Genesis LiveDrive LDD 1800 Series User manual

LiveDrive® Direct Drive
User Manual
LiveDrive LDD 1800 Series
®
Motion Redefined
105678-C
LDD 1800 Series

LDD 1800 Series User Manual 3
105678-C
Copyright
Copyright 2022. Genesis Motion Solutions, LP. All rights reserved.
Printed in Canada.
Trademarks
LiveDrive, MOTION REDEFINED, and the G logo design are trademarks owned by Genesis Motion Solutions, LP in the United
States, and may be registered in certain jurisdictions.
All other trademarks that appear are the property of their respective owners.
Permissions and Restrictions
Information in this publication is subject to change without notice. No part of this document may be reproduced or transmitted in
any form, by photocopy, microfilm, xerography, or any other means, or incorporated into any information retrieval system, elec-
tronic or mechanical, for any purpose, without the express permission of Genesis Motion Solutions, LP.
Published By
Genesis Motion Solutions Canada, LP
6279 202 St Langley, BC Canada V2Y 1N1
genesismotion.com
inf[email protected]
[phone]
Certifications
UL file #E515181
Revision Release Date History
A May 5, 2022 Production release.
B July 20, 2022 Minor edits, post technical review.
C March 1, 2023 Removed specifications (datasheet and web only), updated cabling information, comany name and logo.
Document Control
Document number: 105678

LDD 1800 Series User Manual 4
105678-C
Table of Contents
1. About This Manual ............................................................................................................................................................................... 6
2. Safety Instructions ...............................................................................................................................................................................7
2.1 Safety Symbols.................................................................................................................................................................................................... 7
2.2 Operating Precautions .....................................................................................................................................................................................9
2.3 Operating Environment ....................................................................................................................................................................................9
3. Product Overview ...............................................................................................................................................................................10
3.1 Front View ........................................................................................................................................................................................................... 10
3.2 Rear View............................................................................................................................................................................................................ 11
3.3 Product Nomenclature ....................................................................................................................................................................................12
3.4 Selection and Sizing ........................................................................................................................................................................................12
4. Permissible Shaft Loads...................................................................................................................................................................14
5. Intergrated Features.......................................................................................................................................................................... 15
5.1 Holding Brake .................................................................................................................................................................................................... 15
5.2 Temperature Sensors..................................................................................................................................................................................... 15
6. Housing Materials ..............................................................................................................................................................................16
7. Interfaces .............................................................................................................................................................................................. 17
7.1 Connector Block .................................................................................................................................................................................................17
7.2 Pinouts .................................................................................................................................................................................................................17
7.3 Cabling ................................................................................................................................................................................................................ 18
8. Handling and Transportation..........................................................................................................................................................20
8.1 State on Delivery.............................................................................................................................................................................................. 20
8.2 Handling and Transportation ....................................................................................................................................................................... 20
8.3 Storage.............................................................................................................................................................................................................. 20
9. Installation and Commissioning ..................................................................................................................................................... 21
9.1 Safety Precautions.............................................................................................................................................................................................21
9.2 Design and Installation Positions..................................................................................................................................................................21
9.3 Mechanical Mounting and Assembly..........................................................................................................................................................22
9.4 Sealing Output Interface................................................................................................................................................................................23
9.5 Electrical Connections ...................................................................................................................................................................................24
9.6 Drive Setup and Configuration .....................................................................................................................................................................24

LDD 1800 Series User Manual 5
105678-C
10. Operation........................................................................................................................................................................................... 25
10.1 Commissioning................................................................................................................................................................................................25
10.2 Braking..............................................................................................................................................................................................................25
10.3 Cleaning ...........................................................................................................................................................................................................25
10.4 Deactivation ....................................................................................................................................................................................................26
10.5 Disposal............................................................................................................................................................................................................26
11. Maintenance...................................................................................................................................................................................... 27
11.1 Maintenance .....................................................................................................................................................................................................27
12. Troubleshooting ............................................................................................................................................................................... 29
13. Service and Support .......................................................................................................................................................................30
13.1 Service and Support...................................................................................................................................................................................... 30
14. Certification and Compliance........................................................................................................................................................ 31
14.1 List of Standards ..............................................................................................................................................................................................31
14.2 Declaration of UL Rated Performance......................................................................................................................................................32

