User Manual CHPS-Series Linear Stage Catalog Numbers CHPS-150, CHPS-200, CHPS-250
Important User Information 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.
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.
Summary of Changes Notes: 4 Rockwell Automation Publication CHPS-UM001D-EN-P - July 2014
Table of Contents Preface About This Publication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Who Should Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Chapter 1 Stage Safety Safety Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table of Contents Limit Sensor Flying Leads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Chapter 6 Connecting the Stage Connecting the Stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Attaching the Ground Strap and Interface Cables . . . . . . . . . . . . . . . Thermal Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Optional Limit Sensors . . . . . . . . . . . . .
Table of Contents Appendix A Specifications and Dimensions Static and Static Moment Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Performance Specifications for 325V CHPS-Series Stage . . . . . . . . Performance Specifications for 325V or 650V CHPS-Series Stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Stage Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Accuracy Specification for the CHPS-Series Stage. .
Table of Contents Motor Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 Faults Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 Appendix E Mounting Bolts and Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preface Read this preface to familiarize yourself with the manual. About This Publication This manual provides detailed installation instructions for mounting, wiring, maintaining, and troubleshooting your CHPS-Series Linear Motor Driven Stage. Who Should Use This Manual This manual is intended for engineers or technicians directly involved in the installation, wiring, and maintenance of stages.
Preface Notes: 10 Rockwell Automation Publication CHPS-UM001D-EN-P - July 2014
Chapter 1 Stage Safety Topic Page 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 IMPORTANT Any person that teaches, operates, maintains, or repairs these linear stages must be trained and demonstrate the competence to safely perform the assigned task.
Chapter 1 Stage Safety To prevent injury and damage to the stage, review the safety labels and their warning details and location before using the stage. Safety Labels Location Title A Danger-Pinch Points and Heavy Objects Label Details 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.
Stage Safety Chapter 1 Figure 1 - Warning Label Locations A E F DANGER POINTS PINCHparts inside Moving Lockout /Tagout ARD LIFT HAZ on Lift Two Persrequired or carry DA MA LOCGN ATEETIC Can D FIEL pac be IN THIDS senem har S sitivake mfu AR EA rs l e equ and to ipmoth enter NG ER DANGER HAZARDOU VOLTAGE AND S T LOCKOU POWER G TAGOUT SERVICIN BEFORE C F B D See Safety Labels on page 12 to identify call out letters.
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.
Chapter 2 Understanding Your Stage Topic Page Identifying the Components of Your Stage 16 Recommended Maintenance Interval 18 Identifying Your Stage 18 Rockwell Automation Publication CHPS-UM001D-EN-P - July 2014 15
Chapter 2 Understanding Your Stage Use the diagrams and descriptions to identify individual stage components.
Understanding Your Stage Chapter 2 Component Description Component Number Component Description 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 (M10 x 15.
Chapter 2 Understanding Your Stage Recommended Maintenance Interval Under normal stage use, follow these lubrication guidelines. IMPORTANT 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.
Understanding Your Stage Chapter 2 CHPS - A 8 054 F - F LM C 2 C Cable Management and Termination Bulletin Number A = No Cables or Cable Carrier (Slide Junction Box only) Voltage A= 230V AC B = Cables with Flying Leads and Cable Carrier(1) B= 460V AC (LC motors only) C = Cables with Kinetix MPF Connectors and Cable Carrier(1) D = Cables with D-Connectors and Cable Carrier(1) Frame Size Limits 8= 200 mm base 2 = No limits Stroke For -100 and -120 motor coil lengths Travel lengths start at 6 cm an
Chapter 2 Understanding Your Stage Notes: 20 Rockwell Automation Publication CHPS-UM001D-EN-P - July 2014
Chapter 3 Planning the Stage Installation Stage Mounting Requirements Topic Page Stage Mounting Requirements 21 General Safety Standards for Stage Installations 21 Mounting Restrictions 21 Environmental Factors 22 Mounting Surface Restrictions 22 Clearance Requirements 23 Requirements to be met when mounting your CHPS-Series stage include the following.
