Rockwell Automation MPAS User Manual
User Manual
MP-Series Integrated Linear Stages
Catalog Numbers MPAS-A6xxx1-V05SxA, MPAS-A6xxx2-V20SxA, MPAS-A8xxx1-V05SxA, MPAS-A8xxx2-V20SxA,
MPAS-A9xxx1-V05SxA, MPAS-A9xxx2-V20SxA, MPAS-B6xxx1-V05SxA, MPAS-B6xxx2-V20SxA, MPAS-B8xxx1-V05SxA,
MPAS-B8xxx2-V20SxA, MPAS-B9xxx1-V05SxA, MPAS-B9xxx2-V20SxA, MPAS-A6xxxB-ALMx2C, MPAS-A8xxxE-ALMx2C,
MPAS-A9xxxK-ALMx2C, MPAS-B8xxxF-ALMx2C, MPAS-B9xxxL-ALMx2C
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, CompactLogix, ControlLogix, Kinetix, Logix5000, MP-Series, RSLogix, Studio 5000 Logix Designer, Studio 5000, Ultra3000, SoftLogix, Rockwell Soft ware, and Rockwell Automation, 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
Studio 5000 Logix Designer™ application is the rebranding of RSLogix™ 5000 software 9
Update connector attachment procedure 34
Update the maximum air pressure rating 37
Updated connector and cable information 39…41
Updated dimension drawing for MP-Series Linear Stages (MPAS-A/B8xxx1/2-VxxSxA) 77
Update cable information 88…90
Rockwell Automation Publication MP-UM001D-EN-P - September 2013 3
Summary of Changes
Notes:
4 Rockwell Automation Publication MP-UM001D-EN-P - September 2013
Safety
Table of Contents
Preface
About This Publication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Who Should Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Studio 5000 Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Chapter 1
Safety Labels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Clearances. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
General Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Vertical or Inclined Payload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
End of Travel Impacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Air Freight Restrictions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Motor Model Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Understanding Your Linear Stage
Planning Your Installation
Mounting and Connecting
Chapter 2
Identifying Your Linear Stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Identifying the Components of Your Linear Stage . . . . . . . . . . . . . . . . . . 19
Component Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Maintenance Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Lubrication Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Cable Carrier Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Chapter 3
General Safety Standards for Linear Stage Installations . . . . . . . . . . 23
UL Safety Standards for Linear Stage Installations. . . . . . . . . . . . . . . 24
Mounting Restrictions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Chapter 4
Unpacking, Handling, and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Unpacking Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Store Packaging Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Linear Stage Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Mounting the Linear Stage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Before You Begin the Mechanical Installation. . . . . . . . . . . . . . . . . . . 30
Mount the Linear Stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Connecting the Linear Stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Attach the Ground Strap and Interface Cables . . . . . . . . . . . . . . . . . 35
About the Air Option for Ball Screw Linear Stages . . . . . . . . . . . . . . . . . 37
About the Brake Option for Ball Screw Linear Stages . . . . . . . . . . . . . . . 37
Meeting UL Installation Standards for the Linear Stage . . . . . . . . . . . . . 38
Rockwell Automation Publication MP-UM001D-EN-P - September 2013 5
Table of Contents
Chapter 5
Connector Data
Configuration Guidelines
Maintenance
Linear Stage Power and Feedback Connections . . . . . . . . . . . . . . . . . . . . . 39
PTC Thermal Signal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Chapter 6
Required Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Configuring Your Linear Stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Configuring the Logix Designer Application for
Linear Stages with Kinetix Multi-axis Drives . . . . . . . . . . . . . . . . 45
Setting Axis Properties in the Logix Designer Application. . . . . . . . 45
Tuning Linear Stages by Using the Logix Designer Application. . . 48
Configuring Ultraware Software for Linear Stages
with Ultra3000 Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Setting Travel Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Home to Torque Programming for Kinetix Multi-axis
Drives with Linear Stages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Chapter 7
Before You Begin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Recommended Maintenance Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Bearing Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Strip Seal Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Cover Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Removing and Replacing
Components
Troubleshooting
Dimensions
Chapter 8
