Rockwell Automation CHPS-250 User Manual
User Manual
CHPS-Series Linear Stage
Catalog Numbers CHPS-150, CHPS-200, CHPS-250
Important User Information
IMPORTANT
Read this document and the documents listed in the additional resources section about installation, configuration, and
operation of this equipment before you install, configure, operate, or maintain this product. Users are required to
familiarize themselves with installation and wiring instructions in addition to requirements of all applicable codes, laws,
and standards.
Activities including installation, adjustments, putting into service, use, assembly, disassembly, and maintenance are required
to be carried out by suitably trained personnel in accordance with applicable code of practice.
If this equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may be
impaired.
In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the
use or application of this equipment.
The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and
requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or
liability for actual use based on the examples and diagrams.
No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or
software described in this manual.
Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation,
Inc., is prohibited.
Throughout this manual, when necessary, we use notes to make you aware of safety considerations.
WARNING: Identifies information about practices or circumstances that can cause an explosion in a hazardous environment,
which may lead to personal injury or death, property damage, or economic loss.
ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property
damage, or economic loss. Attentions help you identify a hazard, avoid a hazard, and recognize the consequence.
Identifies information that is critical for successful application and understanding of the product.
Labels may also be on or inside the equipment to provide specific precautions.
SHOCK HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous
voltage may be present.
BURN HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may
reach dangerous temperatures.
ARC FLASH HAZARD: Labels may be on or inside the equipment, for example, a motor control center, to alert people to
potential Arc Flash. Arc Flash will cause severe injury or death. Wear proper Personal Protective Equipment (PPE). Follow ALL
Regulatory requirements for safe work practices and for Personal Protective Equipment (PPE).
Allen-Bradley, Kinetix, Rockwell Software, Rockwell Automation, Ultra are trademarks of Rockwell Automation, Inc.
Trademarks not belonging to Rockwell Automation are property of their respective companies.
Summary of Changes
This manual contains new and updated information. Changes throughout this
revision are marked by change bars, as shown to the right of this paragraph.
New and Updated Information
This table contains the changes made to this revision.
Top ic Pag e
Corrected catalog numbers 18, 29, 59, 60, 87
Added maximum velocity for Kinetix 6500 and Kinetix 300 Drives 74
Rockwell Automation Publication CHPS-UM001D-EN-P - July 2014 3
Summary of Changes
Notes:
4 Rockwell Automation Publication CHPS-UM001D-EN-P - July 2014
Stage Safety
Understanding Your Stage
Table of Contents
Preface
About This Publication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Who Should Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Chapter 1
Safety Labels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Clearances. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
General Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Vertical or Incline Payload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
End Cap Impacts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Air Freight Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Standards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Motor Model Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Chapter 2
Identifying the Components of Your Stage . . . . . . . . . . . . . . . . . . . . . . . . . 16
Component Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Recommended Maintenance Interval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Identifying Your Stage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Planning the Stage Installation
Mounting the Stage
Connector Data
Chapter 3
Stage Mounting Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
General Safety Standards for Stage Installations . . . . . . . . . . . . . . . . . 21
Mounting Restrictions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Clearance Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Chapter 4
Unpacking, Handling, and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Unpacking Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Store Packaging Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Stage Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Mounting the Stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Before You Begin the Mechanical Installation. . . . . . . . . . . . . . . . . . . 28
Mounting the Stage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Mount Your Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Chapter 5
Kinetix Servo Drive Compatible Connectors . . . . . . . . . . . . . . . . . . . . . . . 34
D-Type Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Flying Leads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Junction Box Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Rockwell Automation Publication CHPS-UM001D-EN-P - July 2014 5
Table of Contents
Connecting the Stage
Operation Guidelines and Limit
Configuration
Limit Sensor Flying Leads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Chapter 6
Connecting the Stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Attaching the Ground Strap and Interface Cables . . . . . . . . . . . . . . . 40
Thermal Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Optional Limit Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
TTL Differential Encoder Output Signal. . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Sine/Cos Encoder Output Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Hall Effect Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Motor and Hall Phasing and Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Stage Positive Direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Chapter 7
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Operational Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Travel Limits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Calculating the Stopping Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Overtravel Limit Sensor Position Adjustment. . . . . . . . . . . . . . . . . . . 51
Bumper Stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Troubleshooting
Maintenance
Removing and Replacing Stage
Components
Chapter 8
Before You Begin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
