Aerotech ABL1000 User manual

Revision: 1.03.00
ABL1000 Hardware Manual

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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 © 2003-2019, Aerotech, Inc., All rights reserved.

ABL1000 Hardware Manual Table of Contents
Table of Contents
ABL1000 Hardware Manual 1
Table of Contents 3
List of Figures 4
List of Tables 5
Safety Procedures and Warnings 7
EU Declaration of Incorporation 9
Chapter 1: Overview 11
1.1. Environmental Specifications 12
1.2. Accuracy and Temperature Effects 12
1.3. Basic Specifications 13
1.4. Air Requirements 14
Chapter 2: Installation 15
2.1. Unpacking and Handling the Stage 15
2.2. Dimensions 17
2.3. Securing the Stage to the Mounting Surface 18
2.4. Attaching the Payload to the Stage 20
Load Capability 20
Chapter 3: Electrical Specifications and Installation 21
3.1. Motor and Feedback Connector 22
3.2. Motor and Feedback Wiring 24
3.3. Motor and Feedback Specifications 25
3.4. Limits, Marker, and Machine Direction 27
3.5. Motor and Feedback Phasing 28
Chapter 4: Maintenance 31
4.1. Service and Inspection Schedule 31
4.2. Cleaning and Lubrication 31
4.2.1. Cleaning Process 32
4.3. Troubleshooting 33
Appendix A: Warranty and Field Service 35
Appendix B: Revision History 37
Index 39
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Table of Contents ABL1000 Hardware Manual
List of Figures
Figure 2-1: Shipping Clamps 16
Figure 2-2: ABL1000 Dimensions 17
Figure 2-3: Surface Mounting Holes 19
Figure 2-4: Payload and Multi-Axis Stage Mounting Holes 20
Figure 3-1: Motor and Feedback Wiring 24
Figure 3-2: Machine Direction 27
Figure 3-3: Hall Phasing 28
Figure 3-4: Analog Encoder Phasing Reference Diagram 29
Figure 3-5: Encoder Phasing Reference Diagram (Standard) 29
Figure 4-1: Air Bearing Surfaces Require Periodic Cleaning 32
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ABL1000 Hardware Manual Table of Contents
List of Tables
Table 1-1: Model Numbers and Ordering Options 11
Table 1-2: Environmental Specifications 12
Table 1-3: ABL1000 Series Specifications 13
Table 1-4: Air Specifications 14
Table 3-1: Motor and Feedback Connector 23
Table 3-2: Feedback Specifications 25
Table 3-3: Encoder Specifications 25
Table 3-4: ABL1000 Motor Specifications 26
Table 4-1: Recommended Cleaning Solvents 31
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Table of Contents ABL1000 Hardware Manual
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ABL1000 Hardware Manual Safety
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.
This manual tells you how to carefully and correctly use and operate the ABL1000. Read all parts of this
manual before you install or operate the ABL1000 or before you do maintenance to your system. To prevent
injury to you and damage to the equipment, obey the precautions in this manual. The precautions that follow
apply when you see a Danger or Warning symbol in this manual. If you do not obey these precautions, injury
to you or damage to the equipment can occur. If you do not understand the information in this manual,
contact Aerotech Global Technical SupportThis product has been designed for light industrial manufacturing
or laboratory environments. The protection provided by the equipment could be impaired if the product is
used in a manner not specified by the manufacturer.
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 ABL1000 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.
6. PINCHPOINT! Keep Hands Clear while the stage is in motion.
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 ABL1000 stage must be mounted securely. Improper mounting can result in injury and
damage to the equipment.
5. Use care when moving the ABL1000 stage. Lifting or transporting the ABL1000 stage
improperly can result in injury or damage to the ABL1000.
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. The stage forcer temperature may exceed 75°C.
9. Operators must be trained before operating this equipment.
10. All service and maintenance must be performed by qualified personnel.
11. Eye protection must be worn when in the proximity of compressed air components.
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Safety ABL1000 Hardware Manual
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ABL1000 Hardware Manual Declaration of Conformity
EU Declaration of Incorporation
Manufacturer: Aerotech, Inc.