Before You Begin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Cable Carrier Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Cable Carrier Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Strip Seal Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Cover Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Cover Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Strip Seal Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Side Cover Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Rotary Motor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Chapter 9
Troubleshooting During Commissioning and Start-up . . . . . . . . . . . . . . 69
Operational Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Direct Drive Linear Stage Evaluation Procedure . . . . . . . . . . . . . . . . 71
Ball Screw Linear Stage Evaluation Procedure . . . . . . . . . . . . . . . . . . . 71
Appendix A
MP-Series Linear Stage Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
6 Rockwell Automation Publication MP-UM001D-EN-P - September 2013
Appendix B
Table of Contents
Accessories
Stacking Stages
Interconnect Diagrams
Home to Torque-level Example
Installation, Maintenance, and Replacement Kits . . . . . . . . . . . . . . . . . . . 83
Appendix C
Stage Stacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Specifications for Stacked Stages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Appendix D
Wiring Examples. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Motor/Axis Module Wiring Examples . . . . . . . . . . . . . . . . . . . . . . . . . 88
Appendix E
Applicable Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
About Home to Torque-level Homing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Drive Bipolar Torque Limit Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Disable Soft Overtravel Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Ladder Code Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Potential for Position Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Appendix F
Mounting Bolts and Torque Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Rockwell Automation Publication MP-UM001D-EN-P - September 2013 7
Table of Contents
8 Rockwell Automation Publication MP-UM001D-EN-P - September 2013
Read this preface to familiarize yourself with the rest of the manual.
Preface
About This Publication
Who Should Use This Manual
This manual provides detailed installation instructions for mounting, wiring,
maintaining, and troubleshooting your MP-Series integrated linear stage. For
ease of use, going forward, it is referred to as a linear stage.
This manual is intended for engineers or technicians directly involved in the
installation, wiring, and maintenance of linear stages. Any person that teaches,
operates, or repairs these linear stages must be trained and demonstrate the
competence to safely perform the assigned task.
If you do not have a basic understanding of linear stages, contact your local AllenBradley distributor or Rockwell Automation sales representative for information
on available training courses before using this product.
Read this entire manual before you attempt to install a linear stage into your
machine. Doing so familiarizes you with the linear stage components and their
relationship to each other and the system. After installation, check all system
parameters to be sure you have configured your Logix control system properly. Be
sure to follow all instructions carefully and pay special attention to safety
concerns.
Studio 5000 Environment
The Studio 5000™ Engineering and Design Environment combines engineering
and design elements into a common environment. The first element in the Studio
5000 environment is the Logix Designer application. The Logix Designer
application is the rebranding of RSLogix 5000 software and continues to be the
product to program Logix5000™ controllers for discrete, process, batch, motion,
safety, and drive-based solutions.
The Studio 5000 environment is the foundation for the future of Rockwell
Automation® engineering design tools and capabilities. This environment is the
one place for design engineers to develop all of the elements of their control
system.
Rockwell Automation Publication MP-UM001D-EN-P - September 2013 9
Preface
Additional Resources
These documents contain additional information concerning related products
from Rockwell Automation..
Resource Description
Kinetix Motion Control Selection Guide, publication GMC-SG001 Provides an overview of Kinetix servo drives, motors, actuators, and motion accessories designed
Kinetix 2000 Multi-axis Servo Drive User Manual, publication
2093-UM001
Kinetix 6000 Multi-axis Servo Drive User Manual, publication
2094-UM001
Logix5000™ Controllers General Instructions Reference Manual, publication 1756-
RM003
ControlLogix System User Manual, publication 1756-UM001 Information on configuring and troubleshooting your ControlLogix controller system
SoftLogix Motion Card Setup and Configuration Manual, publication 1784-UM003 Information on configuring and troubleshooting your SoftLogix PCI card
System Design for Control of Electrical Noise Reference Manual, publication GMC-
RM001
Motion Analyzer is available at
http://www.ab.com/motion/software/analyzer.html
Rockwell Automation Product Certification website, publication available at http://
ab.com/
National Electrical Code. Published by the National Fire Protection Association of
Boston, MA.
