Plettenberg NOVA 1 Series User manual

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Operating Manual
ELECTRIC MOTORS
H I G H - E N D E L E C T R I C D R I V E S O L U T I O N S

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Table of contents
Table of contents.........................................................................2
1. About this document.............................................................3
Legal provisions.......................................................................3
Liability ....................................................................................3
Scope of validity ......................................................................4
Target group ............................................................................5
Updated additional information ................................................5
Symbols...................................................................................5
Nomenclature ..........................................................................5
2. Product overview...................................................................6
Introduction..............................................................................6
BLDC Inrunner.........................................................................7
BLDC Outrunner......................................................................7
Brushed DC.............................................................................8
Type designation .....................................................................8
Motor rotation designation .......................................................9
Motor force direction designation .............................................9
3. Safety....................................................................................10
Intended use..........................................................................10
Safety Information .................................................................10
4. Commissioning....................................................................13
Safety during commissioning .................................................13
Assembly & mounting ............................................................13
Cable connections .................................................................14
Soldered connections ............................................................14
Sensors .................................................................................15
Commutation sequences .......................................................15
Thermal management............................................................16
Visual inspection and mechanical inspection .........................17
5. Maintenance.........................................................................17
General..................................................................................17
6. Disposal ...............................................................................17
7. Service / Contact .................................................................18
8. EU Declaration of Conformity.............................................19
9. Appendix ..............................................................................21
NOVA Series..........................................................................22
ADVANCE Series ..................................................................47
ORBIT Series ........................................................................52
ALPHA Series........................................................................69

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1. About this document
The information contained in this document is the sole property of
Plettenberg Elektromotoren GmbH & Co. KG ("Plettenberg”).
Publication, in whole or in part, requires the express written consent
of Plettenberg. An internal company duplication, which is intended
for the evaluation of the product or for the appropriate assignment,
is permitted and not subject to approval.
We shall not be liable for the slightly negligent breach of non-
essential contractual obligations. In the case of slightly negligent
breaches of essential contractual obligations, also if they have been
committed by our legal representatives or our vicarious agents, our
liability is limited to the foreseeable damage typical for the contract.
Unlimited liability on our part exists for damages to body and health
of the customer culpably caused by us, our legal representatives or
our vicarious agents, as well as in the case of intent and gross
negligence and for the absence of the guaranteed quality.
If damage caused by slight negligence on the part of the customer
attributable to us is covered by an existing insurance policy of the
customer, our liability in the event of damage to property and/or
financial loss shall be limited to the disadvantages for the customer
associated with the claim against the insurance company.
We shall not be liable for damage caused by improper handling of
our products as well as improper influence of third parties on our
products, improper assembly and/or installation, overstressing or
overvoltage, unless these are due to our fault or a fault of our
representatives or vicarious agents. The same applies in the event
of unauthorised and improper repairs or interventions in the delivery
item by the purchaser or third parties.
We shall not be liable for damage caused by incorrect information
and communications from the customer, unless these are due to our
fault or a fault of our representatives or vicarious agents.
We expressly point out that our standard motors, motor controllers
and other products have not been subjected to the safety and
endurance tests prescribed for aircraft and aircraft equipment.
Therefore, we are not liable for damage of any kind which occurs
during and/or through the operation of our motors, motor controllers
and other products in manned aircraft or related airborne systems,
such aeroplanes, microlight aircraft, rockets, hang-gliders and
gliders, parachutes, air traffic control systems, etc. We are also
expressly not liable for damages dueto aircraft being grounded. The
use of our products in aircrafts or other airborne systems needs to
be specifically agreed with us and relevant safety and endurance
tests will have to be performed.
Legal provisions
Liability

