Aerotech LaserTurn 1 Series User manual

Revision: 1.07.00
LaserTurn®1
Hardware Manual

Global Technical Support
Go to www.aerotech.com/global-technical-support for information and support about your Aerotech products. 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 15238-2811
www.aerotech.com
United Kingdom Japan
Phone: [phone]
Fax: [phone]
Email: [e-mail]
Phone: [phone]
Fax: [phone]
Email: [e-mail]
Germany China
Phone: [phone]
Fax: [phone]
Email: [e-mail]
Phone: [phone]
Email: [e-mail]
France Taiwan
Phone: [phone]
Email: [e-mail]
Phone: [phone]
Email: [e-mail]
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 © 2014-2018, Aerotech, Inc., All rights reserved.

LaserTurn®1 Hardware Manual Table of Contents
Table of Contents
LaserTurn®1 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
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 16
2.4. Air Requirements 18
2.5. Wet Cut Fluid Requirements 18
2.6. Attaching the Payload to the Stage 19
2.7. Load Capability 20
2.8. Changing the Workholding Devices 21
2.8.1. Collet Installation and Removal Procedure 21
2.9. Gripper Installation (-FT2) 22
2.10. Alignment Gripper Installation (-FT3) 23
Chapter 3: Electrical Specifications and Installation 25
3.1. Motor and Feedback Connectors 26
3.2. Motor and Feedback Wiring 30
3.3. Motor and Feedback Specifications 32
3.4. Limits, Marker, and Machine Direction 35
3.5. Motor and Feedback Phasing 36
Chapter 4: Maintenance 39
4.1. Service and Inspection Schedule 39
4.2. Cleaning and Lubrication 40
4.2.1. Collet & Collet Chuck Lubrication and Cleaning 41
4.2.2. Linear Lubrication and Cleaning Process 42
4.3. Seal Replacement 43
4.3.1. Piston Seal Change Procedure 43
4.3.2. Ringseal O-Ring Replacement 43
4.3.3. Wet Cut Rotary Union Seal Replacement 45
4.4. Wet Cut Rotary Union Removal 48
4.5. Tooling Plate Removal 50
4.6. Troubleshooting 51
Appendix A: Warranty and Field Service 53
Appendix B: Revision History 55
Index 57
www.aerotech.com 3

Table of Contents LaserTurn®1 Hardware Manual
List of Figures
Figure 2-1: LaserTurn®1 Shipping Bracket (Top View) 13
Figure 2-2: LaserTurn®1 Dimensions (part one) 14
Figure 2-3: LaserTurn®1 Dimensions (part two) 15
Figure 2-4: LaserTurn®1 Stage Showing Mounting Holes (Top View) 17
Figure 2-5: LaserTurn®1 Wet Cut Rotary Union Location 20
Figure 2-6: Installation Procedure for Collet 21
Figure 2-7: Gripper Detail 22
Figure 2-8: Alignment Gripper (Right-Handed) 23
Figure 3-1: Motor and Feedback Wiring (Rotary Axis) 30
Figure 3-2: Motor and Feedback Wiring (Linear Axis) 31
Figure 3-3: Machine Direction 35
Figure 3-4: Hall Phasing 36
Figure 3-5: Analog Encoder Phasing Reference Diagram 37
Figure 4-1: Linear Bearing Location 42
Figure 4-2: Typical Ringseal Removal 43
Figure 4-3: Cross-section View of Ringseal Showing O-Rings 44
Figure 4-4: Cross-Section View of Wet Cut Rotary Union 45
Figure 4-5: Rear Carriage Cover with Wet Cut Rotary Union 46
Figure 4-6: Seal Location 46
Figure 4-7: Wet Cut Rotary Union Shaft Inspection 47
Figure 4-8: Wet Cut Rotary Union 48
Figure 4-9: Housing Assembly Showing Rotary Union 49
Figure 4-10: Wet Cut Rotary Union Removal 49
Figure 4-11: Tooling Plate Removal 50
4 www.aerotech.com