Allen-Bradley Industrial Automation Glossary, publication AG-7.1
Drives and Motion Accelerator Toolkit Quick Start, publication IASIMP-QS019 Information on how Bulletin MPAS stages (referred to a gantry A and B in this public ation are
Ultra3000 Digital Servo Drives Installation Manual,
publication 2098-IN003
Ultra3000 Digital Servo Drives Integration Manual,
publication 2098-IN005
Home to Torque-level Example Application Notes,
publication MOTION-AT001
to help make
initial decisions for the motion control products best suited for your system requirements.
How to install, set up, and troubleshoot a Kinetix 2000 drive
How to install, set up, and troubleshoot a Kinetix 6000 drive
The instructions needed to program a Logix5000™ application
Information, examples, and techniques designed to minimize system failures caused by
electrical noise
Drive and motor sizing with application analysis software
For declarations of conformity (DoC) currently available from Rockwell Automation
An article on wire sizes and types for grounding electrical equipment
A glossary of industrial automation terms and abbreviations
used in a drives and motion application.
How to install, set up, and troubleshoot an Ultra™ 3000 drive
Describes Logix Designer application homing routines
You can view or download publications at
http://www.rockwellautomation.com/literature
technical documentation, contact your local Allen-Bradley distributor or
Rockwell Automation sales representative.
10 Rockwell Automation Publication MP-UM001D-EN-P - September 2013
. To order paper copies of
Safety
IMPORTANT
Top ic Pa ge
Safety Labels 12
Clearances 13
General Safety 13
Heat 14
Vertical or Inclined Payload 14
End of Travel Impacts 14
Air Freight Restrictions 14
Standards 15
Motor Model Identification 15
Chapter 1
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 MP-UM001D-EN-P - September 2013 11
Chapter 1 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 linear stage, review the safety labels and the
details and location for each table before using the linear stage.
12 Rockwell Automation Publication MP-UM001D-EN-P - September 2013
Figure 1 - Label Locations for Direct Drive Linear Stages
E
B
D
Product
Nameplate
A
C
F
LIFT HAZARD
Two Person Lift
or carry required
DANGER
PINCH POINTS
Moving parts ins
ide
Lockout /Tagout
270 kPa
40 PSI
MAXIMUM
PRESSURE
E
Product
Nameplate
A
F
DANGER
PINCH POINTS
oving parts inside
M
Tagout
ockout /
L
LIFT HAZARD
Two Person Lift
or carry required
M
D
A
GN
A
L
O
C
E
N
A
TI
TE
C
G
C
F
D
I
a
E
I
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ER
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TH
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CKO
LO
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W
PO
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AG
G
T
N
CI
VI
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E
S
E
R
O
F
E
B
Figure 2 - Label Locations for Ball Screw Linear Stages
Safety Chapter 1
Clearances
Install the linear stage to avoid interference with the building, structures, utilities,
other machines and equipment that can create a trapping hazard of pinch points.
General Safety
Dress cables by using the Clearance Requirements on page 26
cross the path of motion or interfere with the cable carrier motion.
Linear stages are capable of sudden and fast motion. In no event will Rockwell
as a guide. Do not
Automation, Inc. be responsible or liable for indirect or consequential damages
resulting from the use or application of this equipment.
Rockwell Automation Publication MP-UM001D-EN-P - September 2013 13
Chapter 1 Safety
Heat
Vertical or Inclined Payload
End of Travel Impacts
When the stage is running at its maximum rating, the temperature of the carriage
can reach 75
A direct drive (linear motor driven) linear stage mounted vertically or on an
incline does not maintain position when the power is removed. Under the
influence of gravity the carriage and its payload falls to the low end of travel.
