ServoTube 38
Copley
Controls
Corp.
Copley Motion Systems LLC
INSTALLATION GUIDE
Publication Ref: UM03013/A
Copley Motion Systems LLC
Luckyn Lane, Pipps Hill, Basildon, Essex SS14 3BW England
Tel: +44 (0)1268 287070 Fax +44 (0)1268 293344
Prelims ServoTube 38 Installation Guide
Copley
Controls
Corp.
Copley Motion Systems LLC
WARRANTY
Copley Motion Systems guarantees its equipment against faulty components for a period of twelve months from
delivery. Replacement components will be free of charge. Copley Motion Systems shall not in any event be liable for
consequential damage or loss.
Copley Motion Systems operates a customer care facility and all requests for repair and replacement should be
directed to the Customer Care Department. The serial number of the equipment should be quoted in any
communications. The right to change specification and price is reserved by Copley Motion Systems.
DISCLAIMER
Copley Motion Systems makes no guarantees of any kind with regard to this manual. Copley Motion Systems shall not
be liable for errors contained herein or for consequential or incidental damages incurred as a result of acting on
information contained in the manual.
CUSTOMER CARE
For enquiries relating to the operation and use of the ServoTube 38 described in this Manual please contact the
Customer Care Helpdesk, Telephone : +44 (0)1268 287070.
Copley Motion Systems LLC
Luckyn Lane, Pipps Hill, Basildon, Essex SS14 3BW England
Tel: +44 (0)1268 287070 Fax: +44 (0)1268 293344
ã Copley Motion Systems 2005
INTERNATIONAL CONTACT DETAILS
website: http//www.copleycontrols.com
Page (ii)
World Headquarters, USA
Copley Controls Corp.
20 Dan Road,
Canton,
MA 02021
USA
Tel: +1 781 828 8090
Fax: +1 781 828 1750
European Headquarters
Copley Motion Systems LLC
Luckyn Lane,
Pipps Hill,
Basildon, Essex SS14 3BW
England
Tel: +44 (0)1268 287070
Fax: +44 (0)1268 293344
ServoTube 38 Installation Guide Prelims
ServoTube 38
INSTALLATION GUIDE
Contents
Preliminary pages
Title page.............................................(i)
Copyright notice / disclaimer ..................................(ii)
Contents list (this page).....................................(iii)
Warnings ............................................(iv)
Cautions .............................................(v)
Reader’s Notes .........................................(vi)
Abbreviations ..........................................(vii)
Chapters
1 Overview ..........................................1
2 Installation .........................................3
3 Maintenance ........................................9
4 Service ..........................................11
Appendices
A Glossary of terms & Abbreviations ............................13
B Trouble Shooting .....................................17
C Technical Specification ..................................19
Page (iii)
Prelims ServoTube 38 Installation Guide
WARNINGS
Warning symbols and meanings
In this User Manual warning symbols are used. These are intended to alert you to the potential hazards to personnel
which are associated with the equipment described, in all aspects of use, including handling, installation, operation and
maintenance.
Heart pacemakers. Personnel fitted with pacemakers must not handle or work on this equipment.
Strong magnets. The thrust rod contains powerful magnets and will strongly attract ferrous objects.
Damage can occur to computer disks and credit cards.
Electric shock. Potentially lethal voltages may be present during the commissioning and servicing of
this equipment. Isolate and disconnect all sources of electrical supply before working on the
equipment. Particular care needs to be taken when working on or around motor phase connections.
Hot surface. Surface temperatures of up to 80 °C can be present during the commissioning and
servicing of this equipment. Allow the forcer and thrust rod to cool before working on the equipment.
Heavy object. May need two people to lift.
Crush hazard. The forcer may move unexpectedly. Always isolate all sources of electrical supply
before working on the equipment.
General hazard. Follow the advice given.
Electrical safety
This equipment must be earthed using the green/yellow conductor.
EMC precautions
This equipment is intended for use in a light industrial environment. It is recommended that the following precautions be
observed during installation:
Keep all cable lengths to a minimum.
•
Provide as much physical separation as possible between power and signal cables. In particular, avoid long,
•
parallel runs of cables.
Maintain screen continuity throughout the cable run.
•
Use 360 degree screen terminations where possible. “Pig-tail” terminations are not recommended.
•
It is the responsibility of the User to ensure compliance with any local electrical and EMC regulations in force at
•
the time of installation.
Page (iv)
ServoTube 38 Installation Guide Prelims
READER’S NOTES
GENERAL
This manual describes the Installation, Maintenance and Spares of the ServoTube 38 linear motor.
ASSOCIATED PUBLICATIONS
The following publications are associated with the ServoTube 38 User Manual.
Title Reference Number
ServoTube Applications Guide UM03012
XTA Data sheet DS01093
XTB Data sheet DS01094
Xenus User Guide -
Xenus Data Sheet -
Page (v)
Prelims ServoTube 38 Installation Guide
Page (vi)
ServoTube 38 Installation Guide Chapter 1
Overview
Chapter 1
Product Overview
SERVOTUBE 38 ACTUATOR
The ServoTube 38 Actuator is an optimal solution
for industrial position control. Faster than a
ballscrew with the clean reliability of a linear motor,
the ServoTube 38 is a cost-effective alternative to
air cylinders in applications requiring greater
flexibility and control.
