Configuring Manual Edition 04/2008

Transcription

1 SIMODRIVE Drives Configuring Manual Edition 04/2008 Peak load motors of the 1FN3 product family SIMODRIVE 611 simodrive

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3 SIMODRIVE Drives Peak load motors of the 1FN3 product family Configuration Manual Preface General safety guidelines 1 Motor description 2 Motor components and options 3 System integration 4 Coupled motors 5 Order numbers 6 Motor configuration 7 Mounting the motor 8 Connecting the motor 9 Commissioning 10 Operation 11 Maintenance, service and repair 12 Storage and transport 13 Disposal 14 Technical data and characteristics 15 Installation diagrams and dimension tables 16 Appendix A 04/2008 6SN1197-0AB73-0BP0

4 Legal information Legal information Warning notice system This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are graded according to the degree of danger. DANGER indicates that death or severe personal injury will result if proper precautions are not taken. WARNING indicates that death or severe personal injury may result if proper precautions are not taken. CAUTION with a safety alert symbol, indicates that minor personal injury can result if proper precautions are not taken. CAUTION without a safety alert symbol, indicates that property damage can result if proper precautions are not taken. NOTICE Qualified Personnel indicates that an unintended result or situation can occur if the corresponding information is not taken into account. If more than one degree of danger is present, the warning notice representing the highest degree of danger will be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to property damage. The device/system may only be set up and used in conjunction with this documentation. Commissioning and operation of a device/system may only be performed by qualified personnel. Within the context of the safety notes in this documentation qualified persons are defined as persons who are authorized to commission, ground and label devices, systems and circuits in accordance with established safety practices and standards. Proper use of Siemens products Note the following: WARNING Siemens products may only be used for the applications described in the catalog and in the relevant technical documentation. If products and components from other manufacturers are used, these must be recommended or approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation and maintenance are required to ensure that the products operate safely and without any problems. The permissible ambient conditions must be adhered to. The information in the relevant documentation must be observed. Trademarks All names identified by are registered trademarks of the Siemens AG. The remaining trademarks in this publication may be trademarks whose use by third parties for their own purposes could violate the rights of the owner. Disclaimer of Liability We have reviewed the contents of this publication to ensure consistency with the hardware and software described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the information in this publication is reviewed regularly and any necessary corrections are included in subsequent editions. Siemens AG Industry Sector Postfach NÜRNBERG GERMANY Ordernumber: 6SN1197-0AB73-0BP0 P 11/2008 Copyright Siemens AG Technical data subject to change

5 Preface Information on the documentation You will find an overview of the documentation, which is updated on a monthly basis, in the available languages in the Internet under: Select the menu items "Support" "Technical Documentation" "Overview of Publications". The Internet version of DOConCD (DOConWEB) is available at: Information on the range of training courses and FAQs (frequently asked questions) are available on the Internet under: under the menu item "Support" Target group This manual is intended for planning, configuring and mechanical engineers designing drives with linear motors, and also electricians, technicians and service personnel. Objectives This manual provides information on the rules and guidelines that must be observed when configuring a system with peak load motors of the 1FN3 product family. It also helps with the selection of peak load motors of the 1FN3 product family. Standard scope This documentation describes the functionality of the standard version. Extensions or changes made by the machine manufacturer are documented by the machine manufacturer. Other functions not described in this documentation might be able to be executed in the drive system. This does not, however, represent an obligation to supply such functions with a new delivery or when servicing. For reasons of clarity, this documentation does not contain all the detailed information about all types of the product and cannot cover every conceivable case of installation, operation or maintenance. Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0 5

6 Preface Technical Support If you have any technical questions, please contact our hotline: Europe / Africa Asia / Australia America Phone +49 (0) Fax +49 (0) Internet mailto:adsupport@siemens.com Note For technical support telephone numbers for different countries, go to: Calls are subject to charge (e.g. 0.14/min from fixed lines within Germany). Tariffs of other telephone providers may differ. Questions about this documentation If you have any questions (suggestions, corrections) regarding this documentation, please fax or us at: Fax mailto: docu.motioncontrol@siemens.com A fax form is available in the appendix of this document. Internet address for products EC Declaration of Conformity The EC Declaration of Conformity (to Low-Voltage Directive 2006/95/EC) is available at the following Internet address in the folder "Drive Technology": bjid= If you do not have access to the Internet, contact your local Siemens office to obtain a copy of the EC Declaration of Conformity. 6 Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0

7 Preface Further notes Besides the Danger and Warning Concept explained on the back of the cover sheet, this documentation also contains additional notes: Note in this document indicates important information about the product or the respective part of the documentation that is to be considered. Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0 7

8 Preface 8 Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0

9 Table of contents Preface General safety guidelines Introduction Personnel Use for the intended purpose Danger from strong magnetic fields Posting of warning signs Motor description Features Approvals Degrees of protection Motor components and options Overview of the motor construction Variants of the secondary section end pieces Motor rating plate Thermal motor protection Temperature monitoring circuits Description of temperature sensors used System integration System prerequisites Standard integration of the motor Drive system Position measuring system Sensor modules SME9x Separating the cables Cooling system Cooling the motor Cooling circuits Cooling media Specifying the intake temperature Braking concepts Coupled motors Motors connected in parallel Double-sided motors...67 Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0 9

10 Table of contents 6 Order numbers Structure of the order numbers Primary sections Secondary sections Primary section accessories Precision cooler Hall sensor box Connector box SME9x Connection cover Secondary section accessories Secondary section end pieces Cooling sections Secondary section cover Ordering example Motor configuration Subjects worth knowing in advance Operation in the area of reduced magnetic coverage Short-time duty S2 and intermittent duty S Procedure for the configuration Overview of the configuration sequence Definition of the mechanical supplementary conditions Specification of the load cycle Determination of the motor thrust, peak thrust and continuous thrust Selection of the primary sections Specifying the number of secondary sections Checking the dynamic mass Selecting the power module Calculation of the required infeed Examples Positioning in a predefined time Machining center with gantry axis Dimensioning of the cooling system Basics Example: Dimensioning of a cooling system Mounting the motor Safety information/instructions General procedure Checking the mounting dimensions Motor installation procedures Assembling individual motor components Mounting system Checking the motor assembly Connecting the motor Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0

11 Table of contents 9.1 Interfaces Electrical connection Safety information Requirements Electrical connections on the motor Connecting to the terminal block Connecting the temperature monitoring circuits Connection of the position measuring system Connecting the motors in parallel Cable routing regulations Shielding and grounding Connection of the cooling system General information Connection of main and precision cooler Connection of the secondary section cooling system Commissioning Safety information Checks prior to the commissioning Notes on commissioning system elements Operation Safety information Maintenance, service and repair Safety guidelines Maintenance work Storage and transport Safety information Disposal Guidelines for disposal Technical data and characteristics Introduction Definitions of the motor data Explanations of the characteristic curves FN3050 motor data FN3100 motor data FN3150 motor data FN3300 motor data FN3450 motor data FN3600 motor data FN3900 motor data Additional characteristics Attraction force in relation to relative air gap Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0 11

12 Table of contents Continuous thrust in relation to intake temperature Motor thrust in relation to relative air gap Installation diagrams and dimension tables FN3050, 1FN3100, 1FN FN3050-2WC00-0HA1 installation drawings (1 cable) FN3050-2WC00-0xA1 installation drawings (2 cables) FN3100-1FN3150-xW installation drawings (1 cable) FN3100-1FN3150-xW installation drawings (2 cables) FN3050-xW dimension tables FN3100-xW dimension tables FN3150-xW dimension tables Cooling sections Mounting of the Hall sensor box FN3300, 1FN FN3300-xW-1FN3450-xW installation drawings (1 cable) FN3300-xW-1FN3450-xW installation drawings (2 cables) FN3300-xW dimension tables FN3450-xW dimension tables Cooling sections Mounting of the Hall sensor box FN FN3600-xW installation drawings (1 cable) FN3600-xW installation drawings (2 cables) Dimension tables Cooling sections Mounting of the Hall sensor box FN FN3900-xW installation drawings (1 cable) FN3900-xW installation drawings (2 cables) Dimension tables Cooling sections Mounting of the Hall sensor box Dimension drawings of the Hall sensor box A Appendix A.1 Overview of important motor data A.2 Recommended manufacturers A.2.1 Introduction A.2.2 Manufacturers of braking elements A.2.3 Manufacturers of cold water units A.2.4 Manufacturers of anti-corrosion agents A.2.5 Manufacturers of connectors for cooling A.2.6 Manufacturers of plastic hose manufacturers A.2.7 Manufacturers of connector nipples and reinforcing sleeves A.3 Terminal markings A.4 Fax form for recommendations/corrections (copy template) Abbreviations + glossary Index Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0

13 General safety guidelines Introduction These safety guidelines apply for handling linear motors and their components. Please read these safety guidelines carefully to avoid accidents and/or property damage. Problem-free and safe operation is dependent on proper transport, storage, installation, assembly, commissioning, operation and maintenance, as well as protection against soiling and contact with aggressive materials. DANGER There is a danger of death, serious bodily injury and/or property damage if the safety guidelines and instructions are not observed and complied with. It is imperative to observe the safety guidelines in this document also the special safety guidelines in the individual sections! Observe all the warning and instruction signs! Make sure that your end product satisfies all the pertinent standards and legal specifications! The applicable national, local and machine-specific safety regulations and requirements must also be taken into account! In addition to the safety guidelines included in this document, the detailed specifications in the catalogs and offers also apply to the special motor versions. When working with the drive system, be sure to follow the respective operating instructions! Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0 13

14 General safety guidelines 1.1 Introduction Residual risks of power drive systems When carrying out a risk assessment of the machine in accordance with the EU Machinery Directive, the machine manufacturer must consider the following residual risks associated with the control and drive components of a power drive system (PDS). 1. Unintentional movements of driven machine components during commissioning, operation, maintenance, and repairs caused by, for example: Hardware defects and/or software errors in the sensors, controllers, actuators, and connection technology Response times of the controller and drive Operating and/or ambient conditions not within the scope of the specification Parameterization, programming, cabling, and installation errors Use of radio devices / cellular phones in the immediate vicinity of the controller External influences / damage 2. Exceptional temperatures as well as emissions of light, noise, particles, or gas caused by, for example: Component malfunctions Software errors Operating and/or ambient conditions not within the scope of the specification External influences / damage 3. Hazardous shock voltages caused by, for example: Component malfunctions Influence of electrostatic charging Induction of voltages in moving motors Operating and/or ambient conditions not within the scope of the specification Condensation / conductive contamination External influences / damage Improper protective conductor connection at high leakage currents. 4. Electrical, magnetic, and electromagnetic fields that can pose a risk to people with a pacemaker and/or implants if they are too close. 5. Emission of pollutants if components or packaging are not disposed of properly. An assessment of the residual risks of PDS components (see points 1 to 5 above) established that these risks do not exceed the specified limit values. For more information about residual risks of the power drive system components, see the relevant chapters in the technical user documentation. Note The following safety guidelines partly apply generally for direct drives, which also includes linear motors. 14 Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0

15 General safety guidelines 1.2 Personnel Personnel DANGER There is danger of death, serious bodily injury and/or property damage when untrained personnel is allowed to handle direct drives and/or their components. Only personnel who are familiar with and who observe the safety guidelines are allowed to handle direct drives and their components. Installation, commissioning, operation and maintenance may only be performed by qualified, trained and instructed personnel. The personnel must be thoroughly familiar with the content of this guide. All work must be performed by at least two persons. Note Make sure that the information about the sources of danger and the safety measures is available at all times! Keep all the descriptions and safety guidelines concerning direct drives and their components if possible! All descriptions and safety guidelines can also be requested from your local Siemens office Use for the intended purpose DANGER There is a risk of death, serious personal injury and/or serious material damage when direct drives or their components are used for a purpose for which they were not intended. The motors are designed for industrial or commercial machines. They comply with the standards specified in the declaration of conformity. It is prohibited to use them in areas where there is a risk of explosion (Ex-zone) unless they are designed expressly for this purpose (observe the separately enclosed additional instructions where applicable). If increased demands (e.g. touch protection) are made in special cases for use in non-commercial systems these conditions must be ensured on the machine side during installation. Direct drives and their components may only be used for the applications specified by the manufacturer. Please contact your Siemens branch responsible if you have any questions on this matter. Special versions and design variants whose specifications vary from the motors described herein are subject to consultation with your Siemens branch. The motors are designed for an ambient temperature range of -5 C to +40 C. Any alternative requirements specified on the rating plate must be noted! The on-site conditions must comply with the rating plate specifications and the condition specifications contained in this documentation. Any differences regarding approvals or country-specific guidelines must be taken into account separately. Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0 15

16 General safety guidelines 1.4 Danger from strong magnetic fields Danger from strong magnetic fields Occurrence of magnetic fields Strong magnetic fields occur in the components of the motor that contain permanent magnets. The magnetic field strength of the motors results exclusively from the magnetic fields of the components with permanent magnets in the de-energized state. Electromagnetic fields also occur during operation. NOTICE The secondary sections of linear motors are equipped with permanent magnets. Danger from strong magnetic fields DANGER Strong magnetic fields can pose a risk to personnel and cause damage. With regard to the effect of strong magnetic fields on people, the work guideline BGV B 11 "Electromagnetic Fields" applies in Germany. This specifies all the requirements that must be observed in the workplace. In other countries, the relevant applicable national and local regulations and requirements must be taken into account. Persons with pacemakers, metallic implants, and prosthetics that conduct electricity or magnetism are strictly prohibited from directly handling components containing permanent magnets. This applies to, e.g., any work connected with assembly, maintenance or storage. BGV B 11 specifies a limit value of 212 mt for static magnetic fields. This must be observed for distances greater than 20 mm from a secondary section track. The requirements of BGV B 11 must also be taken into account with regard to strong magnetic fields (BGV B11 14). WARNING Personnel who are exposed to magnetic fields in their daily work must maintain a distance of at least 50 mm from a secondary section track. Personnel with pacemakers must maintain a distance of at least 500 mm from a secondary section track. Humans have no sensory organs for picking up strong magnetic fields and have no experience with them as a rule. Therefore, the magnetic forces of attraction emanating from strong magnetic fields are often underestimated. The magnetic forces of attraction may be several kn in the vicinity of the motor components containing permanent magnets (within a distance of less than 100 mm). Example: Magnetic attractive forces are equivalent to a force of 100 kg, which is sufficient to trap someone's foot. 16 Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0