Design engineers must account for this by using a ball screw driven linear stage
with power-off holding brake, or designing in controlled power down circuits or
mechanical controls to prevent the linear stage and its payload from being
damaged when the power fails.
The internal bumpers of the linear stage are designed to take a large impact from
uncontrolled motion. Setting Travel Limits on page 55
bumpers can absorb before risking damage to the linear stage. The carriage
payload must be secured to the carriage 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 linear stage.
ºC (167 ºF).
lists the energy that the
Air Freight Restrictions
When air freighting linear 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. Always 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 direct drive linear stages (catalog numbers MPASA8xxxE-ALMx2C, MPAS-B8xxxF-ALMx2C, MPAS-A9xxxK-ALMx2C, or
MPAS-B9xxxL-ALMx2C) 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 specific Magnetized Material Handling Labels, and instructions
for preparing the Shipper's Declaration for Dangerous Goods.
14 Rockwell Automation Publication MP-UM001D-EN-P - September 2013
Safety Chapter 1
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
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
Motor Model Identification
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
· UL 1740, UL Standard for Safety Industrial Robots and Robotic
Equipment
The nameplate on ball screw driven linear stages lists the specific MP-Series servo
motor model used.
Rockwell Automation Publication MP-UM001D-EN-P - September 2013 15
Chapter 1 Safety
Notes:
16 Rockwell Automation Publication MP-UM001D-EN-P - September 2013
Understanding Your Linear Stage
Top ic Pa ge
Identifying Your Linear Stage 18
Identifying the Components of Your Linear Stage 19
Maintenance Intervals 22
Chapter 2
Rockwell Automation Publication MP-UM001D-EN-P - September 2013 17
Chapter 2 Understanding Your Linear Stage
MPAS - x x xxx x - x xx x x x
Voltage C lass
A = 200V
B = 400V
Actuator Type
AS = Actuator, linear stage
Frame Size
(2)
6 = 150 mm base width
8 = 200 mm base width
9 = 250 mm base width
Stroke Length
(1)
xxx = xxx mm x 10
Mechanical Drive/Motor Typ
1 = Ballscrew/MPLS-x210E-V 2 = Ballscrew/MPLS-x220H-V
B = Direct Drive/6-frame, 200V-class K = Direct Drive/9-frame, 200V-class
E = Direct Drive/8-frame, 200V-class L = Direct Drive/9-frame, 400V-class
F = Direct Drive/8-frame, 400V-class
Feedback
V = Multi-turn high-resolution encoder (absolute feedback) 128 cycle/rev. (ballscrew only)
A = 5 micron resolution incremental magnetic linear encoder (direct drive only)
Screw Lead/Direct Drive
05 = 5.0 mm/rev (0.19 in./rev) ballscrew with rotary motor
20 = 20.0 mm/rev (0.79 in./rev) ballscrew with rotar y motor
LM = Linear motor (direct drive only)
Brake
2 = No brake
4 = 24V DC brake (ballscrew only)
Cable
A = No cable track module (ballscrew only)
C = Cable track module with IP67 intercontec connectors (direct drive only)
Cover
S = Covered with strip seals (IP30 protection)
O = Open
Actuator Series
MP = MP-Series
Identifying Your Linear Stage
Use the following key to identify your linear stage and its options.
(1) For 6-frame direct-drive linear stages, variable xxx (mm stroke x 10) is 012, 018, 024, 030, 036, 042, 054, 066, 078, 090, 102, or 114.
For 8 and 9-frame direct-drive linear stages, variable xxx (mm stroke x 10) is 014, 020, 026, 032, 038, 044, 056, 068, 080, 092, 104, 128, 152, 176, or 194.
For 6-frame ballscrew linear stages, variable xxx (mm stroke x 10) is 012, 018, 024, 030, 036, 042, 054, or 066.
