PI M-403 DG Series User manual

© Physik Instrumente (PI) GmbH & Co. KG
Auf der Römerstr. 1 ⋅76228 Karlsruhe, Germany
Tel. [phone] ⋅Fax: [phone]
[email protected] ⋅www.pi.ws
MP 73E User Manual
M-403Linear Translation Stages
Release: 2.0.1 Date: 25.04.2007
This document describes the
following product(s):
■M-403.xDG
Linear Translation Stage, DC-Motor
■M-403.xPD
Linear Translation Stage, ActiveDrive™
■M-403.x2S
Linear Translation Stage, Stepper Motor

Physik Instrumente (PI) GmbH & Co. KG is the owner of the following company names and trademarks:
PI®, ActiveDrive™, Mercury™, Mercury™ Step
The following designations are protected company names or registered trademarks of third parties:
Windows
Copyright 1999–2007 by Physik Instrumente (PI) GmbH & Co. KG, Karlsruhe, Germany.
The text, photographs and drawings in this manual enjoy copyright protection. With regard thereto, Physik
Instrumente (PI) GmbH & Co. KG reserves all rights. Use of said text, photographs and drawings is
permitted only in part and only upon citation of the source.
First printing 25.04.2007
Document Number MP 73E BSc, Release 2.0.1
M-403_User_MP73E_201.doc
Subject to change without notice. This manual is superseded by any new release. The newest release is
available for download at www.pi.ws (http://www.pi.ws)

About This Document
Users of This Manual
This manual is designed to help the reader to install and operate the M-403 Linear positioning stage. It
assumes that the reader has a fundamental understanding of basic servo systems, as well as motion
control concepts and applicable safety procedures.
The manual describes the physical specifications and dimensions of the M-403 Linear positioning stage
as well as the procedures which are required to put the associated motion system into operation.
Conventions
The notes and symbols used in this manual have the following meanings:
WARNING
Calls attention to a procedure, practice or condition which, if not
correctly performed or adhered to, could result in injury or death.
! CAUTION
Calls attention to a procedure, practice, or condition which, if not
correctly performed or adhered to, could result in damage to equipment.
NOTE
Provides additional information or application hints.
The motion controller and the software tools which might be mentioned in this documentation are
described in their own manuals. All documents are available as PDF files via download from the PI
Website (www.pi.ws (http://www.pi.ws)) or on a product CD. For updated releases contact your Physik
Instrumente sales engineer or write [email protected] (mailto:[email protected]).

Contents
1Introduction 3
1.1 Product Description............................................................................. 3
1.2 Prescribed Use.................................................................................... 4
1.3 Safety Instructions............................................................................... 5
1.4 Model Survey ...................................................................................... 6
1.5 Unpacking ........................................................................................... 7
1.6 Additional Components ....................................................................... 7
2Start-Up 9
2.1 Mechanical Mounting .......................................................................... 9
2.2 Moving the Stage .............................................................................. 11
3Operational Considerations 13
3.1 PWM Amplifiers................................................................................. 13
3.2 Limit Switches ................................................................................... 13
3.3 Reference Switch .............................................................................. 14
3.4 Rotary Encoder ................................................................................. 14
3.5 Motor Controllers............................................................................... 14
3.6 Host PC............................................................................................. 14
4Troubleshooting 16
4.1 Diagnosis .......................................................................................... 16
4.2 Customer Service.............................................................................. 18
5Maintenance 19
6Technical Data 20
6.1 Specifications .................................................................................... 20
6.2 Range and Transmission Ratio Values............................................. 22
6.3 Dimensions ....................................................................................... 22
6.3.1 M-403.xxx ........................................................................................... 23
6.3.2 Accessory Adapter Plates .................................................................. 24
6.4 Pin Assignments ............................................................................... 27
6.4.1 Analog DC-Motor Versions................................................................. 27
6.4.2 DC-Motor ActiveDrive™ (PWM) ......................................................... 28

6.4.3 2-Phase Stepper Motor ...................................................................... 28
7Appendix 29
7.1 Related Products............................................................................... 29
7.2 Motor Controller Details .................................................................... 30
7.2.1 Stepper motor controllers ................................................................... 30
7.2.2 DC Motor Controllers.......................................................................... 30
8Glossary of Terms 33
9Index 37

Introduction
1Introduction
1.1 Product Description
Figure 1: Different motor versions of the M-403 linear stage family with 100 mm
travel range (from left): M-403.4PD (DC-motor/Active Drive(TM)),
M-403.4DG (DC-motor/gearhead) and M-403.42S (stepper motor)
The optimum choice of high-value, low-cost components makes the M-403
family of linear stages very attractive and economical. These stages are
leadscrew-driven and provide a minimum incremental motion to 0.2 µm. The
precision-machined, high-density, stress-relieved aluminum base provides
exceptional stability with minimum weight. M-403 are available in 5 lengths
providing travel ranges from 25 to 200 mm.
