Aerotech LaserTurn 5-ASR User manual

Revision: 1.04.00
LaserTurn®5-ASR
Hardware Manual

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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
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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 © 2014-2018, Aerotech, Inc., All rights reserved.

LaserTurn®5-ASR Hardware Manual Table of Contents
Table of Contents
LaserTurn®5-ASR 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 15
2.3. Securing the Stage to the Mounting Surface 17
2.4. Air Requirements 19
2.5. Wet Cut Fluid Requirements 19
2.6. Attaching the Payload to the Stage 20
2.7. Load Capability 21
2.8. Changing the Workholding Devices 22
2.8.1. Collet Installation and Removal Procedure 22
2.9. Gripper Installation (-FT2) 25
2.10. Alignment Gripper Installation (-FT3 and -FT6) 26
2.11. Gripper Jaw Interface 28
Chapter 3: Electrical Specifications and 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
4.2.1. Collet & Collet Chuck Lubrication and Cleaning 45
4.2.2. Linear Lubrication and Cleaning Process 46
4.3. Seal Replacement 47
4.3.1. Piston Seal Change Procedure 47
4.3.2. Ringseal O-Ring Replacement 47
4.3.3. Wet Cut Rotary Union Seal Replacement 49
4.4. Wet Cut Rotary Union Removal 53
4.5. Linear Hardcover Removal 55
4.6. Troubleshooting 56
Appendix A: Warranty and Field Service 57
Appendix B: Revision History 59
Index 61
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Table of Contents LaserTurn®5-ASR Hardware Manual
List of Figures
Figure 2-1: LaserTurn®5-ASR Shipping Clamps 14
Figure 2-2: LaserTurn®5-ASR Lifting Points 14
Figure 2-3: LaserTurn®5-ASR Dimensions (part one) 15
Figure 2-4: LaserTurn®5-ASR Dimensions (part two) 16
Figure 2-5: LaserTurn®5-ASR Stage Showing Mounting Holes (Top View) 18
Figure 2-6: Tooling Platform Hardware 18
Figure 2-7: LaserTurn®5-ASR Wet Cut Rotary Union Location 21
Figure 2-8: Inserting the Collet into the Collet Nut 23
Figure 2-9: Installing the Collet and Collet Nut 24
Figure 2-10: Gripper Detail 25
Figure 2-11: Alignment Gripper 27
Figure 2-12: Gripper Jaw Interface Dimensions 28
Figure 3-1: Motor and Feedback Wiring (Rotary Axis) 34
Figure 3-2: Motor and Feedback Wiring (Linear Axis) 35
Figure 3-3: Machine Direction 40
Figure 3-4: Hall Phasing 41
Figure 3-5: Analog Encoder Phasing Reference Diagram 42
Figure 4-1: Linear Bearing Grease Nipple 46
Figure 4-2: Ringseal Removal and Replacement 47
Figure 4-3: Typical Ringseal 48
Figure 4-4: Cross-Section View of Ringseal Showing O-Ring 48
Figure 4-5: Cross-Section View of Wet Cut Rotary Union 49
Figure 4-6: Carriage Cover Removal 50
Figure 4-7: Seal Assembly Removal 50
Figure 4-8: Wet Cut Rotary Union Shaft Inspection 52
Figure 4-9: Wet Cut Rotary Union 53
Figure 4-10: Wet Cut Rotary Union Removal 54
Figure 4-11: Linear Hardcover Removal 55
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LaserTurn®5-ASR 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®5-ASR Series Specifications 11
Table 3-1: 4-Pin HPD Motor Connector Pinouts (for Rotary and Linear Axes) 31
Table 3-2: 4-Pin D Motor Mating Connector 31
Table 3-3: 25-Pin D Feedback Connector Pinouts (Rotary Axis) 32
Table 3-4: 25-Pin D Feedback Mating Connector 32
Table 3-5: 25-Pin Feedback Connector Pinouts (Linear Axis) 33
Table 3-6: 25-Pin D Feedback Mating Connector 33
Table 3-7: Feedback Specifications 36
Table 3-8: Rotary Axis Motor Specifications (BM250) 37
Table 3-9: Rotary Axis Motor Specifications, -WCUT (BM250) 38
Table 3-10: Linear Axis Motor Specifications (BLM-264-A) 39
Table 4-1: Recommended Lubricants 45
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Table of Contents LaserTurn®5-ASR 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®5-ASR 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®5-ASR stage must be mounted securely. Improper mounting can result in
injury and damage to the equipment.
