Kollmorgen Seidel PLATINUM DDL IC Series Parts list manual

Linear motors
PLATINUM™ DDL
Technical Description
Edition 03/01

Previous editions
Edition Comment
03/2001 First edition
Symbols used in this manual
danger to personnel,
from electricity and its effects
general warning
general instruction
mechanical hazard
ÞSee Chapter... (cross-reference) ●emphasis
Technical changes to improve the performance of the equipment
may be made without prior notice!
Printed in the Federal Republic of Germany 03/01
Mat.No. 101992
All rights reserved. No part of this document may be reproduced in any form (by printing, photocopying,
microfilm or any other method), or stored, processed, copied or distributed by electronic means without
the written permission of Kollmorgen Seidel.

Contents Drawing Page
Contents...............................................................................3
Safety Instructions ...................................................................4
Manufacturer’s Declaration ..........................................................6
PLATINUM™ DDL 3
Kollmorgen Seidel 03/01 Contents
I General Information
I.1 About this manual ........................................................................7
I.2 Use as directed .........................................................................7
I.3 Design of the motors......................................................................8
I.4 General technical data ....................................................................9
I.5 Standard features .......................................................................10
I.5.1 Frame size .......................................................................10
I.5.2 Secondary section (magnet track) .....................................................10
I.5.3 Primary section (windings) ...........................................................10
I.5.4 Protective devices..................................................................11
I.5.5 Insulation material class .............................................................11
I.5.6 Connections ......................................................................11
I.5.7 Feedback unit .....................................................................11
I.5.8 Options ..........................................................................11
I.6 Technical data..........................................................................12
I.6.1 Terminology ......................................................................12
I.6.2 Technical data PLATINUM™ DDL .....................................................13
II Drawings
II.1 Dimensions ............................................................................14- A.4.035.4/03
II.2 Wiring diagram for Hall-effect option.........................................................15- A.4.035.1/01
III Appendix
III.1 Index .................................................................................16

Safety Instructions
lThe strong magnetic fields which are produced constitute a hazard for persons with
implants, such as cardiac pacemakers, that can be influenced by magnetic fields. As
a general rule, all persons who may suffer impairment to health through the
influence of strong magnetic fields must keep at a safe distance of at least 1 meter
from the motor.
lAlways wear gloves when working on the linear motor. During work on or in the
vicinity of linear motors make sure that at least two finely pointed wedges of tough
non-magnetic material - e.g. V2A - (with a wedge angle of approx. 10°-15°) and a
hammer (approx. 3 kg) are to hand. In an emergency you can then use these tools to
detach objects that are magnetically bound to the magnet track (for instance, to free
trapped parts of the body).
lBecause of the high forces of attraction, special care must be taken within a range of
about 50 mm from the magnet track. Inside this area, heavy (>1kg) or large-area
(>1dm²) objects of steel or iron must not be held in the hand.
lKeep watches and magnetic data media (credit cards, diskettes, etc.) out of the
immediate vicinity (<100 mm) of the linear motor.
lOnly properly qualified persons are permitted to perform activities such as transport,
installation, commissioning and maintenance. Properly qualified persons are those
who are familiar with the transport, assembly, installation, commissioning and
operation of motors, and who have the appropriate qualifications for their job.
Qualifed personnel must know and observe the following standards and directives:
IEC 364 and/or CENELEC HD 384 or DIN VDE 0100
IEC Report 664 or DIN VDE 0110
national accident prevention regulations, or BGV A2
lRead the available documentation before installation and commissioning. Incorrect
handling of the motor can cause injury and damage to persons and equipment.
lIt is mandatory to ensure that the magnet track is properly grounded to the PE
(protective earth) busbar in the switchgear cabinet. Safety for personnel cannot be
assured without a low-resistance protective earth.
lNever pull out a connector during operation. This creates a hazard with the risk of
death, severe injury, or material damage.
lPower connections may still be live, even though the motor is not moving. Never
undo the electrical connections to the motor while a voltage is present. In
unfavorable cases this can cause arcing, with injury and damage to persons and
equipment.
lAfter disconnecting the servo amplifier from the supply power, wait at least five
minutes before touching live parts (such as contacts or studs) or breaking
connections. To be sure, measure the voltage in the DC-link circuit and wait until it
has fallen below 40V.
lDuring operation, motors can have very hot surfaces, depending on their enclosure
rating. Surface temperatures can reach 100°C. Measure the temperature, and wait
until the motor has cooled down to below 40°C before touching it.
4 PLATINUM™ DDL
Safety Instructions 03/01 Kollmorgen Seidel

