Rockwell Automation LX-Series User Manual
User Manual
LX-Series Iron Core Linear Servo Motors
Catalog Numbers
LX030100x, LX030200x, LX030300x, LX030400x, LX030600x, LX030800x,
LX050100x, LX050200x, LX050300x, LX050400x, LX050600x, LX050800x,
LX075100x, LX075200x, LX075300x, LX075400x, LX075600x, LX075800x,
LX100100x, LX100200x, LX100300x, LX100400x, LX100600x, LX100800x,
LX150100x, LX150200x, LX150300x, LX150400x, LX150600x, LX150800x,
LX200100x, LX200200x, LX200300x, LX200400x, LX200600x, LX200800x
Important User Information
IMPORTANT
Solid-state equipment has operational characteristics differing from those of electromechanical equipment. Safety
Guidelines for the Application, Installation and Maintenance of Solid State Controls (publication SGI-1.1
your local Rockwell Automation sales office or online at http://www.rockwellautomation.com/literature/
important differences between solid-state equipment and hard-wired electromechanical devices. Because of this difference,
and also because of the wide variety of uses for solid-state equipment, all persons responsible for applying this equipment
must satisfy themselves that each intended application of this equipment is acceptable.
In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from
the use or application of this equipment.
The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and
requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or
liability for actual use based on the examples and diagrams.
No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or
software described in this manual.
Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation,
Inc., is prohibited.
Throughout this manual, when necessary, we use notes to make you aware of safety considerations.
WARNING: Identifies information about practices or circumstances that can cause an explosion in a hazardous
environment, which may lead to personal injury or death, property damage, or economic loss.
available from
) describes some
ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death,
property damage, or economic loss. Attentions help you identify a hazard, avoid a hazard, and recognize the
consequence
SHOCK HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that
dangerous voltage may be present.
BURN HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that
surfaces may reach dangerous temperatures.
Identifies information that is critical for successful application and understanding of the product.
Allen-Bradley, Anorad, CompactLogix, ControlLogix, Kinetix, Log ix5000, Rockwell Automation, Rockwell Software, RS Logix 5000, TechConnect, Ultra3000, and Ultra5000 are trademarks of Rockwell Automation, Inc
Trademarks not belonging to Rockwell Automation are property of their respective companies.
Table of Contents
Preface
Safety Considerations
Start
About This Publication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Who Should Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Chapter 1
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
High Energy Magnets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Unpacking and Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Air Freight Restrictions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Vertical or Incline Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Operational Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Chapter 2
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Catalog Number Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Linear Motor Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Design Consideration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Motor Air Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Bumpers, Shock Absorbers, or End Stops . . . . . . . . . . . . . . . . . . . . . . . 17
Linear Encoder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Carriage/Heat Sink. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Motor Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Install the LX-Series Linear
Motor
LX-Series Linear Motor
Connector Data
Chapter 3
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Unpacking and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Installing Linear Motor Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Required Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Mount a Single Coil with Multiple Magnet Tracks . . . . . . . . . . . . . . 20
Mount a Single Coil with a Single Magnet Track . . . . . . . . . . . . . . . . 25
Chapter 4
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Linear Motor Coil Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Power Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Thermal Protection Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Hall Effect Module Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Feedback Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Thermal Protection Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Encoder Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Rockwell Automation Publication LX-UM001A-EN-P - March 2011 3
Table of Contents
Chapter 5
Wire the LX-Series Linear
Motor
Configure and Start Up the
LX-Series Linear Motor
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Connect the Linear Motor Coil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Signal and Wire Definitions for Flying Lead Components . . . . . . . . . . . 37
Linear Motor Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Hall Effect Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Making Your Own Extension Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Mounting and Wiring Two Identical Coils in Tandem . . . . . . . . . . . . . . 40
Cables Exit to the Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Cables Exit in the Center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Cables Exit on Opposite Ends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Chapter 6
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Motor Direction Defined. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
What You Need. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Required Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Follow These Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Update Linear Motor Database . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Set Up the Connection to Kinetix 6000, Kinetix 6500/6200, or
Kinetix 2000 Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Set Up the Connection to an Ultra3000 Drive . . . . . . . . . . . . . . . . . . . . . . 51
Verify Motor Encoder Direction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Verify Motor Encoder Resolution. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Verify Linear Motor Wiring and Function. . . . . . . . . . . . . . . . . . . . . . . . . . 54
Additional Adjustments for Cooling Plate Option . . . . . . . . . . . . . . . . . . 58
Appendix A
Interconnect Diagrams
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Wiring Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Appendix B
Sin/Cos Linear Encoder and
Kinetix 6000 Drives
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Kinetix 6000 Drive Feedback Connection . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Encoder Counting Direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Set Up the Axis Properties. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Index
4 Rockwell Automation Publication LX-UM001A-EN-P - March 2011
Preface
About This Publication
Who Should Use This Manual
Additional Resources
This manual provides detailed installation instructions for mounting, wiring, and
maintaining your LX-Series iron core linear servo motors.
