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Service Manual

1. Version 11 06 Sheet 18 of 46 XtraforsPrime servomotor 0409 1 72 _ 0711 CD1a 14 1 41 1111 1 30 1714 30 Version 11 06 ZINFRANOR MAVILOR 0609 CDla 14 ee 0911 CD1a 30 FP 1311 CD1a 30 3314 CDla30 Sheet 19 of 46 SINFRANOR XtraforsPrime servomotor MAVILOR FP 5019 CDla 45 FP 8019 CDla 45 Voltage VVork Torque Limits Curve Voltage VVork Torque Limits Curve 35044 3 5 Cooling The XtraforsPrime motor are self cooling The motors must be installed on the cooling surface equivalent to the aluminium heat sink according to the following table Motor 0023 FP 0034 FP 0055 FP 0105 FP 0207 FP 0307 FP 0409 FP 0609 Heat Sink Plate 150 150 10 300 300 10 300 300 10 300 300 10 300 300 10 300 300 10 400 400 10 400 400 10 Heat Sink Plate 500 500 20 500 500 20 500 500 20 500 500 20 700 700 20 700 700 20 700 700 20 700 700 20 Table 4 Free convection of the motor housing must be guaranteed 3 6 Brake functionality The XtraforsPrime motors can be supplied with
2. 4 27 13 9114 10 Frequency of the current at rated speed 11 Phase number 12 Insulation class 13 Ambient temperature 14 IP protection class 15 Fabrication date code 16 Motor code 17 Serial number Sheet 30 of 46 SINFRANOR XtraforsPrime servomotor MAVILOR 6 Installation The XtraforsPrime servomotors are not permitted to be connected directly to power mains they are only permitted to be operated in combination with an Infranor servo drive The plugs must be connected and fastened correctly Incorrectly connecting the plugs and tightening the nuts can cause problems and damage the servomotor or servo drive 6 1 Power Connection POWER CONNECTOR CONTACT WIRE COLOUR FUNCTION CONTACT PHASE SW 2 BLACK PHASE 1 U W U V ewe 55 to 3314 5019 and 8019 EL Version 11 06 Sheet 31 of 46 ZINFRANOR XtraforsPrime servomotor MAVILOR 6 2 Signal Connection SIGNAL CONNECTOR po RESOLVER INCREMENTAL INCREMENTAL Sin Cos ABSOLUTE EnDat 2 1 ABSOLUTE HIFERFACE DYNAPAR Devices 0 HEIDENHAIN STEGMANN 1m SKS SKM 50 COLOUR COLOUR COLOUR COLOUR COLOUR COLOUR PTE YELLOW BLUE GREY HALLI VIOLET GREEN BLACK A D GREEN BLACK __ ___ WHE RANGE YELLOW
3. 3386 3 N 1 un us ues 3 6 6 ud N 65 59 2 LL un d LA alo lt e pmi lt lu E ee NIO A MET uto Ll Ll LE LE Li Qiu cc o e B 4 D Sheet 27 of 46 Version 11 06 CINFRANOR XtraforsPrime servomotor MAVILOR 4 2 Type of Output Shaft All the XtraforsPrime servomotor shafts comply to DIN 748 They can be supplied with a smooth shaft or keyed shaft The NEMA option 15 also available Smooth shaft A smooth output shaft 15 used for a force fit shaft hub connection that guarantees a zero connection between shaft and hub as well as smooth operation For connection of pinion gears belt disks or similar drive elements please use suitable clamping sets pressure sleeves or other fastening elements Drive elements must be protected against unintentional removal The output shaft has a threaded centre hole which can be used to remove drive elements 4 3 Keyed shaft The keyed shaft can be used for a form fit torque transfer with low demands on the shaft hub connection and for handling torques with a constant direction The keyways for the Xtra