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We expressly point out that our motors, motor controllers and other
products are not designed and approved for use in control systems
of nuclear reactors.
We are not liable for any kind of damage caused during and/or by
the operation of our motors, motor controllers and other products in
control systems of nuclear reactors or in/at nuclear reactors.
We are not liable for damages of any kind that arise from
applications and use of our products that are subject to the German
war weapons act.
Our liability under the product liability act remains unaffected.
Plettenberg Elektromotoren GmbH & Co. KG
Rostocker Straße 30
34225 Baunatal, Germany
T: [phone]
www.plettenbergmotors.com
[e-mail]
© 2023 Plettenberg Elektromotoren GmbH & Co. KG. All rights
reserved.
This document applies for the following motor series:
Motor Type
BLDC
Inrunner
BLDC
Outrunner
Brushed
DC
NOVA 1
ADVANCE 1
ORBIT 1
ALPHA 1
NOVA 3
ADVANCE 3
ORBIT 5
ALPHA 2
NOVA 4 (*)
ADVANCE 5
ORBIT 15
NOVA 5
NOVA 10
NOVA 15 (*)
NOVA 30 (*)
NOVA 50
(*) also available as light-weight version (“LW”)
Across the above stated motor series, Plettenberg offers various
lengths and configurations. Please note that this operating manual
covers all relevant configurations and subvariants.
Scope of validity

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The activities described in this document may only be executed by
qualified, skilled workers. The qualified, skilled workers must
possess the following qualifications:
⚫Knowledge regarding the functional methods and operation for
the product
⚫Knowledge and observation of these instructions with all safety
notes
⚫Technical standards must be observed
Links regarding updated additional information can be found under:
www.plettenbergmotors.com
Symbol
Clarification
Warning, the non-observance of
which leads directly to death or
serious injury
Warning, the non-observance of
which may result in serious injury
Warning, the non-observance of
which may result in minor or
moderate injury
Warning, non-observance of
which may result in damage to
property
Information, which is important
for a specific subject or goal, but
not relevant to safety.
Full name
Name used in this document
Light weight
LW
Clockwise
CW
Counter clockwise
CCW
Electronic speed controller
ESC
Brushless direct current
BLDC
Direct current
DC
Target group
Updated additional
information
Symbols
Nomenclature

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2. Product overview
Plettenberg is a global leader in high-performance rugged BLDC
motors. The product range includes inrunner and outrunner BLDC
as well as brushed DC motors. Our motors range in power from 20W
to 50kW, with up to 95% efficiency levels and up to 26kW/kg power-
to-weight ratio. All our motors are made-to-order and tailored to the
specific requirements of its customers. The customization process
involves adjusting the number of windings, number of poles, stator
length, ingress protection, etc. The result is a motor design, which
leads to the highest possible efficiency over the entire load profile
and covers all critical load points with safety buffer, while minimizing
size and weight. Plettenberg aims to maximize the weight-to-
performance-to-robustness ratio and minimize the total-cost-of-
ownership of its customers.
Customization
Life Cycle
Total Efficiency
Robustness
Quality Solution Focus
All our drive solutions are made-to-
order and tailored to the specific
requirements of our customers.
This can include adjustments to
housing, shaft, number of poles,
winding, cooling, potting, IP rating,
etc. These adjustments allow us to
build the most efficient, lightest
and robust drive solutions for our
customers.
We support our customers
throughout the entire product life
cycle. Our engineers provide
extensive development and system
integration advise and support with
prototyping. Following
development, we manufacture the
final series inhouse for as many
years as required by our
customers. We also offer an
extensive spare parts program.
We take a holistic perspective and
always look at total efficiency over
the entire load profile. We tailor our
products such that endurance and
performance is maximized, and
weight is minimized. Often, a
tailored drive solution can increase
efficiency by 15-30%, mitigate the
need for gearboxes and reduce
overall system cost.
All our drive solutions are rugged
in design and built for application
in harsh environments. Our NOVA
series of BLDC inrunners is
available with ingress protection of
up to 67. This makes them ideally
suited for missions in the harshest
environments, such as snow, desert
or sea water operation.
All our drive solutions are
developed and manufactured at our
HQ in Germany. We employ highly
experienced professionals with
many years of experience. We
believe in products built by hand,
as it provides for the highest
quality and a great degree of
flexibility. We have a strict quality
system which is ISO 9001 certified.
We provide customers with tailored
system solutions, comprising
motor, ESC as well as related
accessories. Next to the hardware,
we provide extensive engineering
and system integration support. In
the case of starter-generators, we
provide the generator as well as
starter-generator electronic boxes.
Introduction