Four models
The ServoTube 38 Actuator incorporates an IP67 rated
forcer and a sealed stainless steel thrust rod enclosing
rare-earth magnets. Four models deliver a continuous
force range of 137-276 N (31-62 lb) with peak forces up
to 1860N (418 lb). Nine stroke lengths are available
from 33- 318 mm
The patented magnetic design of ServoTube 38
generates 25 micron (0.98 mil) repeatability and 400
micron (16 mil) accuracy from a non-contact, integral
position sensor. No external encoder is required.
Position output is industry standard 1V pk-pk sin/cos
signals.
model number and the system comes up tuned and
ready to run. Clear diagnostics make system
commissioning easy. Fill in the blanks to define position,
velocity and acceleration.
SERVOTUBE 38
ServoTube 38 delivers the speed of a belt-drive
system with the clean reliability of a linear motor at
a price unprecedented in the industry. Familiar
form factor, integral position feedback and large air
gap make installation simple.
The ServoTube 38 motor components comprise an
IP67 rated forcer and a sealed stainless steel thrust rod
enclosing rare-earth magnets. Four models deliver a
continuous force range of 137-276 N (31-62 lb) with
peak forces up to 1860 N (418 lb). A range of Thrust
Rods are available for travel lengths up to 1362 mm.
Figure 1.1 - ServoTube 38 Actuator
Maintenance free
The XTA has an internal dry bearing which provides a
clean, quiet, maintenance free performance. Life
expectancy far exceeds typical ballscrew solutions. The
ServoTube 38 Actuator is ideal for push/pull/lift material
handling, packaging and automated assembly
applications. ServoTube 38 accepts a range of industry
standard accessories for simple mechanical integration.
Plug and Play
Flexible mid-stroke position control is simple with Xenus
- a matched, self-tuning indexer complete with plugand-play cabling. Simply select your ServoTube 38
Figure 1.2 - ServoTube 38
The patented magnetic design of ServoTube 38
generates 25 micron (0.98 mil) repeatability and 400
micron (16 mil) accuracy from a non-contact, integral
position sensor. No external encoder is required.
Position output is industry standard 1V pk-pk sin/cos
signals.
Easy Integration
ServoTube 38 is an ideal OEM solution for easy
integration into pick-and-place gantries and general
purpose material handling machines. The load is
mounted directly to the Forcer typically supported by a
single bearing rail. The Thrust Rod is mounted at both
ends, similar to a ballscrew. A large air gap reduces
alignment constraints.
Page 1
Chapter 1 ServoTube 38 Installation Guide
Overview
The tubular motor has superior thermal efficiency,
radiating heat uniformly. High duty cycles are possible
without the need for forced-air or water cooling.
Amplifiers
ServoTube 38 is complemented by a range of matched,
self-tuning servo-amplifiers and indexers complete with
plug-and-play cabling. Amplifiers interface easily to
PLCs and feature CANopen network connectivity for
distributed control applications.
Page 2
ServoTube 38 Installation Guide ` Chapter 2
Installation
Chapter 2
Installation
UNPACKING
Check packaging for signs of damage.
•
Metal surfaces may be hot or below 0oC following prolonged storage.
•
Remove packaging. Do not discard. In the event of items requiring return, it is recommended that the original
•
packaging be used.
Ensure that the delivery note correctly reflects your order and the items delivered.
•
Check equipment for signs of damage. Never use the equipment if it appears damaged in any way.
•
Read the User Guide before installing and using this equipment.
•
INSTALLATION
Intended operating environment
This equipment is intended for use in an environment within the following conditions: -
Operating temperature 0 to +40 °C
Storage temperature -25 to +70 °C
Humidity (relative) 0 to 95% non-condensing
Altitude (above mean sea level) 1000 m
Overvoltage category II
Pollution degree 2
EMC light industrial
Page 3
Chapter 2 ServoTube 38 Installation Guide
Installation
Mechanical - XTA
The outline drawing of the XTA is shown in Figure 2.1. It comprises the forcer with an integrated plastic sleeve bearing
and the thrust rod. The integrated bearing acts as a guide for the moving thrust rod. It is not intended to withstand side
loading. If side loading is expected then it is advised that an external bearing is fitted.
The XTA forcer can be mounted by two methods.
• Using the T -slots in the top of the forcer.
• Using M6 fixings (4 off) on the end flange.
IMPORTANT
When using the end flange fixing method, the fixings and mounting plate must be of a non- ferrous material
such as aluminum, stainless steel, and plastic for example.
Dimensional details for both are given in Figure 2.1.
The recommended tightening torque for the fixings are:
M6 end flange 9 Nm M6 T-nut 10 Nm (both non lubricated i.e. no thread lock)
The thrust rod has optional male and female threaded connections at each end. These are intended to interface to a
number of standard accessories. The thrust rod has an external circlip at each end to restrain the thrust rod within the
forcer. These are not intended as "hard stops" to prevent over-travel and it is the responsibility of the User to prevent the
thrust rod from being ejected from the forcer.
