Rockwell Automation CHPS-250 User Manual

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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

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

RDOUS

VOLTAGE

LOCK

T AND

T PO

WER

BEFO

SERVICING

DANGER

M A

G NE

T IC F

I E LD

LOC

ATE

D IN

T HIS

A R E

Can

be h

ar m

ful t

pac em

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

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

5 (4x)

7 (2x)

9 (2x)

(4x)

16 (2x)

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.

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)+

----------------------------------------------------------





round down + 1





2×=

fasteners

stroke (cm) 30 (cm)+

-----------------------------------------------------------





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

----------------------------------

230

--------- 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

Mounting the Stage Chapter 4

IMPORTANT

T-Slots

Tee nuts are used to mount the stage from underneath. Insert the tee nuts every 120 mm (4.72 in.) in tee slots on the bottom of the unit. Secure the tee nuts by using M6 SHCS as shown in Te e Nu t M ou nt in g

Figure 8 - Tee Nut Mounting

diagram.

Mounting the Stage

Follow these steps to install a stage on its mounting surface.

1. Be sure the mounting surface is clear of any and all foreign material.

Do not use abrasives to clean the surface.

If necessary, stone the mounting surface (acetone or methanol can be applied as cleaning agent).

2. Verify that the flatness of the surface that the stage is to be mounted.

The total indicator reading (TIR) is 0.0254 mm (0.001 in.) per 300 mm (120 in.). TIR or runout, correlates to an overall flatness of a surface.

3. Lift the stage onto the prepared mounting surface

ATT EN TI ON : Do not attempt to move the stage by grasping the cable junction box. Moving the stage in this manner can damage the stage and create a pinch or crush hazard. The junction box is attached to the carrier that is free to move. Lifting the stage in this manner causes uncontrolled movement of the heavy base. Always use a two person lift and grasp the stage by the base at the end caps keeping fingers clear of the carrier’s path of travel.

The two lubrication ports on each end cap (four total) are M10 x1.5 tapped through holes and can be used to install lifting hooks supplied by the customer.

Personal injury and equipment damage can occur if stage is handled improperly.

Rockwell Automation Publication CHPS-UM001D-EN-P - July 2014 31

Chapter 4 Mounting the Stage

4. Align the stage on the mounting surface, and insert the correct number of mounting bolts. Refer to CHPS-Series Stage Dimensions beginning on

page 77

for detailed mounting dimensions.

5. Secure the stage by using all mounting holes. Torque bolts to the values shown in the Mounting Fastener Options

table on page 29.

Mount Your Application

Mount your application to the slide by using the following bolts and torque values:

Cat. No. Bolt Torque

N•m (lb•in)

CHPS-x6xxxx-xLMxxx M6 3.2 (48)

CHPS-x8xxxx-xLMxxx M8 10.1 (90)

CHPS-x9xxxx-xLMxxx M8 10.1 (90)

32 Rockwell Automation Publication CHPS-UM001D-EN-P - July 2014

Connector Data

Top ic Pag e

Kinetix Servo Drive Compatible Connectors 34

D-Type Connectors 35

Flying Leads 36

Junction Box Connectors 37

Limit Sensor Flying Leads 38

Chapter 5

Rockwell Automation Publication CHPS-UM001D-EN-P - July 2014 33

Chapter 5 Connector Data

Mating Cable: Allen-Bradley 2090-XXNPMF-16Sxx

Intercontec P/N BKUA090NN000550003500

Intercontec P/N AKUA034NN00100035000

Mating Cable: Allen-Bradley 2090-XXNFMF-Sxx

Kinetix Servo Drive Compatible Connectors

Pin Color Wire

1 Yellow A+ TTL - Differential Sin+ Analog Differential 1V p-p

2 White/yellow A- TTL - Differential Sin- Analog Differential 1V p-p

3 Brown B+ TTL - Differential Cos+ Analog Differential 1V p-p

4 White/Brown B- TTL - Differential Cos- Analog Differential 1V p-p

5 Violet Index Mark+ TTL - Differential Index+ Differential Pulse 1V p-p

6 White/Violet Index Mark- TTL - Differential Index- Differential Pulse 1V p-p

7 Reserved — — Reserved —

8 Reserved — — Reserved —

9 White/Red +5V DC Encoder and Hall Sensor Power +5V DC Encoder and Hall Sensor Power

10 Black Common — Common —

11 Reserved — — Reserved —

13 Green PTC Temp+

14 White/Black Common — Common —

15 White/Green S1 TTL - Trapezoidal Hall S1 TTL - Trapezoidal Hall

16 Blue S2 TTL - Trapezoidal Hall S2 TTL - Trapezoidal Hall

17 White/Blue S3 TTL - Trapezoidal Hall S3 TTL - Trapezoidal Hall

Case Shield Shield — Shield —

The following tables identify the power and feedback pinouts for the Intercontec circular connectors for use with standard Allen Bradley connectors.

Pin Color Signal

ARed U (A) Phase

B White V (B) Phase

CBlack W (C) Phase

D Green/Yellow Ground

Case Shield Cable Shield

With Incremental Encoder With Analog Encoder

Signal Designations

(1)

Signal Description

PTC Thermistor PTC Temp+

Signal Designations

(1)

Signal Description

PTC Thermistor

(1) PTC Temp- is connected to Common.

34 Rockwell Automation Publication CHPS-UM001D-EN-P - July 2014

Connector Data Chapter 5

A2 A3

Positronic P/N CBD9W4M20000-1702.0 Mating Connector:

Positronic P/N CBD9W4F20000-1701.0

Connector Part Number AMP P/N 207464-2 Mating Connector Part Number AMP P/N 5205207-1

D-Type Connectors

Pin Color Wire

1 Yellow A+ TTL - Differential Sin+ Analog Differential 1V p-p 2 Brown B+ TTL - Differential Cos+ Analog Differential 1V p-p 3 Violet Index Mark + TTL - Differential Index+ Differential Pulse 1V p-p 4 White/Red +5V DC Encoder and Hall Sensor Power +5V DC Encoder and Hall Sensor Power 5Reserved — — — — 6 7 8 9 White/Green S1 TTL - Trapezoidal Hall S1 TTL - Trapezoidal Hall 10 Green PTC Temp+ 11 Reserved — — — — 12 White Blue S3 TTL - Trapezoidal Hall S3 TTL - Trapezoidal Hall 13 Green/Yellow Shield — Shield 14 White/Yellow A- TTL - Differential Sin- Analog Differential 1V p-p 15 White/Brown B- TTL - Differential Cos- Analog Differential 1V p-p 16 White/Violet Index Mark- T TL - Differential Index- Differential Pulse 1V p-p 17 Black,

White/Black 18 Reserved — — — — 19 20 21 22 Blue S2 TTL - Trapezoidal Hall S2 TTL - Trapezoidal Hall 23 Reserved — — — — 24 25

(1) PTC Temp- is connected to Common.

The following tables identify the power and feedback pinouts for D-shell connectors that enable custom cables to be used.

Pin Color Signal

A1 Red U (A) phase

A2 White V (B) phase

A3 Black W (C) phase

A4 Green/Yellow Ground

Case Shield Cable Shield

With Incremental Encoder With Analog Encoder Signal

Designations

(1)

Common — Common —

Signal Description Signal Designations Signal Description

PTC Thermistor PTC Temp+* PTC Thermistor

Rockwell Automation Publication CHPS-UM001D-EN-P - July 2014 35

Chapter 5 Connector Data

Flying Leads

The following tables identify the power and feedback pinouts for flying lead this option lest you to use your own connectors.

ATT EN TI ON : Disconnect input power supply before installing or servicing stage

Stage lead connections can short and cause damage or injury if not well secured and insulated.

Insulate the connections, equal to or better than the insulation on the supply conductors.

Properly ground the stage as described in the drive manual.

Color Signal

Red U (A) phase

White V (B) phase

Black W (C) phase

Green/Yellow Ground

Shield Cable Shield

With Incremental Encoder With Analog Encoder

Color Wire

Yellow A+ TTL - Differential Sin+ Analog - Differential 1V p-p

White/Yellow A- TTL - Differential Sin- Analog - Differential 1V p-p

Brown B+ TTL - Differential Cos+ Analog - Differential 1V p-p

White/Brown B- TTL - Differential Cos- Analog - Differential 1V p-p

Violet Index Mark+ TTL - Differential Index+ Differential Pulse 1V p-p

White/Violet Index Mark- TTL - Differential Index- Differential Pulse 1V p-p

Red +5V Encoder and Hall Sensor Power +5V Encoder and Hall Sensor Power

White/Red +5V Encoder and Hall Sensor Power +5V Encoder and Hall Sensor Power

Black Common — Common —

White/Black Common — Common —

Green PTC Temp+

White/Green S1 TTL - Trapezoidal Hall S1 TTL - Trapezoidal Hall

Blue S2 TTL - Trapezoidal Hall S2 TTL - Trapezoidal Hall

White/Blue S3 TTL - Trapezoidal Hall S3 TTL - Trapezoidal Hall

Green/Yellow Shield — Shield —

(1) PTC Temp- is connected to Common.

Signal Designations

(1)

Signal Description

PTC Thermistor PTC Temp+

Signal Designations

Signal Description

(1)

PTC Thermistor

36 Rockwell Automation Publication CHPS-UM001D-EN-P - July 2014

Connector Data Chapter 5

Pin 1

Signals from slide

To exible feedback cable

ENCA+ ENCB+ INDEX+ POSLIM

HALLS3

GND SHIELD

GND

HALLS2

SHIELD

ENCB-

ENCA-

INDEX-

HALLS1

SHIELD HALLS3 ENCA+ ENCB+ INDEX+ POSLIM

GND HALLS1 HALLS2 ENCAENCBINDEXNEGLIM 5V TEMP+

NEGLIM

GND

TEMP+

1 2 3 4 5 6 7 8 9 10 11 12

1 2 3 4 5 6 7 8

9 10 11 12 13 14 15 16

TP1

Shield terminates to mounting hole

Header 2X3, Right Angle

Header 2X6 Right Angle

Header 2, Right Angle

Header 2x8, Vertical

Junction Box Connectors

The following diagram and tables identify the power and feedback pinouts of the junction box connector, use this information to make custom cables

Item Description

A J1 Feedback connector, output to flex cable, Mating connector is a Molex P/N 43025-1600

B J2 Thermistor signal connector, the input from side

C J3 Hall signal connector, input from side

D J4 Encoder signal connector, input from side

E Mating power connector AMP 359780-1

Rockwell Automation Publication CHPS-UM001D-EN-P - July 2014 37

Chapter 5 Connector Data

Pin With Incremental Encoder With Analog Encoder

1Shield— Shield —

2 S3 TTL - Trapezoidal Hall S3 - TTL - Trapezoidal Hall

3 A+ TTL - Differential Sin+ Analog - Differential 1V p-p

4 B+ TTL - Differential Cos+ Analog - Differential 1V p-p

5 Index Mark+ TTL - Differential Index+ Differential Pulse 1V p-p

8 Common — Common —

9 S1 TTL - Trapezoidal Hall S1 TTL - Trapezoidal Hall

10 S2 TTL - Trapezoidal Hall S2 TTL - Trapezoidal Hall

11 A- TTL - Differential Sin- Analog - Differential 1V p-p

12 B- TTL - Differential Cos- Analog - Differential 1V p-p

13 Index Mark- TTL - Differential Index- Differential Pulse 1V p-p

15 +5V Encoder and Hall Sensor Power +5V Encoder and Hall Sensor Power

16 PTC Temp+

Table 2 - Junction Box Power Connector

Pin Color Signal

1Red U (A) phase

2 White V (B) phase

3 Black W (C) phase

4 Green/Yellow Ground

Table 3 - Junction Box J1 Connector

Signal Designation Signal Description Signal

(1)

PTC Thermistor PTC Temp+

Designation

Signal Description

(1)

PTC Thermistor

(1) PTC Temp- is connected to Common.

Limit Sensor Flying Leads

The limit sensor option comes with flying leads, regardless of the power and feedback termination option ordered.

Color Signal Description

Brown +V

Black Load+

Blue 0V

(1) Load- is connected to 0V.