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Our inrunner motors consist of the NOVA and the ADVANCE
families.
The NOVA series of inrunners feature an extra rugged closed
housing design with ingress protection of up to IP67. The motors
can be applied in the harshest environments, such as desert, snow
and sea water operations. At the same time, the NOVA motors are
designed to be extremely efficient and have market leading power-
to-weight ratios. The NOVA series is available in the power range
from below 1kW to 50kW.
NOVA 15-30. Note: additional measurement sheets included in the Appendix.
The ADVANCE series of inrunners feature a weight-optimized open
housing design. This allows for best-in-class power-to-weight ratios
and makes the motors very suitable for applications with constraints
in space, weight and power supply. The ADVANCE series is
available in the power range from 1kW to 5kW.
Advance 1-30. Note: additional measurement sheets included in the Appendix.
The ORBIT series of outrunners have been developed for
applications with constraints in space, weight and power supply.
Compared to other outrunners in the market, the ORBIT series is
built much more robust and features a reinforced rotor casing. The
ORBIT Series is available in the power range from below 1kW to
15kW.
BLDC Inrunner
BLDC Outrunner

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Orbit 15-25. Note: additional measurement sheets included in the Appendix.
The ALPHA series of brushed DC motors are ideally suited for
industrial and other applications, with highest requirements
regarding power-to-weight ratio, durability, efficiency and cost. The
ALPHA series is available in the power range from below 500W to
1.5kW.
Alpha 2-50. Note: additional measurement sheets included in the Appendix.
Plettenberg motors are designed based a modular system and are
available in +5,000 configurations. Customers are advised to
provide all their relevant details and specifications in the form of the
Plettenberg Specification Sheet (Please reach out to
[e-mail] for more information). Based on the
received information, the engineering team of Plettenberg will
determine the electrical design of the relevant drive system. The
format of the resulting motor design designation is based on a code
system. The below figure provides an illustrative (non-
comprehensive) type designation for a Plettenberg motor.
Brushed DC
Type designation

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HP 875 –50 –B8 SP50 LW PF G5 WK RM
| RM = rear mount / FM = front mount
| Water cooled
| Gearbox (5:1 ratio) / reduction
| Keyway
| Light weight
| Number of poles
| Rotor with armour
| A = Y / B = Δ/ no. of windings
| Active length of the motor in mm
| Rotor diameter in 1/10 mm
| Plettenberg motor type
All sensor guided motors of Plettenberg have a specified direction
of rotation (CW orCCW), which needs to be specified when ordering
the motor. Please use the definitions as illustrated in the below
chart.
Clockwise rotation
(CW)
Counter-clockwise rotation
(CCW)
Plettenberg motors may be specified for pull or push application (or
both for some series). The force direction needs to be specified
when ordering the motor.
Side view: Force (Tractor/Pull)
Side view: Force (Pusher)
Motor rotation
designation
Motor force
direction
designation

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3. Safety
The area of validity is defined as:
⚫Drive unit
The following are considered improper use in the sense of a
foreseeable misuse:
⚫Using the motor in manned aircrafts and other manned airborne
systems
⚫Using the motor in public vehicles and transport
⚫Using the motor as a toy
⚫Using the motor in potentially explosive atmospheres
⚫Any use other than those provided for
The use of our products outside the area of validity needs to be
specifically agreed with us and relevant safety and endurance
tests will have to be performed.
This chapter contains safety instructions which must always be
observed when working on and with the product. In order to prevent
personal injury and property damage and to ensure continuous
operation of the product, always read this chapter carefully and
follow all safety instructions at all times.
Intended use
Safety Information
Slight, moderate or severe injuries
Malfunctions can be caused by electromagnetic interference.
Communication equipment and other devices in the surroundings
must not be exposed to impermissible electromagnetic
interference.
⚫Modifications to the product are not permitted.
⚫Before the first operation, the product must be checked
against damages and the correct connection of all
connections must be checked again.
⚫The phase cables must not touch any metal surfaces.
(capacitive and inductive coupling)
⚫Power cables and control cables must be minimum 3 cm
distance from each other.
⚫The phase cables must not be laid as a coil.
⚫The phase cables must be laid twisted (one turn every
20 cm).