17 General safety guidelines 1.4 Danger from strong magnetic fields DANGER Strong attractive forces on magnetizable materials lead to a great danger of crushing in the vicinity of components with permanent magnets (distance less than 100 mm). Do not underestimate the strength of the attractive forces! Do not carry any objects made of magnetizable materials (e. g. watches, steel or iron tools) and/or permanent magnets close to the motor or close to a component with permanent magnets. For the event of accidents when working with permanent magnets, the following objects must be on hand to free clamped body parts (hands, fingers, feet etc.): a hammer (about 3 kg) made of solid, non-magnetizable material two pointed wedges (wedge angle approx. 10 to 15 ) made of solid, non-magnetizable material (e.g. hard wood) DANGER Any movement of electrically conductive materials in relation to permanent magnets leads to induced voltages. Electrical shock hazard! Movement of components with permanent magnets in relation to electrically conductive materials must be avoided. CAUTION Magnetic fields can lead to loss of data on magnetic or electronic data media. Do not carry any magnetic or electronic data media with you! First aid in the case of accidents involving permanent magnets Stay calm. Press the EMERGENCY STOP switch if the machine is still on. Administer FIRST AID. Call for further help if required. To free jammed body parts (e.g., hands, fingers, feet), pull apart components that are clamped together. To do this, use a hammer to drive a wedge into the separating rift Release the jammed body parts. If necessary, call for an EMERGENCY DOCTOR. Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0 17

18 General safety guidelines 1.5 Posting of warning signs Posting of warning signs All danger areas must be identified by well visible warning and prohibiting signs (pictograms) in the immediate vicinity of the danger. The associated texts must be available in the language of the country in which the product is used. Supplied pictograms Primary sections For all primary sections, warning signs are enclosed in the packaging in the form of permanent adhesive labels. The following table shows the warning signs enclosed with the primary sections and their meaning. Table 1-1 Warning signs according to BGV A8 and DIN enclosed with primary sections and their meaning Sign Meaning Sign Meaning Warning hot surfaces (D-W026) Warning hazardous electric voltage (D-W008) Secondary sections For all secondary sections, warning and prohibiting signs are enclosed in the packaging in the form of permanent adhesive labels. Be sure to attach them visibly to the sides of the secondary section track as close as possible to the motor. Note Do not attach the labels on a secondary section or the secondary section cover! Labels do not adhere well to these surfaces. The following table shows the warning and prohibiting signs enclosed with the secondary sections and their meaning. Table 1-2 Warning signs according to BGV A8 and DIN enclosed with secondary sections and their meaning Sign Meaning Sign Meaning Warning strong magnetic field (D-W013) Warning hand injuries (D-W027) 18 Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0

19 General safety guidelines 1.5 Posting of warning signs Table 1-3 Prohibiting signs according to BGV A8 and DIN enclosed with secondary sections and their meaning Sign Meaning Sign Meaning No pacemakers No metal implants (D-P011) (D-P016) No metal objects or watches (D-P020) No magnetic or electronic data media (D-P021) Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0 19

20 General safety guidelines 1.5 Posting of warning signs 20 Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0

21 Motor description Features Basic features of the motor Motors of the 1FN3 product family are permanent-magnet synchronous linear motors with a modular cooling concept: Depending on the accuracy requirements, the motor can be optionally operated with a primary section precision cooler and/or secondary section cooling. The motors are then thermally neutral toward the machine. The motor is delivered in components (at least primary section and secondary sections) and directly installed on the machine. Due to the series connection of primary and secondary sections, arbitrary motor forces and straight traversing paths of various lengths can be achieved. WARNING The motors cannot be operated directly on the supply system, but may only be operated with a suitable drive system. Standards and regulations The product complies with the standards relating to the Low-Voltage Directive stated in the EC Declaration of Conformity. Advantages for customers are powerful, cost-effective, universal motors with a broad range of types. They distinguish themselves as a result of the high overload capability and power density. Motors of the 1FN3 product family show little susceptibility to harsh environmental conditions. Combined with a primary section precision cooler and secondary section cooling, these motors are to a large extent thermally neutral to the surrounding machine. Double-comb motors can also be configured. Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0 21

22 Motor description 2.1 Features Special features: Modular design: So the motor can be configured to the customer s needs regarding technology and investment costs Low mass and high overload capability: So the motor is ideally suited for acceleration drive applications. The motor is thermally decoupled from the machine using a primary section precision cooler and secondary section cooling, based on the Thermo-Sandwich principle Simple cooling medium connection Full metal encapsulation of the primary section and encased secondary sections for greater ruggedness The secondary section track can be fully covered: This provides an even surface and prevents unwanted particle deposits, especially in the gaps between the secondary sections. Simple electrical connection via an integrated terminal panel Range of applications In conjunction with a drive system with a digital control, the peak load motors of the 1FN3 product family are well-suited as direct drives for linear motion, e.g. for: High-dynamic and flexible machine tool construction Laser machining Handling Technical features Table 2-1 Standard version of the peak load motors of the 1FN3 product family: Technical features Technical feature Motor type Type of construction Cooling Thermal motor protection Rating plate Insulation according to EN Procedure Permanent-magnet excited synchronous linear motor Individual components Water cooling Maximum pressure in the cooling circuit: 10 bar = 1 MPa Connection: with G1/8 pipe thread (in compliance with DIN EN ISO 228-1); special connectors are required to connect hoses/pipes PTC thermistor temperature sensor in a triplet configuration (according to DIN 44081/DIN 44082) and KTY84 thermistor temperature sensor (according to IEC ) in the primary section; A second rating plate is provided for each motor Temperature class 155 (F) Permanent magnets Material: Rare-earth compounds Aging: At operating temperatures and magnetic operating points, aging losses lie below 1 %. Magnetization reserves of 1-2 % exist for the compensation of long-term losses ( years). 22 Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0

23 Motor description 2.1 Features Technical feature Procedure Electrical connection 1FN3100-xW...1FN33900-xW: Terminal panel with cover integrated in the motor, with metric cable glands for signal and power cables. 1FN3050-2W: Signal and power cables with connectors or open ends permanently connected to the motor Encoder system Not included in the scope of supply Selection based on application and converter-specific supplementary conditions Shock hazard protection and protection against the ingress of foreign bodies and water Primary section: IP65 (in accordance with EN and EN ) Secondary section: Comparable to IP 65 Mounted motor: The degree of protection depends on the machine design and so must be set by the machine manufacturer. Minimum requirement: IP 23 Climatic requirements Based on DIN EN (for long-term storage), DIN EN (for transport), and DIN EN (for use in fixed, weather-protected locations) Table 2-2 Climatic ambient conditions Lower air temperature limit: - 5 C Upper air temperature limit: + 40 C (deviates from 3K5) Lower relative humidity limit: 5 % Upper relative humidity limit: 85 % Rate of temperature fluctuations: < 0.5 K/min Condensation: Not permissible Formation of ice: Not permissible Long-term storage: Class 1K3 and class 1Z1 have a different upper relative humidity Transport: Class 2K2 Fixed location: Class 3K3 Devices can only be stored, transported, and operated in locations that are fully protected against the weather (in halls or rooms). Table 2-3 Biological ambient conditions Long-term storage: Transport: Fixed location: Class 1B1 Class 2B1 Class 3B1 Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0 23

24 Motor description 2.1 Features Table 2-4 Chemical ambient conditions Long-term storage: Transport: Fixed location: Class 1C1 Class 2C1 Class 3C2 Operating site in the immediate vicinity of industrial plants with chemical emissions Table 2-5 Mechanically active ambient conditions Long-term storage: Transport: Fixed location: Class 1S2 Class 2S2 Class 3S1 Table 2-6 Mechanical ambient conditions Long-term storage: Transport: Fixed location: Class 1M2 Class 2M2 Class 3M3 24 Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0

25 Motor description 2.2 Approvals Approvals Validity Generally the approvals for the motor are listed on the rating plate. As a rule, these approvals are valid for the operating mode specified in the data sheets. More detailed information on the conditions for the validity of an approval can be obtained from your local Siemens office Degrees of protection Primary section The primary sections meet the requirements for IP65 degree of protection in accordance with EN and EN Secondary sections The secondary sections should be protected from corrosion the best way possible using structural measures. Make sure that the secondary sections are kept free of chips. Suitable covers should be provided for this purpose. It can be assumed that ferromagnetic particles are no longer attracted as of a distance of 150 mm from the surface of the secondary section. The use of abrasive or aggressive substances (such as acids) must be avoided. Installed motor The better the mounting space of the motor is protected from the penetration of mechanical foreign bodies (especially ferromagnetic particles) and aggressive chemical substances, the higher the service life of the motor. The motor area must be kept free of chips and other foreign bodies. The degree of protection of the installed motor according to EN and EN is primarily dictated by the machine construction, but must be at least IP23. WARNING Contamination in the motor compartment can cause the motor to stop functioning or cause wear and tear! The motor compartment must be protected as well as possible from pollution! The use of scrapers to keep the air gap free is not sufficient and is not recommended. Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0 25

26 Motor description 2.3 Degrees of protection 26 Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0

27 Motor components and options Overview of the motor construction Motor components Motors of the 1FN3 product family consist of the following components: Primary section: Basic component of the linear motor With 3-phase winding Integrated main cooler to dissipate the heat loss Precision cooler (optional): Additional cooler to minimize the heat transfer to the machine in accordance with the Thermo-Sandwich principle Recommended for applications with high precision requirements Secondary sections: Mounted side by side these form the reactive part of the motor Consist of a steel base with attached permanent magnets The casing provides the best possible protection against corrosion and external effects Secondary section cover (optional) Mechanical protection for secondary sections Stainless steel plate that can be magnetized (thickness d = 0.4 mm) Adheres to secondary sections Can be removed without tools if worn Available as a continuous band or as a segmented cover with fixed lengths Cooling sections with plug-in connector/nipple (optional): Secondary cooling component Aluminum rail sections with integrated cooling channels Are placed under the secondary sections when high machine precision is required Secondary section end pieces (optional) Secondary cooling component Used to hold down integrated secondary section cover Available in different versions Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0 27

28 Motor components and options 3.2 Variants of the secondary section end pieces Figure 3-1 Components of a 1FN3 linear motor Variants of the secondary section end pieces Use of the secondary section end pieces On the one hand, the secondary section end pieces are used to connect the cooling. Combi distributors and combi adapters / combi end pieces at the start and end of the secondary section track close the cooling circuit and facilitate the cooling medium connection through uniform connectors. On the other hand, they are needed to fix the integrated secondary section cover by means of a wedge which closes the cover flush with the surface, see following figure. 28 Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0

29 Motor components and options 3.2 Variants of the secondary section end pieces Figure 3-2 Secondary section end piece (side view) As standard, combi distributors are used as secondary section end pieces. These are available for all models. Combi adapters / combi end pieces or cover band end pieces can be used as an alternative for 1FN models. Overview of the variants In summary, the following secondary section end piece variants are available: Combi distributor: Standard solution for the use of secondary section end pieces Available for all models Attaches the secondary section cover (band) to the start and end of the secondary section track Implements the connection and parallel distribution of the cooling medium to two (1FN ) or three (1FN ) cooling sections at the start of the secondary section track Implements the convergence of the cooling medium flow and cooling medium discharge connection at the end of the secondary section track Combi adapter / combi end piece: Available for 1FN3050 1FN3450 models Attaches the secondary section cover (band) to the start and end of the secondary section track Implements the cooling medium connection and cooling medium return: The cooling medium intake and return connections are located on the combi adapter. The combi end piece is required for the cooling medium return at the other end of the secondary section track. Cover end piece: Available for 1FN3050 1FN3450 models Attaches the secondary section cover (band) to the start and end of the secondary section track Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0 29

30 Motor components and options 3.3 Motor rating plate Motor rating plate Supplied rating plates A rating plate is attached to each primary section of a 1FN3 motor. Additionally, a second rating plate that the customer can attach to the machine in which the motor is installed is included in the delivery. Note The rating plates should not be misused! If a rating plate is removed from the motor or machine, it must be made unusable. Data on the rating plate The following data is on the rating plate: Order number (MLFB) Maximum velocity at rated force Number of phases Motor type Maximum converter output voltage Rated current Rated force Approvals Temperature class Serial number (CWYY: week and year of fabrication) Degree of protection Max. ambient temperature at rated current Figure 3-3 Data on the rating plate (schematic) 30 Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0

31 Motor components and options 3.4 Thermal motor protection Thermal motor protection Temperature monitoring circuits Temperature monitoring circuits Temp-F and Temp-S The motors are supplied with two temperature monitoring circuits: Temp-F and Temp-S. These temperature monitoring circuits protect the primary sections from inadmissibly high thermal loading and are responsible for temperature monitoring. Both circuits are independent of each other. They are generally evaluated via the drive system. Temp-F The temperature monitoring circuit Temp-F consists of a KTY 84 temperature sensor located at the coils. Under certain circumstances especially with varying current feed of the individual phases this can result in the maximum temperature of the three phase windings not being measured. An evaluation of Temp-F for motor protection is thus not permissible. Temp-F is mainly used for temperature monitoring and can potentially be used to issue a warning that the drive is about to be shut down because Temp-S is being activated. Temp-S The overtemperature shutdown circuit Temp-S enables the temperature of each motor phase to be monitored. This ensures overload protection, even if the current feed is uneven in a primary section's individual phases or if several primary sections are being loaded differently. Note The drive system response time may not exceed one second. The response time is the sudden increase of the PTC elements' resistance up to the current being disconnected (pulse inhibit in the drive system). Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0 31

32 Motor components and options 3.4 Thermal motor protection Description of temperature sensors used Technical properties of the KTY 84 The KTY 84 produces a resistance/temperature characteristic curve that is progressive and approximately linear (see the image below). In addition, the KTY 84 has a low thermal capacity and provides good thermal contact with the motor winding. Resistance / Ω I Test = 2 ma Temperature / C Figure 3-4 Characteristic curve of a KTY 84 Technical data: Resistance when cold (20 C): approx. 580 Ω Resistance when hot (100 C): approx Ω 32 Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0

33 Motor components and options 3.4 Thermal motor protection Technical properties of PTC elements Each PTC element displays a sudden increase in resistance in the region of the rated response temperature ϑnat, see following figure. This gives it a quasi-switching characteristic. Due to low thermal capacity and good thermal contact between the PTC element and the motor winding, the sensors - and therefore the system - are able to react quickly to inadmissibly high temperatures in the winding. The PTC elements of the triplet are connected in series. The characteristics correspond with DIN EN , DIN 44081, and DIN Figure 3-5 Typical characteristic curve of a PTC element; source: DIN / DIN Technical data: According to DIN / DIN 44082, the resistance at the triplet is maximum 3x250 Ω = 750 Ω at T > -20 C and T < ϑnat - 20 K maximum 3x550 Ω = 1650 Ω at T < ϑnat - 5 K minimum 3x1330 Ω = 3990 Ω at T < ϑnat + 5 K minimum 3x4000 Ω = Ω at T < ϑnat + 15 K Note The PTC elements do not switch automatically! An evaluation is required to protect the motor effectively. Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0 33

34 Motor components and options 3.4 Thermal motor protection 34 Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0

35 System integration System prerequisites Typical installation situation of a linear motor Linear motors are built-in motors. The following figure shows a typical installation situation. Figure 4-1 Typical installation situation of a single-sided motor with moving primary section WARNING Contamination in the motor compartment can cause the motor to stop functioning or cause wear and tear! The motor compartment must be protected as well as possible from pollution! The use of scrapers to keep the air gap free is not sufficient and is not recommended. Forces of attraction The forces of attraction between the primary section and the secondary section track can be several 10 kn. Note The mechanical construction must be suitably stiff so that the functionality of the installed motor is not impaired and to avoid direct contact between the primary section and the secondary section. As the air gap decreases, the forces of attraction between the primary section and the secondary section track increase! Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0 35