101 Zeta Drive
Pittsburgh, PA 15238-2811
USA
herewith declares that the product:
ABL1000 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 con-
formity 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 fol-
lowing 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 3/19/2019
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ABL1000 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 Numbers and Ordering Options
ABL1000 Series Linear Air-Bearing Stage
Travel (Required)
-025 25 mm travel
-050 50 mm travel
-100 100 mm travel
Feedback (Required)
-E1 Incremental linear encoder, 1 Vpp amplified sine output
-E2 High-accuracy Incremental linear encoder, 1 Vpp amplified sine output
Cable Management (Optional)
-CMS1 Single axis cable management system
-CMS2 Cable management system for lower (X) axis of XY assembly
-CMS3 Cable management system for upper (Y) axis of XY assembly
-CMS4 Cable management system for use with vertical (Z) or rotary (T) axis
Metrology (Optional)
-PL1 Metrology, uncalibrated with performance plots
-PL2 Metrology, calibrated (HALAR) with performance plots
Accessories (to be ordered as separate line item)
ABF Air-bearing filtration kit
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Overview ABL1000 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: 40 percent to 60 percent RH
The optimal operating humidity is 50 percent RH.
Storage: 30 percent to 60 percent RH, non-condensing in original packaging
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
specific application.
Protection
Rating
ABL1000 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
Due to the small clearances in the air bearing design, extreme temperature environments could cause a
decrease in performance or permanent damage to the stage. Standard Aerotech air-bearing stages are
designed for and built in a 20°C (68°F) environment. The environmental temperature must be controlled to
within 0.25°C per 24 hours to ensure that the ABL1000 specifications are repeatable over an extended period
of time. The severity of temperature effects on all specifications depends on many different environmental
conditions, including how the ABL1000 is mounted. Contact the factory for more details.
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ABL1000 Hardware Manual Overview
1.3. Basic Specifications
Table 1-3: ABL1000 Series Specifications
Model ABL1000-025 ABL1000-050 ABL1000-100
Travel 25 mm 50 mm 100 mm
Drive System Linear Brushless Servomotor
Resolution -E1 2.5 nm
-E2 0.5 nm
Maximum Travel Speed(1) 300 mm/s
Maximum Linear Acceleration 1 g - 10m/s2(no load)
Maximum Horizontal Load(2) 15.0 kg
Accuracy(1)
-E1 ±0.3 µm(3)
±2 µm
±0.3 µm(3)
±2 µm
±0.3 µm(3)
±5 µm
-E2 ±0.2 µm(3)
±1 µm
±0.2 µm(3)
±1 µm
±0.2 µm(3)
±2 µm
Repeatability -E1 ±50 nm
-E2(3) ±50 nm(1); ±100 nm
Straightness and Flatness(4) ±0.25 µm ±0.25 µm ±0.4 µm
Pitch and Yaw ±0.25 arc sec ±0.50 arc sec ±1.0 arc sec
Nominal Stage Weight 4.5 kg 5.5 kg 6.4 kg
Moving Mass 1.9 kg
Operating Pressure(5) 80 psi ±5 psi
Air Consumption(6)(7) 17.5 SLPM
Construction Aluminum Body/Hardcoat
(1) Maximum speed based on stage capability; maximum application velocity may be limited by system data rate and system
resolution.
(2) Max load for XY configuration is 10.0 kg.
(3) Values with Aerotech controls and -PL2 metrology option.
(4) Dependent on flatness of stage mounting surface.
(5) To protect air bearing against under-pressure, an in-line pressure switch tied to the motion controller/amplifier E-Stop is
recommended.
(6) Air supply must be clean, dry to 0° F dew point and filtered to 0.25 μm or better. Recommend nitrogen at 99.9% purity.
(7) Maximum expected air consumption for single axis.
NOTE: Specifications are for single-axis systems measured 25 mm above the tabletop; performance of multi-axis system is payload
and workpoint dependent. Consult the Aerotech factory for multi-axis or non-standard applications.
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Overview ABL1000 Hardware Manual
1.4. Air Requirements
The quality of the air that you supply to the stage is important to the operation of the stage. Aerotech
recommends that you connect the air supply to the air inlet with a polyurethane air hose.
Table 1-4: Air Specifications
Description
Air Quality
Nitrogen(1) l99.99% pure
lfiltered(2) to 0.25 microns
Compressed Air
lfiltered(2) to 0.25 microns
ldry to 0º F dew point
loil free
Operating Air Pressure 80 psi ± 5 psi (517 to 551 kPa)
Air Consumption 17.5 SLPM
Air Inlet Fitting(3) 1/16" ID x 1/8" OD x 18.75 ft length hose
(1) Recommended
(2) The filtration requirement is to prevent particles from clogging the air bearing openings.
(3) Aerotech recommends using a polyurethane air hose.