4. Radial load FP_0307 Frontal Ball Bearing 3000 rpm lifetime 20000 hours Rear Ball Bearing 15 20 Distance on output shaft between load application point and output flange mm Radial load FP_0609 Frontal Ball Bearing 3000 rpm lifetime 20000 hours Rear Ball Bearing 30 40 Distance on output shaft between load application point and output flange mm Radial load FP_0911 Frontal Ball Bearing 3000 rpm lifetime 20000 hours Rear Ball Bearing 30 40 Distance on output shaft between load application point and output flange mm Version 11 06 Sheet 24 of 46 SINFRANOR MAVILOR Radial load FP_0409 Frontal Ball Bearing 3000 rpm lifetime 20000 hours Rear Ball Bearing 40 Distance on output shaft between load application point and output flange mm Radial load FP_0711 Frontal Ball Bearing 3000 rpm lifetime 20000 hours Rear Ball Bearing 30 40 Distance on output shaft between load application point and output flange mm Radial load FP_1111 Frontal Ball Bearing 3000 rpm lifetime 20000 hours Rear Ball Bearing 40 Distance on output shaft between load application point and output flange mm SINFRANOR XtraforsPrime servomotor MAVILOR Radial load 1 311 Frontal Ball Bearing Radial load FP 1 714 Frontal Ball Bearing 3000 rpm 3000 rpm lifetime 20000 hours lifetime 20000 hours Rear Ball Bearing
5. 10 Is A 1 97 2 98 2 67 3 45 5 28 5 44 Nominal Torque at 3000rpm 3 Mn Nm 0 23 0 38 0 46 0 9 1 85 2 54 Peak Torque 10 Mj Nm 1 44 2 4 3 24 6 12 16 2 EMF Constant 5 Ke Vs rad 0 07 0 077 0 12 0 17 0 22 0 29 Torque Constant 5 Kt Nm A 0 12 0 13 0 20 0 29 0 38 0 50 Cogging Torque Ct Nm 0 0 0 0 0 0 Winding Resistance 5 R W 5 1 3 7 6 2 4 8 2 7 2 8 Winding Inductance 5 mH 1 0 1 1 1 6 1 3 1 1 1 2 Rotor Inertia J kgm 10 3 0 0033 0 01 0 02 0 04 0 13 0 19 Mechanical Time Constant Tm ms 1 97 3 53 5 28 3 95 4 27 3 68 Electrical Time Constant Te ms 0 197 0 295 0 260 0 271 0 414 0 419 Thermal Time Constant 5 Tth S 661 712 855 588 980 1126 Thermal Resistance Rth 299 1 78 1 31 1 02 0 77 0 71 Insulation F F F F F F Max winding temperature c 155 155 155 195 155 198 of poles 4 4 8 8 8 8 Axial force Fa N 40 80 100 100 120 120 Radial force Fr N 75 150 230 250 338 367 Weight M kg 0 4 0 7 1 1 2 2 1 2 5 Temperature sensor type PTC PTC PTC PTC PTC PTC With an Aluminium heat sink plate 4 mm 150x150 300x300 300x300 300x300 300x300 300x300 CHARACTERISTICS SYMBOL 0409 FP 0609 0711 0911 1111 1311 1714 Speed at 230 10 5000 3800 4800 3800 3500 3200 3100 Stall Torque 10 Ms Nm 4 2 5 6 6 5 9 11 13 2 18 3 Stall Current 10 Is A 6 46 6 53 9 46 11 63 11 76 13 03 17 34 Nominal Torque at 3000rpm 3 Mn Nm 4 15 5 12 6 10 8 20 9 10 10 75 15 50 Peak Torque 10 Mj
6. Rear Ball Bearing 30 40 Distance on output shaft between load application point Distance on output shaft between load application point and output flange mm and output flange mm Radial load FP 3314 Frontal Ball Bearing Radial load FP 5019 Frontal Ball Bearing 1500 rpm 1500 rpm lifetime 20000 hours lifetime 20000 hours Rear Ball Bearing Rear Ball Bearing 40 50 Distance on output shaft between load application point Distance on output shaft between load application point and output flange mm and output flange mm Radial load FP 8019 Frontal Ball Bearing 1500 rpm lifetime 20000 hours Rear Ball Bearing 30 Distance on output shaft between load application point and output flange mm Version 11 06 Sheet 25 of 46 SINFRANOR XtraforsPrime servomotor MAVILOR 3 9 Tolerances IEC 60072 Shaft extension run out Shaft diameter Normal Reduced 0 lt D lt 10 0 030 0 015 10 lt lt 18 0 035 0 018 18 Dx 30 0 040 0 021 Concentricity and Perpendicularity 10 mm 10 mm Mounting flange diameter Normal Reduced 32 0 08 0 04 40 0 08 0 04 60 0 08 0 04 80 0 08 0 04 95 0 08 0 04 130 0 10 0 05 Version 11 06 Sheet 26 46 XtraforsPrime servomotor 111 111 130 130 130 130 184 184 240 240 42 0034 ss 25 25 5 a 70 1405 1715 53 1 194 218 242 266 258 367 73 3 149 173 197 317 2