LaserTurn®1 Hardware Manual Table of Contents
List of Tables
Table 1-1: Model Numbering System 9
Table 1-2: Environmental Specifications 10
Table 1-3: LaserTurn®1 Series Specifications 11
Table 3-1: 4-Pin HPD Motor Connector Pinouts (for Rotary and Linear Axes) 27
Table 3-2: 4-Pin D Motor Mating Connector 27
Table 3-3: 25-Pin D Feedback Connector Pinouts (Rotary Axis) 28
Table 3-4: 25-Pin D Feedback Mating Connector 28
Table 3-5: 25-Pin Feedback Connector Pinouts (Linear Axis) 29
Table 3-6: 25-Pin D Feedback Mating Connector 29
Table 3-7: Feedback Specifications 32
Table 3-8: Rotary Axis Motor Specifications (S-76-35-A) 33
Table 3-9: Linear Axis Motor Specifications (BLMUC-111-A) 34
Table 4-1: Recommended Lubricants 41
www.aerotech.com 5

Table of Contents LaserTurn®1 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 LaserTurn®1 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 LaserTurn®1 stage must be mounted securely. Improper mounting can result in injury
and damage to the equipment.
5. Use care when moving the LaserTurn®1 stage. Lifting or transporting the LaserTurn®1
stage improperly can result in injury or damage to the LaserTurn®1.
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.
6 www.aerotech.com

LaserTurn®1 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:
LaserTurn®1 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
Date 11/8/2018
www.aerotech.com 7

Table of Contents LaserTurn®1 Hardware Manual
8 www.aerotech.com
This page intentionally left blank.

LaserTurn®1 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 Numbering System
LaserTurn®1 Linear / Rotary Platform
Cutting Configuration (Required)
-DCUT Dry cutting configuration
-WCUT Wet cutting configuration with fluid rotary union
Front Tooling (Required)
-FT1 Front tooling platform
-FT2 Front tooling platform with gripper
-FT3 Front tooling platform with right-hand alignment gripper
-FT4 Front tooling platform with left-hand alignment gripper
Gripper Jaws (Optional)
-J1 Gripper jaws for 0-8 mm tube diameters
Metrology - Linear (Required)
-PL1 Metrology, uncalibrated with performance plots
-PL2 Metrology, calibrated (HALAR) with performance plots
Note: Metrology option applies to linear axis only.
Accessories (To be Ordered as a Separate Line Item)
Collet-D-CLTxx Levin type D collet, 0.1 mm to 8 mm part diameter sizes available
RingSeal-D-RSxx Ring seal for wet cutting (consult with Aerotech for available sizes)
CGF Collet and gripper filtration kit
www.aerotech.com Chapter 1 9

Overview LaserTurn®1 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: 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: 40% to 60% RH
The optimal operating humidity is 50% RH.
Storage: 30% to 60% 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 you need to use your equipment in a location that is 2,000 m above
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 LaserTurn®1 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.
10 Chapter 1 www.aerotech.com