Safety Instructions
lAttach easily visible warning signs (e.g. permanent self-adhesive labels) to the
machine:
Caution:
The linear drives on this machine are fitted with
strong permanent magnets.
STRONG MAGNETIC FIELDS + HIGH MAGNETIC ATTRACTION FORCES !
lThe magnet track must never be stored in an unpacked condition.
Use non-magnetic packaging material that is at least 2 cm thick.
The storage location must be dry and protected from heat.
Put up signs where the motors are stored:
Caution: STRONG MAGNETS
lIf machines or sections of machines are transported with linear motors already
mounted on the motion axes, then these axes must be blocked, to prevent
unintended movement.
PLATINUM™ DDL 5
Kollmorgen Seidel 03/01 Safety Instructions

6 PLATINUM™ DDL
Manufacturer’s Declaration 03/01 Kollmorgen Seidel
Manufacturer’s Declaration
in accordance with the EC Machine Directive 89/392/EEC, Appendix II B
We, the company
Kollmorgen Seidel GmbH & Co. KG
Wacholderstraße 40-42
40489 Düsseldorf
hereby declare that the linear motors of the series PLATINUM™ DDL,
Types ICD05-xxx, ICD10-xxx, IC11-xxx, IC22-xxx, IC33-xxx, IC44-xxx
in the standard implementation are exclusively intended for installation in other machines, and that
their operation is forbidden until it has been ascertained that the machines in which these products
are incorporated fulfil the requirements in the edition 89/392/EEC of the EC Directive.
We confirm that the products designated above conform to the standards listed below:
73/23/EEC EN 60950 UL 1004
EN 60034 EN 60529 UL 547
EN 60204-1 IEC 721-3 UL 674
IEC 34-1 NEMA MG7
Authorized: for the company management
Lawrence D. Kingsley
This declaration does not constitute an assurance of specific features. The safety and protection
instructions in the documentation must be followed in all cases.

I General Information
I.1 About this manual
This manual describes the PLATINUM™ DDL series of linear motors.
This manual is intended for use by qualified and experienced personnel in the
electrical and mechanical engineering industries.
The motors are operated within drive systems, together with the SERVOSTAR™ 400/600
servo amplifiers. Please observe therefore the complete system documentation,
consisting of:
— Installation/commissioning instructions for the servo amplifier
— Installation/commissioning instructions for any expansion cards
which are also installed
— Technical description of the PLATINUM™ DDL series of motors
I.2 Use as directed
Linear motors in the PLATINUM™ DDL series are specially designed as drives for
machines with very demanding dynamic requirements.
The motors may only be operated within the environmental conditions and limits defined
in this documentation.
Motors in the PLATINUM™ DDL series are designed to be controlled exclusively by
digital servo amplifiers of the SERVOSTAR™ 400/600 series, in a speed and/or torque
and/or position control loop. If these motors are driven by any other equipment, we will
not accept any responsibility for the functional characteristics of the drive.
The motors are installed as components in electrical plant or machinery, and may only be
operated as integral parts of such plant or machinery.
These motors must never be connected directly to the electrical supply.
The temperature monitoring that is built into the motor windings must be evaluated in the
SERVOSTAR™ 400/600.
We can only guarantee the conformance of the servo system with the standards named
in the Manufacturer’s Declaration on Page 6 when the components used are exclusively
those delivered by us (servo amplifier, motor, cables etc.).
PLATINUM™ DDL 7
Kollmorgen Seidel 03/01 General Information