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 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). Humidity Avoid excessive humidity. Condensation on metal surfaces can cause stage corrosion. The maximum permissible humidity is 80% relative.
Planning the Stage Installation Chapter 3 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 on page 85 for connector and bend radius requirements. Figure 3 - Minimum Clearance Requirements 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.
Chapter 3 Planning the Stage Installation Notes: 24 Rockwell Automation Publication CHPS-UM001D-EN-P - July 2014
Chapter 4 Mounting the Stage Topic Page 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 IMPORTANT Unpacking, Handling, and Inspection Any person that teaches, operates, maintains, or repairs these stages must be trained a
Chapter 4 Mounting the Stage Inspect the assemblies and confirm, if applicable, the presence of specified options. ATTENTION: 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.
Mounting the Stage Chapter 4 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. 1/4 End Cap 1/4 1/4 1/4 End Cap Support Straps 6.
Chapter 4 Mounting the Stage 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.
Mounting the Stage Chapter 4 1940 mm stroke length = 194.0 cm 194 cm + 36 230 fasteners = ---------------------------------- = --------- = 19.167 12 12 round down = 19 fasteners = 19 + 1 = 20 × 2 = 40 fasteners 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.
Chapter 4 Mounting the Stage Figure 6 - Through Bolt Mounting IMPORTANT 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.
Mounting the Stage Chapter 4 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 Tee Nut Mounting diagram. Figure 8 - Tee Nut Mounting T-Slots 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. IMPORTANT Do not use abrasives to clean the surface.
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.
Chapter 5 Connector Data Topic Page Kinetix Servo Drive Compatible Connectors 34 D-Type Connectors 35 Flying Leads 36 Junction Box Connectors 37 Limit Sensor Flying Leads 38 Rockwell Automation Publication CHPS-UM001D-EN-P - July 2014 33
Chapter 5 Connector Data The following tables identify the power and feedback pinouts for the Intercontec circular connectors for use with standard Allen Bradley connectors.
Connector Data The following tables identify the power and feedback pinouts for D-shell connectors that enable custom cables to be used. D-Type Connectors 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 M A1 A2 A3 A4 Positronic P/N CBD9W4M20000-1702.0 Mating Connector: Positronic P/N CBD9W4F20000-1701.
Chapter 5 Connector Data The following tables identify the power and feedback pinouts for flying lead this option lest you to use your own connectors. Flying Leads ATTENTION: 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.
Connector Data Junction Box Connectors Chapter 5 The following diagram and tables identify the power and feedback pinouts of the junction box connector, use this information to make custom cables B A Pin 1 9 C D 12 6 16 8 7 Pin 1 E 4 Pin 1 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 sid
Chapter 5 Connector Data Table 2 - Junction Box Power Connector Pin Color Signal 1 Red U (A) phase 2 White V (B) phase 3 Black W (C) phase 4 Green/Yellow Ground Table 3 - Junction Box J1 Connector Pin With Incremental Encoder With Analog Encoder Signal Designation Signal Description Signal Designation Signal Description 1 Shield — Shield — 2 S3 TTL - Trapezoidal Hall S3 - TTL - Trapezoidal Hall 3 A+ TTL - Differential Sin+ Analog - Differential 1V p-p 4 B+ TTL - Diff
Chapter 6 Connecting the Stage Connecting the Stage Topic 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 The installation procedure assumes you prepared your system for correct electrical bonding and understand the importance of electrical
Chapter 6 Connecting the Stage 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.
Connecting the Stage Chapter 6 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.
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 ATTENTION: PTC thermistor supplies a signal that indicates the stage temperature limit condition.
Connecting the Stage Optional Limit Sensors Chapter 6 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.
Chapter 6 Connecting the Stage 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(1) 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 μm and 0.
Connecting the Stage Sine/Cos Encoder Output Signals Chapter 6 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 Incremental 2 channels V1 and V2 differential sinusoids in quadrature (90° phase shifted) 20 μm 0.6 …1.