PTC Thermal Signal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Hall Effect Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Hall to Back EMF Phasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Motor Coil Resistance Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Chapter 9
Before You Begin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Lubricate the Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Optical Encoder Scale Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Strip Seal Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Cover Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Chapter 10
Before You Begin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Cable Carrier Module Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Cable Carrier Module Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Strip Seal Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Stage Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Stage Side Cover Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Strip Seal Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Stage Cover Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Side Cover Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
6 Rockwell Automation Publication CHPS-UM001D-EN-P - July 2014
Appendix A
Table of Contents
Specifications and Dimensions
Accessories
Static and Static Moment Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Performance Specifications for 325V CHPS-Series Stage . . . . . . . . 70
Performance Specifications for 325V or
650V CHPS-Series Stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
General Stage Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Accuracy Specification for the CHPS-Series Stage. . . . . . . . . . . . . . . 73
Commutation Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Limit Sensor Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
PTC Thermistor Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Encoder Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Maximum Velocity for Allen-Bradley Drives. . . . . . . . . . . . . . . . . . . . 74
Environmental Specifications for CHPS-Series Stages . . . . . . . . . . . 75
CHPS-Series Stage Travel versus Weight Specifications . . . . . . . . . 75
CHPS-Series Stage Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
CHPS-Series Stage Technical Specifications. . . . . . . . . . . . . . . . . . . . . . . . 83
Appendix B
Interconnect Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Power Cable Dimensions
(catalog number 2090-XXNPMF-16Sxx) . . . . . . . . . . . . . . . 85
Feedback Cable Dimensions
(catalog number 2090-XXNFMF-Sxx). . . . . . . . . . . . . . . . . . 86
Installation, Maintenance, and Replacement Kits . . . . . . . . . . . . . . . . . . . 87
Accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Stacking Stages
Start-up Guide for CHPS-Series Stage
with Ultra3000 Drive and Ultraware
Software
Appendix C
Stage Stacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Specifications for Stacked Stages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Appendix D
Using This Appendix. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Wiring the CHPS-Series Stage to the Ultra3000 Drive . . . . . . . . . . . . . . 91
Linear Motor File Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Creating a CHPS-Series Stage Motor File . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Recommended Start-up Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
CHPS-Series Stage and Ultra3000 Drive Troubleshooting Reference. 96
Positive Phasing Direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Encoder Counting Polarity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Oscilloscope Verification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Oscilloscope Diagram for Ultra3000 Drive . . . . . . . . . . . . . . . . . . . . . 98
Reference Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Commutation Diagnostics Utility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Self-sensing Commutation and Startup. . . . . . . . . . . . . . . . . . . . . . . . 100
Main Screen Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Rockwell Automation Publication CHPS-UM001D-EN-P - July 2014 7
Table of Contents
Motor Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Faults Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Appendix E
Mounting Bolts and Torque Values
Index
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
8 Rockwell Automation Publication CHPS-UM001D-EN-P - July 2014
Read this preface to familiarize yourself with the manual.
Preface
About This Publication
Who Should Use This Manual
This manual provides detailed installation instructions for mounting, wiring,
maintaining, and troubleshooting your CHPS-Series Linear Motor Driven
Stage.
This manual is intended for engineers or technicians directly involved in the
installation, wiring, and maintenance of stages. Any person that teaches, operates,
maintains, or repairs these stages must be trained and demonstrate the
competence to safely perform the assigned task.
If you do not understand the linear motor stages, contact your local Rockwell
Automation sales representative for information on training courses before using
this product.
Read this entire manual before you attempt to install your stage into your motion
system. This familiarizes you with the stage components, their relationship to
each other and the system.
After installation, check the configuration of the system parameters to be sure
they are properly set for the stage in your motion system.
Follow all instructions carefully and pay special attention to safety concerns.
Additional Resources
Resource Description
High Precision Linear Motor Driven Stages Selection Guide,
publication CHPS-SG001
Kinetix® 2000 Multi-axis Servo Drive User Manual,
publication 2093-UM001
Kinetix 6000 Multi-axis Servo Drive User Manual, publication
2094-UM001
LZ Family of Linear Motors Brochure, publication PMC-BR001 Provides product specifications, outline drawing, ratings, and wiring information to aid
LC Family of Linear Motors Brochure, publication PMC-BR002
These documents contain additional information concerning related products
from Rockwell Automation.
Provides product specifications, ratings, certifications, system interface, and wiring
diagrams to aid in product selection.
Describes how to configure and use Kinetix 2000 multi-axis servo drives.
Describes how to configure and use Kinetix 6000 multi-axis servo drives.
in product selection.
Provides product specifications, outline drawing, ratings, and wiring information to aid
in product selection.
Rockwell Automation Publication CHPS-UM001D-EN-P - July 2014 9
Preface
Notes:
10 Rockwell Automation Publication CHPS-UM001D-EN-P - July 2014
Chapter 1
IMPORTANT
Stage Safety
Top ic Pag e
Safety Labels 12
Clearances 13
General Safety 13
Heat 13
Vertical or Incline Payload 13
End Cap Impacts 13
Air Freight Transportation 14
Standards 14
Motor Model Identification 14
Any person that teaches, operates, maintains, or repairs these linear stages
must be trained and demonstrate the competence to safely perform the
assigned task.
