SIMODRIVE Drives Peak load motors of the 1FN3 product ......Peak load motors of the 1FN3 product...

SIMODRIVE Drives Peak load motors of the 1FN3 product family

simodrive

Configuring Manual Edition 04/2008

SIMODRIVE 611

Peak load motorsof the 1FN3 product family

Preface

General safety guidelines

1

Motor description

2Motor 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

11Maintenance, service and repair

12

Storage and transport

13

Disposal

14Technical data and characteristics

15Installation diagrams and dimension tables

16

Appendix

A

SIMODRIVE

Drives Peak load motors of the 1FN3 product family

Configuration Manual

04/2008 6SN1197-0AB73-0BP0

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 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.

Qualified Personnel 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 48 48 90026 NÜRNBERG GERMANY

Ordernumber: 6SN1197-0AB73-0BP0 Ⓟ 11/2008

Copyright © Siemens AG 2008. Technical data subject to change

Peak load motors of the 1FN3 product family Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0 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: http://www.siemens.com/motioncontrol

Select the menu items "Support" → "Technical Documentation" → "Overview of Publications".

The Internet version of DOConCD (DOConWEB) is available at:

http://www.automation.siemens.com/doconweb

Information on the range of training courses and FAQs (frequently asked questions) are available on the Internet under:

http://www.siemens.com/motioncontrol 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.

http://www.siemens.com/motioncontrolhttp://www.automation.siemens.com/doconwebhttp://www.siemens.com/motioncontrol

Preface

Peak load motors of the 1FN3 product family 6 Configuration Manual, 04/2008, 6SN1197-0AB73-0BP0

Technical Support If you have any technical questions, please contact our hotline: Europe / Africa Asia / Australia America

Phone +49 (0) 180 5050 – 222 +86 1064 719 990 +1 423 262 2522 Fax +49 (0) 180 5050 – 223 +86 1064 747 474 +1 423 262 2289 Internet http://www.siemens.com/automation/support-request E-mail mailto:[email protected]

Note

For technical support telephone numbers for different countries, go to: http://www.siemens.com/automation/service&support

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 e-mail us at: Fax +49 9131 98 63315 E-mail mailto: [email protected]

A fax form is available in the appendix of this document.

Internet address for products http://www.siemens.com/motioncontrol

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":

http://support.automation.siemens.com/WW/llisapi.dll?func=cslib.csinfo&lang=de&siteid=csius&objid=19183574

If you do not have access to the Internet, contact your local Siemens office to obtain a copy of the EC Declaration of Conformity.

http://www.siemens.com/automation/support-requestmailto:[email protected]://www.siemens.com/automation/service&supportmailto: [email protected]://www.siemens.com/motioncontrolhttp://support.automation.siemens.com/WW/llisapi.dll?func=cslib.csinfo&lang=de&siteid=csius&objid=19183574

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.

Preface



Table of contents

Preface ...................................................................................................................................................... 5

1 General safety guidelines ........................................................................................................................ 13

1.1 Introduction ..................................................................................................................................13

1.2 Personnel .....................................................................................................................................15

1.3 Use for the intended purpose.......................................................................................................15

1.4 Danger from strong magnetic fields.............................................................................................16

1.5 Posting of warning signs ..............................................................................................................18

2 Motor description ..................................................................................................................................... 21

2.1 Features .......................................................................................................................................21

2.2 Approvals .....................................................................................................................................25

2.3 Degrees of protection...................................................................................................................25

3 Motor components and options................................................................................................................ 27

3.1 Overview of the motor construction .............................................................................................27

3.2 Variants of the secondary section end pieces .............................................................................28

3.3 Motor rating plate .........................................................................................................................30

3.4 Thermal motor protection.............................................................................................................31 3.4.1 Temperature monitoring circuits ..................................................................................................31 3.4.2 Description of temperature sensors used ....................................................................................32

4 System integration ................................................................................................................................... 35

4.1 System prerequisites ...................................................................................................................35

4.2 Standard integration of the motor ................................................................................................36

4.3 Drive system ................................................................................................................................37

4.4 Position measuring system..........................................................................................................38

4.5 Sensor modules SME9x ..............................................................................................................41

4.6 Separating the cables ..................................................................................................................43