This manual is intended for engineers or technicians directly involved in the
installation, wiring, and maintenance of LX-Seriesiron core linear motors.
If you do not have a basic understanding of linear motors, contact your local
Rockwell Automation sales representative for information on available training
courses before using this product.
These documents contain additional information concerning related Rockwell
Automation products.
Resource Description
LX-Series Iron Core Linear Servo Motor
Product Profile publication LX-PP001
LX-Series Iron Core Linear Servo Motor
Technical Data, publication LX-TD001
Kinetix 2000 Multi-axis Servo Drive User
Manual, publication 2093-UM001
Product highlights and catalog number
ordering key for LX-Series linear motors
Specification and outline drawings for
LX-Series linear motors
How to install, set up, and troubleshoot a
Kinetix 2000 drive
Kinetix 6000 Multi-axis Servo Drive User
Manual, publication 2094-UM001
Ultra3000 Digital Servo Drives Installation
Manual, publication 2098-IN003
Ultra3000 Digital Servo Drives Integration
Manual, publication 2098-IN005
Ultra3000 Digital Servo Drives User
Manual, publication 2098-UM001
Motion Analyzer CD, download at
www.http://ab.com/e-tools
Motion Modules in Logix5000 Control
Systems User Manual,
publication LOGIX-UM002
System Design for Control of Electrical
Noise Reference Manual,
publication GMC-RM001
Kinetix Motion Control Selection Guide,
publication GMC-SG001
Safety Guidelines for the Application,
Installation, and Maintenance of Solid State
Controls, publication SGI-IN001
How to install, set up, and troubleshoot a
Kinetix 6000 drive
How to install, set up, and troubleshoot an
Ultra3000 drive
Instruction on configuring Ultra3000 and
Ultra5000 drives, creating and configuring
project, source, and header files, and
creating and running programs
Drive and motor sizing with application
analysis software
Information on configuring and
troubleshooting your ControlLogix and
CompactLogix SERCOS interface modules,
and using the home to torque-level
sequence
Information, examples, and techniques
designed to minimize system failures
caused by electrical noise
Information about Kinetix products
Characteristics, application, installation,
and maintenance of solid state controls
Rockwell Automation Publication LX-UM001A-EN-P - March 2011 5
Preface
Resource Description
Allen-Bradley Industrial Automation
Glossary, publication AG-7.1
Rockwell Automation Product Certification
Website, publication available at
www.http://www.ab.com
National Electrical Code. Published by the
National Fire Protection Association of
Boston, MA.
Industrial Automation Wiring and Grounding
Guidelines, publication 1770-4.1
A glossary of industrial automation terms
and abbreviations
For declarations of conformity (DoC)
currently available from Rockwell
Automation
An article on wire sizes and types for
grounding electrical equipment
Provides general guidelines for installing a
Rockwell Automation industrial system
You can view or download publications at http://www.rockwellautomation.com/
literature/. To order paper copies of technical documentation, contact your local
Rockwell Automation distributor or sales representative.
