Rockwell Automation LC-Series User Manual

ANORAD

LC Series Linear Motors

USER MANUAL

October 2006

Item Number 814036

Publication Number LC-UM001C-EN-P

i

Important User Information

Because of the variety of uses for the products described in this publication,
those responsible for the application and use of this motor assembly must
satisfy themselves that all necessary steps have been taken to assure that each
application and use meets all performance and safety requirements, including
any applicable laws, regulations, codes and standards.

The illustrations, charts, sample programs and layout examples shown in this
guide are intended solely for purposes of example. Since there are many
variables and requirements associated with any particular installation, Anorad
does not assume responsibility or liability (to include intellectual property
liability) for actual use based upon the examples shown in this publication.

Reproduction of the contents of this copyrighted publication, in whole or part,
without written permission of Anorad Corporation, is prohibited.

Throughout this manual we use notes to make you aware of safety
considerations:

ATTENTION

Identifies information about practices or circumstances
that can lead to personal injury or death, property damage
or economic loss

!

Attention statements help you to:

• identify a hazard

• avoid a hazard

• recognize the consequences

IMPORTANT

Identifies information that is critical for successful
application and understanding of the product.

Item Number 814036 - Rev C

Table of Contents

Important User Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i

Introduction

Using This Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Product Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Product Line Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Motor Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Installation

Unpacking and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

Identifying the Linear Motor Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Coil Assembly (example) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Magnet Track Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Cooling Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Motor Layout Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3

Motor Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-15

Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-15

Motor Air Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

Motor Mechanical Installation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

Electrical Wiring/Interface Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-19

Motor/Hall Phasing and Sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-21

Operational Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-22

Motor (Coil) Thermal Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-23

Troubleshooting

Hall Effect/Thermal Signal Module Troubleshooting and Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

Troubleshooting the module: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Removal/Installation of the Hall Effect Module: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Basic Motor Checks - Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3

Coil Resistance Measurements - Ohmmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Motor Back EMF Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4

Waveshape/Phasing and Calculating Back EMF Constant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Back EMF Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Calculating the Back EMF Constant: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Checking the Magnet Plate Butting Polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6

Item Number 814036 - Rev C

iii

Item Number 814036 - Rev C

Introduction

Chapter

1

Using This Manual

Product Description

This motor manual is designed to help you install, integrate and start-up your
new Anorad Linear Motor. You do not have to be an expert in motion control.
However, this manual does assume you have a fundamental understanding of
basic electronics, mechanics, as well as motion control concepts and applicable
safety procedures.

The intent of this manual is to assist the user in the mechanical and electrical
installation of the Anorad LC Series Linear Motor.

Read this entire manual before you attempt to install your linear motor into
your motion system. Doing so will familiarize you with the linear motor
components and their relationship to each other and the system

After installation, check all system parameters to insure you have configured
your linear motor into your motion system properly.

Be sure to follow all instructions carefully and lastly but foremost pay special
attention to safety concerns.

General

The LC Linear Motor Series is described in this section. Product features are
explored and the part numbering system is explained. This basic information
will help you develop an understanding of the linear motor’s basic
configuration. This configuration information is then used as the fundamental
understanding required to guide you through the rest of this manual.

Product Line Description

Anorad's LC Series of steel core linear motors represents the most advanced
linear motor technology available. The LC linear motor utilizes a unique patent
pending laminated steel core design. Coupled with the latest magnetic
materials and optimized by Finite Element Analysis (FEA), a very high force
density is achieved. The LC Linear Motors ares available in models with
continuous forces from 84.5 N to 5658 N, (19 lbf to 1272 lbf), and peak forces
from 195.7N to 9314 N, (44 lbf to 2094 lbf). Other frame sizes are available
with higher forces.

1 Item Number 814036 - Rev C

1-2 Introduction

For servo drives that require commutation feedback, an optional trapezoidal
(digital) Hall effect feedback module may be attached to the front of the motor
coil. The LC may also be commutated via software. Anorad offers a full line of
compatible servo controls and drives.

