Aerotech ABRS Series User manual

Revision: 1.08.00
ABRS Hardware Manual

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you can complete Product Return (RMA) forms and get information about repairs and spare or replacement parts. To get help
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it available before you call.
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Phone: [phone]
Fax: [phone]
101 Zeta Drive
Pittsburgh, PA 15238-2811
www.aerotech.com
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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 companies.
Copyright © 2006-2020, Aerotech, Inc., All rights reserved.

Table of Contents
ABRS Hardware Manual 1
Table of Contents 3
List of Figures 4
List of Tables 5
Safety Procedures and Warnings 6
EU Declaration of Incorporation 7
Chapter 1: Overview 9
1.1. Environmental Specifications 10
1.2. Accuracy and Temperature Effects 10
1.3. Basic Specifications 11
1.4. Air Requirements 12
1.5. Vacuum Operation 12
Chapter 2: Installation 13
2.1. Unpacking and Handling the Stage 13
2.2. Dimensions 14
2.3. Securing the Stage to the Mounting Surface 18
2.4. Attaching the Payload to the Stage 20
Chapter 3: Electrical Installation 21
3.1. Motor and Feedback Connectors 22
3.2. Motor and Feedback Wiring 26
3.3. Motor and Feedback Specifications 28
3.4. Limits, Marker, and Machine Direction 33
3.5. Motor and Feedback Phasing 34
Chapter 4: Maintenance 37
4.1. Service and Inspection Schedule 37
4.2. Cleaning and Lubrication 38
4.3. Troubleshooting 39
Appendix A: Warranty and Field Service 41
Appendix B: Revision History 43
Index 45
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ABRS Hardware Manual Table of Contents

List of Figures
Figure 1-1: ABRSSeries Rotary Air-Bearing Stage 9
Figure 2-1: ABRS150MP Dimensions 14
Figure 2-2: ABRS200MP Dimensions 15
Figure 2-3: ABRS250MP Dimensions 16
Figure 2-4: ABRS300MP Dimensions 17
Figure 2-5: Top View of an ABRS250MP Stage Showing Mounting Holes 19
Figure 2-6: Side View of an ABRS250MP Stage Showing Tapped Fixturing Holes 19
Figure 3-1: Motor and Feedback Wiring (single connector, ABRS150MP) 26
Figure 3-2: Motor and Feedback Wiring (two connectors, ABRS200MP, ABRS250MP,
ABRS300MP) 27
Figure 3-3: Machine Direction 33
Figure 3-4: Hall Phasing 34
Figure 3-5: Analog Encoder Phasing Reference Diagram (-E1 Encoder Option) 35
Figure 3-6: Digital Encoder Phasing Reference Diagram (-E2 Encoder Option) 35
List of Figures ABRS Hardware Manual
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List of Tables
Table 1-1: Model Options 9
Table 1-2: Environmental Specifications 10
Table 1-3: ABRS Series Specifications 11
Table 2-1: Stage to Mounting Surface Hardware 18
Table 2-2: ABRS Series Load Capability 20
Table 3-1: 25-Pin Motor and Feedback Connector Pinout 23
Table 3-2: Mating Connector Part Numbers for the 25-Pin Motor and Feedback Connector 23
Table 3-3: 4-Pin Motor ConnectorPinout 24
Table 3-4: Mating Connector Part Numbers for the 4-Pin Motor Connector 24
Table 3-5: 25-Pin Feedback Connector Pinout 25
Table 3-6: Mating Connector Part Numbers for the 25-Pin Feedback Connector 25
Table 3-7: Feedback Specifications 28
Table 3-8: Encoder Resolution Specifications 28
Table 3-9: Maximum Speed (rpm) Per Encoder Option 28
Table 3-10: ABRS150MP Motor Specifications (S-50-39-A) 29
Table 3-11: ABRS200MP Motor Specifications (S-76-35-A) 30
Table 3-12: ABRS250MP Motor Specifications (S-130-39-A) 31
Table 3-13: ABRS300MP Motor Specifications (S-180-44-A) 32
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ABRS Hardware Manual List of Tables

