Aerotech ASR1000 User manual

Revision: 1.00.00
ASR1000 Rotary Stage
Hardware Manual

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Fax: [phone]
Email: [e-mail]
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 © 2017-2018, Aerotech, Inc., All rights reserved.

ASR1000 Hardware Manual Table of Contents
Table of Contents
ASR1000 Rotary Stage Hardware Manual i
Table of Contents iii
List of Figures iv
List of Tables v
Safety Procedures and Warnings vi
EU Declaration of Incorporation vii
Chapter 1: Overview 1
1.1. Environmental Specifications 2
1.2. Accuracy and Temperature Effects 2
1.3. Basic Specifications 3
Chapter 2: Installation 5
2.1. Unpacking and Handling the Stage 5
2.2. Dimensions 6
2.3. Securing the Stage to the Mounting Surface 7
2.4. General Mechanical Setup 9
2.5. Load Capability 10
Chapter 3: Electrical Specifications and Installation 11
3.1. Motor and Feedback Connectors 12
3.2. Motor and Feedback Wiring 15
3.3. Motor and Feedback Specifications 17
3.4. Machine Direction 18
3.5. Motor and Feedback Phasing 19
Chapter 4: Maintenance 21
4.1. Service and Inspection Schedule 21
4.2. Cleaning and Lubrication 22
4.3. Troubleshooting 23
Appendix A: Warranty and Field Service 25
Appendix C: Revision History 27
Index 29
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Table of Contents ASR1000 Hardware Manual
List of Figures
Figure 2-1: ASR1000 Dimensions 6
Figure 2-2: ASR1000 Stage Showing Mounting Plate (Top View) 8
Figure 2-3: ASR1000 Stage Without Mounting Plate (Bottom View) 8
Figure 2-4: Load Capability 10
Figure 3-1: Motor and Feedback Wiring (-CN1 Option) 15
Figure 3-2: Motor and Feedback Wiring (-CN2 Option) 16
Figure 3-3: Machine Direction 18
Figure 3-4: Motor Phasing 19
Figure 3-5: Analog Encoder Phasing Reference Diagram 20
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ASR1000 Hardware Manual Table of Contents
List of Tables
Table 1-1: Model Options 1
Table 1-2: Environmental Specifications 2
Table 1-3: ASR1000 Series Specifications 3
Table 2-1: Stage to Mounting Surface Hardware 7
Table 3-1: 4-Pin HPD Motor Connector Pinouts (-CN1Option) 12
Table 3-2: 4-Pin D Motor Mating Connector 12
Table 3-3: 25-Pin D Motor Connector Pinouts (-CN2Option) 13
Table 3-4: 25-Pin D Motor Mating Connector 13
Table 3-5: 25-Pin D Feedback Connector Pinouts 14
Table 3-6: 25-Pin D Feedback Mating Connector 14
Table 3-7: Feedback Specifications 17
Table 3-8: Encoder Specifications 17
Table 3-9: BM250 Motor Specifications 17
Table 4-1: Troubleshooting 23
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Table of Contents ASR1000 Hardware Manual
Safety Procedures and Warnings
Read this manual in its entirety before installing, operating, or servicing this product. If you do not understand
the information contained herein, contact an Aerotech representative before proceeding. Strictly adhere to
the statements given in this section and other handling, use, and operational information given throughout
the manual to avoid injury to you and damage to the equipment.
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.
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 ASR1000 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 ASR1000 must be mounted securely. Improper mounting can result in injury and
damage to the equipment.
5. Use care when moving the ASR1000 . Lifting or transporting the ASR1000 improperly can
result in injury or damage to the ASR1000.
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.
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ASR1000 Hardware Manual Table of Contents
EU Declaration of Incorporation
Manufacturer: Aerotech, Inc.
