Aerotech ALAR-SP User manual

Revision 2.00
ALAR-SP Large Aperture Rotary Stage
HARDWAREMANUAL

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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 © 2007-2022, Aerotech, Inc., All rights reserved.

Table of Contents
ALAR-SP Large Aperture Rotary Stage 1
Table of Contents 3
List of Figures 4
List of Tables 5
EU Declaration of Incorporation 6
Safety Procedures and Warnings 7
Installation and Operation 8
Electrical Warnings 9
Motor-Related Warnings 10
Pinch Points 11
Handling and Storage 12
Chapter 1: Overview 15
1.1. Environmental Specifications 16
1.2. Accuracy and Temperature Effects 16
1.3. Basic Specifications 17
1.4. Vacuum Operation 19
Chapter 2: Installation 21
2.1. Dimensions 21
2.2. Securing the Stage to the Mounting Surface 26
2.3. Attaching the Payload or Fixturing to the Stage 28
Chapter 3: Electrical Installation 29
3.1. Motor and Feedback Connectors 30
3.2. Motor and Feedback Wiring 34
3.3. Motor and Feedback Specifications 36
3.4. Limits, Marker, and Machine Direction 40
3.5. Motor and Feedback Phasing 41
Chapter 4: Maintenance 43
4.1. Service and Inspection Schedule 43
4.2. Cleaning and Lubrication 44
4.3. Travel Adjustment 45
4.3.1. Electrical Limit Adjustments 45
4.3.2. Mechanical Hard Stop Adjustments 46
4.4. Troubleshooting 47
Appendix A: Warranty and Field Service 49
Appendix B: Revision History 51
Index 53
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List of Figures
Figure 1-1: Lifting Bolts 13
Figure 2-1: ALAR100SP Dimensions 21
Figure 2-2: ALAR150SP Dimensions 22
Figure 2-3: ALAR200SP Dimensions 23
Figure 2-4: ALAR250SP Dimensions 24
Figure 2-5: ALAR325SP Dimensions 25
Figure 2-6: ALAR Stage Mounting Holes 27
Figure 3-1: Electrical Connections 30
Figure 3-2: ALARMotor and Feedback Wiring (Incremental Encoder Options) 34
Figure 3-3: ALARMotor and Feedback Wiring (Absolute Encoder Option) 35
Figure 3-4: Machine Direction 40
Figure 3-5: Hall Phasing Diagram 41
Figure 3-6: Encoder Phasing Reference Diagram (Standard/Square Wave) 42
Figure 3-7: Encoder Phasing Reference Diagram (Analog/Sine Wave) 42
Figure 4-1: Limit Flag Adjustment 46
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List of Tables
Table 1-1: Model Numbers and Ordering Options 15
Table 1-2: Environmental Specifications 16
Table 1-3: ALAR Series Specifications (ALAR100SP, ALAR150SP, ALAR200SP) 17
Table 1-4: ALAR Series Specifications (ALAR250SP, ALAR325SP) 18
Table 2-1: Stage Mounting Surface Flatness Requirement 26
Table 2-2: Stage to Mounting Surface Hardware 26
Table 2-3: Mounting Interface Flatness Requirement 28
Table 3-1: High Power D-Style Motor Connector Pinout 31
Table 3-2: Mating Connector Part Numbers for the Motor Connector 31
Table 3-3: Feedback Connector Pinout (Incremental Encoder Options) 32
Table 3-4: Mating Connector Part Numbers for the Feedback Connector 32
Table 3-5: Feedback Connector Pinout (Absolute Encoder Option) 33
Table 3-6: Mating Connector Part Numbers for the Feedback Connector 33
Table 3-7: Hall-Effect Sensor Specifications 36
Table 3-8: Thermistor Specifications 36
Table 3-9: Encoder Specifications 36
Table 3-10: Encoder Resolution 36
Table 3-11: Maximum Speed Per Encoder Option 37
Table 3-12: Limit Switch Specifications 37
Table 3-13: ALAR-SP Motor Specifications (ALAR100SP, ALAR150SP, ALAR200SP) 38
Table 3-14: ALAR-SP Motor Specifications (ALAR250SP, ALAR325SP) 39
Table 4-1: Troubleshooting 47
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EU Declaration of Incorporation
Manufacturer Aerotech, Inc.