4.7 Cooling system.............................................................................................................................44 4.7.1 Cooling the motor.........................................................................................................................44 4.7.2 Cooling circuits.............................................................................................................................51 4.7.3 Cooling media ..............................................................................................................................53 4.7.4 Specifying the intake temperature ...............................................................................................54

4.8 Braking concepts .........................................................................................................................56

5 Coupled motors ....................................................................................................................................... 59

5.1 Motors connected in parallel ........................................................................................................59

5.2 Double-sided motors....................................................................................................................67

Table of contents


6 Order numbers......................................................................................................................................... 69

6.1 Structure of the order numbers ................................................................................................... 69

6.2 Primary sections.......................................................................................................................... 69

6.3 Secondary sections..................................................................................................................... 70

6.4 Primary section accessories ....................................................................................................... 70 6.4.1 Precision cooler........................................................................................................................... 70 6.4.2 Hall sensor box ........................................................................................................................... 70 6.4.3 Connector box............................................................................................................................. 71 6.4.4 SME9x......................................................................................................................................... 71 6.4.5 Connection cover ........................................................................................................................ 71

6.5 Secondary section accessories .................................................................................................. 72 6.5.1 Secondary section end pieces .................................................................................................... 72 6.5.2 Cooling sections.......................................................................................................................... 73 6.5.3 Secondary section cover............................................................................................................. 73

6.6 Ordering example........................................................................................................................ 74

7 Motor configuration .................................................................................................................................. 75

7.1 Subjects worth knowing in advance............................................................................................ 75 7.1.1 Operation in the area of reduced magnetic coverage................................................................. 75 7.1.2 Short-time duty S2 and intermittent duty S3 ............................................................................... 76

7.2 Procedure for the configuration................................................................................................... 78 7.2.1 Overview of the configuration sequence..................................................................................... 78 7.2.2 Definition of the mechanical supplementary conditions.............................................................. 80 7.2.3 Specification of the load cycle..................................................................................................... 82 7.2.4 Determination of the motor thrust, peak thrust and continuous thrust........................................ 84 7.2.5 Selection of the primary sections ................................................................................................ 85 7.2.6 Specifying the number of secondary sections ............................................................................ 87 7.2.7 Checking the dynamic mass ....................................................................................................... 89 7.2.8 Selecting the power module........................................................................................................ 89 7.2.9 Calculation of the required infeed ............................................................................................... 90

7.3 Examples..................................................................................................................................... 90 7.3.1 Positioning in a predefined time.................................................................................................. 90 7.3.2 Machining center with gantry axis............................................................................................... 97

7.4 Dimensioning of the cooling system ......................................................................................... 104 7.4.1 Basics........................................................................................................................................ 104 7.4.2 Example: Dimensioning of a cooling system ............................................................................ 105

8 Mounting the motor................................................................................................................................ 109

8.1 Safety information/instructions.................................................................................................. 109

8.2 General procedure .................................................................................................................... 110

8.3 Checking the mounting dimensions .......................................................................................... 110

8.4 Motor installation procedures.................................................................................................... 111

8.5 Assembling individual motor components................................................................................. 116

8.6 Mounting system ....................................................................................................................... 124

8.7 Checking the motor assembly................................................................................................... 125

9 Connecting the motor ............................................................................................................................ 127

Table of contents


9.1 Interfaces ...................................................................................................................................127

9.2 Electrical connection ..................................................................................................................128 9.2.1 Safety information ......................................................................................................................128 9.2.2 Requirements.............................................................................................................................129 9.2.3 Electrical connections on the motor...........................................................................................131 9.2.4 Connecting to the terminal block................................................................................................136 9.2.5 Connecting the temperature monitoring circuits ........................................................................137 9.2.6 Connection of the position measuring system...........................................................................141 9.2.7 Connecting the motors in parallel ..............................................................................................143 9.2.8 Cable routing regulations ...........................................................................................................145 9.2.9 Shielding and grounding ............................................................................................................146

9.3 Connection of the cooling system..............................................................................................146 9.3.1 General information ...................................................................................................................146 9.3.2 Connection of main and precision cooler...................................................................................147 9.3.3 Connection of the secondary section cooling system................................................................148

10 Commissioning ...................................................................................................................................... 151

10.1 Safety information ......................................................................................................................151

10.2 Checks prior to the commissioning............................................................................................152