High-Load and Maintenance-Free
All models are equipped with high-precision linear guiding rails and
recirculating ball bearings. The recirculating ball bearings are maintenance
free and immune to cage migration. The choice of components and careful
mounting guarantees high load capacity, longer lifetime and high guiding
accuracy.
The stages can carry up to 20 kg and push/pull up to 50 N.
Three Motor Drive Options
M-403.xPD versions feature the high-performance ActiveDrive™ system.
The ActiveDrive™ design, developed by PI, features a high-efficiency PWM
(pulse width modulation) servo-amplifier mounted side-by-side with the DC
motor and offers several advantages:
■Increased efficiency, by eliminating power losses between the
amplifier and motor
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Introduction
■Reduced cost of ownership and improved reliability, because no
external driver is required
■Elimination of PWM amplifier noise radiation, by mounting the
amplifier and motor together in a single, electrically shielded case
M-403.xDG models are equipped with a DC motor and a shaft-mounted
optical encoder, providing a minimum incremental motion of 0.2 µm.
M-403.x2S models feature a direct-drive, 2-phase stepper motor, providing
very smooth operation and a resolution of 0.1 µm per step.
Limit and Reference Switches
For the protection of your equipment, non-contact Hall-effect limit and
reference switches are installed. The direction-sensing reference switch
supports advanced automation applications with high precision.
The M-403 / M-413 and M-404 / M-414 series of linear stages form a modular
system. The M-403 is the basic family, providing travel ranges from 25 to 200
mm. M-413 is designed for higher loads with travel ranges from 100 to 300
mm. The M-404 and M-414 stages have the same travel ranges and load
capacities, but offer higher precision and more speed..
1.2 Prescribed Use
Correct operation of the M-403 positioners is only possible in combination
with a suitable controller/driver (ordered separately) and software.
The controlling device must be able to read out and process the signals from
reference and limit switches and the incremental position encoder to ensure
proper performance of the servo-control system.
Based on their design and realization, the M-403 stages are intended for
single-axis positioning, adjusting and shifting of loads at various velocities.
M-403 positioners can be mounted horizontically or vertically. To achieve the
specified guiding accuracy, the positioners have to be mounted on a flat
surface to avoid torsion of the basic profile.
The positioners may only be used for applications suitably in accordance
with the device specifications.
Respect the safety instructions given in this User Manual. The operator is
responsible for the correct installation and operation of the M-403.
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Introduction
The verification of the technical specifications by the manufacturer does not
imply the validation of complete applications. In fact the operator is
responsible for the process validation and the appropriate releases.
The M-403 meets the specifications as defined by DIN EN 61010 for safe
operation under normal ambient conditions. See the specifications table for
details.
1.3 Safety Instructions
!
CAUTION
Read this before operating the equipment covered in this manual.