(1)

38 Rockwell Automation Publication CHPS-UM001D-EN-P - July 2014

Chapter 6 Connecting the Stage

Top ic Page

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

Connecting the Stage

The installation procedure assumes you prepared your system for correct electrical bonding and understand the importance of electrical bonding for correct operation of the system. If you are unfamiliar with electrical bonding, the section Attaching the Ground Strap and Interface Cables

briefly describes and

illustrates correct system grounding techniques.

ATT EN TI ON : Plan the installation of your stage so that you can perform all cutting, drilling, tapping, and welding with it removed. Be careful to keep any metal debris from falling into it. Metal debris or other foreign matter can become lodged in the stage, that can result in damage to components.

SHOCK HAZARD: To avoid hazard of electrical shock, perform all mounting and wiring of the stage prior to applying power. Once power is applied, connector terminals can have voltage present even when not in use.

Rockwell Automation Publication CHPS-UM001D-EN-P - July 2014 39

Chapter 6 Connecting the Stage

M5 x 0.8 -6H Ground Screw

Braided Ground Wire 12 mm (0.5 in) min.

Lug

Attaching the Ground Strap and Interface Cables

The only electrical connections necessary between the stage and the drive system are the ground strap and the two cables.

1. For electrical safety, connect the ground screw on the chassis of the stage to the ground bus for your system.

To reduce the effects of electromagnetic interference (EMI), bond the stage with a braided ground strap, 12 mm (0.5 in.) wide minimum, to a grounded metal surface. This creates a low-impedance return path for high-frequency energy.

2. Torque the ground screw at the stage to 2 N•m (18 lb•in)

3. Form a drip loop in each cable at a point directly before it attaches to the

stage. Refer to the Connecting Kinetix Type Motor and Feedback Cables diagram for a visual example.

ATTENTION: Be sure that cables are installed and restrained to prevent uneven tension or flexing at the cable connectors.

Excessive and uneven lateral force at the cable connectors can result in the connector’s environmental seal opening and closing as the cable flexes.

Failure to observe these safety procedures could result in damage to the motor and its components.

40 Rockwell Automation Publication CHPS-UM001D-EN-P - July 2014

Connecting the Stage Chapter 6

Align flat surfaces.

Power Connector

Feedback Connector

Cable Drip Loop

4. Attach the feedback cable, and the power cable to the stage.

ATTENTION:

Do not connect or disconnect the stage feedback cable, or the power cable while power is applied to them. Inadvertent pin connections can result in unexpected motion or result in irreversible damage to the components.

For Kinetix type connectors. a. Carefully align each cable connector with the respective motor

connector as shown in Figure 1.

b. Do not apply excessive force when mating the cable and stage

connectors. If the connectors do not go together with light hand force, realign and try again.

ATTENTION: Be sure that cables are installed and restrained to prevent uneven tension or flexing at the cable connectors. Excessive and uneven lateral force at the cable connectors can result in the connector’s environmental seal opening and closing as the cable flexes. Failure to observe these safety procedures could result in damage to the motor and its components.

c. Hand tighten the knurled collar five to six turns to fully seat each

connector.

Figure 9 - Connecting Kinetix Type Motor and Feedback Cables

ATTENTION: Keyed connectors must be properly aligned and hand-

tightened the recommended number of turns.

Improper alignment is indicated by the nee d for excessive force, such a s the use of tools, to fully seat connectors.

Connectors must be fully tightened for connector seals to be effective.

Failure to observe these safety procedures could result in damage to the motor, cables, and connector components.

Rockwell Automation Publication CHPS-UM001D-EN-P - July 2014 41

Chapter 6 Connecting the Stage

Thermal Protection

Connect the stage PTC thermistor signal to the drive or control system to create a thermal protection system.

PTC Thermistor Signal Characteristics

Temperature °C (°F) Resistance in Ohms

Up to 100 (212) ≤ 750 Up to 105 (221) ≤ 7500 Up to 110 (221) ≥ 10,000

ATT EN TI ON : PTC thermistor supplies a signal that indicates the stage temperature limit condition. Connect this signal to control system or drive system so it shuts down the stage power upon reaching a limit condition. Multiple levels of stage thermal protection are strongly recommend.

The following thermal protection methods are also recommended.

• Typically digital drives use RMS current protection and or estimated

temperature vs. time (I

T) software protection schemes. Activated and set these available features according to the stage model ratings for your application.

• Set the maximum value of ± peak-current-magnitude limits of your drive to the stage’s peak-current rating.

• For drives without stage protection features, install stage fuses (current rating not to exceed stage continuous RMS) according to local and National Electrical Code. Uses time-delay type fuses that are rated for the drive PWM output voltage.

42 Rockwell Automation Publication CHPS-UM001D-EN-P - July 2014

Connecting the Stage Chapter 6

Main Circuit

Brown

Black

Blue

+V com

+ V

Limit

Adjustable Positive OT Limit on this side

Limit Sensor cables exit here

Adjustable Negative OT Limit on this side

Optional Limit Sensors

Two limit sensors, positive overtravel (OT) and negative OT, provide electrical protection for stage overtravel. Their physical location is shown in Component

Description diagram on page 16 they and can be adjusted up to 30 mm (1.2 in.)

toward the center of travel. The electric characteristics are shown here.

• Input Power: 12

…28V DC, 15 mA circuit draw + 50 mA maximum

sourcing = 65 mA total.

• Output: PNP, Open collector Normally Closed, 50 mA maximum sourcing.

Figure 10 - Limit Sensor Orientation

Rockwell Automation Publication CHPS-UM001D-EN-P - July 2014 43

Chapter 6 Connecting the Stage

Counter clock frequency (MHz)

encoder velocity m s⁄()

resolution μm()

------------------------------------ -----------------------

4× (safety factor)=

Incremental 2 channels A and B in quadrature (90° phase shifted)

Quadrature edge separation

Reference

Index Mark pulse in synchronised to one position count. Repeatability of position (uni-directional) is maintained if temperature is 15…35 °C (59…95 °F) and speed is <250 mm/s (9.8 in./s).

ENC A+ ENC B+

Index Mark +

Drive or Controller

Standard RS422A line receive circuit

Square wave dierential line driver to EIA RS422A

120 Ω

(1)

Readhead ENC A +, ENC B +, & Index Mark +

ENC A -, ENC B -, & Index Mark -

TTL Differential Encoder Output Signal

Use the following information to connect a stage with a TTL Differential Encoder.

The incremental encoder typically have the following quadrature edge separation.

Encoder Typical Edge Separation @ Maximum Velocity

μm ns m/s

1 100 5

0.5 90 3

0.1 90 0.7

(1) Speeds based on 3 m maximum cable length and a minimum readhead input of 5V.

To calculate the minimum recommended counter frequency for 1

0.5

μm encoders, use the following formula.

The minimum recommend counter frequency for the 0.1

Figure 11 - TTL Differential Encoder Timing Diagram

μm encoder is 12 MHz.

(1)

μm and

44 Rockwell Automation Publication CHPS-UM001D-EN-P - July 2014

Figure 12 - TTL Differential Encoder Termination

(1) Total termination resistance in ohms.

Connecting the Stage Chapter 6

Incremental 2 channels V1 and V2 dierential sinusoids in quadrature (90° phase shifted)

Dierential pulse V0 - 18°…108° Duration 126° (electrical) Repeatability of position (uni-directional) is maintained if temperature is 15…35 °C and speed is <250 mm/s

Reference

20 μm

90°

0.6 …1.2V p-p with green LED indication and 120 Ω termination

108º

-18º 0º

Sine = (V1+)-(V1-)

Cosine = (V2+)-(V2-)

0.8…1.2V p-p

(V0+) -(V0-)

Readhead

Drive or Controller

120 Ω

(1)

ENC A +, ENC B +, & Index Mark +

ENC A -, ENC B -, & Index Mark -

Sine/Cos Encoder Output Signals

Use the following information to connect a stage with a Sine/Cosine Encoder option to a drive or controller that processes sine/cosine position feedback.

The sine/cos encoder amplitude is 0.90V p-p minimum up to 2 meters per second. 0.60V p-p up to 4 meters per second.

Figure 13 - Sine/Cos Encoder Timing

Recommended termination = 120 Ω resistors, V0, V1, V2.

Figure 14 - Sine/Cos Encoder Termination

(1) Total termination resistance in ohms.

Rockwell Automation Publication CHPS-UM001D-EN-P - July 2014 45

Chapter 6 Connecting the Stage

Hall S1 Hall S2 Hall S3

Hall Signal

Drive

Isink

Isink = 10 mA Maximum Rp = External pull-up resistor

Hall Effect Circuit

Motor and Hall Phasing and Sequence

Use the following information to connect the Hall Effect circuit to your servo drive.

• Input power: 5

• Output: NPN, Open Collector, 10 mA maximum

Consult drive manual or supplier for wiring instructions for your drive. Motor wiring is phase and commutation sensitive. Motor Phasing Diagram standard phase and sequence relationship of the motor when phased in the positive direction. The Hall signals are used by a compatible three-phasebrushless servo drive to perform electronic commutation. Two types of servo drive Hall-based commutation techniques are possible, Trapezoidal Hall Mode and Encoder Software Mode with Hall startup. For optimal commutation and force generation, the selected servo drive must be compatible with the motor phasing and be wired correctly.

• Observe maximum applied voltage specification.

• Consult drive manual or supplier for drive wiring instructions. Wiring is

phase and commutation sensitive.

• Terminate per drive manual instructions.

• Hall Signals, 120

• Refer to CHPS-Series Stage Connector Data starting on page 33

termination options, pin, and wire designations.

…24 V DC, 10 mA maximum

shows the

Spacing, Open Collector Transistor 24V maximum.

for

ATT EN TI ON : Incorrect motor, Hall, or encoder wiring can cause runaway conditions.

46 Rockwell Automation Publication CHPS-UM001D-EN-P - July 2014

As shown in the Motor Phasing Diagram:

IMPORTANT

0° 60° 120° 180°

240°

300°

360°

Back

EMF

Voltage

Digital

Hall

Signals

Linear Travel mm (in.)

Motor Type

U-V

W-U

V-W

50 (1.97)

60 (2.36)

S1 in phase with W-U Back EMF S2 in phase with U-V Back EMF S3 in phase with V-W Back EMF

Phase sequence = S1 leads S2 leads S3. Spacing is 120°.

Figure 15 - Motor Phasing Diagram

Back EMF Voltage vs. Hall Signals

Connecting the Stage Chapter 6

Phasing direction = Slide toward positive end block,

Phasing direction = Positive stage direction.

Rockwell Automation Publication CHPS-UM001D-EN-P - July 2014 47

Chapter 6 Connecting the Stage

(+)

(-)

Slide End Cap + Slide = Slide Assembly

Positive Direction

Stage Positive Direction

Stage positive direction is defined by a location of a Slide End Cap.

48 Rockwell Automation Publication CHPS-UM001D-EN-P - July 2014

Chapter 7

IMPORTANT

Operation Guidelines and Limit Configuration

Introduction

Operational Guidelines

This chapter gives you operational guidelines and limit sensor position adjustment procedures.

Top ic Pag e

Operational Guidelines 49

Travel Limits 50

Calculating the Stopping Distance 50

Overtravel Limit Sensor Position Adjustment 51

Bumper Stops 53

Please read the following notices about using your stage.

ATT EN TI ON : A runway condition is caused by incorrect motor, Hall, or encoder wiring. It results in uncontrolled speeding of the stage. Keep away from the line of travel while commissioning the stage.

The customer is responsible for ensuring the servo control system safely controls the stage with regards to maximum force, acceleration, speed, and preventing runaway conditions.

ATT EN TI ON : Stages are capable of very high forces, accelerations and speeds. Moving parts can cause personnel injury. Before running the stage, make sure all components are secure.

Check that the stage travel and air gap is clear of foreign matter and tools.

Objects hit by the moving stage can cause personnel injury or damage to the equipment.

ATT EN TI ON : Do not operate the stage with protective covers removed. Do not go near electrically live parts. High voltages can cause personal injury or death.