For 8 and 9-frame ballscrew linear stages, variable xxx (mm stroke x 10) is 012, 018, 024, 030, 036, 042, 054, 066, 078, 090, or 102.
(2) The 150 mm (6-frame) linear stages are available in ballscrew (200 and 400V-class) and direct drive (200V-class only).
The 200 mm (8-frame) linear stages are available in ballscrew and direct drive (200 and 400V-class).
The 250 mm (9-frame) linear stages are available in ballscrew and direct drive (200 and 400V-class).
18 Rockwell Automation Publication MP-UM001D-EN-P - September 2013
Understanding Your Linear Stage Chapter 2
7 (2x)
6
8 (4x)
9 (4x)
2 (4x)
4
3
1
5 (2x)
10
11
12 (4x)
13 (2x)
14
15
Identifying the Components of Your Linear Stage
Use the diagrams and descriptions to identify individual components of the
linear stages.
Not all components are part of the direct drive or the ball screw linear stage. For
example, the direct drive linear stage does not have component 20
Motor and the ball screw linear stage does not have component 6
- Rotary
- Cable Carrier
Module.
Figure 3 - Components of the Direct Drive Linear Stage (MPAS-xxxxxxx-ALMx2C)
Refer to Component Descriptions beginning on page 21 for the name and
description of each numbered item.
Rockwell Automation Publication MP-UM001D-EN-P - September 2013 19
Chapter 2 Understanding Your Linear Stage
18
17
19
20
16
12 (4x)
13 (2x)
7 (2x)
8 (4x)
9 (4x)
2 (4x)
4
3
1
5 (2x)
21
Figure 4 - Components of the Ball Screw Linear Stage (MPAS-xxxxxx-VxxSxA)
Refer to Component Descriptions beginning on page 21 for the name and
description of each numbered item.
20 Rockwell Automation Publication MP-UM001D-EN-P - September 2013
Understanding Your Linear Stage Chapter 2
Component Descriptions
Item Name Notes
1 Ground Screw and Ground Label Use the labeled M5 x 0.8 - 6H ground screw to connect the linear stage to a facility safety ground.
2 Bearing Lubrication Ports These capped ports provide access to the linear bearings without dismantling the linear stage. In addition, these
. Carriage
4 Top Cover This protective cover has magnetic edges that keep the upper edge of the strip seals in place. A cover is an option on
5 Side Cover These protective covers have magnetic edges that keep the lower edge of the strip seal in place. Side covers are an
6 Cable Carrier Module This assembly contains the power an d I/O wiring for direct drive linear stages. It facili tates quick and easy replacement
7 Stainless Steel Strip Seal These replaceable flexible stainless steel strips permit the linear stage to move while isolating the internal mechanism
8 Seal Guide These guides lets the strip seal to move smoothly around the carriage of the linear stage.
9 Seal Strip Clamps These clamps hold the strip seal in place. When replacing the seal strips, they are used to position it so it lays smooth
10 Magnetic Encoder Readhead This encoder readhead has a 5 micron resolution and very low maintenance needs.
11 Encoder Strip Part of the encoder system that provides magnetic encoded polarities to the encoder readhead.
12 Bearing These support bearings guide the carriage on the bearing rail and require periodic lubrication.
13 Bearing Rail These rails provide the linear track that the carriage assembly rides on, they must be kept free of debris.
14 Motor Coil This coil is par t of the two piece linear motor. When it is excited by a drive, it generates magnetic forces that interact
15 Magnet Track This track of powerful static magnets is the other half of a linear motor.
16 Ball Nut Lubrication Port This capped ports provide access to the ball nut without dismantling the linear stage.
17 Ball Screw Shaft This is part of the mechanical power system on ball screw linear stages. This shaft must be kept free of debris.
