TQ ILM-E User manual

Assembly Instructions
ILM-E Servo Kits
Edition 10/2021 EN

Assembly Instructions | ILM-E Servo Kits
2 Edition 10/2021 EN
We have checked the content of this document for conformity with the unit described
in it. There may nevertheless still be differences, so we cannot guarantee complete
accuracy and correctness.
However, the information in this document is reviewed regularly and any necessary
corrections are included in subsequent editions.
All trademarks mentioned in this manual are the property of their respective owners
(see section 1.12 on page 7).
Copyright © TQ-Systems GmbH
TQ-Drives is a trademark of the TQ-Group.
TQ-Systems GmbH | Mühlstr. 2, Gut Delling | 82229 Seefeld | Germany
Phone: [phone] | Fax: [phone]
[e-mail] | www.tq-robodrive.com

Assembly Instructions | ILM-E Servo Kits
3Edition 10/2021 EN
Contents
1 Introduction ....................................................................................................................... 4
1.1 Notes on the assembly instructions ......................................................................... 4
1.2 Description ................................................................................................................ 4
1.3 Revision index ........................................................................................................... 5
1.4 Supplementary documents ...................................................................................... 5
1.5 Explanation of the symbols used ............................................................................. 5
1.6 Training ...................................................................................................................... 5
1.7 Declaration of incorporation .................................................................................... 5
1.8 Serial number ............................................................................................................ 5
1.9 Warranty .................................................................................................................... 6
1.10 Transportation and storage .................................................................................... 6
1.11 Environmentally-friendly disposal ........................................................................... 7
1.12 Trademarks ............................................................................................................... 7
2 Safety ................................................................................................................................. 8
2.1 Hazard classification ................................................................................................. 8
2.2 Target group ............................................................................................................. 8
2.3 Intended use ............................................................................................................. 9
2.4 Working environment and operation ..................................................................... 9
2.5 Safety instructions for the ILM-E servo kit ............................................................ 10
2.6 Warning labels ......................................................................................................... 11
3 Technical data .................................................................................................................. 12
3.1 Data sheet ................................................................................................................. 12
3.2 Connection diagram (star-serial configuration) .................................................... 12
3.3 Installation dimensions ........................................................................................... 13
4 Solder pads on the connection board ........................................................................... 14
5 Assembly .......................................................................................................................... 15
5.1 Stator ........................................................................................................................ 17
5.1.1 Tools and equipment required ........................................................................ 17
5.1.2 Shrink-fitting .................................................................................................... 18
5.2 Rotor ....................................................................................................................... 20
5.2.1 Tools and equipment required ...................................................................... 20
5.2.2 Bonding process ............................................................................................ 21
5.2.3 Inserting the rotor into the stator ................................................................ 22
6 Declaration of incorporation .......................................................................................... 23

Assembly Instructions | ILM-E Servo Kits
4 Edition 10/2021 EN
Introduction
1 INTRODUCTION
1.1 Notes on the assembly instructions
These instructions contain important information that should be followed
when installing the ILM-E servo kits.
►Read all the instructions carefully before starting assembly to avoid possible risks
and mistakes.
►These instructions are part of the product. Keep the instructions in a safe place for
future reference.
WARNING
►Follow ALL danger and warning instructions and notes on precautionary measures.
►Read section „2 Safety“ on page 8 carefully.
1.2 Description
RoboDrive’s ILM-E series of stator-rotor instal-
lation kits provides solutions for structurally
integrated drive engineering. An ILM-E (internal
rotor motor – Evolution) servo kit consists of a
stator and a rotor with permanent magnets for
installation in machines and devices in the com-
mercial environment.
The RoboDrive technology provides the highest
power density at maximum torque and overload
capability in a compact design.
The flexible concept offers solutions for a variety
of demanding drive applications. Alternative
nominal currents, increased rotational speeds
and customised torque-speeds are available
upon request.
The implementation of customer-specific solutions to achieve a compact and thermal-
ly-optimized design is supported by extensive documentation and RoboDrive develop-
ment expertise.
ILM-E servo kits offer the following stand-out features:
—Installation kits for maximum freedom of design
—Hollow shaft capability
—Low voltage 12 V – 48 V
—Excellent copper fill factor offering high torque density and dynamic response
Fig. 1: ILM-E servo kit