Rockwell Automation Publication CHPS-UM001D-EN-P - July 2014 11
Chapter 1 Stage Safety
Location Title Label Details
A Danger-Pinch Points
and Heavy Objects
The linear stage presents a muscle strain hazard if one person attempts to
lift it. When attempting to move the linear stage use a two-person-lift to
prevent personal injury or damage to the linear stage.
To Installer - There exists a Crush and Cut hazard while installing the linear
stage. The linear stage weighs from 13…63 kg (28…140 lb).
To User - The Pinch Point label identifies a moving object hazard, caused by
the movement of the carriage on the linear stage. Never put fingers, hands,
or limbs near the linear stage while running motion commands. Before
executing any motion command, check that all maintenance tools have
been removed from linear stage.
All types of linear stages, especially uncovered, present a pinch point
hazard. This hazard may occur if fingers or hands come between the end
cap and a moving carriage. Always lift the linear stage by the base and
keep fingers and hands away from the opening and edges parallel to the
carriage.
B Danger-Hazardous
Voltage
The Hazardous Voltage label identifies the junction box as a hazardous
voltage area of the linear stage. To avoid injury be sure to follow LockoutTagout procedures before attempting maintenance on these linear stages.
C Danger-Strong
Magnets
The Strong Magnets label identifies non-ionizing radiation found in the
linear stage. Magnet channels inside the linear stage are constructed with
strong magnets. Strong magnets can disrupt the functionality of automatic
implantable cardioverter defibrillators (AICD); people with a pacemaker
should not work near the linear stage. Maintenance personnel working on
the linear stage should avoid the use of metallic tools and secure items
such as badge clip and other personal effects that could be attracted by the
strong magnets. Strong magnets can erase magnetic media. Never allow
credit cards or floppy disks to contact or come near the linear stage.
D Do Not Lift by
Junction Box
Do not attempt to move the linear stage by grasping the cable junction box.
Moving the linear stage in this manner will damage the linear stage and
create a pinch or crush hazard. The junction box is attached to the carriage,
which is free to move. Lifting the linear stage in this manner will allow
uncontrolled movement of the heavy base. Always use a two-person lift
and grasp the linear stage by the base at the end caps. Always keep
fingers clear of the carriage’s path of travel.
E Stay Clear
Do not put hands or objects on the linear stage cover. Doing so could
deform the cover and damage the linear stage, causing excessive wear on
the cover supports or scraping noises when the linear stage is in motion.
F Sharp Edges
Always remove strip seals before removing the top or side covers. If it
becomes necessary to remove the top or side covers or change the strip
seal, exercise care when working near or on the strip seal. The edges of
the strip seal are sharp and can cut if accidentally hit or if handled
inappropriately.
Safety Labels
To prevent injury and damage to the stage, review the safety labels and their
warning details and location before using the stage.
12 Rockwell Automation Publication CHPS-UM001D-EN-P - July 2014
Figure 1 - Warning Label Locations
H
A
Z
A
RDOUS
VOLTAGE
LOCK
O
U
T AND
TA
GO
U
T PO
WER
BEFO
R
E
SERVICING
DANGER
DANGER
M
A
G
NE
T
IC
F
I
E
LD
S
LOC
ATE
D
IN
T
HIS
A
R
E
A
Can
be
h
ar
m
ful
t
o
pac
em
ak
ers a
nd
ot
her
sen
si
t
i
ve
equ
i
pment
LIFT HAZARD
Two Person Lift
or carry required
DANGER
PINCH POINTS
Moving parts inside
Lockout /Tagout
A
E
F
B
D
F
C
See Safety Labels on page 12 to identify call out letters.
Stage Safety Chapter 1
Clearances
General Safety
Heat
Vertical or Incline Payload
End Cap Impacts
Install the stage to avoid interference with the building, structures, utilities, other
machines and equipment that can create a trapping hazard of pinch points.
Dress cables by using the Clearance Requirements
diagram on page 23 as a guide.
Do not cross the path of motion or interfere with the cable carrier motion.
Stages are capable of sudden and fast motion. Always Lockout-Tagout stage
systems before doing maintenance. Systems integrated with stages must contain
interlock mechanisms that prevent motion while users are accessing the stage.
Rockwell Automation is not responsible for misuse, or improper implementation
of their equipment.
When running the stage at its maximum rating, the temperature of the slide can
reach 75
ºC (167 ºF).
A vertically or inclined mounted stage does not maintain position with the power
removed. Under the influence of gravity, the slide and its payload falls to the low
end of travel. Design engineers must design in controlled power down circuits or
mechanical controls to prevent the stage and its payload from being damaged
when the power fails.
The internal bumpers of the stage are designed to absorb a large impact from
uncontrolled motion. The table on page 53
lists the energy that the bumpers can
absorb before risking damage to the stage. The payload must be secured to the
slide such that it does not sheer off in the event of an impact in excess of the
bumper ratings.