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Cut injures, loss of eyesight!
⚫The product must never be contaminated with foreign bodies
/ adhesives / paint during assembly.
⚫Modifications to the product are forbidden.
⚫Always ensure that the motor is properly fastened.
⚫Always ensure that the motor controller settings are correct.
⚫The product must be sufficiently cooled.
⚫Operation of the motor at idling speed without load is
prohibited.
Electric shock, burns, fire
Caused by energised parts.
⚫The product must always be protected against overheating,
dirt and moisture, otherwise the components will be
damaged. This can cause short circuits.
⚫The product as well as the contacts must be inspected for
overheating, soiling, deformation, fire and moisture before
commissioning.
⚫Assembly and disassembly must be carried out only when in
de-energised condition.
⚫Always ensure proper handling.
⚫Modifications to the product are not permitted.
⚫Always ensure that the motor is properly fastened.
⚫The bending radius of the connecting cables must be greater
than 6x outer diameter.
⚫The product must be sufficiently cooled.
⚫Operation of the motor at idling speed without load is
prohibited.

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Injuries due to crushing, being caught up
Malfunction due to electromagnetic interference.
⚫The control and phase cables must not be extended. The
product must be inspected and the fastening must be
controlled again before commissioning.
⚫Modifications to the product are not permitted.
Danger from magnetic radiation
Malfunction / destruction of magnetically sensitive parts.
⚫The motor must never come into contact with magnetically
sensitive parts such as pacemakers or data carriers. The
strong magnets can lead to damage and / or malfunction or
extinction of these.
Crushing, pulling in / being caught up
Caused by careless touching and too small a distance from
rotating parts.
⚫There must be sufficient distance retained to the motor so that
no people or objects can be caught up or drawn in.
Burns
Caused by carelessly touching hot surfaces.
⚫The surfaces could be hot after operating the product. Always
let the product cool down.

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4. Commissioning
Thermal overload / destruction
⚫Always ensure sufficient cooling for the motor (air or water
cooling)
⚫A high load on the motor is only permissible in short operation.
Under no circumstances must the motor exceed the
temperature of 100°C.
⚫Only motor controllers and regulators approved by
Plettenberg must be used.
Safety during
commissioning
Severe, moderate or minor injuries.
Destruction or damage to the product
⚫Safety instructions from Chapter 2 must be complied with!
⚫Test runs with prop should only be executed outdoors or with
special safety equipment, such as caged test stand.
⚫The side and front of the rotating plane needs to be kept clear.
Assembly &
mounting
Destruction / damage of the motor
⚫Always use suitable screws or bolts.
⚫Sawed or ground screws or bolts can destroy the thread in the
motor’s bearing shield.
⚫After each use, the motor must cool down again to ambient
temperature.
⚫Only motor controllers and regulators approved by Plettenberg
must be used.
⚫Never exceed the maximum screw-in depth. Screws or bolts
which are screwed too far will damage or destroy the motor.
⚫Only use original screws or bolts.
⚫Do not use a sensor-guided motor against its specified
direction of rotation.

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Mounting of the motor shall be performed on a firm base with an
appropriate number of bolts. Please refer to the Appendix for
recommended bolt sizes and torque. Depending on the model, the
motor may be specified for front mounting, back mounting or both.
Please contact us for any questions on mounting and installation.
Only motor controllers and regulators approved by Plettenberg must be
used. If other motor controllers or regulators are used, Plettenberg
cannot assume any guarantee or liability in the event of destruction of
the motor, regulator or the motor controller.
Motor connection cables must never be shortened or extended.
The three motor phases must be connected to the motor controller
according the manufacturer´s instructions.
The sensor cable must be connected to the motor controller in
accordance with the manufacturer´s specifications.
Additionally required tools/materials
(not included)
•No-clean lead-free solder
•Heat shrink tubing
•Cable
•Soldering iron rated at least 100 W
•Hot air gun
A wide portfolio of flexible high temperature cables of different
cross-sections, colors and requirements is available from
Plettenberg. For more information, please reach out to
[e-mail].
⚫The motor phases must not be shortened without prior
consultation. Crimping of connections must also not be
executed without previous consultation.
Cable connections
Soldered
connections
Destruction of / damage to the motor due to poor-quality or
high-resistance connections.
Burns
Caused by carelessly touching hot surfaces.