7. m J m 27 mass of the load p pitch Jv Inertia of the screw Belt 2 Jg m R Jp J Inertia of the drum mass of the load m massof belt R Radius of the drum Pinion J J m LIPIP Version 11 06 Sheet 41 of 46 SINFRANOR XtraforsPrime servomotor MAVILOR J Inertia of pinion Radius of pinion massof massof the chariot Inertia of the motor Winch 2 Jg J 9 3 Torque calculations Gear transmission M N i 1 77 N n 0 6 0 95 Version 11 06 Sheet 42 of 46 XtraforsPrime servomotor MAVILOR Belt transmission _ 60 V M R u m 8 7 1 M 1 25M M n i Screw lead transmission M p tm g F 4h R F 44 0 15 3070090700 R 0 75 0 94 0 8 0 95 7 0 8 0 95 M p 7 V 1 54 1 m 14 1 Version 11 06 Sheet 43 of 46 SINFRANOR XtraforsPrime servomotor MAVILOR Winch Mc M Version 11 06 Sheet 44 of 46 SINFRANOR XtraforsPrime servomotor MAVILOR NOTES Version 11 06 Sheet 45 of 46 XtraforsPrime servomotor SINFRANOR MAVILOR Infranor Sales Offices and Distributors REP OF CHINA INFRANOR MOTION CONTROL TECHNOLOGY
8. 11 367 FP 1714 FP 3314 FP 5019 FP 8019 258 0207 0307 0409 0609 4 B e Q Q x ca lt CI N uU m e o N H CERE 53 un in 18 lt lt a NI CV CN CN NIAN a x x X X X X x x x X X X X lt lt lt lt lt lt i Hn ii x e LL in in CN CN BE ed alaja X olo al 60 la N 13 xX x X X X X x S Alola z iL gt 2 151 21212512 in b N z O N N 5 uy N ajo v lt lt 3 d Ln 09 gt 7 Ln in N wn Q 72 N S
9. 12 661 2909 Fax 27 12 661 1262 SLOVENIA JMB Commerc d o o Tel 386 2 80 333 81 82 83 Fax 386 2 80 333 80 SLOVAKIA ECS Sluzby s r o Tel 421 2 4564 3147 Fax 421 2 4525 9606 TURKEY DAYE MAKINE Tel 90 216 641 68 84 Fax 90 216 641 68 86 TAIWAN EU POR Co Ltd Tel 886 2 291 457 67 Fax 886 2 291 453 37 VIETNAM LIEN MINH HUNG Trading Tel 84 8 9 032 578 Fax 84 8 9 290 758
10. 08 4 36 Thermal Time Constant 5 Tth 661 712 855 588 980 Insulation F F F F F of lur 4 4 8 8 8 Radial force Fr N 75 150 230 250 338 NEUE Sensor um PTC PTC PTC PTC PTC 1 25000 rpm values achievable with GD1 amp CD1 Drive Speed Limit Converter 2 15000 rpm values achievable with GD1 amp CD1 Drive Max Current Bandwidth 1 2 3 From FP 1714 to big sized Nominal Torque at 1500rpm 4 From FP 1714 to big sized the width size is 20mm the rest 10mm 5 With heat sink included When the motor is mounted with encoder the performances could be changed because of the temperature or speed limit of the electronics please ask factory for more details Version 11 06 Sheet 17 of 46 SINFRANOR XtraforsPrime servomotor MAVILOR 3 4 Functional curves The curves shown here below have been obtained with 1 400VAC drive The motors were mounted in a heat sink plate of aluminium see table 4 and with an increment of temperature on the winding of 130 at 25 C Amb Plot 1 Limit 10 Input voltage Plot 2 Limit Nominal Input voltage Plot 3 Limit 10 Input voltage Plot 4 Limit Continuous Oper ation FP 0023 CDla 5 1 0034 CDla 5 1 ef LLLA K ee mein 105 CDlaS CDla 7 2 FP 0307 CDla 72
