Operation Manual
Coreless linear motor AL3800
Version:
Date:
3.6
2019/07/19
Documented motors – AL38xx
Documented motors – AL38xx
Linear servomotor Speed
(max.)
AL3803-0000-000x 2.7 m/s FP = 700 N Fca = 141 N Ica = 5.6 A
AL3803-0001-000x 6.6 m/s FP = 700 N Fca = 141 N Ica = 13.9 A
AL3806-0000-000x 2.7 m/s FP = 1400 N Fca = 282 N Ica = 11.3 A
AL3806-0001-000x 6.6 m/s FP = 1400 N Fca = 282 N Ica = 28.0 A
AL3809-0000-000x 2.7 m/s FP = 2100 N Fca = 423 N Ica = 16.9 A
AL3809-0001-000x 6.6 m/s FP = 2100 N Fca = 423 N Ica = 42.0 A
AL3812-0000-000x 2.7 m/s FP = 2800 N Fca = 564 N Ica = 22.6 A
AL3812-0001-000x 6.6 m/s FP = 2800 N Fca = 564 N Ica = 56.0 A
AL3818-0000-000x 2.7 m/s FP = 4200 N Fca = 846 N Ica = 34.0 A
Peak force for 3 sec. Continuous
force
with air cooling
Peak current
with air cooling
Coreless linear motor AL3800 3Version: 3.6
Table of content
Table of content
Documented motors – AL38xx.................................................................................................................3
1 Foreword ....................................................................................................................................................7
1.1 Notes on the documentation..............................................................................................................7
1.2 Documentation issue status ..............................................................................................................8
1.3 Intended use......................................................................................................................................8
2 Guidelines and Standards ........................................................................................................................9
2.1 EC declaration of conformity .............................................................................................................9
3 Safety........................................................................................................................................................10
3.1 Safety instructions ...........................................................................................................................10
3.2 Special safety instructions for the AL38xx.......................................................................................11
4 Handling ...................................................................................................................................................13
4.1 Transport .........................................................................................................................................13
4.2 Storage ............................................................................................................................................13
4.3 Maintenance / Cleaning...................................................................................................................13
4.4 Disposal...........................................................................................................................................13
5 Product identification..............................................................................................................................14
5.1 AL38xx scope of delivery.................................................................................................................14
5.2 AL38xx type key ..............................................................................................................................14
6 Technical description..............................................................................................................................15
6.1 Design of the motors .......................................................................................................................15
6.2 General technical data.....................................................................................................................15
6.2.1 Power derating................................................................................................................. 16
6.3 Standard features ............................................................................................................................17
6.3.1 Coil unit, primary part (N/S) ............................................................................................. 17
6.3.2 Magnet yoke, secondary part .......................................................................................... 17
6.4 Additional equipment .......................................................................................................................18
6.4.1 Screws and locating pins ................................................................................................. 18
6.4.2 Servo drive and feedback system.................................................................................... 18
7 Mechanical installation ...........................................................................................................................19
7.1 Specification of the mounting surfaces............................................................................................19
7.2 Installation sequence.......................................................................................................................20
7.3 Mounting the magnet yokes ............................................................................................................20
7.4 Assembling the coil unit...................................................................................................................21
7.5 Dismantling sequence .....................................................................................................................21
8 Electrical installation...............................................................................................................................22
8.1 Important notes................................................................................................................................22
8.2 Connection of motors with flying wires ............................................................................................23
8.3 Connection of motors with preassembled cables ............................................................................23
8.3.1 AX5000 connection diagram for AL38xx and absolute value encoder ............................ 24
8.3.2 AX5000 connection diagram for AL38xx and Sin/Cos encoder with zero pulse.............. 25
8.4 Calculation of the brake resistor ......................................................................................................26
8.5 Temperature sensor ........................................................................................................................26
Coreless linear motor AL38004 Version: 3.6
Table of content
8.5.1 PTC specification............................................................................................................. 26
8.5.2 NTC Specification ............................................................................................................ 27
8.6 Polarity test......................................................................................................................................27
9 Commissioning........................................................................................................................................28
9.1 Important notes................................................................................................................................28
9.2 General commissioning ...................................................................................................................28
9.2.1 Parameterization.............................................................................................................. 28
9.2.2 Commissioning ................................................................................................................ 29
9.2.3 Optimizing the control settings......................................................................................... 29
9.3 Troubleshooting...............................................................................................................................30
10 Technical data..........................................................................................................................................31
10.1 Term definitions ...............................................................................................................................31
10.2 AL38xx.............................................................................................................................................32
10.2.1 Technical drawing AL38xx............................................................................................... 33
11 Support and Service................................................................................................................................34
Coreless linear motor AL3800 5Version: 3.6
Table of content
Coreless linear motor AL38006 Version: 3.6
Foreword
1 Foreword
1.1 Notes on the documentation
This description is only intended for the use of trained specialists in control and automation engineering who
are familiar with the applicable national standards.