5. Use care when moving the LaserTurn®5-ASR stage. Lifting or transporting the
LaserTurn®5-ASR stage improperly can result in injury or damage to the LaserTurn®5-
ASR.
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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LaserTurn®5-ASR 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®5-ASR 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 6/22/2018
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Table of Contents LaserTurn®5-ASR Hardware Manual
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LaserTurn®5-ASR 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®5-ASR Linear / Rotary Platform
Travel (Required)
-200 200 mm linear axis travel
-300 300 mm linear axis travel
Feedback (Required)
-E1 Incremental linear encoder, 1 Vpp (linear axis)
-E2 High-accuracy incremental linear encoder, 1 Vpp (linear axis)
Rotary Speed (Required)
-SS Standard speed rotary axis
-HS High speed rotary axis
Cutting Configuration (Required)
-DCUT Dry cutting configuration
-WCUT Wet cutting configuration with fluid rotary union
Front Tooling (Optional)
-FT1 Metric front tooling platform
-FT2 Metric front tooling platform with gripper
-FT3 Metric front tooling platform with alignment gripper
-FT4 English front tooling platform
-FT5 English front tooling platform with gripper
-FT6 English front tooling platform with alignment gripper
Gripper Jaws (Optional)
-J1 Gripper jaws for 0-10 mm tube diameters
Rear Tooling (Optional)
-RT1 Metric rear tooling platform
-RT2 English rear tooling platform
Metrology - Linear (Required)
-PL1 Metrology, uncalibrated with performance plots
-PL2 Metrology, calibrated (HALAR) with performance plots
Metrology - Rotary (Required)
-PL1 Metrology, uncalibrated with performance plots
-PL2 Metrology, calibrated (HALAR) with performance plots
Accessories (To be Ordered as a Separate Line Item)
Collet-ER16-
CLTxxx ER16 collet (consult with Aerotech for available sizes)
RingSeal-ER16-
RSxx Ring seal for wet cutting, ER16 collet (consult with Aerotech for available sizes)
CGF Collet and gripper filtration kit
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Overview LaserTurn®5-ASR 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 percent 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 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 LaserTurn®5-ASR 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.
The thermal expansion coefficient of the encoder scale is 8.0 ppm/°C. Travel will increase or decrease at
this rate as the temperature of the encoder scale temperature deviates from 20°C (68°F).
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LaserTurn®5-ASR Hardware Manual Overview
1.3. Basic Specifications
Table 1-3: LaserTurn®5-ASR Series Specifications
Linear Axis Rotary Axis
Travel 200 mm 300 mm ±360° Continuous
Accuracy
-E1 Calibrated:±1 µm
Uncalibrated:±8 µm
Calibrated:±1 µm
Uncalibrated:±12 µm ±73 µrad (±15 arc sec)
-E2 Calibrated: ±1 µm
Uncalibrated:±5 µm
Bidirectional Repeatability ±0.5 µm ±15 µrad (±3 arc sec)
Straightness ±2 µm ±3 µm N/A
Flatness ±2 µm ±3 µm N/A
Pitch 39 µrad (8 arc sec) 49 µrad (10 arc sec) N/A
Yaw 39 µrad (8 arc sec) 49 µrad (10 arc sec) N/A
Maximum Speed(1) 2 m/s 800 rpm
2000 rpm (-HS option)
Tube Capacity N/A 10 mm (ER16, dry cut)
5.8 mm (ER16, wet cut)
Maximum Force (continuous) 197.2 N N/A
Maximum Torque (continuous) N/A 2.3 N·m (dry cut)
1.6 N·m (wet cut)
Load Capacity(2)
Axial 3.0 kg
Radial 2.0 kg
Moment 3 N·m
Moving Mass (unloaded) 18 kg N/A
Rotor Inertia (unloaded) N/A 0.0006 kg·m2
Stage Mass with Tooling
Platforms 65 kg 69 kg N/A
Collet Type(3) N/A ER16
Collet Runout (4) N/A <25 µm
Minimum System Air Pressure
(5) 100 psig
Material Hardcoated Aluminum Stage Body
Stainless Steel Collet Chuck
Mean Time Between Failure
(MTBF) 10,000 Hours
1. Maximum speed is based on stage capability. Actual speed may be limited by system data rate, resolution, or amplifier selection.
2. Maximum loads are mutually exclusive. Loading limits are due to the collet chuck mechanism. Contact Aerotech directly if part load
requirement exceeds specifications.
