ACS-Based Motion Controllers for High Precision Motorized Positioning Stages
A-800 Series of Advanced Motion Capability with Unique Servo Control Algorithms
- Designed for PI electromechanical motor-driven stages, including linear, voice coil, brushless DC, brush DC, and stepper (open and closed loop)
- ACS high performance motion controllers and drives
- Combines multi-axis motion control, real-time EtherCAT based networking, and advanced servo algorithms
- Widely used in demanding applications for precision automation, semiconductor equipment, photonics, medical devices, and advanced manufacturing systems
- CE Marked
In high-precision automation, the motion controller does far more than move a stage from one position to another. It determines how accurately the system follows complex trajectories, how quickly it settles, how effectively it rejects vibration and disturbances, and how precisely (multi-axis) motion is synchronized with lasers, cameras, metrology systems, and other process equipment.
For laser processing, dedicated control functions can synchronize laser triggering and power modulation directly with position and velocity, maintaining consistent pulse spacing and feature geometry even along curves, corners, and rapidly changing scan paths. The result is not simply better motion, but tighter integration between positioning and the manufacturing process itself.
PI’s ACS-based motion controllers combine scalable EtherCAT architecture with advanced servo and trajectory-control algorithms engineered to extract the maximum performance from precision motion systems. Technologies such as ServoBoost™, PILOT, input shaping, dynamic error compensation, active gantry control, and high-speed contouring help increase acceleration and throughput while reducing following error, vibration, velocity ripple, and settling time.
High-End, Feature-Rich Motion Controllers for Three-Phase, Voice-Coil, DC, BLDC and Stepper Motors
High-End, Feature-Rich Motion Controllers for Three-Phase, Voice-Coil, DC, BLDC and Stepper Motors
PI offers standardized, fully configured motion-control solutions based on high-performance ACS control and drive technology. Available in 19-inch 2U and 4U rackmount enclosures, these systems are designed to control a wide range of motor types, including three-phase linear and rotary motors, voice-coil actuators, brushed DC motors, brushless DC motors, and stepper motors.
Each controller is delivered tested, configured, and tuned for the associated PI motion system, reducing setup time and simplifying integration. Depending on the application and options, the controllers support advanced multi-axis synchronization and error compensation, high-speed trajectory generation, precision servo control, high-speed alignment, flexible I/O and integration with external sensors and automation equipment.
The modular architecture also makes it easier to expand the system as requirements grow. Additional axes can be added through EtherCAT node expansion, allowing the same control platform to support anything from a single precision stage to a complex, coordinated multi-axis positioning system.
Contact a PI motion-control expert to discuss the appropriate controller configuration, drive capacity, feedback options, and software functions for your application.
High-End Controller Variants
A-8xx.21Axx / A-8xx.21Bxx:
- Supports up to 8 axes (A-811, A-812, A-814, A-824, A-828)
- From 2.5/5A to 10/20A at 60VDC Bus (72VDC for high power)
- Bus voltage interlocked
A-8xx.2MD0x
- Supports up to 8 axes (A-814, A-824, A-828)
- From 2.5/5A to 5/10A at 48VDC Bus
- Safe torque-off according to EN IEC 61800-5-2
A-82x.2PMD0x / A-82x.2PA0x
- Supports up to 8 axes (A-824, A-828)
- Supports high and low power drives for enhanced noise management for application needs
- Supports 5/10A at 48VDC Bus and 6.6/20A at 96VDC Bus
- Safe torque-off according to EN IEC 61800-5-2
A-8xx.2NMD0x
- Supports up to 8 axes (A-812, A-824, A-828)
- Features NanoPWM technology for ultra-low-noise positioning applications
- Industry leading move and settle times, standstill jitter, and velocity smoothness
- Optimized for applications including wafer metrology and inspection, lithography, and lase processing
- Supports 3.3/10A and 6.6/20A at 96VDC Bus
- Safe torque-off according to EN IEC 61800-5-2
Economic Controllers with Streamlined Capabilities
See table below for comparison with high-end controllers.
A-811.CED05
- Compact single-axis benchtop format (180 mm × 270 mm × 80 mm W × L × H)
- Supports 5/10A at 48VDC, external power supply (included)
- Safe torque-off according to EN IEC 61800-5-2
A-8xx.2ED0x
- 19” 2U rack supporting up to 4 axes
- From 2.5/5A to 10/20A at 48VDC Bus
- Safe torque-off according to EN IEC 61800-5-2
Comparison Between High-End and Economic Controller Features
Compatible Features | High-End Series | Economic Series |
Max Number of Axes | 8 (64 via EtherCAT expansion) | 4 |
EtherCAT Axes & I/O Expansion | ✅Yes | ❌No |
Max MPU Cycle | 5 kHz | 1 kHz |
Motor Types Supported | Brushless, DC Brush, Voice Coil, Stepper (open or closed loop) | |
Encoder Types Supported | Incremental Sin/Cos and Absolute. AqB on request. | |
Max Available ACSPL+ Buffers | 64 | 6 |
Industrial Network Protocols | TCP/IP, Modbus TCP, EtherNet/IP | |
Host Programming | Python, C/C++, COM, .NET, Matlab (license required) | |
✅Yes | ❌No | |
✅Yes | ❌No | |
✅Yes | ✅Yes | |
✅Yes | ❌No | |
✅Yes | ❌No | |
✅Yes | ❌No | |
✅Yes | ❌No | |
✅Yes | ❌No | |
✅Yes | ❌No | |
✅Yes | ❌No | |
For custom controllers, contact a PI expert for details.
| Product Category | A = ACS Controllers or Air Bearing Stages |
| Product Type | 8 = Controllers, Accessories and Spares |
| Size | 1 = 2U box 2 = 4U box |
| Number of Axes | 1 = one axis 2 = two axes 4 = four axes 6 = six axes 8 = eight axes |
| Control/Drive Type | See High-End vs. Economic versions above Options include: 21, 2M, 2E, 2N, 2P, 2NM, 2PM. These represent different performance levels and capabilities. Talk to a PI applications engineer to determine the one that provides the best cost/performance balance together with the associated mechanics and your application. |
| Encoder Type | A = Analog (Sin/Cos) Encoder B = Absolute BiSS-C Encoder D = Factory Configurable For other options, contact PI. |
| Current | See individual controller datasheets for details. Options include: 00, 02, 03, 05, 06, 10, 15, representing drives delivering peak currents between 5A and 30A. Contact a PI applications engineer if more information is needed |
Special Features for Laser Processing
For high throughput / precision laser processing, a special laser control modules is available which provides additional flexibility and capabilities with respect to position based output synchronization for laser triggering. Additonal information on laser processing is available in our Webinar “Latest Advances in Laser Drilling of VIA holes”.
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