It is essential that the documentation and the following notes and explanations are followed when installing
and commissioning the components.
It is the duty of the technical personnel to use the documentation published at the respective time of each
installation and commissioning.
The responsible staff must ensure that the application or use of the products described satisfy all the
requirements for safety, including all the relevant laws, regulations, guidelines and standards.
Disclaimer
The documentation has been prepared with care. The products described are, however, constantly under
development.
We reserve the right to revise and change the documentation at any time and without prior announcement.
No claims for the modification of products that have already been supplied may be made on the basis of the
data, diagrams and descriptions in this documentation.
Trademarks
Beckhoff®, TwinCAT®, EtherCAT®, EtherCAT P®, Safety over EtherCAT®, TwinSAFE®, XFC® and XTS® are
registered trademarks of and licensed by Beckhoff Automation GmbH.
Other designations used in this publication may be trademarks whose use by third parties for their own
purposes could violate the rights of the owners.
Patent Pending
The EtherCAT Technology is covered, including but not limited to the following patent applications and
patents:
EP1590927, EP1789857, DE102004044764, DE102007017835
with corresponding applications or registrations in various other countries.
The TwinCAT Technology is covered, including but not limited to the following patent applications and
patents:
EP0851348, US6167425 with corresponding applications or registrations in various other countries.
EtherCAT® is registered trademark and patented technology, licensed by Beckhoff Automation GmbH,
Germany
Copyright
© Beckhoff Automation GmbH & Co. KG, Germany.
The reproduction, distribution and utilization of this document as well as the communication of its contents to
others without express authorization are prohibited.
Offenders will be held liable for the payment of damages. All rights reserved in the event of the grant of a
patent, utility model or design.
Coreless linear motor AL3800 7Version: 3.6
Foreword
1.2 Documentation issue status
Origin of the document
This documentation was originally written in German. All other languages are derived from the German
original.
Product features
Only the product features specified in the current user documentation are valid. Further information given on
the product pages of the Beckhoff homepage, in emails or in other publications is not authoritative.
Issue Comment
3.6 Chapter update:
Connection of motors with flying wires 8.2; NTC Specification 8.5.2
3.5 Chapter update:
Disposal 4.4
3.4 Chapter update:
EC declaration of conformity 2.1; Technical drawing AL38xx 10.2.1
3.3 Chapter update:
1.0 Foreword; 3.0 Safety
3.2 Chapter update:
8.2
3.1 Chapter update:
10.2
3.0 Complete revision
2.1 Version February 2005
1.3 Intended use
The ironless linear servomotors of the series AL38xx are cogging-free and therefore particularly suitable as
drives for axes with low mass or high demands on synchronism, e.g. in machines in the semiconductor
industry.
The thermal protection contact incorporated in the motor windings must be analyzed and monitored.
WARNING
Caution - Risk of injury!
Electronic equipment is not fail-safe. The machine manufacturer is responsible for ensuring
that the connected motors and the machine are brought into a safe state in the event of a
fault in the drive system.
The linear servomotors from the AL38xx series are exclusively installed as components into electrical
systems or machines and may only be put into operation as integrated components of the system or
machine.
The motors may only be operated under the ambient conditions defined in this documentation.
Coreless linear motor AL38008 Version: 3.6
Guidelines and Standards
2 Guidelines and Standards
CAUTION
Danger for persons, the environment or equipment
Linear servomotors from the AL38xx series are not products within the meaning of the EC machinery directive. Operation of the linear servomotors in machines or systems is only permitted once the machine or system manufacturers has provided evidence of CE conformity of the complete machine or system.
