Aerotech ABL8000 Series ABL80020 User manual

ABL8000 Series Stage
User’s Manual
(Revision 1.00.00)
Dedicated to the Science of Motion
Aerotech, Inc.
101 Zeta Drive,
Pittsburgh, PA, 15238
Phone:412-963-7470
Fax:412-963-7459
www.aerotech.com

Technical Support
Go to www.aerotech.com/service-and-support.aspx for information and support about your Aerotech prod-
ucts. The website provides downloadable resources (such as up-to-date software, product manuals, and
Help files), training schedules, and PC-to-PC remote technical support. You can also complete Product
Return (RMA) forms and get information about repairs and spare or replacement parts.
For immediate help, contact a service office or your sales representative. Have your customer order number
available before you call or include it in your email.
United States
(World Headquarters)
Phone: [phone]
Fax: [phone]
Email: [e-mail]
101 Zeta Drive
Pittsburgh, PA 15238
www.aerotech.com
United Kingdom
Phone: [phone]
Fax: [phone]
Email: [e-mail]
Japan
Phone: [phone]
Fax: [phone]
Email: [e-mail]
Germany
Phone: [phone]
Fax: [phone]
Email: [e-mail]
China
Phone: [phone]
Email: [e-mail]
France
Phone: [phone]
Email: [e-mail]
Taiwan
Phone: [phone]
Email: [e-mail]
N O T E : Aerotech continually improves its product offerings; listed options may be superseded at any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 : All drawings and illustrations are for reference only and were complete and accurate as of this
manual’s release. The most recent system drawings and schematics can be found on your software CD
ROM or on www.aerotech.com.
N O T E : This manual and any additional instructions included with the ABL8000 should be read in their
entirety before operating the ABL8000 .
N O T E : This product is intended for light industrial manufacturing or laboratory use.
Revision History 1.00.00 March 12, 2012
This manual contains proprietary information and may not be reproduced, disclosed, or used in
whole or in part without the express written permission of Aerotech, Inc. Product names mentioned
herein are used for identification purposes only and may be trademarks of their respective com-
panies.
Copyright © 2012, Aerotech, Inc. All rights reserved.

ABL8000 User's Manual Table of Contents
Table of Contents
Table of Contents iii
List of Figures iv
List of Tables v
Chapter 1: Overview 1
1.1. Standard Features 2
1.1.1. Optional Features 3
1.2. Dimensions 4
1.3. Safety Procedures and Warnings 6
1.4. EC Declaration of Incorporation 7
Chapter 2: Installation 9
2.1. Unpacking and Handling the Stage 10
2.2. Preparing the Mounting Surface 11
2.3. Securing the Stage to the Mounting Surface 12
2.4. Attaching the Payload to the Stage 14
2.5. Electrical Installation 14
2.6. Air 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 22
3.5. End of Travel Limits 25
3.5.1. Limit Switch Operation 25
3.5.2. Limit Switch Wiring 25
3.6. Standard Motor Wiring 26
3.7. 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: Revision History 33
Index 35
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Table of Contents ABL8000 User's Manual
List of Figures
Figure 1-1: Typical ABL8000 Series Positioning Stage 1
Figure 1-2: ABL8000 Series Stage 2
Figure 1-3: ABL8000 Stage Dimensions (-SC Option) 4
Figure 1-4: ABL8000 Stage Dimensions (-LC Option) 5
Figure 2-1: Lifting Features 10
Figure 2-2: Results of Flat Versus Non-Flat Mounting 11
Figure 2-3: Surface Mounting Screws 12
Figure 2-4: Mounting Holes in the Stage Table 13
Figure 2-5: Motor and Feedback Connections (-SINGLE-CMS option) 14
Figure 2-6: Motor and Feedback Connections (-XY-CMS option) 15
Figure 2-7: Motor and Feedback Connections (-XY-CMS Customer Cable option) 15
Figure 2-8: Motor and Feedback Connections (-XY-CMS Customer Hose option) 15
Figure 2-9: Motor and Feedback Connection (-XY-CMS Customer Cable & Hose option) 16