Assembly Instructions | ILM-E Servo Kits
5Edition 10/2021 EN
Introduction
—Concentrated windings for low losses
—Thermally-optimized actuator design thanks to structural integration
—Drive systems developed to optimize weight and installation space on the basis of
load profile analyses
—High bandwidth and minimal harmonics for optimal control quality
1.3 Revision index
Manual Edition Language
ILM-E Servo Kit Assembly Instructions 10/2021, initial version EN
Table 1: Revision index
1.4 Supplementary documents
Installation drawings and data sheets are available for different sizes on our website.
1.5 Explanation of the symbols used
►This symbol indicates an action to be taken.
—This symbol indicates a list.
1.6 Training
The manufacturer offers training courses on the general handling of the ILM-E servo kits.
Please contact the TQ-Drives division of TQ-Systems GmbH as required.
1.7 Declaration of incorporation
The ILM-E servo kits are regarded as "partly-completed machinery" as defined in the
Machinery Directive 2006/42/EC. The declaration of incorporation is an integral part of
this installation manual (see section 6 on page 23).
1.8 Serial number
—The serial number is shown on the label attached to the stator.
—The serial number is shown on the label attached to the rotor.
NOTE
The label on the rotor must be removed without leaving any residues before the rotor is
installed.

Assembly Instructions | ILM-E Servo Kits
6 Edition 10/2021 EN
Introduction
1.9 Warranty
TQ-Systems GmbH guarantees that, if used for the agreed purpose, the ILM-E servo kits
fulfil the contractually defined specifications and functionality and correspond to the
state of the art at the time of delivery.
The warranty is limited to material, manufacturing and processing defects.
The manufacturer’s liability and warranty shall not apply in the following cases:
—Genuine parts were not replaced with genuine parts or parts approved by
TQ-Systems GmbH.
—The assembly or set-up work was carried out without following these assembly
instructions or was otherwise carried out incorrectly.
—Unauthorised repairs
—Incorrect operation
—Incorrect use
—Application of force
—Other modifications to the contractual product
NOTE
The warranty period is 12 months and starts upon delivery to the customer.
Please contact the TQ-Drives Division of TQ-Systems GmbH for all claims under the
warranty.
1.10 Transportation and storage
—The stator and rotor of the ILM-E servo kit are shipped in separate packing units.
—Always transport the ILM-E servo kits in the original packaging to avoid mechanical
damage or damage due to static electricity.
—During transportation, avoid hard impacts or vibrations that could affect the
ILM-E servo kits.

Assembly Instructions | ILM-E Servo Kits
7Edition 10/2021 EN
Introduction
1.11 Environmentally-friendly disposal
DANGER
Danger of death by powerful magnetic fields
The life of persons with passive or active implants such as pacemakers, defibrillators, insu-
lin pumps etc. is put at risk if they stand in the vicinity of the ILM-E servo kit.
►Make sure that no persons who could possibly be affected by powerful magnetic fields
are able to approach the ILM-E servo kit. They must maintain a safe distance of at least
2 m.
►Instruct persons in the vicinity of the potential risk.
The ILM-E servo kits must not be disposed of in the residual waste bin.
►In Germany, metal and plastic components should be disposed of at the local recy-
cling centre. The national regulations in other EU states should also be followed.
►In Germany, electrical components should be disposed of in accordance with the
Electrical and Electronic Equipment Act (ElektroG). In other EU states, the na-
tional implementation of the Waste Electrical and Electronic Equipment Directive
2002/96/EC (WEEE) should be followed.
►The regulations and statutory requirements in your own country concerning disposal
should also be followed.
1.12 Trademarks
—LOCTITE® is a trademark of Henkel.
—Kapton® is a trademark of DuPont.