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Plettenberg motors are available with various positioning and
temperature sensors, which are used for commutation and
monitoring. The below table provides an overview on the availability
of sensor types. Motor series not included below are only available
for sensorless operation.
Sensor Types
Motor Type
Positioning Sensor
Temperature
Sensor
Stator
Rotor
Shaft
NOVA 1




NOVA 3




NOVA 4




NOVA 5


()

NOVA 10


()

NOVA 15




NOVA 30




NOVA 50




ORBIT 15




Note: (  ) is defined as not available in standard.
Plettenberg’s standard positioning sensor is the “stator-sensor”,
whereby three hall sensors with 120-degree electrical spacing are
installed in the stator. Depending on the application, a “rotor-sensor”
or a “shaft-sensor”can be viable alternatives. Plettenberg can also
integrate custom encoder and positioning sensors.
All sensor guided motors of Plettenberg have a specified direction
of rotation (CW or CCW), which needs to be defined when ordering
the motor. Our sensors have an operating voltage of 5V.
Block commutation with sensors
The feedback of the rotor position is implemented through a
positioning sensor integrated into the motor. The sensors are
electrically offset by 120-degree and deliver six different switch
positions per revolution. The three partial windings are driven bythe
motor controller in accordance with the sensor information.
Do not use a sensor-guided motor against its specified
direction of rotation.
Sensors
Commutation
sequences
Destruction of / damage to the motor controller due to short-
circuits or incorrect wiring.

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Forwards switch positions:
Step 1
Step 2
Step 3
Step 4
Step 5
Step 6
Fault 1
Fault 2
Phase A (U)
+
Z
-
-
Z
+
Z
Z
Phase B (V)
Z
+
+
Z
-
-
Z
Z
Phase C
(W)
-
-
Z
+
+
Z
Z
Z
Sensor A
1
1
0
0
0
1
0
1
Sensor B
0
1
1
1
0
0
0
1
Sensor C
0
0
0
1
1
1
0
1
Reverse switch positions:
Step 1
Step 2
Step 3
Step 4
Step 5
Step 6
Fault 1
Fault 2
Phase A (U)
-
-
Z
+
+
Z
Z
Z
Phase B (V)
Z
+
+
Z
-
-
Z
Z
Phase C (W)
+
Z
-
-
Z
+
Z
Z
Sensor A
1
1
0
0
0
1
0
1
Sensor B
0
0
0
1
1
1
0
1
Sensor C
0
1
1
1
0
0
0
1
Plettenberg motors are optimized for the highest possible heat
dissipation from the stator windings to the surface of the housing
and the cooling fins. Depending on the type of motor, Plettenberg
offers air- as well as water-cooled versions. When commissioning
and/or integrating the motor, it needs to be ensured that sufficient
cooling is available to ensure highest performance and prevent
permanent damage.
The general guideline for air-cooled motor is that the air needs to
flow through the entire cooling fins in axial direction. The specific
required air flow/speed required depends on the type of motor, load
profile and customer application. Therefore, Plettenberg
recommends consulting its engineering team to receive a detailed
Index
Description
Z
High-resistance
+
Plus
-
Minus
1
> 3V
0
< 2V
Thermal
management