Figure 2-10: Air Fitting Location 16
Figure 3-1: Cantilevered Load Capability (-SCConstruction) 22
Figure 3-2: Cantilevered Load Capability (-LCConstruction) 23
Figure 3-3: CantileverLength Diagram 24
Figure 3-4: Normally Closed (NC) and Normally Open (NO) Limit Switch Wiring 25
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ABL8000 User's Manual Table of Contents
List of Tables
Table 1-1: Ordering Example (ABL80050-LC-M-P-NC-LN50AS-SINGLE-CMS) 3
Table 1-2: Model Numbers and Ordering Options 3
Table 3-1: Environmental Specifications 17
Table 3-2: Series Specifications (ABL80020 - ABL80040) 18
Table 3-3: Series Specifications (ABL80050 - ABL80100) 19
Table 3-4: Electrical Specifications 20
Table 3-5: Recommended Controller 20
Table 3-6: ABL8000 Series Motor Specifications 21
Table 3-7: Motor Connector Pin Assignments 26
Table 3-8: Feedback Connector Pin Assignments 27
Table 4-1: Recommended Cleaning Solvents 29
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Table of Contents ABL8000 User's Manual
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ABL8000 User's Manual Overview
Chapter 1: Overview
This manual describes Aerotech’s ABL8000 series of air bearing positioning stages. Figure 1-1 shows a typ-
ical ABL8000 positioning stage.
The ABL8000 series stages supports travel distances ranging from 200 mm to 1000 mm. The -LC con-
struction of the ABL8000 has a long carriage that is optimized for load capacity and stiffness, and it is typ-
ically used as the lower axis of an XY stage stack. The -SC construction has a short carriage and is typically
used as the upper axis of an XY stage stack due to its lower mass than the -LC construction.
This chapter introduces standard and optional features of the ABL8000 stages, explains the model numbering
system, and gives general safety precautions.
Figure 1-1: Typical ABL8000 Series Positioning Stage
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Overview ABL8000 User's Manual
1.1. Standard Features
The ABL8000 stage incorporates completely non-contact air bearing surfaces, linear motors, and feedback
devices to provide a minimum maintenance stage. There is no mechanical contact to wear or require lubri-
cation, making these stages ideal for clean room and medical applications.
The ABL8000 incorporates air-on-air preload on both vertical and horizontal surfaces for enhanced bearing
stiffness. The wide stance of the ABL8000 coupled with the air-on-air bearing type results in a stage with out-
standing 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
velocity control is important.
Figure 1-2: ABL8000 Series Stage
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ABL8000 User's Manual Overview
1.1.1. Optional Features
The ABL8000 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 details.
Table 1-1: Ordering Example (ABL80050-LC-M-P-NC-LN50AS-SINGLE-CMS)
Series Travel (mm) Carriage
Mounting and Grid Pat-
tern Motor Limits
Linear
Encoder Options
ABL80 050 -LC -M -P -NC LN50AS -SINGLE-CMS
Table 1-2: Model Numbers and Ordering Options
ABL8000 Series Linear Air-Bearing Stage
ABL80020 200 mm (8 in) travel linear air-bearing stage with linear motor and limits
ABL80030 300 mm (12 in) travel linear air-bearing stage with linear motor and limits
ABL80040 400 mm (16 in) travel linear air-bearing stage with linear motor and limits
ABL80050 500 mm (20 in) travel linear air-bearing stage with linear motor and limits
ABL80075 750 mm (30 in) travel linear air-bearing stage with linear motor and limits
ABL80100 1000 mm (40 in) travel linear air-bearing stage with linear motor and limits
Carriage
-SC 250 mm (10 in) length carriage (single-axis or y-axis use only; requires -5
motor)
-LC 400 mm (16 in) length carriage (required for x-axis in XY configuration;
requires -10 motor)
NOTE:When mounting the ABL8000 in an XY configuration, the maximum upper axis length is 400 mm.