The bolts securing the end caps are not be able to sustain multiple impacts and
can eventually sheer. Correct the cause of the uncontrolled motion that caused
the impact before continuing the use of the stage.
Rockwell Automation Publication CHPS-UM001D-EN-P - July 2014 13
Chapter 1 Stage Safety
Air Freight Transportation
When air freighting stages special preparations and precautions must be taken.
The following information outlines the basic requirements at the publication
date of this document. However, regulations are subject to change and additional
area or carrier restrictions can be imposed. Check with your carrier or logistics
specialist regarding current local, regional, and national transportation
requirements when shipping this product.
The 200 mm or a 250 mm stages contain magnetized material, as classified by
International Air Transport Association (IATA) Dangerous Goods Regulations.
An IATA trained individual must be involved when shipping this product via
domestic or international air freight. Packing Instruction 902 provides
information regarding the preparation of this product for air transportation.
Follow these regulations for general marking and labeling requirements, the
application of Magnetized Material Handling Labels, and instructions for
preparing the Shipper's Declaration for Dangerous Goods.
As a minimum, refer to the following IATA Dangerous Goods Regulations:
• Subsection 1.5: Training
• Subsection 3.9.2.2: Classification as Magnetized Material
• Subsection 4.2: Identification as UN 2807, Magnetized Material, Class 9,
Packing Instruction 902
• Subsection 7.1.5: Marking
• Subsection 7.2: Labeling
• Subsection 7.4.1: Magnetized Material Label
• Section 8: Shipper’s Declaration for Dangerous Goods
Standards
Motor Model Identification
When shipped via ground in the United States, these products are not considered
a U.S. D.O.T. Hazardous Material and standard shipping procedures apply.
Standards and requirements applicable to this product include, but are not
limited to, the following:
• ANSI/RIA R15.06, Industrial Robots and Robot Systems Safety
Requirements - Teaching Multiple Robots
• ANSI/NFPA 79, Electrical Standard for Industrial Machinery
• CSA/CAN Z434, Industrial Robots and Robot Systems- General Safety
Requirements
• EN60204-1, Safety of Machinery. Electrical Equipment of Machines
The nameplate lists the motor model for the stage.
14 Rockwell Automation Publication CHPS-UM001D-EN-P - July 2014
Understanding Your Stage
Top ic Pa ge
Identifying the Components of Your Stage 16
Recommended Maintenance Interval 18
Identifying Your Stage 18
Chapter 2
Rockwell Automation Publication CHPS-UM001D-EN-P - July 2014 15
Chapter 2 Understanding Your Stage
4
1
5 (4x)
6
7 (2x)
8
9 (2x)
10
(4x)
2
(4x)
3
15
21
6
14
(4x)
13
12
11
17
16 (2x)
18
19
20
Identifying the Components of Your Stage
Use the diagrams and descriptions to identify individual stage components.
Figure 2 - Components of Your Linear Stage
16 Rockwell Automation Publication CHPS-UM001D-EN-P - July 2014
Component Description
Understanding Your Stage Chapter 2
Component
Number
1 Ground Screw and Ground Label Use the labeled M5 x 0.8 - 6H ground screw to connect to the linear stage to a facility safety ground.
2 Bearing Lubrication Ports These capped ports provide access to the linear bearings without dismantling the stage. In addition these tapped holes
3 Stage Slide Your application hardware mounts to this slide by using provide mounting holes.
4 Stage Cover If the strip seals are used this protective cover the stage has magnetic edges to keep the upper edge of the strip seals in
5 Seal Guide These guides lets the strip seal to move smoothly around the stage slide.
6 Cable Carrier Module Facilitates quick and easy replacement. Replace the cable carrier module every 10 million cycles.
7 Stage Side Cover If the strip seals are used this protective cover the stage has magnetic edges to keep the lower edge of the strip seals in
8 Side Cover Support These supports are used on long stages to stabilize the side cover.
9 Stainless Steel Strip Seal These replaceable, flexible stainless steel strips permit the stage to move while isolating the internal mechanism of the
10 Strip Seal Clamps These clamps hold the strip seal in place. When replacing the strip seals, they are used to position it so it lays smooth against
11 Index Mark Part of the encoder system that provides a home location for the encoder.
12 Optical Encoder Readhead This encoder readhead comes in various resolutions and requires little maintenance.
13 Encoder Scale Part of the encoder system that provides an optical pattern to be read by the encoder readhead. It must be kept free of
14 Bearing These support bearings guide the slide on the bearing rail, they require periodic lubrication.
15 Motor Coil This coil is part of the two piece linear motor. When excited by a linear drive, it generates magnetic forces that interact with
16 Bearing Rail These rails provide the linear track that the slide assembly rides on, they must be kept free of debris.
17 Magnet Track This track of powerful static magnets is the other half of a li near motor. LC line ar motor option shown. LZ linear motor option
18 Limit Blade Provides a mechanical trigger to the limit sensor.
19 Limit Sensor These optional sensors output a signal when the limit blade passes in front of them. The position of these sensors can be
20 Hall Sensor Module Three Hall sensors in this module are provide for commutation startup and phase alignment. They can also be use for
21 Bumper Stop These springs absorb slide and payload energy in the event the stage loses control. See page 53 for absorption limits.