6 Rockwell Automation Publication LX-UM001A-EN-P - March 2011
Safety Considerations
Chapter
1
Introduction
Labels
Table 1 - Safety Labels
Title Location Label Details
Magnetic Field
Danger
This chapter describes the safety issues encountered while using a linear motor
and the precautions you can take to minimize risk. Potential hazards discussed
here are identified by labels affixed to the device.
Topic Page
Labels 7
High Energy Magnets 9
Vertical or Incline Installation 10
Operational Guidelines 11
Here you will find the safety and identification labels affixed to your linear motor
components. To prevent injury and damage to the linear motor, review the safety
label and its details and location before using the linear motor
A The Magnetic Fields label identifies non-ionizing radiation
DANGER
MAGNETIC FIELDS
LOCATED IN THIS AREA.
Can be harmfull to
pacemakers and other
sensitive equipment.
found in the magnet tracks. Magnet tracks are constructed
with strong magnets. Strong magnets can disrupt the
functionality of automatic implantable cardioverter
defibrillators (AICD); people with a pacemaker should not
work near the magnet tracks. Maintenance personnel
working near the magnet tracks should avoid the use of
metallic tools and secure items, such as a badge clip and
other personal effects, that could be attracted by the strong
magnets. Strong magnets can erase magnetic media. Never
let credit cards or electronic media contact or come near the
magnet tracks.
.
Rockwell Automation Publication LX-UM001A-EN-P - March 2011 7
Chapter 1 Safety Considerations
D
A
C
B
Table 2 - Identification Labels
Title Location Label Details
Coil Nameplate B This nameplate shows the coil catalog number, serial
number, operating voltage, and frequency.
Magnet Track
Nameplate
RoHS Compliant D LX-Series linear motor components are RoHS compliant.
C This nameplate shows the magnet track catalog number,
serial number, operating voltage, and frequency.
RoHS COMPLIANT
Directive 2002/95/EC
Label Locations for LX-Series Linear Motor
8 Rockwell Automation Publication LX-UM001A-EN-P - March 2011
Safety Considerations Chapter 1
High Energy Magnets
Linear motor magnets contain high energy magnets that attract ferrous metals
from a considerable distance. Precautions must be taken while unpacking,
handling, and shipping by air.
Unpacking and Handling
Unpack magnet tracks one at a time. Repack magnet tracks after inspection and
before they are stocked or staged for installation. Leave protective wrapping,
cardboard, and flux containment plates in place until the magnet track is
installed. Clear the inspection and repacking area of any ferrous metals that will
be attracted to or attract the magnetic assembly. If magnet tracks must be
unpacked at the same time, maintain a distance of 1.5 m (5 ft) between
assemblies.
Air Freight Restrictions
When air freighting linear motors special preparations and precautions must be
taken. The following information outlines the basic requirements at the
publication date of this document. However, regulations are subject to change
and additional area or carrier restrictions may be imposed. Always check with
your carrier or logistics specialist regarding current local, regional, and national
transportation requirements when shipping this product.
Linear motor magnet tracks contain magnetized material, as classified by
International Air Transport Association (IATA) Dangerous Goods Regulations.
An IATA trained individual must be involved when shipping this product via
domestic or international air freight. Packing Instruction 902 provides
information regarding the preparation of this product for air transportation.
Follow these regulations for general marking and labeling requirements, the
application of specific Magnetized Material Handling Labels, and instructions for
preparing the Shipper's Declaration for Dangerous Goods.
At a minimum, refer to the following IATA Dangerous Goods Regulations:
• Subsection 1.5: Training
• Subsection 3.9.2.2: Classification as Magnetized Material
• Subsection 4.2: Identification as UN 2807, Magnetized Material, Class 9,
Packing Instruction 902
• Subsection 7.1.5: Marking
• Subsection 7.2: Labeling
• Subsection 7.4.1: Magnetized Material Label
• Section 8: Shipper's Declaration for Dangerous Goods
When shipped via ground in the United States, these products are not considered
a U.S. D.O.T. Hazardous Material and standard shipping procedures apply.