Motor Features

• Steel core design for high force density

• Sinusoidal flux density and low-cog design yields smooth motion

• Robust design for heavy duty applications

• Modular magnet tracks permit unlimited travel

• Internal thermal sensor gives added motor protection

Maintenance

Anorad linear motors require no maintenance when operated in a relative clean
environment. For operation in harsh and dirty environments minimal clean is
recommended every 6 months:

• Clean the metallic debris and other contaminants from the air gap. To
effectively remove the metal debris use a strip of masking tape.
Simply put a strip of tape on the magnet track an then remove it.
Keeping the magnet track clean will prevent witness marks. Witness
marks are caused by metal debris being dragged across the surface of
the stainless steel by the magnet field of the moving coil. Witness
marks have no effect on the performance of the motor.

Item Number 814036 - Rev C

Installation

Chapter

2

Unpacking and Inspection

Inspect motor assemblies to make certain no damage has occurred in
shipment. Any damage or suspected damage should be immediately
documented. Claims for damage due to shipment are usually made against the
transportation company. Also contact Anorad immediately for further advise.

ATTENTION

!

Identify what options your linear motor is equipped with. Ensure the
information listed on the purchase order correlates to the information on the
packing slip that accompanied your motor components Verify that the quantity
of magnet plates received matches your job requirements. Inspect the
assemblies and confirm, if applicable, the presence of specified options.

Linear Motors contain powerful permanent magnets which
require extreme caution during handling. When handing
multiple magnet plates do not allow the plates to come in
contact with each other. Do not disassemble the magnet
plates. The forces between plates are very powerful and can
cause bodily injury. Persons with pacemakers or Automatic
Implantable Cardiac Defibrillator (AICD) should maintain
a minimum distance of 12 inches from magnet assemblies.
Additionally, unless absolutely unavoidable, a minimum
distance of 5 feet must be maintained between magnet
assemblies and other magnetic/ferrous composite
materials. Use only non-metallic instrumentation when
verifying assembly dimension prior to installation (e.g.
calipers, micrometers, laser equipment, etc.)

1 Item Number 814036 - Rev C

2-2 Installation

Identifying the Linear Motor

Coil Assembly (example)

Typ e

LC-030-100-D-0-T-TR-0

Special Configurations: Blank = Standard

UL Rated: Blank = Not UL Rated; UL = UL Rated

Cable Length: 0 = 300 mm; 1 = 600 mm; 2 = 1000 mm

Thermal Sensor: TR = PTC Thermal Sensor;
TS = Thermal Switch

Feedback: 0 = none; T = Trapezoidal Hall Effect

Cooling: 0 = No Cooling

Winding Code: D, E

Coil Length: 100 = 100 mm; 200 = 200 mm; 300 = 300
mm; 400 = 400 mm; 600 = 600 mm; 800 = 800 mm

Frame Size: 030, 050, 075, 100, 150, 200

Model

Magnet Track Only

LCM-030-100-C

Cooling Plate

LCCP-030-100-AC

Special Configurations: Blank = Standard

Magnet Cover: C = Cover Standard)

Magnet Track Length: 100 = 100 mm; 250 = 250
mm; 400 = 400 mm; 500 = 500 mm

Frame Size: 030, 050, 075, 100, 150, 200

Model

Cooling: AC = Air Cooling; WC Water Cooling

Magnet Track Length: 100 = 100 mm; 250 = 250
mm; 400 = 400 mm; 500 = 500 mm; 600 = 600
mm; 800 = 800 mm

Frame Size: 030, 050, 075, 100, 150, 200

Item Number 814036 - Rev C

Model

Installation 2-3

Motor Layout Drawings

15.00
[0.591]

+1.00

65.00
0

+0.039

[2.559

]

-0.000

M5 X 0.8 X 15MM TOTAL DEPTH

THREADS START 5MM DEEP

25.00

[0.984]

15.00

[0.591]

11.50

[0.453]

SEE TABLE FOR QTY

Ø5.50 [0.216]

Figure 2.1 LC-30 Coil and Cooling Plate Drawing

Dimensions mm [in]

