Aerotech AGS15000HL Series User manual

AGS15000HL Series Stage
User’s Manual
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 1.01.00 February 21, 2011
Revision 1.00.00 October 31, 2008
Product names mentioned herein are used for identification purposes only and may be trademarks of
their respective companies.
© Aerotech, Inc. 2011

AGS15000HL Hardware 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. Linear Motor / Linear Encoder 2
1.1.2. Rugged Design 2
1.1.3. CMS Options 2
1.1.4. Turnkey Operation 2
1.2. Optional Features 3
1.2.1. Additional Axes 3
1.2.2. Cleanroom Compatability 3
1.2.3. Electronics / Controller 3
1.3. Model Numbers 4
1.4. Safety Procedures and Warnings 6
1.5. EC Declaration of Incorporation 8
Chapter 2: Installation 9
2.1. Unpacking and Handling the Stage 9
2.2. Mounting the System to a Machine Base 10
2.3. Attaching the Payload to the Stage 12
2.4. Electrical Installation 12
2.5. Air Requirements 12
Chapter 3: Operating Specifications 13
3.1. Environmental Specifications 13
3.2. Load Capability 13
3.3. Basic Specifications 14
3.4. Overtravel Safety 16
Chapter 4: Maintenance 17
4.1. Service and Inspection Schedule 17
4.2. Cleaning and Lubrication 17
4.3. Linear Lubrication and Cleaning Procedure 18
4.4. Linear Encoder Cleaning and Maintenance Procedure 19
4.5. System Calibration Procedure 20
Appendix A: Warranty and Field Service 21
Appendix B: Technical Changes 23
Appendix C: Payload and Performance Plots 25
Index 27
Reader's Comments 29
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Table of Contents AGS15000HL Hardware Manual
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AGS15000HL Hardware Manual List Of Figures
List of Figures
Figure 2-1: Compliant Mounting, With and Without Mounting Bolt 10
Figure 4-1: Location of Grease Nipples (approximate) 18
Figure 4-2: Removing Upper Axis Encoder Cover 19
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List of Figures AGS15000HL Hardware Manual
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AGS15000HL Hardware Manual List of Tables
List of Tables
Table 1-1: Model Numbering System 4
Table 3-1: Environmental Specifications 13
Table 3-2: AGS15000HL Series Specifications 14
Table 3-3: AGS15000HL Motor Specifications 15
Table B-1: Current Changes (1.01.00) 23
Table B-2: Archived Changes 24
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List of Tables AGS15000HL Hardware Manual
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AGS15000HL Hardware Manual Overview
Chapter 1: Overview
The AGS15000HL series of Cartesian gantry systems is designed for ultra-precision contouring capabilities,
providing outstanding performance and versatility in a wide range of automation platforms. To ensure high
contouring accuracy, the bridge’s center of gravity is kept in line with the lower axis bearings and forcers to
minimize pitch and roll errors at the work point.
AGS15000HL systems can be found in production plants around the world, in applications including precision
micromachining, stencil cutting, fuel cell manufacturing, flat sheet processing, high-speed pick-and-place,
automated assembly, vision inspection, dispensing stations, and high-accuracy inspection.
This manual describes Aerotech’s AGS15000HL series positioning gantry. This chapter introduces standard
and optional features of the AGS15000HL, and gives general safety precautions.
N O T E : This manual should be read in its entirety before operating the AGS15000HL system.
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Overview AGS15000HL Hardware Manual
1.1. Standard Features
1.1.1. Linear Motor / Linear Encoder
Aerotech’s high-performance brushless linear servomotors drive the AGS15000HL to speeds up to 3 m/s
and accelerations up to 5 g. Dual linear motors and encoders are included on the lower axis for the highest
level of performance and precision. The rugged noncontact optical linear encoders offer resolutions to 1 nm
when coupled with Aerotech’s encoder multiplier. Optimized to account for thermal expansion, the design
ensures high accuracy under all operating conditions.
1.1.2. Rugged Design
The linear motor is a noncontact device, resulting in no backlash, wear, or maintenance. The bearings are
preloaded linear motion guides with wiper seals and grease fittings, and are mounted to provide optimized
stiffness and load distribution.
1.1.3. CMS Options
Extensive R&D has resulted in an optimized cable management system (CMS) that has been field proven
as the industry’s most reliable design. Large bend radii and high-flex cables ensure that the AGS15000HL
provides millions of cycles of maintenance-free operation. In the unlikely event of a component failure, a mod-
ular design ensures that part replacement is fast and easy. The CMS on the AGS15000HL has also been
designed to provide smooth and quiet operation.
All customer cabling and pneumatics can be routed through the system cable management. Connectors are
provided at the workpiece and at the opposite end of the cable management, greatly simplifying final
machine integration.