101 Zeta Drive
Pittsburgh, PA 15238-2811
USA
herewith declares that the product:
ASR1000 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, i.e., 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
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
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Table of Contents ASR1000 Hardware Manual
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ASR1000 Hardware Manual Overview
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
ASR1000 Direct Drive Rotary Stage
Connector (Required)
-CN1 4-pin HPD motor and 25-pin D feedback connectors
-CN2 25-pin D motor and 25-pin D feedback connectors
Mounting Plate (Optional)
-MP1 Mounting plate
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Overview ASR1000 Hardware Manual
1.1. Environmental Specifications
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.
Table 1-2: Environmental Specifications
Ambient
Temperature
Operating: 16° to 25° C (61° to 77° 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. Excessive floor or acoustical vibration
can affect system performance. Contact Aerotech for information regarding your spe-
cific application.
Protection
Rating
The ASR1000 stages have limited protection against dust, but not water. This equates
to an ingress protection rating of IP50.
Use Indoor use only
1.2. Accuracy and Temperature Effects
Extreme temperature changes could cause a decrease in performance or permanent damage to the stage.
Aerotech stages are designed for and built in a 20°C (68°F) environment. Any deviation from standard
operating temperature will affect stage accuracy. The severity of temperature effects on all stage
specifications depends on many different environmental conditions, including how the stage is mounted.
Contact the factory for more details.
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ASR1000 Hardware Manual Overview
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.
Table 1-3: ASR1000 Series Specifications
ASR1000
Travel ±360° continuous
Shaft Diameter 19 mm
Shaft Thread 0.7500-32NS-3
Maximum Aperture Diameter 14 mm ±0.5 mm
Drive System Direct-Drive Brushless Servomotor
Feedback 8192 cycles/rev; analog output encoder (standard)
Maximum Rotary Speed (1) 2000 rpm
Accuracy(1) ±72.8 µrad (±15 arc sec)
Repeatability(1) ±14.6 µrad (±3 arc sec)
Inertia 9.0 x 10-5 kg·m2
Nominal Stage Weight 4.4 kg
Maximum Load Axial 3.0 kg
Moment 5 N·m
Continuous
Current, Stall
Apk 10
Arms 7.1
Bus Voltage Up to 320 VDC
Axis Error Motion Axial 2.5 µm
Radial 5.0 µm
Material Stage Shaft Stainless Steel
Stage Body Aluminum
Finish Stage Shaft Stainless Steel
Stage Body Black Anodize
1. Maximum speed based on stage capability; maximum application velocity may be limited by system data rate and system
resolution.
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Overview ASR1000 Hardware Manual
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ASR1000 Hardware Manual Installation
Chapter 2: Installation
W A R N I N G : ASR1000 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
W A R N I N G : It is the customer's responsibility to safely and carefully lift and move the
ASR1000.
lMake sure that all moving parts are secure before moving the ASR1000. Unsecured
moving parts may shift and cause bodily injury.
lImproper handling could adversely affect the performance of the ASR1000. Use care when
moving the ASR1000
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 ASR1000from its protective shipping container. Gently set the ASR1000 on a smooth,
flat, and clean surface.
Before operating the ASR1000, it is important to let it stabilize at room temperature for at least 12 hours.
Allowing it to stabilize 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.
Each ASR1000 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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Installation ASR1000 Hardware Manual
2.2. Dimensions
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 DVD
or on www.aerotech.com.
Figure 2-1: ASR1000 Dimensions
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ASR1000 Hardware Manual Installation
2.3. Securing the Stage to the Mounting Surface
W A R N I N G : Do not attempt to manually move the ASR1000 if it is connected to a power
source.
W A R N I N G : Make sure that all moving parts are secure before moving the ASR1000.
Unsecured moving parts may shift and cause bodily injury.
W A R N I N G : The ASR1000 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 in order to achieve the maximum
performance from the ASR1000 stage. When it is mounted to a non-flat surface, the stage can be distorted
as 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 1 µm per 50 mm.
N O T E : The ASR1000 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 ASR1000. Shimming should be avoided if possible. If shimming is required, it
should be minimized to retain maximum rigidity of the system.
ASR1000 series stages have a fixed mounting pattern as shown in Figure 2-2 and Figure 2-3.
