PI UPL-120 User manual

User Manual
UPL120UM0001, valid for UPL-120
ASt, 8/9/2023
PI miCos GmbH, Freiburger Straße 30, 79427 Eschbach, Germany
Phone [phone]
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UPL-120
High-Precision Z Stage
© 2023 Physik Instrumente (PI) GmbH & Co. KG, Karlsruhe, Germany. The text, photographs, and
drawings in this manual are protected by copyright. With regard thereto, Physik Instrumente (PI) GmbH &
Co. KG retains all the rights. The use of any text, images and drawings is permitted only in part and only
when indicating the source.
Original instructions
First printing: 8/9/2023

User Manual
UPL120UM0001, valid for UPL-120
ASt, 8/9/2023
PI miCos GmbH, Freiburger Straße 30, 79427 Eschbach, Germany page 2 / 27
Phone [phone]
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Contents
1Introduction 4
1.1 About this Document .............................................................................................................................. 4
1.1.1 Objective and Target Group of this User Manual ...........................................................................................4
1.1.2 Symbols and Typographic Conventions ..........................................................................................................4
1.1.3 Figures............................................................................................................................................................. 4
1.1.4 Other Applicable Documents..........................................................................................................................5
1.1.5 Downloading Manuals .................................................................................................................................... 5
1.2 European Declarations of Conformity..................................................................................................... 5
1.3 Customer Service..................................................................................................................................... 6
2Safety 7
2.1 Intended Use ........................................................................................................................................... 7
2.2 Organizational Measures......................................................................................................................... 7
2.3 General Safety Instructions ..................................................................................................................... 7
2.3.1 Measures during Installation .......................................................................................................................... 8
2.3.2 Measures during Startup and Operation ........................................................................................................8
2.3.3 Measures during Maintenance.......................................................................................................................9
3Product Description 10
3.1 Model Overview .................................................................................................................................... 10
3.2 Product View ......................................................................................................................................... 11
3.3 Product Labeling.................................................................................................................................... 11
3.4 Scope of Delivery................................................................................................................................... 11
4Unpacking 12
5Installation and Startup 13
5.1 Notes on Installation ............................................................................................................................. 13
5.2 Mounting the UPL-120 .......................................................................................................................... 13
5.3 Mounting the Load ................................................................................................................................ 14
5.4 Connecting the UPL-120 to the Controller ............................................................................................ 15
5.5 Starting up the UPL-120 ........................................................................................................................ 16
6Maintenance 17
6.1 Maintenance Run .................................................................................................................................. 17
6.2 Lubrication............................................................................................................................................. 17
7Troubleshooting 18
8Technical Data 19
8.1 Specifications......................................................................................................................................... 19

User Manual
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8.1.1 Data Table ..................................................................................................................................................... 19
8.1.2 Limit Switch Specifications............................................................................................................................22
8.2 Forces and Torques of the UPL-120 ...................................................................................................... 22
8.3 Maximum Ratings.................................................................................................................................. 23
8.4 Ambient Conditions and Classifications ................................................................................................ 23
8.5 Dimensions ............................................................................................................................................ 24
8.6 Pin Assignment ...................................................................................................................................... 25
8.6.1 Motor Connector .......................................................................................................................................... 25
8.6.2 Linear Encoder Connector ............................................................................................................................ 26
9Old Equipment Disposal 27

User Manual
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1Introduction
1.1 About this Document
1.1.1 Objective and Target Group of this User Manual
This user manual contains the information necessary for using the UPL-120 as intended.
We assume that the user has basic knowledge of closed-loop systems, motion control concepts,
and applicable safety measures.
1.1.2 Symbols and Typographic Conventions
The following symbols and typographic conventions are used in this document:
CAUTION
Dangerous situation
If not avoided, the dangerous situation will result in minor injury.
Actions to take to avoid the situation.
NOTICE
Dangerous situation
If not avoided, the dangerous situation will result in damage to the equipment.
Actions to take to avoid the situation.
INFORMATION
Information for easier handling, tricks, tips, etc.
Symbol Meaning
1.
2.
Action consisting of several steps whose sequential order must be
observed
Action consisting of one or several steps whose sequential order is
irrelevant
1.1.3 Figures
For better understandability, the colors, proportions, and degree of detail in illustrations can
deviate from the actual circumstances. Photographic illustrations may also differ and must not
be seen as guaranteed properties.