LaserTurn®1 Hardware Manual Overview
1.3. Basic Specifications
Table 1-3: LaserTurn®1 Series Specifications
Linear Axis Rotary Axis
Travel 100 mm ±360° Continuous
Accuracy ±2 µm (standard)
±0.5 µm (calibrated) ±121 μrad (±25 arc sec)
Bidirectional Repeatability ±0.2 µm ±20 μrad (±4 arc sec)
Straightness ±1 µm N/A
Flatness ±1 µm N/A
Pitch 25 μrad (5 arc sec) N/A
Yaw 15 μrad (3 arc sec) N/A
Maximum Speed(1) 300 mm/s 1000 rpm
Tube Capacity N/A 7.9 mm (Dry Cut)
3.0 mm (Wet Cut)(2)
Maximum Force (Continuous) 30.6 N/A
Maximum Torque (Continuous) N/A 0.48 N·m
Load Capacity(3)
Axial 2 kg
Radial 0.5 kg
Moment 0.75 N·m
Moving Mass (unloaded) 6 kg N/A
Rotor Inertia(unloaded) N/A 0.0005 kg·m2
Stage Mass with Tooling Platforms 12 kg N/A
Collet Type(4) N/A Type D (Levin)
Collet Runout(5) N/A <30 μm
Minimum System Air Pressure(6) 100 psig
Material Hardcoated Aluminum Stage Body; Stainless Steel Collet Chuck
Mean Time Between Failure 10,000 Hours
1. Maximum speed based on stage capability. Requires the selection of an appropriate amplifier with sufficient voltage and current.
2. Maximum tube diameter is reduced to 6.7 mm for dry cutting with the -WCUT option.
3. Maximum loads are mutually exclusive. Loading limits are due to the collet chuck mechanism. Contact Aerotech directly if part load
requirement exceeds specifications.
4. Collet chuck accepts type D collets (Levin Lathe and Son™).
5. Measured TIR of a precision gage pin with an ultra-precision Type D collet 3 mm away from the collet face at 80 psi applied air
pressure and no load.
6. Collet chuck mechanism is normally-open. Collet mechanism requires air to close collet chuck. Air supply must be dry (0º F dew
point) oil-less air OR 99.99% pure nitrogen. Air or nitrogen must be filtered to 1 micron particle size or better.
www.aerotech.com Chapter 1 11

Overview LaserTurn®1 Hardware Manual
12 Chapter 1 www.aerotech.com
This page intentionally left blank.

LaserTurn®1 Hardware Manual Installation
Chapter 2: Installation
W A R N I N G : LaserTurn®1 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
N O T E : If any damage has occurred during shipping, report it immediately.
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 LaserTurn®1. Unsecured
moving parts may shift and cause bodily injury.
lImproper handling could adversely affect the performance of the LaserTurn®1. Use care
when moving the LaserTurn®1.
lLift only from the base of the linear axis.
lDo not use the rotary axis as a lifting point.
lDo not use the [QTY-4] tapped holes on top of the rotary axis as lifting points.
Carefully remove the LaserTurn®1from its protective shipping container. Gently set the LaserTurn®1 on a
smooth, flat, and clean surface.
Before operating the LaserTurn®1, 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 LaserTurn®1 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.
Red, anodized aluminum shipping brackets have been installed to prevent unwanted motion and potential
damage from occurring during shipment. The brackets must be removed before the LaserTurn®1 can be
operated. Retain the brackets and hardware for future use.
Figure 2-1: LaserTurn®1 Shipping Bracket (Top View)
www.aerotech.com Chapter 2 13

Installation LaserTurn®1 Hardware Manual
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 2-2: LaserTurn®1 Dimensions (part one)
14 Chapter 2 www.aerotech.com

LaserTurn®1 Hardware Manual Installation
Figure 2-3: LaserTurn®1 Dimensions (part two)
www.aerotech.com Chapter 2 15

Installation LaserTurn®1 Hardware Manual
2.3. Securing the Stage to the Mounting Surface
W A R N I N G : Do not attempt to manually move the LaserTurn®1 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 LaserTurn®1.
Unsecured moving parts may shift and cause bodily injury.
W A R N I N G : The LaserTurn®1 must be mounted securely. Improper mounting can result in
injury and damage to the equipment.
D A N G E R : PINCHPOINT! Keep Hands Clear while the stage is in motion.
The mounting surface must be flat and have adequate stiffness in order to achieve the maximum
performance from the LaserTurn®1 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 LaserTurn®1 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 LaserTurn®1. Shimming should be avoided if possible. If shimming is required, it
should be minimized to retain maximum rigidity of the system.
Use the [QTY. 8] M5 SHCS to secure the stage to the mounting surface. Typical screw torque is 4.1 N·m.
Move the stage carriage to access the base plate mounting holes (refer to Figure 2-4).
W A R N I N G : Do not attempt to move the carriage (or table top) of the LaserTurn®1 until the
shipping brackets have been removed. Moving the carriage with the shipping brackets installed
can cause permanent damage to the LaserTurn®1.
16 Chapter 2 www.aerotech.com