Rockwell Automation Publication CHPS-UM001D-EN-P - July 2014 49

Chapter 7 Operation Guidelines and Limit Configuration

IMPORTANT

Travel Limits

CHPS-Series stages offer three methods for containing slide travel: software travel limits, optional overtravel limit sensors, and standard bumpers stops. For safest operation use all three.

Set software travel limits and overtravel limit sensors according to the maximum speed of the servo drive system and the payload of the application. You can determine the Deceleration Distance between the slide and the end-of-travel bumpers based on the combination of the Deceleration Rate of the load, and the available peak force from the stage-drive. Do a calculation similar to the one in

Calculating the Stopping Distance

for your application.

Bumper Stop on the stage can stop the slide up to the ratings listed in the table on page 53.

Bumper stops are not intended as range of motion stops, but they can stop the moving slide up to the ratings listed in Bumper Stops

on page 53.

Calculating the Stopping Distance

In the following example we calculate the stopping distance for a 10 kg payload on a CHPS-x8xE-xLMxxxx stage driven by a Kinetix 6000 drive (2094-xxxxx) by using the specification found in Appendix A necessary.

. Substitute values for your system as

Known Values:

Slide Moving Mass = 10.32 kg Payload = 10 kg

(1)

Maximum Programmable Velocity Available Peak Force

(2)

= 600 N @ 23.2 A

, Vmax = 2 m/s

o-pk

Start with:

Total Moving Mass = m = Payload + Stage Moving Mass

= 10 kg + 10.23 kg = 22.23 kg

So the maximum deceleration rate, Dmax is 26.99 m/s

(1) Velocity and kinetic energy can be much higher due to a uncontrolled worst-case motion constrained by the stroke and power

capacity of the motor drive paring only.

(2) Approximation only; actual peak force typically decreases as speed increases.

50 Rockwell Automation Publication CHPS-UM001D-EN-P - July 2014

Operation Guidelines and Limit Configuration Chapter 7

IMPORTANT

Calculate the deceleration time, Td.

to calculate the deceleration distance.

Use T

Therefore, you set the software travel limits to 74 mm.

Velocity and deceleration distance can be much higher due to an uncontrolled worst-case motion constrained by the stroke and power capacity of the motordrive paring only.

Drive Current Limitation

Your available peak force can be limited by your drive’s peak current.

For example a drive with a peak rating of 15 A

has available peak force 386 N.

o-pk

Here is the calculation:

Overtravel Limit Sensor Position Adjustment

Maximum stage travel is defined as the distance the slide can travel between end caps such that the bumper stop can touch the end cap but not be compress. You can shorten the slide travel up to 30 mm (1.18 in.) by adjusting the overtravel limit sensor.

Rockwell Automation Publication CHPS-UM001D-EN-P - July 2014 51

Chapter 7 Operation Guidelines and Limit Configuration

IMPORTANT

End Block

Bumper Stop

Overtravel Limit Sensor

Limit Blade

Slide

39 mm

adjust

up to 30 mm

Original position

Can cause programming anomaly.

Correct

Overtravel Limit Sensor

Limit Blade

Slide

Overtravel Limit Sensor

Limit Blade

End Block

Bumper Stop

Make adjustments without compressing the bumper.

To adjust overtravel limit sensor:

1. Measure location from end block to the inside tip of the overtravel limit sensor.

2. Loosen screw and slide the overtravel limit sensor toward center of stage. It can be adjusted up to 30 mm.

52 Rockwell Automation Publication CHPS-UM001D-EN-P - July 2014

3. Redress the limit sensor cables with the cable clips. Make sure wires are

Do not adjust the switch more than 30 mm. Doing so can cause a programming anomaly.

neatly against the base and do not interfere with the motion of the limit blade.

Operation Guidelines and Limit Configuration Chapter 7

(1) Velocity and kinetic energy can be much higher due to a uncontrolled worst-case motion constrained by the stroke and power

capacity of the motor drive pairing only.

Bumper Stops

In addition to software overtravel limits and limit sensors the end of travel bumper stops can stop the slide up to the ratings listed. Bumper stops are not intended to be used as range of motion stops.

Table 4 - Bumper Stop Energy Limits for Stage End of Travel

Cat. No. Bumper Stop Energy Limit

CHPS-x6xxxx-xLMxxx 37.3 J (330 in•lb)

CHPS-x8xxxx-xLMxxx 45.5 J (403 in•lb)

CHPS-x9xxxx-xLMxxx 35.2 J (312 in•lb)

ATT EN TI ON : If energy greater than the bumper capacity is anticipated in the application, provide additional mechanical means for safely stopping the slide.

To calculate kinetic energy of the slide with your payload use the formula

J in jules M = moving mass in kg (slide + payload)

V = maximum velocity of stage in your application in m/s

(1)

Rockwell Automation Publication CHPS-UM001D-EN-P - July 2014 53

Chapter 7 Operation Guidelines and Limit Configuration

Notes:

54 Rockwell Automation Publication CHPS-UM001D-EN-P - July 2014

Chapter 8 Troubleshooting

Top ic Pa ge

Before You Begin 55

PTC Thermal Signal 55

Hall Effect Module 55

Hall to Back EMF Phasing 57

Motor Coil Resistance Measurements 58

Before You Begin

PTC Thermal Signal

The following test equipment is required:

• Ohm meter

• Two-channel storage oscilloscope

At ambient room temperature, approximately 25 °C (77 °F), check that the resistance measurement between PTC Temp+ and Common (pins 13 and 14, respectively) on the feedback connector is

The table lists increase in resistance at higher temperatures outside the normal operating temperature envelope.

Table 5 - PTC Thermistor Signal Characteristics

Temperature °C (°F) Resistance in Ohms

Up to 100 (212) ≤ 750

Up to 105 (221) ≤ 7500 Up to 110 (230) ≥ 10,000

≤ 750 Ω.

Hall Effect Module

Use this procedure to verify the Hall Effect module is operating properly.

1. With drive power OFF, verify the Hall circuit is properly connected to the drive by using stage and drive interface wiring specifications.

2. Disconnect stage power leads from the drive.

3. Apply power to the Hall device by setting the drive control power to ON.

4. Use an oscilloscope to check waveforms at S1, S2 and S3 at the feedback

connector.

Rockwell Automation Publication CHPS-UM001D-EN-P - July 2014 55

Chapter 8 Troubleshooting

TIP

0° 60° 120° 180°

240°

300°

360°

Move the slide slowly and steadily by hand in the specified phasing direction to generate the Hall waveform.

5. Check for proper logic levels (approximately 0V = low, V+= high) and correct signal sequence (S1 leads S2, and S2 leads S3) with approximately 120° electrical spacing between signal transitions.

Hall Effect Leads

Color Name Signal Description

White/Green S1 Trapezoidal Hall, TTL-Single

Blue S2 Trapezoidal Hall, TTL-Single

White/Blue S3 Trapezoidal Hall, TTL-Single

Figure 16 - Hall Signals Waveforms

Connect the common probe from the scope to the Hall signal common.

To determine the location of the signal common, refer to the Stage Power and Feedback Connections beginning on page 40

6. Before assuming a Hall module fault check Hall field wiring or drive Hall circuit interface.

56 Rockwell Automation Publication CHPS-UM001D-EN-P - July 2014

Troubleshooting Chapter 8

EXAMPLE

Hall to Back EMF Phasing

Verify the Hall to Back EMF Phasing with this procedure.

1. With drive power OFF.

2. Verify the Hall circuit is connected to the drive as describe in the CHPS-

Series Connector Data beginning on page 33

3. Disconnect the stage motor power leads from the drive.

To observe W-U Back EMF phase polarity, connect oscilloscope probe tip to the W phase and the common probe to the U phase.

4. Apply power to the Hall device by setting the drive control power to ON.

5. Slowly and steadily move the stage by hand to perform the Hall signal test,

except this time check the motor phases are in-phase with the Hall signal as shown in the Motor Phasing Schematic

Make sure the phase error between Hall signal and in-phase Back EMF does not exceed ± 5 electrical degrees.

6. If poor results were obtained in step 5 repeat the test at the stage power terminations to check field wiring

ATTENTION: Dangerous voltages, forces and energy levels exist in servo controlled systems. Extreme care must be exercised when operating, maintaining or servicing the stage to prevent harm to personnel or equipment.

on page 58.

Rockwell Automation Publication CHPS-UM001D-EN-P - July 2014 57

Chapter 8 Troubleshooting

IMPORTANT

Lamination

Frame

ptn

ptp

U V

Motor Phases

Motor Ground

Shield

ptp

= R

ptn

X 2

Motor Coil Resistance Measurements

If a motor coil electrical problem is suspected perform this check.

1. Let the coil attain ambient room temperature, approximately 25 °C (77 °F).

2. Verify the drive power is OFF.

3. Disconnect all stage leads (phases and ground) from the drive.

4. Measure the phase-to-phase (ptp) resistance of the phase combinations (U

to V, V to W, and W to U) and record the values.

Verify these three readings are approximately equal to each other.

Figure 17 - Motor Phasing Schematic

Compare the phase resistance readings to the cold resistance specification of the coil model. See CHPS-Series Stage Technical Specifications

page 83

If the three readings are balanced but vary from the specified reading, the reason can be a special coil model. Cable resistance can cause the result to be significantly higher.

5. To rule out the cable resistance, disconnect the stage cable and repeat the procedure this time at the stage motor power termination at the junction box.

6. Measure and verify the phase-to-ground resistance for each phase is >100 MΩ. A lower reading indicates a potential electrical problem.

To rule out a field cable problem disconnect the stage cable and repeat the procedure this time at stage motor power termination.

If any reading with the cable disconnected is

≤ 100 MΩ, consult Rockwell

Automation; the stage can have an internal electrical problem

Do not perform coil or insulation electrical stress tests (Megger or Hi-Pot test) without consulting Rockwell Automation technical support.

58 Rockwell Automation Publication CHPS-UM001D-EN-P - July 2014

Chapter 9

IMPORTANT

Maintenance

Topic Page

Before You Begin 59

Lubricate the Bearing 60

Optical Encoder Scale Maintenance 60

Strip Seal Cleaning 61

Cover Cleaning 61

Any person that teaches, operates, maintains, or repairs these stages must be trained and demonstrate the competence to safely perform the assigned task.

Before You Begin

The following tools are required to lubricate and clean your stage.

ATT EN TI ON : Lockout tagout power before servicing.

• 0.5 m (14 in.) or larger clamp with soft jaws.

• Grease (catalog number MPAS-CART).

• Grease gun kit (catalog number MPAS-GPUMP) with tip type installed

and primed.

• Air line with maximum pressure of 10 psi.

• Lint free cloth.

• A few drops of isopropyl alcohol if necessary for cleaning encoder scale.

Rockwell Automation Publication CHPS-UM001D-EN-P - July 2014 59

Chapter 9 Maintenance

Bearing Lubrication Ports (2x per end cap)

Lubricate the Bearing

Your stage requires lubrication 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.

1. Position slide at end of travel and clamp it to hold the stage against end cap.

ATTENTION: Do not use clamp across the side panels. This can deform and damage the side panels.

Optical Encoder Scale Maintenance

2. Remove the lubrication port protective caps.

3. Insert the tip of grease gun in the lubrication port. Push in until contact

with bearing grease nipple is felt.

4. Pump handle until back pressure is felt or two strokes are completed.

5. Repeat steps 3 and 4 to the second bearing on this side.

6. Move slide to opposite end of travel and repeat steps 1

7. Remove clamp.

8. Reinstall the protective caps on all the lubrication ports.

1. If installed remove strip seal and side cover on the side opposite the cable

carrier.

2. Clear any coarse or abrasive particles with a clean air line with maximum pressure of 10 psi.

3. Clean scale with a clean dry cloth. Avoid the use of solvents.

4. If necessary use isopropyl alcohol sparingly, apply with a wetted cloth by

using a gentle wiping action.

…5.

5. Reinstall side cover and strip seal, if used.

60 Rockwell Automation Publication CHPS-UM001D-EN-P - July 2014

Maintenance Chapter 9

IMPORTANT

Strip Seal Cleaning

Cover Cleaning

Clean the strip seals, if installed, by using a lint free cloth lightly saturated with isopropyl alcohol

Repl ace the stri p seal if it c annot be cleane d, or if an uneven or scored surface is detected during cleaning.