Always keep the User Manual safe and close to the described device. In
case of loss or damage to the instructions, please order a new copy from
your PI distributor or download one from www.pi.ws (http://www.pi.ws).
Also keep and add all further information (e.g. extended instructions or
Technical Notes) to the User Manual.
Read carefully the User Manuals of all other components involved such as
controllers or software.
Read the following before operating the equipment covered in this manual:
WARNING—CRUSH HAZARD
Never put anything where the moving platform or any connected object
could possibly trap it! The moving platform can accelerate rapidly and
generate high forces which can cause damage or injury.
!
CAUTION
Be aware that the stage could start an unexpected move when first
connected to the motor controller.
Be aware that failure of the motor controller may crash the stage against
a hard stop.
Crashes can cause irreparable damage. Do not disable limit switches in
software. Test limit switch operation at low speeds. Stop system if
necessary. Do not let it run against a hard stop.
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Introduction
1.4 Model Survey
A total of 15 M-403 standard versions is available. They differ in terms of
drive types and travel ranges. The drive type and the travel range are
encoded in the model number.
The drive section options are shown in the table below. The “x” in the model
number stands for the travel range code.
Models M-403.xDG M-403.xPD M-403.x2S
Drive type DC-Motor, gearhead,
2.5 W
DC- Motor,
ActiveDrive™, 26 W
2-phase-stepper motor
Position
encoder
Yes Yes No
Limit switch Yes Yes Yes
Direction-sensi
ng reference
switch
Yes Yes Yes
The travel range differences and their encoding in the model number are as
follows (here the “xx” in the model number stands for the drive-type code):
Models M-403.1xx M-403.2xx M-403.4xx M-403.6xx M-403.8xx
Travel range in
mm
25 50 100 150 200
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Introduction
Figure 2: M-403 linear stage versions (from left): M-403.1PD, M-403.2PD,
M-403.4PD, M-403.6PD and M-403.8PD provide travel ranges from 25 to
200 mm
1.5 Unpacking
Unpack the M-403 Linear positioning stage with care. Compare the contents
against the items covered by the contract and against the packing list.
The following components are included:
■M-403 Linear Translation Stage
■C-815.38 motor cable for connecting to motor controller
■Screw set with 6 M4 x 30 and 4 M6 x 2 screws for mounting
■User manual for M-403 (this document) in printed form
■M-403.xPD only: M-500.PS power supply with line cord
Inspect the contents for signs of damage. If parts are missing or you notice
signs of damage, contact PI immediately.
Save all packing materials in case the product need be shipped again.
1.6 Additional Components
Depending on your application, you might need the following accessories (p.
23) for use with the M-403 Linear Positioning Stage :
■M-403.AP1: Adapter plate for mounting stages with PI standard hole
pattern on M-403 stages,
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Introduction
■M-403.AP2: Z-axis adapter plate for vertical mount of M-403 stages on
M-403 stages,
■M-403.AP3: Universal adapter plate for mounting M-403 stages on
stages with PI standard hole pattern.
Contact your PI sales engineer or write [email protected] if you need additional
components.
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Start-Up
2Start-Up
2.1 Mechanical Mounting
NOTE
If the counter-sunk mounting holes in the stage base are covered by the
platform, you must first move the platform to a position which allows
access. Read "Moving the Stage (p. 11)" for instructions.
Figure 3: M-ounting hole locations on stage, identical for all models
To mount an M-403 stage on a base plane, use the two holes for M6 screws
or the four counter sunk holes for M4 screws in the stage base and the
corresponding mounting screws which come with the stage. The
arrangement of the M6 holes complies with the 25 mm-hole pattern of
standard metric honeycomb tables.
You have best access to the M6 mounting holes, when the platform is at its
central reference switch (for reaching the reference position see the User
Manual of the motor controller used).