Safety Procedures and Warnings
This manual tells you how to carefully and correctly use and operate the ABRS.
lRead all parts of this manual before you install or operate the ABRS or before you do
maintenance to your system.
lTo prevent injury to you and damage to the equipment, obey the precautions in this
manual.
If you do not understand the information in this manual, contact Aerotech Global Technical
Support.
N O T E : Aerotech continually improves its product offerings; listed options may be superseded at any
time. All drawings and illustrations are for reference only and were complete and accurate as of this
manual’s release. Refer to www.aerotech.com for the most up-to-date information.
D A N G E R : This product contains potentially lethal voltages. To reduce the possibility of
electrical shock, bodily injury, or death the following precautions must be followed.
1. Access to the ABRS and component parts must be restricted while connected to a power
source.
2. Do not connect or disconnect any electrical components or connecting cables while
connected to a power source.
3. Disconnect electrical power before servicing equipment.
4. All components must be properly grounded in accordance with local electrical safety
requirements.
5. Operator safeguarding requirements must be addressed during final integration of the
product.
W A R N I N G : To minimize the possibility of electrical shock, bodily injury or death the
following precautions must be followed.
1. Moving parts can cause crushing or shearing injuries. Access to all stage and motor parts
must be restricted while connected to a power source.
2. Cables can pose a tripping hazard. Securely mount and position all system cables to avoid
potential hazards.
3. Do not expose this product to environments or conditions outside of the listed
specifications. Exceeding environmental or operating specifications can cause damage to
the equipment.
4. The ABRS stage must be mounted securely. Improper mounting can result in injury and
damage to the equipment.
5. Use care when moving the ABRS stage. Lifting or transporting the ABRS stage improperly
can result in injury or damage to the ABRS.
6. This product is intended for light industrial manufacturing or laboratory use. Use of this
product for unintended applications can result in injury and damage to the equipment.
7. If the product is used in a manner not specified by the manufacturer, the protection
provided by the product can be impaired and result in damage, shock, injury, or death.
8. Operators must be trained before operating this equipment.
9. All service and maintenance must be performed by qualified personnel.
Safety Procedures and Warnings ABRS Hardware Manual
6 www.aerotech.com

EU Declaration of Incorporation
Manufacturer: Aerotech, Inc.
101 Zeta Drive
Pittsburgh, PA 15238-2811
USA
herewith declares that the product:
ABRS Air-Bearing Direct Drive Rotary Stage
is intended to be incorporated into machinery to constitute machinery covered by the Directive 2006/42/EC
as amended;
and that the following harmonized European standards have been applied:
EN ISO 12100:2010
Safety of machinery - Basic concepts, general principles for design
EN 60204-1:2010
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, for example, as a whole, including the equipment referred to in
this Declaration.
This is to certify that the aforementioned product is in accordance with the applicable requirements of the
following Directive(s):
EU 2015/863 RoHS3 Directive
Authorized Representative: Simon Smith, European Director
Address: Aerotech Ltd
The Old Brick Kiln, Ramsdell, Tadley
Hampshire RG26 5PR
UK
Name
/ Alex Weibel
Position Engineer Verifying Compliance
Location Pittsburgh, PA
Date 7/17/2020
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ABRS Hardware Manual EU Declaration of Incorporation

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EU Declaration of Incorporation ABRS Hardware Manual
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Chapter 1: Overview
N O T E : Aerotech continually improves its product offerings; listed options may be superseded at any
time. All drawings and illustrations are for reference only and were complete and accurate as of this
manual’s release. Refer to www.aerotech.com for the most up-to-date information.
Table 1-1: Model Options
ABRS Series Air-Bearing Direct-Drive Rotary Stage
ABRS150MP 150 mm wide air-bearing rotary stage with 0.82 N·m peak torque output
ABRS200MP 200 mm wide air-bearing rotary stage with 2.12 N·m peak torque output
ABRS250MP 250 mm wide air-bearing rotary stage with 9.42 N·m peak torque output
ABRS300MP 300 mm wide air-bearing rotary stage with 23.98 N·m peak torque output
Feedback (Required)
-E1 Incremental encoder, 1 Vpp
-E2 Incremental encoder, Digital RS422 (x50 interpolation)
Accessories (To be Ordered as a Separate Line Item)
-ABF Air bearing filtration kit
Figure 1-1: ABRSSeries Rotary Air-Bearing Stage
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ABRS Hardware Manual Chapter 1: Overview