Rockwell Automation Publication LX-UM001A-EN-P - March 2011 9
Chapter 1 Safety Considerations
Vertical or Incline Installation
A linear motor driven system mounted vertically or on an incline will not
maintain position when the power is removed. Under the influence of gravity, the
motion platform and its payload will fall to the low end of travel. Design
engineers should allow for this by designing in controlled power-down circuits or
mechanical controls to prevent the linear motor driven system and its payload
from being damaged when the power fails.
ATTENTION: Linear motors are capable of high accelerations, sudden
and fast motion. Rockwell Automation is not responsible for misuse, or
improper implementation of this equipment.
ATTENTION: Linear motor driven systems must have end of travel
bumpers. They must be designed to take a large impact from uncontrolled
motion. The payload must be secured to the system such that it will not
sheer off in the event of an impact in excess of the bumper ratings.
ATTENTION: The Hall effect module contains an electrostatic discharge
(ESD) sensitive device. You are required to follow static-control
precautions when you install, test, service, or repair this assembly. If you
do not follow ESD control precautions, components can be damaged. If
you are not familiar with static control precautions, refer to Guarding
Against Electrostatic Damage, publication 8000-4.5.2
applicable ESD awareness handbook.
, or any other
BURN HAZARD: When the linear motors are running at their maximum
rating, the temperature of attached heat sinks can reach 100 ºC (212 ºF).
SHOCK HAZARD: An assembled linear motor will generate power if the
coil or magnet track is moved. Unterminated power cables present an
electrical shock hazard. Never handle flying leads or touch power pins
while moving the motor.
10 Rockwell Automation Publication LX-UM001A-EN-P - March 2011
Safety Considerations Chapter 1
IMPORTANT
Operational Guidelines
Please read and follow the guidelines shown here to safely operate the linear
motor created from these linear motor components.
ATTENTION: Observe maximum safe speed. Linear motors are capable
of very high forces, accelerations, and speeds. The maximum obtainable
acceleration and speed is based on the drive output (bus voltage and
current settings). The allowable maximum speed is application specific
and partly based on the linear motion mechanics supplied by others.
ATTENTION: Moving parts can cause injury. Before operating the linear
motor, make sure all components are secure and magnet mounting
hardware is below the magnet surface. Remove all unused parts from the
motor travel assembly to prevent them from jamming in the motor air gap
and damaging the coil or flying off and causing bodily injury.
You are responsible for making sure the servo control system safely
controls the linear motor with regards to maximum safe force,
acceleration, and speed, including runaway conditions.
A runaway condition can be caused by incorrect motor, hall effect, and
position feedback wiring resulting in violent uncontrolled motion.
ATTENTION: Keep away from the line of motor travel at all times.
Always have bumpers in place and securely fastened before applying
power to your linear motor.
ATTENTION: High voltage can kill. Do not operate with exposed wires.
Do not go near electrically live parts.
ATTENTION: Large Position Error Tolerances, such as those calculated by
the Auto Tune function in RSLogix 5000 programming software, or when
configuring a new axis with RSLogix 5000 software, can lead to
undetected and repetitive high energy impacts against axis end stops if
proper precautions are not in place. These tolerances can also lead to
undetected and repetitive high energy impacts against unexpected
obstructions. Such impacts can lead to equipment damage and/or serious
injury.
To identify the safety concerns that you have with default Position Error
Tolerance or after an Auto-Tune Function go to the Rockwell Automation
Knowlegebase. Click Find Technical Support Answers and search for
Answer Id 55937.