I.3 Design of the motors
PLATINUM™ DDL linear motors (series ICxx and ICDxx) are 3-phase, flat linear motors
for sinusoidal commutation, with a patented construction of the laminated winding
section. They can be fitted with almost every type of linear measurement system which is
suitable for operation with linear motors.
The winding sections (primary sections) are completely enclosed and encapsulated, and
thus have excellent protection for use under tough industrial conditions. The T-profiles
which are fitted for mounting them onto the framework of the machine provide a versatile
but nevertheless firm mechanical coupling system.
Thanks to this patented design, you can achieve
lvery high continuous driving forces
lvery high peak forces
lextremely low cogging
la comparatively low motor inductance
in spite of the compact external dimensions.
These features mean that PLATINUM™ DDL linear motors are not only suited for
applications in the machine tool industry, but present advantages for all applications that
require
llow levels of motor heating combined with high continuous driving forces
loutstanding control loop characteristics and high precision
lhigh static and dynamic stiffness (low compliance) in the drive chain
Linear motor series ICxx
If an occasion should arise where even the substantial continuous driving force of an
uncooled ICxx linear motor is insufficient, then every size of motor in this series can also
be fitted with integral water cooling. This enables a doubling of the already considerable
driving force. The external dimensions remain the same, thus offering the option of simply
retrofitting a motor with water cooling in situations where the machine stays the same, but
the demands have been increased. The electrical connections and the water feed are at
the front, but on opposite sides, which simplifies cabling and reduces the susceptibility to
interference.
If very high demands are placed on the thermal insulation of the motor (i.e. to prevent
expansion of the machine) then it is a good idea to plan in an additional cooling plate, as
a thermal isolation device.
Linear motor series ICDxx
For applications where component height and weight are the decisive criteria, we
recommend the ICDxx motor series. ICDxx motors produce similarly high peak forces to
the ICxxx motors, but with significantly smaller masses, thus permitting extremely high
acceleration. They are therefore very suitable for applications with extreme dynamic
requirements, which would otherwise require coreless motors.
ICDxx linear motors can not be fitted with internal water cooling.
8 PLATINUM™ DDL
General Information 03/01 Kollmorgen Seidel

I.4 General technical data
Climatic class 3K3 as per EN 50178
Ambient temperature +5 to +40°C at site altitudes up to 1000m a.m.s.l.
(under rated conditions) You must consult our applications department
for ambient temperatures above 40°C
with encapsulated motors.
Permissible humidity 85% relative humidity, no condensation
(under rated conditions)
Power derating 1% per °C in the range 40°C to 50°C
(current and force) and up to 1000m a.m.s.l.
For sites above 1000m a.m.s.l. and 40°C
6% for 2000m a.m.s.l.
17% for 3000m a.m.s.l.
30% for 4000m a.m.s.l.
55% for 5000m a.m.s.l.
No derating for sites above 1000m a.m.s.l. if
temperature is reduced by 10°C per 1000m
Technical data ÞI.6
PLATINUM™ DDL 9
Kollmorgen Seidel 03/01 General Information

I.5 Standard features
I.5.1 Frame size
There are no standardized frame sizes for linear motors, but the modular design of the
ICxx and ICDxx motors nevertheless makes it possible to find a mechanically suitable
motor for just about every drive situation.
The magnets and windings are constructed in such a manner that they have a pole
interval (from one North pole to the next North pole) of 32 mm. This corresponds to one
complete rotation of the current vector.
The performance figures that are given in the technical data are valid for motors which
are mounted on an aluminium plate that is at least 10mm thick, and has an area that is 3
times as large as the motor flange. If full loading of the motor is planned, then an area
that matches this cooling plate must be designed into the machine to provide adequate
heat removal, to prevent the motor overheating (see the corresponding remarks in the
technical data).
When dimensioning vertical axes, take note of the “standing load” on the motor caused
by the applied weight.
For the correct selection of the motor to fit the ambient conditions and installation
situation, we recommend that you take advantage of the support provided by our sales
and applications engineers (especially if it is a first-time application).
I.5.2 Secondary section (magnet track)
All the magnet tracks in the ICxx and ICDxx motors are fitted with high-magnetization
NeFeB magnets (32mm from one North pole to the next North pole).
The magnets are glued onto a steel plate. The steel plate and the magnets are
nickel-plated, to prevent corrosion and other environmental problems.
The magnet track is fitted with a stainless steel cover over the magnets, to protect them
from possible mechanical damage.
The entire magnet track can be assembled from modules with lengths of 64, 128 or
256mm. When ordering the motor, please specify the quantities of the individual module
types, as well as the type of motor.
I.5.3 Primary section (windings)
The primary sections (winding assemblies) of the linear motors are completely cast in an
epoxy resin, and painted black. This ensures a high level of protection and optimum
sealing of the windings. Aluminium end covers and steel side covers shield the
surroundings from the electromagnetic influence of the winding heads.
10 PLATINUM™ DDL
General Information 03/01 Kollmorgen Seidel