Component Description
(M10 x 15. -6H) can be used to secure lifting hooks (not provided)
place.
place.
stage from environmental contaminants.
the top and side stage covers.
The TTL encoder option provides quadrature incremental position feedback with a differential signal on a RS-422.
The Sine/Cosine encoder option provides a 1 volt peak-to-peak sine and cosine output at a period of 20 μm. The Sine/Cosine
encoder is also known as an analog encoder.
contamination for proper operation.
the magnet track creating motion. LC linear motor option shown. LZ linear motors have a different configuration.
has a magnet channel.
adjusted to suit your application, see Operation Guidelines and Limit Configuration
trapezoidal commutation of the motor.
section on page 49.
Rockwell Automation Publication CHPS-UM001D-EN-P - July 2014 17
Chapter 2 Understanding Your Stage
IMPORTANT
Bulletin Number
Volt age
A= 230V AC
Frame Size
6= 150 mm base
Stroke
Travel lengths sta rt at 6 cm and are avai lable in 6 cm increme nts.
For example: 006 for 6 cm travel or 054 for 54 cm travel.
Maximum travel = 120 cm.
Motor
A= LZ-030-T-120-D
B= LZ-030-T-240-D
C= LZ-030-T-240-E
Feedback
F= 1.0 micron incremental optical encoder, with integral index mark
G= 0.5 micron incremental optical encoder, with integral index mark
H= 0.1 micron incremental optical encoder, with integral index mark
I= 1V p-p sine/cosine encoder, 20 μm signal period, with integral index mark
CHPS - A 6 054 A - F LM C 2 C
Cable Management and Termination
A = No Cabl es or Cable Carrie r (Slide Junc tion Box only)
B = Cables with Flying Leads and Cable Carrier
(1)
C = Cables with Kinetix MPF Connectors and Cable Carrier
(1)
D = Cables with D-Connec tors and Cable Car rier
(1)
Limits
2 = No limits
5 = Two end of travel limits
Protection
S = Covered with strip seals (IP 30)
(2)(3)
C = Covered without strip seals
(2)
O = Open without any cover, without strip seals
LM Specifier
LM = Linear Motor
Recommended Maintenance Interval
Identifying Your Stage
Under normal stage use, follow these lubrication guidelines.
You determine the frequency of re-lubrication that is best suited to your
application as an application's environment, motion profile, and duty cycle
can effect the re-lubrication time period required.
Lubricate the stage every 6 months or 2500 km (1550 mi) of travel, which ever
comes first. Use the MPAS grease gun kit and grease cartridge (catalog numbers
MPAS-GPUMP and MPAS-CART respectively). See maintenance section for
lubrication procedures.
Refer to Maintenance beginning on page 59
for lubrication procedures.
Use the following key to identify the options that your stage is equipped with. Be
sure the information listed on the purchase order correlates to the information on
the packing slip that accompanied your stage components. Inspect the assemblies
and confirm, if applicable, the presence of specified options.
18 Rockwell Automation Publication CHPS-UM001D-EN-P - July 2014
Bulletin Number
Volt age
A= 230V AC
B= 460V AC (LC motors only)
Frame Size
8= 200 mm base
Stroke
For -100 and -120 motor coil lengths
Travel lengths start at 6 cm and are available in 6 cm increments.
For example: 006 for 6 cm travel or 054 for 54 cm travel.
Maximum travel = 126 cm.
Travel lengths start at 8 cm and are available in 6 cm increments.
For -200 or -240 motor coil lengths.
For example: 008 for 8 cm travel or 020 for 20 cm travel.
Maximum travel = 122 cm.
Motor
A= LZ-030-T-120-D E= LC-050-200-D
B= LZ-030-T-240-D F= LC-050-200-E
C = LZ-030-T-240-E
D= LC-050-100-D
Cable Management and Termination
A = No Cables or Cable Carrier (Slide Junction Box only)
B = Cables with Flying Leads and Cable Carrier
(1)
C = Cables with Kinetix MPF Connectors and Cable Carrier
(1)
D = Cables with D-Connectors and Cable Carrier
(1)
Limits
2 = No limits
5 = Two end of travel limits
Protection
S = Covered, with strip seals (IP 30)
(2)(3)
C = Covered, without strip seals
(2)
O = Open, without cover, without strip seals
LM Specifier
LM = Linear Motor
Feedback
F = 1.0 micron incremental optical encoder, with integral index mark
G = 0.5 micron incremental optical encoder, with integral index mark
H = 0.1 micron incremental optical encoder, with integral index mark
I = 1V p-p sine/cosine encoder, 20 μm signal period, with integral
index mark
Bulletin Number
Volt age
A= 230V AC
B= 460V AC (LC motors only)
Frame Size
9= 250 mm base
Stroke
Travel lengths start at 8 cm and are available in 6 cm increments.