Page 4
ServoTube 38 Installation Guide ` Chapter 2
XTA3804
XTA3806
XTA3808
XTA3810
ALL DIMENSIONS IN MM
THRUST ROD
Note: 1. Actuator is double acting
Tolerance +/-2mm
33.0
70.0
42.0
40.3
38.2
84.0
38.0
43.0
43.0
4 MTG HOLES
M6 X 10 DEEP
141
12.0
29.0 PITCH TYP
60.0
258.0
40.0
27.0
187.0
83.0
46.0
8 MTG HOLES
M4 X 8 DEEP
5.5 59.0
= 58.0 =
= 37.0 =
= 60.0 =
4 MTG HOLES
M4 X 8 DEEP
8.2
14.0
11. 8
6.8
141
29.0 PITCH TYP
60.012.0
329.0
40.0
27.0
89.0
252.0
46.0
8 MTG HOLES
M4 X 8 DEEP
ACTUATOR ENVELOPE
= (2 X STROKE ) + 390
(See Note 1)
ACTUATOR ENVELOPE
= (2 X STROKE ) + 319
(See Note 1)
ACTUATOR ENVELOPE
= (2 X STROKE ) + 461
(See Note 1)
141
29.0 PITCH TYP
60.012.0
471.0
27.0
40.0
93.0
390.0
46.0
8 MTG HOLES
M4 X 8 DEEP
ACTUATOR ENVELOPE
= (2 X STROKE ) + 532
(See Note 1)
38.0
28.0 AF
38.0
OVERALL LENGTH +/-1mm
23.0
M10 X
20.0
MTG BOSS
ACTIVE LENGTH +/-1mm
400.0
27.0
40.0 141
93.0
319.0
60.012.0
29.0 PITCH TYP
46.0
8 MTG HOLES
M4 X 8 DEEP
MTG HOLE
M10 X 12 DEEP
A(2:1)
T - SLOT DETAIL
Installation
Figure 2.1 - XTA Outline drawings and mounting details
Page 5
Chapter 2 ServoTube 38 Installation Guide
Installation
Mechanical - XTB
The XTB is shown in Figure 2.2. It comprises the forcer and the thrust rod. With the addition of thrust rod supports and a
linear bearing a moving forcer solution can be implemented.
The XTB forcer can be mounted by two methods. T -slots are available in the top of the forcer but more normally the
forcer is mounted to bearing carriages to allow the use of a linear bearing. Dimensional details for both are shown in
Figure 2.2. The recommended tightening torque for the fixings are:
M4 bearing to forcer 4 Nm M6 T-nut 10 Nm
The thrust rod can be mounted using thrust rod supports (part number 400 885 361). The thrust rod support comprises
a split clamp with two M10 pinch bolts.
All torque figures are non-lubricated i.e. no thread lock.
As the XTB has a moving forcer it is supplied with highly flexible cables suitable for continuous flexing operation. In
order to achieve the best reliability and life from these cables it is advised that some form of cable management system
is used. Typically, this will be an energy chain mounted parallel to the direction of motion. Always follow the
manufacturers recommendations when installing cables into energy chains. In particular:
Observe cable minimum bend radius requirements (see Appendices).
•
Never allow the cable to be under tension within the energy chain.
•
Physically separate cables within the energy chain to prevent premature failure due to abrasion.
•
Never cross cables within the energy chain.
•
Be careful to prevent the cable from twisting or becoming kinked during installation into the energy chain.
•
Page 6
THRUST ROD
XTB3804
XTB3806
XTB3808
XTB3810
ALL DIMENSIONS IN MM
40.0
33.0
70.0
42.0
40.3
38.0
84.0
218.0
12.0
70.0
174.0
29.0 PITCH TYP
60.0
8 MTG HOLES
M4 X 8 DEEP
5.5 59.0
= 58.0 = = 37.0 = = 60.0 =
4 MTG HOLES
M4 X 8 DEEP
EITHER SIDE
8.2
14.0
11. 8
6.8
141
289.0
76.0
239.0
29.0 PITCH TYP
60.012.0
8 MTG HOLES
M4 X 8 DEEP
360.0
80.0
306.0
29.0 PITCH TYP
60.012.0
8 MTG HOLES
M4 X 8 DEEP
431.0
80.0
377.0
29.0 PITCH TYP
60.0
12.0
8 MTG HOLES
M4 X 8 DEEP
38.0
THRUST ROD
LENGTH OF
141
141
141
A(2:1)
T - SLOT DETAIL
ServoTube 38 Installation Guide ` Chapter 2
Installation
Figure 2.2 - XTB Outline drawings and mounting details
Page 7
Chapter 2 ServoTube 38 Installation Guide
XENUS
AMPLIFER
PARKER
COMPAX 3
AMPLIFIER
J2
J8
POD
POWER CABLE
SENSOR CABLE
TO J2
POD
POWER CABLE
SENSOR CABLE
TO X3
TO X13
TO J8
X13
X3
Installation
Electrical
All electrical connections to the XTA and XTB are made via two cables, see Figure 2.3. One carries power to the forcer
and the other carries signals from the position sensor. These cables are supplied either pre-terminated for a specific
drive or with flying leads. Where they are pre-terminated, simply plug the cables into the relevant connectors on the
drive:
Forcer Power
Connector reference
Posion sensor
connector reference
Amplifier
J2 J8 Copley Xenus
X3 X13 Parker Compax 3
For cable reference numbers refer to Chapter 4 - Service.