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Start-Up
You can assemble stacked XY- or XYZ-systems with M-403 stages. For
mounting, use the M4 x 30 screws which come with the stages:
■For an XY-system, use the four counter-sunk holes for M4 in the base
of the upper M-403 stage and the four M4 threaded holes in the
moving platform of the lower M-403 stage (see Fig. above).
■For Z-axis mounting, the M-403.AP2 Z-axis adapter plate is required.
First mount this plate on the front of the Z-axis stage using the two M4
threaded holes in the stage base (see Fig. above). Then affix the
adapter plate to the moving platform of the lower M-403 stage (see
Fig. below).
Figure 4: Z-axis mounting
To mount a stage with PI standard hole pattern on an M-403 stage, the
M-403.AP1 adapter plate is required.
To mount a M-403 stage upon a stage with PI standard hole pattern, the
M-403.AP3 adapter plate is required.
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Start-Up
2.2 Moving the Stage
WARNING—CRUSH HAZARD
Never put anything where the moving platform or any connected object
could possibly trap it! The moving platform can accelerate rapidly and
generate high forces which can cause damage or injury.
NOTE
The positive direction of motion is away from the end where the motor is
mounted.
Figure 5: M-4xx stage unit, arrow indicates positive direction of motion
Prior to operation, you should read the documentation for your motor
controller. If using any PWM stages read the section about PWM amplifiers
(p. 13) carefully.
To operate a stage, proceed as follows:
1 Install/connect the controller following the instructions in the
controller manual. If you are going to use a host computer, install the
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Start-Up
host software in the host computer. This procedure is described in
the controller User Manual and/or associated software manuals.
2 Connect the stage to the controller using the connecting cable (part
number C-815.38), which comes with the stage. With multi-axis
controllers, be sure to note the axis designation of the connection
selected.
3 M-403 versions with ActiveDrive™ (PWM) only: Connect the stage
to the M-500.PS power supply, which comes with the stage and
connect the power supply to line power (wide range). To activate the
M-500.PS power supply switch the "-/o"-button to position "-".
4 Command a few test moves to make sure everything is working
properly.
For best performance and system compatibility we recommend using PI
controllers.
Most PI controllers come with a graphic-user-interface-software which is
easy to setup and allows quick installation and testing.
NOTE
Most standard controllers and / or software from PI use a DAT file which
contains information on all standard micropositioners and installs
automatically with the host software. This file, called pistages.dat, also
includes an initial set of PID servo-control parameters for each stage
type. If your system does not use pistages.dat, possible PID parameters
are included in this manual.
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Operational Considerations
3Operational Considerations
3.1 PWM Amplifiers
The M-403.xPD stages feature a DC servo-motor with a high-efficiency PWM
amplifier mounted side by side. This ActiveDrive™ system provides
maximum dynamic performance. An external plug-in power supply
(M-500.PS) is provided to supply the built-in amplifier. This architecture
allows high torque and high velocities while loading the motor controller with
control signals only.
3.2 Limit Switches
All M-403 positioners are equipped with non-contact, Hall-effect limit
switches (with TTL drivers).
Each limit switch sends an overtravel signal on its own dedicated line to the
controller. It is the controller that is then responsible for stopping the motion.
If it does not do so in time, the positioner will run into the hard stop.
On stepper-motor versions, limit switch outputs are active low, on other
versions, active high.
!
CAUTION
Crashes can cause irreparable damage. Do not disable limit switches in
software. Test limit switch operation at low speeds. Stop system if
necessary. Do not let it run against a hard stop.
Limit Switch Specifications:
Type: magnetic (Hall-effect) sensors
Supply.voltage +5 V / GND, supplied by the motor controller through the motor
connector.