101 Zeta Drive
Pittsburgh, PA 15238-2811
USA
herewith declares that the product:
ALAR 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):
2011/65/EU RoHS 2 Directive
EU 2015/863 Amendment RoHS 3 Directive
Authorized
Representative / Simon Smith, European Director
Aerotech Ltd
The Old Brick Kiln, Ramsdell, Tadley
Hampshire RG26 5PR
UK
Engineer Verifying
Compliance / Alex Weibel
Aerotech, Inc.
101 Zeta Drive
Pittsburgh, PA 15238-2811
USA
Date 7/18/2022
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Safety Procedures and Warnings
IMPORTANT: This manual tells you how to carefully and correctly use and operate the
stage.
lRead all parts of this manual before you install or operate the stage or before you do
maintenance to your system.
lTo prevent injury to you and damage to the equipment, obey the precautions in this
manual.
lAll specifications and illustrations are for reference only and were complete and
accurate as of the release of this manual. To find the newest information about this
product, refer to www.aerotech.com.
If you do not understand the information in this manual, contact Aerotech Global
Technical Support.
IMPORTANT: This product has been designed for light industrial manufacturing or
laboratory environments. If the product is used in a manner not specified by the
manufacturer:
lThe protection provided by the equipment could be impaired.
lThe life expectancy of the product could be decreased.
Safety notes and symbols are placed throughout this manual to warn you of the potential risks at the
moment of the safety note or if you fail to obey the safety note.
Shock/Electrocution Hazard Pinch, Shear, or Crush Hazard
General/Conditional Awareness Rotational Machinery Hazard
Hot Surface Hazard Pinch/Entanglement Hazard
Magnetic Field Hazard Trip Hazard
Heavy, Bulky Lifting Hazard Appropriate Equipment Required
Pressure/Explosive Atmosphere
Hazard Electrostatic Discharge Hazard
A blue circle symbol is an action or tip that you should obey. Some examples include:
General tip Read the manual/section
Wear personal protective equipment
(PPE): Safety Glasses If applicable, do not lift unassisted
Wear personal protective equipment
(PPE): Gloves
Wear personal protective equipment
(PPE): Hearing Protection
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Installation and Operation
To decrease the risk of damage to the equipment, you must obey the precautions that follow.
DANGER: General Hazard Warning!
This product can produce high forces and move at velocities that could cause injury.
The user is responsible for its safe operation. The following general equation is
provided to assist with risk assessments in regards to contact and pinch points:
WARNING: General Hazard Warning!
lOnly trained operators should operate this equipment.
lAll service and maintenance must be done by approved personnel.
lUse this product only in environments and operating conditions that are approved in
this manual.
lNever install or operate equipment that appears to be damaged.
lMake sure that the product is securely mounted before you operate it.
lUse care when you move the ALAR or you could negatively affect the performance of
it.
WARNING:Trip Hazard!
Route, house, and secure all cables, duct work, air, or water lines. Failure to do so could
introduce trip hazards around the system that could result in physical injury or could
damage the equipment.
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Electrical Warnings
To decrease the risk of electrical shock, injury, death, and damage to the equipment, obey the
precautions that follow.
DANGER: Electrical Shock Hazard!
lStage motor phase voltage levels could be hazardous live.
lPersonnel are protected from hazardous voltages unless electrical interconnections,
protective bonding (safety ground), or motor/stage enclosures are compromised.
lDo not connect or disconnect stage/motor interconnections while connected to a live
electrical power source.
lBefore you set up or do maintenance, disconnect electrical power.
lIt is the responsibility of the End User/System Integrator to make sure that stages are
properly connected and grounded per Engineering Standards and applicable safety
requirements.
lIt is the responsibility of the End User/System Integrator to configure the system
drive or controller within the Aerotech motor/stage electrical and mechanical
specifications.
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Motor-Related Warnings
Aerotech motors are capable of producing high forces and velocities. Obey all warnings and all
applicable codes and standards when you use or operate a stage or system that incorporates
Aerotech motors.
DANGER: Mechanical Hazard!
Personnel must be made aware of the mechanical hazards during set up or when you
do service to the stage.
lUnintentional manual movement into the stage "end-of-travel" stops, could damage
the stage or undo precision alignments.
lStage movement could create pinch points, entanglement hazards, or rotational
mechanical hazards.
DANGER: Hot Surface Hazard!
lThe stage/motor frame temperature could exceed 70°C in some applications.
lDo not touch the stage/motor frame while it is in operation.
lWait until the stage/motor has cooled before you touch it.