1.1. Environmental Specifications
Table 1-2: Environmental Specifications
Ambient
Temperature
Operating: 10° to 35° C (50° to 95° F)
The optimal operating temperature is 20° C ±2° C (68° F ±4° F). If at any time the
operating temperature deviates from 20° C, degradation in performance could occur.
Storage: 0° to 40° C (32° to 104° F) in original shipping packaging
Humidity Operating: 20% to 60% RH
Storage: 10% to 70% RH, non-condensing in original packaging
Altitude
Operating: 0 m to 2,000 m (0 ft to 6,562 ft) above sea level
Contact Aerotech if your specific application involves use above 2,000 m or below sea
level.
Vibration
Use the system in a low vibration environment. Excessive floor or acoustical vibration
can affect system performance. Contact Aerotech for information regarding your spe-
cific application.
Protection
Rating
The ABRS stages are not suited for dusty or wet environments. This equates to an ingress
protection rating of IP00.
Use Indoor use only
W A R N I N G : Do not expose this product to environments or conditions outside of the listed
specifications. Exceeding environmental or operating specifications can cause damage to the
equipment.
1.2. Accuracy and Temperature Effects
Aerotech products are designed for and built in a 20°C (68°F) environment. Extreme temperature changes
could cause a decrease in performance or permanent damage to the ABRS. At a minimum, the
environmental temperature must be controlled to within 0.25ºC per 24 hours to ensure the ABRS
specifications are repeatable over an extended period of time. The severity of temperature effects on all
specifications depends on many different environmental conditions, including how the ABRS is mounted.
Contact the factory for more details.
1.1. Environmental Specifications ABRS Hardware Manual
10 www.aerotech.com

1.3. Basic Specifications
N O T E : Aerotech continually improves its product offerings; listed options may be superseded at any
time. All drawings and illustrations are for reference only and were complete and accurate as of this
manual’s release. Refer to www.aerotech.com for the most up-to-date information.
Resolution is dependent upon the encoder resolution and the controller interpolation.
Table 1-3: ABRS Series Specifications
ABRS Series ABRS150MP ABRS200MP ABRS250MP ABRS300MP
Width 150 mm 200 mm 250 mm 300 mm
Tabletop Diameter 128.1 mm 178.1 mm 228.1 mm 278.1 mm
Height 80 mm 90 mm 100 mm 110 mm
Aperture 8 mm 20 mm 35 mm 75 mm
Travel ±360° Continuous
Bus voltage 80 VDC 340 VDC
Fundamental Encoder
Resolution 3600 lines/rev 8192 lines/rev 11,840 lines/rev 18,000 lines/rev
Max Speed(1) 300 rpm 300 rpm 500 rpm 500 rpm
Accuracy(2) ±3 arc sec ±2 arc sec ±2 arc sec ±2 arc sec
Bidirectional Repeatability <2 arc sec <1 arc sec <1 arc sec <1 arc sec
Max
Load(3)
Axial 8 kg 31 kg 66 kg 97 kg
Radial 4 kg 15 kg 36 kg 51 kg
Tilt 3 N·m 10 N·m 28 N·m 45 N·m
Axial Error Synchronous <175 nm <100 nm <100 nm <100 nm
Asynchronous <20 nm
Radial Error Synchronous <450 nm <250 nm <250 nm <250 nm
Asynchronous <20 nm
Tilt Error(4) Synchronous <9.7 µrad
(<2.0 arc sec)
<3.4 µrad
(<0.7 arc sec)
<2.4 µrad
(<0.5 arc sec)
<2.4 µrad
(<0.5 arc sec)
Asynchronous <0.4 µrad
(<0.08 arc sec)
<0.3 µrad
(<0.06 arc sec)
<0.2 µrad
(<0.04 arc sec)
<0.2 µrad
(<0.04 arc sec)
Operating Pressure(5) 80 psig (5.5 bar) + 0 psig (0.0 bar)/-10 psig (0.7 bar)
Air Consumption(6) <56.6 SLPM (<2 SCFM)
Inertia (unloaded) 3,850 kg·mm213,800 kg·mm239,100 kg·mm2102,000 kg·mm2
Total Mass 4.8 kg 9.1 kg 15.6 kg 24.5 kg
Material Aluminum
Finish Hard Coating (62 Rockwell Hardness)
1. Maximum speed based on stage capability. Maximum application velocity may be limited by system data rate and system
resolution.
2. Certified with each stage. Requires the use of an Aerotech controller.
3. Maximum loads are mutually exclusive.
4. All error motion specifications are measured at 60 rpm.
5. To protect air bearing against under-pressure, an in-line pressure switch tied to the motion controller/amplifier E-Stop is
recommended.
6. Air supply must be clean, dry to 0° F dew point and filtered to 0.25 μm or better. Recommend nitrogen at 99.9% purity.
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ABRS Hardware Manual 1.3. Basic Specifications