1.1.4. Turnkey Operation
Aerotech’s years of experience manufacturing precision positioning and control systems can be leveraged
by acquiring a turnkey system. Typical options include Z-theta mechanisms, risers to accommodate auto-
mated parts handling equipment, and machine bases that are designed to accommodate the entire controls
and electronics subsystems.
Aerotech manufactures a wide range of high-performance amplifiers and advanced motion controllers that
are optimized for high-performance automation applications.
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AGS15000HL Hardware Manual Overview
1.2. Optional Features
1.2.1. Additional Axes
Additional motion axes can be integrated onto the 2-axis AGS15000HL system. Typically, one or two addi-
tional axes (linear or rotary) are integrated onto the carriage of the cross axes. All system alignments and met-
rology are qualified with these additional axes integrated onto the system. Separate Hardware Manuals will
be provided for additional axes integrated onto the AGS15000HL system.
1.2.2. Cleanroom Compatability
The AGS15000HL can be configured for up to Class 10 cleanroom operation. Standard features for Class 10
cleanroom operation are:
lStainless Hardware
lCustom cable management (depending on the level of cleanroom, a trackless cable carrier may be util-
ized)
lCleanroom grease – refer to section 4.2 for grease specification.
1.2.3. Electronics / Controller
The AGS15000HL is typically part of a complete Aerotech motion control system, which is adjusted at the
factory for optimum performance. Setup usually involves connecting a stage to the appropriate drives with
the cables provided. Refer to your electrical documentation package for further information.
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Overview AGS15000HL Hardware Manual
1.3. Model Numbers
The stage model number indicates the optional features on a particular stage. To determine the options on a
particular stage, refer to the table below.
Example: AGS15-500-500-HL-10X2-10-LT50X5-LT50X5-GR
Table 1-1: Model Numbering System
AGS15000 Series Linear Motor Gantry
AGS15500-500 500 mm x 500 mm (20 in x 20 in) Cartesian gantry with linear motor, linear encoder, and lim-
its
AGS15750-750 750 mm x 750 mm (30 in x 30 in) Cartesian gantry with linear motor, linear encoder, and lim-
its
AGS151000-
1000
1000 mm x 1000 mm (40 in x 40 in) Cartesian gantry with linear motor, linear encoder, and
limits
AGSxxxx-yyyy Other travels available; please consult factory
Loading
-HL High loading
Motor
-10 Brushless linear motor – BLM-264-A (upper Y-axis only)
-10X2 Dual brushless linear motor – dual BLM-386-A (lower X-axis only)
-10HX2 Dual brushless linear motor – dual BLMH-382-A (lower X-axis only)
Limits
-NC Normally closed end of travel limit switches (STANDARD)
-NO Normally open end of travel limit switches
Standard Linear Encoders
-LT50AS Dual linear encoder for lower axis; amplified sine output; linear encoder for upper axis
-LT50X50 Dual linear encoder for lower axis; 0.1 micron line driver output; linear encoder for upper
axis
-LT75AS Dual linear encoder for lower axis; amplified sine output; linear encoder for upper axis
-LT75X50 Dual linear encoder for lower axis; 0.1 micron line driver output; linear encoder for upper
axis
-LT100AS Dual linear encoder for lower axis; amplified sine output; linear encoder for upper axis
-LT100X50 Dual linear encoder for lower axis; 0.1 micron line driver output; linear encoder for upper
axis
Base Plate
-GR500-500 Granite baseplate for AGS15500-500
-GR750-750 Granite baseplate for AGS15750-750
-GR1000-1000 Granite baseplate for AGS151000-1000
-GRR500-500 Granite baseplate for AGS15500-500 with 150 mm (6 in) risers
-GRR750-750 Granite baseplate for AGS15750-750 with 150 mm (6 in) risers
-GRR1000-1000 Granite baseplate for AGS151000-1000 with 150 mm (6 in) risers
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AGS15000HL Hardware Manual Overview
Accessories (to be ordered as separate line item)
Z100 100 mm (4 in) travel z-stage
Z150 150 mm (6 in) travel z-stage
THETA 360° travel theta axis
MB500-500 Steel weldment machine base for AGS15500-500
MB750-750 Steel weldment machine base for AGS15750-750
MB1000-1000 Steel weldment machine base for AGS1000-10000
Table 1-1: Model Numbering System (continued)
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Overview AGS15000HL Hardware Manual
1.4. 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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AGS15000HL Hardware 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 AGS15000HL Hardware Manual
1.5. EC Declaration of Incorporation
Manufactorer: Aerotech, Inc.