36 System integration 4.2 Standard integration of the motor Standard integration of the motor WARNING The motors cannot be operated directly on the supply system, but may only be operated with a suitable drive system. The motors are operated within a system. Generally, a drive system and a position measuring system (WMS) are part of this system. The motors are also connected to a cooling system. A sensor module (SME) that combines the signals of the WMS and the temperature signals is required for the evaluation of all of the temperature sensors. A terminal block is required when power cable and temperature signal cable are combined in the motor cable (see motor variant 1). The following figure is a schematic diagram of the integration of a motor in such a system. Drive System Signal cable SME Cable(s) WMS WMS Power cable Temp. signal cable Power cable Temp. signal cable Terminal block Motor variant 1 1 cable open ends Motor variant 2 2 cables open ends/connector Cooler connector cables Cooler connector cables Cooling system Cooling system Figure 4-2 Integration of a motor in the system For special drive requirements, the system configuration may differ from that shown above. 36 Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0

37 System integration 4.3 Drive system Drive system Components The drive system that feeds a motor comprises an infeed module, a power module and a control module. For the SIMODRIVE 611 drive system, the control module is integrated in the power module. In order to operate several motors simultaneously on a single drive system, additional power modules and/or Control Units can be combined with an appropriately dimensioned infeed module. Operation of the linear motors with SIMODRIVE The linear motors can be operated from SIMODRIVE 611digital and SIMODRIVE 611universal HR drive systems together with controllers as shown in the following table. The following conditions apply: The selection of the power module depends on the rated current or the maximum motor current The linear motors are to be configured as feed drives The position measuring system depends on the application Table 4-1 Suitable controllers for the SIMODRIVE 611 digital and SIMODRIVE 611 universal HR drive systems SIMODRIVE 611 digital SIMODRIVE 611 universal HR No control -- x SINUMERIK 810D x (with CCU 3) -- SINUMERIK 840D x -- SINUMERIK 840Di -- x SIMATIC -- x Permissible voltages The SIMODRIVE 611 drive system is dimensioned for direct operation on TN line supply systems. The following table shows the permissible rated voltages of TN line supply systems that apply to the motors. Table 4-2 Permissible rated voltages of TN line supply systems, resulting DC link voltages and converter output voltages Permissible line supply voltage Resulting DC link voltage UZK Drive output voltage (rms value) Uamax 400 V 600 V (controlled) 425 V (controlled) 540 V (uncontrolled) 380 V (uncontrolled) 480 V 648 V (uncontrolled) 460 V (uncontrolled) Adaptation transformers that have been tailored to the system are available for operation on IT or TT line supply systems. Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0 37

38 System integration 4.4 Position measuring system Position measuring system Methods to determine the pole position of the motor When 1FN3 peak load motors are operated with SIMODRIVE, a motion-based procedure for determining the pole position is permitted. If a Hall sensor box is installed, this can also be used to determine the pole position, regardless of whether the method is motion-based or saturation-based. Suitable measuring systems The selection of the measuring system to determine the position of the motor in the machine depends on the application and drive-specific supplementary conditions. Generally, the following measuring systems can be used: Incremental measuring system After each power-off state, the machine must travel to a reference point, as the motor position is not stored in the controller. Also, movements are not recorded while the power is off. In general, incremental measuring systems are less expensive. They also offer the possibility to record the measurement path magnetically. This is an advantage when optical reading processes cannot be used. Higher speeds can be reached if open incremental encoders are used. Absolute measuring system with EnDat interface The scanning principle of absolute value encoders is constructed the same way as for incremental encoders. However, the number of reading tracks is larger. Using this, the current position value can be recognized without traversing distance and be transmitted in series to the EnDat interface. The length of measurement path is limited and the system is more expensive due to the more complex measurement track. The output signal Vpp of both measurement systems is a sinusoidal / cosinusoidal signal of 1 V (peak to peak value) The resolution of the position measuring system depends on the requirements placed on the accuracy and noise immunity. Mounting the measuring system The measuring system should be as rigid as possible and mounted as close as possible to the motor components. Note Assistance for optimizing the mounting of the measuring system, e.g., through calculation of the resonant frequencies of the position control loop can be obtained from your local Siemens office. 38 Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0

39 System integration 4.4 Position measuring system Manufacturer recommendations The encoder system is not included in the scope of supply. Due to the wide range of different applications, it is impossible to provide a comprehensive list of suitable encoders. Examples of absolute length measuring systems with EnDat: LC 100 and LC 400 models, Heidenhain, Examples of incremental length measuring systems (1 Vpp): LS 100 and LS 400 models, Heidenhain Use of the Hall sensor box Hall sensor box is used in incremental position measuring systems. It measures the motor pole position duirng power-up so that the drive can carry out a reference point approach (coarse synchronization). After the reference point approach, then a changeover can be made to a pole position angle saved in the software (fine synchronization). A Hall sensor box is required for motors for which, due to technical reasons, a software-based detection of the pole position is not possible. The Hall sensor must be adjusted to the individual motor and its pole width and is mounted at a certain position with respect to the primary section. Selection criteria for Hall sensor boxes The selection of the Hall sensor box depends on: the motor type ( or ) the location where the Hall sensor box is to be mounted opposite to the terminal end (standard) on the terminal end (variant) the required cable outlet direction straight lateral Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0 39

40 System integration 4.4 Position measuring system Hall sensor box mounting types MLFB Hall sensor box MODELS Mounting on the terminal end HSB Overall length of primary section Mounting opposite the terminal end Overall length of primary section HSB odd..3n....1n.. or..5w....3w....1w.. MLFB Hall sensor box 1FN3002-0PH00-0AA0 1FN3005-0PH01-0AA0.1N.. /..2N../.3N../.4N.. or.1w../..2w../.3w./.4w../.5w.. even 4N....2N.. or..4w....2w.. 1FN3002-0PH01-0AA0 1FN3002-0PH01-0AA0.1N.. /..2N../.3N../.4N.. or.1w../..2w../.3w./.4w../.5w.. Distance between holes = mm (± n 30 mm) odd..3n....1n.. or..5w....3w....1w.. even Figure 4-3 Hall sensor box mounting types for models 050 to N....2N.. or..4w....2w.. Distance between holes = 50.0 mm (± n 30 mm) 1FN3005-0PH00-0AA0 1FN3002-0PH00-0AA0 40 Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0

41 System integration 4.5 Sensor modules SME9x MLFB Hall sensor box 1FN3003-0PH01-0AA0 MODELS Mounting on the terminal end HSB Overall length of primary section Mounting opposite the terminal end Overall length of primary section HSB odd..3n....1n.. or..3w....1w.. MLFB Hall sensor box 1FN3006-0PH01-0AA0 or.1n../..2n../.3n../.4n...1w../..2w../.3w../.4w.. even..4n....2n.. or..4w....2w.. 1FN3003-0PH01-0AA0 1FN3003-0PH00-0AA0 odd..3n....1n.. or..3w....1w.. 1FN3006-0PH00-0AA0 or.1n../..2n../.3n../.4n...1w../..2w../.3w../.4w.. Distance between holes = mm (± n 46 mm) even Figure 4-4 Hall sensor box mounting types for models 300 to N....2N.. or..4w....2w.. Distance between holes = 70.0 mm (± n 46 mm) 1FN3003-0PH00-0AA Sensor modules SME9x The SME9x (Sensor Module External) provides motor protection evaluates the actual operating temperature allows motor sensors to be connected close to the motor and allows the PMS (position or angular position measuring system) to be connected close to the motor provides safety isolation compliant with EN for connection of temperature monitoring circuits for drives with 1FN1 linear motors, 1FN3 linear motors and 1FW6 torque motors. It therefore allows various types of external PMS to be used. Due to its rugged construction, the SME9x can be mounted directly in the machine. Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0 41

42 System integration 4.5 Sensor modules SME9x Note Please observe the guidelines in the chapter "Connection of the temperature monitoring circuits". Connecting the temperature monitoring circuits (Page 137) Device design Figure 4-5 Models and design of SME9x Device models There are a total of four different device models. They differ in the number of connections for the temperature sensors, the type of connector for the position and angular position measuring system (PMS) and in the option for connecting a Hall sensor box (HSB). For interface designations, refer to the following table. 42 Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0

43 System integration 4.6 Separating the cables Table 4-3 Device versions with interface designations, system: SIMODRIVE 611 and POSMO CD/CA MLFB: 1FN1910-0AA20-xxxx Interface Designation Meaning SME91 SME92 SME93 SME94-1AA0-2AA0-3AA0-4AA0 X1 INVERTER Output to the drive converter control board, 17 pin X X X X X2 SCALE Input for the incremental PMS, 12 pin X3 SCALE Input for EnDat PMS, 17 pin X X X4 HALLSENSOR Input for HSB, 9 pin X X X X X5 TEMP1 Input for temperature sensor, 7 pin X6 TEMP2 Input for temperature sensor, 7 pin X X X X X X The SME92 and SME94 are suitable for applications where two motors are operated in parallel on one drive converter. The PTC sensors or bimetallic thermoswitches and the KTY 84 sensors of both motors can be connected to the SME92 or SME94. For more information see SME9x manual Separating the cables Separating the cables Depending on the type, signal and power cables can be routed in one cable coming from the motor. To connect an SME9x close to the motor, this cable must be separated into signal cable and power cable, using a terminal block. The customer should supply this terminal block. Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0 43

44 System integration 4.7 Cooling system Cooling system Cooling the motor Necessity of a cooling system During operation, the motor heats up. To maintain the highest possible power density, water cooling is necessary. Note Throughout this document, "cooling" refers to water cooling of the motor. Components The cooling system of the 1FN3 motors may consist of a variety of components: Primary section main cooler Primary section precision cooler Secondary section cooling These components are structurally separated for motors of the 1FN3 product family. They enable the configuration of a cooling system according to the Thermo-Sandwich principle. Structure of a cooling system according to the Thermo-Sandwich principle. In the Thermo-Sandwich principle, components of the cooling system are layered on top of each other. All components are separated by an insulating layer (see the image below). The thermal flow from the primary section into the machine assembly is restricted by this multi-layer cooling design: Heat is dissipated in each component of the cooling system. Therefore, the residual amount of heat that ultimately reaches the machine is very low. Figure 4-6 Schematic representation of the Thermo-Sandwich principle 44 Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0

45 System integration 4.7 Cooling system Functions of the cooling components Primary section main cooler The primary section main cooler is directly built into the primary section and cools it. Under rated conditions, it removes between 85 % and 90 % of the arising heat. This suffices to achieve the rating data listed in the data sheets. The primary section main cooler has no effect on the heat insulation of the motor from the machine. Primary section precision cooler The primary section precision cooler dissipates residual heat (2 % to 10 % of the entire power loss) from the primary section. The temperature increase of the outer surface of the primary section precision cooler is thus maintained in a very small fluctuation range in comparison with the intake temperature of the primary section precision cooler. Together with the secondary section cooling system, the primary section precision cooler prevents thermal transfer into the attached mechanical assembly, thereby ensuring that the behavior of the motor in the machine remains almost 100 % thermally neutral. Secondary section cooling system The secondary section cooling system also dissipates residual heat of the motor. The heat dissipated by the secondary section cooling system amounts to about 5 % to 8 % of the total power loss of the motor under rated conditions. Selecting the cooling components On principle, the following must be taken into consideration when selecting the cooling components used: If the thermal effect of the motor does not have a negative impact on the mechanical machine assembly, then the main cooler alarm is sufficient. If increased requirements are placed on the precision of the machine, the primary section precision cooler and secondary section cooling system via the Thermo-Sandwich principle must be used. Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0 45

46 System integration 4.7 Cooling system Details of the thermal encapsulation 1FN3 motors are cooled according to the Thermo-Sandwich principle. The following figure shows details of the thermal encapsulation. Air Precision cooler (external cooling circuit) Main cooler (internal cooling circuit) Air gap Figure 4-7 Secondary section cooling (cooling sections made of aluminium) Thermal encapsulation of 1FN3 motors Cooling of the primary section/primary section main cooler As standard, the motor is cooled using water and an anticorrosive agent at an intake temperature of TINT = 35 C. If this temperature is changed, the continuous force of the motor changes with respect to the table value FN. Thermal insulation of the primary section/primary section precision cooler The primary section is insulated on the lower side by the air gap. On the top side, the (optional) primary section precision cooler shields the surrounding area from excessively high motor temperatures. Thermo-insulators on the screwed connections and the air chamber located in between reduce heat transfer from the primary section. The lateral radiation panels of the primary section precision cooler also form air filled spaces and insulate the primary section laterally from the machine. Under rated conditions, the temperature increase of the outer surface of the primary section precision cooler compared to the intake temperature is a maximum of 4 K. If the primary section precision cooler is not used, the temperatures on the surface of the motor may exceed 100 C. Thermal insulation of the secondary section/secondary section cooling system The secondary section is cooled by a cooling circuit, which as standard consists of cooling sections and two combi-distributors as secondary section end pieces. The secondary sections must be cooled in the case of: Applications with high heat loss entries in the secondary sections Applications whose machine base does not guarantee cooling via the secondary section contact surface Otherwise, secondary section cooling is optional. Air 46 Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0

47 System integration 4.7 Cooling system CAUTION High temperatures can lead to the demagnetization of the permanent magnets! The secondary sections must not exceed a temperature of 70 C! For 1FN3600 and 1FN3900 motors, secondary section cooling is imperative for the proper function of the motors as the large amount of heat transferred from the primary section to the secondary sections cannot be dissipated to the machine bed via the secondary sections' contact surfaces. Basic secondary section cooling components Generally, cooling sections and secondary section end pieces are required for the cooling of the secondary sections of the 1FN3 motors. Cooling sections The cooling sections are laid between the machine base and the secondary sections and together with these screwed to the machine base. The following two figures show the resulting cooling system without secondary section end pieces. The blue dotted lines indicate the cooling medium flow. Figure 4-8 Secondary section cooling consisting of cooling sections with hose connector nipples for 1FN motor models (side and top view) Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0 47

48 System integration 4.7 Cooling system Figure 4-9 Secondary section cooling consisting of cooling sections with hose connector nipples for 1FN motor models (side and top view) As of model 600 three cooling sections with a total of six cooling channels are used. The lateral profiles protrude just a little beyond the secondary section. The middle (additional) cooling section is attached by the line of screws in the center of the secondary sections. The surfaces of the cooling sections are thermally optimized. The heat is transferred to the contact area of the secondary section track and from there to the cooling channel. Toward the machine structure, however, the contact area is small, so that the heat transfer is kept at a minimum. The cooling sections are available in lengths up to 3 m. Secondary section end pieces The following secondary section end pieces at the start and end of the secondary section track close the cooling circuit and facilitate the cooling medium connection through uniform connectors: Combi distributor Combi adapter / combi end piece As standard, combi distributors are used as secondary section end pieces. These are available for all models. Combi adapters / combi end pieces can be used as an alternative for 1FN models. Cover band end pieces are not directly involved in the cooling of the secondary sections. The following figures show the secondary section cooling with different secondary section end piece models. 48 Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0