LaserTurn®1 Hardware Manual Installation
Figure 2-4: LaserTurn®1 Stage Showing Mounting Holes (Top View)
www.aerotech.com Chapter 2 17

Installation LaserTurn®1 Hardware Manual
2.4. Air Requirements
The air pressure supplied to the collet holder is important in ensuring that the material or tool is released
properly, or for the optional gripper, that the material is held securely.
lIf compressed air is used, it must be filtered to 1 micron, dry to 0º F dew point, and oil free.
lIf nitrogen is used, it must be 99.99% pure and filtered to 1 micron.
The chuck becomes fully closed at approximately 4-7 bar (60-100 psig) depending on the collet size. Higher
pressures will not cause damage to the rotary union.
When the gripper options are ordered, the supply pressure will need to be regulated down (refer to Section
2.9. and Section 2.10. for more information). As with the collet chuck, the supply pressure can be regulated
to control the grip force during stage indexing.
2.5. Wet Cut Fluid Requirements
Water or cutting fluid used during wet cut operations must be conditioned to meet certain requirements
ensuring seal functionality and service life of the wet cut rotary union.
lWater or cutting fluid must be filtered to 5 microns or better.
lA fluid filter must be installed upstream of the rotary union between the pump outlet and the rotary union
inlet.
18 Chapter 2 www.aerotech.com

LaserTurn®1 Hardware Manual Installation
2.6. Attaching the Payload to the Stage
To prevent damage to the stage or parts, test the operation of the stage before any material is held in the
collet or gripper. Proceed with the electrical installation and test the motion control system. Document all
results for future reference. For information on electrical connections, refer to the documentation of the
motion control system and Chapter 3.
Linear
The LaserTurn®1 has optional front and rear tooling platforms. The surfaces of these platforms are precision
surfaces that have been machined flat.
Rotary
To operate the collet, clean compressed air or nitrogen must be supplied to the stage (refer to Section 2.4.).
The one-touch air inlet fitting accepts 4 mm OD plastic air line. Simply push the air line into the fitting and
supply air to the stage. The CGF pneumatics kit option contains the required air supply components, such as
valves, filters, and airlines.
Once air is supplied, material of the appropriate size can be placed in the collet. All collets supplied by
Aerotech are clearly labeled with their clamping size range and collet style. Be sure to use only the correct
size material in the collet. If an incorrect material size is clamped, the accuracy of the collet could be
compromised. Refer to Section 2.8.1. for collet installation.
W A R N I N G : The size of material should match the collet size and be inserted into the collet
at least 2/3 the length of the collet bore. Material that is larger or smaller than the collet or not
inserted far enough into the collet will affect system performance, particularly material runout. In
worst-case scenarios, the collet could be damaged and have to be replaced.
www.aerotech.com Chapter 2 19

Installation LaserTurn®1 Hardware Manual
2.7. Load Capability
The LaserTurn®1 is designed for tubular manufacturing applications. With this in mind, the tubes loaded into
the collet chuck of the rotary axis must fall within the maximum load parameters in Section 1.3.
N O T E : Maximum loads are mutually exclusive. Loading limits are due to the collet chuck mechanism.
Contact Aerotech directly if part load requirement exceeds specifications.
If the LaserTurn®1 is configured for wet cut, it will have a rotary union attached to the end of the rotary shaft
(Figure 2-5). A 1/8 in NPT tapped hole is provided on the end of the rotary union shaft to allow for connecting
a pressure vessel or extension tube. To prevent damage or performance degradation of the stage, the
unsupported length and weight of the attached pressure vessel is limited.
N O T E : Aerotech recommends the following limitations on the size and weight of an unsupported
pressure vessel:
lLength past end of rotary union (L): <200 mm
lMoment about end of rotary union (M): <0.75 N-m
If these limits are exceeded, it is recommended that an external steady-rest or support be implemented.
Figure 2-5: LaserTurn®1 Wet Cut Rotary Union Location
20 Chapter 2 www.aerotech.com