A buildup of foreign material on the strip seal degrades the performance of the linear stage. This buildup coupled with rapid movement of the slide and the resulting friction can score the surface and create a burnished appearance on the strip seal

Elements contributing to a typical buildup on the strip seals are dust, grease, and other contaminates normally encountered in any operating environment that is not strictly controlled.

Refer to the Strip Seal Removal

Replacement procedure on page 66 when performing this task.

Clean the covers at the same time you clean the strip seals. Use pressurized air and a lint free cloth lightly saturated with isopropyl alcohol to remove any dirt or grease.

procedure on page 65 and Strip Seal

Rockwell Automation Publication CHPS-UM001D-EN-P - July 2014 61

Chapter 9 Maintenance

Notes:

62 Rockwell Automation Publication CHPS-UM001D-EN-P - July 2014

Chapter 10

TIP

Removing and Replacing Stage Components

Top ic P ag e

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

Before You Begin

Cable Carrier Module Removal

The following tools are required before you begin removal and replacement procedures.

• To r q u e w re nc h

• Phillips head screw driver

• 2.5 mm hex wrench

• 3 mm hex wrench

• 4 mm hex wrench

• Fine-point permanent marker

• Tin snips

• Loctite 222

Use this procedure to remove the cable carrier module assembly.

Mark the location of the end bracket before removing the cable carrier, this makes it easier to align the carrier when re-installing.

1. Remove the four (4) pan head screws from junction box side cover.

2. Remove the two (2) button head cap screws (BHCS) from the junction

box cover.

Rockwell Automation Publication CHPS-UM001D-EN-P - July 2014 63

Chapter 10 Removing and Replacing Stage Components

Junction Box Side Cover

Junction Box Cover

Cable Carrier Module

Angle Bracket

End Bracket

Feedback Connector

Motor Power Connector

M3 0.5 X8 LG Phillips Pan Head Screws (4x)

M4 X 0.7 X 8 LG BHCS (2x)

M4 X 0.7 X 10 LG SHCS (2x)

M3 X 0.5 X 8 LG SHCS (2x)

3. Remove junction box cover assembly.

ATTENTION: Never pull on wires when disconnecting power and feedback connectors. Damage to the connector can occur.

4. Separate motor power connector by squeezing the side tabs and pulling on the housing. Do not pull on the wires

Figure 18 - Cable Carrier Module Replacement

Cable Carrier Module Installation

5. Separate the feedback connector from the circuit board by pushing on the center tab and pulling up on the connector housing. Do not pull on wires.

6. Remove the two (2) SHCS from the angle bracket.

7. Lay the cable carrier out flat and mark the location of the end bracket on

the base.

8. Loosen but do not remove the two (2) SHCS that secure the end bracket to the stage base.

9. Remove cable carrier.

Align the cable carrier module with the marks made before removing and follow cable carrier removal procedure in reverse.

64 Rockwell Automation Publication CHPS-UM001D-EN-P - July 2014

Removing and Replacing Stage Components Chapter 10

IMPORTANT

Stainless Steel Strip Seal (2x)

Strip Seal Clamp (4x)

Seal Guide (4x)

3M SHCS (2x per guide)

3M SHCS (8x)

Strip Seal Removal

Figure 19 - Stage Seal Components .

Handle strip seal material with care. The strip seal has sharp edges that can cut if mishandled

1. Loosen the strip seal clamps at each end of the stage.

2. Carefully grasp the end of the strip seal and slide it out of the stage.

Stage Cover Removal

Stage Side Cover Removal

1. Remove strip seals following strip seal removal procedure.

2. Remove the (4) M4 screws securing the stage cover to the end caps.

3. Remove cover.

Figure 20 - Cover Removal

1. Remove strip seals following strip seal removal procedure.

2. Remove the (2) M4 x.07 screws securing the side cover to the end caps.

3. Remove side cover by dropping it down so the lower lip clears the channel.

Rockwell Automation Publication CHPS-UM001D-EN-P - July 2014 65

Chapter 10 Removing and Replacing Stage Components

1) Mark needed strip length.

2) Mark strip width centerline.

3) Make two 45° marks to centerline.

4) Use tin snips to cut along 45° marks.

Strip Seal Replacement

ATT EN TI ON : Handle strip seal material with care. Strip seal has sharp edges

that can cause personal injury if mishandled.

1. Remove power from unit and Lockout-Tagout the power source.

2. Follow the instructions below on how to measure, mark, and cut new strip

seals.

3. Position slide at middle of travel.

4. Loosen end clamps and screws on one seal guide enough to expose center

metal section of guide.

5. Thread new strip seal, point end first, through the seal guides, slide and end clamps.

6. Center and smooth strip seal against top cover and side panel magnetic strips.

7. With very light pressure hold the seal guide against the strip seal and tighten the seal guide.

8. Tighten only one end clamp.

9. Move the slide by hand through travel and make sure the strip seal seats

smoothly against the cover and side panel magnet strips. Pulling against the tightened end clamp to help smooth the seal.

10. Once the seal lays flat and smooth against the top cover and side panel, tighten the second end clamp.

11. With the outside edge of the end clamps as a guide, use tin snips to cut and remove excess strip seal material.

66 Rockwell Automation Publication CHPS-UM001D-EN-P - July 2014

Removing and Replacing Stage Components Chapter 10

Seal Guide

0.8 mm (0.015 in.) Shim

Strip Seal

12. Position slide at the far ends of travel and re-adjust seal guide by inserting a

0.8 mm (0.015 in.) shim between seal guide and strip seal.

13. Return stage to service.

Stage Cover Installation

Side Cover Installation

1. Starting at the end cap with the magnetic warning label. Install (2) M3x25SHCS and torque to 4N•m (35lbf•in). Make sure the cover makes contact with the end cap.

2. On the opposite end install (2) M3 x 30 SHCS and bottom out the screw. The cover does not contact the end cap on this side it floats on the screw.

1. Insert side cover into the stage base by holding it with the top slightly tilted outward and hooking bottom in the channel near bottom of the base.

2. Starting at the end cap with the magnetic warning label or the MP motor. Install (1) M4 x 0.7 x 30 LG SHCS and torque to 4 N•m (35 lb•in). Make sure the side cover makes contact with the end cap.

3. On the opposite end install (1) M4 x 0.7 x 30 LG SHCS and torque

2.26 N•m (20 lb•in). The side cover does not contact the end cap on this side.

Rockwell Automation Publication CHPS-UM001D-EN-P - July 2014 67

Chapter 10 Removing and Replacing Stage Components

Notes:

68 Rockwell Automation Publication CHPS-UM001D-EN-P - July 2014

Appendix

Specifications and Dimensions

This appendix is a supplement to this document. Associated Kinetix publications listed in Additional Resources specifications can supersede the information in this appendix.

Top ic Page

Static and Static Moment Loads 70

Performance Specifications for 325V CHPS-Series Stage 70

Performance Specifications for 325V or 650V CHPS-Series Stage 71

Accuracy Specification for the CHPS-Series Stage 73

General Stage Specifications 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

on page 9 and information in product

Rockwell Automation Publication CHPS-UM001D-EN-P - July 2014 69

Appendix A Specifications and Dimensions

Roll Moment Load

Lateral Force Load

Pitch Moment Load

Reverse Radial Force Load Radial Force Load

Yaw Moment Load

Static and Static Moment Loads

The figure depicts the Static and Static Moment Loads in the tables that follow.

Table 6 - Static and Static Moment Loads on Linear Stages

The static moment and force ratings shown in the tables are the maximum permissible values possible before permanent damage to the linear stage can occur. To determine the estimated L10 bearing and ball screw life of CHPS-Series Integrated Linear Stages, use Motion Analyzer software version 4.4 or later.

Performance Specifications for 325V CHPS-Series Stage

Maximum cable length 10 m (33 ft). Please contact Applications Engineering concerning application requiring longer cables.

70 Rockwell Automation Publication CHPS-UM001D-EN-P - July 2014

Specifications and Dimensions Appendix A

Table 7 - Performance Specifications for 150 mm frame size CHPS-Series Linear Stages

Cat. No. Slide Mass Continuous

(1) (2)

Peak Maximum

Static Load

Max Static Moment Loads

(3)

Current Thrust Current Thrust Pitch Yaw Roll

kg (lb) A rms (Ao-pk) N (lbf) A rms (Ao-pk) N (lbf) kN (lbf) kN (lbf)

N•m (ft•lb) N•m (ft•lb)

CHPS-A6xxxA-xLMxxx 4.64 (10.23) 2.3 (3.3) 80 (18) 7.0 (9.9) 239 (54) 38.0 (8722) 71 (52) 183 (134) 97 (71)

CHPS-A6xxxB-xLMxxx 6.48 (14.28) 4.7 (6.6) 160 (36) 14.0 (19.9) 479 (108) 38.0 (8722) 128 (94) 327 (241) 97 (71)

CHPS-A6xxxC-xLMxxx 6.48 (14.28) 2.3 (3.3) 160 (36) 7.0 (9.9) 479 (108) 38.0 (8722) 128 (94) 327 (241) 97 (71)

(1) Measured at 20 °C (68 °F) ambient. (2) For covered and sealed stages derate by 10% (3) Values apply to bearing rating only. Contact Applications Engineering for structural considerations.

Table 8 - Performance Specifications for 200 mm frame size CHPS-Series Linear Stages

Cat. No. Slide Mass Continuous

(1) (2)

Peak Maximum

Static Load

Max Static Moment Loads

(3)

Current Thrust Current Thrust Pitch Yaw Roll

kg (lb) A rms (Ao-pk) N (lbf ) A rms (Ao-pk) N (lbf) kN (lb) kN (lbf)

N•m (ft•lb) N•m (ft•lb)

CHPS-A8xxxA-xLMxxx 4.59 (10.1) 2.1 (3.0) 72 (16) 6.3 (8.9) 215 (48) 66 (14836) 171 9126) 412 (304) 270 (199)

CHPS-A8xxxB-xLMxxx 6.58 (14.5) 4.2 (6.0) 144 (32) 12.6 (17.9) 431 (97) 66 (14836) 270 (199) 620 (457) 270 (199)

CHPS-A8xxxC-xLMxxx 6.58 (14.5) 2.1 (3.0) 144 (32) 6.3 (8.9) 431 (97) 66 (14836) 270 (199) 620 (457) 270 (199)

(1) Measured at 20 °C (68 °F) ambient. (2) For covered and sealed stages derate by 10%. (3) Values apply to bearing rating only, Contact Applications Engineering for structural considerations.

(3)

Performance Specifications for 250 mm frame size CHPS-Series Linear Stages

Cat. No. Slide Mass Continuous

(1)(2)

Peak Maximum

Static Load

Max Static Moment Loads

(3)

Current Thrust Current Thrust Pitch Yaw Roll

kg (lb)

A rms (Ao-pk)

N (lbf) A rms (Ao-pk) N (lbf ) kN (lbf) kN (lbf)

N•m (ft•lb) N•m (ft•lb)

CHPS-A9xxxG-xLMxxx 8.58 (18.9) 1.9 (2.7) 109 (25) 5.8 (8.2) 328 (74) 93.6 (21042) 170 (125) 385 (283) 508 (375)

CHPS-A9xxxH-xLMxxx 9.62 (21.2) 3.8 (5.4) 219 (49) 11.5 (16.3) 656 (147) 93.6 (21042) 324 (239) 734 (541) 508 (375)

CHPS-A9xxxI-xLMxxx 9.62 (21.2) 1.9 (2.7) 219 (49) 5.8 (8.2) 656 (147) 93. 6 (21042) 324 (541) 734 (541) 508 (375)

(1) Measured at 20 °C (68 °F) ambient. (2) For covered and sealed stages derate by 10%. (3) Values apply to bearing rating only. Contact Applications Engineering for structural considerations.

(3)

Performance Specifications for 325V or 650V CHPS-Series Stage

Maximum cable length 10 m (33 ft). Please contact Applications Engineering concerning application requiring longer cables.