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1.1.4 Other Applicable Documents
Document number Document
MP146EK Short instructions for positioners with electric motors
User manual of the electronics used
The latest versions of the user manuals can be downloaded from our website.
1.1.5 Downloading Manuals
INFORMATION
If a manual is missing or problems occur with downloading:
Contact our customer service department (p. 6).
Downloading manuals
1. Open the website www.pi.ws.
2. Search the website for the product number (e. g., L-412).
3. Click the corresponding product to open the product detail page.
4. Click the Downloads tab.
The manuals are shown under Documentation. Software manuals are shown under
General Software Documentation.
5. Click the ADD TO LIST button for the desired manual and then click REQUEST.
6. Fill out the request form and click SEND REQUEST.
The download link will then be sent to the email address entered.
1.2 European Declarations of Conformity
For the UPL-120, declarations of conformity were issued according to the following European
statutory requirements:
EMC Directive
RoHS Directive
The standards applied for certifying conformity are listed below.
EMC: EN 61326-1
Safety: EN 61010-1
RoHS: EN IEC 63000

User Manual
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1.3 Customer Service
For enquiries and orders, contact your PI miCos representative or send us an email:
[email protected]
If you have any questions concerning your system, provide the following information:
Product and serial numbers of all products in the system
Firmware version of the controller (if applicable)
Version of the driver or the software (if applicable)
Operating system on the PC (if applicable)
If possible: Take photographs or make videos of your system that can be sent to our customer
service department if requested.
Customer service address:
Physik Instrumente (PI) GmbH & Co. KG
Auf der Römerstraße 1
76228 Karlsruhe
Germany

User Manual
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2Safety
2.1 Intended Use
UPL-120 is a a laboratory device as defined by DIN EN 61010. UPL-120 is intend for indoor use
and in an environment that is free of dirt, oil, and lubricants.
In accordance with its design, the UPL-120 is intended for positioning, adjusting and lifting loads
on one axis at various velocities. The UPL-120 can be mounted horizontally or vertically.
The intended use of the UPL-120 is only possible in conjunction with suitable electronics. The
electronics must provide the required operating voltages. To ensure proper performance of the
servo-control system, the electronics must be able to read out and process the signals from
reference and limit switches, and from the incremental position encoder. The electronics are
not included in the scope of delivery of the UPL-120.
2.2 Organizational Measures
User Manual
Always keep this user manual available with the UPL-120.
Add all information from the manufacturer such as supplements or technical notes
to the user manual.
If you give UPL-120 to a third party, also include this user manual as well as other
relevant information provided by the manufacturer.
Only use the device on the basis of the complete user manual. Missing information
due to an incomplete user manual can result in minor injury and damage to
equipment.
Only install and operate UPL-120 after you have read and understood this user
manual.
General Personnel Qualification
UPL-120 may only be installed, started up, operated, maintained, and cleaned by authorized
and appropriately qualified personnel.
2.3 General Safety Instructions
The operator is responsible for installing and operating the UPL-120 correctly
CAUTION
UPL-120 is built according to state-of-the-art technology and recognized safety standards.
Improper use of the UPL-120 may result in personal injury and/or damage to the UPL-120.
Use UPL-120 only for its intended purpose and when it is in perfect condition.
Read the user manual.
Eliminate any malfunctions that may affect safety immediately.

