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 This manual is superseded by any new release.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
www.pi.ws M-403 MP 73E Release 2.0.1 Page 3

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.
www.pi.ws M-403 MP 73E Release 2.0.1 Page 4

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.
www.pi.ws M-403 MP 73E Release 2.0.1 Page 5

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
www.pi.ws M-403 MP 73E Release 2.0.1 Page 6

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,
www.pi.ws M-403 MP 73E Release 2.0.1 Page 7