WARNING
THE THRUST ROD ON BOTH XTA AND XTB MUST BE EARTHED. THIS CAN BE ACHIEVED BY
EARTHING THE CONNECTED MECHANICAL PARTS ON THE USER’S MACHINE.
Figure 2.3 - Schematic showing connection of XTA / XTB to the Xenus Amplifier and Parker Compax 3 Amplifier
Page 8
ServoTube 38 Installation Guide Chapter 3
Maintenance
Chapter 3
Maintenance
XTA
The XTA is low maintenance and as such requires only minimal periodic inspection.
The integral bearing is dry running, requiring no lubrication.
Periodically:
Check that the thrust rod can move freely over the entire stroke.
•
Clean any accumulated debris from the thrust rod surface (ferrous material, in particular, can be attracted to the
•
thrust rod surface).
Check all fixings are tight and secure.
•
XTB
The XTB is low maintenance and as such requires only minimal periodic inspection.
Where an external linear bearing is used, please consult the bearing manufacturer for recommendations on lubrication
types and lubrication intervals.
Periodically:
Check that the forcer can move freely over the entire stroke.
•
Clean any accumulated debris from the thrust rod surface (ferrous material, in particular, can be attracted to the
•
thrust rod surface).
Check all fixings are tight and secure.
•
Check all flexing cables for signs of wear or damage.
•
WARNING
ISOLATE AND DISCONNECT ALL SOURCES OF ELECTRICAL SUPPLY BEFORE WORKING
ON THE EQUIPMENT.
CABLE REPLACEMENT
If a cable needs to be replaced it will be necessary to gain access to the termination box inside the pod, see Figure 3.1.
Removal
Unscrew the four M3 pod cover fixings.
•
Note that the fixings are of different lengths.
Make a record from where each fixing is removed so they can be correctly replaced later.
Remove the pod cover from the termination box.
•
Unscrew the pressure nut from the cable gland.
•
Disconnect the power cable from the screw terminal connector, TB1 and the earth terminal and/or unplug the
•
sensor cable from the PCB at connector PL1.
Page 9
Chapter 3 ServoTube 38 Installation Guide
POWER CABLE
M3 FIXING SCREWS (4 OFF)
SENSOR CABLE
POD LID
POD
MICRO CONNECTOR
ON PCB, PL1
SENSOR CABLE
POWER CABLE
CABLE
GLAND
SCREW TERMINAL
CONNECTOR, TB1
Maintenance
Loosen the two fixings on the cable clamp.
•
Pull the cable out through the cable gland.
•
Replacement
Re-fitting is the reverse of the removal procedure.
Feed the new cable(s) through the cable
•
gland.
Connect the cable(s) including the earth
•
lead.
Tighten the cable retaining clamp.
•
Take care not to damage the sealing
•
gasket on the termination box when
replacing the cover.
Replace the fixings according to the record
•
made when they were removed.
Tighten the four M3 fixings to a torque of
•
0.7 Nm.
Figure 3.1 - Power and Sensor cable connection details in the pod
Page 10
ServoTube 38 Installation Guide Chapter 4
Service
Chapter 4
Service
SERVICE
Should you need to return any items to Copley Motion Systems, before doing so, please call our Sales co-ordinator on
+44 (0)1268 287070 or send a fax to +44 (0)1268 293344 in order to obtain an RMA (Returned Materials Authorisation)
number. The RMA number should then be quoted on all items returned and quoted for all enquiries.
Please note that when returning items it is recommended that the original packaging be used.
SPARES
The available spares for the XTA and XTB are listed in Tables 4.1 and 4.2.
Table 4.1 Cables avaialable: terminated for Xenus, Parker Compax 3 and with flying leads
Description Xenus Parker Compax 3 Flying leads
Non-flexing cables
XTA power cable 3m 450 477 003A 450 477 083A 450 477 043A
XTA sensor cable 3m 450 477 023 450 477 103 450 477 063
XTA power cable 5m 450 477 005A 450 477 085A 450 477 045A
XTA sensor cable 5m 450 477 025 450 477 105 450 477 065
Flexing cables
XTB power cable 3m 450 477 003 450 477 083 450 477 043
XTB sensor cable 3m 450 477 023 450 477 103 450 477 063
XTB power cable 5m 450 477 005 450 477 085 450 477 045
XTB sensor cable 5m 450 477 025 450 477 105 450 477 065
Table 4.2 Hardware
Description Order Code
M6 T-nut 046 205 007
Circlip - stainless steel 400 870 138
To place an order for spare parts please telephone or fax your order to the Sales co-ordinator:
Tel : +44 (0)1268 287070
Fax: +44 (0)1268 293344
Page 11
Chapter 4 ServoTube 38 Installation GuideService
Page 12
ServoTube 38 Installation Guide Appendices
Appendices
CONTENTS
APPENDIX A - GLOSSARY OF TERMS & ABBREVIATIONS
APPENDIX B - TROUBLE SHOOTING
APPENDIX C - TECHNICAL SPECIFICATION
Page 13
Appendices ServoTube 38 Installation Guide
Page 14
ServoTube 38 Installation Guide Appendices
Appendix A
Glossary of Terms & Abbreviations
GLOSSARY OF TERMS
TERM DESCRIPTION OF TERM
Peak force Peak force is the force produced when the peak current is applied to the motor. It is the product of
Force constant (N/Apk) and Peak current (Apk).