DANGER:Risk of Explosive Atmosphere!
lStandard Aerotech stage/motors are not rated for applications with explosive
atmospheres such as air-born dust or combustible vapors.
lDo not operate stage/motors outside of Aerotech environmental specifications.
DANGER: Magnetic Field Hazard!
Aerotech stage/motors contain magnets which can present a Magnetic Field Hazard.
lDo not disassemble a stage motor under any circumstances.
lStrong magnetic fields could interfere with external/internal medical devices.
lStrong magnetic fields could present mechanical hazards such as pinch points.
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Pinch Points
A pinch point is a mechanical hazard that can occur when there are exposed parts of the stage or
system that can move. For example, the travel of a stage tabletop could expose the user to a pinch
point between the tabletop and the stage housing. The images that follow will show you typical
external and internal pinch point locations.
DANGER: Mechanical Hazard!
lSystem travel can cause crush, shear, or pinch injuries.
lOnly trained operators should operate this equipment.
lDo not put yourself in the travel path of machinery.
lRestrict access to all motor and stage parts
owhen the system moves under power (during normal operation, for example).
owhen the system is moved manually (during the installation process or when you
do maintenance, for example).
lMotors are capable of very high speeds and acceleration rates.
Figure 1: Typical Pinch Point Locations
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Handling and Storage
IMPORTANT: It is the responsibility of the customer to safely and carefully lift and
move the stage.
lBe careful when you move or transport the stage.
lRetain the shipping materials for future use.
lTransport or store the stage in its protective packaging.
WARNING: Electrostatic Discharge (ESD) Sensitive Components!
Wear an ESDwrist strap when you handle, install, or do service to the system assembly.
You could damage the power supply or drives if you fail to observe the correct
ESDpractices.
Inspect the shipping container for any evidence of shipping damage. If any damage exists, notify the
shipping carrier immediately.
Remove the packing list from the shipping container. Make sure that all the items specified on the
packing list are contained within the package.
The documentation for the stage is on the included installation device. The documents include
manuals, interconnection drawings, and other documentation pertaining to the system. Save this
information for future reference.
Each stage has a label listing the system part number and serial number. These numbers contain
information necessary for maintenance or system hardware and software updates. Locate this label
and record the information for later reference.
Unpacking and Handling
It is the responsibility of the customer to safely and carefully lift and move the stage.
IMPORTANT: All electronic equipment and instrumentation is wrapped in antistatic
material and packaged with desiccant. Ensure that the antistatic material is not
damaged during unpacking.
DANGER:Lifting Hazard! Use care when you move the ALAR or you could negatively
affect the performance of it.
lUse the correct lifting techniques, mechanical assistance, or additional help to lift or
move this product.
lDo not use the cables or the connectors to lift or move this product.
lMake sure that all moving parts are secure before you move the stage. Unsecured
moving parts could shift and cause injury or damage to the equipment.
lIf the stage is heavy, a single person lift could cause injury. Use assistance when you
lift or move it.
oRefer to Section 2.1. Dimensions for dimensions
oRefer to Section 1.3. Basic Specifications for weight specifications.
Carefully remove the stagefrom its protective shipping container.
lLift this product only by the base.
lUse lifting hardware if it has been provided (refer to Figure 1-1).
lFor multi-axis assemblies, always lift the system by the lower axis.
lUse a cart, dolly, or similar device to move the stage to a new location.
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Gently set the stage on a smooth, flat, and clean surface. Use compressed nitrogen or clean, dry, oil-
free air to remove any dust or debris that has collected during shipping.
Before you operate the stage, let it stabilize at room temperature for at least 12 hours. This will
ensure that all of the alignments, preloads, and tolerances are the same as they were when they
were tested at Aerotech.
Each stage has a label listing the system part number and serial number. These numbers contain
information necessary for maintenance or system hardware and software updates. Locate this label
and record the information for later reference.
Figure 1-1: Lifting Bolts
Storage
Store the stage in the original shipping container. If the original packaging included ESDprotective
packaging, make sure to store the stage in it. The storage location must be dry, free of dust, free of
vibrations, and flat.
Refer to Section 1.1. Environmental Specifications
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Chapter 1: Overview
Table 1-1: Model Numbers and Ordering Options
ALAR Series Mechanical-Bearing Direct-Drive Rotary Stage
ALAR100SP 100 mm clear aperture
ALAR150SP 150 mm clear aperture
ALAR200SP 200 mm clear aperture
ALAR250SP 250 mm clear aperture
ALAR325SP 325 mm clear aperture
Motor (Required)
-M1 Standard motor
-M2 High power motor
NOTE:-M1 and -M2 motor options only apply to the 250 mm and 325 mm aperturestages.