I.5.4 Protective devices
The ICD motors are fitted with thermistors. IC motors, on the other hand, have
thermostats fitted (floating n.c./break contacts). The resistance value or switching point
can be found in the technical data. Thermal monitoring does not provide protection
against sudden overloading. The thermal monitoring must be integrated into the
monitoring system of the SERVOSTAR™ 400/600 digital servo amplifier.
I.5.5 Insulation material class
The windings in the primary (winding) section meet insulation class F as per DIN 57530.
I.5.6 Connections
The motors are fitted with connectors for the power feed and the thermal protection
devices.
The mating connectors are not included in the delivery package. We can supply
pre-assembled cables for the power feed and thermal protection.
Follow the wiring diagram in Chapter II.2.
If the primary (winding) section is the moving part of the drive, then high-flexibility cables
must be used, suitable for trailing applications.
I.5.7 Feedback unit
As an option, the winding sections can be fitted with a digital Hall-effect sensor unit for
commutation.
Follow the wiring diagram in Chapter II.2.
The performance of a linear motor drive is decisively affected by the length measurement
system which is used. We therefore recommend that only high-resolution linear
measurement systems are used, with 1Vpk-pk sine-cosine signals, such as:
optical length measurement system
LIDA 185 from Heidenhain, resolution 25 intervals / mm
Further information can be found on the Internet, under: http://www.heidenhain.de
magnetic length measurement system
from Siko, resolution 1 interval / mm
Further information can be found on the Internet, under: http://www.siko.de
optical tape length measurement system
from Renishaw, resolution 50 intervals / mm with 120Wtermination resistance
Further information can be found on the Internet, under: http://www.renishaw.com
I.5.8 Options
-Hall- Hall sensor for commutation
PLATINUM™ DDL 11
Kollmorgen Seidel 03/01 General Information

I.6 Technical data
I.6.1 Terminology
Peak force Fpeak [N]
The peak force is used as a design parameter for the acceleration and braking of the
load. The motor should not be reqired to generate this force for more than 5 seconds.
The direction of the force is defined as positive when the winding section moves towards
the bolted cable connections (see dimensioned drawing in Chapter II.1).
Peak current Ipeak [Arms]
This is the current required to produce the peak force Fpeak.
The direction of the force is defined as positive when the winding section moves towards
the bolted cable connections (see dimensioned drawing in Chapter II.1).
Continuous force Fcont [N]
This is the force that the motor can generate continuously, provided that appropriate heat
removal can be provided. The performance data are valid for motors which are cooled by
an aluminium plate that is at least 10mm thick, and has an area that is 3 times as large as
the motor flange.
The rest of the cooling is provided by natural air convection.
Continuous current Icont [Arms]
This is the current required to produce the continuous force Fcont. Current that exceeds
this value for some time is likely to result in overheating of the motor.
Motor constant KM[N/ W]
A figure for the efficiency of the motor. The larger the motor constant, the lower the power
losses for a given force. At full power, KMis somewhat reduced as the borderline of
magnet saturation is aproached.
Voltage constant KE[Vpeak/m/s]
The voltage constant is the motor e.m.f. (as a peak value between two terminals) that is
induced at 1 meter per second.
Force constant KF[N/Arms]
The ratio of continuous force to continuous current. This constant enables the calculation
of the driving force as a function of the current.
Theoretical maximum acceleration [g]
The maximum off-load acceleration at peak current.
Magnetic attraction force [N]
The attractive force that the magnet track exerts on the winding section when no current
is flowing. This increases by about 15% when current flows through the winding.
12 PLATINUM™ DDL
General Information 03/01 Kollmorgen Seidel