The motor is not moving, there is no forced cooling and no additional heat-sinking. The duration of
the peak force is thermally limited and is therefore only allowable for a period of 1 second.
Continuous stall
force
Peak current Peak current is the current required to heat the motor phases to their maximum operating
Continuous stall
current
Force constant Force constant is the peak force produced when 1 ampere (peak) flows into one phase and 0.5
Continuous stall force is the force produced when the continuous current is applied to the motor.
It is the product : Force constant (N/Apk) x Continuous stall current (Apk)
or : Force constant (N/A
The motor is not moving and there is no forced cooling.
It is quoted with and without the addition of a 25 x 25 x 2.5 cm heatsink plate mounted with
thermal grease to the mounting surface of the motor.
temperature when the ambient temperature is 25°C, the motor is not moving, there is no forced
cooling and no additional heat-sinking.
It is the maximum allowable current before demagnetisation of the magnets occurs when the
magnet temperature is 100°C.
The duration of the peak current is thermally limited and is therefore only allowable for a period of
1 second.
Continuous stall current is the current required to heat the motor phases to their maximum
operating temperature when the ambient temperature is 25°C, the motor is not moving and there
is no forced cooling.
It is quoted with and without the addition of a 25 x 25 x 2.5 cm heatsink plate mounted with
thermal grease to the mounting surface of the motor.
ampere (peak) flows out of the remaining two phases (as in sinusoidal commutation) quoted in
N/Apk. Alternatively, it is the peak force produced when 0.707 ampere (rms) flows into one phase
and 0.353 ampere (rms) flows out of the remaining two phases (again as in sinusoidal
commutation) quoted in N/Arms.
) x Continuous stall current (A
rms
rms
).
Back EMF Back EMF constant is the peak phase to phase voltage generated when the motor is travelling at
a velocity of 1m/s.
Fundamental
motor constant
Eddy current loss Eddy current loss is the amount of opposing force produced by the motor when it is travelling at a
Sleeve clogging
force
Resistance Resistance is measured phase to phase at temperatures of 25°C and 100°C.
Inductance Inductance is measured phase to phase at a frequency of 1 kHz. The actual value of inductance
Fundamental motor constant is the continuous stall force divided by the square root of the power
dissipated in the motor at that continuous stall force.
velocity of 1m/s.
Sleeve clogging force is the amount of force variation produced by having an iron sleeve. The
variation is independant of motor current.
varies as the motor position varies so it is the minimum value that is quoted.
Page 15
Appendices ServoTube 38 Installation Guide
TERM DESCRIPTION OF TERM
Electrical time
constant
Continuous
working voltage
Electrical time constant is the time taken for a step current input to the motor to reach 63.2% of its
value.
Continuous working voltage is the maximum allowable continuous voltage between any two motor
phases or between any motor phase and the motor safety earth.
Pole pitch Pole pitch is the distance in millimetres for one complete electrical cycle (between like magnetic
poles).
Power dissipation Power dissipation is the maximum power that can be dissipated by the motor when the motor
phases are at their maximum operating temperature, the ambient temperature is 25°C, the motor
is not moving and there is no forced cooling. It is quoted with and without the addition of a 25 x 25
x 2.5cm heatsink plate mounted with thermal grease to the mounting surface of the motor.
Maximum phase
temperature
R
thphase-houslng
Maximum phase temperature is the maximum operating temperature for the motor phases. It is
limited to provide a safe operating temperature for the magnets.
R
thphase-houslng
is the temperature rise from the motor housing to the motor phases for an input
power of 1 watt to the motor. The motor is not moving, there is no forced cooling and no additional
heatsinking.
R
thhousing-ambient
R
thhousing-ambient
is the temperature rise from ambient temperature to the motor housing for an input
power of 1 watt to the motor. The motor is not moving and there is no forced cooling. It is quoted
with and without the addition of a 25 x 25 x 2.5cm heatsink plate mounted with thermal grease to
the mounting surface of the motor.
Thermal time
constant
Thermal time constant is the time taken for the motor phases to cool to 36.8% of the difference
between motor phase and ambient temperatures when there is no current flowing, the motor is not
moving there is no forced cooling and no additional heatsinking.
ABBREVIATIONS
The abbreviations used in this Guide are listed in the following table.