11. 2048 ppr ABSOLUTE Endot 2 1 Multiturn ABSOLUTE EnDot 2 1 Singleturn ABSOLUTE Hiperface Multiturn T MEN OUTPUT SHAFT ABSOLUTE Hiperface Singleturn TANDARD WITHOUT KEYWAY SHAFT SEAL INCREMENTAL COMMUTATION 1024 ppr NEMA DIMENSIONS INCREMENTAL 4 COMMUTACION 2048 pp SPECIAL HALL EFFECT SENSOR gt n U TANDARD STANDARD WITHOUT KEYWAY gt CODE N 20700001600 WITHOUT BRAKE MODEL TORQUE 2 Nm FRAME 70 207 BRAKE WITH BRAKE BUS VOLTAGE 400 VAC SHAFT STANDARD FLANGE STANDARD BRAKE WITHOUT BRAKE FEEDBACK SYSTEM WITH RESOLVER TRANSMITTER 278 ELECTRICAL ROTABLE 90 CONNECTORS STANDARD B5 FRONT FLANGE NEMA DIMENSIONS SPECIAL SPECIFICATION STANDARD Uu T m m gt gt gt Version 11 06 Sheet 29 of 46 XtraforsPrime servomotor MAVILOR 1 Stall Torque 2 Peak Torque 3 Motor Type 4 Voltage constant 5 Torque constant 6 Nominal speed 7 Supply voltage of the drive 9 Power at nominal speed 9 Current at nominal power and speed Version 11 06 ZINFRANOR m s n 12 5 11 ZINFRANOR MAVILOR Power Hp Rated Volt 2p L Ph Cont Serv Nom Speed rpm Stall Nm Peak Torque Nm Kt Nm A Ke Vs rad T IP
12. Nm 25 2 33 6 39 54 66 79 2 109 8 EMF Constant 596 Ke Vs rad 0 38 0 50 0 39 0 44 0 54 0 59 0 61 Torque Constant 5 Kt Nm A 0 65 0 86 0 67 0 77 0 94 1 01 1 06 Cogging Torque Ct Nm 0 0 0 0 0 0 0 Winding Resistance 5 R W 2 0 2 4 1 5 1 1 0 9 1 1 0 5 Winding Inductance 5 L mH 1 2 1 4 1 2 1 1 1 0 1 1 1 0 Rotor Inertia J kgm 10 3 0 48 0 63 1 16 1 72 2 28 2 85 6 02 Mechanical Time Constant Tm ms 3 84 3 53 6 42 5 64 4 15 5 10 4 40 Electrical Time Constant Te ms 0 593 0 585 0 828 0 955 1 080 1 061 2 097 Thermal Time Constant 5 Tth 1005 1108 992 1157 1340 1604 2249 Thermal Resistance Rth 0 71 0 57 0 43 0 38 0 46 0 32 0 41 Insulation F F F F F F F Max winding temperature c 155 155 155 155 155 155 155 N of poles 8 8 8 8 8 8 8 Axial force Fa N 160 160 200 200 200 200 360 Radial force Fr N 572 606 550 600 650 685 770 Weight M kg 4 2 4 3 5 6 7 8 3 9 6 14 2 Temperature sensor type PTC PTC PTC PTC PTC PTC PTC With an Aluminium heat sink plate 4 mm 400x400 400x400 500x500 500x500 500x500 500x500 700x700 Version 11 06 Sheet 16 of 46 XtraforsPrime servomotor MAVILOR 48 VDC CHARACTERISTICS SYMBOL UNITS 0023 FP 0034 0055 0105 0207 Stall us m Ms Nm 0 24 0 4 0 54 1 2 Nominal Torque at 3000rpm 3 Mn Nm 0 23 0 38 0 46 0 9 1 85 EMF Constant T Ke Vs rad 0 05 0 06 0 07 0 09 0 09 mm Ct Nm 0 0 0 0 0 e Inductance 5 mH 0 5 0 7 0 5 0 4 0 2 Mechanical Time Constant Tm ms 1 94 3 48 5 40 4
13. Shanghai Co Ltd Room 601 No 448 HongCao Rd Shanghai P R China CN 200233 Tel 86 21 6145545 FRANCE INFRANOR S A Immb Newton 1 Georges Besse F 92160 ANTONY Tel 33 0 156451600 GERMANY INFRANOR GmbH Donaustrasse 19a D 63452 HANAU Tel 49 6181 180 120 Fax 49 6181 180 1290 ARGENTINA TEKMATIC S A Tel 54 11 4222 5040 Fax 54 11 4201 2478 AUSTRIA SPORK ANTRIEBSSYSTEME GMBH Tel 43 22527 1110 Fax 43 22527111029 AUSTRALIA RUTTY amp CO Tel 61 2 9457 2222 Fax 61 2 9457 2299 BULGARIA ZGPU Group Ltd Tel 359 66 800 926 Fax 359 66 800 925 COLOMBIA SERVELEC Ltda Tel 57 1 295 1333 Fax 57 1 263 78 13 CZECH REPUBLIC RONAX DEVICES s r o Tel 420 595 172 338 Fax 420 595 172 339 DENMARK DELTA ELEKTRONIK A S Tel 45 437 1 8088 Fax 45 437 1 8038 EGYPT AEE Advanced Electronic Engineering Tel 202 24185020 Fax 202 24159265 Version 11 06 NETHERLANDS INFRANOR S A Einsteinstraat 6 Po Box 1317 NL 3260 LP OUD BEIJERLAND Tel 31 186 610 155 Fax 31 186 614 535 SPAIN INFRANOR SPAIN S L U C Occit nia 24 08911 BADALONA Barcelona Tel 34 934 601 631 Fax 34 933 999 608 SWITZERLAND INFRANOR SA Rue des Uttins 27 CH 1401 Yverdon Les Bains Tel 41 0 24 447 02 90 41 0 24 447 02 91 UNITED KINGDOM INFRANOR L T D Unit 60A Smithbrook kilns Cranleigh UK Surrey GU6 8JJ Tel 44 1483 274887 Fax 44 1483 27603