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2.3.1 Measures during Installation
NOTICE
The UPL-120 may be damaged by excessively long screws and wrongly mounted parts.
When mounting the UPL-120, make sure that the mounting screws do not interfere with
the stage motion. The screw heads must not protrude from the countersunk holes.
Observe the depth of the mounting holes in the moving platform.
Only use screws of the correct length for the respective mounting holes.
Only mount the UPL-120 and the loads on the mounting fixtures (holes) intended for this
purpose.
NOTICE
The UPL-120 heats up during operation. High temperatures can influence your application.
Install the UPL-120 so that your application is not affected by the dissipating heat.
NOTICE
Cable extensions can affect the performance of the UPL-120 and damage the electronics.
Only use genuine PI miCos parts to connect the UPL-120 to the electronic equipment.
Do not use cable extensions. If you need longer cables, use cable extensions from PI miCos.
Avoid short circuiting the lines for motor voltages since this can damage the electronics.
2.3.2 Measures during Startup and Operation
Do not put your UPL-120 into operation until it is fully mounted and connected.
CAUTION
Unintentional motion of the UPL-120 is possible when it is connected to the controller for the
first time. Defective software or incorrect operation of the software can also result in
unintentional motions.
Do not place any objects in areas where they can be caught by moving parts.
NOTICE
Collision of a part in motion at the end of the travel range and high accelerations can cause
damage to or wear on the mechanical system.
Ensure that the automatic limit switch halt is supported by the controller, or that it is
activated in the controller.
Do not disable the evaluation of the limit switch signals by the controller.
Check the function of the limit switches at about 10% to 20% of the maximum velocity.
In the event of a malfunction of the limit switches, stop motion immediately.
Ensure that the end of the travel range is approached at low velocity.

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Set the control signal so that the moving part does not stop abruptly or try to continue
motion at the end of the travel range.
Determine the maximum velocity for your application.
NOTICE
Your system can be damaged by uncontrolled oscillation of the UPL-120. Noise generated
during operation of the UPL-120 is a typical sign of oscillation.
If noise occurs during operation of the UPL-120:
Immediately switch off the servo-control system for the UPL-120.
Check the settings of the servo-control parameters of your controller.
NOTICE
Highest dynamic force and holding force are achieved at a control signal level of 100 %;
however, during continuous operation the motor/drive may overheat.
During continuous operation at room temperature, do not exceed a maximum of 90 % of
the control signal level.
For continuous operation at other temperatures, observe the maximum permissible duty
cycle in relation to the ambient temperature or contact our customer service department
for more information (p. 6).
2.3.3 Measures during Maintenance
NOTICE
The UPL-120 is precision adjusted.
Do not loosen any sealed screws.
NOTICE
Dirt, oil, lubricants and condensation will render the motor/drive inoperable.
Keep the motor of the UPL-120 free of lubricants.
Keep the UPL-120 free of dirt and condensation.

User Manual
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3Product Description
3.1 Model Overview

User Manual
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3.2 Product View
3.3 Product Labeling
The image shows the position of the safety labels on the UPL-120.
3.4 Scope of Delivery
Product number Description
66359x1x30[-0001] UPL-120 according to your order
6635500025 Mounting material
K623000083 Hexagon wrench key SW3
Y-MIC-1260 Measurement report
MP146EK Short instructions for positioners with electric motors

User Manual
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4Unpacking
1. Unpack the UPL-120 with care.
2. Compare the contents against the items covered by the contract and against the
packing list. If parts are incorrectly supplied or missing, contact PI immediately.
3. Inspect the contents for signs of damage. If you notice signs of damage, contact PI
immediately.
4. Keep all packaging materials and the transport lock in case the product needs to be
transported again later.

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5Installation and Startup
5.1 Notes on Installation
INFORMATION
Maximum tightening torques of the mounting screws to be used:
M3 DIN912: 1.5Nm
M4 DIN912: 2.0Nm
M5 DIN912: 2.5Nm
M6 DIN912: 3.0Nm
5.2 Mounting the UPL-120
INFORMATION
To achieve the stated specifications, the evenness of the mounting surface must be < 5 µm
sein. (reference surface of PI miCos measuring granite: 3 µm).
INFORMATION
Dust, dirt, or foreign matter between the underlying surface and the stage can lead to a
warping of the UPL-120's base body. With this, the stated specificationscannot be guaranteed.
Tools and accessories
Mounting material (6635500025, in scope of delivery):
DIN 912 screws and DIN 6325 dowel pins, m6 tolerance field
Hexagon wrench key SW3 (K623000083, in scope of delivery)
Requirements
You have read and understood the general safety instructions (p. 7).
You have provided a suitable underlying surface with the holes necessary for the screws
and if required, locating pins. For the position and depth required for the holes, see
"Dimensions" (p. 24).
The underlying surface flatness is < 5 μm.
The underlying surface is free from dust, dirt, and other foreign matter.