Rockwell Automation Publication LX-UM001A-EN-P - March 2011 11
Chapter 1 Safety Considerations
Notes:
12 Rockwell Automation Publication LX-UM001A-EN-P - March 2011
Start
Chapter
2
Introduction
Use this chapter to become familiar with the linear motor components, their
maintenance needs, and their configuration.
Topic Page
Catalog Number Explanation 14
Linear Motor Components 15
Design Consideration 16
Maintenance 18
Motor Storage 18
Rockwell Automation Publication LX-UM001A-EN-P - March 2011 13
Chapter 2 Start
UL Rating
0 = Not UL Recognized U = UL Recognized
Cable Termination
0 = Flying Leads
1 = Speedtec Circular Din-type Connector with Round
Encoder Connector
Cable Length
1 = 600 mm
2 = 1000 mm
Thermal Protection
S = Thermal Switch
T = Positive Temperature Coefficient (PTC) Thermal Sensor
Feedback
N = No Feedback
H = Hall Effect (trapezoidal)
Reserved For Future Option
0 = None
Winding Code
D = D Winding
E = E Winding
F = F Winding
G = G Winding
Coil Length
100 = 134.0 mm (5.28 in.) 400 = 434.0 mm (17.09 in.)
200 = 234.0 mm (9.21 in.) 600 = 634.0 mm (25.31 in.)
300 = 334.0 mm (13.15 in.) 800 = 834.0 mm (32.84 in.)
Frame Size
030 075 150
050 100 200
Bulletin Number
LX
LX xxx xxx x x x x x x x
LDC - x xxx xxx
Magnet Track Length
100 = 100 mm (4.15 in.)
500 = 500 mm (19.7 in.)
Frame Size
030 075 150
050 100 200
Magnet Plate Designation
M = Magnet Plate
Bulletin Number
LDC
Cooling Plate
Coil Length
100 = 134.0 mm (5.28 in.) 400 = 434.0 mm (17.09 in.)
200 = 234.0 mm (9.21 in.) 600 = 634.0 mm (25.31 in.)
300 = 334.0 mm (13.15 in.) 800 = 834.0 mm (32.84 in.)
Frame Size
030 075 150
050 100 200
Bulletin Number
LDC
LDC - xxx - xxx - CP
Catalog Number Explanation
An iron core linear motor is comprised of a coil and one or more magnet tracks.
The fo llowi ng ke ys s how the cata log defini tion for the L X-Serie s linear motors.
14 Rockwell Automation Publication LX-UM001A-EN-P - March 2011
Start Chapter 2
1
2
3
5
6
7
LDC-M050500
Magnet Track Shown
LX050200xxxxx1x
Motor Coil Shown
4
Linear Motor Components
Use the diagrams and descriptions to identify the unique components of the
linear motor.
Figure 1 - Components of Iron Core Motor Coil and Magnet Track
Component
Number
1 Iron core motor coil
2 Magnet track High powered static magnets create the flux field the powered coil interacts with.
3 Encoder connector
4 Feedback connector
5 Power connector
6 Thermal protection connector Connects the thermal protection signal to the feedback connector.
7 Hall effect module
Component Description
Copper coils are contained in an epoxy form. When powered, the coil interacts with
the flux field of the magnet track.
Connect your encoder here by using the connector kit, catalog number LDC-ENCCNCT.
Connect to your drive feedback by using either catalog number 2090-CFBM7DFCDAFxx (for moving coil) or 2090-XXNFMF-Sxx (for moving magnet).
Connect to your drive power by using either catalog number 2090-CPWM7DFxxAFxx (for moving coil) or 2090-XXNPMF-xxSxx (for moving magnet).
This module provides input signals for commutation startup. Replacement catalog
numbers for the Hall effect module are LDC-HALL-C for the LXxxxxxxxxxx1x and
LDC-HALL-F for the LXxxxxxxxxxx0x.
Rockwell Automation Publication LX-UM001A-EN-P - March 2011 15
Chapter 2 Start
Overall dimension with cooling plate.
Overall dimension
without cooling plate.