14. Torque Constant 5 Cogging Torque Winding Resistance 5 Winding Inductance 5 Rotor Inertia Mechanical Time Constant Electrical Time Constant Thermal Time Constant 5 Thermal Resistance Insulation Max winding temperature N of poles Axial force Radial force Weight Temperature sensor type With an Aluminium heat sink plate 4 CHARACTERISTICS Max Speed at 400V 10 Stall Torque 10 Stall Current 10 Nominal Torque at 3000rpm 3 Peak Torque 10 EMF Constant 5 Torque Constant 5 Cogging Torque Winding Resistance 5 Winding Inductance 5 Rotor Inertia Mechanical Time Constant Electrical Time Constant Thermal Time Constant 5 Thermal Resistance Insulation Max winding temperature N of poles Axial force Radial force Weight Temperature sensor type With an Aluminium heat sink plate 4 Version 11 06 SYMBOL rpm Tm Te Tth Rth Fa Fr SYMBOL rpm Tm Te Tth Rth Fa Fr UNITS nm Nm A Nm Nm Vs rad Nm A Nm kgm7 10 3 ms ms c W kg mm UNITS nm Nm A Nm Nm Vs rad Nm A Nm Q mH kgm 10 3 ms ms kg mm FP 0409 5300 4 2 3 57 4 15 25 2 0 68 1 18 0 6 5 3 8 0 48 3 90 0 585 1005 0 70 155 8 160 572 4 2 PTC 400x400 FP 1714 3500 18 3 10 67 15 50 109 8 0 99 1 71 0 1 23 2 6 6 02 4 36 2 114 2249 0 41 155 8 360 770 14 2 700 700 She
15. flows through it in unit time The value is given in C W Version 11 06 Sheet 13 of 46 CINFRANOR XtraforsPrime servomotor MAVILOR Mass It is the weight of the motor without accessories The value is given in kg Radial load It expresses the shaft radial load applied in the middle of the output shaft which will give a basic rating life of the bearings of 20000 hours Axial load It expresses the shaft axial load which will give a basic rating life of the bearings of 20000 hours Insulation It refers to the maximum operation temperature allowed 3 3 Characteristics 400 VAC CHARACTERISTICS SYMBOL UNITS FP 0023 0034 FP 0055 FP 0105 FP 0207 FP 0307 Stall Torque 10 Ms Nm 0 24 0 40 0 54 2 7 Nominal ae at n 3 Mn Nm 0 23 0 38 0 46 0 9 1 85 2 54 x Ke Vs rad 0 099 0 155 0 145 0 23 0 38 0 43 Te Ct Nm 0 0 0 0 0 0 Winding Inductance 596 on c E E 7 Time Constant 1 94 3 53 5 33 4 02 4 26 3 68 Thermal Time 1126 rcc c V of poles Radial force Temperature sensor type Version 11 06 Sheet 14 of 46 XtraforsPrime servomotor SINFRANOR MAVILOR CHARACTERISTICS Max Speed at 400V 10 Stall Torque 10 Stall Current 10 Nominal Torque at 3000rpm 3 Peak Torque 10 EMF Constant 595
16. is given in Vs rad Torque constant The ratio between the current in rms value is supplied to the motor and the torque in the output shaft measured in Nm The value is given in Nm A Reluctance torque Cogging The maximum torque needed to move the shaft without power It characterizes the stepping effect of the rotor which should be as low as possible The value is given in Nm Winding resistance The resistance is measured between two phases at 25 T ambient The values is given in Winding inductance The inductance is measured between two phases The value is given in mH Rotor inertia It is inertia of the rotor without any accessories The value is given kg m 10 Version 11 06 Sheet 12 of 46 ZINFRANOR XtraforsPrime servomotor MAVILOR