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Mounting the UPL-120 on an underlying surface
1. Optional: Insert the locating pins into the corresponding holes in the underlying surface.
2. Align the UPL-120 on the underlying surface so that the corresponding mounting holes
in the UPL-120 and underlying surface are in line.
3. Optional: Put the UPL-120 onto the underlying surface so that the locating pins can be
inserted into the corresponding locating holes of the UPL-120.
4. Tighten all screws in the mounting holes.
5. Check that the UPL-120 is sitting firmly on the underlying surface.
5.3 Mounting the Load
Tools and accessories
Mounting material (6635500025, in scope of delivery):
DIN 912 screws and DIN 6325 dowel pins, m6 tolerance field
Hexagon wrench key SW3 (K623000083, in scope of delivery)
Requirements
You have mounted the UPL-120 onto the surface properly
The UPL-120 is not connected to the electronics.
You have prepared the load so that it can be fixed to the mounting holes in the motion
platform:
The gap between the center of gravity of the load and the center of the motion
platform is as small as possible in all directions.
At least three points are provided for fixing the load on the motion platform.

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Mouting the load on the UPL-120
1. Optional: Insert the locating pins into the corresponding holes in the motion platform.
2. Align the load on the motion platform so that the mounting holes selected in the
platform can be used to mount the load.
3. Optional: Place the load onto the motion platform so that the locating pins are inserted
into the corresponding locating holes in the load.
4. Tighten the screws in all mounting holes.
5. Check that the load is sitting firmly on the motion platform.
5.4 Connecting the UPL-120 to the Controller
Tools and accessories
Suitable electronics
Drive cable, suitable for the electronics
If necessary: Suitable screwdriver for the locking screws of the connectors.
Requirements
You have read and understood the user manual for the electronics.
You have installed the electronics properly.
The electronics are switched off.
Connecting the UPL-120
1. If necessary: Remove the ESD protective caps from the connectors of the UPL-120.
2. Connect the drive connector of the UPL-120 (D-sub HD 15 plug) to the drive connector
on the electronics.

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3. Additionally, for models with linear encoder:
Connect the sensor connector of the UPL-120 (D-sub 9 plug) to the sensor connector on
the electronics.
4. If necessary: Secure the connection against unintentional loosening.
5.5 Starting up the UPL-120
Requirements
You have read and understood the general safety instructions.
You have installed the UPL-120 correctly.
You have read and understood the user manual for the electronics used.
If a digital controller is used: You have read and understood the manual for the PC
software used.
The electronics and if required, the PC software, have been installed (see the user
manual for the electronics).
Starting up the UPL-120
5. Start the electronics (see the user manual for the electronics, p. 5).
6. Configure the electronics for the UPL-120 during startup:
7. If you are using a digital controller from PI: In the PC software, select the entry in the
positioner database that matches the UPL-120 exactly.
8. If you are using electronics from another manufacturer: Configure the electronics
according to the parameters of the UPL-120 (p. 19).
9. Start a few motion cycles for testing purposes (see the user manual for the electronics).

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6Maintenance
Depending on the operating conditions and the period of use of the UPL-120, the maintenance
measures described below are required.
6.1 Maintenance Run
The maintenance run is performed to redistribute the existing lubricant on the guidings of the
UPL-120.
To evenly distribute the existing lubricant on the guides, perform a maintenance run
across the entire travel range after 500 hours of operation, or after 1 year at the
latest.
If the UPL-120 is to be operated continuously in an industrial environment over a
small travel range (less than 20 percent of the entire travel range), perform a
maintenance run across the entire travel range every 5000 motion cycles.
6.2 Lubrication
Under laboratory conditions, the guidings of the UPL-120 need to be lubricated in exceptional
cases only. For continuous industrial use, the lubrication intervals must be defined individually.
Do not lubricate the guides of the UPL-120 without consulting our customer service
department (p. 6).
To lubricate the guidings, follow the instructions specified in the maintenance
manual, which you can obtain from our customer service department.