Rockwell Automation Publication CHPS-UM001D-EN-P - July 2014 71

Appendix A Specifications and Dimensions

Table 9 - Performance Specifications for 200 mm frame size CHPS-Series Linear Stages

Cat. No. Slide Mass Continuous

(1)(2)

Peak Maximum

Static Load

Max Static Moment Loads

(3)

Current Thrust Current Thrust Pitch Yaw Roll

kg (lb) A rms (Ao-pk) N (lbf ) A rms (Ao-pk) N (lbf ) kN (lbf ) kN (lbf)

N•m (ft•lb) N•m (ft•lb)

CHPS-x8xxxD-xLMxxx 5.64 (12.4) 3.1 (4.3) 132 (30) 8.3 (11.7) 302 (68) 66 (14836) 171 9126) 412 (304) 270 (199)

CHPS-x8xxxE-xLMxxx 8.34 (18.4) 6.2 (8.7) 265 (60) 16.5 (23.3) 600 (135) 66 (14836) 270 (199) 620 (457) 270 (199)

CHPS-x8xxxF-xLMxxx 8.34 (18.4) 3.1 (4.3) 265 (60) 8.2 (11.6) 600 (135) 66 (14836) 270 (199) 620 (457) 270 (199)

(1) Measured at 20 °C (68 °F) ambient. (2) For covered and sealed stages derate by 10%. (3) Values apply to bearing rating only. Contact Applications Engineering for structural considerations.

Performance Specifications for 250 mm frame size CHPS-Series Linear Stages

Cat. No. Slide Mass Continuous

(1)(2)

Peak Maximum

Static Load

Max Static Moment Loads

(3)

Current Thrust CurrentThrust PitchYaw Roll

kg (lb) A rms (Ao-pk) N (lbf) A rms (Ao-pk) N (lbf ) kN (lbf ) kN (lbf )

N•m (ft•lb) N•m (ft•lb)

CHPS-x9xxxJ-xLMxxx 11.54 (25.4) 3.0 (4.2) 385 (87) 8.1 (11.5) 882 (198) 93.6 (21042) 170 (125) 385 (283) 508 (375)

CHPS-x9xxxK-xLMxxx 9.69 (21.4) 3.0 (4.2) 193 (43) 8.1 (11.5) 441 (99) 93.6 (21042) 324 (239) 734 (541) 508 (375)

CHPS-x9xxxL-xLMxxx 11.54 (25.4) 6.0 (8.5) 385 (87) 16.2 (22.9) 882 (198) 93.6 (21042) 324 (541) 734 (541) 508 (375)

(3)

(1) Measured at 20 °C (68 °F) ambient. (2) For covered and sealed stages derate by 10%. (3) Values apply to bearing rating only. Contact Applications Engineering for structural considerations.

72 Rockwell Automation Publication CHPS-UM001D-EN-P - July 2014

Specifications and Dimensions Appendix A

General Stage Specifications

Cat. No Repeatability Accuracy

CHPS-xxxxxx-FLMxxx ±1.0 ±3 μm/25 mm NTE ±10 μm/300 mm

CHPS-xxxxxx-GLMxxx ±1.5

CHPS-xxxxxx-HLMxxx ±2.0

CHPS-xxxxxx-ILMxxx Interpolation

(1) Non-cumulative. For higher performance or software error mapping, please contact Applications Engineering. (2) Accuracy specification is based upon a 5 kg test load, measured 35 mm above the center of the slide, fully supported on a granite surface. (3) Based upon a fully suppor ted and clamped in place unit, mounted on a rigid surface with flatness of 0.012/300 x 300 mm, NTE 0.025 mm overall (0.0004/12 x 12 in., NTE

0.001 in. overall)

The following sections contain general specifications.

Accuracy Specification for the CHPS-Series Stage

(1)(2)(3)

μm (in.) μm (in.) μm (in.)

(±0.0001 in./1 in. NTE ±0.0004 in./12 in.)

Dependent

Straightness and Flatness

±3 μm/25 mm NTE ±8 μm/300 mm (±0.0001 in./1 in. NTE ±0.0003 in./12 in.)

Commutation Sensor

Description Specifications

Input Power 5…24V DC, 10 mA max.

Output NPN, open collector, 10 mA max.

(3)

Limit Sensor Specification

Description Specifications

Input Power 12…28V DC, 15 mA max.

Output PNP, open collector, normally closed 50 mA max.sourcing

PTC Thermistor Specifications

Temp °C (°F) Resistance (Ohm)

Up To 100 (212) Less than 750

Up To 105 (221) Less than 7500

Up To 110 (230) Greater than 10,000

Rockwell Automation Publication CHPS-UM001D-EN-P - July 2014 73

Appendix A Specifications and Dimensions

IMPORTANT

Encoder Specifications

Type Signal Specification

Power Supply 5V DC ±5%

Digital A/B/Index RS422 Differential Line Driver

Analog Sine/Cosine 0.6…1.2V p-p Differential Analog

Integral Index Mark Differential Pulse 0.8…1.3V p-p

Contact Application Engineering for third party drives and controllers. The controls need to meet a minimum recommended counter clock frequency that varies with encoder type and resolution and required peak speed.

Maximum Velocity for Allen-Bradley Drives

Table 10 - Maximum Velocity for 150 mm frame size CHPS-Series Linear Stages with Allen-Bradley Drives

Incremental Encoder Option Maximum Velocity

Digital Resolution

μm/count μm m/s m/s m/s m/s m/s

1 — 5.0 4.0 4.0 1.5 2.0

0.5 — 3.0 2.0 2.0 0.7 —

0.1 — 0.7 0.5 — — —

— 20 4.0 2.0 2.0 2.0 —

Sine/Cosine Period

Veloc ity, max

Ultra™ 3000 and Ultra5000 Drives

Kinetix 2000 and Kinetix 6500 Drives

Kinetix 6000 Drive

Table 11 - Maximum Velocity for 200 and 250 mm frame size CHPS-Series Linear Stages with Allen-Bradley Drives

Incremental Encoder Option Maximum Velocity

Digital Resolution

μm/count μm m/s m/s m/s m/s m/s

1 — 5.0 4.0 4.0 1.5 2.0

0.5 — 3.0 2.0 2.0 0.7 —

0.1 — 0.7 0.5 0.5

— 20 4.0 2.0 2.0 2.0 —

(1) LC motor option only.

Sine/Cosine Period

Veloc ity, max

Ulta3000 and Ultra5000 Drives

Kinetix 2000 and Kinetix 6500 Drives

(1)

Kinetix 6000 Drive

——

Kinetix 300 Drive

74 Rockwell Automation Publication CHPS-UM001D-EN-P - July 2014

Specifications and Dimensions Appendix A

Unit Mass

Travel Length

Mass (kg)

LZ-030-T-120-D

LZ-030-T-240-X

120

240

360

480

600

720

840

960

Environmental Specifications for CHPS-Series Stages

Attribute Value

Ambient temperature 0...40 °C (32...104 °F)

Storage temperature -30...70 °C (-22...158 °F)

Relative humidity 5…95% non-condensing

Shock 20 g peak, 6 ms duration

Vibration 0.1 grms @ Hz, 30…2000 Hz

Cable carrier lifetime 10,000,000 cycles

CHPS-Series Stage Travel versus Weight Specifications

CHPS-Series Stage (150 mm frame size)

Rockwell Automation Publication CHPS-UM001D-EN-P - July 2014 75

Appendix A Specifications and Dimensions

Unit Mass

120

240

360

480

600

720

840

960

Travel Length

Mass (kg)

LZ-030-T-120-D

LC-050-100-D

Unit Mass

140

260

380

500

620

740

860

980

Travel Length

Mass (kg)

LZ-030-T-240-X

LC-050-200-X

Unit Mass

140

260

380

500

620

740

860

980

Travel Length

Mass (kg)

LZ-050-T-120-D

LC-075-100-D

LZ-050-T-240-X

LC-075-200-X

CHPS-Series Stage (200 mm frame size)

76 Rockwell Automation Publication CHPS-UM001D-EN-P - July 2014

CHPS-Series Stage (250 mm frame size)

Specifications and Dimensions Appendix A

(4X) M6 x 1.0-6H

12.0 (0.47)

25.0 (0.98)

25.0

(0.98)

165

(6.50)

30 (1.18)

Slide

239

(9.41)

167

(6.57)

62 (2.44)

(4X) Ø 7.0 (0.28) Thru

Pilot Hole

45.0 (1.80)

115

(4.53)

30.0 (1.18)

123.8

(4.88)

46.8

(1.84)

181.5

(7.15)

238.6 (9.39)

8.5

(0.33)

32.0

(1.26)

92.0

(3.62)

150

(5.9)

7.6

(0.30)

Tra ve l

165

(6.50)

30.5 (1.20) Mechanical Overtravel

30.5 (1.20)

Mechanical

Overtravel

120 (4.72) Toe Clamp/T-Nut Spacing

350.0

(13.87)

Bracket located ±51 (2.0) from center of travel.

See Detail A

(4X) M10 x 1.5-6H Thru (2 per end cap) Access point for lubricating linear bearings. Provision to use lifting hooks (not provided).

Detail A

9.3 (0.37) Depth, max

Toe Clamp is standard for

covered stages. Mount to base

using M6 x1.0 socket cap screw.

T-Nut Mount to base using M6 x1.0 hardware (optional accessory).

Ground Screw

M5 x 0.8-6H

+ Travel

CHPS-Series Stage Dimensions

Stage are designed to metric dimensions. Inch dimensions are conversions from millimeters. Dimensions without tolerances are for reference.

Figure 21 - CHPS-A6xxxA-xLMxxx

Travel Length mm (in.)

Shortest 60 (2.36)

Increments 60 (2.36)

Longest 1620 (63.78)

Rockwell Automation Publication CHPS-UM001D-EN-P - July 2014 77

Appendix A Specifications and Dimensions

(4X) M6 x 1.0-6H

12.0 (0.47)

25.0 (0.98)

25.0

(0.98)

165

(6.50)

87 (3.42)

Slide

339

(13.35)

167

(6.57)

104.5 (4.11)

(4X) Ø 7.0 (0.28) Thru

Pilot Hole

45.0 (1.80) 130

(5.12)

30.0 (1.18)

123.8 (4.88)

46.8

(1.84)

181.5 (7.15)

238.6

(9.39)

8.5

(0.33)

32.0

(1.26)

92.0

(3.62)

150

(5.9)

7.6

(0.30)

Tra ve l

165

(6.50)

30.5 (1.20) Mechanical Overtravel

30.5 (1.20) Mechanical

Overtravel

120 (4.72) Toe Clamp/T-Nut Spacing

450.0

(17.71)

Bracket located ±51 (2.0) from center of travel.

See Detail A

(4X) M10 x 1.5-6H Thru (2 per end cap) Access point for lubricating linear bearings. Provision to use lifting hooks (not provided).

Detail A

9.3 (0.37) Depth, max

Toe Clamp is standard for

covered stages. Mount to base

using M6 x1.0 socket cap screw.

T-Nut Mount to base using M6 x1.0 hardware (optional accessory).

Ground Screw

M5 x 0.8-6H

+ Travel

Figure 22 - CHPS-A6xxxB/C-xLMxxx

Travel Length mm (in.)

Shortest 60 (2.36)

Increments 60 (2.36)

Longest 1560 (61.42)

78 Rockwell Automation Publication CHPS-UM001D-EN-P - July 2014

Figure 23 - CHPS-x8xxxA/D-xLMxxx

25.4

(1.0)

Slide

239

(9.41)

130.8

(5.15)

44 (1.72)

216.7

(8.53)

(2.20)

Ø 5.8 (0.23) Thru Ø 9.7 (0.38) T

hru 14.2 (0.56)

120

(4.72)

30.0 (1.38)

105.5 (4.15)

55.4

(2.18)

(4X) M8 x 1.25-6H (4X) Ø 6.8 (0.27)

12.0 (0.47)

45.2 (1.78) T

hru

215.7 (8.49)

166.6

(6.56)

28.0

(1.10)

232

(9.13)

288.9

(11.38)

46.8

(1.84)

8.5

(0.33)

37.8

(1.49)

130.8 (5.15)

200

(7.9)

5.2

(0.206)

25.4 (1.0)

Mechanical Overtravel

340

(13.4)

+ Travel

Bracket located ±51 (2.0) from center of travel.