1.4. Air Requirements
W A R N I N G : Wear eye protection when you are close to compressed air components.
W A R N I N G : Do not attempt to rotate the stage table until the air supply has been installed. If
separate thrust and journal ports are present, air must be supplied to both. Moving the stage
table without air supplied can cause permanent damage to the stage.
Connect the air supply hose(s) to the air inlet fitting(s). The location of the air inlet(s) is shown in the
dimensional drawings (Section 2.2.).
It is important to the operation of the ABRS that the air supply meets Aerotech specifications. For
compressed air, the air must be filtered to 0.25 microns, dry to 0°F dew point, and oil free. For nitrogen, the
nitrogen must be 99.99% pure and filtered to 0.25 microns. Filtration is required to prevent particles from
clogging the air bearing orifices and other parts.
Air pressure must be in the range of 551 kPa ± 34 kPa (80 psi ± 5 psi) with an airflow rate of 56 SLPM
(standard liters per minute) at 551 kPa for a single axis. Aerotech recommends that you connect the air
supply with a polyurethane air hose.
Aerotech also recommends that you install a pressure switch (Aerotech P/N: MCA03094) tied to the motion
controller's emergency stop (ESTOP)that will remove power to the air bearing if pressure drops below 40 psi
(a drop in pressure could result in contact between bearing surfaces which could cause damage to the
surfaces). Aerotech’s ABF accessory kit incorporates air filtration plus a pressure monitoring switch.
Some stage models include a separate port for the thrust and journal air bearings. In some applications, you
could want to “lock-down” the stage by removing air pressure to the thrust bearing while air pressure is
maintained to the journal bearing. Power must be removed from the stage while it is “locked-down” to avoid
damage to the thrust bearing surfaces. It is highly recommended to consult the factory for detailed
assistance if this “lock-down” feature is to be used.
1.5. Vacuum Operation
The ABRS is an air-bearing stage and is not compatible with operation in a vacuum environment. Contact
Aerotech for alternate solutions.
1.4. Air Requirements ABRS Hardware Manual
12 www.aerotech.com

Chapter 2: Installation
W A R N I N G : ABRS installation must be in accordance to instructions provided by this
manual and any accompanying documentation. Failure to follow these instructions could result
in injury or damage to the equipment.
2.1. Unpacking and Handling the Stage
D A N G E R / H E A V Y : Do not attempt to manually lift a stage that is too heavy (in excess of
18 kg). Refer to Section 1.3. for stage mass specifications.
lDo not attempt to manually lift heavy loads single handed.
lUse a fork lift or cart to transport the stage.
W A R N I N G : It is the customer's responsibility to safely and carefully lift the stage.
lMake sure that all moving parts are secure before moving the ABRS. Unsecured moving
parts may shift and cause bodily injury.
lImproper handling could adversely affect the performance of the ABRS. Use care when
moving the ABRS.
lLift only by the base. Do not use the tabletop or cables as lifting points.
N O T E : If any damage has occurred during shipping, report it immediately.
Carefully remove the ABRS stagefrom its protective shipping container.
lLift only from the base.
lDo not use any of the cables as lifting points.
lDo not use the tabletop as a lifting point.
W A R N I N G : Do not attempt to rotate the stage table until the air supply, detailed in Section
1.4., has been installed. If separate thrust and journal ports are present, air must be supplied to
both. Moving the stage table without air supplied can cause permanent damage to the stage.
Gently set the ABRS stage on a smooth, flat, and clean surface.
Allow the stage to stabilize at room temperature for at least 12 hours before you attempt to operate it. A
stabilized stage 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-free air to remove any dust or debris
that has collected during shipping.
Each ABRS 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 information for later reference.
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ABRS Hardware Manual Chapter 2: Installation

2.2. Dimensions
N O T E : Aerotech continually improves its product offerings; listed options may be superseded at any
time. All drawings and illustrations are for reference only and were complete and accurate as of this
manual’s release. Refer to www.aerotech.com for the most up-to-date information.
Figure 2-1: ABRS150MP Dimensions
2.2. Dimensions ABRS Hardware Manual
14 www.aerotech.com

Figure 2-2: ABRS200MP Dimensions
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ABRS Hardware Manual 2.2. Dimensions

Figure 2-3: ABRS250MP Dimensions
2.2. Dimensions ABRS Hardware Manual
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Figure 2-4: ABRS300MP Dimensions
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ABRS Hardware Manual 2.2. Dimensions