LDD 1800 Series User Manual 6
105678-C
1. About This Manual
The purpose of this manual is to provide clear information on the wide range of application options when using the LiveDrive®
LDD 1800 series motors from Genesis Motion Solutions.
It contains information for robot and machinery designers responsible for selecting, operating, and maintaining the motor.
This manual also contains an overview of the various features, specifications of the product, as well as information on the setup,
installation and commissioning, operation and maintenance of the LDD 1800 series motors.
Unless otherwise specified, all measurements within this guide are in metric units.
Scope
The information in this user manual is intended for qualified technicians or operators who are tasked with installing, commission-
ing, operating, troubleshooting or maintaining a system.
Knowledge and Permissions
We assume that any personnel working with this product have a good working knowledge of servomotor applications, and access
to any and all tools or safety equipment required.
Important
This manual is limited to the motor alone and does not include the robot or system in which it is used.

LDD 1800 Series User Manual 7
105678-C
2. Safety Instructions
This section summarizes the safety precautions, hazards and mitigation actions associated with handling, installing, and
operating LiveDrive® LDD 1800 series motors. Tasks such as installing, commissioning, tuning, and operating electric motors
should only be done by qualified personnel.
If the content in this document is unclear, please contact Genesis Motion Solutions prior to installation or operation. Non-compli-
ance with the safety and technical recommendations may lead to injury or damage to property and environment.
2.1 Safety Symbols
Electric Shock
Electric shock may result in serious injury or death. The motor operates at high voltages and may become energized under
certain circumstances.
Sparking or Arcing Hazard
Sparking or arcing may be present in the event of a motor failure.
No Pacemakers
The motor is a high current electrical device and may present EMI levels dangerous to those with pacemakers or other sensi-
tive medically necessary equipment.
High Temperature
The motor operates at high internal temperatures. The motor, in addition to the mounting equipment, cables, and control
panel may become hot during operation.
Fire
The motor may create a fire hazard in the event of an equipment failure.
Crushing, Impacting, Pinching
The motor is designed to rotate at high speeds. Depending on the equipment setup, risk of crushing, impact or pinching may
be present.
Entanglement
The motor is designed to rotate at high speeds. Depending on the equipment setup, risk of entanglement may be present.
Warning
Death or severe bodily injury can occur.
!

LDD 1800 Series User Manual 8
105678-C
2.1.1 Shock Hazard
• The motor operates at hazardous voltages. Electric shock may result in serious injury or death.
• Do not touch the motor, shaft or connected conductive components (the load on the shaft) while the motor is enabled.
• Do not conduct work on live (energized) equipment. Prior to connecting or disconnecting cables, ensure that the system
power is off and locked out.
• Do not disassemble the motor. Only qualified personnel may work on the motor and must use insulated tools
(as per IEC 60900).
• Avoid contact with power connector pins, since back-driving the motor can create hazardous voltages (Back EMF) on the
power wires.
• Do not operate the motor with any exposed leads. Terminate or insulate and protect any unused leads on the drive end of
the cables.
• The motor drive (provided by customer) must include fault detection that will disconnect power to the motor in the event of
a short circuit (for example, line-to-line and line-to-ground), or other fault (for example, over-speed, over-voltage and over-
current).
• The motor drive (provided by customer) must include a main disconnect and circuit breaker on the main power for overload
protection.
• Branch circuit power-surge protection shall be provided by customer in accordance with National/ International electrical
code and regulations. It must include a main disconnect, circuit breaker and surge protection device (SPD) on the main
power for overvoltage and overcurrent protection.
2.1.2 Sparking/Arcing Hazard
Motor or component overheating may result in sparking/arcing and motor failure.
• Verify that system grounding is in place. For information on motor grounding through the power cable, see section "7.3
Cabling".
• Ensure the internal motor temperature sensor is connected to a thermal shutdown circuit.
• Do not allow the motor to remain in a stall condition. A stall condition is defined as when the motor is generating torque but
prevented from rotating.
Removing connectors while power is enabled may result in sparking/arcing or unexpected motion. Excessive bending of cables
may result in internal cable damage.
• Disable all power to the motor before disconnecting any cables or terminals.
• Ensure there is enough space around the motor to safely bend the cables.
2.1.3 Electromagnetic and Magnetic Interference
Electromagnetic interference may affect performance of personal medical equipment and implants. Personnel with personal
electric medical equipment or a ferromagnetic prosthesis must not operate the motor.