2.1 EC declaration of conformity
Provision of EU Declaration of Conformity:
Beckhoff Automation GmbH & Co. KG will be glad to provide you with EU declarations of conformity
and manufacturer's declarations for all products upon request to info@beckhoff.com.
Coreless linear motor AL3800 9Version: 3.6
Safety
3 Safety
3.1 Safety instructions
Safety regulations
Please note the following safety instructions and explanations!
Product-specific safety instructions can be found on following pages or in the areas mounting, wiring,
commissioning etc.
Exclusion of liability
All the components are supplied in particular hardware and software configurations appropriate for the
application. Modifications to hardware or software configurations other than those described in the
documentation are not permitted, and nullify the liability of Beckhoff Automation GmbH & Co. KG.
Personnel qualification
This description is only intended for trained specialists in control, automation and drive engineering who are
familiar with the applicable national standards.
Description of symbols
In this documentation the following symbols are used with an accompanying safety instruction or note. The
safety instructions must be read carefully and followed without fail!
DANGER
Serious risk of injury!
Failure to follow the safety instructions associated with this symbol directly endangers the life and health of
persons.
WARNING
Risk of injury!
Failure to follow the safety instructions associated with this symbol endangers the life and health of persons.
CAUTION
Personal injuries!
Failure to follow the safety instructions associated with this symbol can lead to injuries to persons.
NOTE
Damage to the environment or devices
Failure to follow the instructions associated with this symbol can lead to damage to the environment or
equipment.
Tip or pointer
This symbol indicates information that contributes to better understanding.
UL pointer
This symbol indicates important information about the UL-compliant.
Coreless linear motor AL380010 Version: 3.6
3.2 Special safety instructions for the AL38xx
The safety instructions are designed to avert danger and must be followed during installation,
commissioning, production, troubleshooting, maintenance and trial or test assemblies.
The linear servomotors from the AL3xxx series are not capable of running independently and are always
installed into a machine or system. After installation the additional documentation and safety instructions
provided by the machine manufacturer must be read and followed.
WARNING
Serious risk of injury through high electrical voltage!
• Negligent, improper handling of the linear servomotor and bypassing of the safety devices can lead to personal injury or death through electric shock.
• It must be ensured that the protective conductor has been firmly connected.
• The machine manufacturer must prepare a hazard analysis for the machine, and must
take appropriate measures to ensure that unexpected movements cannot lead to injury
to persons or to objects.
• Power leads may be live, even if the motor is not running. Never undo the electrical connections to the motor when it is live. Under unfavorable conditions arcing may occur, resulting in injury and damage to contacts.
• Disconnect the linear servomotor from the servo drive and secure it against reconnection before working on electrical parts with a voltage > 50 V.
• The DC link voltage of the servo drive may exceed 890VDC. Wait until the DC link capacitors are discharged before touching live terminals. The voltage measured between the
DC+ and DC- terminals (X02) must have dropped to below 50 VDC.
Safety
WARNING
Serious risk of injury through hot surfaces!
• The surface temperature may exceed 50 °C, resulting in a risk of burns.
• Avoid touching the housing during or shortly after operation.
• Leave the linear servomotor to cool down for at least 15 minutes after it is switched off.
• Use a thermometer to check whether the surface has cooled down sufficiently.
NOTE
Danger to the environment or devices
• Carefully read this manual before using the linear servomotor thoroughly, paying particular attention to
the safety instructions. In the event of any uncertainties please notify your sales office immediately and
refrain from working on the linear servomotor.
• Only well trained, qualified electricians with sound knowledge of drive equipment may work on the device.
• Adhere without fail to the climatic conditions for the installation. Further information can be found in the
chapter Technical data and Mechanical installation.
• If a linear servomotor is installed in a machine it must not be commissioned until proof of compliance of
the machine with the latest version of the EC Machinery Directive has been provided. This includes all
relevant harmonized standards and regulations required for implementation of this Directive in national
legislation.
NOTE
Damage to the device due to inappropriate treatment
Treat the components of the linear servomotor with care, both in the packed and unpacked state. The magnet yokes are particularly sensitive. Never let the magnet yokes fall on the floor.
Coreless linear motor AL3800 11Version: 3.6
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