Travel (Required)
- Continuous travel
-TR010 Limited travel, ±5 degrees
-TR020 Limited travel, ±10 degrees
-TR030 Limited travel, ±15 degrees
-TR060 Limited travel, ±30 degrees
-TR090 Limited travel, ±45 degrees
-TR120 Limited travel, ±60 degrees
-TR180 Limited travel, ±90 degrees
-TR240 Limited travel, ±120 degrees
-TR300 Limited travel, ±150 degrees
-TR340 Limited travel, ±170 degrees
Feedback (Required)
-E1 Incremental encoder, 1 Vpp sine
-E2 Incremental encoder, x4 interpolation
-E3 Incremental encoder, x20 interpolation
-E4 Incremental encoder, x40 interpolation
-E5 Incremental encoder, x100 interpolation
-E6 Incremental encoder, x200 interpolation
-E7 Absolute encoder
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1.1. Environmental Specifications
WARNING:General Hazard Warning! Do not expose this product to environments or
conditions outside of the listed specifications. You could damage the equipment if you
exceed the environmental or operating specifications.
DANGER:Risk of Explosive Atmosphere!
lStandard Aerotech stage/motors are not rated for applications with explosive
atmospheres such as air-born dust or combustible vapors.
lDo not operate stage/motors outside of Aerotech 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.
The stage should be packaged with desiccant if it is to be stored for an extended
time.
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. Floor or acoustical vibration can
affect system performance. Contact Aerotech for information regarding your
specific application.
Protection
Rating
These stages are not suited for dusty or wet environments. This equates to an
ingress protection rating of IP00.
Use Indoor use only
1.2. Accuracy and Temperature Effects
Aerotech products are designed for and built in a 20°C (68°F) environment. Temperature changes
could cause a decrease in performance or permanent damage to the stage. At a minimum, the
environmental temperature must be controlled to within 0.25ºC per 24 hours to ensure the stage
specifications are repeatable over an extended period of time. The severity of temperature effects
on all specifications depends on many different environmental conditions, which include how the
stage is mounted. Contact the factory for more details.
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1.3. Basic Specifications
Resolution is dependent on encoder resolution and controller interpolation.
Table 1-3: ALAR Series Specifications (ALAR100SP, ALAR150SP, ALAR200SP)
ALAR100SP ALAR150SP ALAR200SP
Aperture 100 mm 150 mm 200 mm
Motor Brushless Slotless
Continuous Current 2.7 Apk 6.2 Apk 5.3 Apk
1.9 Arms 4.4 Arms 3.75 Arms
Peak Current, Stall 10.8 Apk 24.8 Apk 34.8 Apk
7.6 Arms 17.5 Arms 24.6 Arms
Bus Voltage Up to 340 VDC
Unlimited Travel Yes
Maximum Limited Travel ±170°
Maximum Velocity @ 160 V Bus
(1) 300 rpm 250 rpm 90 rpm
Maximum Acceleration 1364 rad/s21330 rad/s2361 rad/s2
Resolution (Minimum
Incremental Motion)(2)
0.1 µrad
(0.02 arc-sec)
0.08 µrad
(0.016 arc-sec)
0.06 µrad
(0.012 arc-sec)
Incremental Encoder Line Count 31,488 lines/rev 40,000 lines/rev 55,040 lines/rev
Maximum Torque 23.9 N·m 42.9 N·m 126.8 N·m
Continuous Torque 6.0 N·m 10.7 N·m 19.3 N·m
Stage Mass 16.3 kg 18.6 kg 40.4 kg
Stage Mass with Limits 17 kg 19.6 kg 43.1 kg
Shaft Inertia 0.022 kg·m20.040 kg·m20.320 kg·m2
Shaft Inertia with Limits 0.026 kg·m20.051 kg·m20.359 kg·m2
Axial Load 1550 N (348 lb) 1950 N (438 lb) 4675 N (1051 lb)
RadialLoad 1350 N (303 lb) 1925 N (433 lb) 4775 N (1073 lb)
Moment Load 250 N·m 450 N·m 1600 N·m
Repeatability ±2.4 µrad (±0.5 arc sec)
Accuracy(3) ±9.7 µrad (±2 arc sec)
Tilt-Error Motion 9.7 µrad (2.0 arc sec)
(1) Square-wave digital encoder options will limit maximum speed below the listed value.