18 Ball Nut Transfers mechanical power from the ball screw shaft to the carriage. It requires periodic lubrication.
19 Side Cover Support These supports stabilize the side cover on long linear stages.
20 Rotary Motor A Rockwell Automation MPLS rotary motor drives the ball screw mechanis m. It is a specially configured MP-Series
21 Air Port Provides an external air supply connection for a ball screw linear stage. A maximum of 270 kPa (40 psi) of pressurized
This is where your load mounts. The carriage has both mounting holes and pilot guide holes.
tapped holes (M10 x 1.5 -6H) can be used to secure lifting hooks (not provided).
the direct drive linear stages.
option on the direct drive linear stages.
of this wear item. It is available as a spare part.
of the linear stage from the users environment. Keep the strip seals clean, and never apply a lubricant as this attracts
contaminants.
against the top and side covers.
with the magnet track creating motion.
rotary motor, and is available as a spare part.
air can be applied to minimize the ingress of particulates from a dusty environment.
Rockwell Automation Publication MP-UM001D-EN-P - September 2013 21
Chapter 2 Understanding Your Linear Stage
Maintenance Intervals
This section lists typical maintenance intervals for your linear stage, and
references the section where maintenance procedures are described.
Lubrication Intervals
Refer to the Chapter 7 for lubrication procedures. The following lubrication
intervals are recommended.
• Direct drive linear stages every 6 months or 5000 km of travel
• Ball screw linear stages every 3 months or 150,000,000 revolutions
Cable Carrier Replacement
The cable carrier module’s useful lifetime is approximately 10,000,000 cycles.
Refer to the Chapter 8
for removal and replacement procedures.
22 Rockwell Automation Publication MP-UM001D-EN-P - September 2013
Chapter 3
Planning Your Installation
Top ic Pa ge
General Safety Standards for Linear Stage Installations 23
UL Safety Standards for Linear Stage Installations 24
Mounting Restrictions 24
Requirements to be met when mounting your linear stage include the following.
General Safety Standards for Linear 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
Rockwell Automation Publication MP-UM001D-EN-P - September 2013 23
Chapter 3 Planning Your Installation
UL Safety Standards for Linear Stage Installations
All linear stage installations must follow UL 1740 - Standard for Safety for
Robots and Robotic Equipment.
UL 1740 covers robots and robotic equipment rated at 600V or less and intended
for installation in accordance with the National Electrical Code, ANSI/NFPA
70. Because end user installation of a robot and robotic equipment can vary for
each user application, guidelines for end-product installation can be evaluated to
the applicable sections of ANSI/RIA R15.06, Standard for Industrial Robots and
Robot Systems-Safety Requirements. Portions of the requirements in this
standard have been excerpted from the Robotic Industries Association's (RIA)
Standard for Industrial Robots and Robot Systems – Safety Requirements,
ANSI/RIA R15.06.
ANSI/RIA R15.06 specifically requires two safety features be in the design.
• A Power Enable light must be installed that meets all of these conditions:
– Must be amber or yellow in color.
– Must not have a screw type base or contain a filament.
– Must be visible from all approaches to the work cell.
– Must illuminate to indicate that drive power is available and motion is
possible.
For example, an Allen-Bradley 855T Control Tower Stack Light can be
used with socket mount status indicators. Incandescent bulbs are not
permitted.
• Provide a means of emergency movement without drive power available.
This must include a provision for a brake release on a ball screw linear
stage.
For additional information, refer to the Emergency Brake Release for Ball
Screw Linear Stage Example on page 38.