10.3 Notes on commissioning system elements................................................................................152

11 Operation............................................................................................................................................... 153


12 Maintenance, service and repair............................................................................................................ 155

12.1 Safety guidelines........................................................................................................................155

12.2 Maintenance work......................................................................................................................157

13 Storage and transport ............................................................................................................................ 159


14 Disposal................................................................................................................................................. 161

14.1 Guidelines for disposal...............................................................................................................161

15 Technical data and characteristics......................................................................................................... 163

15.1 Introduction ................................................................................................................................163

15.2 Definitions of the motor data ......................................................................................................163

15.3 Explanations of the characteristic curves ..................................................................................167

15.4 1FN3050 motor data ..................................................................................................................170

15.5 1FN3100 motor data ..................................................................................................................173

15.6 1FN3150 motor data ..................................................................................................................197

15.7 1FN3300 motor data ..................................................................................................................215

15.8 1FN3450 motor data ..................................................................................................................239

15.9 1FN3600 motor data ..................................................................................................................278

15.10 1FN3900 motor data ..................................................................................................................299

15.11 Additional characteristics ...........................................................................................................317 15.11.1 Attraction force in relation to relative air gap .............................................................................317

Table of contents


15.11.2 Continuous thrust in relation to intake temperature .................................................................. 318 15.11.3 Motor thrust in relation to relative air gap.................................................................................. 319

16 Installation diagrams and dimension tables ........................................................................................... 321

16.1 1FN3050, 1FN3100, 1FN3150.................................................................................................. 321 16.1.1 1FN3050-2WC00-0HA1 installation drawings (1 cable) ........................................................... 321 16.1.2 1FN3050-2WC00-0xA1 installation drawings (2 cables) .......................................................... 323 16.1.3 1FN3100-1FN3150-xW installation drawings (1 cable) ............................................................ 325 16.1.4 1FN3100-1FN3150-xW installation drawings (2 cables) .......................................................... 327 16.1.5 1FN3050-xW dimension tables................................................................................................. 329 16.1.6 1FN3100-xW dimension tables................................................................................................. 331 16.1.7 1FN3150-xW dimension tables................................................................................................. 333 16.1.8 Cooling sections........................................................................................................................ 336 16.1.9 Mounting of the Hall sensor box ............................................................................................... 337

16.2 1FN3300, 1FN3450................................................................................................................... 339 16.2.1 1FN3300-xW-1FN3450-xW installation drawings (1 cable)...................................................... 339 16.2.2 1FN3300-xW-1FN3450-xW installation drawings (2 cables) .................................................... 343 16.2.3 1FN3300-xW dimension tables................................................................................................. 345 16.2.4 1FN3450-xW dimension tables................................................................................................. 347 16.2.5 Cooling sections........................................................................................................................ 349 16.2.6 Mounting of the Hall sensor box ............................................................................................... 351

16.3 1FN3600.................................................................................................................................... 352 16.3.1 1FN3600-xW installation drawings (1 cable) ............................................................................ 352 16.3.2 1FN3600-xW installation drawings (2 cables)........................................................................... 354 16.3.3 Dimension tables....................................................................................................................... 356 16.3.4 Cooling sections........................................................................................................................ 358 16.3.5 Mounting of the Hall sensor box ............................................................................................... 359

16.4 1FN3900.................................................................................................................................... 361 16.4.1 1FN3900-xW installation drawings (1 cable) ............................................................................ 361 16.4.2 1FN3900-xW installation drawings (2 cables)........................................................................... 365 16.4.3 Dimension tables....................................................................................................................... 367 16.4.4 Cooling sections........................................................................................................................ 370 16.4.5 Mounting of the Hall sensor box ............................................................................................... 371

16.5 Dimension drawings of the Hall sensor box.............................................................................. 373

A Appendix................................................................................................................................................ 375

A.1 Overview of important motor data............................................................................................. 375

A.2 Recommended manufacturers.................................................................................................. 378 A.2.1 Introduction ............................................................................................................................... 378 A.2.2 Manufacturers of braking elements........................................................................................... 378 A.2.3 Manufacturers of cold water units ............................................................................................. 379 A.2.4 Manufacturers of anti-corrosion agents .................................................................................... 380 A.2.5 Manufacturers of connectors for cooling................................................................................... 380 A.2.6 Manufacturers of plastic hose manufacturers ........................................................................... 381 A.2.7 Manufacturers of connector nipples and reinforcing sleeves.................................................... 381

A.3 Terminal markings..................................................................................................................... 381

A.4 Fax form for recommendations/corrections (copy template) .................................................... 382

Abbreviations + glossary........................................................................................................................ 383

Index...................................................................................................................................................... 385


General safety guidelines 11.1 1.1 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!