Chapter 6 Connecting the Stage Hall Effect Circuit Use the following information to connect the Hall Effect circuit to your servo drive. • Input power: 5…24 V DC, 10 mA maximum • Output: NPN, Open Collector, 10 mA maximum V+ Rp Hall Signal Isink Hall S1 Hall S2 Hall S3 Drive Isink = 10 mA Maximum Rp = External pull-up resistor Motor and Hall Phasing and Sequence Consult drive manual or supplier for wiring instructions for your drive. Motor wiring is phase and commutation sensitive.
Connecting the Stage Chapter 6 As shown in the Motor Phasing Diagram: 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 W-U Back EMF Voltage U-V V-W S1 Digital Hall Signals S2 S3 0° Linear Travel mm (in.) 60° 120° 180° 240° 300° 360° 50 (1.97) 60 (2.
Chapter 6 Connecting the Stage Stage Positive Direction Stage positive direction is defined by a location of a Slide End Cap.
Chapter 7 Operation Guidelines and Limit Configuration Introduction Operational Guidelines This chapter gives you operational guidelines and limit sensor position adjustment procedures. Topic Page 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. ATTENTION: A runway condition is caused by incorrect motor, Hall, or encoder wiring.
Chapter 7 Operation Guidelines and Limit Configuration 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.
Operation Guidelines and Limit Configuration Chapter 7 Calculate the deceleration time, Td. Use Td to calculate the deceleration distance. Therefore, you set the software travel limits to 74 mm. IMPORTANT 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.
Chapter 7 Operation Guidelines and Limit Configuration To adjust overtravel limit sensor: 1. Measure location from end block to the inside tip of the overtravel limit sensor. Bumper Stop End Block Slide Limit Blade Overtravel Limit Sensor 2. Loosen screw and slide the overtravel limit sensor toward center of stage. It can be adjusted up to 30 mm. Correct Make adjustments without compressing the bumper.
Operation Guidelines and Limit Configuration Chapter 7 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.
Chapter 7 Operation Guidelines and Limit Configuration Notes: 54 Rockwell Automation Publication CHPS-UM001D-EN-P - July 2014
Chapter 8 Troubleshooting Topic Page 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 The following test equipment is required: • Ohm meter • Two-channel storage oscilloscope PTC Thermal Signal 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 ≤ 750 Ω.
Chapter 8 Troubleshooting 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.
Troubleshooting Hall to Back EMF Phasing Chapter 8 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 CHPSSeries Connector Data beginning on page 33. 3. Disconnect the stage motor power leads from the drive. EXAMPLE 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.
Chapter 8 Troubleshooting 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.
Chapter 9 Maintenance Topic Page Before You Begin 59 Lubricate the Bearing 60 Optical Encoder Scale Maintenance 60 Strip Seal Cleaning 61 Cover Cleaning 61 IMPORTANT Before You Begin Any person that teaches, operates, maintains, or repairs these stages must be trained and demonstrate the competence to safely perform the assigned task. The following tools are required to lubricate and clean your stage. ATTENTION: Lockout tagout power before servicing. • 0.5 m (14 in.
Chapter 9 Maintenance 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. Bearing Lubrication Ports (2x per end cap) 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. 2.
Maintenance Strip Seal Cleaning Chapter 9 Clean the strip seals, if installed, by using a lint free cloth lightly saturated with isopropyl alcohol IMPORTANT Replace the strip seal if it cannot be cleaned, 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.
Chapter 9 Maintenance Notes: 62 Rockwell Automation Publication CHPS-UM001D-EN-P - July 2014
Chapter 10 Removing and Replacing Stage Components Topic Page 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 The following tools are required before you begin removal and replacement procedures. • Torque wrench • Phillips head screw driver • 2.
