits
ABL20120 1200 mm (48 in) travel linear air-bearing stage with linear motor and limits
Motor
-10 Brushless linear motor (BLMC-192-A)
Cabling
-RIBBON Flat ribbon cabling
-ROUND E-chain and round wire cabling
Standard Linear Encoders
-LT10AS Linear encoder for ABL20010; amplified sine output
-LT20AS Linear encoder for ABL20020; amplified sine output
-LT30AS Linear encoder for ABL20030; amplified sine output
-LT40AS Linear encoder for ABL20040; amplified sine output
-LT50AS Linear encoder for ABL20050; amplified sine output
-LT75AS Linear encoder for ABL20075; amplified sine output
-LT100AS Linear encoder for ABL20100; amplified sine output
-LT120AS Linear encoder for ABL20120; amplified sine output
-LT10X5 Linear encoder for ABL20010; 1.0 micron line driver output
-LT20X5 Linear encoder for ABL20020; 1.0 micron line driver output
-LT30X5 LInear encoder for ABL20030; 1.0 micron line driver output
-LT40X5 Linear encoder for ABL20040; 1.0 micron line driver output
-LT50X5 Linear encoder for ABL20050; 1.0 micron line driver output
-LT75X5 Linear encoder for ABL20075; 1.0 micron line driver output
-LT100X5 Linear encoder for ABL20100; 1.0 micron line driver output
-LT120X5 Linear encoder for ABL20120; 1.0 micron line driver output
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ABL2000 Series Stage User's Manual Overview
High-Accuracy Linear Encoders
-LN10AS High-accuracy linear encoder for ABL20010; amplified sine output
-LN20AS High-accuracy linear encoder for ABL20020; amplified sine output
-LN30AS High-accuracy linear encoder for ABL20030; amplified sine output
-LN40AS High-accuracy linear encoder for ABL20040; amplified sine output
-LN50AS High-accuracy linear encoder for ABL20050; amplified sine output
-LN75AS High-accuracy linear encoder for ABL20075; amplified sine output
-LN100AS High-accuracy linear encoder for ABL20100; amplified sine output
-LN120AS High-accuracy linear encoder for ABL20120; amplified sine output
High-Accuracy/High-Resolution Linear Encoders
-LZAS10 High-accuracy/high-resolution linear encoder for ABL20010; amplified sine output
-LZAS20 High-accuracy/high-resolution linear encoder for ABL20020; amplified sine output
Laser Interferometer Feedback Option
-LZR Laser interferometer feedback; amplified sine output
Limits
-NC Normally-closed end of travel limit switches (standard)
-NO Normally-open end of travel limit switches
Options
-X-Y-CMS Cable management system for X-Y assembly; order with X-axis only
Table 1-2: Model Numbers and Ordering Options (continued)
1.1.2. Cable Management Systems
ABL2000 stages come with two options for connecting cables; flat ribbon cable or round wire cables. For
round wire cable applications, a plastic cable carrier chain is used to route and protect the cables. For travel
lengths of 400 mm and less, flat ribbon cable is used without a plastic chain. For 500 mm and greater travel
lengths, ribbon cable is also encased in a plastic chain. Please consult the factory for more details on wire
style selection.
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Overview ABL2000 Series Stage User's Manual
1.2. Dimensions
Figure 1-2: ABL2000 Dimensions
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ABL2000 Series Stage User's Manual Overview
1.3. 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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Overview ABL2000 Series Stage User's Manual
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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ABL2000 Series Stage User's Manual Overview
1.4. EC Declaration of Incorporation
Manufactorer: Aerotech, Inc.
101 Zeta Drive
Pittsburgh, PA 15238
USA
herewith declares that the product:
Aerotech, Inc. ABL2000 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: March 2, 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

Overview ABL2000 Series Stage User's Manual
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ABL2000 Series Stage User's Manual Installation
Chapter 2: Installation
This chapter describes the installation procedure the ABL2000 stage, including handling the stage properly,
securing the stage to the mounting surface, attaching the payload, and making the electrical connections.
Installation must follow the instructions in this chapter. Failure to follow these instructions
could result in injury and damage to the equipment.
2.1. Unpacking and Handling the Stage
Carefully remove the stage from the protective shipping container. Before operating the stage, it is important
to let the stage to stabilize at room temperature for at least 12 hours. Clean the stage by blowing it off with
pressurized nitrogen or clean, oil-less air.
Before the stage can be operated, the shipping clamps must be removed. These are the only red anodized
parts on the stage and must all be removed.
The stage should be lifted from the bottom of the base. Do not attempt to lift or move the stage from the table,
hardcover, or end plates.
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. If any damage has occurred during shipping, report it immediately.
Do not attempt to move the stage until the air supply, detailed inSection 2.6. , has been
installed. Moving the stage table without air supplied can cause permanent damage to the
stage.
Manually lifting or transporting stages can result in injury.
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Installation ABL2000 Series Stage User's Manual
2.2. Preparing the Mounting Surface
The mounting surface should be flat and have adequate stiffness in order to achieve the maximum per-
formance from the ABL2000. When an ABL2000 series stage is mounted to a non-flat surface, the stage can
be distorted as the mounting screws are tightened. This distortion will decrease the overall accuracy of the
stage. Adjustments to the mounting surface must be done before the stage is secured. The effects of flat-
ness on mounting are illustrated in Figure 2-1.
N O T E : To maintain accuracy, the mounting surface should be flat within 1 µm per 50 mm.
Figure 2-1: Results of Flat Versus Non-Flat Mounting
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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ABL2000 Series Stage User's Manual Installation
2.3. Securing the Stage to the Mounting Surface
In order to mount the stage to the mounting surface, the magnet track for the linear motor must be removed.
The following is the procedure for removing the magnet track, mounting the stage, and replacing the com-
ponents.
The stage must be mounted securely. Improper mounting can result in injury and damage to
the equipment.
The magnet track contains strong magnets. Exercise caution when handling them. Keep
the magnet tracks away from each other and all ferrous material (such as steel).
Procedure for ABL2000 mounting:
1. Remove hardcover from lower axis, if present (See 2.3)
2. Remove either end plate (See 2.3)
3. Supply air to lower axis so that magnet track screws can be accessed. The red shipping clamp must be
removed in order for the carriage to move freely.
4. Remove screws holding magnet track to base (See 2.3)
DO NOT remove screws that have security-torx heads. These screws are for magnet track
assembly and removal may cause bodily injury.
5. Note the orientation of the magnet track as there can be more than one in the assembly and orientation is
important. Carefully remove magnet tracks from assembly. The magnet tracks are highly magnetic and
should be kept away from each other and all ferrous material.
6. Mount ABL2000 onto mounting surface using M8 mounting screws and washers.
7. Follow mounting instructions in reverse order to re-assemble. Use caution when handling and installing
the magnet tracks.
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Installation ABL2000 Series Stage User's Manual
Figure 2-2: Hardcover and End Plate Mounting Screws
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