1
2
3
Design Consideration
The information provided here is critical to using linear motor components.
Design your system to comply with the following points to run safely and
successfully.
Motor Air Gap
Maintaining the air gap is critical to proper installation and operation of the
linear motor components. Use the coil, and magnet drawings in the LX-Series
Iron Core Linear Servo Motor Technical Data, publication LX-TD001
cooling plate drawings in the Kinetix Motion Control Selection Guide,
publication GMC-SG001
to calculate the installation envelope dimension. Size
the carriage, bearings, and base plate to withstand the force of attraction between
the coil and magnet track. By maintaining the installation envelope dimension in
your design, the vertical air gap requirement will be met. The following diagram
shows the critical dimensions.
and the
Item Description
1 Magnet track
2Coil
3 Optional cooling plate assembly
16 Rockwell Automation Publication LX-UM001A-EN-P - March 2011
Start Chapter 2
1
1
3
4
2
Bumpers, Shock Absorbers, or End Stops
Include in your design a mechanical stop at each end of travel. Design the stops so
they can prevent the moving mass from leaving its travel limits. Take into
consideration the maximum speed and inertia of your moving mass when
designing your mechanical stops. The following diagram shows a minimal system
with mechanical stops.
Figure 2 - Mechanical Stops
Item Description
1 Mechanical stops
2 Carriage/heat sink
3 Encoder readhead
4 Encoder strip
Linear Encoder
Your linear motor components need to be integrated with a linear encoder
purchased from a third party.
Carriage/Heat Sink
The linear motor coil requires a heat sink to maintain performance. The heat sink
requires a minimal mass and surface area as shown in LX-Series Iron Core Linear
Servo Motor Technical Data, publication LX-TD001
carriage in a moving coil system or be designed into the base in a moving magnet
system.
. It can also serve as the
Rockwell Automation Publication LX-UM001A-EN-P - March 2011 17
Chapter 2 Start
Maintenance
Motor Storage
Linear motors require no maintenance when operated in relatively clean
environments. For operation in harsh and dirty environments, we recommend
cleaning every 6 months.
Clean the metallic debris and other contaminants from the air gap. Use a strip of
masking tape to remove the metal debris. Apply a strip of tape on the magnet
track and 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.
The motor storage area should be clean, dry, vibration free, and have a relatively
constant temperature. If a motor is stored on equipment, it should be protected
from the weather. All motor surfaces subject to corrosion should be protected by
applying a corrosion resistant coating.
18 Rockwell Automation Publication LX-UM001A-EN-P - March 2011
Install the LX-Series Linear Motor
Chapter
3
Introduction
Unpacking and Inspection
In this section you will unpack, inspect, and install your linear motor components
by creating your own linear motor.
Topic Page
Unpacking and Inspection 19
Installing Linear Motor Components 20
Mount a Single Coil with Multiple Magnet Tracks 20
Mount a Single Coil with a Single Magnet Track 25
Read the following guidelines to handle magnet tracks carefully.
ATTENTION: Linear motors contain powerful permanent magnets
which require extreme caution during handling. When handing
multiple magnet tracks do not allow the tracks to come in contact
with each other. Do not disassemble the magnet tracks. The forces
between tracks are very powerful and can cause bodily injury.
Persons with pacemakers or Automatic Implantable Cardiac
Defibrillator (AICD) should maintain a minimum distance of 0.33 m
(1 ft) from magnet assemblies. Additionally, unless absolutely
unavoidable, a minimum distance of 1.5 m (5 ft) must be
maintained between magnet assemblies and other magnetic/
ferrous composite materials. Use only non-metallic
instrumentation when verifying assembly dimension prior to
installation.
Inspect motor components and verify they are damage free. Any damage or
suspected damage should be immediately documented. Claims for damage due to
shipment are usually made against the transportation company. Contact
Rockwell Automation for further advice:
• Compare the purchase order with the packing slip.
• Check the quantity of magnet tracks received matches your job
requirements.