A
Ampere peak PCB Printed circuit board
pk
A
AWG American Wire Gauge PVC Poly Vinyl Chloride
COS cosine s second
EMC Electro-Magnetic Compatibility TYP Typical
EMF Electro-Motive Force UL Underwriters Laboratory
mm millimetre W Watt
MTG Mounting °C degrees Celsius
Ampere root mean square PUR Polyurethane
rms
d.c. direct current SIN sine
kg kilogramme V Volt
m metre V
mA milliampere V
mH millihenry V
N Newton mm micrometre (micron)
pk-pk
Volt peak
pk
Volt peak to peak
Volt root mean square
rms
Page 16
PTC Positive Temperature Coefficient
ServoTube 38 Installation Guide Appendices
Appendix B
Troubleshooting
TROUBLESHOOTING CHART
Check to see if the problem you are experiencing is listed in the chart below. If the problem cannot be solved with
reference to this chart, contact the customer services department.
Fault Possible cause Action
Forcer/thrust rod fails to
move and produces no
force.
Forcer/thrust rod fails to
move but does produce
force.
Forcer/thrust rod moves
but is jerky in motion.
Forcer/thrust rod moves
in wrong direction.
1. Drive not powered.
2. Forcer phase connections not made.
3. Forcer over-temperature sensor not
connected.
4. Forcer over-temperature.
1. One or more motor phase connections not
made or made incorrectly.
2. One or more position sensor connections
not made or made incorrectly.
3. Forcer/thrust rod mechanically blocked.
Incorrect pole pitch set up or phase offset
between position sensor and forcer back emf.
One or more position sensor and forcer
phase connections made incorrectly.
1. Apply power to drive.
2. Check forcer phase connections on
drive.
3. Check forcer over-temperature sensor
connections on drive.
4. Allow forcer to cool.
1. Check forcer phase connections on
drive.
2. Check position sensor connections on
drive.
3. Check forcer/thrust rod is free to move.
Check drive or controller set up.
Check position sensor and forcer phase
connections on drive.
Page 17
Appendices ServoTube 38 Installation Guide
Page 18
ServoTube 38 Installation Guide Appendices
Appendix C
Technical Datasheet
ELECTRICAL SPECIFICATIONS
MOTOR TYPE 3804 3806 3808 3810 units
S (1) P (1) S (1) P (1) S (1) P (1) S (1) P (1)
Peak force @ 25oC ambient for 1 sec 744 372 1116 558 1488 744 1860 930 N
Peak current @ 25oC ambient for 1 sec 20 20 20 20 20 20 20 20 A
With 25 x 25 x 2.5 cm heatsink plate
Continuous stall force @ 25oC ambient (2) 137.3 137.3 186.9 186.9 232.1 232.1 276.2 276.2 N
Continuous stall current @ 25oC ambient 2.61 5.23 2.37 4.74 2.20 4.41 2.10 4.20 A
3.69 7.39 3.35 6.71 3.12 6.23 2.97 5.94 A
Without heatsink plate
Continuous stall force @ 25oC ambient (2) 120.1 168.2 212.7 255.0 N
Continuous stall current @ 25oC ambient 2.28 4.57 2.13 4.27 2.02 4.04 1.94 3.88 A
3.23 6.46 3.01 6.03 2.86 5.72 2.74 5.49 A
pk
rms
pk
rms
pk
Force constant (sine commutation) 52.6 26.3 78.9 39.4 105.2 52.6 131.5 65.7 N/A
37.2 18.6 55.8 27.9 74.4 37.2 93.0 46.5 N/A
Back EMF constant (phase to phase) 43.0 21.5 64.4 32.2 85.9 42.9 107.4 53.7 Vpk/m/s
Fundamental motor constant 14.54 14.54 17.80 17.80 20.56 20.56 22.99 22.99 N/ W
Eddy current loss 3.7 3.7 3.7 3.7 3.7 3.7 3.7 3.7 N/m/s
Sleeve cogging force 7.3 7.3 4.2 4.2 8.3 8.3 5.6 5.6 +/-N
Resistance @ 25oC (phase to phase) 6.77 1.69 10.16 2.54 13.54 3.38 16.93 4.23 Ohm
Resistance @ 100oC (phase to phase) 8.73 2.18 13.10 3.27 17.45 4.36 21.82 5.45 Ohm
Inductance @ 1kHz (phase to phase) 8.52 2.13 12.78 3.19 17.04 4.26 21.30 5.32 mH
Electrical time constant 1.26 1.26 1.26 1.26 1.26 1.26 1.26 1.26 ms
Continuous working voltage 380 380 380 380 380 380 380 380 V d.c.
Pole pitch (one electrical cycle) 71.2 71.2 71.2 71.2 71.2 71.2 71.2 71.2 mm
XTA Peak acceleration (3) 250 125 313 156 357 179 391 196 m/s
XTA Maximum speed (4) 4.7 4.9 3.8 5.3 3.1 4.9 2.6 4.4 m/s
XTB Peak acceleration (5) 244 122 276 138 295 147 307 154 m/s
XTB Maximum speed (4) 6.2 9.4 4.5 7.6 3.5 6.2 2.8 5.2 m/s
Notes
(1) S=series motor phases, P=parallel motor phases.