3. LaserTurn®5-ASR collet chuck accepts Rego-Fix ER collets manufactured to DIN6499 specifications only.
4. Measured TIR of a precision gage pin chucked with an ultra-precision ER collet (DIN6499), 10 mm away from collet face.
5. Collet chuck mechanism is normally-closed. Collet mechanism requires air to open collet chuck. Air supply must be dry (0ºF dew-
point) oil-less air OR 99.99% pure Nitrogen. Air or nitrogen must be filtered to 1 micron particle size or better.
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Overview LaserTurn®5-ASR Hardware Manual
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LaserTurn®5-ASR Hardware Manual Installation
Chapter 2: Installation
W A R N I N G : LaserTurn®5-ASR 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®5-ASR.
Unsecured moving parts may shift and cause bodily injury.
lImproper handling could adversely affect the performance of the LaserTurn®5-ASR. Use
care when moving the LaserTurn®5-ASR.
lLift the stage only by the base at [QTY-4] 3/8-16 tapped holes. Do not use the stage table
or motor as a lifting points.
Carefully remove the LaserTurn®5-ASRfrom its protective shipping container. Gently set the LaserTurn®5-
ASR on a smooth, flat, and clean surface.
Before operating the LaserTurn®5-ASR, 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®5-ASR 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 (see Figure 2-1). The brackets must be removed before the
LaserTurn®5-ASR can be operated. The brackets are secured with M6 Socket Head Cap Screws and can be
removed with a 5 mm hex wrench. Retain the brackets and hardware for future use.
Four 3/8-16 threaded holes are provided for attaching lifting equipment. See Figure 2-2 for the location of the
lifting points. The [QTY. 4] 3/8-16 bolts in these holes must extend up at least 2.5 inches (64 mm) in order to
clear the stationary hardcover on the linear axis.
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Installation LaserTurn®5-ASR Hardware Manual
Figure 2-1: LaserTurn®5-ASR Shipping Clamps
Figure 2-2: LaserTurn®5-ASR Lifting Points
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LaserTurn®5-ASR Hardware Manual 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 2-3: LaserTurn®5-ASR Dimensions (part one)
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Installation LaserTurn®5-ASR Hardware Manual
Figure 2-4: LaserTurn®5-ASR Dimensions (part two)
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LaserTurn®5-ASR 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 LaserTurn®5-ASR 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®5-
ASR. Unsecured moving parts may shift and cause bodily injury.
W A R N I N G : The LaserTurn®5-ASR 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®5-ASR 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®5-ASR 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®5-ASR. 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] M8 or 5/16 SHCS (may have [QTY. 10 or 12] depending on selected options) to secure the
stage to the mounting surface. Typical screw torque is 16.8 N-m. Move the stage carriage to access the
base plate mounting holes (refer to Figure 2-5).
If the stage is equipped with optional tooling platforms, you must make sure that the stage base and tooling
platforms are aligned correctly. If they are incorrectly aligned, stage performance can decrease, and damage
to the stage can occur. To align the tooling platforms, loosen the [QTY. 2] M6 SHCS in each platform. This
allows the tooling platform to sit flush on the mounting surface. Then re-tighten the [QTY. 2] M6 SHCS.
Typical screw torque is 6.9 N·m. The stage is now ready to be secured to the mounting surface.
W A R N I N G : Do not attempt to move the carriage (or table top) of the LaserTurn®5-ASR until
the lifting and shipping brackets have been removed. Moving the carriage with the lifting and
shipping brackets installed can cause permanent damage to the LaserTurn®5-ASR.
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Installation LaserTurn®5-ASR Hardware Manual
Figure 2-5: LaserTurn®5-ASR Stage Showing Mounting Holes (Top View)
Figure 2-6: Tooling Platform Hardware
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LaserTurn®5-ASR Hardware Manual Installation
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 microns.
The chuck becomes fully open at approximately 4-5.5 bar (60-80 psig) depending on the collet size. Higher
pressures will not cause damage to the rotary union, but high flow rates will result. Because of the
noncontact rotary union design on collet-equipped stages, a small amount of leakage will occur.
Approximate leakage rates of between 10 Lpm (0.5 CFM) and 40 Lpm (1.4 CFM), depending on pressure,
will be observed when the collet is open.
N O T E : When operating the LaserTurn®5-ASR, supply 5 psi to the collet at all times. This will act as an
air purge and help prevent contaminants from entering the rotary union.
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.
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Installation LaserTurn®5-ASR Hardware Manual
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®5-ASR 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.
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