49 System integration 4.7 Cooling system Figure 4-10 Secondary section cooling for 1FN FN3450 motor models with combi distributors (side and top view) Figure 4-11 Secondary section cooling for 1FN3600 and 1FN3900 motor models with combi distributors (side and top view) Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0 49

50 System integration 4.7 Cooling system Figure 4-12 Secondary section cooling for 1FN FN3450 motor models with combi adapter and combi end piece (side and top view) Figure 4-13 Secondary section cooling consisting of cooling sections with hose connector nipple and cover band end pieces on both sides for all 1FN3050 1FN3450 motor models (side and top view) Note Due to the high pressure drop, secondary section cooling with a combi adapter / combi end piece can only be used for short traversing distances up to a length of approximately 2 m. The pressure drop must be checked for the entire cooling system! 50 Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0

51 System integration 4.7 Cooling system Materials used The following table lists the materials that are used for the cooling system in the motors. Table 4-4 Materials used for the cooling system Precision cooler Main cooler Secondary section cooling /1.4305; ; Viton SF-Cu; /1.4305; Viton; Delo 5327 AlMgSi0.5 (anodized) ; ; Viton; Delo Cooling circuits Conditions for the design The design of the individual cooling circuits bears similarities to the way in which the individual components are used in that they are both governed by the requirements of the motor. Cooling circuit requirements We recommend that the cooling circuits be designed as closed systems, to prevent the growth of algae. The maximum permissible pressure is 10 bar. Note We do not recommend that the cooling circuits of machines are also used to cool the motors: Due to accumulated dirt and long-term deposits, blockage may result! This especially applies to cooling-lubricating medium circuits. If the cooling circuits of the machines are also used to cool the motors, then they must fulfill all of the requirements listed here. Also note the demands on the cooling medium as well as the maximum standstill times of cooling circuits according to the specifications of the cooling medium manufacturer! Interconnecting cooling circuits To simplify the connection system and pipework, cooling circuits of the individual cooling system components can either be connected in parallel or in series. In this case, temperature and pressure differences between the intake and return must be carefully taken into consideration. Note With a series connection, the cooling medium should first flow through the secondary section cooling system and the primary section precision cooler and then through the main cooler. Otherwise, the heat from the main cooler is actively input into the machine via the secondary section cooling system and the primary section precision cooler. Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0 51

52 System integration 4.7 Cooling system CAUTION Rigid connections between the cooling circuits can lead to problems with leaks! It is strongly recommended that only flexible connections (hoses) be used for the interconnection of cooling circuits! Example of the interconnection of cooling circuits The following figure shows two examples for the series connection of different cooling circuits: On the left, all cooling circuits of the motor are connected in series. On the right, the cooling circuits of the primary section precision cooler and the primary section main cooler of a motor form a series connection. The resulting cooling circuits are connected in parallel. The secondary section cooling systems of both motors are also connected in series. Figure 4-14 Examples for the interconnection of various different circuits (schematic diagram) Use of cold water units When using cold water units, you can choose between the use of one cold water unit OR several cold water units unregulated cold water units OR regulated cold water units A comparatively cost-effective system is the use of an unregulated cold water unit that can be connected to all coolers used, e.g. in a series connection. In this case, the disadvantage is that the intake temperature can fluctuate. The maximum power density of the motor and its thermal insulation to the machine cannot be considered to be constant, which must be taken into consideration in the design. However, it is of course also possible to assign each cooler its own regulated cold water unit. With regard to the cooling system, this permits the complete control of the power density of the motor and its heat insulation to the machine since the intake temperature is always kept constant. Figure 4-15 Example of the use of cold water units 52 Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0

53 System integration 4.7 Cooling system The temperature control of the main cooler intake line is not necessarily required, even when the Thermo-Sandwich principle is used. This allows good compromise: The main cooler is operated with an unregulated cold water unit, while at the same time the primary section precision cooler and the secondary section cooling system are connected in parallel to a regulated cold water unit. The diagram above is a schematic representation of this design. In this case, the regulated cold water unit must be designed for only about 20 % of the total power loss. The parallel connection of the cooling circuits of the primary section precision cooler and the secondary section cooling system ensure that the intake temperature of the primary section precision cooler and the secondary section cooling system are the same. Recommended manufacturers Recommended manufacturers of cold water units are listed in the appendix Cooling media Provision of the cooling medium The customer must provide the cooling medium. Only water with anti-corrosion agent should be used as the cooling medium. Reason for the use of water with an anti-corrosion agent The use of untreated water may lead to considerable damage and malfunctions due to water hardness deposits, the formation of algae and slime, as well as corrosion, for example: Worsening of the heat transfer Higher pressure losses due to reductions in cross-sectional area Blockage of nozzles, valves, heat exchangers and cooling ducts For this reason, water as a cooling medium must contain an anti-corrosion agent that reliably prevents deposits and corrosion even under extreme conditions. General requirements placed on the cooling medium The cooling medium must be pre-cleaned or filtered in order to prevent the cooling circuit from becoming blocked. The formation of ice is not permitted! Note The maximum permissible size for particles in the cooling medium is 100 μm. Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0 53

54 System integration 4.7 Cooling system Requirements placed on the water The water used as the basis of the cooling medium must fulfill the following minimum requirements: Concentration of chloride: c < 100 mg/l Concentration of sulfate: c < 100 mg/l 6.5 ph value 9.5 Please check further requirements with the manufacturer of the anti-corrosion agent! Requirements placed on the anti-corrosion agent The anti-corrosion agent must fulfill the following requirements: The basis is ethylene glycol (also called ethanediol) The water and anti-corrosion agent do not segregate The freezing point of the water used is reduced to at least -5 C The anti-corrosion agent used must be compatible with the fittings and cooling system hoses used as well as the materials of the motor cooler Check these requirements, especially in regard to material compatibility, with the cooling unit manufacturer and the manufacturer of the anti-corrosion agent! Recommended manufacturers Recommended manufacturers of anti-corrosion agents are listed in the appendix Specifying the intake temperature Fundamentals Two variables play a role when specifying the intake temperature of the coolers: the power density of the motor and damage due to condensation. Power density The lower the intake temperature of the cooling, the higher the heat losses of the motor that can be dissipated. Therefore the power density of the motor is increased. 54 Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0

55 System integration 4.7 Cooling system Condensation Generally, condensation arises when parts of the cooling circuit or outer parts are colder than the surrounding air: The air in the vicinity of the colder surfaces is cooled down. The relative humidity thus rises and possibly reaches the limit value of 100 %. To minimize the formation of condensation, the intake temperature of the cooling circuits may lie a maximum of 3 K below the temperature of the surrounding air. When the machines are used in regions with very high humidity, the intake temperature should even be higher than the temperature of the surrounding air. Specifying the intake temperature The following rules apply when specifying the flow temperature: Lowest intake temperature possible for the highest possible power density An intake temperature that is not too low to avoid condensation Note The motor itself is not sensitive to condensation. Condensation, however, can lead to damage of the encased machine (e.g. rust). Condensation must be avoided! Select the intake temperatures, especially that of the primary section precision cooler, in such a way that no condensation can occur. The following figure shows a solution for the control of the intake temperature of the cooling circuits. The ambient temperature of the machine should be selected as a reference variable of the intake temperature for a subsequent control: TVORL = TUmgebung - 3 K protects the areas close to the motor from condensation. If the intake temperature is controlled via a fixed setpoint controller, the temperature value depends on the maximum ambient temperature. TVORL = TUmgebung,MAX - 3 K. If the constant feed force of the motor must be completely utilized, the intake temperature must be limited to a maximum of 35 C. In this case, moisture condensation may occur for unfavorable environmental conditions. Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0 55

56 System integration 4.8 Braking concepts Figure 4-16 Characteristic of the intake temperature of the cooling circuits Comparison of the possible controls With the servo control, the intake temperature is adapted to the current ambient temperature at the location of use of the motor. In this way, the motor can generally be kept cooler than with the fixed setpoint control. The service life and power density of the motor thus increase. The servo control is therefore better than the control of the intake temperature via a fixed setpoint controller. A further favorable possibility is the use of two separately controllable cooling circuits. One cooling circuit supplies the precision cooler and has a cooling medium servo control with a linear characteristic curve and no limitation of the intake temperature. The second cooling circuit supplies the main cooler and has a cooling medium servo control which limits the intake temperature to 35 C Braking concepts Safety guideline WARNING Malfunctions can lead to uncontrolled motion of the drive. Due to the high kinetic energy stored in the machine slides with large masses and high velocities, machine damage is very probable. Take measures to stop the motor in case of a malfunction! 56 Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0

57 System integration 4.8 Braking concepts Possible malfunctions Malfunctions can occur e.g. for: Power failure Encoder failure, encoder monitoring responds Higher-level control failure (e.g., NCU); bus failure Control Unit failure Drive fault NC fault Braking concepts The design and calculation of brake systems depends on the maximum kinetic energy, i.e., on the maximum mass of the machine slide and its maximum speed. It can therefore only be performed for a specific machine. The only reliable way of braking the machine slide on the axis in the event of a malfunction is to use sufficiently dimensioned damping and impact absorption elements at the ends of the traversing distances. If there are several slides on one axis, damping and impact absorption elements must also be mounted between the slides. In order to dissipate the kinetic energy of the slide before it hits the damping elements, the following additional measures should be applied: 1. Electrical braking using the energy in the DC link: The DC link must have capacitor modules that store enough energy to brake the machine slide safely in the event of a power failure. At the same time, brake resistors that prevent the voltage in the DC link from exceeding the maximum permissible value must be installed. Disadvantage: This measure does not work if the Control Unit fails. It may also be ineffective if the encoder system fails. Also see the documentation of the drive system used! 2. Electrical braking by short-circuiting the primary section (corresponds to an armature short-circuit): If there is no appropriate function in the drive system being used, when a fault situation develops, the motor connection terminals are disconnected from the drive system and short-circuited using a contactor that automatically closes. Also see the documentation of the drive system used. Disadvantage: The braking force depends on the velocity and is not sufficient to brake the slide completely. Note If electric braking by short-circuiting the primary section without braking resistors is used, special contactors are required because the currents can be very high. - The release timing for the drive system must be taken into account. Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0 57

58 System integration 4.8 Braking concepts 3. Mechanical braking via braking elements: The braking capacity must be dimensioned as highly as possible so that the slide can be safely braked at maximum kinetic energy. Disadvantage: The relatively long response time of the brake control system leads to long, unbraked traversing distances. We recommend that all three measures be implemented together. Measures (2) and (3) are used as an additional protection here in case Measure (1) fails: The short-circuiting of the primary section works at high velocities first and then the mechanical brake takes effect at lower velocities. Recommended manufacturers Recommended manufacturers of braking elements are listed in the appendix Use of a holding brake Due to latching forces, the motors can be pulled into a preferred magnetic position if the motor is no longer supplied with power from the drive. In the process, if the drive is already at a standstill, unexpected movements may occur up to a half magnetic pole pitch in both directions. To prevent possible damage to the workpiece and/or tool, the use of a holding brake may be appropriate. Due to the missing mechanical self-locking, a holding brake should be provided in case of inclined or vertical drives without weight compensation so that the drive can be shut down and deenergized in any position. A holding brake may also be required if: The bearing friction does not compensate or exceed the latching forces and unexpected movements result Unexpected movements of the drive can lead to damage (e.g. a motor with a large mass also achieves a large kinetic energy) Weight-loaded drives must be shut down and de-energized in any position 58 Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0

59 Coupled motors Motors connected in parallel Prerequisite for the parallel connection The position of the primary sections connected in parallel to each other must fulfill certain conditions for operation. The prerequisite for an electrical parallel connection of motors is therefore a sufficiently rigid coupling. Note Only linear motors with identical order numbers should be connected in parallel. This means that the motors have: The same forces The same winding type The same secondary section type The same air gap When more than one motor is operated in parallel on one converter, observe the relevant national guidelines. In particular, special precautions must be taken in North America (special motor protection). Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0 59

60 Coupled motors 5.1 Motors connected in parallel Arrangement options Two primary sections, which are to be electrically operated in parallel, can be assigned to either a single secondary section track or to two individual secondary section tracks. The cable outlets can run in the same or opposite direction. For motors connected electrically in parallel (Master M and Stoker S), this results in four basic mechanical arrangements that are shown in the following table. Table 5-1 Basic mechanical arrangements of motors connected in parallel One secondary section track Same cable outlet direction TANDEM arrangement Opposite cable outlet direction JANUS arrangement Two secondary section tracks PARALLEL arrangement ANTIPARALLEL arrangement Reference points for aligning the primary sections Note If linear motors on a joint secondary section track are connected in parallel, the position of the primary sections with respect to one another must exhibit a specific grid to achieve a matching pole position. With separate secondary section tracks, the position of the tracks to one another must also be taken into account. The reference points for aligning the linear motors connected in parallel are as follows: For the primary section: The hole that is located farthest from the cable outlet of the primary section For the secondary section: The mounting hole closest to the N mark The following figure shows these reference points. 60 Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0

61 Coupled motors 5.1 Motors connected in parallel Figure 5-1 Reference points for aligning the primary sections connected in parallel The distance between the holes Δsb is the distance between the reference hole of the stoker and the reference hole of the master. The sign specifies the shift in the positive direction of motion. Note When specifying the position of the master and the stoker, the position of the master reference hole is always x = 0. Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0 61

62 Coupled motors 5.1 Motors connected in parallel Same cable outlet direction The phase sequence of master and stoker is identical for the same cable outlet. Correspondingly, the position of master and stoker to the position of the permanent magnets of the secondary section track(s) must be identical, see following figure. Reference hole Cable outlet direction Master N S N S N S N S N S N S N S N S 2τM x M Reference hole 2τM: Pole pair width xm = xs!!! Cable outlet direction N S N S N S N Stoker S N S N S N S N S x S Figure 5-2 Position of master and stoker with the same cable outlet direction For the TANDEM arrangement, the distance between the holes must correspond to an integer multiple of the pole pair width; see the image below: Δsb = n 2τM with n = 0, 1, 2, Figure 5-3 Position of master and stoker with TANDEM arrangement For the PARALLEL arrangement, there is also the possibility of shifting the second secondary section track by Δx, see following figure. The distance between the holes is calculated as follows: Δsb = Δx + n 2τM with n = 0, 1, 2, 62 Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0

63 Coupled motors 5.1 Motors connected in parallel Figure 5-4 Position of master and stoker with PARALLEL arrangement Opposite cable outlet direction One phase of the stoker is assigned as in the case of master, the other two are switched. Therefore, the position of the primary sections with respect to the permanent magnets of the secondary section track is no longer identical: The stoker must be shifted by a distance of Δs0 2τM so that the force generation in both motors is the same. Such a distance is easiest to define in the JANUS arrangement: Δs0 is the smallest possible distance between the reference holes of the master and stoker, see following figure. Figure 5-5 Position of master and stoker with cable outlet running in opposite direction and minimum distance between the reference holes Accordingly, in the JANUS arrangement, distances between the holes are possible that result from Δsb = Δs0 + n 2τM with n = 0, 1, 2, For the ANTIPARALLEL arrangement, there is also the possibility of shifting the second secondary section track by Δx. The distance between the holes is calculated as follows: Δsb = Δs0 + Δx + n 2τM with n = 0, 1, 2, Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0 63