(2) Reduce continuous stall force to 89% at 40°C ambient.
rms
pk
2
2
(3) Based on a 33 mm stroke and no payload.
(4) Based on triangular move over maximum stroke and no payload.
(5) Based on a moving forcer and no payload.
Page 19
Appendices ServoTube 38 Installation Guide
THERMAL SPECIFICATIONS
MOTOR TYPE 3804 3806 3808 3810 units
Maximum phase temperature 100 100 100 100
Thermal resistance R
thphase-housing
0.23 0.16 0.13 0.11
o
C
o
C/W
With 25 x 25 x 2.5 cm heatsink plate
Power dissipation @ 25oC ambient 89.3 110.3 127.1 144.2 Watt
Thermal resistance R
thhousing-ambient
0.61 0.52 0.46 0.41
o
C/W
Without heatsink plate
Power dissipation @ 25oC ambient 68.2 89.3 107.0 123.0 Watt
Thermal resistance R
thhousing-ambient
0.87 0.68 0.57 0.50
o
C/W
Thermal time constant 1677 1798 1924 2056 s
MECHANICAL SPECIFICATIONS
MOTOR TYPE XTA 3804 XTA 3806 XTA 3808 XTA 3810 XTB 3804 XTB 3806 XTB 3808 XTB 3810 units
Maximum stroke 318 318 318 318 1362 1291 1219 1148 mm
Forcer mass 2.75 3.75 4.75 5.75 2.55 3.55 4.55 5.55 kg
Forcer mass
(including bearings)
Thrust rod
mass/metre
- - - - 3.05 4.05 5.05 6.05 kg
8.3 8.3 8.3 8.3 8.3 8.3 8.3 8.3 kg/m
Page 20
ServoTube 38 Installation Guide Appendices
POSITION SENSOR
The position sensor outputs analogue, differential sine and cosine signals for providing position feedback. Figure C.1
shows the relationships between motor phase back EMF and position sensor outputs for one direction of motion (as
shown by arrows in Figures C.1 and C.2). It should be noted that +SIN or -SIN is always in phase with motor phase U.
For the motion shown, -SIN is in phase with motor phase U. For motion in the opposing direction +SIN is in phase with
motor phase U.
Figure C.1- The relationships between motor phase back EMF and position sensor outputs
Figure C.2 - Arrows indicate direction of motion
SPECIFICATION VALUE UNITS
Output signal period 71.2 mm
Signal amplitude (between +/- signals) 1 V
Output current ±10 mA
Supply voltage 5 ± 0.25 V d.c.
Supply current (output current =0) 15 ± 5 mA
Resolution (1) 20
Position Repeatability (2) ±25
Absolute Accuracy (3) ±400
pk-pk
mm
mm
mm/m
Notes
(1) Dependent on amplifier. (2) Dependent on amplifier. Under constant operating conditions. Self-heating of the thrust rod by the motor will cause
expansion in the thrust rod during the initial warm up period. In high duty applications (corresponding to an internal motor temperature of 80°C) a 1
metre thrust rod will expand typically by 250 mm. (3) Maximum error over 1metre under constant operating conditions.
Page 21
Appendices ServoTube 38 Installation Guide
MOTOR OVER TEMPERATURE SENSOR
It is strongly recommended that the motor over-temperature sensor is connected to the drive amplifier or
servo controller at all times in order to reduce the risk of damage to the motor due to excessive temperatures.
Protection is provided by three, positive temperature coefficient (PTC) thermistors embedded in the motor phases. As
the motor phase temperature approaches 100°C, the PTC thermistors exhibit a sharp increase in electrical resistance.
This change in resistance can be detected by circuitry within the drive amplifier or servo controller and used to reduce
or disable the output of the drive amplifier in order to protect the motor.
SPECIFICATION VALUE UNITS
Resistance in the temperature range
-20oC to +70oC
Resistance at 85oC 1650 Ohms
Resistance at 95oC <3990 Ohms
Resistance at 105oC <12000 Ohms
Response time for a 20oC to 100oC
temperature step to register a trip
Maximum continuous voltage 30 Vd.c.
60 to 750 Ohms
3 s
CABLE
The XTA has two separate cables providing connections for motor power and position sensor. The standard cables
supplied are flexible but are not intended for continuous flex or energy chain applications.
SPECIFICATION POWER SENSOR
Overall diameter (nominal) 8.2 mm 7.8 mm
Outer jacket material PVC PVC
Number of conductors 4 4 x twisted pair
Size of conductors 1.5mm2 (16 AWG) 0.14mm2 (26 AWG)
Screened / Unscreened Screened Screened
Operating voltage 600 V
Minimum bending radius-fixed routing 41 mm 40 mm
Operating temperature-fixed routing -40 oC to + 90 oC -40 oC to +70 oC
UL style 2586 105 oC 600 V 21083 90 oC 300 V
rms
300 V
rms
As an option, flexible cables are available that are suitable for continuous flex or energy chain applications. These
cables are standard on the XTB.