Chapter 10 Removing and Replacing Stage Components 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 M3 0.5 X8 LG Phillips Pan Head Screws (4x) Junction Box Cover Junction Box Side Cover M4 X 0.7 X 8 LG BHCS (2x) Cable Carrier Module M4 X 0.
Removing and Replacing Stage Components Strip Seal Removal Chapter 10 Figure 19 - Stage Seal Components . Strip Seal Clamp (4x) Seal Guide (4x) 3M SHCS (2x per guide) 3M SHCS (8x) IMPORTANT Stainless Steel Strip Seal (2x) 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 1.
Chapter 10 Removing and Replacing Stage Components Strip Seal Replacement ATTENTION: 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. 1) Mark needed strip length. 3) Make two 45° marks to centerline. 2) Mark strip width centerline. 4) Use tin snips to cut along 45° marks. 3.
Removing and Replacing Stage Components Chapter 10 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. Strip Seal Seal Guide 0.8 mm (0.015 in.) Shim 13. Return stage to service. Stage Cover Installation 1. Starting at the end cap with the magnetic warning label. Install (2) M3 x 25 SHCS and torque to 4 N•m (35 lbf•in). Make sure the cover makes contact with the end cap. 2.
Chapter 10 Removing and Replacing Stage Components Notes: 68 Rockwell Automation Publication CHPS-UM001D-EN-P - July 2014
Appendix A Specifications and Dimensions This appendix is a supplement to this document. Associated Kinetix publications listed in Additional Resources on page 9 and information in product specifications can supersede the information in this appendix.
Appendix A Specifications and Dimensions 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 Pitch Moment Load Reverse Radial Force Load Radial Force Load Yaw Moment Load Roll Moment Load Lateral Force Load 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.
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(3) Current Thrust Current Thrust kg (lb) A rms (Ao-pk) N (lbf) A rms (Ao-pk) N (lbf) CHPS-A6xxxA-xLMxxx 4.64 (10.23) 2.3 (3.3) 80 (18) 7.0 (9.9) CHPS-A6xxxB-xLMxxx 6.48 (14.28) 4.7 (6.6) 160 (36) CHPS-A6xxxC-xLMxxx 6.48 (14.28) 2.3 (3.
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(3) Current Thrust Current Thrust kg (lb) A rms (Ao-pk) N (lbf) A rms (Ao-pk) N (lbf) CHPS-x8xxxD-xLMxxx 5.64 (12.4) 3.1 (4.3) 132 (30) 8.3 (11.7) CHPS-x8xxxE-xLMxxx 8.34 (18.4) 6.2 (8.7) 265 (60) CHPS-x8xxxF-xLMxxx 8.34 (18.4) 3.1 (4.
Specifications and Dimensions General Stage Specifications Appendix A The following sections contain general specifications. Accuracy Specification for the CHPS-Series Stage Repeatability Accuracy(1)(2)(3) Straightness and Flatness(3) μm (in.) μm (in.) μm (in.) CHPS-xxxxxx-FLMxxx ±1.0 CHPS-xxxxxx-GLMxxx ±1.5 ±3 μm/25 mm NTE ±10 μm/300 mm (±0.0001 in./1 in. NTE ±0.0004 in./12 in.) ±3 μm/25 mm NTE ±8 μm/300 mm (±0.0001 in./1 in. NTE ±0.0003 in./12 in.) CHPS-xxxxxx-HLMxxx ±2.
Appendix A Specifications and Dimensions 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.
Specifications and Dimensions Appendix A 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.