For example: 008 for 8 cm travel or 020 for 20 cm travel.
Maximum travel = 122 cm.
Motor
G = LZ-050-T-120-D
H = LZ-050-T-240-D
I = LZ-050-T-240-E
J = LC-075-100-D
K = LC-075-200-D
L = LC-075-200-E
Cable Management and Termination
A = No Cabl es or Cable Carrie r (Slide Junc tion Box only)
B = Cables with Flying Leads and Cable Carrier
(1)
C = Cables with Kinetix MPF Connectors and Cable Carrier
(1)
D = Cables with D-Connectors and Cable Carrier
(1)
Limits
2 = No limits
5 = Two end of travel limits
Protection
S = Covered, with strip seals (IP 30)
(2)(3)
C = Covered, without strip seals
(2)
O = Open, without cover, without strip seals
LM Specifier
LM = Linear Motor
Feedback
F = 1.0 micron incremental optical encoder, with integral index mark
G = 0.5 micron incremental optical encoder, with integral index mark
H = 0.1 micron incremental optical encoder, with integral index mark
I = 1V p-p sine/cosine encoder, 20 μm signal period, with integral
index mark
CHPS - A 8 054 F - F LM C 2 C
CHPS - A 9 054 G - F LM C 2 C
(1) Not for upside down mounting.
(2) Contact Applications Engineering for upside down mounting.
(3) Strip seal and covers required for wall mount applications.
Understanding Your Stage Chapter 2
Rockwell Automation Publication CHPS-UM001D-EN-P - July 2014 19
Chapter 2 Understanding Your Stage
Notes:
20 Rockwell Automation Publication CHPS-UM001D-EN-P - July 2014
Chapter 3
Planning the Stage Installation
Top ic Pa ge
Stage Mounting Requirements 21
General Safety Standards for Stage Installations 21
Mounting Restrictions 21
Environmental Factors 22
Mounting Surface Restrictions 22
Clearance Requirements 23
Stage Mounting Requirements
Requirements to be met when mounting your CHPS-Series stage include the
following.
General Safety Standards for Stage Installations
General safety standards and requirements include, but are not limited to, the
following:
• ANSI/RIA R15.06, Industrial Robots and Robot Systems Safety
Requirements - Teaching Multiple Robots
• ANSI/NFPA 79, Electrical Standard for Industrial Machinery
• CSA/CAN Z434, Industrial Robots and Robot Systems- General Safety
Requirements
• EN60204-1, Safety of Machinery. Electrical Equipment of Machines
Mounting Restrictions
When locating your CHPS-Series stage include the following.
• Environmental Factors
• Mounting Surface Restrictions
• Mounting Orientation
• Clearance Requirements
Rockwell Automation Publication CHPS-UM001D-EN-P - July 2014 21
Chapter 3 Planning the Stage Installation
Environmental Factors
Factor Applicability
Temperature The stage does not require any special cooling considerations. Avoid mounting it near any
Humidity Avoid excessive humidity. Condensation on metal surfaces can cause stage corrosion. The
Access and Interference When possible, locate the system where sufficient working space is available to per form
Dust and airborne
contaminants
Vibration Install the stage in a location free of excessive vibration.
Ambient Light Have sufficient light readily available to enable inspection, testing and other functions to
heat generating objects, such as a heat register. Sustained average temperature must not
be greater than 40 °C (104 °F), nor less than 0 °C (32 °F).
maximum permissible humidity is 80% relative.
periodic maintenance.
Avoid installing where a trapping hazard or pinch point occurs as a result of interference
with the building, structures, utilities, and other machines and equipment.
Avoid placing the stage in areas where excessive dust or other airborne contaminants are
present. Chemical fumes or vapors can cause damage to internal components.
be performed on the stage.
Mounting Surface Restrictions
Mounting Orientation Restriction
Surface Stages are to be bolted or clamped to a flat, stable, and rigid surface along its entire
Ceiling - inverted surface A ceiling mount (inverted on a horizontal sur face) is not recommended. Stages mounted
Wall - horizontal Horizontal wall mount stages must be installed with the cable carrier below the stage.
Wall - vertical or incline Stages mounted vertically on a wall must have a tr avel of 1 m ( 3.28 ft) o r less. Sta ges with
length. Flatness deviation in the mounting surface must be less than or equal to
0.025 mm over a 300 x 300 mm (0.001 in. over a 12 x 12 in.) area.