Unique features or functions associated with the robotic application, not
specifically addressed in UL 1740, shall also be evaluated to other applicable
standards and requirements. These can include, but are not limited to the
following:
• UL 3101-1, Electrical Equipment for Laboratory Use; Part 1: General
Requirements
• UL 544, Medical and Dental Equipment
• UL 79, Power Operated Pumps for Petroleum Product Dispensing
Systems
• ANSI/NFPA 79, Electrical Standard for Industrial Machinery
Mounting Restrictions
When locating your MPAS stage include the following:
24 Rockwell Automation Publication MP-UM001D-EN-P - September 2013
Planning Your Installation Chapter 3
• Environmental Factors
• Mounting Surface Restrictions
• Mounting Orientations for Direct Drive Linear Stages
• Mounting Orientations for Ball Screw Linear Stages
• Clearance Requirements
Environmental Factors
Factor Applicability
Temperature The linear stage does not require any special cooling considerations. Avoid mounting it near any heat generating objects, such as a heat
Humidity Avoid excessive humidity that can cause condensation on metal surfaces and consequently stage corrosion. The maximum permissible
Access and interference When possible, locate the system where sufficient working space is available to perform periodic maintenance.
Dust and airborn e contaminants Avoid placing the stage in areas where excessive dust or other airborne contaminants are present. Chemical fumes or vapors can cause damage
Vibration The linear stage must be installed in a location free of excessive vibration.
Ambient light Sufficient light must be readily available to enable inspection, testing, and other functions to be performed on the stage.
register. Sustained average operating temperature must not be greater than 40 °C (104 °F), nor less than 0 °C (32 °F).
noncondensing humidit y is 80% relative.
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.
to internal compon ents.
Mounting Surface Restrictions
Surface Restriction
Flatness Stages are to be bolted or clamped to a flat, stable, and rigid surface along its entire 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 linear stage.
Mounting Orientations for Direct Drive Linear Stages
Mounting Orientation Restriction
Ceiling - inverted surface A ceiling mount (inverted on a horizontal surface) is not recommended. Stages mounted in this orientation are subject to premature cable
Wall - horizontal Horizontal wall mount stages must be of the covered and sealed configuration.
Wall - vertical or incline Vertical wall mount or inclined stages must be of the covered and sealed configuration.
carrier failure.
Stages mounted horizontally on a wall must have a travel of 1 m (3.28 ft) or less. Stages with a travel length greater than 1 m (3.28 ft) are
subject to premature cable carrier failure.
Stages mounted vertically on a wall must have a travel of 1 m (3.28 ft) or less. Stages with a travel length greater than 1 m (3.28ft) are subject
to premature cable carrier failure.
Rockwell Automation Publication MP-UM001D-EN-P - September 2013 25
Chapter 3 Planning Your Installation
419 mm (16.5 in.) Clearance Both Ends for Lubrication Access
3.2 mm (0.125 in.) Clearance Around Entire Stage
MPAS-xxxxxxx-ALMx2C
MPAS-xxxxxxx-VxxSxA
Additional clearance is required for power
and feedback cables.
Mounting Orientations for Ball Screw Linear Stages
Mounting Orientation Restriction
Ceiling - inverted surface A ceiling mount (inverted on a horizontal surface) must be of the covered and sealed configuration, and have a travel of 300 mm (11.8 in.) or
Wall - horizontal A horizontal wall mount stages must be of the covered and sealed configuration.
Wall - vertical or incline Vertical wall mount or inclined stages must have a brake option. Application of the holding brake option through operating program settings
less.
prevents uncontrolled motion.
Clearance Requirements
The figures depict the minimum clearances for each stage type.
Power and feedback cables can impose additional clearance requirements. Refer
to Installation, Maintenance, and Replacement Kits on page 83
and bend radius requirements.
Figure 5 - Minimum Clearance Requirements
for connector
26 Rockwell Automation Publication MP-UM001D-EN-P - September 2013
Mounting and Connecting
IMPORTANT
Top ic Pa ge
Unpacking, Handling, and Inspection 27
Linear Stage Storage 30
Mounting the Linear Stage 30
Connecting the Linear Stage 34
About the Air Option for Ball Screw Linear Stages 37
About the Brake Option for Ball Screw Linear Stages 37
Meeting UL Installation Standards for the Linear Stage 38
Chapter 4
Unpacking, Handling, and Inspection
Any person that teaches, operates, maintains, or repairs these linear stages
must be trained and demonstrate the competence to safely perform the
assigned task.