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thermal simulation. For applications with insufficient or non-ideal
airflow, Plettenberg has a wide range to active and passive cooling
solutions available.
For water-cooled motors, Plettenberg recommends minimum flow
of 7 litres-per-minute at max. 40 degrees Celsius inlet temperature.
Coolant pressure shall not exceed 2 bar/ 29 PSI. For specific
pressure drops by motor type please reach out to us.
Plettenberg motors of the NOVA series are equipped with a
temperature sensor. The sensor measures the temperature in the
stator, which shall never exceed 100 degrees Celsius.
All fastening screws or bolts for the motor must be checked for
tightness before commissioning.
It needs to be ensures that all energized cables, plugs and sockets
are insulated sothat unintentional switching on of the motor by cable
contact is prevented.
5. Maintenance
The housing surfaces can be cleaned with compressed air and a
dry, lint-free cloth.
The maintenance requirements can vary by the type of motor.
Please consult [e-mail] for detailed
information on requirements.
6. Disposal
A motor that has reached the end of its service life is electrical scrap.
Electrical scrap consists of valuable materials, which can be
recovered as secondary raw materials, but also of environmentally
hazardous substances.
Information regarding optimum material recycling is available from
commercial waste disposal companies.
Visual inspection
and mechanical
inspection
General

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7. Service / Contact
Please contact us for any questions and/or information on service.
Plettenberg Elektromotoren GmbH & Co. KG
Rostocker Straße 30
34225 Baunatal, Germany
T: [phone]
www.plettenbergmotors.com
[e-mail]

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8. EU Declaration of Conformity
In the sense of the EU Directives
•EMC Directive 2014/30/EU Appendix IV
•Low Voltage Directive 2014/35/EU Appendix IV
•RoHS Directive 2011/65/EU Appendix I
Plettenberg Elektromotoren GmbH & Co. KG
Rostocker Straße 30
34225 Baunatal, Germany
hereby declares, as the manufacturer, that the articles and objects described below
comply with the provisions of the relevant community harmonisation legislation referred
to above.
Motor type
NOVA 1
ADVANCE 1
ORBIT 1
ALPHA 1
NOVA 3
ADVANCE 3
ORBIT 5
ALPHA 2
NOVA 4
ADVANCE 5
ORBIT 15
NOVA 5
NOVA 10
NOVA 15
NOVA 30
NOVA 50
Emitted interference
EMC Directive Article 6 Appendix I.1.a
DIN EN 61000-6-3:2011-09
Electromagnetic Compatibility (EMC)- Part 6-3:
Generic standards - Interference emission for
residential areas, business and commercial areas as
well as small businesses
(IEC 61000-6-3:2006 + A1:2010); German Edition
EN 61000-6-3:2007 + A1:2011
Immunity to interference
EMC Directive Article 6 Appendix I.1.b
DIN EN 61000-6-1:2007-10
Electromagnetic Compatibility (EMC)- Part 6-1:
Generic standards - Immunity for residential
environments, business and commercial areas as well
as small businesses
(IEC 61000-6-1:2005);
Safety of machinery
DIN EN 60335-1:2012-10
Safety
Household and similar electrical appliances - Part 1:
General requirements (IEC 603351:2010, modified);
DIN EN ISO 12100:2010
Safety of machinery - General principles for design -
Risk assessment and risk mitigation ISO 12100:2010:
German
Edition EN ISO 12100

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Maximum permissible concentrations
in homogeneous materials in % by
weight
RoHS Directive Appendix II
Lead 0.1%
Cadmium 0.01%
Polybrominated biphenyl (PBB) 0.1%
Polybrominated diphenyl ether (PBDE) 0.1%
Mercury 0.1%
Hexavalent chromium 0.1%
Note:
The sole responsibility for drawing up this declaration of conformity lies with the manufacturer. This declaration of conformity will
lose its validity when the product is converted, extended or altered in any othermanner without the express consentof Plettenberg
Elektromotoren GmbH & Co. KG and when components, not belonging to Plettenberg Elektromotoren GmbH & Co. KG, or
accessories are installed in the product as well as in the event of improper connection or improper use of the product.
Baunatal, 14.07.2023. ........................................................................
(Bastian Greiner, Managing Director)
........................................................................
(Boris Imhoff, Managing Director)
DIN EN 60204-11:2014-10
Safety for Machinery –Electrical Equipment for
Machinery –Part 1: General requirements
(IEC 44/709/CDV:2014); German Edition
FprEN 60204-1:2014