Assun AM-CL2242MAN Series User manual

Assun Motor
Product Manual
For Metal Brush DC Motor
of
AM-CL2242MAN Series
2nd edition. 28 Aug 2023
All Rights Reserved
Assun Motor Pte Ltd
Shenzhen Zhengyuan Motor Co., Ltd

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Contents
Assun Motor ............................................................................................................................................................ 1
Product Manual ...................................................................................................................................................... 1
1. About the Manual....................................................................................................................................... 3
1.1 Validity of This Document ......................................................................................................... 3
1.2 Using This Document .................................................................................................................. 3
1.3 Definition of Terms ...................................................................................................................... 3
1.4 Definition of Symbols .................................................................................................................. 4
2. Product Safety .............................................................................................................................................. 5
2.1 Intended Product Usage ............................................................................................................ 5
2.2 Product Usage Safety .................................................................................................................. 6
2.3 Product Disposal/Recycling ...................................................................................................... 7
3. Product Series Information ...................................................................................................................... 8
3.1 Product Series Structure Introduction ................................................................................... 8
3.2 Product Model Information ...................................................................................................... 9
4. Product Function and Usage ............................................................................................................... 10
4.1 Motor Installation and Power Connection ........................................................................ 10
4.2 Motor Functions......................................................................................................................... 11
5. Maintenance .............................................................................................................................................. 12
Contact ................................................................................................................................................................. 13
Singapore ................................................................................................................................................... 13
China…………………………………………………………………………………………………………………………………13

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1. About the Manual
1.1 Validity of This Document
The manual is for the AM-CL2242MAN series product manufactured by Assun Motor which is a
direct current Metal brush motor. The manual contains detailed descriptions of the safety and
functional usage of this motor product series. It helps the user install and connect the motor and
also guides the user in relevant control function usage.
All data in this manual are based on the actual manufacturing and standard testing of the AM-
CL2242MAN series product. The standard testing condition is when the motor is installed
horizontally and subjected to an environment temperature of 25℃.
For relevant parameter summaries of the product series, please go to the required product on
our website and download the “Product Sheet”. For customized parameters or dimension, please
contact our sales personnel.
1.2 Using This Document
Please read this document carefully before installing and setting up the product and pay attention
to the second chapter under “Product Safety”, and strictly follow the warnings and instructions.
Please retain this document throughout the entire working life of the product, and keep the
document accessible to the operating and, if necessary, maintenance personnel at all times.
1.3 Definition of Terms
Term Meaning
PWM Pulse Width Modulation
CW/CCW Clockwise/Counter Clockwise
FG Pulse Frequency Generator Pulse

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VIL/VIH Voltage Input Low / Voltage Input High
Pin Control Function Connect Pin
Cable Power Connection Cable
GND Ground / Negative Pole
Vcc Direct Current Voltage
RPM Revolution per Minute
1.4 Definition of Symbols
Caution! Hazard to persons. Disregarding may lead to injury.
Warning! Improper operation will damage the product
. Caution! Hazardous due to hot surface.

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2. Product Safety
2.1 Intended Product Usage
The Assun Motor AM-CL2242MAN series DC brushed coreless motor product, which we are
describing here in this manual, is used for rotating under a DC supply. It is suitable for different
types of DC driving systems, such as automation system actuators and many other precision
driving systems. There are no internal electronics in the motor. Metal brushes and commutators
work together to achieve current direction change and keep the rotor rotating. Functions such as
PWM speed control, CW/CCW direction change, RPM output signal, and Brake and Servo Control
(Torque, Speed & Position) can be achieved after connection with a suitable controller and/or
encoder.
The product must be properly installed when in use and shall be operated in an environment with
good heat dissipation conditions. In normal installation conditions, when the operational
parameters have not exceeded the maximum continuous values, the winding temperature must
be maintained below 85℃. The product can be used alone or coupled to a gearbox to achieve
the required output torque and RPM.
The product is not suitable for operation in environments with high humidity or excessive dust.
During the operation, please adhere to the parameter limits as shown in the Product Sheet by
adjusting the power supply and running state, to achieve the optimum operational output and
longer product life.
For usage of the product in a special environment, please contact our local sales or service staff
for consultation and get relevant advice or customized service.
This product is NOT SUITABLE for applications where the failure of the product could result in the
death of an individual or group of individuals.

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2.2 Product Usage Safety
The product is a high-speed rotating device. Please make sure the product is properly mounted
before operation to prevent potential hazards to people or equipment. Please refer to Chapter
4.1 of this manual for further installation guidance.
The motor surface temperature could be high after long-term operation. Please exercise caution
when touching or handling the product.
The power supply must be filtered DC. The input voltage must be within the rated value for normal
operation. The current cannot be over the rated value continuously to avoid overheating and
damaging the motor components.
Please install the motor in an environment with a good heat sink and/or ventilation. Inadequate
heat dissipation will lead to the motor winding temperature exceeding the limit of 85℃ and will
cause thermal damage to the internal electronic parts and winding, resulting in motor malfunction
and/or failure.