• Identify the options that came with your linear motor.
• Inspect the assemblies and confirm the presence of specified options.
Rockwell Automation Publication LX-UM001A-EN-P - March 2011 19
Chapter 3 Install the LX-Series Linear Motor
IMPORTANT
TIP
IMPORTANT
Installing Linear Motor Components
Use one of the following procedures to install the magnet track or tracks and the
motor coil.
Required Tools
• Aluminum straight edge
• Non-magnetic M4 or M5 hex wrench
• Magnet channel alignment tool
The alignment tool is shipped attached to the cables next to the
Hall effect module. Remove before operating the linear motor.
Use non-magnetic tools and hardware made of beryllium
copper, 300 series stainless steel. If these tools are not
available, proceed carefully as the magnet track attracts
magnetic and ferrous items.
Mount a Single Coil with Multiple Magnet Tracks
Follow these steps to install a single coil with multiple magnet tracks.
ATTENTION: To avoid damage due to the magnetic attraction
between the magnet tracks, maintain a minimum distance of 1.5 m
(5 ft) between the magnet tracks that are being installed and the
magnet tracks awaiting installation. Keep the protective cardboard
and the metal plate in place until the installation is complete.
ATTENTION: Never attempt to place the coil assembly directly on
the magnet plates. Strong magnetic attraction will cause
uncontrolled movement causing a pinch hazard and possible
damage to the components.
1. Clear the magnet track mounting surface of foreign material.
If necessary stone the mounting surface, acetone or methanol may be
applied as cleaning agent.
Do not use abrasives to clean the surface.
2. Verify the flatness of the surface to which the magnet track is to be
mounted.
Total Indicator Reading (TIR) is 0.127 mm (.005 in.) per
300 mm (12.0 in.). TIR or runout correlates to the overall flatness
requirement of the surface.
20 Rockwell Automation Publication LX-UM001A-EN-P - March 2011
Install the LX-Series Linear Motor Chapter 3
3. Verify the dimension of the opening for the magnet track, coil, and cooling
plate if used.
4. Remove all burrs and clean the motor coil mounting surface.
5. Position the carriage toward the end of travel where you want the cable to
exit.
6. Install the motor under the carriage, using M5 x 0.8 bolts that extend
through the slide by at least 12 mm (0.5 in.), but no more then
20 mm (0.7 in.).
7. Tighten the screws but do not torque.
Rockwell Automation Publication LX-UM001A-EN-P - March 2011 21
Chapter 3 Install the LX-Series Linear Motor
IMPORTANT
3
2
Alignment Holes
8. On the opposite end of the base, install the first magnet track using
M5 x 0.8 x 16 mm Socket Head Captive Screw (SHCS).
Do not tighten screws.
Use non-magnetic tools and hardware such as beryllium copper,
300 series stainless steel. If not available proceed with care
since ferrous items will be attracted to the magnet tracks.
9. Install additional magnet tracks.
Place each magnet track on the base and slide towards the previously install
magnet track. For correct magnetic polarity the alignment holes should all
be on the same side.
22 Rockwell Automation Publication LX-UM001A-EN-P - March 2011
Install the LX-Series Linear Motor Chapter 3
Shim
4
5
6
10. Move the carriage with motor coil installed over the installed magnet
tracks.
There may be some resistance while moving onto the tracks, this is normal.
11. Measure the gap between the motor coil and magnet track using plastic
shim stock.
The gap should be 0.79 mm (0.031 in.) to 1.70 mm (0.067 in.). If gap is
too large, add a brass or a stainless steel shim between the motor coil and
carriage. If the gap is too small, machine the slide or place shims under the
bearing pucks.
12. Install the remaining magnet tracks in the order shown.
13. Slightly loosen the mounting screws on the exposed magnet tracks.
Do not loosen the magnet tracks that are covered by the motor coil.
Rockwell Automation Publication LX-UM001A-EN-P - March 2011 23
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