LDD 1800 Series User Manual 9
105678-C
2.1.4 Handling and Installation Safety
LiveDrive® motors can weigh upwards of 16 kg. Carrying or lifting the motor without adequate protection (such as safety footwear),
assistance, or safe lifting practices, may result in equipment damage and personal harm.
• Wear adequate personal protection equipment and follow safe lifting practices.
2.2 Operating Precautions
The motor can impart significant mechanical energy:
• Unexpected movements of the motor (and attached components) may occur due to control instability, wiring damage or
internal motor damage.
• During a sudden power-shutdown event, the motor may continue to move.
• Components attached to the motor housing and shaft may loosen over time (this could occur if inappropriate bolted joints
are not correctly torqued or if there is excessive vibration) and may be ejected as projectiles.
Establish an appropriate boundary around the motor during operation or troubleshooting. Appropriate shielding and/or working
boundaries are especially important when working with eccentric loads.
• Ensure the e-stop (emergency stop button) is wired correctly and nearby the operator.
• Perform regular verifications of critical mechanical connections.
• Monitor for unusual vibration and noise. Cease operation and resolve issue(s) if unusual vibration or noise are detected.
2.2.1 High Temperatures
The motor, frame, and components attached to the shaft, connectors and cables may become hot during operation.
• Be aware of hot surfaces on the motor. Internal temperatures of 110°C are possible during operation.
• Always ensure parts have had sufficient time to cool prior to touching the motor.
• Ensure the internal motor temperature sensor is connected to a thermal shutdown circuit. Please refer to the motor
datasheet for maximum operating temperature.
2.2.2 Equipment Damage
Inspect the motor for damages prior to installation, commissioning, and operation. Contact Genesis Motion Solutions for addi-
tional
guidance if the motor is damaged.
2.3 Operating Environment
LiveDrive® motors must not be used in applications requiring special environmental considerations; examples include vacuum or
clean room applications, or those with atmospheres that are potentially explosive or radioactive. Contact Genesis Motion Solu-
tions for further information.

LDD 1800 Series User Manual 10
105678-C
3. Product Overview
Genesis Motion Solutions LiveDrive® LDD 1800 series are high torque density, direct-drive motors developed for robotics and
automation machinery. The motors are brushless, permanent-magnet, 3-phase synchronous motors. Loads can be directly
coupled to the output without the need for additional transmission components (i.e. belts or gears). The simple construction of
machines using LDD 1800 series motors allows higher system reliability and cleanliness through the elimination of lubricated
gearboxes.
Compared with other servo motor technology, our LiveDrive® technology delivers much higher torque at comparatively lower
speed. The LDD 1800 series motors are well suited to the following types of applications:
• If factory floor space is at a premium, our reduced motor size means a smaller footprint enabling space efficient designs
• In demanding and highly dynamic applications that require a high torque and low inertia/high stiffness, and instant response
• In highly dynamic packaging or assembly line environments that require higher speed, backlash-free positioning
• In hygienic environments requiring IP67 washdown and no contamination by lubricants
3.1 Front View
Figure 1 — Front view
Output Shaft
Stator
Rotor
Shaft Seal
Front End Cover
End Cap (Mounting Surface)
Connector Block
Bearing
Frame