Aerotech also recommends that you install a pressure switch (P/N: MCA03094) tied to the motion
controller's emergency stop (ESTOP)that will remove power to the air bearing if pressure drops below 40 psi
(a drop in pressure could result in contact between bearing surfaces which could cause damage to the
surfaces). For easier air-supply setup, you can purchase pneumatic kits and filter/filter-dryer kits from
Aerotech. Aerotech’s ABF Air Filtration Unit incorporates air filtration plus a pressure monitoring switch.
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ABL1000 Hardware Manual Mechanical Specifications and Installation
Chapter 2: Installation
W A R N I N G : ABL1000 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 the stage.
lMake sure that all moving parts are secure before moving the ABL1000. Unsecured moving
parts may shift and cause bodily injury.
lImproper handling could adversely affect the performance of the ABL1000. Use care when
moving the ABL1000.
N O T E : If any damage has occurred during shipping, report it immediately.
Carefully remove the ABL1000from its protective shipping container. Gently set the ABL1000 on a smooth,
flat, and clean surface.
Before operating the ABL1000, 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 ABL1000 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.
Shipping Clamps
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
ABL1000 can be operated. Retain the brackets and hardware for future use.
W A R N I N G : Do not attempt to move the carriage (or table top) of the ABL1000 until the
shipping brackets have been removed. Moving the carriage with the shipping brackets installed
can cause permanent damage to the ABL1000.
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Mechanical Specifications and Installation ABL1000 Hardware Manual
Figure 2-1: Shipping Clamps
N O T E : After removing the shipping brackets, retain them for future use. Do not transport or ship the
ABL1000 without the shipping brackets attached.
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ABL1000 Hardware Manual Mechanical Specifications and Installation
2.2. Dimensions
Figure 2-2: ABL1000 Dimensions
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Mechanical Specifications and Installation ABL1000 Hardware Manual
2.3. Securing the Stage to the Mounting Surface
The mounting surface must be flat and have adequate stiffness in order to achieve the maximum
performance from the ABL1000 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.
W A R N I N G : Make sure that all moving parts are secure before moving the ABL1000.
Unsecured moving parts may shift and cause bodily injury.
D A N G E R : Strong rare-earth magnets are present in the linear motor magnet track. Loose
metal objects (tools, watches, keys, etc.) may cause personal injury and/or damage to the
equipment.
W A R N I N G : The ABL1000 must be mounted securely. Improper mounting can result in injury
and damage to the equipment.
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 stage base is precision machined and verified for flatness prior to stage assembly at the
factory. If machining is required to achieve the desired flatness, it should be performed on the mounting
surface rather than the stage base. Shimming should be avoided if possible. If shimming is required, it
should be minimized to improve the rigidity of the system.
Procedure to mount the ABL1000:
W A R N I N G : Do not attempt to move the carriage of the ABL1000 until the air supply, detailed
in Section 1.4., has been installed. Moving the stage table without air supplied can cause
permanent damage to the stage.
1. Supply air to the stage with the air inlet. Refer to Section 1.4. for more information on air supply.
2. Manually move the stage to one end of travel. Half of the mounting holes for the stage will show. See
Figure 2-3.
3. Mount the stage to the base with M5 screws. The number of mounting holes depends on stage travel.
4. After half of the mounting screws are installed, move the stage to the opposite end of travel to access
the remaining screws. Repeat the installation process for these holes.
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ABL1000 Hardware Manual Mechanical Specifications and Installation
Figure 2-3: Surface Mounting Holes
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Mechanical Specifications and Installation ABL1000 Hardware Manual
2.4. Attaching the Payload to the Stage
To prevent damage to the payload or stage, test the operation of the stage before the payload is attached.
Aerotech recommends that customers use a representative payload during start-up to prevent accidental
damage to the stage and the payload. Proceed with the electrical installation and test the motion control
system in accordance with the system documentation. Document all results for future reference. For
information on electrical installation refer to Chapter 3 and the documentation delivered with the stage.
N O T E : If your ABL1000 was purchased with Aerotech controls, it might have been tuned with a
representative payload based on the information provided at the time of order. If the ABL1000 is started up
without a payload, the servo gains provided by Aerotech with the shipment may not be appropriate and
servo instability can occur. Refer to the controller help file for tuning assistance.
The payload must be flat, rigid, and comparable to the stage in quality to maintain optimum performance.
N O T E : For valid system performance, the mounting interface should be flat within 1 µm per 25 mm.
Figure 2-4: Payload and Multi-Axis Stage Mounting Holes
Load Capability
Applied loads should be symmetrically distributed whenever possible (i.e., the payload should be centered
on the stage table and the entire stage should be centered on the support structure).
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