(2) Resolution assumes -E1 encoder with 2000X controller multiplication.
(3) Certified with each stage. Requires an Aerotech controller.
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Table 1-4: ALAR Series Specifications (ALAR250SP, ALAR325SP)
ALAR250SP-M1 ALAR250SP-M2 ALAR325SP-M1 ALAR325SP-M2
Aperture 250 mm 325 mm
Motor Brushless Slotless
Continuous Current 5.3 Apk 7.95 Apk 5.1 Apk 7.65 Apk
3.75 Arms 5.62 Arms 3.63 Arms 5.41 Arms
Peak Current, Stall 34.8 Apk 52.2 Apk 31.2 Apk 46.8 Apk
24.6 Arms 36.9 Arms 22.1 Arms 33.1 Arms
Bus Voltage Up to 340 VDC
Unlimited Travel Yes
Maximum Limited Travel ±170°
Maximum Velocity(1) 140 rpm 150 rpm
Maximum Acceleration 287 rad/s2185 rad/s2
Resolution (Minimum
Incremental Motion)(2) 0.05 µrad (0.01 arc-sec) 0.04 µrad (0.009 arc-sec)
Incremental Encoder Line Count 64,800 lines/rev 76,800 lines/rev
Maximum Torque 137.8 N·m 206.7 N·m 213.8 N·m 320.8 N·m
Continuous Torque 21.0 N·m 31.5 N·m 35.0 N·m 52.4 N·m
Stage Mass 51.3 kg 61.2 kg
Stage Mass with Limits 54.5 kg 64.9 kg
Shaft Inertia 0.500 kg·m21.01 kg·m2
Shaft Inertia with Limits 0.573 kg·m21.2 kg·m2
Axial Load 4950 N (1113 lb) 5825 N (1310 lb)
RadialLoad 5200 N (1169 lb) 6650 N (1495 lb)
Moment Load 1825 N·m 2650 N·m
Repeatability ±2.4 µrad (±0.5 arc sec)
Accuracy(3) ±9.7 µrad (±2 arc sec)
Tilt-Error Motion 9.7 µrad (2.0 arc sec)
(1) Square-wave digital encoder options will limit maximum speed below the listed value.
(2) Resolution assumes -E1 encoder with 2000X controller multiplication.
(3) Certified with each stage. Requires an Aerotech controller.
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1.4. Vacuum Operation
Vacuum option preparations are available as special orders. Contact Aerotech for more information.
There are two vacuum preparation options:
lLow Vacuum (for use in atmospheric pressures to 10-3 Torr)
lHigh Vacuum (preparation for environments from 10-3 to 10-6 Torr).
Special preparations include:
lParts are lubricated with vacuum-compatible lubricants.
lMaterials, fasteners, and coatings are selected to be compatible with the specified level of
vacuum.
lHigh-vacuum systems are designed to eliminate trapped volumes.
lPrior to assembly, stage parts are thoroughly cleaned in a clean environment.
lThe stage is packaged in a special polyethylene bag.
Vacuum Guidelines
To ensure that the stage will continue to perform well in the vacuum environment, use the
guidelines that follow (in addition to standard handling, installation, and lubrication guidelines
outlined in this manual).
1. Do not remove the stage from its sealed bag until it is ready to use.
2. Always handle the stage in a clean environment and use powder-free polyethylene gloves to
prevent any contaminants from adhering to the surface of the stage.
3. During installation, use cleaned, vented, stainless steel fasteners to secure the stage.
4. Reduced air pressure eliminates significant convective heat transfer. This, coupled with the
viscous vacuum-compatible lubricants, could result in excessive motor operating temperatures.
Because of this, consider all continuous torque ratings to be 40 to 60% lower than the value
specified for operation in normal atmospheric environment. Reduce motor usage accordingly.
5. We recommend that you use a small quantity of Braycote® 602EF grease or a compatible
substitute of equal quality lubricant in vacuum applications.
6. To reduce outgassing during the initial pump-down to vacuum pressure, Aerotech recommends
that you bake out vacuum systems when you first install them into the vacuum chamber. Bake
the vacuum components at 60 °C for 24 to 48 hours to desorb water vapor from surfaces and
degas polymers (such as cable insulation).
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