64 Coupled motors 5.1 Motors connected in parallel Dimensions for the parallel connection The pole pair width 2τM and, for the opposite cable outlet direction, the minimum distance Δs0 are decisive for the position of primary sections connected in parallel, see following figure. Both variables are specified in the following table. Figure 5-6 Position of primary sections connected in parallel on a second secondary section track Table 5-2 Pole pair width and minimum distance of 1FN3 peak load motors connected in parallel 1FN FN Pole pair width 2τM [mm] Minimum distance Δs0 [mm] Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0

65 Coupled motors 5.1 Motors connected in parallel Example: Calculation of distance between holes for ANTIPARALLEL arrangement Requirements: Motor type: 1FN3300 1Wxxx Δs0 = mm 2τM = 46 mm Both motors should be side by side if possible (see following figure) Δx should be as small as possible Figure 5-7 Target position of the master and stoker in the example Steps: First the JANUS arrangement should be considered as shown in the following figure for Step 1. The shift sv required to bring the stoker to the desired position in this arrangement depends on the primary section length lp, the distance between the hole and the front face of the primary section lp,b and on the minimum distance between holes for the JANUS arrangement Δs0: sv = lp + (Δs0-2lP,B) with lp = 221 mm with lp,b = 50.5 mm sv = 221 mm + ( ) mm sv = mm (negative because the shift is to the left) As the secondary section tracks should be shifted as little as possible in relation to one another, if possible, the shift sv should be a multiple of the pole pair width 2τM. The optimum case (Δx = 0) would be Δs = sv = -n 2τM. The n for which sv - Δs becomes minimum is determined via: In this example, the stoker must be shifted five pole pair widths to the left in Step 2. Thus, the following applies for Δs: Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0 65

66 Coupled motors 5.1 Motors connected in parallel Δs = -5 2 τm = mm = -230 mm The difference sv - Δs must be compensated by shifting the secondary section track: Δx = mm -(-230 mm) = 1.2 mm In this case, the secondary section track with the stoker must be shifted 1.2 mm to the left. The distance between holes can now be defined: Δsb = Δs0 + Δs + Δx Δsb = mm mm -1.2 mm = -120 mm The stoker reference hole is therefore 120 mm to the left of the master reference hole. Figure 5-8 Dimensions (with counting direction) for the specified example 66 Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0

67 Coupled motors 5.2 Double-sided motors Double-sided motors Structural options for double-sided motors The following figure shows the variants in which a double-sided motor can be implemented: (a) Two standard secondary section tracks are mounted on a support plate the incline of the permanent magnets is not parallel (b) Two magnet tracks with parallel incline are stuck onto the support plate (c) A magnet track is integrated in the support plate Figure 5-9 Principle structure of a double-sided motor Advantages and disadvantages In the case of Variant (a), two standard primary sections can be used since both primary sections work with the standard polarity of the secondary sections. Therefore, in principle this variant can be implemented for all motors. Due to the lower dynamic mass for Variants (b) and (c), these double-sided motors are suited for very high dynamic requirements. Since a primary section must work with the inverse polarity of the secondary section, an inverse winding is required here. This is only available for certain motor types and on request. Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0 67

68 Coupled motors 5.2 Double-sided motors Construction of the support plate The support plate for the application-specific secondary section track must be manufactured by the customer in agreement with the Siemens office responsible. The minimum thickness of the support plate only depends on the motor forces to be transferred. It is approximately 2 mm thick. For reasons of stiffness, this dimension corresponding to the structure of the application-specific secondary section should be increased as different air gaps on the left and right result in different forces of attraction. The difference of the attraction forces of the motors must be transferred to the guide via the support plate and its connecting structure. If the stiffness of the support plate is too low, impermissibly high deformation may result. Even though theoretically the forces of attraction are compensated in the case of double-sided motors, forces of up to about 25 % of the force of attraction of a motor have an effect on the support plate. Configuration Double-sided motors are mainly configured in the normal way. Only difference: In this case, the dynamic mass is the mass of the secondary section system. This means that the following must be taken into consideration: The mass of the secondary sections or the mass of the magnetic material The mass of the (special) secondary section covers The mass of the mount of the support plate The mass of the guide elements The mass of the length measuring system 68 Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0

69 Order numbers Structure of the order numbers The order number consists of a combination of alphanumeric characters, the machine-readable product designation MLFB. When placing an order it suffices to specify the unique MLFB. The MLFB consists of three blocks that are separated by hyphens. The first block of the MLFB comprises seven digits. These represent the model and type of the primary section or the secondary section. Additional features are coded in the second block. The third block is provided for additional data. Note that not every theoretical combination is possible in practice Primary sections Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0 69

70 Order numbers 6.3 Secondary sections Secondary sections Primary section accessories Precision cooler Hall sensor box The Hall sensor box can be mounted opposite to the primary section s terminal end or on the terminal end of the primary section. The standard location is opposite to the primary section s terminal end. 70 Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0

71 Order numbers 6.4 Primary section accessories Connector box SME9x Connection cover For 1FN3 linear motors all connection covers can be ordered separately. Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0 71

72 Order numbers 6.5 Secondary section accessories Table 6-1 Variants available to order Connection cover Primary section models Thread for screw gland 1FN3002-0PB01-0AA0 1FN3100 and 1FN3150 1x PG16 1FN3003-0PB02-0AA0 1FN3300 and 1FN3900 1x PG21 1FN3003-0PB03-0AA0 1FN3300 and 1FN3900 1x PG29 1FN3002-0PB04-0BA0 1FN3100 and 1FN3150 2x M20 1FN3003-0PB04-0BA0 1FN3300 and 1FN3900 2X M20 1FN3003-0PB05-0BA0 1FN3300 and 1FN3900 1xM20 and 1xM32 Table 6-2 Order designations for connectors Connector type Connector size MLFB Power connection 1.5 6FX2003-0LA10 Power connection 1 6FX2003-0LA00 Signal connection M17 6FX2003-0SU Secondary section accessories Secondary section end pieces 72 Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0

73 Order numbers 6.5 Secondary section accessories Cooling sections Secondary section cover Segmented cover Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0 73

74 Order numbers 6.6 Ordering example Cover with metal band Ordering example An order could look like this: Components Quantity Order No. [MLFB] Primary section 1 1FN3150 3WC00 0AA1 Primary section precision cooler 1 1FN3150 3PK00 0AA0 Secondary sections (Length of the secondary section track: 1440 mm) 12 1FN3150 4SA00 0AA0 Secondary section cover (metal band) 1 1FN3150 0TB00 1BC0 Cooling sections with plug-type coupling 2 1FN3002 0TK04 1BC0 Combi distributor 2 1FN3150 0TJ01 0AA0 Hall sensor box (standard, straight cable outlet) 1 1FN3005 0PH00 0AA0 74 Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0

75 Motor configuration Subjects worth knowing in advance Operation in the area of reduced magnetic coverage If the primary section moves beyond the ends of the secondary section track, the motor force is reduced. Fundamentals and information The available motor force is almost proportional to the percentage of the surface with magnetic coverage to the total magnetically active surface of the primary section. Depending on the extent of the frictional forces in the guides, the motor force of the drive may be too low to independently return to the secondary section track if the degree of coverage is too low. External force is then required to return to the track. Note The degree of coverage should not be below 50 % in order to ensure that the drive can independently return to the secondary section track. In the area of reduced magnetic coverage, the phases are non-symmetrically loaded - especially at high velocities. This leads to additional heating. Note The velocity in areas of reduced magnetic coverage should not exceed 25 % of the rated velocity vmax,fn. The area of reduced magnetic coverage should be used only to approach parking or service positions, but not for machining. When a Hall sensor box (HSB) is used for the identification of the position, ensure that the HSB is located above the magnets of the secondary section track when the system is switched on and that the primary section can move on its own. The drive is normally operated position-controlled. As the loss of motor force changes the behavior of the control circuit, stable operation can only be achieved when the value of the position controller gain kv is reduced. The appropriate kv value for each case depends on the mechanical design of the respective machine. It can only be determined by tests during the commissioning. The search for the suitable value of kv should start with 5 % of its value at full magnetic coverage. Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0 75

76 Motor configuration 7.1 Subjects worth knowing in advance Short-time duty S2 and intermittent duty S3 Short-time duty S2 In the case of short-time duty S2, the load time is so short that the final thermal state is not reached. The subsequent zero-current break is so long that the motor practically cools down completely. CAUTION An excessive load can lead to the destruction of the motor. The load may not exceed the value IMAX specified in the data sheets! The motor may only be operated for a limited time t < tmax with a current IN < IM IMAX. The time tmax can be calculated using the following logarithmic formula: with ν = (IM / IN) 2 and the thermal time constant tth. The thermal time constants, the maximum currents and the rated currents of the motors can be taken from the data sheets. Note The above equation applies under the prerequisite that the starting temperature of the motor corresponds with the intake temperature of the water cooling system TVORL! Example: The 1FN3300-2WC00-0AA1 motor should be operated from a cold state at maximum current. IMAX = 39.2 A, IN = 12.6 A; which results in ν = tth = 120 s The motor may only be operated for a maximum of 13 s at maximum current. 76 Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0

77 Motor configuration 7.1 Subjects worth knowing in advance Intermittent duty S3 With intermittent duty S3, periods of load times tb with constant current alternate with periods of standstill times ts with no current feed. The motor heats up during the load time and then cools down again while at standstill. After a sufficient number of load cycles with a cycle duration tspiel = tb + ts, the temperature characteristic oscillates between a constant maximum value To and a constant minimum value Tu, see following figure. Figure 7-1 Current and temperature characteristic for intermittent duty S3 For currents IN < IM IMAX, the rms continuous current may not exceed the rated current: Whereby the cycle duration should not be longer than 10 % of the thermal time constant tth. If a longer cycle duration is necessary, please contact your local Siemens office. Example With a thermal time constant of tth = 120 s, the maximum permissible cycle duration tspiel is s = 12 s. Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0 77

78 Motor configuration 7.2 Procedure for the configuration Procedure for the configuration Overview of the configuration sequence Basics The selection of a suitable linear motor depends on: The peak force and continuous force required for the application The desired velocity and acceleration The installation space available The desired or possible drive arrangement (e.g. single-sided, parallel, or double-sided arrangement) The required cooling system 78 Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0

79 Motor configuration 7.2 Procedure for the configuration Sequence As a rule, the motor selection is an iterative process as, especially with high dynamic direct drives, the intrinsic mass of the motor type also determines the required powers. The following figure is a flowchart of this process. Figure 7-2 Flowchart for the drive configuration Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0 79

80 Motor configuration 7.2 Procedure for the configuration Definition of the mechanical supplementary conditions Introduction The supplementary conditions that influence the selection of the motor include: Dynamic masses (incl. motor mass) Gravitation Friction Machining forces Travel lengths The drive configuration The first three points are considered in more detail here. Dynamic masses All machine parts, equipment in the power chain, covers, mounting parts, etc. that the motor has to move, must be included in the calculation of the dynamic mass. The mass of the motor itself is also required. As this is not known the motor still has to be selected the mass of a motor type that is approximately suitable must be used. If, during the further calculation, it is found that the assumed mass is badly incorrect, an additional iteration step is required for the motor selection. In contrast to rotary drives with a mechanical gear reduction, all load masses are fully included in the acceleration capacity of the drive for a direct drive. Gravitation Every mass is subject to gravity. The motor must thus compensate part of the gravitational force FG that has an effect on the dynamic mass. This component Fg depends on the dynamic mass m, the mounting position of the axis in relation to the earth's normal (angle α) and any weight compensation used. The following figure shows the forces on the motor due to gravitation for an inclined mounting position. The variable F is the component of the gravitational force perpendicular to the inclined axis. Figure 7-3 Forces on the motor for an inclined mounting position 80 Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0

81 Motor configuration 7.2 Procedure for the configuration According to the force components in the above figure, the component of the gravitational force that has to be compensated by the motor is calculated using Fg = m g cos α with the gravitational acceleration g. When using a weight compensation, you must consider that the compensation does not automatically amount to 100 % and is linked to additional friction forces and inert masses. Friction Friction that impedes the movement of a linear motor occurs between the guide carriage and the guide rail. The corresponding force Fr opposes the direction of motion of the slide. Essentially, the frictional force Fr consists of a constant component Frc and a component Frν that is proportional to the speed v: Fr = Frc + Frν Both components depend on the type of linear guide used and its loading. Depending on the mechanical structure, the loading includes all gravitational forces (F from the above figure) and magnetic forces of attraction Fmagn between the motor components as well as the clamping forces Fspann between the various guide elements. All these forces result in a force Fn which is perpendicular ("normal") to the axis: Fn = F + Fmagn + Fspann If Frc = μrc Fn and Frv = μrv v Fn is set, the resulting frictional force is Fr = μrc Fn + μrv v Fn Note High linear motor speeds can also result in extremely high frictional force values. Note the specifications of the linear guide manufacturer for the calculation of the frictional forces! The following figure shows a simplified example for the speed curve and the correspondingly occurring frictional forces in a motor. Figure 7-4 Example of frictional forces Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0 81

82 Motor configuration 7.2 Procedure for the configuration Specification of the load cycle In addition to the frictional and gravitational forces, the load cycle is decisive for the selection of the motor. The load cycle contains information regarding the sequence of motion of the drive axis and the machining forces that occur in the process. The sequence of motion can be specified as a distance - time diagram, speed - time diagram or acceleration - time diagram, see following figure. In accordance with the following relationships: the diagrams for the sequence of motion can be converted to one other. Figure 7-5 Example for the sequence of motion of a linear motor in diagrams The inertia forces resulting from the sequence of motion that the motor must compensate, are proportional to the acceleration a and the dynamic mass m: Fa= m a They oppose the direction of acceleration. 82 Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0

83 Motor configuration 7.2 Procedure for the configuration A machining force - time diagram for a motor could look like the following figure. The speed - time diagram serves as a comparison. Figure 7-6 Example of a machining force - time diagram Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0 83

84 Motor configuration 7.2 Procedure for the configuration Determination of the motor thrust, peak thrust and continuous thrust Determination of the motor thrust The thrust that the motor has to provide consists of the sum of the individual forces at any time. The signs of the forces must be taken into account! The following figure shows an example of the individual forces for a linear motor and the resulting motor thrust FM. Figure 7-7 Example of the individual forces for a linear motor and the resulting motor thrust Determination of the peak thrust The peak thrust FMAX that the motor must provide can be easily determined from the above figure. 84 Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0