Appendix A Specifications and Dimensions CHPS-Series Stage (200 mm frame size) Unit Mass 35 Mass (kg) 30 25 20 15 LC-050-100-D LZ-030-T-120-D 10 960 840 720 600 480 360 240 120 Travel Length Unit Mass 40 Mass (kg) 35 30 25 20 LC-050-200-X LZ-030-T-240-X 15 980 860 740 620 500 380 260 140 Travel Length CHPS-Series Stage (250 mm frame size) Unit Mass 70 60 Mass (kg) 50 40 30 LZ-050-T-240-X LZ-050-T-120-D LC-075-200-X LC-075-100-D 20 10 0 980 Rockwell Automation Publication CHP
Specifications and Dimensions Appendix A Stage are designed to metric dimensions. Inch dimensions are conversions from millimeters. Dimensions without tolerances are for reference. CHPS-Series Stage Dimensions Figure 21 - CHPS-A6xxxA-xLMxxx (4X) M6 x 1.0-6H 12.0 (0.47) 30.5 (1.20) Mechanical Overtravel Slide 239 (9.41) 25.0 (0.98) Travel 165 (6.50) 25.0 (0.98) 30 (1.18) 167 (6.57) 165 (6.50) (4X) Ø 7.0 (0.28) See Detail A 46.8 (1.84) 238.6 (9.39) 181.5 (7.15) 30.5 (1.
Appendix A Specifications and Dimensions Figure 22 - CHPS-A6xxxB/C-xLMxxx (4X) M6 x 1.0-6H 12.0 (0.47) 30.5 (1.20) Mechanical Overtravel Slide 339 (13.35) 165 (6.50) 25.0 (0.98) Travel 25.0 (0.98) 87 (3.42) 167 (6.57) 165 (6.50) (4X) Ø 7.0 (0.28) See Detail A 46.8 (1.84) 238.6 (9.39) 181.5 (7.15) 45.0 (1.80) Thru Pilot Hole 130 (5.12) 120 (4.72) Toe Clamp/T-Nut Spacing 104.5 (4.11) (4X) M10 x 1.5-6H Thru (2 per end cap) Access point for lubricating linear bearings.
Specifications and Dimensions Appendix A Figure 23 - CHPS-x8xxxA/D-xLMxxx (4X) M8 x 1.25-6H 12.0 (0.47) (4X) Ø 6.8 (0.27) 45.2 (1.78) Thru (2X) Ø 5.5 (0.22) Thru Pilot Hole 25.4 (1.0) Mechanical Overtravel Slide 239 (9.41) 25.4 (1.0) 28.0 (1.10) 25.4 (1.0) Mechanical Overtravel 25.4 (1.0) Travel 130.8 (5.15) 44 (1.72) 215.7 (8.49) 216.7 (8.53) 166.6 (6.56) 55.4 (2.18) See Detail A 46.8 (1.84) 120 (4.72) Ø 5.8 (0.23) Thru Ø 9.7 (0.38) Thru 14.2 (0.56) (4X) M10 x 1.
Appendix A Specifications and Dimensions CHPS-x8xxxB/C/E/F-xLMxxx (4X) M8 x 1.25-6H 12.0 (0.47) (4X) Ø 6.8 (0.27) 45.2 (1.78) Thru (2X) Ø 5.5 (0.22) Thru Pilot Hole 25.4 (1.0) Mechanical Overtravel Slide 339 (13.35) 25.4 (1.0) 28.0 (1.10) 25.4 (1.0) Mechanical Overtravel 25.4 (1.0) Travel 130.8 (5.15) 104 (4.09) 215.7 (8.49) 216.7 (8.53) 166.6 (6.56) 55.4 (2.18) See Detail A 46.8 (1.84) Ø 5.8 (0.23) Thru Ø 9.7 (0.38) Thru 14.2 (0.56) (4X) M10 x 1.
Specifications and Dimensions Appendix A Figure 24 - CHPS-x9xxxG/J-xLMxxx (4X) M8 x 1.25-6H 12.0 (0.47) (4X) Ø 6.8 (0.27) 45.2 (1.78) Thru 25.4 (1.0) Mechanical Overtravel 28.0 (1.10) 264.7 (10.42) 25.4 (1.0) 46.8 (1.84) 8.5 (0.33) 38.3 (1.51) 281 (11.06) 120 (4.72) 25.4 (1.0) 56.2 (2.22) 120 (4.72) Toe Clamp/T-Nut Spacing Ø 5.8 (0.23) Thru Ø 9.7 (0.38) Thru 14.2 (0.56) 380.6 + Travel (14.96) Ground Screw M5 x 0.8-6H 105.4 (4.15) 30.0 (1.18) 172.2 (6.78) 249 (9.8) 44 (1.73) 25.4 (1.