101 Zeta Drive
Pittsburgh, PA 15238
USA
herewith declares that the product:
Aerotech, Inc. AGS15000HL 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

AGS15000HL Hardware Manual Installation
Chapter 2: Installation
This chapter describes the installation procedure for the AGS15000HL series gantry, including handling the
stage properly, preparing the mounting surface to accept the stage, securing the stage to the mounting sur-
face, 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 system from the protective shipping container. The AGS15000HL system is supplied
on a granite base plate. An additional system base (typically steel) may also be included with the system. A
fork truck is recommended as a means of moving the system. If there is no system base, or if the system
must be moved independently of its base for any reason, always use a piece of wood or similar material
between the forks and the granite. 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 help to ensure that all of the alignments, preloads, and
tolerances are the same as they were when tested at Aerotech.
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 system. Manually lifting or transporting stages can result in injury.
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Installation AGS15000HL Hardware Manual
2.2. Mounting the System to a Machine Base
If the system was shipped with a machine base, remove the red shipping brackets before using the system.
Level the base plate by adjusting the leveling feet on the machine base. If the system is to be placed on a
base after delivery, it is important to do so properly for optimal performance. It should be supported in three or
four places unless otherwise specified during the system approval process. A compliant mounting scheme
(shown in Figure 2-1) is recommended for most cases. Consult with Aerotech to ensure that this method is
acceptable for a specific application.
For compliant mounting, the machine base mounting surfaces should be coplanar within 0.25 mm (.010 in). A
compliant material at least 6 mm (0.25 in) thick should be inserted between the base and granite base plate
(contact Aerotech for recommended materials). Mounting screws may be used if extra security is desired
between the base plate and machine base. If they are used, compliant washers should be placed under the
screw heads. Tighten screws only ¼ to ½ turn past “finger tight”, using a generous amount of a thread-lock-
ing compound to keep the screws in place. This compliant mounting method allows for small height dif-
ferences between mounting surfaces, thermal expansion mismatch due to different base plate and machine
base materials, and also provides vibration isolation between the floor and the gantry system. If a compli-
antly mounted system is to be transported, the base plate should be rigidly attached to the machine base dur-
ing shipping.
Figure 2-1: Compliant Mounting, With and Without Mounting Bolt
When a system requires extremely high accuracy or ground vibrations are especially prominent, a more com-
plex isolation system may be necessary. Air isolation may be used but is only recommended for systems
with relatively low dynamics. An active isolation system may achieve the same results and can be used for
systems with higher dynamics. Aerotech can supply system properties that may help in sizing these spe-
cialized systems.
If relative motion between the gantry system and machine base is absolutely unacceptable for a given appli-
cation, hard mounting may be necessary. Mounting tolerances, thermal mismatch, and environmental vibra-
tions must be considered when designing a hard mounting scheme. If these issues are not addressed
properly, the base plate may become distorted and affect system performance. Contact Aerotech to deter-
mine whether system specifications can be guaranteed with a specific mounting method.
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AGS15000HL Hardware Manual Installation
The stage must be mounted securely. Improper mounting can result in injury and damage to
the equipment.
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Installation AGS15000HL Hardware Manual
2.3. Attaching the Payload to the Stage
To prevent damage to the stage or parts, test the operation of the stage before any fixturing or customer
equipment is integrated onto the system. Proceed with the electrical installation and test the motion control
system.
After testing, a payload may be attached to the upper axis carriage face. The payload must have a mounting
surface that is flat within .013 mm (.0005 in) to prevent distortion of the carriage. If a payload is to be
attached at any other point on the gantry, contact Aerotech for flatness requirements.
2.4. Electrical Installation
Aerotech motion control systems are adjusted at the factory for optimum performance. The AGS15000HL
stage is typically part of a complete Aerotech motion control system; setup involves connecting a stage to
the appropriate drives with the cables provided.
Connect the provided cables to the motor and feedback connectors on the stage. Labels on the drive indicate
the appropriate connections. Refer to your drive manuals and documentation for additional installation and
operation information. In some cases, if the system is uniquely configured, a drawing showing system inter-
connects is supplied.
Never connect or disconnect any electrical component or connecting cable while power is
applied, or serious damage may result.
The stage's protective ground is located on the motor power connector. This ground must be
connected to a ground connection (the cables provided by Aerotech will create this con-
nection).
2.5. Air Requirements
It is recommended that air cooling be utilized for the linear motors if duty cycle, speeds, and/or accelerations
are high. Consult an Aerotech applications engineer to determine if air cooling is required or recommended
for a specific application. The air requirements are dependent on the system specifications (cleanliness,
etc).
N O T E : For Cleanroom applications, clean, dry nitrogen is recommended since the motor cooling
exhausts into the work area. Recommended specifications for Nitrogen are 99.99% pure and filtered to 0.25
microns.
N O T E : When operating the AGS15000HL it is recommended that 20 psig air be available at the motor
inlet for adequate cooling.
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