H

G

F

E

D

C

B

A

66.67

[2.625]

L

H

G

F

E

L

D

C

B

A

66.67

[2.625]

33.65

[1.325]

X

33.65

[1.325]

8.00

[0.315

30.0

[1.18]

±0.13

±0.005]

53.72

±0.13

[2.115

±0.005]

45.72

±0.13

±0.005]

[1.800

OPTIONAL COOLING

PLATE ASSEMBLY

(Ø.25" TUBING)

[1.181]

30.00
OPTIONAL HALL
EFFECT MODULE
Ø6.0 [0.24] CABLE
(FLYING LEADS)

THERMISTOR CABLE
Ø3.0 [0.12]
(FLYING LEADS)
POWER CABLE
4 COND SHIELDED
SEE TABULATION
(FLYING LEADS)

SEE TABULATION

27.5

[1.08]

38.00

[1.496]

6.35

Ø
[0.250]
OD COPPER
TUBING

REF AIR GAP

1.22 ±0.42
[.045 ±0.16]

60.00

[2.362]

31.24

[1.230]

-A-

REF

Table 2.A LC-30 Coil and Cooling Plate Dimensions

Coil Size L A B C D E F G H Hole Qty

(N)

30 x 100 134.00

4 0.25

(5.28)

30 x 200 234.00

(9.21)

30 x 300 334.00

(13.15)

30 x 400 434.00

(17.09)

30 x 600 634.00

(25.31)

30 x 800 834.00

(32.84)

100.00
(3.937)

133.33
(5.249)

133.33
(5.249)

133.33
(5.249)

133.33
(5.249)

166.67
(6.562)

200.00
(7.874)

233.33
(9.186)

233.33
(9.186)

233.33
(9.186)

266.67
(10.499)

300.00
(11.811)

333.33
(13.123)

333.33
(13.123)

366.67
(14.436)

433.33
(17.060)

433.33
(17.060)

500.00
(19.686)

533.33
(20.997)

566.66
(22.310)

633.33
(24.934)

700.00
(27.559)

766.66
(30.184)

80.25

10 0.38

12 0.64

16 0.89

20 1.16

Item Number 814036 - Rev C

Flatness

-A-

(0.010)

(0.010)

(0.015)

(0.025)

(.035)

(.045)

2-4 Installation

Figure 2.2 LC-30 Magnet Channel Layout Drawing

60.00

[2.362]

24.50

[0.965]

48.00

[1.890]

6.00

[0.236]

50.00

[1.969]

"N" PLACES

12.50
[0.492]

L +/- 0.25 [+/- 0.010]

Track #1 Track #2

Y +/- 0.08 [+/- 0.003]

AIR GAP WILL RESULT FROM

SETTING THE PLATES TO SETUP

DIMENSION SHOWN

Table 2.B LC-30 Magnet Track Dimensions

Magnet Track

LYHole

Length

100 mm 99.0

(3.90)

250 mm 249.0

(9.80)

400 mm 399.0

(15.71)

75.00
(2.953)

225.00
(8.853)

375.00
(14.764)

Ø5.50 [0.216] THRU
C'BORE Ø9.50 [0.375] X 5.0 [0.197] DP

50.0
[1.969]
MOUNTING HOLE
DIMENSION

25.00
[0.984]
SETUP
DIMENSION

SEE CHART FOR QTY

13.26

±0.16

[0.522

±0.006]

+0.026

Ø

3.988

-0.000

+0.0010

]

[0.1570

-0.0000

8.00

[0.315]

-A-

N Flatness

Qty

-A- TIR

410.06
(.002)

10 4 0.25

(.010)

16 7 0.38

(.015)

500 mm 499.0

(19.65)

475.00
(18.750)

20 9 0.50

(.020)

Item Number 814036 - Rev C

25.00

[0.984]

+1.00

85.00
0

+0.039

[3.346

]

-0.000

30.00

[1.181]