Flatness must be maintained during operation of the stage.
in this orientation are subject to premature cable carrier failure.
Stages mounted horizontally on a wall must have a travel of 1m (3.28 ft) or less. Stages
with a travel length greater than 1 m (3.28 ft) are subject to premature cable carrier
failure.
a travel length greater than 1 m (3.28 ft) are subject to premature cable carrier failure.
22 Rockwell Automation Publication CHPS-UM001D-EN-P - July 2014
Planning the Stage Installation Chapter 3
Covered Stage: 419 mm (16.5 in.)
Clearance on Both Ends for Lubrication Access
Uncovered Stage: 3.2 mm (0.125 in.)
Clearance All Around
Cabling: 19 mm (0.75 in.) Clearance for Cable Routing
Clearance Requirements
The figures depict the minimum clearances for each stage type.
Power and feedback cables can impose additional clearance requirements. Refer
to Interconnect Cables
Figure 3 - Minimum Clearance Requirements
on page 85 for connector and bend radius requirements.
Rockwell Automation Publication CHPS-UM001D-EN-P - July 2014 23
Chapter 3 Planning the Stage Installation
Notes:
24 Rockwell Automation Publication CHPS-UM001D-EN-P - July 2014
Chapter 4
IMPORTANT
Mounting the Stage
Top ic Pag e
Unpacking, Handling, and Inspection 25
Unpacking Procedure 26
Store Packaging Material 28
Stage Storage 28
Mounting the Stage 28
Before You Begin the Mechanical Installation 28
Determine the Number of Fasteners Required 28
Determine the Type of Fastener to Use 29
Mounting the Stage 31
Mount Your Application 32
Unpacking, Handling, and Inspection
Any person that teaches, operates, maintains, or repairs these stages must
be trained and demonstrate the competence to safely perform the assigned
task.
Inspect packaging to make certain no damage occurred in shipment. Document
any damage or suspected damage. Claims for damage due to shipment are usually
made against the transportation company. If you suspect damage, contact
Rockwell Automation immediately for further advice.
Be sure the information listed on the purchase order correlates to the information
on the packing slip for your stage and its accessories.
Rockwell Automation Publication CHPS-UM001D-EN-P - July 2014 25
Chapter 4 Mounting the Stage
Users Manual
Packing End Caps
Desiccant
Inspect the assemblies and confirm, if applicable, the presence of specified
options.
ATT EN TI ON : Linear motor driven stages contain powerful permanent magnets
that require extreme caution during handling. Do not disassemble the stage.
The forces generated by permanent magnets are very powerful and can cause
bodily injury.
Persons with pacemakers or automatic implantable cardiac defibrillators (AICD)
must maintain a minimum distance of 0.3 m (12 in.) from magnet assemblies.
Additionally, unless absolutely unavoidable, a minimum distance of 1.5 m (5 ft)
must be maintained between magnet assemblies and other magnetic or ferrous
composite materials. Calipers, micrometers, laser equipment, and other types of
instrumentation must be nonmetallic.
Unpacking Procedure
The following tools are recommended for unpacking the stage:
• Utility knife
• 2.5mm, 5mm, and 6mm hex keys
• Packing tape
1. Place carton on flat stable surface with the tape seam side facing you.
2. Use a utility knife to score the packing tape on the edges of the carton.
3. Lift center cover to reveal the stage.
4. Remove the packing end caps.
ATT EN TI ON : Never attempt a single-person lift. Personal injury and equipment
damage can occur if the linear stage is handled improperly.
26 Rockwell Automation Publication CHPS-UM001D-EN-P - July 2014
Mounting the Stage Chapter 4
Support Straps
1/4 1/4 1/4 1/4
End Cap End Cap
Shipping Brace
M6 x 30 SHCS (2x) for
CHPS-x6xxxx-xLxxx (150 mm)
M8 x 30 SHCS (2x) for
CHPS-x8xxxx-xLxxx (200 mm) and
CHPS-x9xxxx-xLxxx (250 mm)
Shipping Clamp
M3 SHCS, washer, and nut (4x)
M6 x 75 SHCS (2x) for
CHPS-x6xxxx-xLxxx (150 mm)
M6 x 75 SHCS (2x) for
CHPS-x8xxxx-xLxxx (200 mm) or
CHPS-x9xxxx-xLxxx (250 mm)
5. Remove the linear stage from the packaging supports.
• For stages shorter than 1 meter (39.3 in.), use two people and lift the
linear stage by grasping the base near the end caps only.
• For stages 1 meter (39.3 in.) or longer, use support straps at the 1/4
and 3/4 length points to avoid distorting the base. Use this support
system whenever the linear stage must be lifted.