(4X) M10 x 1.5-6H Thru (2 per end cap) Access point for lubricating linear bearings. Provision to use lifting hooks (not provided).

Ground Screw

M5 x 0.8-6H

25.4 (1.0) Mechanical Overtravel

Detail A

(2X) Ø 5.5 (0.22) Thru

Pilot Hole

120 (4.72) Toe Clamp/ S

quare Nut Spacing

See Detail A

6.0 (0.24) Depth, max

Toe Clamp is standard for

covered stages. Mount to base

using M6 x1.0 socket cap screw.

Square Nut Mount to base using M6 x1.0 hardware (optional accessory).

Tra ve l

Specifications and Dimensions Appendix A

Travel Length mm (in.)

Shortest 60 (2.36)

Increments 60 (2.36)

Longest 1680 (66.14)

Rockwell Automation Publication CHPS-UM001D-EN-P - July 2014 79

Appendix A Specifications and Dimensions

25.4

(1.0)

Slide

339

(13.35)

130.8 (5.15)

104 (4.09)

216.7

(8.53)

116.3 (4.58)

Ø 5.8 (0.23) Thru Ø 9.7 (0.38) T

hru 14.2 (0.56)

120

(4.72)

30.0 (1.38)

105.5 (4.15)

55.4

(2.18)

(4X) M8 x 1.25-6H (4X) Ø 6.8 (0.27)

12.0 (0.47)

45.2 (1.78) T

hru

215.7

(8.49)

166.6 (6.56)

28.0

(1.10)

232

(9.13)

288.9

(11.38)

46.8

(1.84)

8.5

(0.33)

37.8

(1.49)

130.8 (5.15)

200

(7.9)

5.2

(0.206)

25.4 (1.0)

Mechanical Overtravel

440

(17.35)

+ Travel

Bracket located ±51 (2.0) from center of travel.

(4X) M10 x 1.5-6H Thru (2 per end cap) Access point for lubricating linear bearings. Provision to use lifting hooks (not provided).

Ground Screw

M5 x 0.8-6H

25.4 (1.0) Mechanical Overtravel

Detail A

(2X) Ø 5.5 (0.22) Thru

Pilot Hole

120 (4.72) Toe Clamp/ Square Nut Spacing

See Detail A

6.0 (0.24) Depth, max

Toe Clamp is standard for

covered stages. Mount to base

Square Nut Mount to base using M6 x1.0 hardware

Tra ve l

CHPS-x8xxxB/C/E/F-xLMxxx

Travel Length mm (in.)

Shortest 80 (3.15)

Increments 60 (2.36)

Longest 1580 (62.2)

80 Rockwell Automation Publication CHPS-UM001D-EN-P - July 2014

Figure 24 - CHPS-x9xxxG/J-xLMxxx

25.4

(1.0)

Slide

279

(10.98)

130.8

(5.15)

44 (1.73)

265.7

(10.46)

56.2

(2.22)

Ø 5.8 (0.23) Thru Ø 9.7 (0.38) T

hru 14.2 (0.56)

120

(4.72)

30.0 (1.18)

105.4 (4.15)

(4X) M8 x 1.25-6H (4X) Ø 6.8 (0.27)

12.0 (0.47)

45.2 (1.78) T

hru

264.7

(10.42)

208.6

(8.21)

28.0

(1.10)

281

(11.06)

338.14

(13.31)

46.8

(1.84)

8.5

(0.33)

38.3

(1.51)

172.2

(6.78)

249

(9.8)

5.6

(0.22)

25.4 (1.0)

55.4

(2.18)

25.4 (1.0)

Mechanical Overtravel

380.6

(14.96)

+ Travel

Bracket located ±51 (2.0) from center of travel.

Ground Screw

M5 x 0.8-6H

25.4 (1.0) Mechanical Overtravel

Detail A

(2X) Ø 5.5 (0.22) Thru

Pilot Hole

120 (4.72) Toe Clamp/T

-Nut Spacing

See Detail A

6.5 (0.26) Depth, max

Toe Clamp is standard for

covered stages. Mount to base

using M6 x1.0 socket cap screw.

T-Nut Mount to base using M6 x 1.0 hardware (optional accessory).

(4X) 9/16-12 UNC Thru (2 per end cap) Access point for lubricating linear bearings. Provision to use lifting hooks (not provided).

Tra ve l

Specifications and Dimensions Appendix A

Travel Length mm (in.)

Shortest 80 (3.15)

Increments 60 (2.36)

Longest 1640 (64.6)

Rockwell Automation Publication CHPS-UM001D-EN-P - July 2014 81

Appendix A Specifications and Dimensions

25.4

(1.0)

Slide

339

(13.35)

130.8 (5.15)

104 (4.09)

265.7

(10.46)

116

(4.58)

Ø 5.8 (0.23) Thru Ø 9.7 (0.38) T

hru 14.2 (0.56)

120

(4.72)

30.0 (1.18)

105.4 (4.15)

(4X) M8 x 1.25-6H (4X) Ø 6.8 (0.27)

12.0 (0.47)

45.2 (1.78) T

hru

264.7

(10.42)

208.6

(8.21)

28.0

(1.10)

281

(11.06)

338.14

(13.31)

46.8

(1.84)

8.5

(0.33)

38.3

(1.51)

172.2 (6.78)

249

(9.8)

5.6

(0.22)

25.4 (1.0)

55.4

(2.18)

25.4 (1.0)

Mechanical Overtravel

440.6

(17.35)

+ Travel

Bracket located ±51 (2.0) from center of travel.

Ground Screw

M5 x 0.8-6H

25.4 (1.0) Mechanical Overtravel

Detail A

(2X) Ø 5.5 (0.22) Thru

Pilot Hole

120 (4.72) Toe Clamp/T

-Nut Spacing

See Detail A

6.5 (0.26) Depth, max

Toe Clamp is standard for

covered stages. Mount to base

using M6 x1.0 socket cap screw.

T-Nut Mount to base using M6 x 1.0 hardware (optional accessory).

(4X) 9/16-12 UNC Thru (2 per end cap) Access point for lubricating linear bearings. Provision to use lifting hooks (not provided).

Tra ve l

Figure 25 - CHPS-x9xxxH/I/K/L-xLMxxx

Travel Length mm (in.)

Shortest 80 (3.15)

Increments 60 (2.36)

Longest 1580 (62.2)

82 Rockwell Automation Publication CHPS-UM001D-EN-P - July 2014

Specifications and Dimensions Appendix A

CHPS-Series Stage Technical

Use this specification to make stage dependent calculations.

Specifications

Cat. No. Total Moving

Mass

kg (lb) Ohms Ohms N/A

CHPS-A6xxxA-xLMxxx 5.39 (11.85) 7.2 9.3 24.1 (5.42)

CHPS-A6xxxB-xLMxxx 7.09 (15.6) 3.6 4.6 24.1 (5.42)

CHPS-A6xxxC-xLMxxx 7.09 (15.6) 14.3 18.6 48.2 (10.83)

CHPS-A8xxxA-xLMxxx 6.70 (14.73) 7.2 9.3 24.1 (5.42)

CHPS-A8xxxB-xLMxxx 8.87 (19.52) 3.6 4.6 24.1 (5.42)

CHPS-A8xxxC-xLMxxx 8.87 (19.52) 14.3 18.6 48.2 (10.83)

CHPS-x8xxxD-xLMxxx 7.57 (16.65) 3.8 4.9 30.3 (6.81)

CHPS-x8xxxE-xLMxxx 10.23 (22.5) 1.9 2.4 30.3 (6.81)

CHPS-x8xxxF-xLMxxx 10.23 (22.5) 7.5 9.8 60.7 (13.64)

CHPS-A9xxxG-xLMxxx 8.56 (18.84) 9.4 12.2 40.2 (9.04)

CHPS-A9xxxH-xLMxxx 10.70 (23.53) 4.7 6.1 40.2 (9.04)

CHPS-A9xxxI-xLMxxx 10.70 (23.53) 18.8 24.5 80.4 (18.07)

CHPS-x9xxxJ-xLMxxx 10.02 (22.04) 4.9 6.4 45.5 (10.29)

CHPS-x9xxxK-xLMxxx 13.16 (28.95) 2.5 3.2 45.5 (10.29)

CHPS-x9xxxL-xLMxxx 13.16 (28.95) 9.9 12.8 91.0 (20.46)

Coil Resistance (p - p) Force Constant

@25 °C (77 °F) @100 °C (212 °F)

0 - peak

(lbf/A

0 - peak

)

Rockwell Automation Publication CHPS-UM001D-EN-P - July 2014 83

Appendix A Specifications and Dimensions

Notes:

84 Rockwell Automation Publication CHPS-UM001D-EN-P - July 2014

Accessories

14.0 (0.55)

28.0 (1.1)

75 (2.9)

142 (5.59)

BR+ BR-

Dimensions are in mm (in.)

Start of Bend Radius

Cable Shield

(overall)

Connector

Diameter

Cable

Diameter

Bend Radius

Brown

Black

Blue

Green/Yellow

Cable Shield

(for brake wires, not used for linear motor stages)

A B C

F G E H L

16 AWG BROWN 16 AWG BLACK 16 AWG BLUE 16 AWG GRN/YEL 18 AWG WHITE 18 AWG BLACK 18 AWG WHITE 18 AWG RED

U V W

BR+ BR 1 2

SHIELD

Top ic P age

Interconnect Cables 85

Installation, Maintenance, and Replacement Kits 87

Appendix

Interconnect Cables

Power Cable Dimensions (catalog number 2090-XXNPMF-16Sxx)

The maximum cable length of 10 m (32.8 ft).

1 Bend radius (BR) is the specified minimum bend radius for cable assemblies. For standard cable, BR is a one-time flex

application. Flex cables have a much higher BR to withstand flex applications. BR can vary on user-fabricated cables.

Pin Gauge Color Signal Designation

A16Brown U

B16Black V

C16Blue W

GND 16 Green/Yellow GND

Rockwell Automation Publication CHPS-UM001D-EN-P - July 2014 85Rockwell Automation Publication CHPS-UM001D-EN-P - July 2014 85

Appendix B Accessories

(2.1)

(2.2)

(3.9)

(0.4)

(1.0)

Dimensions are in mm (in.)

Start of

Bend Radius

Connector

Diameter

Cable

Diameter

Bend Radius

A+

A -

B+

B -

I+

I -

+5V

COM

+9V

TS+

TS -

MTR RRAME

ABS

COM

28 AWG BLACK

28 AWG WHITE/BLACK

28 AWG RED

28 AWG WHITE/RED

28 AWG GREEN

28 AWG WHITE/GREEN

16 AWG GRAY

16 AWG WHITE/GRAY

22 AWG ORANGE

22 AWG WHITE/ORANGE

28 AWG BLUE

28 AWG WHITE /BLUE

28 AWG YELLOW

28 AWG WHITE/YELLOW

28 AWG BROWN

28 AWG WHITE/BROWN

DRAIN

141715

Appendix B Accessories

Pin Gauge Color Signal Designation

F18White BR+

G18Black BR-

E18White 1

Not used for CHPS Stages

H18Red 2

L N/A N/A N/A

SHIELD

Feedback Cable Dimensions (catalog number 2090-XXNFMF-Sxx)

The maximum cable length of 10 m (32.8 ft).

86 Rockwell Automation Publication CHPS-UM001D-EN-P - July 2014

1 Bend radius (BR) is the specified minimum bend radius for cable assemblies. For standard cable, BR is a one -time flex

application. Flex cables have a much higher BR to withstand flex applications. BR can vary on user-fabricated cables.

Accessories Appendix B

Installation, Maintenance, and Replacement Kits

Description Cat. No Comments

Grease Pump Maintenance Kit MPAS-GPUMP Includes grease pump, one grease cartridge, and all necessary tips.

Grease Cartridge MPAS-CART Refill cartridge for grease pump.