2.3. Securing the Stage to the Mounting Surface
W A R N I N G : Make sure that all moving parts are secure before moving the ABRS. Unsecured
moving parts may shift and cause bodily injury.
W A R N I N G : Do not attempt to manually move the ABRS if it is connected to a power source.
W A R N I N G : The ABRS must be mounted securely. Improper mounting can result in injury
and damage to the equipment.
The mounting surface must be flat and have adequate stiffness to achieve the maximum performance from
the ABRS stage. When it is mounted to a non-flat surface, the stage can be distorted while the mounting
screws are tightened. This distortion will decrease overall accuracy. Adjustments to the mounting surface
must be done before the stage is secured.
Inspect the mounting surface for dirt or unwanted residue and clean if necessary. Use precision flatstones
on the mounting surface to remove any burrs or high spots. Clean the mounting surface with a lint-free cloth
and acetone or isopropyl alcohol and allow the cleaning solvent to completely dry. Gently place the stage on
the mounting surface.
N O T E : To maintain accuracy, the mounting surface must be flat to within 2 µm TIR.
N O T E : The stage base is precision machined and verified for flatness prior to stage assembly at the
factory. If machining is required to achieve the desired flatness, it should be performed on the mounting
surface rather than the stage base. Shimming should be avoided if possible. If shimming is required, it
should be minimized to improve the rigidity of the system.
ABRS series stages have a fixed mounting pattern (as shown in Figure 2-5).
The ABRS should be mounted with the axis of rotation in the vertical direction using the counterbored
mounting holes shown in Figure 2-5. Mounting the stage with the axis of rotation in a horizontal orientation is
not recommended because this orientation can have a negative effect on performance. Do not use the
tapped fixturing holes shown in Figure 2-6 to mount the stage in either axis of rotation orientation. Consult
Aerotech for more information if your application requires a horizontal axis of rotation configuration.
Tightening torque values for the mounting hardware are dependent on the properties of the surface to which
the stage is being mounted. Values provided in Table 2-1 are typical values and may not be accurate for your
mounting surface. Refer to Section 2.2. for specific model mounting locations and dimensions.
Table 2-1: Stage to Mounting Surface Hardware
Mounting Hardware Typical Screw
Torque
ABRS150, ABRS200 6 mm SHCS 7 N·m
ABRS250, ABRS300 8 mm SHCS 17 N·m
2.3. Securing the Stage to the Mounting Surface ABRS Hardware Manual
18 www.aerotech.com

Figure 2-5: Top View of an ABRS250MP Stage Showing Mounting Holes
Figure 2-6: Side View of an ABRS250MP Stage Showing Tapped Fixturing Holes
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ABRS Hardware Manual 2.3. Securing the Stage to the Mounting Surface

2.4. Attaching the Payload to the Stage
Inspect the mounting surface for dirt or unwanted residue and clean if necessary. Clean the mounting
surface with a lint-free cloth and acetone or isopropyl alcohol and allow the cleaning solvent to completely
dry.
Aerotech recommends that customers use a representative payload during start-up to prevent accidental
damage to the stage and the payload. Proceed with the electrical installation and test the motion control
system in accordance with the system documentation. Document all results for future reference. For
information on electrical installation refer to Chapter 3 and the documentation delivered with the stage.
N O T E : If your ABRS was purchased with Aerotech controls, it might have been tuned with a
representative payload based on the information provided at the time of order. If the ABRS is started up
without a payload, the servo gains provided by Aerotech with the shipment may not be appropriate and
servo instability can occur. Refer to the controller help file for tuning assistance.
The payload must be flat, rigid, and comparable to the stage in quality to maintain optimum performance.
Additionally, the payload must be reasonably balanced in order to maintain stage accuracy. Consult
Aerotech to determine if the payload may potentially result in any deterioration of stage performance.
Refer to Section 2.2. for the location of the mounting holes on the stage tabletop to mount payloads. The
payload mounting holes have reinforced threads to allow frequent removal and installation of mounting
screws.
N O T E : For valid system performance, the mounting interface should be flat within 2 µm TIR.
W A R N I N G : Refer to the dimensions in Section 2.2. for maximum allowable thread
engagement. A screw extending through the stage table can affect travel and damage the
stage.
The ABRS rotary stage loading specifications are shown in Table 2-2.
Table 2-2: ABRS Series Load Capability
ABRS150MP ABRS200MP ABRS250MP ABRS300MP
Max Load – Axial* 8 kg 31 kg 66 kg 97 kg
Max Load – Radial* 4 kg 15 kg 36 kg 51 kg
Max Load – Tilt* 3 N·m 10 N·m 28 N·m 45 N·m
* Maximum loads are mutually exclusive.
2.4. Attaching the Payload to the Stage ABRS Hardware Manual
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