Assembly Instructions | ILM-E Servo Kits
8 Edition 10/2021 EN
Safety
2 SAFETY
These instructions contain notes that you must follow for your own personal safety and
to avoid injury and damage to property. They are highlighted by warning triangles and
are shown as follows according to the level of danger.
2.1 Hazard classification
DANGER
The signal word designates a hazard with a high degree of risk which, if it is not avoided,
will result in death or severe injury.
WARNING
The signal word designates a hazard with a medium degree of risk which, if it is not avoid-
ed, will result in death or severe injury.
CAUTION
The signal word designates a hazard with a low degree of risk which, if it is not avoided,
could result in minor or moderate injury.
NOTE
A note as used in these instructions contains important information about the product or
about a part of the manual to which particular attention should be paid.
2.2 Target group
The activities described in this manual must only be carried out by technicians with the
following qualifications:
—Training in the installation and commissioning of electrical devices (qualified elec-
trician as defined in EN 50110–1: a person with technical training, knowledge and
experience sufficient to allow them to recognise and avoid the risks that might be
posed by electricity)
—Extensive knowledge in the fields of electrical engineering and drive technology
—Training in electrical and mechanical hazards and the local safety requirements
—Knowledge of the relevant standards and directives
—Knowledge and observance of this document and all the safety instructions
Any employee who does not have the relevant training must be given appropriate
training and instruction. The instruction is to be given by authorised personnel with the
appropriate training.

Assembly Instructions | ILM-E Servo Kits
9Edition 10/2021 EN
Safety
2.3 Intended use
The ILM-E servo kits must be used only for the applications listed in the technical de-
scriptions, i.e. as a structurally-integrated drive. Any different or more extensive usage
will be regarded as contrary to the intended use and will invalidate the warranty.
The ILM-E servo kits are regarded as "partly-completed machinery" as defined in the
Machinery Directive 2006/42/EC and must not be brought into service until it has been
determined that the machines in which the ILM-E servo kits are to be installed conform
to the provisions of the Machinery Directive 2006/42/EC.
The ILM-E servo kits are not domestic appliances; as components they are intend-
ed exclusively for reuse for commercial or professional purposes as defined by
IEC/EN 61000–3–2.
Intended use also includes compliance with this manual and the instructions it contains.
If the ILM-E servo kits are to be used safely and without interruption, they must have
been correctly transported, stored, assembled and set up.
For any use contrary to the intended use, TQ-Systems GmbH shall accept no liability for
any damage that may occur and offers no warranty that the product will work perfectly
and correctly.
2.4 Working environment and operation
The ILM-E servo kits must only be operated under the conditions of use and within the
performance limits specified in the documentation.
The ILM-E servo kits are not permitted to be used in the following areas:
—in potentially explosive areas
—in areas in which harmful substances as defined in EN 60721 may be encountered,
such as oils, acids, gases, vapours or dusts
—underwater
—in areas exposed to radiation
—in a vacuum

Assembly Instructions | ILM-E Servo Kits
10 Edition 10/2021 EN
Safety
2.5 Safety instructions for the ILM-E servo kit
DANGER
Danger of death by powerful magnetic fields
The life of persons with passive or active implants such as pacemakers, defibrillators, insu-
lin pumps etc. is put at risk if they stand in the vicinity of the ILM-E servo kit.
►Make sure that no persons who could possibly be affected by powerful magnetic fields
are able to approach the ILM-E servo kit. They must maintain a safe distance of at least
2 m.
►Instruct persons in the vicinity of the potential risk.
►Attach warning instructions, stating POWERFUL MAGNETIC FIELDS at the installation
area and storage location.
—The rotors of the ILM-E servo kit will attract other magnetic materials. The forces of
attraction can be so great that the magnets of the servo kit splinter on impact and
tiny fragments fly into the eyes.
►Wear safety goggles to protect your eyes until you have finished installing the
ILM-E servo kit.
—If the ILM-E servo kit is operated below the specified temperature, the magnets can
become detached from the rotor and fly around due to thermal stressing of the
adhesive.
►Always operate the ILM-E servo kit within the specified temperature range.
—If the ILM-E servo kit operating voltage is too high, it will exceed the maximum
permitted rotational speed. There is a risk of parts becoming detached and flying
around.
►Always operate the ILM-E servo kit within the specified voltage and speed
ranges.
—The electromagnetic interference (EMI) emitted by the ILM-E servo kit is negligible in
nominal operation. However it is not possible to entirely exclude the possibility that
it will affect electrical devices.
—Fast acceleration of the ILM-E servo kit rotor can cause an inadequately secured
ILM-E servo kit to move suddenly and be flung out of its original position.
—The drive train that is connected to the ILM-E servo kit must be designed for the
maximum rotational speed of the ILM-E servo kit, otherwise the drive train may be
damaged or crack.