Mechanical time constant It characterizes the speed increase for an input voltage step The value shows the time to achieve the 63 of the maximum speed for the input voltage w 100 JxR m KexKt 50 25 0 0 33 3 66 6 99 9 t 4 1m The values is given in s Electrical time constant It characterizes the current increase 1 the motor winding for a voltage step 10096 75 50 25 0 0 33 3 66 6 99 9 Te gt The value is given in ms when L is in mH and R in Q Thermal resistance It is the temperature difference across a structure when a unit of heat energy
17. of sensors encoders and monitoring devices defective components software or firmware errors Dangerous movements can occur immediately after equipment is switched on or even after an unspecified time of trouble free operation The monitoring in the drive components will normally be sufficient to avoid faulty operation in the connected drives Regarding personal safety especially the danger of bodily injury and material damage this alone cannot be relied upon to ensure complete safety Until the integrated monitoring functions become effective it must be assumed in any case that faulty drive movements will occur The extent of faulty drive movements depends upon the type of control and the state of operation 1 Dangerous movements Danger to life severe bodily 87 44 5 harm or material damage by motor unintentional movement Ensure personal safety by means of qualified and tested higher level monitoring devices or measures integrated in the installation Unintended machine motion is possible if monitoring devices are disabled bypassed or not activated Pay attention to unintended machine motion or other malfunction in any mode of operation Keep free and clear of the machine s range of motion and moving parts Possible measures to prevent people from accidentally entering the machine s range of motion use Safety fences Version 11 06 Sheet 8 of 46 CINFRANOR XtraforsPrime servomotor MAVILOR use
18. shaft end is made up of the installation forces e g stress caused by installation and operational forces e g thrust caused by slanted pinions The maximum axial force Fa depends on the bearing type and the desired lifespan of the bearings The fixed bearing is secured on the B flange with a retaining plate The floating ball bearing is preloaded on the A flange with a spring in the direction of the B flange Axial forces in the direction of the A flange can cause the spring bias to be overcome and the shaft is shifted by the amount of axial play in the bearing 0 1 to 0 2 mm approx This shift can cause problems on motors with holding brakes or motors with encoders DANGER Because the high axial forces on the motor shaft during installation the bearings could be damaged and the operation of the motor holding brake could be so heavily influenced that it has no or only a reduced braking effect Encoder errors could also occur Therefore excessive pressure or shocks to the front of the shaft end or the rear housing cover should be avoided at all costs Loads caused by a hammer definitely exceed the permissible values Radial force The radial force Fr on the shaft end is made up of installation forces e g belt tension on pulleys and operation forces e g load torque on the pinion The maximum radial force Fr depends on the shaft end type bearing type average speed position where the radial force is applied and the desir