Mounting and Grid Pattern
-M Metric dimension mounting pattern and holes
-U English dimension mounting pattern and holes
Motor
-P MT-P magnet track
-S MT-S magnet track
Limits
-NC Normally-closed end of travel limit switches (standard)
-NO Normally-open end of travel limit switches
Linear Encoders
-LNAS Linear encoder, amplified sine output at 4 µm fundamental period
-LTAS High-accuracy linear encoder, amplified sine output at 20 µm fundamental
period
Options
-SINGLE-CMS Cable management system for single-axis applications
-SINGLE-CUST.HOSE Single CMS; 0.25 inch customer hose
-SINGLE-CUST.CABLE Single CMS; one customer cable
-SINGLE-CUST.CABLE &
HOSE
Single CMS; once customer cable and 0.25 inch hose
-XY-CMS Cable management system for X-Y assembly; order with each axis
-XY-CUST.HOSE XY CMS; customer hose
-XY-CUST.CABLE XY CMS; customer cable
-XY-CUST.CABLE & HOSE XY CMS; customer cable & hose
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Overview ABL8000 User's Manual
1.2. Dimensions
355.6 [14.00] 80.0 [3.15]
113.8 [4.48]
63.1 [2.48]
63.1 [2.48]
406.4 [16.00]
254.0 [10.00]M8-1.25 Thru
[.375-16] Thru
Stage Mtg.
Holes (D)
M6-1.0 Thd
[.250-20] Thd
Top Mtg.
Holes (8)
231.9 [9.13]
204.0 [8.03]
1/2 Travel 1/2 Travel
Of Travel &
Mtg. Holes
C
L
486.4 [19.15]
31.2 [1.23]
Customer Cable Connection
Stage Feedback Connection
Stage Motor Connection
Stage Air Line Connection
BASIC
MODEL
TOTAL
TRAVEL
DIMENSIONS - MILLIMETERS [INCHES]
A
A
B
BBC C
C D
ABL80100-SC 1000.0 [40.00] 1346.2 [43.00] 228.6 [9.00] 285.8 [11.25] 10
ABL80075-SC 750.0 [30.00] 1092.2 [43.00] 228.6 [9.00] 285.8 [11.25] 10
ABL80050-SC 500.0 [16.00] 838.2 [33.00] 228.6 [9.00] - 6
ABL80040-SC 400.0 [16.00] 736.6 [29.00] 228.6 [9.00] - 6
ABL80030-SC 300.0 [12.00] 635.0 [25.00] 177.8 [7.00] - 6
ABL80020-SC 200.0 [8.00] 533.4 [21.00] 177.8 [7.00] - 6
Figure 1-3: ABL8000 Stage Dimensions (-SC Option)
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ABL8000 User's Manual Overview
BASIC
MODEL
TOTAL
TRAVEL
DIMENSIONS - MILLIMETERS [INCHES]
A B C D
ABL80100-LC 1000.0 [40.00] 1498.6 [59.00] 228.6 [9.00] 285.8 [11.25] 10
ABL80075-LC 750.0 [30.00] 1244.6 [49.00] 228.6 [9.00] 285.8 [11.25] 10
ABL80050-LC 500.0 [16.00] 990.6 [39.00] 228.6 [9.00] - 6
ABL80040-LC 400.0 [16.00] 889.0 [35.00] 228.6 [9.00] - 6
ABL80030-LC 300.0 [12.00] 787.4 [31.00] 228.6 [9.00] - 6
ABL80020-LC 200.0 [8.00] 685.8 [27.00] 228.6 [9.00] - 6
177.8 [7.00]
177.8 [7.00]
406.4 [16.00]
406.4 [16.00]
M8-1.25 Thru
[.375-16] Thru
Stage Mtg.
Holes (D)
M8-1.25 Thd
[.375-16] Thd
Top Mtg.
Holes (6)
355.6 [14.00]
1/2 Travel
Of Travel &
Mtg. Holes
C
L
A
Customer Cable Connection
Stage Feedback Connection
Stage Motor Connection
Stage Air Line Connection
1/2 Travel
BBC C
355.6 [14.00] 80.0 [3.15]
113.8 [4.48]
486.4 [19.15]
31.2 [1.23]
Figure 1-4: ABL8000 Stage Dimensions (-LC Option)
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Overview ABL8000 User's Manual
1.3. Safety Procedures and Warnings
The following statements apply wherever the Warning or Danger symbol appears within this manual. Failure
to observe these precautions could result in serious injury to those individuals performing the procedures
and/or damage to the equipment. Operators should be trained before operating this equipment.