Assembly Instructions | ILM-E Servo Kits
11Edition 10/2021 EN
Safety
—The ILM-E servo kit reaches high temperatures during operation. If there is a thermal
bridge between the housing and the ILM-E servo kit installed in it, there is a risk of
burns on the housing surface.
—Body parts (fingers, arms, hair, etc.) may be injured or torn off due to the rotation
of exposed mechanical parts such as motor shafts. There is also the risk that items
of clothing (ties, scarves, chains, rings, etc.) or objects (cables, etc.) may be wound
onto the motor shaft and injure the wearer.
►Never touch rotating components (motor shafts, clutches, etc.).
►Do not wear belts, chains, ties or clothing with wide sleeves at the workplace.
►Wear a hairnet if you have long hair.
►Make sure that there are no exposed rotating parts.
—Rotating shafts can crack and parts (such as screws, etc.) can be flung about.
►Secure rotating shafts with a protective cover.
—Install the ILM-E servo kit only in a dry environment.
—Protect the ILM-E servo kit against moisture and wet conditions.
2.6 Warning labels
►Attach warning labels that indicate the relevant risks to the machines in which the
ILM-E servo kits are installed.
►Make sure that the warning labels are always clearly identifiable.
►Replace any damaged warning labels.
►Replace any warning labels that are missing.

Assembly Instructions | ILM-E Servo Kits
12 Edition 10/2021 EN
Technical data
3 TECHNICAL DATA
3.1 Data sheet
You will find the technical data for the ILM-E servo kits in the data sheet provided in the
ILM-E servo kits download area.
3.2 Connection diagram (star-serial configuration)
Connections A, B and C can be found on the ILM-E servo kit.
A
B
C
U1
U2
L1
L3 L2
W1
W2
V1
V2
Fig. 2: Measuring points on the ILM-E servo kit (star-serial configuration)

Assembly Instructions | ILM-E Servo Kits
13Edition 10/2021 EN
Technical data
Measured variable Measured values
Nominal voltage Un* [V]
See data sheet in the download area
Nominal current In* [A]
Terminal resistance
RTT* at 20 °C [m]
Terminal inductance
LTT * [H]
Table 2: Measuring points on the ILM-E servo kit (star-serial configuration)
3.3 Installation dimensions
The installation dimensions of the ILM-E servo kit are shown in the relevant
drawing which can be found in the download area for the product concerned.
Fig. 3: Dimension designations

Assembly Instructions | ILM-E Servo Kits
14 Edition 10/2021 EN
Solder pads on the connection board
4 SOLDER PADS ON THE CONNECTION BOARD
Fig. 4 shows the solder pads on the connection board by way of example. Detailed
drawings for your specific ILM-E servo kit can be found on our website.
Fig. 4: Solder pads on the connection board

Assembly Instructions | ILM-E Servo Kits
15Edition 10/2021 EN
Assembly
5 ASSEMBLY
The assembly processes listed below are merely suggestions, and their applicability
and safety must be assessed by the responsible technician (see 2.2).
DANGER
Danger of death by powerful magnetic fields
The life of persons with passive or active implants such as pacemakers, defibrillators, insu-
lin pumps etc. is put at risk if they stand in the vicinity of the ILM-E servo kit.
►Make sure that no persons who could possibly be affected by powerful magnetic fields
are able to approach the ILM-E servo kit. They must maintain a safe distance of at least
2 m.
►Instruct persons in the vicinity of the potential risk.
►Attach warning instructions stating POWERFUL MAGNETIC FIELDS to the packaging, at
the installation area and at the storage location.
DANGER
Danger of death by electric shock.
The ILM-E servo kit is supplied with electrical voltage for operation. Touching live conduc-
tors can result in death or severe injuries.
►Use the main switch to switch off all power to the complete system before starting
installation or maintenance work.
►Observe the five safety rules (DIN VDE 0105–100) for working on electrical systems:
—Disconnect from mains (all-pole disconnection of a system from live parts)
—Secure against reconnection
—Check that the system is voltage-free
—Earth and short-circuit
—Cover or block off access to adjacent live parts