6. Move the linear stage to a solid support surface before removing the
shipping brace.
ATT EN TI ON : The carriage is free to move once the shipping brace is removed.
Use additional care when handling the linear stage after the brace is removed.
Unexpected carriage movement can cause personal injury.
7. Remove the four socket head cap screws (SHCS) from the shipping brace.
8. Lift the shipping brace off the stage and set it aside.
10. Remove the four SHCS that secure the shipping clamp.
Rockwell Automation Publication CHPS-UM001D-EN-P - July 2014 27
9. Remove the plastic wrap enclosing the stage and set it aside.
Chapter 4 Mounting the Stage
fasteners
stroke (cm) 26 (cm)+
12
----------------------------------------------------------
round down + 1
2×=
fasteners
stroke (cm) 30 (cm)+
12
-----------------------------------------------------------
round down +1
2×=
11. Remove the four square nuts loosened in the previous step, by sliding each
nut to the end of channel.
Store Packaging Material
Keep the carton in case the unit needs to be returned for warranty service or
stored for an extended period of time.
1. Tape screws and clamp hardware to the shipping brace.
2. Put end caps in their original positions on the center cover and place all
packing material inside the carton.
3. Lightly tape carton closed and store in dry place.
Stage Storage
Mounting the Stage
Store the stage in area that is clean, dry, vibration free, and at a relatively constant
temperature. Refer to Environmental Specifications for CHPS-Series Stage on
page 75
for more detailed information.
This section discusses mounting methods for your stage.
Before You Begin the Mechanical Installation
The machine designer is most qualified to determine the number and type of
fasteners to use for mounting the stage. The following information is a guide for
the decision-making process.
Determine the Number of Fasteners Required
The length of the stage determines the number of mounting fasteners that are
required.
Use one of the following equations to calculate the required mounting hardware.
Figure 4 - Fasteners Required for Stages with 150 mm and 200 mm frame size (CHPS-x6xxxxxLMxxx and CHPS-x8xxx-xLMxxx)
Figure 5 - Fasteners Required for Stages 250 mm frame size (CHPS-x9xxx-xLMxxx)
or example, if you are mounting an CHPS-B8194F-ALM02C stage.
28 Rockwell Automation Publication CHPS-UM001D-EN-P - July 2014
Mounting the Stage Chapter 4
fasteners 19 1+202× 40 fasteners===
fasteners
194 cm + 36
12
----------------------------------
230
12
--------- 1 9 . 1 6 7===
round down 19=
1940 mm stroke length = 194.0 cm
Determine the Type of Fastener to Use
Three types of fasteners that can be used to mount the stage.
• Through bolts
• Toe clamps
• Tee nut or square nut
Toe clamps are supplied with the catalog number CHPS-x6xxx stages, and
covered types of the catalog number CHPS-x8xxx and CHPS-x9xxx stages.
Refer to the Mounting Fastener Options
type.
table for an illustration of each fastener
Table 1 - Mounting Fastener Options
Tor que
Fastener Order Illustration User Supplies
(1)
Through B olt
Toe clamps MPAS-TOE M6 x 1.0 x 16 mm min Covered stages 5.5 (48)
(2)
MPAS-x-TNUT
Tee nuts
– M5 x 1.0 x 16 mm min Uncovered stages 2.3 (30)
(3)
M6 x1.0 Securing a stage from
(4)
Recommended For
beneath the mounting
surface.
N•m (lbf•in)
Tee Nut 6.7 (60)
Square Nut 2.3 (30)
(1) Through bolt mounting is not an option for catalog number CHPS-x6xxxx-xLMxxx (150 mm) stages.
(2) The tee nut mount for a catalog number CHPS-x8xxxx-xxxxx (200 mm) stage is a square nut in a tee slot.
(3) Where x is the frame size of a stage, 6 = CHPS-x6xxxx-xxxxx (150 mm), 8 = CHPS-x8xxxx-xxxxx (200 mm), 9 = CHPS-x9xxxx-xxxxx (250 mm).
(4) You supply the bolts.
Rockwell Automation Publication CHPS-UM001D-EN-P - July 2014 29
Chapter 4 Mounting the Stage
IMPORTANT
120 mm
(4.72 in.)
Figure 6 - Through Bolt Mounting
Through bolt mounting is not available for the catalog number
CHPS-x6xxxx-xxxxx (150 mm) stages.
An uncovered stage is a good candidate for through bolt mounting.
For covered stages, toe clamps are the easiest method for mounting. On sides of
the base secure a toe clamps every 120 mm (4.72 in) by using M6 SHCS as shown
in the Toe Clamps Mounting
diagram. Use slots formed into outside edge of the
stage base.
Figure 7 - Toe Clamps Mounting
30 Rockwell Automation Publication CHPS-UM001D-EN-P - July 2014
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