85 Motor configuration 7.2 Procedure for the configuration Determination of the continuous thrust In addition to the peak thrust, the required continuous thrust of the motor is decisive for its dimensioning. The maximum continuous thrust of the motor Feff is calculated from the square mean of the motor thrust over the entire time of a sequence of motion and may not exceed the rated thrust FN: When the motor thrust is constant over sections as in the following figure, this simplifies the integral for the sum: Figure 7-8 Continuous thrust with motor thrust constant over sections The above equations apply only under the prerequisite that saturation effects can be ignored. For more exact calculations, the forces must be replaced by the corresponding currents Selection of the primary sections Requirement Whether a primary section can fulfill the requirements from the load cycle, depends on the following items: The continuous thrust of the primary section (rated thrust FN) must be greater than or equal to the determined continuous thrust value Feff of the load cycle. The primary section should have approx. 10 % control reserve with respect to the peak thrust FMAX, in order to avoid undesired limitation effects for overshoot of control loops. All required thrusts can be achieved at the required speeds. Overload phases of the load cycle must not lead to shutdown by the temperature monitoring. In addition to the requirements from the load cycle, mechanical installation conditions may influence the choice of motor. The same motor thrusts may often be generated by different types of primary sections. Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0 85

86 Motor configuration 7.2 Procedure for the configuration If several primary sections are involved in the thrust generation of the axis, the values for the peak and continuous thrusts of the individual motors must be added. If the distribution of thrust among the individual motors is not even, such as in the case of the gantry axis with an uneven distribution of weight, the thrust requirements on the individual motors must be taken into consideration separately. Procedure The first two items are used for a preselection of the possible primary sections. If some supplementary conditions such as the machining forces and frictional forces are not exactly known, it is best to plan with larger reserves. To determine whether a primary section actually fulfills the requirements from the load cycle, the motor force - speed characteristic curve, which results from the required sequence of motion and the motor force - time diagram, is required. Whereby only the absolute values for motor thrust and speed are decisive, not the directions. All points of the motor force - speed characteristic curve must be below the force - speed characteristic curve of the primary section that is specified in the data sheets. Figure 7-9 Example for points of a motor force - speed characteristic curve in comparison with the force - speed characteristic curve of the primary section 86 Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0

87 Motor configuration 7.2 Procedure for the configuration As an example, the above figure shows some points of the motor force - speed characteristic curve at times t1... t4 in comparison with the force - speed characteristic curve of a primary section: t1: This point is not critical as it lies below the force - speed characteristic curve of the motor. t2, t3: These points are not critical as they lie below the force - speed characteristic curve of the motor. It should be checked, however, whether the motor can be run as long as intended at overload. t4: If such a point occurs, the required motor thrust cannot be achieved at this speed. In this case, you must select another primary section at which the point t4 lies below the force - speed characteristic curve. Note Not in all motor operating states are all three phases evenly loaded with current, for example: Standstill with current feed of the motor, for example, for: The compensation of a weight Start up against a brake system (damping and impact absorption elements) Low speeds (< 0.5 m/min) Cyclic traversing distances less than the pole width With long-term uneven loading, the motor may be operated only at about 70 % of the rated thrust, see F0* in the data sheets. For precise dimensioning, please contact your local Siemens office Specifying the number of secondary sections Basics Irrespective of the length, the secondary sections must have the same magnetic track width as the selected primary section. This can be guaranteed through a selection using the MLFB (order numbers): The MFLB digits that indicate the frame size of the motor must be the same. The number of required secondary sections depends on: The desired traversing distance The drive arrangement Specifying the total length of the secondary section track The total length of a secondary section track determines the number of required secondary sections. It depends on the length of the desired traversing path, the number of primary sections on this secondary section track and, if applicable, the use of a Hall sensor box. Note The calculation of the total length of the secondary section track specified here guarantees the maximum motor force over the entire traversing path. Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0 87

88 Motor configuration 7.2 Procedure for the configuration A single primary section on the secondary section track If it is intended that only one primary section should be on the secondary section track, the length of the secondary section track is calculated using the length of the required traversing distance and the magnetically active length of the primary section (see the image below). Note The magnetically active length of the primary section without the use of a Hall sensor box (lp,akt) is shorter than when a Hall sensor box is used (lp,akt,h). The variable lp,akt is specified in the dimension drawings. The length lp,akt,h then results from the drawings for the attachment of the Hall sensor box. Figure 7-10 Determination of the length of the secondary section track with one primary section Several primary sections on a secondary section track If several primary sections are to be mounted on a secondary section track, the required length of the secondary section increases by the active length of the additional primary sections and the distances between them (see the image below). Figure 7-11 Determination of the length of the secondary section track with several primary sections 88 Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0

89 Motor configuration 7.2 Procedure for the configuration If the various primary sections are operated from separate drive systems with separate measuring systems, for example, for gantry or master/slave operation, the distance between the primary sections is limited only by mechanical supplementary conditions such as the length of the connecting plugs and the bending radii of the cables. As long as the primary sections are being electrically operated in parallel on a drive system, the pole position of the two primary sections must be the same. The distance can only accommodate certain values. Specifying the number of secondary sections The total required length of the secondary section track is calculated from the individual secondary sections. The available lengths are listed in the motor data Checking the dynamic mass Procedure The dynamic mass of the motor or the axis is determined at the latest after the secondary sections have been selected. With this data, the assumptions specified as mechanical supplementary conditions can be checked. When the mass of the motor assumed there differs considerably from the actual mass of the motor, a new calculation of the load cycle is required Selecting the power module The required power modules are selected according to the peak and continuous currents that occur in the load cycle. If several primary sections are operated in parallel on one drive system, then the summed values of the peak and continuous currents must be taken into account. A selection of available power modules can be found, for example, in the relevant catalogs. Note In systems where direct drives are used on controlled infeeds, electrical oscillations can occur with respect to ground potential. These oscillations are, among other things, influenced by: The lengths of the cables The rating of the infeed/regenerative feedback module The number of axes The size of the motor The winding design of the motor The type of line supply The place of installation The oscillations lead to increased voltage loads and may damage the main insulation! We thus recommend using an HFD commutating reactor with damping resistance for damping the oscillations. For specific details, refer to the documentation of the drive system being used or contact your local Siemens office. Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0 89

90 Motor configuration 7.3 Examples Calculation of the required infeed Basics The electrical infeed power PEL of the linear motors can be determined from the delivered mechanical power PMECH and the occurring losses PV. PEL = PMECH + PV = FM v + 3 RSTR Ieff 2 The variable v from the above equation is the speed as was specified in the load cycle. The effective current Ieff results from the motor thrust FM and the force constant of the motor kf: The line resistance RSTR(TN) = RSTR,20[1 + α(tn - 20 C)] with the temperature coefficient α = /K for copper should be used as the upper estimation for PEL. The value kf,20 can be taken from the data sheets as a force constant. Procedure The electrical power can be calculated for every point in time in the load cycle. For the selection of an infeed unit for the DC link, it generally suffices to determine the required maximum infeed power for the load cycle for high dynamic direct drives: the constant input is generally considerably lower. The maximum infeed power is usually required when accelerating to the maximum speed. Since accelerating is only for a very short period in the case of high dynamic drives, the 200 ms value can generally be used as design criterion for the maximum infeed power of the infeed units. In the case of several axes, the infeed powers of the individual axes are to be added together with the corresponding simultaneity conditions for the selection of the infeed unit Examples Note Possible differences to data provided in the data sheets have no effect on the calculation method shown here Positioning in a predefined time Predefinitions In the case of positioning in predefined time, only the end points of the path and the duration of the individual motion sections are predefined. Objective An appropriate primary segment of the peak load motors of the 1FN3 product family, the appropriate secondary sections and the number of required secondary sections are to be found for the following specifications: 90 Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0

91 Motor configuration 7.3 Examples The motor should move on a horizontal axis during time t1 to a certain point smax. It should then wait there for time t2 and then return to the starting position. The following figure shows these variables in a distance - time diagram. Figure 7-12 Example 1: Representation of the predefined variables in the distance/time graph The individual predefined variables are: Traversing distance smax = 260 mm = 0.26 m Traversing time t1 = 0.21 s Dwell time t2 = 0.18 s Mass to be moved (without motor mass) m = 50 kg Constant friction Fr = 100 N Horizontal axis Fg = 0 In addition, a power module is to be selected and the maximum infeed power calculated. Supplementary conditions/specification of the load cycle Traversing profile The form of the velocity profile during time t1 is not explicitly specified. Therefore, a suitable velocity profile must be specified first. The image below shows various examples of possible traversing distances. Figure 7-13 Example 1: Examples of velocity profiles Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0 91

92 Motor configuration 7.3 Examples The solid line indicates the velocity profile that is easiest to implement: With this profile, only one constant acceleration phase and one constant deceleration phase are required to reach position smax (also see the image below). This type of velocity profile has the shortest positioning times. Figure 7-14 Example 1: Sequence of motion for the simplest velocity profile From the specified values, you can calculate how great the maximum velocity and maximum acceleration (deceleration) of the motor must be: 92 Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0

93 Motor configuration 7.3 Examples Since the required force for this is not yet known, FMAX should be assumed. The value for the maximum velocity vmax then corresponds with the values listed for vmax,fmax in the data sheets. A velocity vmax = 2.48 m/s =149 m/min is relatively often above the maximum permissible values vmax,fmax for the 1FN3 peak load motors. Therefore, in this example, the traversing profile is to be modified in order to increase the possible selection. Another simple velocity profile that will now be explored here features, in addition to the constant acceleration and constant deceleration, a phase in which the motor is to be run at maximum velocity (see the image below). Figure 7-15 Example 1: Modified velocity profile For the maximum velocity that the motor should achieve, the following should apply: smax vmax t1 Otherwise, the duration of time t1 will not be long enough to position the motor at smax. In the current example, the following must apply for the maximum velocity of the motor: vmax 1.24 m/s = 74.3 m/min Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0 93

94 Motor configuration 7.3 Examples In comparison with the previous profile, a higher acceleration amax must be used so that the motor will be positioned in the same amount of time t1. At the defined maximum velocity, this acceleration can be calculated: A primary section can be selected using this data. Selecting the primary section In order that the configuration is not too restricted, a maximum velocity of vmax = 1.5 m/s = 90 m/min is assumed. With this condition for the maximum velocity, only a few primary sections are eliminated from the selection. This results in amax = 41 m/s 2 for the acceleration. The maximum power FMAX that the motor must supply is calculated as follows: FMAX = m a + Fr = 50 kg 41 m/s N FMAX = 2150 N A small motor that can attain this force is the 1FN3100-4WC00-0AA1. Even the previously assumed 90 m/min does not exceed the given maximum velocity at peak force vmax,fmax. Checking the mechanical supplementary conditions You must now check two points: Is the reserve force of the selected primary section also sufficient for the mass of the primary section (which has not yet been taken into account)? Does the continuous force lie below the permissible continuous force? Reserve force The mass of the primary section with precision cooler amounts to 8.5 kg; the total dynamic mass m thus amounts to (50+8.5) kg = 58.5 kg. The maximum force that the motor must supply is: FMAX = m a + Fr = 58.5 kg 41 m/s N FMAX = 2499 N This force cannot be supplied by the previously selected motor. Therefore, a new primary section has to be selected. A further primary section that fulfills all requirements is the 1FN3100-5WC00-0AA1. The mass of this primary section with precision cooler amounts to 10.4 kg; the motor must therefore supply a maximum force of approximately 2576 N. The maximum force listed in the data sheet is 2750 N. That would be sufficient, however, the recommended control margin of 10 % is no longer available. Another primary section that fulfills all requirements is the 1FN3150-4WC00-0AA1. The mass of this primary section with precision cooler amounts to 11.4 kg; the motor must therefore supply a maximum force of approximately 2617 N. The maximum force listed in the data sheet is 3300 N. The recommended control reserve of 10 % is also available with this maximum force. 94 Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0

95 Motor configuration 7.3 Examples Continuous force The image below shows the force/time graph for the entire sequence of motion for this example. Figure 7-16 Example 1: Force/time graph and continuous force of the load cycle in this example To calculate the continuous force, the summation formula can be used here since the motor force Fm is constant in sections: The continuous force therefore remains below the permissible value of 1350 N. Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0 95

96 Motor configuration 7.3 Examples Interim result For the example shown here, the primary section 1FN3150-4WC00-0AA1 is suitable. Specifying the number of secondary sections Type of secondary section The secondary section suitable for primary section 1FN3150-4WC00-0AA1 is found using the MLFB. The suitable secondary section has the Order No. 1FN3150-4SA00-0AA0. Length of the secondary section track The magnetically active length of the primary section lp,akt is 420 mm. Together with the traversing distance smax, the length of the secondary section track lspur is calculated as follows: lspur = lp,akt + smax = ( ) mm lspur = 680 mm Number of secondary sections The 1FN3150-4SA00-0AA0 secondary sections have a length of ls = 120 mm. Therefore, six secondary sections are required; the total length of the secondary section track is mm = 720 mm. Selecting the power module The selected motor has the following data: Maximum force FMAX = 3300 N Rated force FN = 1350 N Maximum current IMAX = 38.2 A Rated current IN = 14.3 A A suitable power module for this data is selected from the relevant catalog. Calculating the maximum infeed power The electrical infeed power is calculated using the mechanical power PMECH and the power loss PV. Both values in this example reach the maximum if the motor runs at the maximum velocity and force indicated by the required load cycle. In the example shown here, these values are as follows: vmax = 1.5 m/s FMAX = 2617 N This results in the following upper estimation for the maximum infeed power: with 96 Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0

97 Motor configuration 7.3 Examples The maximum infeed power is therefore: The value 9440 W must be added to the infeed powers of other loads that are also operated on the DC link. A corresponding infeed/regenerative feedback module can thus be selected Machining center with gantry axis Introduction In machining centers, there are often arrangements with three linear motor axes riding on each other, as shown in the following figure. When dimensioning the linear drives, it must be taken into account that the subordinate axes also have to move the masses of the riding axes. With the arrangement in the following figure, the y-axis also carries the mass of the z-axis. For the x-axis which is at the very bottom (outside), the mass of the y-axis as well as that of the z-axis must be taken into account. 1 Y 2 2 Figure 7-17 Three linear motor axes riding on top of each other in the x, y and z directions Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0 97

98 Motor configuration 7.3 Examples Objective Peak load motors X1 and X2 of the 1FN3 product family are to be found for the arrangement in the previous figure. Supplementary conditions Condition for the x axis The x axis is designed as a gantry: Motor X1 and motor X2 each have a separate position measuring system and a separate drive system, but move in synchronism. Velocity/time graph The required velocity/time graph consists of phases of constant velocity and phases of constant acceleration, see following figure. Each acceleration should have a value of a = 2g (g: gravitational acceleration; g = 9.81 m/s 2 ). The motor should have a standstill phase at the end of the motion cycle. Figure 7-18 Example 2: Velocity/time graph for the gantry During time t4, a workpiece is to be machined with velocity vb and constant force Fb. A general friction of Fr = 300 N per side should be assumed. 98 Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0