Assembly Instructions | ILM-E Servo Kits
16 Edition 10/2021 EN
Assembly
DANGER
Danger of death by electric shock or arcing at the power connections of the
ILM-E servo kit
The contacts of the power connections carry potentially fatal voltages and high current
strengths. Removing the cables to the power connections of the ILM-E servo kit during
operation can cause arcing, resulting in serious or fatal injury.
Depending on the installed buffer capacity, the DC link of a connected inverter can contin-
ue to carry dangerous voltages for some time, even after the power supply to the entire
system is switched off.
►Never detach electrical connections on the ILM-E servo kit or the inverter while they are
live.
►Use a permitted meter to check that the power connections are voltage-free before
you carry out installation work on the device.
WARNING
Danger of eye injuries caused by splintering magnetic parts
The rotors of the ILM-E servo kit will attract other magnetic materials. The forces of attrac-
tion can be so great that the magnets of the servo kit splinter on impact and tiny frag-
ments fly into the eyes.
►Wear safety goggles to protect your eyes until you have finished installing the
ILM-E servo kit.
►Keep the rotors of the ILM-E servo kit away from other magnetic materials.

Assembly Instructions | ILM-E Servo Kits
17Edition 10/2021 EN
Assembly
5.1 Stator
5.1.1 Tools and equipment required
—Non-magnetic tool
—Cleaning agents
—Antistatic coat
—ESD grounding wrist strap
—Safety goggles
—Protective gloves
—Assembly sleeve
—Drawing available as a download
—Dimensions according to the outer diameter of the stator, as shown in the
drawings
—Dowel pin
—Adhesive for securing the dowel pin
—Other dimensions corresponding to those in the drawing on the website
Fig. 5: Assembly sleeve

Assembly Instructions | ILM-E Servo Kits
18 Edition 10/2021 EN
Assembly
5.1.2 Shrink-fitting
WARNING
Danger of burns on hot surfaces
Contact with the housing at the temperatures required for shrink-fitting can cause severe
burns.
►Wear appropriate heat protection for your hands throughout the entire process.
—Clean and degrease the housing and stator with isopropyl alcohol.
—Apply a small amount of adhesive in the groove identified for the dowel pin in the
design guidelines and insert the dowel pin into the groove.
Fig. 6: Housing with dowel pin
 Dowel pin
—Heat the stator housing to 100 °C for roughly 45 minutes.
NOTE
Select a temperature that is appropriate for your selected materials and ambient tempera-
tures.

Assembly Instructions | ILM-E Servo Kits
19Edition 10/2021 EN
Assembly
—Remove the housing from the oven and align the stator in the housing as shown in
the design guidelines.
Fig. 7: Stator alignment
 Dowel pin
—Use the press-in tool to carefully press the stator into the housing until the pole
cap/base of the stator touches the bottom surface of the housing.
NOTE
Make sure that the alignment/positioning of the stator does not change when it is pressed in.
Be careful not to press on the PCB while pressing the stator in.
Fig. 8: Pressing-in process

Assembly Instructions | ILM-E Servo Kits
20 Edition 10/2021 EN
Assembly
Fig. 9: Final stator position
 Dowel pin
 Dowel pin
—Allow the housing to cool to room temperature.
—Once the housing has cooled to room temperature, check that the stator is seated
firmly and without gaps in the housing.
5.2 Rotor
WARNING
Danger of eye injury and skin irritation by adhesives
The adhesives used for bonding can cause severe eye injuries and skin irritations.
►Wear safety goggles to protect your eyes and wear safety gloves until you have fin-
ished installing the ILM-E servo kit.
►Read and follow the safety data sheets provided with the adhesive.
5.2.1 Tools and equipment required
—Non-magnetic tool
—Bonding adhesive for rotor (e.g. LOCTITE 648)
—Kapton tape
—Cleaning agents
—Lint-free cloths
—Antistatic coat
—ESD grounding wrist strap
—Safety goggles
—Protective gloves