I.6.2 Technical data PLATINUM™ DDL
Data Symbol Unit
ICD05-050 ICD10-050 ICD10-100 IC11-030 IC11-050 IC22-030 IC22-050 IC22-100 IC33-150 IC44-150
Peak force Fpeak N 280 560 1130 375 625 750 1250 2500 5625 7500
Peak current Ipeak A 8.5 15.8 15.8 11.3 11.3 11.0 11.0 22.0 33.1 44.1
Continuous force (at 130°C) Fcont N 87 171 315 151 276 298 548 1198 2718 3617
Continuous current (at 130°C) Icont A 2.0 3.8 3.5 4.0 4.4 3.9 4.4 9.5 14.4 19.2
DC-link voltage UDC V 330 560
Motor constant (at 130°C) KMN/ W14.5 20.5 31.3 18.9 26.9 26.4 37.7 58.5 90.7 105
Voltage constant (peak, at 25°C) KEV/m/s 36.3 36.4 72.8 30.9 51.4 61.7 103 103 154 154
Force constant (rms, at 25°C) KFN/A 44.5 44.6 89.2 37.8 62.9 75.6 126 126 189 189
Max. continuous dissipation PcW 36 69 101 64 106 128 212 420 897 1193
Winding resistance
phase-phase, at 25°C R20 W4.5 2.2 3.9 1.9 2.6 3.9 5.3 2.2 2.1 1.5
Winding inductance
phase-phase, with rated air gap L mH 14.4 7.3 13.9 16.7 26.7 33.4 53.4 26.0 25.8 19.3
Rated air gap without cover - mm 0.8 (± 0.2)
Rated air gap with cover - mm 0.6 (± 0.2)
Thermal transfer resistance from Cu
winding to external structure Rth °C/W 2.9 1.52 1.04 1.64 0.99 0.82 0.50 0.25 0.12 0.088
Magnetic attractive force FakN 0.9 1.8 3.6 1.1 1.9 2.3 3.9 7.8 17.7 23.5
Theoretical max. acceleration amax g 30.2 30.7 33.7 15.3 17.7 15.9 18.5 20.4 21.0 21.0
Enclosure protection class - - IP 55
Insulation class - - F(DIN 57530)
Thermostat switching point - °C - 120 ±5
Thermistors - W/120°C 1650 -
Magnet track type
(k = length) --
MC-050-k MC-050-k MC-100-k MC-030-k MC-050-k MC-030-k MC-050-k MC-100-k MC-150-k MC-150-k
Magnet track, effective width b mm 50 50 100 30 50 30 50 100 150 150
Magnet track, length k mm 64, 128, 256
Winding section, weight ±15% mpkg 1 2 3.5 2.5 3.5 5 7 12.5 27 36
Magnet track, weight ±15% / length mskg/m 4 4 7 5.5 7.5 5.5 7.5 13 21 21
The performance data are valid for cooling by an aluminium plate that is at least
10mm thick, and has an area that is 3 times as large as the motor flange.
PLATINUM™ DDL 13
Kollmorgen Seidel 03/01 General Information

II Drawings
II.1 Dimensions
14 PLATINUM™ DDL
Drawings 03/01 - A.4.035.4/03 Kollmorgen Seidel

II.2 Wiring diagram for Hall-effect option
PLATINUM™ DDL 15
Kollmorgen Seidel 03/01 - A.4.035.1/01 Drawings

III Appendix
III.1 Index
16 PLATINUM™ DDL
Appendix 03/01 Kollmorgen Seidel
Aacceleration, theor. max. .........12
ambient temperature ...........9
attractive force, magnetic ........12
Cconnections ...............11
Contents ..................3
continuous current ............12
continuous force .............12
Ddimensions ................14
Ffeedback unit ...............11
force constant ..............12
frame size ................10
IIndex ...................16
insulation class ..............11
Mmagnet track ...............10
Manufacturer’s Declaration ........6
motor constant ..............12
Ppeak current ...............12
peak force ................12
power derating...............9
Ssafety instructions .............4
Ttechnical data ..............13
temperature monitoring .........11
Vvoltage constant .............12
Wwinding section ..............10

This side has been deliberately left blank.
PLATINUM™ DDL 17
Kollmorgen Seidel 03/01 Appendix

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Systempartner / System partners / Partenaires du systéme