99 Motor configuration 7.3 Examples Until now, the individual variables have been: Velocities: Times: vmax = 1.5 m/s = 90 m/min vb = 0.5 m/s = 30 m/min t1 = 76.5 ms t2 = 180 ms t3 = 51.0 ms t4 = 100 ms t5 = 102 ms t6 = 200 ms t7 = 76.5 ms t8 = 80 ms Note: The times during the acceleration phases are calculated using: Example: Forces: Fb = 1000 N Fr = 300 N Note: Fr is assumed to be constant for reasons of simplicity Mass to be moved The mass to be moved is made up of the mass of the primary sections, which are still unknown, and the mass of the y-axis. It should, therefore, be noted that the mass of the y-axis is not generally distributed evenly across the two motors X1 and X2: It depends on the position of the centers of gravity of the frame and slide of the y-axis, see following figure. Figure 7-19 Example 2: Distribution of the mass of the y-axis across the two motors: Relevant lengths Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0 99

100 Motor configuration 7.3 Examples In the example shown here, the following lengths and masses apply: Lengths: Masses: lges = 1200 mm = 1.2 m ls,y,x1,min = 300 mm = 0.3 m ls,y,x1 = 600 mm = 0.6 m ms,y = 180 kg mr,y = 280 kg The mass mr,y,x1 that motor X1 must support using the frame of the y-axis is calculated as follows: Analogous to this, the mass ms,y,x1 is a part of the mass of the y-slide (ms,y): The total mass to be moved by motor X1 is given by: The variable mx1 is the mass of the primary section X1, as opposed to the mass MX1 to be moved by motor X1. At the same time, the motor X2 must accelerate a mass that consists of its primary section mass mx2 and the mass of the y-axis that is not accelerated by the motor X1: The center of gravity of the frame does not change when the motor is in motion. MX1 thus only changes due to the motion of the slide of the y-axis: The mass that motor X1 must move is maximum when ls,y is minimum: For the variables shown in this example, this results in the following maximum mass MX1: In this example, since the center of gravity of the frame lies exactly between motors X1 and X2, the following applies: MX1,MAX = MX2,MAX. This means that any subsequent observations only need to be made for motor X1. Specifying the load cycle If you initially ignore the mass of the primary section of motor X1, the maximum force that the motor requires for acceleration results from the maximum mass to be moved MX1: Fa,MAX = MX1,MAX 2g = 275 kg m/s 2 Fa,MAX = N 5400 N If the mass of the primary section is not taken into consideration, this results in the load cycle shown in the image below. 100 Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0

101 Motor configuration 7.3 Examples Figure 7-20 Example 2: Force/time graph of the load cycle in this example (Pre)selection of the primary section The maximum force of the load cycle is required during acceleration; see the image below: FMAX,X N The 1FN3300-4WC00-0AA1 motor can therefore be considered from the 1FN3 peak load motors. This motor fulfills all previous requirements with a maximum force of 6900 N and a maximum velocity vmax,fmax of 125 m/s. Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0 101

102 Motor configuration 7.3 Examples Checking the mechanical supplementary conditions Reserve force With the mass of the primary section 1FN3300-4WC00-0AA1 of 24 kg (with precision cooler), this results in a maximum force of approximately 6170 N. The specified maximum force is 6900 N and is therefore sufficient. The recommended control margin of 10 % is also available. Continuous force You must now check whether the continuous force is lower than the rated force Fr of the selected primary section. The load cycle corresponds to the following image: Figure 7-21 Example 2: Load cycle with primary section 1FN3300-4WC00-0AA1 In principle, the continuous force is again calculated from the summation formula The only thing that must be considered is that during time t5, the direction of motion of the motor reverses and the frictional force Fr changes its sign. Time t5a from the image above is calculated according to the velocity/time graph, using straight line sets: This results in a value of approximately 3468 N for the continuous force Feff. This does not lie as specified below the rated force FN = 2450 N of the primary section selected. Therefore, a new primary section has to be selected. Another possible primary section is primary section 1FN3450-4WB50-0AA1. The mass of this primary section with precision cooler amounts to 33.1 kg; the motor must therefore supply a maximum force of approximately 6350 N. Therefore, the maximum force of N specified in the data sheet is sufficient. The recommended control margin of 10 % is also available. This results in approximately 3574 N for the continuous force Feff when selecting the primary section 1FN3450-4WB50-0AA1. As required, this is below the rated force FN = 3860 N of the primary section selected. 102 Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0

103 Motor configuration 7.3 Examples Interim result The primary section 1FN3450-4WB50-0AA1 is selected for both motor X1 and motor X2. Specifying the number of secondary sections Only secondary section 1FN3450-4SA00-0AA0 is suitable for this motor. This secondary section has a length of ls = 184 mm. Together with the magnetically active length of the 1FN3450-4WB50-0AA1 primary section of lp,akt = 644 mm, the required length of the secondary section track can be put together using individual secondary sections. Selecting the power module The selected motors have the following data: Maximum force FMAX = N Rated force FN = 3860 N Maximum current IMAX = 89.8 A Rated current IN = 30.4 A A suitable power module for this data can be selected from the relevant catalog. If no power increase is planned in the long term, it is sufficient to use a power module providing the current actually used at the moment: This calculation can be used to approximate the value of IMAX. The selected power module should still have some power reserve. Calculating the maximum infeed power The mechanical power PMECH and power loss PV of one motor reach their maximum values when the motor is running at maximum velocity and maximum force according to the required load cycle. In the example shown here, these values are as follows: vmax = 1.5 m/s FMAX = 6350 N With gantry axes, the infeed powers of motors X1 and X2 are added together. The sum reaches the maximum when the weight is distributed unevenly, since the power loss of the motors increases quadratically with the force that the motor must supply. This means that the maximum infeed power will be needed if motor X1 actually needs to supply the maximum force FMAX. For motor X2, the mass to be accelerated is calculated as follows: MX2 = mx2 + (mr,y + ms,y) - (mr,y,x1 + ms,y,x1) MX2 = 33.1 kg + (280 kg kg) kg MX2 = kg and therefore force FX2 that has to be supplied is calculated as follows: FX2 = MX2 2g + Fr FX2 = kg m/s N FX2 = 4580 N Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0 103

104 Motor configuration 7.4 Dimensioning of the cooling system This results in the following infeed power at maximum velocity: Quantity kf,20 = 127 N/A is used as the upper estimate for kf, quantity RSTR(TN) for RSTR with: The maximum infeed power is thus: A value of approximately kw must be added to the infeed powers of other loads also operated on the DC link. A corresponding infeed/regenerative feedback module can thus be selected Dimensioning of the cooling system Basics Individual coolers Starting from the required continuous thrust Feff, the heat QK,i that must be dissipated by the individual coolers can be calculated first. At the same time, this corresponds to the refrigerating capacity Pkühl,i that a recooling unit or a heat exchanger must have for the relevant cooling system. The values for the rated thrust FN and the heat to be dissipated under full load QK,MAX can be found in the data sheets. The volume flow is defined, whereby the value listed in the tables of the data sheets should be used. The pressure drop associated with the volume flow can be taken from the characteristic curves for the primary section main cooler, the primary section precision cooler, and the secondary section cooling system. The temperature increase ΔTK,i between the intake and return lines of the individual coolers can be determined from the following at the given volume flow: Whereby the ρ and cρ variables designate the density or the specific heating capacity of the cooling medium water: ρ = 998 kg/m 3, cρ = 4180 J/(kg K). 104 Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0

105 Motor configuration 7.4 Dimensioning of the cooling system Series connection of coolers If cooling circuits are connected in series, the greatest volume flow for the individual coolers is decisive for the entire system: V gesamt = max(v 1, V 2, V 3, ) Pressure drops and temperature increases are determined and summed up: Δpgesamt = ΔpK,1 + ΔpK,2 + ΔpK,3 + ΔTgesamt = ΔTK,1 + ΔTK,2 + ΔTK,3 + If a recooling unit or a heat exchanger is used for all cooling circuits together, the necessary refrigerating capacity Pkühl is calculated from the individual refrigerating capacities Pkühl: Pkühl = Pkühl,1 + Pkühl,2 + Pkühl,3 + = QK,1 + QK,2 + QK, Example: Dimensioning of a cooling system Note Possible differences to data provided in the data sheets have no effect on the calculation method shown here. Prerequisite A motor with a primary section of the 1FN3300-2WC00 series should be operated with a continuous force Feff = 0.8 FN. A primary section main cooler is necessary for this application. The primary section precision cooler and the secondary section cooling system should also be used to prevent heat being transferred to the machine. The secondary section track has a length of 4 m. There is a coupling point for the cooling sections. The intake and return lines of the secondary section cooling system are connected via combi distributors. The medium flows through the primary section precision cooler, secondary section cooling system and primary section main cooler of the cooler in that order. To maintain the temperature difference of 4 K between the intake temperature and the surface of the primary section precision cooler, the recommended values from the corresponding data sheet are used. Data from data sheet: Volume flow: V gesamt = 4 l/min for all coolers Pressure drop: ΔpP,H = 0.32 bar for main cooler ΔpP,P = 0.33 bar for precision cooler ΔpS = 0.09 bar/m for cooling sections ΔpKV = 0.42 bar for each combi distributor ΔpKS = 0.31 bar for each coupling point Maximum heat dissipation: QP,H,MAX = 995 W for main cooler QP,P,MAX = 35 W for precision cooler QS,MAX = 93 W for secondary section cooling system Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0 105

106 Motor configuration 7.4 Dimensioning of the cooling system Calculating the refrigerating capacity Individual cooling circuits The following results for the individual cooling circuits: Pkühl,P,H = QP,H 995 W = W Pkühl,P,P = QP,P 35 W = 22.4 W Pkühl,S = QS 93 W = W Total cooling In the case of a cooler that has been dimensioned for the entire series connection, the following values must be assumed for the minimum cooling capacity: Pkühl,gesamt = Pkühl,P,H + Pkühl,P,P + Pkühl,S = W W W Pkühl,gesamt = W Calculating the pressure drop Pressure drop in the secondary section cooling system The secondary section cooling system consists of a coupling point, two combi distributors and two parallel cooling sections, each with a length of ls = 4 m. In total, the pressure drop of the secondary section cooling system is: ΔpS,ges = 2 ΔpS ls + 2 ΔpKV + ΔpKS The result is: ΔpS,ges = bar/m 4 m bar bar ΔpS,ges = 1.87 bar Total cooling For the total cooling, the following results: Δpgesamt = ΔpP,H + ΔpP,P + ΔpS,ges = 0.32 bar bar bar Δpgesamt = 2.52 bar 106 Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0

107 Motor configuration 7.4 Dimensioning of the cooling system Calculating the temperature increase Individual cooling circuits The values for the individual cooling circuits are calculated as follows: Total cooling For the total cooling, the following results: ΔTgesamt = ΔTP,H + ΔTP,P + ΔTS,ges = 2.3 K K K ΔTgesamt = 2.59 K Conclusion For a cooler to be able to cool the motor under the conditions described in this section, it must be dimensioned for about 720 W. The pressure loss amounts to about 3 bar and the temperature difference between the intake and return lines of the cooling system to about 3 K. Recommended manufacturers Recommended manufacturers of cold water units are listed in the appendix Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0 107

108 Motor configuration 7.4 Dimensioning of the cooling system 108 Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0

109 Mounting the motor Safety information/instructions DANGER When installing direct drives, you may have to work near unpacked components with permanent magnets. The resulting danger from strong magnetic fields is, therefore, particularly high. Only remove the packaging from the motor components immediately prior to installation. Never place metals on magnetic surfaces and vice versa! Never use magnetizable tools! If these tools are required, they must be held firmly with both hands and moved slowly toward the direct drive. All work must be performed by two persons! Prevent unintentional movement of pre-installed direct drives! Only perform installation work on machinery which is de-energized and isolated from the power supply. Risk of electric shock! WARNING Sharp edges can cause cuts. Wear protective gloves! WARNING Falling objects can injure feet. Wear safety shoes! WARNING Defective connecting cables can cause an electric shock and/or material damage (e.g. by fire). When installing the motor, make sure that the connecting cables are not damaged, are not under tension, cannot be caught up in moving parts, and that the minimum bending radius is adhered to. It is not permissible to hold or pull the motor using the cables! Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0 109

110 Mounting the motor 8.2 General procedure General procedure The installation of a linear motor is divided into the following steps: 1. Checking the mounting dimensions before the installation of the motors 2. Cleaning of the attachment surfaces of motor parts and the machine 3. Installation of primary sections, secondary sections and components 4. Checking the motor installation Checking the mounting dimensions Basics For the observance of the electrical and system-technical properties of the motor, only the mounting dimensions and not the measurable air gap are decisive. The mounting dimensions must lie within the specified tolerances over the complete traversing distance. Checking The mounting dimensions can be checked before installing the motor, e.g. using final dimensions and feeler gauges. Mounting dimensions for the motor installation The following figure shows the mounting dimensions for the motor installation. The associated values are specified in the following table. In addition, the rated air gap the geometric distance between primary section and secondary section track with or without secondary section cover is specified in this table. Figure 8-1 Mounting dimensions for the motor installation 110 Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0

111 Mounting the motor 8.4 Motor installation procedures Table 8-1 Dimensions for the air gap and mounting dimensions for installing the motor, according to image above Mounting tolerance Rated air gap with secondary section cover Rated air gap without secondary section cover Mounting dimension with precision and secondary section cooler Mounting dimension with precision cooler and without secondary section cooler Mounting dimension without precision cooler and secondary section cooler Mounting dimension without precision cooler and with secondary section cooler 1FN3050-xW, 1FN3100-xW [mm] [mm] [mm] hm1 [mm] ± FN3150-xW ± FN3300-xW ± FN3450-xW ± FN3600-xW ± FN3900-xW ± hm2 [mm] hm3 [mm] hm4 [mm] NOTICE An air gap that is smaller than the rated air gap increases the risk of a motor failure. A reduction of the mounting dimension is not recommended. The motor becomes more robust by increasing the mounting dimensions Motor installation procedures General procedures There are three different procedures for installing a linear motor in a machine: Assembly with divided secondary section track Assembly through the insertion of the slide Assembly through the mounting of the motor components Motor assembly with divided secondary section track The easiest way is to assemble the motor with a divided secondary section track. The prerequisite is that the entire secondary section track can be divided into two sections, of which each has at least the length of the slide. During assembly, you must work against the attraction force of the secondary sections. Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0 111

112 Mounting the motor 8.4 Motor installation procedures Procedure 1. Assembly of the slide including the linear guide and the primary section 2. Move the slide to one side and mount the secondary section on the other side. 3. Move the slide over the secondary section. The attraction forces are taken up by the linear guides. WARNING When moving the primary section onto the secondary section (Step 3), drawing forces towards the secondary section will occur for a short time. Danger of crushing! Make sure that your fingers do not reach into the danger zone! 4. Assembly of the second secondary section. 112 Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0