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Please use the motor according to the parameter limits in the spec, otherwise, it may cause the
motor to exceed current limits or overheat, which could lead to irreversible damage to the
motor.
The motor is not suitable for operating in highly humid and dusty environments. High humidity
or excessive dust concentration could lower the motor's performance and shorten the motor’s
lifespan.
The product is a precision Brushed DC motor with high-accuracy assembly requirements.
Please do not disassemble the product on your own.
2.3 Product Disposal/Recycling
This series of motor products are manufactured with different types of metals, alloy materials,
chemical adhesives, and lubricants. Please dispose it properly as recyclable material. For a detailed
product material listing please refer to Chapter 3.1.

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3. Product Series Information
3.1 Product Series Structure Introduction
AM-CL2242MAN series products are a series of precision DC brushed motors with coreless and
self-supporting rotors. The casing diameter is φ22mm, length is 42mm, and rated power is 4.8W
– 9.2W, with a net weight of approximately 80g. For detailed series information and parameters
please refer to the “Product sheet” on our website.
The series product is an inner rotor brushed DC motor, relying on the brushed and commutators
to change winding current directions and thus attract the permanent magnetic rotors to rotate in
synchronization. The product's basic structure is depicted in illustration 1.
Illustration 1. Exploded Product View
This series of products is manufactured using different types of metal, alloy material, and chemical
products. Specific material usage is shown in Table 1.

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Table 1. Product Material Matrix
Part End Cover Winding Bearing Magnet Shaft Housing
Material
Stainless
Steel Copper Stainless Steel NdFeB Stainless Steel Aluminium Alloy
Part Brush Commutator Adhesive Grease Cushion Others
Material
Precious
Metal Copper Epoxy Resin
Fluorine
Grease
Stainless
Steel
Other Metal and
Plastic
3.2 Product Model Information
To make it convenient for the customer to choose a specific part number or model and
understand the part number methodology, please refer to Illustration 2 below for the explanation
of the model number composition principle.
Illustration 2. Part Number Nomenclature
Customers can choose suitable products based on their types and characteristics shown in the
part naming methodology. If products with special characteristics are required, please contact
our regional salesperson for customized service.

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4. Product Function and Usage
The series of products have two power-connecting metal plates at the rear end, connecting to
the DC power supply positive and negative. Customers could choose to have a rear shaft or not
to have a rear shaft. Rear shaft is needed when the motor is working with the encoder. When an
encoder is not needed, the motor usually does not have a rear shaft.
The motor is using ball bearings thus there will be a boss in both the front and back cover. When
connecting to a gearbox or encoder, the customer should consider the boss dimension to comply.
There are threaded holes on the front/back cover for connection to the gearbox/encoder.
Note: The motor power supply should be connected according to the guidance for the motor to
rotate in a Clockwise direction. CW/CCW direction is defined when looking from the front end of
the motor. When the power supply is reversed, the motor will rotate in Counter Clockwise
direction.
Typically we propose to operate the motor in CW direction.
4.1 Motor Installation and Power Connection
The motor must be properly and securely mounted, typically utilizing the threaded holes in the
front cover to fix the motor. It will be proposed to install the motor to metal parts, or installed in
well-ventilated environments for better heat dissipation.
There are two copper plates at the end of the motor and perpendicular to the end cover in default
condition, but when installed with an encoder or used in other space-limiting conditions the
plates will go sideways. The power cable shall be connected to the copper plates according to
the marking on the end cover so that the motor will rotate in the CW direction. If the power
supply is reversed, the motor will rotate in the CCW direction. After the motor is installed, double-
check the rotating direction. Wrong rotating direction using the wrong cable connection may
damage the relevant equipment.

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4.2 Motor Functions
When the motor is connected to the controller with the PWM function, the motor speed can be
controlled. The percentage of low input voltage is regarded as the duty cycle. The higher the duty
cycle, the higher the motor's rotating speed will be. When the duty cycle reaches 100%, the motor
reaches its top speed. When the duty cycle is lower than 5%, the motor will stop running.
Note: Please avoid setting the duty ratio below 5%. When the duty cycle is needed to be lower
than 5%, please set it directly to 0%.
When a motor is not connected to the controller with rotation direction control, the motor will be
able to rotate in CW/CCW directions manually.
Note: When the rotating speed is over 100 rpm, please take precautions: do not reverse the
motor direction while the motor is rotating! It is highly recommended to stop the motor before
reversing the motor rotational direction.
When a motor is connected to a controller with a brake function, the motor will be controlled by
the brake accordingly.
Note: When using the brake function, the motor power supply voltage will rise due to the motor's
back EMF adding to the supply voltage. The user shall test and adjust the speed for the motor to
start braking based on the specified load condition. To prevent the voltage from going too high
when braking, please set the motor to start braking at a lower speed to protect the motor and
electronics components.
When the motor is connected to the Servo Controller, control of Speed, Torque, and Position can
be achieved. When under servo control, the torque, speed, and power shall not exceed the
motor’s rated value. If the motor needs to operate beyond the rated value, please contact our
company for more detailed information.

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5. Maintenance
The product series is maintenance free, please do not disassemble on your own. There are no
repairable components inside the motor. Regarding any quality issue or maintenance needs,
please contact our regional service person for relevant technical support.
Ignoring this warning will void the warranty.

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Contact
Singapore
Tel: [phone]
Email: [e-mail]
Add: 1092 Lower Delta Road, #06-05, Singapore 169203.
China
Tel: [phone]
Email: [e-mail]
Add: 7th Floor, Blk 6, Yongping Industrial Area, 9 Tongfu Road. Shenzhen, P.R.China.