19. 400 xxxxR CR022 xxxxR CC022 xxxxR FP 1714 FP 33 14 CM400 xxxxR CRO22 xxxxR CC022 xxxxR FP 5019 FP 8019 CM400 xxxxB CRO22 xxxxR CC022 xxxxR Required length in centimeters Version 11 06 Sheet 38 of 46 XtraforsPrime servomotor MAVILOR 9 Applications 9 1 Process to select the servomotor 1 CALCULATE Inertia of the load J kg m 2 Acceleration required f rad s o rad s Acceleration torque of the load Mg Nm J kgm rad s Resistant torque Nm Speed of the motor required n rpm 2 SELECT THE MOTOR Nominal torque Nominal speed 3 CALCULATE THE TOTAL INERTIA Jr Je kgm 4 CALCULATE THE ACCELERATION AND DECELERATION TORQUE 12 M M M J kgm rad s 5 CALCULATE THE TORQUE rms M 1 M2t ts Ttotaltime s pus Duty Cycle Ma t t2 t3 t4 Mp Version 11 06 Sheet 39 of 46 XtraforsPrime servomotor MAVILOR 9 2 Inertia calculations 2 R Jp 1 Direct transmission J J J p Density n Gear Transmission zu PELIS _ _ 43 Z Zm R R R m i reduction rato N speed R Pitch radius Z teeth m module Version 11 06 Sheet 40 of 46 XtraforsPrime servomotor MAVILOR Lead screw transmission 2 J
20. 7 UNITED STATES INFRANOR INC 299 Ballardvale Street Suite 4 Wilmington MA 01887 1013 Tel 1 9789889002 Fax 19789889112 MAVILOR MOTORS SA P I Can Bernades Subira C Empord 11 13 08130 Sta Perp tua de Mogoda Barcelona Spain Tel 34 93 574 36 90 Fax 34 93 574 35 70 FINLAND SKS GROUP Tel 358 20 764 6750 Fax 358 20 764 6820 GREECE KYMA GmbH Tel 30 2 310556 239 Fax 30 2 310566 491 HUNGARY SYNCRODAN Kft Tel 36 1265 0677 Fax 36 1265 0677 INDIA GROUP INTELMAC Tel 91 20 24318111 Fax 91 20 2431 8116 IRAN RAD ELECTRIC Co Tel 98 21 3391 0071 Fax 98 21 3397 3805 ISRAEL ABIRY TECHNOLOGIES L T D Tel 972 36470471 Fax 972 36470472 ITALY ELCAM S P A Tel 39 0 266200980 Fax 39 0 266200989 JAPAN Co Ltd Tel 81 3 5298 2700 Fax 81 3 5298 2888 Sheet 46 of 46 KOREA HKP Co Ltd Tel 82 2 3431 3182 Fax 82 2 3431 3183 MALAYSIA SOUTH PACIFIC RADIO Co SDN BHD Tel 60 5 2538 555 Fax 60 5 2541 161 MEXICO INDUSTRIAL MAGZA Tel 52 55 53 63 23 31 Fax 52 55 55 60 07 56 MOROCCO ADVANCED AUTOMATION Tel 212 22 86 19 29 22 86 19 39 Fax 212 22 86 34 35 NORWAY FERMAR ASSOCIATES Tel 47 2233 5301 Fax 47 2233 5301 POLAND LEMI BIS Tel 48 71 339 00 29 30 Fax 48 71 339 05 01 RUSSIA May Electronics Components Tel 7 495 2288898 Fax 7 495 2288898 SOUTH AFRICA Pro Vey Pty Ltd Tel 27
21. BLUE SASIN YELLOW S4 SIN BROWN YELLOW BLACK NEM n NEM BROWN BLACK S3 COS BLACK S3 COS WHITE HALL HALLS BLUE BLACK EN BLUE BLACK PINK a 5005 56005 BLUE RED BLACK RED BLACK B BLACK 05 RED RED BLUE YELLOW BLACK GREEN CI III e e e e ee ORANGE VIOLET D VIOLET nur PRED T 5 gy BO GREY GNO OVMemory GREY GREY DV _ BREY ge BNXOV EN NN WHITE SbL Memary WHITE SCL Memary WHITE SCL Memary WHITE SCL Memory WHITE SCL Memary WHITE SCL Memary WHITE SCL Memary BLUE SDA Memary BLUE SDA Memary BLUE SDA Memary BLUE SDA Memary BLUE SDA Memary BLUE SDA Memary BLUE SDA Memary Version 11 06 Sheet 32 of 46 XtraforsPrime servomotor MAVILOR 6 3 Connector position The XtraforsPrime servomotor mounts a revolving angled connector this allows different positions Version 11 06 Sheet 33 of 46 ZINFRANOR XtraforsPrime servomotor MAVILOR 7 Conditions of use 7 1 Ambient temperature The characteristics specified for the XtraforsPrime servomotor apply in the following conditions Ambient temperature of 25 Operating temperature 40 to 70 C Altitude of to 1000 m above sea l