M5 X 0.8 X 15MM TOTAL DEPTH

THREADS START 5MM DEEP

Figure 2.3 LC-50 Coil and Cooling Plate Drawing

Dimensions mm [in]

H

G

F

E

D

C

B

A

66.67

[2.625]

L

33.65

[1.325]

X

Installation 2-5

53.72 ±0.13

[2.115 ±0.005]

45.72 ±0.13

[1.800 ±0.005]

OPTIONAL COOLING

PLATE ASSEMBLY
(Ø 0.25" TUBING)

30.00
[1.181]
OPTIONAL HALL
EFFECT MODULE
Ø6.0 [0.24] CABLE
(FLYING LEADS)

THERMISTOR CABLE
Ø3.0 [0.12]

(FLYING LEADS)

POWER CABLE
4 COND SHIELDED
SEE TABULATION
(FLYING LEADS)

SEE TABULATION

REF AIR GAP

1.22 ±0.42
[0.045 ±0.16]

80.0
[3.15]

31.24
[1.230]

-A-

REF

25.00

[0.984]

12.50

[0.492]

SEE TABLE FOR QTY

Ø5.50 [0.216]

H

G

F

E

D

C

B

A

66.67

[2.625]

L

8.00 ±0.13

[0.315 ±0.005]

33.65

[1.325]

[1.18]

30.0

38.1

[1.50]

[1.969]

6.35

Ø
[0.250]

OD COPPER

TUBING

50.00

Item Number 814036 - Rev C

2-6 Installation

Table 2.C Coil and Cooling Plate Dimensions

Coil SizeLABCDEFGHHole Qty

(N)

50 x 100 134.00

40.25

(5.28)

50 x 200 234.00

(9.21)

50 x 300 334.00

(13.15)

50 x 400 434.00

(17.09)

30 x 600 634.00

(25.31)

30 x 800 834.00

(32.84)

100.00
(3.937)

133.33
(5.249)

133.33
(5.249)

133.33
(5.249)

133.33
(5.249)

166.67
(6.562)

200.00
(7.874)

233.33
(9.186)

233.33
(9.186)

233.33
(9.186)

266.67
(10.499)

300.00
(11.811)

333.33
(13.123)

333.33
(13.123)

366.67
(14.436)

433.33
(17.060)

433.33
(17.060)

500.00
(19.686)

533.33
(20.997)

566.66
(22.310)

633.33
(24.934)

700.00
(27.559)

766.66
(30.184)

80.25

10 0.38

12 0.64

16 0.89

20 1.16

Flatness

-A-

(0.010)

(0.010)

(0.015)

(0.025)

(0.035)

(0.045)

Figure 2.4 LC-50 Magnet Track Drawing

Ø5.50 [.216] THRU
C'BORE Ø9.50 [.375] X 5.0 [.197] DP
SEE CHART FOR QTY

24.50

[0.965]

50.00

[1.969]

"N" PLACES

L +/- 0.25 [+/- 0.010]

50. 00
[1.969]
MOUNTING HOLE
DIMENSION

13.26 ±0.16

[0.522 ±0.006]

80.00
[3.150]

68.00

[2.677]

6.00

[0.236]

12.50

[0.492]

Track #1 Track #2

+/- 0.08 [+/- 0.003]

Y

AIR GAP WILL RESULT FROM

SETTING THE PLATES TO SETUP

DIMENSION SHOWN

Table 2.D Magnet Track Dimensions

Magnet Track

L Y Hole Qty N Flatness -A-

Length

100 mm 99.0

(3.90)

250 mm 249.0

(9.80)

400 mm 399.0

(15.71)

500 mm 499.0

(19.65)

75.00
(2.953)

225.00
(8.853)

375.00
(14.764)

475.00
(18.750)

410.06

10 4 0.25

16 7 0.38

20 9 0.50

25.00
[0.984]
SETUP
DIMENSION

Ø 3.988

[0.1570

TIR

(.002)

(.010)

(.015)

(.020)

+0.026

-0.000

+0.0010

-0.0000

[0.315]

]

8.00

-A-

Item Number 814036 - Rev C