Toe Clamp Installation Kit MPAS-TOE 10 toe clamps per package

Tee Nut Installation Kit MPAS-6-TNUT 10 Tee nuts per package

Cable Carrier Modules MPAS-6xxxB-CABLE xxx = cm stroke:

Strip Seal Replacement Kits MPAS-6xxxB-SEAL xxx = cm stroke:

Side Covers Replacement Kit MPAS-6xxxB-SIDE xxx = cm stroke:

Top Cover Replacement Kit MPAS-6xxxB-TOP xxx = cm stroke:

Accessories available for installing stages, replacing items, and performing maintenance at regular intervals are listed in the tables that follow.

Accessories

MPAS-8-TNUT

MPAS-9-TNUT

012, 018, 024, 030, 036, 042, 054, 066, 078, 090, 102, or 114

MPAS-8xxxE-CABLE xxx = cm stroke:

014, 020, 026, 032, 038, 044, 056, 068, 080, 092, 104, 128, 152, 176, or 194

MPAS-9xxxK-CABLE xxx = cm stroke:

014, 020, 026, 032, 038, 044, 056, 068, 080, 092, 104, 128, 152, 176, or 194

012, 018, 024, 030, 036, 042, 054, 066, 078, 090, 102, or 114

MPAS-8xxxE-SEAL xxx = cm stroke:

014, 020, 026, 032, 038, 044, 056, 068, 080, 092, 104, 128, 152, 176, or 194

MPAS-9xxxK-SEAL xxx = cm stroke:

014, 020, 026, 032, 038, 044, 056, 068, 080, 092, 104, 128, 152, 176, or 194

012, 018, 024, 030, 036, 042, 054, 066, 078, 090, 102, or 114

MPAS-8xxxE-SIDE xxx = cm stroke:

014, 020, 026, 032, 038, 044, 056, 068, 080, 092, 104, 128, 152, 176, or 194

MPAS-9xxxK-SIDE xxx = cm stroke:

014, 020, 026, 032, 038, 044, 056, 068, 080, 092, 104, 128, 152, 176, or 194

012, 018, 024, 030, 036, 042, 054, 066, 078, 090, 102, or 114

MPAS-8xxxE-TOP xxx = cm stroke:

014, 020, 026, 032, 038, 044, 056, 068, 080, 092, 104, 128, 152, 176, or 194

MPAS-9xxxK-TOP xxx = cm stroke:

014, 020, 026, 032, 038, 044, 056, 068, 080, 092, 104, 128, 152, 176, or 194

Rockwell Automation Publication CHPS-UM001D-EN-P - July 2014 87

Appendix B Accessories

Notes:

88 Rockwell Automation Publication CHPS-UM001D-EN-P - July 2014

Appendix

The MPAS-x8xxxx is capable of mounting to the top of either a MPAS-x8xxxx or a MPAS-x9xxxx by bolting through the slide on the bottom stage and into T-nut slots on the top stage.

The MPAS-x6xxxx is capable of mounting to the top of another MPAS-x6xxxx by bolting through toe-clamps to the slide on the bottom stage.

Stacking Stages

This appendix provides information about center-stacked stage configurations.

Top ic Pa ge

Stage Stacking 89

Specifications for Stacked Stages 90

Stage Stacking

Certain combinations of MPAS linear stages are designed to be stacked on top of one another. Stacking forms an X-Y axis arrangement. A center-stack arrangement mounts the top axis in the middle of the bottom axis. The top stage is centered on the bottom stage.

Table 12 - Stacking Stages

Rockwell Automation Publication CHPS-UM001D-EN-P - July 2014 89

Appendix C Stacking Stages

Specifications for Stacked Stages

Linear stage specifications are based on mounting the stage to a precision base along the entire length of the stage, and MPAS stage specifications follow this convention. In the case of stacked stages, the top axis is no longer supported along its entire length, and this alters both the precision and the load carrying capability of that stage. Furthermore, linear stage specifications are based on a specified test payload with a low center of gravity that is centered on the carriage. Deviations from the test payload condition can impact the performance of both the top and bottom linear stages.

The following table provides information about the payload that the top stage, or axis, can carry without derating the life of its bearings from those specified for the same stage mounted as a single-axis stage on a precision base.

Table 13 - Centered Stack Combinations Not Requiring Derating

Catalog Numbers of Centered Stack Linear Stages

MPAS-x6xxxx on MPAS-x6xxxx Ball Screw or Direct Drive

MPAS-x8xxxx on MPAS-x8xxxx Direct Drive

MPAS-x8xxxx on MPAS-x9xxxx Direct Drive

MPAS-x8xxxx on MPAS-x8xxxx Ball Screw

MPAS-x8xxxx on MPAS-x9xxxx Ball Screw

Y-axis Travel Mass of Payload

300 10.0 kg (22 lb)

420 8.0 kg (17.6 lb)

540 5.0 kg (11 lb)

660 4.0 kg (8.8 lb)

320 14.0 kg (30.8 lb)

560 6.5 kg (14.3 lb)

800 3.0 kg (6.6 lb)

320 14.0 kg (30.8 lb)

560 6.5 kg (14.3 lb)

800 3.0 kg (6.6 lb)

300 14.0 kg (30.8 lb)

540 6.5 kg (14.3 lb)

780 3.0 kg (6.6 lb)

300 14.0 kg (30.8 lb)

540 6.5 kg (14.3 lb)

780 3.0 kg (6.6 lb)

(1)

(1) Payload is based solely on bearing and structure limitations.

For other stacking arrangements, please contact Rockwell Automation Application Engineering.

90 Rockwell Automation Publication CHPS-UM001D-EN-P - July 2014

Appendix

IMPORTANT

Start-up Guide for CHPS-Series Stage with Ultra3000 Drive and Ultraware Software

This appendix is a supplement to CHPS-Series stage and Kinetix drive manuals. The information in the current product manuals supersedes this appendix.

Top ic Pa ge

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

Reference Information 99

Using This Appendix

Wiring the CHPS-Series Stage to the Ultra3000 Drive

This appendix is for use with CHPS-Series stages. This document addresses CHPS-Series stage-motor file parameter values and commutation wiring. Basic start-up test procedures and troubleshooting information is also given.

Motor, commutation, feedback parameters, and wiring affect commutation, and must be correct for proper motor-drive operation. Improper setup can cause stage control problems including erratic behavior, bad spots, runaway, and thermal failure.

The CHPS-Series stage has four termination options. The Kinetix/MPF option is recommended for plug & play to Kinetix and Ultra family servo drives. Kinetix MPF interconnect cable makes it easy to wire the stage and set-up commutation with the Ultra3000 Drive. drives and Logix® version Ultra3000 drives are the same.

If you are not using Kinetix/MPF termination option, properly wire the stage to the Ultra drive by using the following connectivity information. Refer to the CHPS-Series Stage Connector Data for additional information.

The wiring for non-Logix Ultra3000

Rockwell Automation Publication CHPS-UM001D-EN-P - July 2014 91

Appendix D Start-up Guide for CHPS-Series Stage with Ultra3000 Drive and Ultraware Software

Connector Data Summary

CHPS-Series Stage Signal Designation Ultra3000 Drive

Motor phase U U Motor phase U Motor phase V V Motor phase V Motor phase W W Motor phase W Encoder A+ (digital) or Sin+ (analog) CN2-1 Encoder A+ (digital) or Sin+ (analog) Encoder A - (digital) or Sin - (analog) CN2-2 Encoder A - (digital) or Sin - (analog) Encoder B+ (digital) or Cos+ (analog) CN2-3 Encoder B+ (digital) or Cos+ (analog) Encoder B - (digital) or Cos - (analog) CN2-4 Encoder B - (digital) or Cos - (analog) Hall S1 CN2-12 Hall S1 Hall S2 CN2-13 Hall S2 Hall S3 CN2-8 Hall S3

Terminal or Pin Signal Designation

Linear Motor File Parameters

Creating a CHPS-Series Stage Motor File

The following guide supplements the information found in the Ultra3000 drive manuals. Some of the motor parameters are critical for commutation and motor protection. Incorrect entry of theses motor parameters can cause motor problems,

Ultraware assumes a linear motor is functionally equivalent to a rotary motor. However, the functional equivalent to a rotary motor is a complete linear motor driven stage. To account for the difference, the parameters highlighted in bold in the Linear Motor Parameter File (.mdb extension)

table shown below must be

adjusted to stage level specifications.

Complete CHPS-Series stage motor specifications are in the linear motor specifications information contained in this manual or the motor’s data sheet. Identify the stage motor option for your CHPS-Series stage and use the corresponding data.

Conversion Factors:

• Ultra3000 drive ampere units are measured at the peak of the sine wave, not RMS. Standard CHPS-Series stag e motors are rated both ways. Be sure to select the correct value. If necessary, use the following conversion.

ampere peak = 1.4 x RMS

92 Rockwell Automation Publication CHPS-UM001D-EN-P - July 2014

Start-up Guide for CHPS-Series Stage with Ultra3000 Drive and Ultraware Software Appendix D

• All Ultra drive electrical parameters are defined phase-to-phase. Standard CHPS-Series stage motors are specified phase-to-phase. If necessary, use the following conversion.

phase-to-phase = 2 x phase-to-neutral

Table 14 - Linear Motor Parameter File (.mdb extension)

Parameter Units Enter Comment

Force Constant N/A

Mass kg Motor model coil mass Standard CHPS-Series stages are intended for moving coil (slide) use.

Electrical Cycle Length m 0.05 for LC motors

Resistance Ohms Motor’s cold resistance Phase-to-phase directly from motor specifications.

Inductance mH Motor’s inductance Phase-to-phase directly from motor specifications.

Rated Voltage V AC Drive’s input AC voltage. LC motors are rated up to 460V AC.

Flux Saturation table — — Leave default values.

Maximum Speed m/s Lowest maximum velocity Choose the lowest maximum velocity between the encoder or the application

Intermittent Current: A

Continuous Current A

Max Current Boost — 0% For standard CHPS-Series stages without forced cooling.

Encoder Type — Select applicable type per CHPS-

Commutation Type — Sinusoidal

Startup Type — Desired commutation mode The recommended and default setting Hall Inputs and has no motion on startup.

Hall Input Offset degrees 0 For standard CHPS-Series stage motor models.

Lines/Meter — Enter the encoder lines per meter of travel. Lines are pre-quadrature resolution.

Integral Limits — Unchecked For the standard CHPS-Series stage limits option. The standard limits option is not

Integral Thermostat — Check For the standard CHPS-Series stage motor options. The PTC thermistor signal is

0-peak

lines/m 250,000 1 μm/count incremental

Motor’s linear region force constant

0.06 for LZ motors

Motor’s peak current rating Use the motor rating in the CHPS-Series Stage Selection Guide. Do not use the

Motor’s continuous current rating Use the motor rating in the CHPS-Series Stage Selec tion Guide. Do not use the

Series stage option code

500,000 0.5 μm/count incremental

2,500,000 0.1 μm/count incremental

12,500 Analog sin/cos, 20 μm period

Convert if necessary. Standard CHPS-Series stage motors specify the correct unit value.

Standard CHPS-Series stage motors specify the electrical cycle length in mm. Electrical cycle equals 2 x magnet pitch.

LZ motors are rated up to 230V AC. For stages with 0.1 um encoder option, the maximum drive input is 115V AC.

restriction. The encoder maximum velocity for the Ultra3000 drive is found in the CHPS-Series stage specifications.

values from the Motor Product Profile. The CHPS-Series LZ motors are restricted to 3x continuous current. Consult with an application engineer if you are considering increasing this value.

values from the Motor Product Profile. For CHPS-Series stages with cover and seals option, derate the base value by 10%.

Use Incremental for digital encoder or Sine/Cosine for analog encoder. Sine/Cosine requires additional set up per the Ultra3000 Drive manual.

For self-sensing, refer to the section on Self-Sensing Commutation and Startup.

Alternatively, for incremental encoders, calculate the counts/meter and divide by 4 to get lines/meter. Following are the values for the standard CHPS-Series stage encoders:

compatible with the CN2 input circuit that expects an NPN open collector limit signal.

compatible with the Ultra3000 drive thermal input circuit. Except for very earliest Ultra Drives.