Appendix A Specifications and Dimensions Figure 25 - CHPS-x9xxxH/I/K/L-xLMxxx (4X) M8 x 1.25-6H 12.0 (0.47) (4X) Ø 6.8 (0.27) 45.2 (1.78) Thru 28.0 (1.10) 264.7 (10.42) 25.4 (1.0) 46.8 (1.84) 8.5 (0.33) 38.3 (1.51) 281 (11.06) 25.4 (1.0) 116 (4.58) 120 (4.72) Toe Clamp/T-Nut Spacing Ø 5.8 (0.23) Thru Ø 9.7 (0.38) Thru 14.2 (0.56) 440.6 + Travel (17.35) Ground Screw M5 x 0.8-6H 105.4 (4.15) 30.0 (1.18) Detail A 5.6 (0.22) Toe Clamp is standard for covered stages. Mount to base using M6 x1.
Specifications and Dimensions CHPS-Series Stage Technical Specifications Cat. No. Appendix A Use this specification to make stage dependent calculations. Total Moving Mass Coil Resistance (p - p) Force Constant @25 °C (77 °F) @100 °C (212 °F) kg (lb) Ohms Ohms N/A 0 - peak (lbf/A 0 - peak) 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.
Appendix A Specifications and Dimensions Notes: 84 Rockwell Automation Publication CHPS-UM001D-EN-P - July 2014
Appendix B Accessories Topic Page Interconnect Cables 85 Installation, Maintenance, and Replacement Kits 87 Power Cable Dimensions (catalog number 2090-XXNPMF-16Sxx) Interconnect Cables The maximum cable length of 10 m (32.8 ft). Dimensions are in mm (in.) Brown Black Cable Shield (overall) 75 (2.9) Blue Green/Yellow BR+ BR- 75 (2.9) Start of Bend Radius 28.0 (1.1) Bend Radius1 Cable Shield (for brake wires, not used for linear motor stages) 142 (5.
Appendix B Accessories Pin Gauge Color Signal Designation F 18 White BR+ G 18 Black BR- E 18 White 1 H 18 Red 2 L N/A N/A N/A Not used for CHPS Stages SHIELD Feedback Cable Dimensions (catalog number 2090-XXNFMF-Sxx) The maximum cable length of 10 m (32.8 ft). 54 (2.1) Start of Bend Radius Dimensions are in mm (in.) 57 (2.2) Bend Radius 1 99 (3.9) 26 (1.0) Connector Diameter 1 12 11 16 10 2 13 9 3 14 15 8 17 4 7 5 6 10 (0.
Accessories Installation, Maintenance, and Replacement Kits Appendix B Accessories available for installing stages, replacing items, and performing maintenance at regular intervals are listed in the tables that follow. Accessories 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.
Appendix B Accessories Notes: 88 Rockwell Automation Publication CHPS-UM001D-EN-P - July 2014
Appendix C Stacking Stages This appendix provides information about center-stacked stage configurations. Stage Stacking Topic Page Stage Stacking 89 Specifications for Stacked Stages 90 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.
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.
Appendix D 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.
Appendix D Start-up Guide for CHPS-Series Stage with Ultra3000 Drive and Ultraware Software Connector Data Summary CHPS-Series Stage Signal Designation Motor phase U Motor phase V Motor phase W Encoder A+ (digital) or Sin+ (analog) Encoder A - (digital) or Sin - (analog) Encoder B+ (digital) or Cos+ (analog) Encoder B - (digital) or Cos - (analog) Hall S1 Hall S2 Hall S3 Linear Motor File Parameters Ultra3000 Drive Terminal or Pin U V W CN2-1 CN2-2 CN2-3 CN2-4 CN2-12 CN2-13 CN2-8 Signal Designation Mot
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/A0-peak Motor’s linear region force constant Convert if necessary.