If a mounting plate is included on the stage, mount using [QTY-4] M6 or 1/4-20 bolts (refer to Figure 2-2). If
the stage is configured without a mounting plate, use the [QTY-4] M6 tapped holes on the bottom of the
stage to attach an alternative means of mounting (see Figure 2-3). Refer to Section 2.2. Dimensions for
mounting dimensions.
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
M6 or 1/4-20 SHCS 7 N·m
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Installation ASR1000 Hardware Manual
Figure 2-2: ASR1000 Stage Showing Mounting Plate (Top View)
Figure 2-3: ASR1000 Stage Without Mounting Plate (Bottom View)
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ASR1000 Hardware Manual Installation
2.4. General Mechanical Setup
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Installation ASR1000 Hardware Manual
2.5. Load Capability
The ASR1000 is designed for tubular manufacturing applications.
N O T E : Maximum loads are mutually exclusive.
Figure 2-4: Load Capability
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ASR1000 Hardware Manual Operating Specifications
Chapter 3: Electrical Specifications and Installation
W A R N I N G : Electrical installation must be performed by properly qualified personnel.
Electrical installation requirements will vary depending on product options. Installation instructions in this
section are for ASR1000 stages equipped with standard Aerotech motors intended for use with an Aerotech
motion control system. Contact Aerotech for further information regarding products that are otherwise
configured.
Aerotech motion control systems are adjusted at the factory for optimum performance. When the ASR1000
is part of a complete Aerotech motion control system, setup usually involves connecting the ASR1000 to the
appropriate drive chassis with the cables provided. Labels on the system components usually indicate the
appropriate connections.
If system level integration was purchased, an electrical drawing showing system interconnects has been
supplied with the system (separate from this documentation).
The electrical wiring from the motor and encoder are integrated at the factory. Refer to the sections that
follow for standard motor wiring and connector pin assignments.
W A R N I N G : Applications requiring access to the stage while it is energized will require
additional grounding and safeguards. The System Integrator or qualified installer is responsible
for determining and meeting all safety and compliance requirements necessary for the
integration of this stage into the final application.
D A N G E R : Remove power before connecting or disconnecting electrical components or
cables. Failure to do so may cause electric shock.
W A R N I N G : Operator access to the base and tabletop must be restricted while connected to
a power source. Failure to do so may cause electric shock.
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Operating Specifications ASR1000 Hardware Manual
3.1. Motor and Feedback Connectors
Stages equipped with standard motors and encoders come from the factory completely wired and
assembled.
N O T E : If using standard Aerotech motors and cables, motor and encoder connection adjustments are
not required.
The protective ground connection of the ASR1000 provides motor frame ground protection only. Additional
grounding and safety precautions are required for applications requiring access to the stage while it is
energized. The System Integrator or qualified installer is responsible for determining and meeting all safety
and compliance requirements necessary for the integration of this stage into the final application.
D A N G E R : Remove power before connecting or disconnecting electrical components or
cables. Failure to do so may cause electric shock.
W A R N I N G : The protective ground connection must be properly installed to minimize the
possibility of electric shock.
W A R N I N G : Operator access to the base and tabletop must be restricted while connected to
a power source. Failure to do so may cause electric shock.
C A U TI O N : The stage controller must provide over-current and over-speed protection.
Failure to do so may result in permanent damage to the motor and stage components.
Table 3-1: 4-Pin HPD Motor Connector Pinouts (-CN1Option)
Pin Description Connector
A1 Motor Phase A
A2 Motor Phase B
A3 Motor Phase C
1 Motor Shield (EMIshield)
2 Reserved
3 Reserved
4 Reserved
5 Reserved
A4 Frame ground (motor protective ground)
Table 3-2: 4-Pin D Motor Mating Connector
Mating Connector Aerotech P/N Third Party P/N
Backshell ECK00656 Amphenol #17E-1726-2
Sockets [QTY. 4] ECK00659 ITT Cannon #DM53744-6
Connector ECK00657 ITT Cannon #DBMM9W4SA197
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