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7Troubleshooting
Problem Possible causes Solution
Reduced positioning
accuracy
Warped base body 
Mount the UPL-120 onto a flat surface. The
recommended flatness of the surface
is < 5 µm.
Increased wear due to small
motion over a long period of time

Perform a maintenance run over the entire
travel range.
Mechanical system
does not move; no
operating noise can be
heard.
Controller not correctly
connected or defective.

Check all connecting cables.
Check the controller.
If necessary, check the power adapter of
the UPL-120.
For models with
stepper motor: Actual
position deviates from
the displayed position.
The motor is overloaded by an
external load torque or the mass
to be driven in the case of strong
acceleration or deceleration.
The motor skips steps. The information on the
current position is lost without the controller
detecting the state.
Use a stepper motor in the application to
determine the maximum velocity for a
stage.
Start a new reference move.
If the problem that occurred with your system is not listed in the table above or cannot be
solved as described, contact our customer service (p. 6).

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8Technical Data
8.1 Specifications
8.1.1 Data Table
Motion Unit Tole-
rance
6635911030,
6635911130
6635921030,
6635921130-0001
Active axes Z Z
Travel range in Z mm 13 13
Maximum velocity in Z, unloaded mm/s 6 3
Flatness (Linear crosstalk in X with
motion in Z)
µm Typ. ±3 ±3
Straightness (Linear crosstalk in Y with
motion in Z)
µm Typ. ±3 ±3
Yaw (Rotational crosstalk in θX with
motion in Z)
µrad Typ. ±100 ±100
Pitch (Rotational crosstalk in θY with
motion in Z)
µrad Typ. ±100 ±100
Positioning Unit Tole-
rance
6635911030 6635911130
Minimum incremental motion in Z µm Typ. 0.1 0.1
Unidirectional repeatability in Z µm Typ. ±0.125 ±0.125
Bidirectional repeatability in Z µm Typ. 4 2
Reference switch Encoder index Encoder index
Reference switch repeatability µm 1 1
Limit switches Optical Optical
Integrated sensor Incremental linear
encoder
Sensor signal A/B quadrature, RS-
422
Sensor resolution nm 50
Motor encoder Incremental rotary
encoder
Incremental
rotary
encoder
Sensor signal motor encoder A/B quadrature, RS-
422
A/B quadrature,
RS-422

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Positioning Unit Tole-
rance
6635911030 6635911130
Auflösung Motorencoder Cts./ rev. 20000 20000
Positioning Unit Tole-
rance
6635921030 6635921130-0001
Minimum incremental motion in Z µm Typ. 0.1 0.05
Unidirectional repeatability in Z µm Typ. ±0.1 ±0.075
Bidirectional repeatability in Z µm Typ. 3 1
Reference switch Encoder index Encoder index
Reference switch repeatability µm 1 1
Limit switches Optical Optical
Integrated sensor Incremental linear
encoder
Sensor signal Sin/cos, 1 V peak-
peak
Sensor signal periode µm 20
Drive Properties Unit
Tole-
rance
6635911030,
6635911130
6635921030,
6635921130-0001
Drive type DC motor 2-phase stepper
motor
Operating voltage V 24 24
Peak voltage V 48 48
Nominal current, RMS A Typ. 1.1 1.2
Motor resolution
Full steps/
rev.
200
Drive force in Z N Typ. 200 150
Resistance phase-phase Ω Typ. 5.78 1.25
Inductance phase-phase mH 1.1 1.2
Mechanical Properties Unit Tole-
rance
6635911030,
6635911130
6635921030,
6635921130-0001
Permissible push force in Y N max. 150 150
Permissible push force in Z N Max. 200 150