Rockwell Automation Publication CHPS-UM001D-EN-P - July 2014 93

Appendix D Start-up Guide for CHPS-Series Stage with Ultra3000 Drive and Ultraware Software

Table 14 - Linear Motor Parameter File (.mdb extension)

Parameter Units Enter Comment

Software Protection — — —

Thermal Protection Rth(w-a)

Thermal Protection Cth(w-a)

ºC /W Calculate The thermal resistance with the winding at ambient temperature:

For LC motors, enter the rated thermal resistance value, multiply by 1.1 for covered and sealed stages. For 150 frame stage that use only LZ motor, enter the rated thermal resistance value. For 200 and 250 frame stages: LZ motors, enter 1.1x the rated thermal resistance value. In addition for all stages with LZ motors, multiply this value again by 1.1 for a covered and sealed stage.

W/s/

ºC Calculate Energy absorption: Cth = tm/Rth where tm is the motor's thermal time constant

in seconds. Leave the value as found if a valid LC or LZ file is used. If necessary, use the following tm values based on the heat sink size and cooling method: LC motors: tm = 1800 (seconds) LZ motors: tm = 1200 (seconds)

Recommended Start-up Sequence

Follow these steps for optimal motor commutation, performance, overcurrent, and overtemperature protection.

1. Set General Axis Parameters (.udb file extension) a. Auto Motor Iden = disabled for linear motors. b. Motor Model: select as needed. c. Total Moving Mass in kg = coil mass or magnet mass + moving

structure mass+ moving cable assembly mass + customer load.

d. Current Limits in Amperes peak - set as needed for the application. The

drive uses the lowest value between the drive rating and the motor

rating. e. Display Precision - Set to 2 decimal places. f. User Current Fault in Amperes peak - this is the continuous current. Set

as needed for the application. The drive uses the lowest value between

drive rating and the motor rating. To avoid nuisance tripping of the fast-

acting protection, it can need to be set slightly higher.

2. Follow instructions from the standard drive manual and other applicable documentation. Pay special attention to electrical noise control by using cable shielding, shield termination, grounding, and bonding.

3. Wiring must match the CHPS-Series stage and Ultra drive connectivity table provided on page 92

. Incorrect wiring or Hall offset combinations can result in motor motion that has excessive force ripple and increased current, temperature, or reduced force per unit of current.

4. Verify that the correct motor file is selected or correct custom motor parameter values are entered.

5. User Current Fault parameter - this value must not exceed the CHPSSeries stage motor’s continuous current rating.

94 Rockwell Automation Publication CHPS-UM001D-EN-P - July 2014

Start-up Guide for CHPS-Series Stage with Ultra3000 Drive and Ultraware Software Appendix D

6. Current Limit parameters - the positive and negative current limit, must not exceed the CHPS-Series stage motor’s intermittent current rating. Set per the application requirements.

7. Verify correct encoder polarity and test distance count. Encoder must count in positive direction when CHPS-Series stage is moving in the positive stage direction as shown in Stage Positive Direction

on page 48. Also see CHPS-Series Stage and Ultra3000 Drive Troubleshooting

Reference on page 96. Incorrect encoder sequencing can cause a runaway

motor condition or incorrect commutation.

8. Perform Commutation Diagnostics only if enough free +/- travel distance is available. You can guarantee optimal commutation only by doing oscilloscope verification.

You can use the following checks for non-optimal commutation verification. These tests cannot detect bad spots and other anomalies.

• Use Current Control Panel mode to give a small positive current

command. Verify the stage moves in the positive direction.

• Check for consistent force resistance over whole travel by pushing the

slide to multiple locations.

• Check that the amount of current to move the load and overcome

friction forces at a low steady speed are correct.

• The motor’s force constant (Kf ) can also be verified with a force gauge.

The Ultraware software command units for current scaling are in

/V.

0-peak

9. When current mode tests successfully, perform auto velocity or manual velocity tuning with the Ultraware oscilloscope function, do this even if you are using current mode to control your application. This further evaluates commutation and check for a good step response.

Rockwell Automation Publication CHPS-UM001D-EN-P - July 2014 95

Appendix D Start-up Guide for CHPS-Series Stage with Ultra3000 Drive and Ultraware Software

IMPORTANT

(+)

(-)

Slide End Cap + Slide = Slide Assembly

Positive Direction

CHPS-Series Stage and Ultra3000 Drive Troubleshooting Reference

The section contains troubleshooting reference for the CHPS-Series stage and Ultra3000 drive combination.

Positive Phasing Direction

Positive stage direction = slide moving towards junction box or cable exit end as shown here.

Encoder Counting Polarity

Encoder must count in positive direction when moving in the positive direction.

Incorrect encoder sequencing can cause a runaway motor condition or incorrect commutation.

96 Rockwell Automation Publication CHPS-UM001D-EN-P - July 2014

Start-up Guide for CHPS-Series Stage with Ultra3000 Drive and Ultraware Software Appendix D

0° 60° 120° 180° 240° 300° 360°

Oscilloscope Verification

Correct stage and Ultra3000 drive wiring yields the phase relationship shown in Hall Oscilloscope Diagram.

Figure 26 - Hall Oscilloscope Diagram

• Data capture direction - stage positive phasing direction as shown in

Positive Phasing Direction

on page 96.

• S1 leads S2 leads S3, 120° electrical spacing.

• For standard stages have following phase relationship:

S1 in phase with W-U S2 in phase with U-V S3 in phase with V-W

• Hall probe GND to Hall common and, for W-U for example, coil probe tip = W and probe GND = U

• If wiring is correct the causes for incorrect phasing are: – non-standard coil or Hall assembly – coil electrical problem – Hall module electrical or mechanical problem

Rockwell Automation Publication CHPS-UM001D-EN-P - July 2014 97

Appendix D Start-up Guide for CHPS-Series Stage with Ultra3000 Drive and Ultraware Software

0° 60° 120° 180° 240° 300° 360°

BEMF

Hall

Oscilloscope Diagram for Ultra3000 Drive

Motor with Hall offset = 0° While moving slide in positive direction.

Ultra Drive phasing pairs:

S1 vs. W-U

Ultra3000 DriveS2 vs. U-V

S3 vs. V-W

98 Rockwell Automation Publication CHPS-UM001D-EN-P - July 2014

Start-up Guide for CHPS-Series Stage with Ultra3000 Drive and Ultraware Software Appendix D

Reference Information

Refer to these sections for information about the following:

• Commutation Diagnostics Utility

• Self-sensing Commutation and Startup

• Main Screen Setup

• Motor Screen

• Faults Screen

Commutation Diagnostics Utility

This test utility is intended for custom motors that do not have verified optimal phasing information. It can be used instead of the Ultraware oscilloscope based

(1)

phasing method given in the Ultra3000 Drive Manual make false recommendations if the test set-up current level is too low, or an obstruction is encountered during the test motion. The CHPS-Series stage wiring must not deviate from the standard wiring. Do not use the utility if the free travel distance of the application is less than the required ± test motion.

These are the pre-test requirements.

. The test utility can

1. Check for mechanical problems with the stage assembly.

2. Use a test current value high enough to overcome non-acceleration forces

of stiction and friction, cable drag, magnetic attraction. A typical value used is 15…20%. But values as high as 40% can be necessary.

3. Verify the free travel range from motor starting position is at least two magnet pitches or 1 electrical cycle, in the negative direction, and four magnet pitches or 2 electrical cycles, in the positive direction.

(1) The phasing diagram in the drive manual is for phase-to-neutral measurements. This requires use of a balanced resistor Y network

to create a virtual neutral. Alternatively, the phase-to -phase diagrams and procedures in the Ultra 100/200 can be used because they are equivalent to each other after the phase shift correction is made.

Rockwell Automation Publication CHPS-UM001D-EN-P - July 2014 99

Appendix D Start-up Guide for CHPS-Series Stage with Ultra3000 Drive and Ultraware Software

Self-sensing Commutation and Startup

This type of commutation does not use the Hall effect sensor. Motors with a Hall effect sensor connection can be set to self-sensing commutation, the Hall effect signals are ignored. Self-sensing start-up is not commutation diagnostics. You can perform commutation diagnostics at any time on Hall effect or self-sensing motors. Self-sensing start-up refers to the motor motion initialization that is executed automatically after every power-up and enabling of the system. It synchronizes the arbitrary encoder position or count to the drive’s initial commutation angle.

This is the self-sensing start-up sequence:

• Enable is activated.

• Motor locks into detent or zero force position > up to ± one magnet pitch

(½ electrical cycle) of motion jerk.

• After jerk motion settles out in 1 or 2 seconds, motor executes a slow speed

test move of approximately two magnet pitches or one electrical cycle in the positive direction.

• Drive disables, ready for normal operation.

During this startup, the drive evaluates the test motion. A fault indicates that the motor motion was not as expected. Possible reasons include the following:

• Mechanical problem with the stage such as excessive stiction, friction, or

cable drag.

• Obstruction during test motion.

• Incorrect coil or encoder wiring.

• Encoder or signal problems, device fault, wiring problem, noise.

• During startup, the drive uses a fixed 1/6 of the peak motor or drive

current, whichever is lower.

Ultraware software version 1.3 with firmware revision 1.16 (or greater) has improved functionality with proper alignment under any single obstruction:

• If during the positive test move, after detent, an obstruction is

encountered, a test move is done in the opposite direction after reinitializing the new detent.

• If an obstruction prevents the motor from going to the real detent, for

example, detent past negative hard stop, the Ultra drive senses a false detent during the test move due to false alignment. After re-initializing of the new detent a second test move is done in the positive direction.

• The self-sensing routine can take 2x longer because of obstructions.

• If a second obstruction is detected during whole routine, such as low test

current or too high friction, the test faults.

• The new versions lets a user programmable test current value.

• Limit signals sent to the Ultra Drive are ignored during self-sensing start-

up.

100 Rockwell Automation Publication CHPS-UM001D-EN-P - July 2014

Rockwell Automation CHPS-250 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Summary of Changes

New and Updated Information

Table of Contents

Preface

About This Publication

Who Should Use This Manual

Additional Resources

Chapter 1

Stage Safety

Safety Labels

Figure 1 - Warning Label Locations

Clearances

General Safety

Heat

Vertical or Incline Payload

End Cap Impacts

Air Freight Transportation

Standards

Motor Model Identification

Understanding Your Stage

Chapter 2

Identifying the Components of Your Stage

Figure 2 - Components of Your Linear Stage

Component Description

Recommended Maintenance Interval

Identifying Your Stage

Chapter 3

Planning the Stage Installation

Stage Mounting Requirements

General Safety Standards for Stage Installations

Mounting Restrictions

Environmental Factors

Mounting Surface Restrictions

Clearance Requirements

Figure 3 - Minimum Clearance Requirements

Chapter 4

Mounting the Stage

Unpacking, Handling, and Inspection

Unpacking Procedure

Store Packaging Material

Stage Storage

Mounting the Stage

Before You Begin the Mechanical Installation

Determine the Number of Fasteners Required

Figure 5 - Fasteners Required for Stages 250 mm frame size (CHPS-x9xxx-xLMxxx)

Determine the Type of Fastener to Use

Table 1 - Mounting Fastener Options

Figure 6 - Through Bolt Mounting

Figure 7 - Toe Clamps Mounting

Figure 8 - Tee Nut Mounting

Mounting the Stage

Mount Your Application

Connector Data

Chapter 5

Kinetix Servo Drive Compatible Connectors

D-Type Connectors

Flying Leads

Junction Box Connectors

Table 2 - Junction Box Power Connector

Table 3 - Junction Box J1 Connector

Limit Sensor Flying Leads

Chapter 6

Connecting the Stage

Connecting the Stage

Attaching the Ground Strap and Interface Cables

Figure 9 - Connecting Kinetix Type Motor and Feedback Cables

Thermal Protection

Optional Limit Sensors

Figure 10 - Limit Sensor Orientation

TTL Differential Encoder Output Signal

Figure 11 - TTL Differential Encoder Timing Diagram

Figure 12 - TTL Differential Encoder Termination

Sine/Cos Encoder Output Signals

Figure 13 - Sine/Cos Encoder Timing

Figure 14 - Sine/Cos Encoder Termination

Hall Effect Circuit