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



3. Hazardous shock voltages caused by, for example:

– Component malfunctions

– Influence of electrostatic charging

– Induction of voltages in moving motors


– Condensation / conductive contamination


– 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.

General safety guidelines 1.2 Personnel


1.2 1.2 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.

1.3 1.3 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.

General safety guidelines 1.4 Danger from strong magnetic fields


1.4 1.4 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.

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.

General safety guidelines 1.5 Posting of warning signs


1.5 1.5 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 4844-2 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 4844-2 enclosed with secondary sections and their meaning


Warning strong magnetic field

(D-W013)

Warning hand injuries (D-W027)



Table 1- 3 Prohibiting signs according to BGV A8 and DIN 4844-2 enclosed with secondary sections and their meaning


No pacemakers (D-P011)

No metal implants (D-P016)

No metal objects or watches (D-P020)

No magnetic or electronic data media

(D-P021)


Motor description 22.1 2.1 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 Peak load motors of the 1FN3 product family 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.

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 Procedure

Motor type Permanent-magnet excited synchronous linear motor Type of construction Individual components Cooling 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

Thermal motor protection PTC thermistor temperature sensor in a triplet configuration (according to DIN 44081/DIN 44082) and KTY84 thermistor temperature sensor (according to IEC 60034-11) in the primary section;

Rating plate A second rating plate is provided for each motor Insulation according to EN 60034-1

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 (10-100 years).



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 60529 and EN 60034-5)

• 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 60721-3-1 (for long-term storage), DIN EN 60721-3-2 (for transport), and DIN EN 60721-3-3 (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: Class 1B1 Transport: Class 2B1 Fixed location: Class 3B1



Table 2- 4 Chemical ambient conditions

Long-term storage: Class 1C1 Transport: Class 2C1 Fixed location: Class 3C2

Operating site in the immediate vicinity of industrial plants with chemical emissions

Table 2- 5 Mechanically active ambient conditions

Long-term storage: Class 1S2 Transport: Class 2S2 Fixed location: Class 3S1

Table 2- 6 Mechanical ambient conditions

Long-term storage: Class 1M2 Transport: Class 2M2 Fixed location: Class 3M3

Motor description 2.2 Approvals


2.2 2.2 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.

2.3 2.3 Degrees of protection

Primary section The primary sections meet the requirements for IP65 degree of protection in accordance with EN 60529 and EN 60034-5.

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 60529 and EN 60034-5 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.

Motor description 2.3 Degrees of protection



Motor components and options 33.1 3.1 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

Motor components and options 3.2 Variants of the secondary section end pieces


Figure 3-1 Components of a 1FN3 linear motor

3.2 3.2 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.

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 1FN3050…450 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 (1FN3050…450) or three (1FN3600…900) 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


– 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


Motor components and options 3.3 Motor rating plate


3.3 3.3 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)

Rated current

Temperature class

Serial number(CWYY: week andyear of fabrication)

Degree ofprotection

Approvals

Motor type

Maximum converteroutput voltage

Maximum velocity at rated force

Rated force

Max. ambient temperature at rated current

Number ofphases

Figure 3-3 Data on the rating plate (schematic)

Motor components and options 3.4 Thermal motor protection


3.4 3.4 Thermal motor protection

3.4.1 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).



3.4.2 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.

Res

ista

nce

/ Ω

Temperature / °C

ITest = 2 mA

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. 1000 Ω



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 60947-8, DIN 44081, and DIN 44082.

Figure 3-5 Typical characteristic curve of a PTC element; source: DIN 44081 / DIN 44082

Technical data: According to DIN 44081 / 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 = 12000 Ω at T < ϑNAT + 15 K

Note

The PTC elements do not switch automatically! An evaluation is required to protect the motor effectively.


System integration 44.1 4.1 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!

System integration 4.2 Standard integration of the motor


4.2 4.2 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.