D A N G E R : To minimize the possibility of electrical shock and bodily injury or death, dis-
connect all electrical power prior to making any electrical connections.
D A N G E R : 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 ABL8000 is connected to a power source.
D A N G E R : To minimize the possibility of bodily injury or death, disconnect all electrical
power prior to making any mechanical adjustments.
D A N G E R : Moving parts of the ABL8000 can cause crushing or shearing injuries. All per-
sonnel must remain clear of any moving parts.
W A R N I N G :If the ABL8000 is used in a manner not specified by the manufacturer, the pro-
tection provided by the ABL8000 can be impaired and result in damage, shock, injury or death.
W A R N I N G :Cables can pose a tripping hazard. Securely mount and position all ABL8000
cables to avoid potential hazards.
W A R N I N G :Do not expose the ABL8000 to environments or conditions outside the spec-
ified range of operating environments. Operation in conditions other than those specified can
cause damage to the equipment.
W A R N I N G :The ABL8000 must be mounted securely. Improper mounting can result in
injury and damage to the equipment.
W A R N I N G :Use care when moving the ABL8000. Manually lifting or transporting the
ABL8000 can result in injury.
W A R N I N G :Only trained personnel should operate, inspect, and maintain the ABL8000.
W A R N I N G :This ABL8000 is intended for light industrial manufacturing or laboratory use.
Use of the ABL8000 for unintended applications can result in injury and damage to the equip-
ment.
W A R N I N G :Before using this ABL8000, perform an operator risk assessment to determine
the needed safety requirements.
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ABL8000 User's Manual Overview
1.4. EC Declaration of Incorporation
Manufacturer: Aerotech, Inc.
101 Zeta Drive
Pittsburgh, PA 15238
USA
herewith declares that the product:
Aerotech, Inc. ABL8000 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 - Part 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 September 2010
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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 ABL8000 User's Manual
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ABL8000 User's Manual Installation
Chapter 2: Installation
This chapter describes the installation procedure for the ABL8000 stage, including handling the stage, pre-
paring the mounting surface to accept the stage, securing the stage to the mounting surface, attaching the
payload, and making the electrical connections.
W A R N I N G :Installation must follow the instructions in this chapter. Failure to follow these
instructions could result in injury and damage to the equipment.
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Installation ABL8000 User's Manual
2.1. Unpacking and Handling the Stage
Carefully remove the ABL8000 from the protective shipping container. Before operating the ABL8000, it is
important to let the ABL8000 stabilize at room temperature for at least 12 hours. Allowing the ABL8000 to sta-
bilize to room temperature will ensure that all of the alignments, preloads, and tolerances are the same as
they were when tested at Aerotech. Use compressed nitrogen or clean, dry, oil-less air to remove any dust or
debris that has collected during shipping. Set the ABL8000 on a smooth, flat, and clean surface.
ABL8000 stages come equipped ½”-13 threaded holes in the base for use with eyebolts and lifting straps (not
provided). If lifted by hand, the stage should be lifted from the bottom of the base. Do not attempt to lift or
move the stage by the table, cable brackets, or end plates. For multi-axis assemblies, always lift the system
by the lower axis. Lifting by the upper axis may disturb precision alignments on the system.
Figure 2-1: Lifting Features
Each ABL8000 has a label listing the system part number and serial number. These numbers contain infor-
mation necessary for maintaining or updating system hardware and software. Locate this label and record
the information for later reference. If any damage has occurred during shipping, report it immediately.
W A R N I N G :Improper handling could adversely affect the ABL8000’s performance. Use care
when moving the stage.
W A R N I N G :Do not attempt to move the stage's carriage (or table top) until the air supply,
detailed in Section 2.6. , has been installed. Moving the carriage without air supplied can cause
permanent damage to the stage.
W A R N I N G :Do not attempt to move the ABL8000's carriage (or table top) until the shipping
brackets have been removed. Moving the carriage with the shipping brackets installed can
cause permanent damage to the ABL8000.