Signal output: TTL level
Sink / Source capab. 20 mA at 18°C
Signal logic (stepper motors) active low; normal operation: high, limit sensor reached: low
Signal logic (DC-motors): active-high; normal motor operation: low, limit sensor reached: high
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Operational Considerations
3.3 Reference Switch
All stage versions are equipped with a direction-sensing Hall-effect reference
switch, which is located at about the midpoint of the travel range. This sensor
provides a TTL signal indicating whether the positioner is to the positive or
negative side of a fixed point. The rising or falling edge of this signal can be
used to indicate a known reference position within 0.5 µm accuracy
(depending on the controller). The difference in the reference point when
approached from the positive or the negative side is about 0.2 mm to 0.4 mm.
See the controller User Manual and/or associated software manuals for the
commands which make use of the reference signal.
3.4 Rotary Encoder
M-403.xDG and M-403.xPD are equipped with DC motors with a
shaft-mounted position encoder. It provides highly accurate signals
whenever the position changes by a known, small amount. By monitoring the
encoder pulses, called counts, the controller can keep track of the relative
motion of the stage. To discover the absolute position, it is necessary to drive
the stage to a limit or reference switch. Most controllers have commands to
automate this procedure, which is called referencing.
3.5 Motor Controllers
M-403-series micropositioners can be connected to the same motor
controllers as other micropositioners from PI.
DC motor controllers from PI can control both analog and ActiveDrive™
(PWM) motor versions. The required operating mode is set
automatically—depending on the controller model, either directly when the
controller is powered up, or when the user chooses the connected positioner
type in the control software.
If networking several positioners, you have to keep in mind that stepper
motor devices can only be networked with other stepper-motor devices.
This manual includes a list of suitable controllers.
3.6 Host PC
Most controllers from PI are in turn controlled by a host PC provided by the
user.
The controller is either installed directly in the PC (e.g. C-843 PCI board) or
connected to it over a communications interface. See the controller User
Manual for details.
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Operational Considerations
PI provides software and/or drivers that run on the host PC to control the
system. Typically, there will be a control program with a graphic user
interface for testing and simple operation, and, in addition, DLL, COM and/or
LabView drivers for users who wish to use custom software. If the controller
is a PC ISA or PCI card, there will also be hardware drivers to install. See the
controller user and software manuals for installation details.
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Troubleshooting
4Troubleshooting
4.1 Diagnosis
Positioner does not move.
Cables not connected properly:
■Check the connecting cables.
For positioners with ActiveDrive™ only:
Check if power supply is connected:
■Verify that the included MS-500.PS power supply is connected and
turned on.
Positioner or positioner cable is defective:
■Replace positioner with a working positioner of the same type to test a
new combination of controller and positioner (positioners of a different
type may malfunction due to unsuitable parameter settings on the
controller).
Test cable and / or replace with a working cable of the syme type.
Unusually high friction in the spindle-nut-system:
■Clean the spindle and add new lubricant.
Wrong command or wrong syntax:
■Check the error code (with PI-GCS command set, use ERR?; see
controller and software manuals for the error code explanations).
Positioner is not referenced:
■In the GCS command set, some closed-loop motion commands are
not executed if the mechanics has not been referenced—(ERR?
replies "5", see controller and software manuals). Reference the axis
as described in the controller and user manuals.
Wrong axis commanded:
■Check if commanded axis is that of the desired positioner.
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Troubleshooting
Incorrect configuration:
■Check for anomalous parameter settings on the controller.
Positioner starts to move but stops after a short time.
Unusually high friction in the spindle-nut-system:
■Clean the spindle and add new lubricant.
Positioner does not reach position with expected accuracy.
Motion parameters are not optimized:
■Adjust the motion parameters according to the values given in this
document.
Positioner runs jerkily and not smooth enough.
Motion parameters are not optimized:
■Adjust the motion parameters according to the values listed in this
document.
Positioner did not stop in time and ran into a hard stop.
The controller has not stopped the positioner in time:
■Too high velocity. See chapter "Limit Switches".
■Turn off the motor. If possible, you may push the positioner out of the
end zone manually.
■The end of the leadscrew has an Allan wrench socket so it can be
cranked manually.
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