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) 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.
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.
Appendix D Start-up Guide for CHPS-Series Stage with Ultra3000 Drive and Ultraware Software 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.
Start-up Guide for CHPS-Series Stage with Ultra3000 Drive and Ultraware Software Appendix D Oscilloscope Verification Correct stage and Ultra3000 drive wiring yields the phase relationship shown in Hall Oscilloscope Diagram. Figure 26 - Hall Oscilloscope Diagram S1 S2 S3 0° 60° 120° 180° 240° 300° 360° • Data capture direction - stage positive phasing direction as shown in Positive Phasing Direction on page 96. • S1 leads S2 leads S3, 120° electrical spacing.
Appendix D Start-up Guide for CHPS-Series Stage with Ultra3000 Drive and Ultraware Software Oscilloscope Diagram for Ultra3000 Drive Motor with Hall offset = 0° While moving slide in positive direction. BEMF Hall 0° 60° 120° 180° 240° Ultra Drive phasing pairs: S1 vs. W-U S2 vs. U-V Ultra3000 Drive S3 vs.
Start-up Guide for CHPS-Series Stage with Ultra3000 Drive and Ultraware Software Reference Information Appendix D Refer to these sections for information about the following: • Commutation Diagnostics Utility • Self-sensing Commutation and Startup • Main Screen Setup • Motor Screen • Motor Screen • Faults Screen Commutation Diagnostics Utility This test utility is intended for custom motors that do not have verified optimal phasing information.
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.
Start-up Guide for CHPS-Series Stage with Ultra3000 Drive and Ultraware Software Appendix D The following in an example of a CHPS-Series stage custom motor file created in Ultraware Motor Database utility. For linear stages with a size 200 frame, LZ-030-T-120-D linear motor, 1 μm encoder, cover/seals, and no integral limits.
Appendix D Start-up Guide for CHPS-Series Stage with Ultra3000 Drive and Ultraware Software Main Screen Setup On this screen, enter CHPS-Series stage motor file, Current Limits not-toexceed motor file, Display Precision, and access the Current Control Panel.
Start-up Guide for CHPS-Series Stage with Ultra3000 Drive and Ultraware Software Appendix D Motor Screen On this screen, enter Total Moving Mass, check for correct Motor Model and parameters, and access the Motor Feedback Diagnostics Utility.
Appendix D Start-up Guide for CHPS-Series Stage with Ultra3000 Drive and Ultraware Software Faults Screen On this screen, enter the continuous current in User Current Fault field, not to exceed the motor file continuous current value.
Appendix E Mounting Bolts and Torque Values Table 15 - Recommended Seating Torque for Metric Bolts Plain Cadmium Plated Zinc Pitch N•m (lbf•in) N•m (lbf•in) N•m (lbf•in) 0.35 0.29 (2.6) 0.22 (1.95) 0.41(3.64) 0.40 0.60 (5.3) 0.45 (3.98) 0.84 (7.42) 0.45 1.24 (11) 0.93 (8.25) 1.74 (15.4) M3 0.5 2.15 (19) 1.61 (14.25) 3.00 (26.6) M4 0.7 4.6 (41) 3.47 (30.75) 6.48 (57.4) M5 0.8 9.6 (85) 7.20 (63.75) 13.4 (119) M6 1.0 15.8 (140) 11.9 (105) 22.1 (196) M8 1.25 39.
Appendix E Mounting Bolts and Torque Values Table 16 - Recommended Seating Torque for Mild Steel Rb 87 or Cast Iron Rb 83 UNC Bolt Size (1), (2) UNF Plain Cadmium Plated Plain Cadmium Plated N•m (lbf•in) N•m (lbf•in) N•m (lbf•in) N•m (lbf•in) 0.18 (1.6) (3) #0 — — 0.24 (2.1) (3) #1 0.44 (3.89) (3) 0.53 (4.7) (3) 0.46 (4.1) (3) 0.34 (3.0) (3) #2 0.71 (6.3) (3) 0.53 (4.7) (3) 0.76 (6.8) (3) 0.58 (5.1) (3) #3 1.08 (9.6) (3) 0.81 (7.2) (3) 1.16 (10.3) (3) 0.87 (7.7) (3) #4 1.