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ABL8000 User's Manual Installation
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 ABL8000. When an ABL8000 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. The effects of flatness on
mounting are illustrated in Figure 2-2.
N O T E : To maintain accuracy, the mounting surface should be flat within 1 µm per 150 mm. A laboratory-
grade AA granite surface plate is recommended.
Mounting Surface
Mounting Surface
Mounting to a Flat Surface
Mounting Surface
Mounting Surface
Note the curved surface of the granite.
Mounting to a Curved Surface (exaggerated)
Figure 2-2: Results of Flat Versus Non-Flat Mounting
N O T E : The ABL8000 base is precision machined and verified for flatness prior to product assembly at
the factory. If machining is required to achieve the desired flatness, it should be performed on the mounting
surface rather than the ABL8000 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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Installation ABL8000 User's Manual
2.3. Securing the Stage to the Mounting Surface
D A N G E R : Strong rare-earth magnets are present in the linear motor magnet track. Loose
metal objects (tools, watches, keys, etc.) may cause personal injury and/or damage to the
equipment.
W A R N I N G :The ABL8000 must be mounted securely. Improper mounting can result in
injury and damage to the equipment.
Procedure for ABL8000 mounting:
1. Prepare the stone mounting surface and bottom of the stage base with precision flatstones to
remove any burrs or high spots.
2. Clean the mounting surface and bottom of the stage with the appropriate cleaners (acetone or iso-
propyl alcohol for the stage bottom).
3. Place the stage on the mounting surface
4. Remove the lifting brackets and shipping bracket (Figure 2-1)
5. Turn on the air supply to the air bearing.
W A R N I N G :Do not attempt to move the stage's carriage (or table top) until the air supply,
detailed in Section 2.6. , has been installed. Moving the carriage without air supplied can cause
permanent damage to the stage.
6. Slide the air bearing carriage to one end of travel and screw down with M6 (or ¼-20) socket head
cap screws and flat washers in the exposed mounting locations. Do not fully tighten at this time, but
bring within 1/4 turn of screw head engagement
Figure 2-3: Surface Mounting Screws
7. Slide the air-bearing carriage to the opposite end of travel and install the stage mounting screws in
the exposed mounting holes. As in step 6, do not tighten the screws yet, but bring within 1/4 turn of
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ABL8000 User's Manual Installation
engagement
8. For some travel lengths, the central mounting points of the stage base might need to be accessed
through holes in the stage carriage. Slide the carriage to expose the central mounting holes and
insert the mounting screws and washers.
Figure 2-4: Mounting Holes in the Stage Table
9. Tighten the mounting screws (begin from the center out for best accuracy). The usual torque value
for M6 socket head cap screws is 8 N-m .
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Installation ABL8000 User's Manual
2.4. Attaching the Payload to the Stage
To prevent damage to payloads, test the operation of the stage before the payload is attached to the stage
table. Proceed with the electrical installation and test the motion control system in accordance with the sys-
tem documentation. Document all results for future reference. For information on electrical connections,
refer to Section 2.5. and the documentation delivered with the stage.
The payload should be flat, rigid, and comparable to the stage in quality.
N O T E : For valid system performance, the mounting interface should be flat within 1 µm per 50 mm.
2.5. Electrical Installation
Aerotech motion control systems are adjusted at the factory for optimum performance. When the ABL8000
is part of a complete Aerotech motion control system, setup usually involves connecting a stage to the appro-
priate drive chassis with the cables provided. Labels on the system components usually indicate the appro-
priate connections.
Refer to the appropriate system manuals and documentation for additional installation and operation infor-
mation. If the system is uniquely configured, a drawing showing system interconnects is supplied.
See Section 3.6. for standard wiring pin assignments.
W A R N I N G :Never connect or disconnect any electrical component or connecting cable
while power is applied, or serious damage can result.
W A R N I N G : Refer to Section 3.6. for the location of the ABL8000's protective ground. If you
are using cables other than those provided by Aerotech, you must connect the ground pins to a
ground connection.
Figure 2-5: Motor and Feedback Connections (-SINGLE-CMS option)
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