SPECIFICATION POWER SENSOR
Overall diameter (nominal) 7.6 mm 7.8 mm
Outer jacket material PUR PVC
Number of conductors 4 4 x twisted pair
Size of conductors 1.5mm2 (16 AWG) 0.14mm2 (26 AWG)
Screened / Unscreened Screened Screened
Operating voltage 300 V
Minimum bending radius-flexible routing 38 mm 58 mm
Operating temperature-flexible routing -40 oC to + 80 oC +5 oC to +70 oC
UL style 20233 80 oC 300V 21083 90 oC 300 V
rms
300 V
rms
Page 22
ServoTube 38 Installation Guide Appendices
1
7 8
22
PL1
TB1
1 2 3
CONNECTIONS
Connections within the forcer termination box are as follows:
TB1 FUNCTION CONDUCTOR DESIGNATION
1 Motor phase U Black 1
2 Motor phase V Black 2
3 Motor phase W Black 3
Chassis Protective earth + both cable screens Green/Yellow
Figure C.4 - Power cable connection at TB1
FUNCTION CONDUCTOR DESIGNATION
1 +SIN Blue
2 -SIN Black paired with Blue
3 +COS White
4 -COS Black paired with White
5 +5Vd.c. Red
6 0V Black paired with Red
7 +TH (Thermistor) Green
8 -TH (Thermistor) Black paired with Green
Figure C.5 - Sensor cable connection at PL1 on the
Sensor PCB
Page 23
Appendices ServoTube 38 Installation Guide
XTA3804S force/velocity
PEAK
CONTINUOUS
0
100
200
300
400
500
600
700
800
0 1 2 3 4 5
Velocity (m/s)
Force (N)
XTA3804P force/velocity
PEAK
CONTINUOUS
0
100
200
300
400
0 1 2 3 4 5
Velocity (m/s)
Force (N)
XTA3806S force/velocity
PEAK
CONTINUOUS
0
200
400
600
800
1000
1200
0 1 2 3 4
Velocity (m/s)
Force (N)
XTA3806P force/velocity
PEAK
CONTINUOUS
0
100
200
300
400
500
600
0 1 2 3 4 5 6
Velocity (m/s)
Force (N)
XTA3808S force/velocity
PEAK
CONTINUOUS
0
200
400
600
800
1000
1200
1400
1600
0 1 2 3 4
Velocity (m/s)
Force (N)
XTA3808P force/velocity
PEAK
CONTINUOUS
0
200
400
600
800
0 1 2 3 4 5
Velocity (m/s)
Force (N)
XTA3810S force/velocity
PEAK
CONTINUOUS
0
200
400
600
800
1000
1200
1400
1600
1800
2000
0 1 2 3
Velocity (m/s)
Force (N)
XTA3810P force/velocity
PEAK
CONTINUOUS
0
200
400
600
800
1000
0 1 2 3 4 5
Velocity (m/s)
Force (N)
XTA FORCE / VELOCITY PROFILES (WITH AN OPERATING VOLTAGE OF 325 VD.C.)
S=series motor phases P=parallel motor phases
Page 24
Figure C.6 - XTA force / velocity profiles
ServoTube 38 Installation Guide Appendices
XTB3804S force/velocity
PEAK
CONTINUOUS
0
100
200
300
400
500
600
700
800
0 1 2 3 4 5 6 7
Velocity (m/s)
Force (N)
XTB3804P force/velocity
PEAK
CONTINUOUS
0
100
200
300
400
0 1 2 3 4 5 6 7 8 9 10
Velocity (m/s)
Force (N)
XTB3806S force/velocity
PEAK
CONTINUOUS
0
200
400
600
800
1000
1200
0 1 2 3 4 5
Velocity (m/s)
Force (N)
XTB3806P force/velocity
PEAK
CONTINUOUS
0
100
200
300
400
500
600
0 1 2 3 4 5 6 7 8
Velocity (m/s)
Force (N)
XTB3808S force/velocity
PEAK
CONTINUOUS
0
200
400
600
800
1000
1200
1400
1600
0 1 2 3 4
Velocity (m/s)
Force (N)
XTB3808P force/velocity
PEAK
CONTINUOUS
0
200
400
600
800
0 1 2 3 4 5 6 7
Velocity (m/s)
Force (N)
XTB3810S force/velocity
PEAK
CONTINUOUS
0
200
400
600
800
1000
1200
1400
1600
1800
2000
0 1 2 3
Velocity (m/s)
Force (N)
XTB3810P force/velocity
PEAK
CONTINUOUS
0
200
400
600
800
1000
0 1 2 3 4 5 6
Velocity (m/s)
Force (N)
XTB FORCE / VELOCITY PROFILES (WITH AN OPERATING VOLTAGE OF 325 VD.C.)
S=series motor phases P=parallel motor phases
Figure C.7 - XTB force / velocity profiles
Page 25
Copley
Controls
Corp.
Copley Motion Systems LLC
Luckyn Lane, Pipps Hill, Basildon, Essex SS14 3BW England
Tel: +44 (0)1268 287070 Fax +44 (0)1268 293344
Ref: UM03013/A
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