Mounting Bolts and Torque Values Appendix E Table 17 - Recommended Seating Torque for Brass Rb 72 UNC Bolt Size (1), (2) UNF Plain Cadmium Plated Plain Cadmium Plated N•m (lbf•in) N•m (lbf•in) N•m (lbf•in) N•m (lbf•in) 0.18 (1.6) (3) #0 — — 0.24 (2.1) (3) #1 0.43(3.8) (3) 0.33 (2.9) (3) 0.46 (4.1) 0.34 (3.0) (3) #2 0.71 (6.3) (3) 0.53 (4.7) (3) 0.77 (6.8) (3) 0.58 (5.1) (3) #3 1.08 (9.6) (3) 0.81 (7.2) (3) 1.16 (10.3) (3) 0.87 (7.7) (3) #4 1.52 (13.5) (3) 1.1 (10) (3) 1.
Appendix E Mounting Bolts and Torque Values Table 18 - Recommended Seating Torque for Aluminum Rb 72 (2024-T4) UNC Bolt Size (1), (2) UNF Plain Cadmium Plated Plain N•m (lbf•in) N•m (lbf•in) N•m (lbf•in) N•m (lbf•in) (3) 0.18 (1.6) (3) #0 — — 0.24 (2.1) #1 0.44 (3.8) (3) 0.33 (2.9) (3) 0.46 (4.1) (3) #2 0.71 (6.3) (3) (3) (3) #3 1.08 (9.6) (3) 0.81 (7.2) (3) 1.16 (10.3) (3) 0.87 (7.7) (3) #4 1.52 (13.5) (3) 1.1 (10) (3) 1.67 (14.8) (3) 1.24 (11) (3) #5 2.3 (20) (3) 1.
Index A accessibility 22 accessories feedback interconnect cable 86 power interconnect cable 85 accuracy specifications 73 ambient temperature defined 75 analog differential encoder 45 ANSI/NFPA 79 - electrical for industrial machines 21 ANSI/RIA R15.
Index G ground screw 40 torque 40 strap 40 grounding 40 H Hall effect circuit 46 Hall effect module 55 Hall phasing 46 heat 13 high-frequency energy 40 humidity 22 humidity range 75 I incline payload 13 index mark 17 installation clearance requirements 22 installation 66 removal 65 maitenance 59 metric bolts torque 105 motor file creating 92 motor phasing 46 mounting 22 before mounting 23, 28 bolt through 29 ceiling 22 incline 22 inverted 22 square nut 31 square nuts 29 surface 22 surface restrictions 2
Index PTC thermistor resistance values 42 R readhead 17 reference documents standards 21 CSA/CAN Z434 - industrial robot safety 21 repeatability specifications 73 requirements 22, 23 restrictions 22 clearance 23 mounting 23 roll 70 S safety bolts 12 cover 12 end caps 13 hazardous voltage 12 heat 12 impacts 13 junction box 12 labels 12 pinch points 12 sharp edges 12 strong magnets 12 sudden motion 13 seal guide 17 shearing bolts 13 shipping brace 28 clamp 28 container storage 28 dangerous goods declaratio
Index Ultraware .
Index Notes: Rockwell Automation Publication CHPS-UM001D-EN-P - July 2014 113
Rockwell Automation Support Rockwell Automation provides technical information on the Web to assist you in using its products. At http://www.rockwellautomation.com/support you can find technical and application notes, sample code, and links to software service packs. You can also visit our Support Center at https://rockwellautomation.custhelp.com/ for software updates, support chats and forums, technical information, FAQs, and to sign up for product notification updates.