Inspect packaging to make certain no damage has occurred in shipment. Any
damage or suspected damage must be immediately documented. Claims for
damage due to shipment are usually made against the transportation company.
Contact Allen-Bradley immediately for further advice.
Be sure the information listed on the purchase order correlates to the information
on the packing slip for your linear stage and its accessories. Inspect the assemblies
and confirm, if applicable, the presence of specified options.
ATT EN TI ON : Direct drive linear stages contain powerful permanent magnets
that require extreme caution during handling. Do not disassemble the linear
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.
Rockwell Automation Publication MP-UM001D-EN-P - September 2013 27
Chapter 4 Mounting and Connecting
User Manual
Packing End Caps
Desiccant
Unpacking Procedure
The following tools are recommended for unpacking the linear stage:
• Utility knife
• 2.5mm, 5mm, and 6mm hex keys
• Packing tape
Unpack your linear stage by doing the following.
1. Place the carton on a flat stable surface with the tape seam side facing you.
2. Use a utility knife to score the packing tape at the edges of the carton.
3. Lift center cover to reveal the linear 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
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 only the base near the end caps.
28 Rockwell Automation Publication MP-UM001D-EN-P - September 2013
Mounting and Connecting Chapter 4
Support Straps
1/4 1/4 1/4 1/4
End Cap End Cap
Shipping Brace
3M SHCS, washer, and nut (x4)
Shipping Clamp
M6 x 75 SHCS (x2) for
MPAS-x6xxxxx (150 mm)
M6 x 75 SHCS (x2) for
MPAS-x8xxxxx (200 mm) or
MPAS-x9xxxxx (250 mm)
M6 x 30 SHCS (x2) for
MPAS-x6xxxxx (150 mm)
M8 x 30 SHCS (x2) for
MPAS-x8xxxxx (200 mm) or
MPAS-x9xxxxx (250 mm)
• 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.
The figure below lists the correct hex wrench for each linear stage.
8. Lift the shipping brace off the linear stage and set it aside.
9. Remove the plastic wrap enclosing the linear stage and set it aside.
10. Remove the four SHCS that secure the shipping clamp.
11. Remove the four square nuts loosened in the previous step, by sliding each
Rockwell Automation Publication MP-UM001D-EN-P - September 2013 29
nut to the end of channel.
Chapter 4 Mounting and Connecting
fasteners
stroke (cm) + 36 (cm)
12
----------------------------------------------------
round down 1+
2×=
fasteners
stroke (cm) + 26 (cm)
12
----------------------------------------------------
round down 1+
2×=
Store Packaging Material
Keep the carton and packing materials in case the linear stage needs to be
returned for warranty service or stored for an extended period of time.
1. Tape screws and clamp hardware to the plywood board brace.
2. Put the 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 a dry place.
Linear Stage Storage
Mounting the Linear Stage
The linear stage storage area must be clean, dry, vibration free, and have a
relatively constant temperature. Refer to Environmental Specifications for MPSeries Linear Stages in the Kinetix Linear Motion Specifications Technical Data
GMC-TD002
for more detailed information.
This section discusses mounting methods and procedures for both linear stage
types.
Before You Begin the Mechanical Installation
The machine designer is the best person to determine the number and type of
fasteners to use when mounting your linear stage The following information is
supplied to assist in your decision-making.
Determine the Number of Fasteners Required
The length of the linear stage determines the number of mounting fasteners that
are required.
Use one of the following equations to calculate the required mounting hardware.
Figure 6 -
Figure 7 -
30 Rockwell Automation Publication MP-UM001D-EN-P - September 2013
Fasteners Required for Direct Drive Linear Stage (MPAS-
Fasteners Required for Ball Screw Linear Stage (MPAS-
xxxxxxx
-ALMx2C)
xxxxxxx- VxxSx
A)
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