113 Mounting the motor 8.4 Motor installation procedures Motor assembly through the insertion of the slide If the secondary section track cannot be divided into several sections e.g. because the total length of the secondary section track is too short or with a double-sided motor the moving component of the motor (slide) can be inserted in the stationary housing with the already installed motor components, see following figure. Normally, a special engaging device is used for this. Figure 8-2 Insertion of the secondary section with a double-sided motor WARNING In this procedure, drawing forces towards the stationary motor component occur. Danger of crushing! Before inserting ferromagnetic components of the linear motor into the active zone of the stationary motor component, remember that guiding or supporting elements (motor bearing) must already be effective! Motor assembly through the mounting of the motor components In the third procedure for motor assembly, the primary section is mounted on the secondary section track before assembly in the slide using a spacer and an extractor. The primary section is then mounted on the slide pushed over it. This procedure is the most difficult of the described procedures. It should be used only if the other procedures are not possible. The spacer and the extractor must be provided by the customer. Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0 113

114 Mounting the motor 8.4 Motor installation procedures Procedure 1. Assembly of the secondary section track 2. Mounting of the primary section With the aid of an extractor, the primary section is positioned centrally above the secondary section track and lowered onto a spacer. WARNING Danger of crushing when mounting the primary section on the secondary section! Never place the primary section directly onto the secondary section, but rather use a spacer made of non-magnetizable material (e.g. a board made of hard wood). 3. Removing the extractor The extractor and the thrust bearing blocks are removed, the spacers remain between the primary section and the secondary section. 4. Assembly of the slide. The primary section lifts into its specified position when the slide is evenly screwed into place. After that, the spacers are removed. The extractor The extractor to be made by the customer consists of a sufficiently thick plate of non-magnetic material with through holes for mounting the primary section and threaded holes to take the forcing-off screws. The following figures show the principle structure. Two thrust bearing blocks, also of non-magnetic material, are used to guide the forcing-off screws. The spacer prevents direct contact between the primary section and the secondary section. 114 Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0

115 Mounting the motor 8.4 Motor installation procedures WARNING When the primary section is being mounted, attraction forces work towards the secondary section track. Danger of crushing! The forcing-off screws must be at least long enough that the primary section is located outside of the immediate vicinity of the secondary sections (distance greater than 100 mm) when it is assembled. Figure 8-3 Principle structure of an extractor Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0 115

116 Mounting the motor 8.5 Assembling individual motor components Figure 8-4 Principle structure of an extractor (longitudinal section) Assembling individual motor components Assembly of the secondary sections The secondary sections are screwed to the machine bed using friction-locked screw connections. The optional cooling sections that can be installed are screwed onto the secondary sections in between the secondary sections and the machine bed. The mounting dimensions without secondary section cooling are reduced by the height of the cooling sections. Note The shaft of the bolts, which are used to attach the secondary section to the machine base may not reach the thread. If required, the appropriate hole in the machine base must be lowered. For each secondary section, the letter N located on the secondary sections must always point in the same direction, see following figure. Figure 8-5 Position of the "N" mark on 1FN3 secondary sections 116 Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0

117 Mounting the motor 8.5 Assembling individual motor components The secondary sections are screwed down in the order shown in the following figure. Figure 8-6 Screwed joint sequence of 1FN3 secondary sections DANGER There is a high risk of crushing fingers etc. when handling unpacked secondary sections! It is essential to observe the regulations when handling components with permanent magnets! Assembly of the secondary section cooling system If the secondary section cooling system is used, the cooling sections and secondary section end pieces are to be mounted before assembling the secondary sections. In order to attach the secondary section end pieces, the wedges must be removed. The mounting screws for the wedges are standard steel socket head cap screws (hex socket, DIN 7984 M3x6). Stainless steel fillister-head screws (Phillips head H1, DIN 7985 M3x8) may be used as well. The respective number of screws for each option is specified in the following table. To mount the secondary section end pieces, use the same screws as for mounting the secondary sections. Table 8-2 Number of mounting screws for the wedge of the secondary section end pieces 1FN Combi adapter Combi end piece Combi distributor Cover end piece Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0 117

118 Mounting the motor 8.5 Assembling individual motor components If cooling sections with plug-in connectors are used, proceed as follows: 1. At first, only fix the cooling sections with a few screws so that all threads in the machine bed are visible. These screws have to be removed later, so do not tighten too much! 2. Slide secondary section end piece No. 1 without wedge axially onto the plug-in connectors of the cooling sections. 3. Screw in the mounting screws of secondary section end piece No. 1, but do not tighten. 4. Slide secondary section end piece No. 2 without wedge axially onto the plug-in connectors of the cooling sections. 5. Screw in the mounting screws of secondary section end piece No. 2, but do not tighten. 6. Tighten the mounting screws of the secondary section end pieces. 7. Check cooling circuit for leaks (pressure check at a maximum of 10 bar). 8. Check again whether all threads in the machine bed are visible. 9. Screw the secondary sections together with the cooling sections. But first remove the fastening screws! 10. Mount the secondary section end piece wedges if the cover band is not used as a secondary section cover. Note Removing the fastening screws too early may result in excessive deformation and overload of the plug-in connectors due to the tare weight of the cooling sections, especially with a vertically arranged secondary section track. Therefore, especially with a vertically arranged secondary section track, remove the screws used to position the cooling sections step by step. The following figure shows how to position and fasten the cooling sections and combi distributors. Figure 8-7 Position of the cooling sections and combi distributors (illustration without fastening screws) Assembly of the secondary section cover The secondary section cover protects the secondary section track. The assembly method depends on the type of cover used. Two different variants are available: Continuous cover band Segmented cover 118 Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0

119 Mounting the motor 8.5 Assembling individual motor components Cover band The cover band is used in environments with heavy dust loads which could deposit in the spaces of the segmented cover. NOTICE Contamination in the motor compartment can cause the motor to stop functioning or cause wear and tear! Irrespective of the use of the cover band, the motor area must be suitably protected from contamination and dirt! The use of scrapers to keep the air gap free is not sufficient and is not recommended. Covering long secondary section tracks with cover bands is more complicated than with segments. If the traversing distance of the axis is greater than twice the slide length, proceed as follows: 1. Mount the primary section below the slide. 2. Push the slide on one side of the traversing distance and mount the secondary sections on the other side up to the middle of the traversing distance. 3. Mark the length of the mounted secondary sections plus the required clamping length on the cover band. 4. From the mark, slide the cover band under the primary section to the side without secondary sections. Starting from the mark, place the other half onto the secondary sections. 5. Push the slide over the covered secondary sections. The magnetic forces are taken up by the guides. 6. Lift the cover band carefully from the machine frame and mount the remaining secondary sections underneath. 7. Place the second half of the secondary section cover onto the secondary section track. 8. Lock both ends on the secondary section end pieces using the wedges. Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0 119

120 Mounting the motor 8.5 Assembling individual motor components If the traversing distance of the axis is less than twice the slide length or access for mounting the secondary section cover is limited, proceed as follows: 1. Assembly of the secondary sections with the slide plate removed. 2. Starting from one end, place the magnetic secondary section cover onto the secondary sections and fasten both ends on the secondary section end pieces with the wedges. 3. Place the primary section with spacer and extractor onto the secondary section track. 4. Mount the slide onto the guide. Align the slide with the mounting holes of the primary section. 5. Release the primary section from the secondary section track using the extractor and fix it to the slide. Segmented cover Mounting the segmented cover is usually easier than mounting the cover band: 1. Mounting the first segment: Position the edge of the first segment from the top in an angle of 45 flush with the outer edge of the last secondary section and lower it in alignment with the secondary section track. As soon as you feel the magnetic attraction force, the segment can be released: It will align itself to the correct position. 2. Checking the correct position: The first cover segment should reach to the middle of a secondary section. 3. All other segments are mounted the same way as the first one. The following figures show Steps 1 and 3. Figure 8-8 Mounting of the first segment of the segmented secondary section cover 120 Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0

121 Mounting the motor 8.5 Assembling individual motor components Figure 8-9 Mounting of a further segment of the segmented secondary section cover It is recommended that the butt joints of the cover segment be offset to the butt joints of the secondary sections, see also Step 2. In this way the secondary section track is protected better against dust and the cover segments join better with one another. This offset is achieved when the cover segments at the ends of the secondary section track have a (n+0.5) length instead of the integral length of the secondary sections, see following figure. Example: Segment position of the segmented secondary section cover Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0 121

122 Mounting the motor 8.5 Assembling individual motor components To demount the segmented secondary section cover, lift the segments on one side transverse to the travel direction, see following figure. Figure 8-10 Demounting a segment of the segmented secondary section cover Assembling the primary section The primary section is screwed to the primary section back via the threaded bore holes in a friction-locked joint. Note that the terminal end of the primary section usually points in the same direction as the north pole mark N on the secondary sections. CAUTION Wrong bore hole depths for the fastening screws can damage the motor components or, due to an insufficiently solid attachment of the motor components to the machine, cause other unfavorable conditions. Note the maximum and minimum bore hole depths for the fastening screws! Assembling of the Hall sensor box CAUTION Incorrect installation of the Hall sensor box can result in uncontrollable travel movements of the motor and damage to the machine. Be sure to follow the installation diagrams! Starting at a certain minimum distance, the distance between the primary section and the Hall sensor box can only be increased by the multiple of the pole pair width 2τM - specified in the diagrams as count factor NP. 122 Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0

123 Mounting the motor 8.5 Assembling individual motor components The cable outlet direction and position of the Hall sensor within the Hall sensor box are firmly allocated. Therefore, be sure to follow the respective installation diagrams when installing the Hall sensor box with regard to position and alignment with the primary section. Note If several primary sections are operated on one drive system (e.g. with PARALLEL arrangement), the master is always to be used as reference for the Hall sensor box. Be sure to mount the Hall sensor box so that a distance of x = 35 mm between the top of the Hall sensor box and the bottom of the primary section is maintained, see following figure. This ensures an automatic adjustment of the correct distance d between the Hall sensor box and the secondary section track. Figure 8-11 Specified dimension for mounting the Hall sensor box (HSB) The Hall sensor box cable can be dragged and may thus be integrated into cable drag chains. Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0 123

124 Mounting the motor 8.6 Mounting system Mounting system General rules The following must be considered when mounting the motor components (primary and secondary sections) on the machine structure Use screws of property class 10.9 Use only new, unused screws The mounting surfaces must be free from oil and grease and must not be painted Optimum surface roughness depth of the connection surface (Rz value = 10 to 40 μm) The number of joints should be minimized to keep the amount of settling of material and screws down (settling effect) Do not exceed the maximum bore hole depth on the primary section The screws are best tightened so that the angle of rotation is controlled. They should, however, at least be tightened with a calibrated torque wrench with as short a bit as possible Gradually tighten the screws Select a large clamp length lk for securing the screws, if possible lk/d > 5; Alternate: Secure the screws to prevent them from coming loose (e.g. with Loctite 242) Tightening torques for screws of property class 10.9 Valid for screws of property class 10.9 Friction coefficient μtot = 0.1 M5 M6 M8 7.6 Nm 13.2 Nm 31.8 Nm Minimum bore hole depth for secondary section screws The following table is valid for screws of property class It shows bore hole depths for the most common machine bed materials. For materials other than those shown here, the bore hole depth should be calculated using VDI guideline Material EN GJL-250 EN GJL-300 EN GJS G-ALZN10Si8Mg St 37 St 50 Bore hole depth 1.4 d 1.3 d 0.7 d 2.8 d 1.8 d 1.3 d 124 Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0

125 Mounting the motor 8.7 Checking the motor assembly Maximum bore hole depth for secondary section screws The maximum bore hole depth is specified by the customer's threaded holes in the machine bed. Minimum bore hole depth for primary section screws Minimum bore hole depth = 1.1 d Maximum bore hole depth for primary section screws The maximum bore hole depth can be found on the installation drawing of the appropriate motor in the configuration manual Checking the motor assembly Checking the smooth running of the slide The motor assembly must be especially checked for the smooth running of the slide. DANGER Any movement of primary sections in relation to secondary sections leads to induced voltages at the motor connections. Electrical shock hazard! Motor power connections must be properly connected and insulated. Before moving the slide, remove all tools and objects from the traversing range and clean the surface of the magnets with a cloth. The slide of the linear motor must be able to be moved over the entire traversing range with even, minimum friction. The slide may not jam! If you suspect a jam, check the air gap at the appropriate position! Note When the motor is moved evenly, increased resistances ("power waves") may be noticeable at regular intervals, especially in case of short-circuits of the phases. These are connected with the motor type and do not indicate faulty mounting. Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0 125

126 Mounting the motor 8.7 Checking the motor assembly Checking the air gap After installing the motor components, the air gap can be subjected to an optional, approximate, spot check. A non-magnetic strip (e.g. of aluminum, plastic, cardboard, etc.) with a thickness of 0.5 mm must be able to be pushed through the air gap between the primary section and the secondary section track without a considerable amount of force. Generally, this test is not necessary. If the mounting dimensions are correct, the correct air gap is automatically obtained. If the tolerances for the air gap are exceeded, this is usually due to incorrect installation. Note The air gap must be checked when the motor is cold (T < 30 C). 126 Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0

127 Connecting the motor Interfaces Position of the connections The connections for the electrical and cooling systems are together on an end face of the primary section. They are thus easily accessible for installation and servicing. All dimensions for the position of the connection elements can be taken from the installation diagrams. NOTICE The connection system requires installation space! Depending on the connection system, cables and hoses used, sufficient installation space should be provided in the longitudinal direction of the primary section. Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0 127

128 Connecting the motor 9.2 Electrical connection Electrical connection Safety information DANGER Parts of electrical devices may be under voltage. There is a risk of electric shock. When the primary section is moving, a voltage is present at the motor terminals that increases proportionally with the speed. During idling, the voltage amplitude at the motor terminals is the same as the voltage of the DC link voltage converter. All work involving the electrics must always be carried out by skilled personnel when the device is disconnected from the power supply and the motor is at a standstill. Observe the regulations for working on electrical installations. In particular, the following safety rules for working on electrical installations in accordance with EN /BGV A3 must be adhered to: Disconnecting the system Secure against switching back on Make sure that the equipment is de-energized Ground and short-circuit Cover or cordon off adjacent live parts It is only possible to work on electrical devices when they are de-energized. The protective conductor should be the first thing to be connected and the last to be disconnected. All circuits must meet the requirements of safe electrical disconnection in accordance with EN DANGER There is a danger of death, serious bodily injury (electrical shock) and/or property damage if direct drives are connected incorrectly. The motors may only be connected according to the instructions. Direct connection of the motors to the three-phase supply is not permissible. Consult the documentation of the drive system being used. Protective measures against residual voltages DANGER There is a shock hazard danger due to the residual voltages at the motor terminals! When the power supply voltage is switched-out, active parts of the motor can have a charge of more than 60 μc. In addition, at open-circuit cable ends - e.g. when a connector is withdrawn - even after the power has been disconnected, a voltage or more than 60 V can be present for 1 s. This is the reason that you must apply the appropriate measures to provide protection against residual voltages! 128 Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0

129 Connecting the motor 9.2 Electrical connection Requirements Standard connection to SIMODRIVE The following diagram is a schematic representation of the standard electrical connection of SIMODRIVE drive systems with MOTION-CONNECT prefabricated cables. or or Figure 9-1 Standard connection of the motors to the Simodrive 611 drive system Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0 129