Temp. signal cable

Motor variant 11 cable

open ends

Power cable

Motor variant 22 cables open ends/connector

Terminal block

SMEDrive System Signal cable

Temp. signal cable

Cable(s) WMS

Power cable

Cooling system

Cooling system

Cooler connectorcables

Cooler connectorcables

WMS

Figure 4-2 Integration of a motor in the system

For special drive requirements, the system configuration may differ from that shown above.

System integration 4.3 Drive system


4.3 4.3 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) 540 V (uncontrolled)

425 V (controlled) 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.

System integration 4.4 Position measuring system


4.4 4.4 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.



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 (050…150 or 300…900)

● 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



Hall sensor box mounting types

even

MLFBHall sensor box

Distance between holes = 50.0 mm (± n • 30 mm)


MODELS 050 + 100 + 150MODELS 050 + 100 + 150

1FN3002-1FN3002-0PH01-0PH01-0AA00AA0

1FN3002-1FN3002-0PH00-0PH00-0AA00AA0

HSB Overall length of primary section

.1N.. /..2N../.3N../ .4N..or .1W../..2W../.3W./.4W../.5W..

Overall length of primary section HSBMounting on the terminal end Mounting opposite the terminal end

1FN3005-1FN3005-0PH01-0PH01-0AA00AA0

1FN3002-1FN3002-0PH01-0PH01-0AA00AA0

odd

odd

even

1FN3005-1FN3005-0PH00-0PH00-0AA00AA0

1FN3002-1FN3002-0PH00-0PH00-0AA00AA0

MLFBHall sensor box

..3N.. ..1N..or ..5W.. ..3W.. ..1W..

4N.. ..2N..or ..4W.. ..2W..

..3N.. ..1N..or ..5W.. ..3W.. ..1W..

..4N.. ..2N..or ..4W.. ..2W..

.1N.. /..2N../.3N../ .4N..or .1W../..2W../.3W./.4W../.5W..

Figure 4-3 Hall sensor box mounting types for models 050 to 150

System integration 4.5 Sensor modules SME9x


even

MLFBHall sensor box



MODELS 300 + 450 + 600 + 900MODELS 300 + 450 + 600 + 900

1FN3003-1FN3003-0PH01-0PH01-0AA00AA0

1FN3003-1FN3003-0PH00-0PH00-0AA00AA0

HSB Overall length of primary section

.1N../..2N../.3N../.4N..or .1W../..2W../.3W../.4W..

Overall length of primary section HSBMounting on the terminal end Mounting opposite the terminal end

1FN3006-1FN3006-0PH01-0PH01-0AA00AA0

1FN3003-1FN3003-0PH01-0PH01-0AA00AA0

odd

odd

even

1FN3006-1FN3006-0PH00-0PH00-0AA00AA0

1FN3003-1FN3003-0PH00-0PH00-0AA00AA0

MLFBHall sensor box

..3N.. ..1N.. or ..3W.. ..1W..

..4N.. ..2N.. or ..4W.. ..2W..

..3N.. ..1N.. or ..3W.. ..1W..

..4N.. ..2N.. or ..4W.. ..2W..

.1N../..2N../.3N../.4N..or .1W../..2W../.3W../.4W..

Figure 4-4 Hall sensor box mounting types for models 300 to 900

4.5 4.5 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 61800-5-1 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.

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.

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

X X

X3 SCALE Input for EnDat PMS, 17 pin X X X4 HALLSENSOR Input for HSB, 9 pin

X X

X5 TEMP1 Input for temperature sensor, 7 pin

X X X X

X6 TEMP2 Input for temperature sensor, 7 pin

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.

4.6 4.6 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.

System integration 4.7 Cooling system


4.7 4.7 Cooling system

4.7.1 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



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.



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)

Air

Main cooler(internal cooling circuit)

Secondary section cooling(cooling sections made of aluminium)

Air gap

Figure 4-7 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.



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

1FN050…450 motor models (side and top view)



Figure 4-9 Secondary section cooling consisting of cooling sections with hose connector nipples for

1FN600…900 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 1FN3050…450 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.



Figure 4-10 Secondary section cooling for 1FN3050...1FN3450 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)



Figure 4-12 Secondary section cooling for 1FN3050...1FN3450 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!



Materials used The following table lists the materials that are

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