22. CINFRANOR XtraforsPrime servomotor MAVILOR CINFRANOR MAVILOR SERVICE MANUAL XtraforsPrime Version 11 06 Version 11 06 Sheet 1 of 46 SINFRANOR XtraforsPrime servomotor MAVILOR Version 11 06 Sheet 2 of 46 XtraforsPrime servomotor MAVILOR Page 1 Introduction to the product 3 2 Safety Guideline 4 2 1 Appropriate use 4 2 2 Explanations 4 2 3 Hazards by improper use 5 2 4 Transport and storage 9 2 5 Installation 5 2 6 Protection against touching electrical parts 6 2 7 Protection against dangerous movements 6 2 8 Protection against contact with hot parts 7 2 9 Protection during handling and mounting 7 3 Technical data 9 3 1 General description 9 3 2 Definitions 9 3 3 Characteristics 12 3 4 Functional curve 16 3 5 Cooling 18 3 6 Brake functionality 18 3 7 Grease life 19 3 8 Shaft load 20 3 9 Tolerances 24 4 Dimensions 25 4 Dimensions sheet 25 4 2 Type of shaft end 26 4 3 Keyed shaft 26 4 4 Optional flange mounting 26 5 Codification 27 6 Installation 20 6 1 Power connection 20 6 2 Signal connection 30 6 3 Connector position 30 7 Conditions of use 32 7 1 Ambient temperature 32 7 2 Mechanical environmental conditions 34 7 2 1 Vibration and Shock 34 7 2 1 Enclosure protection IP 34 7 3 Balancing 34 9 Accessories 35 8 1 Cables 35 9 Applications 37 9 1 Process to select the servomotor 37 9 2 Inertia calculations 38 9 3 Tor
23. ER harm or material damage by an unintentional motor movement High electrical voltage due to wrong connections Danger to life or bodily harm by electric shock Health hazard for persons with heart pacemakers metal implants and hearing aids in proximity to electrical equipment Surface of machine housing could be extremely hot Danger of injury Danger of burns Risk of injury due to improper handling Bodily harm caused by crushing shearing cutting and mechanical shock 2 4 Transport and Storage During transport and storage devices must be protected from excessive stress mechanical load temperature humidity aggressive atmosphere etc Servo drives contain components sensitive to electrostatic charges which can be damaged by inappropriate handling It 15 therefore necessary to provide the required safety precautions against electrostatic discharges during installation or removal of servo drives 2 5 Installation The installation must take place according to the service manual using suitable equipment and tools Devices may only be installed without voltage applied and by qualified personnel Before installation voltage to the switching cabinet should be switched off and prevented from being switched on again The general safety regulations and national accident prevention guidelines Council Directive 89 391 CEE must be observed when working with high voltage systems Electrical installation must be carried out acc
24. Prime servomotor MAVILOR 8 Accessories 8 1 Cables Power cables BOOTLACE FERRULE TELECRIMP 0 75 BLUE 316 0033 BOOTLACE FERRULE TE ECRIMP Imn RED 316 0040 6 PIN CONNECTOR 306 0093 SHIELDING COPPER TAPE SOCKET 8804 0002 306 0130 88007 014 HEATSHRINK SHIELD 410 0052 LONG 25mm 423 0025 MAVILOR MOTORS S A 09 5 20 50 c me ON ORDER CM100 xxxxR Example Version 11 06 Sheet 37 of 46 CINFRANOR XtraforsPrime servomotor Signal cables BOOTLAC RULE TELECRIMP 0 25mn LILA 316 0034 17 PIN CONNECTOR 651 0315 SHIELDING COPPER TAPE SOCKET 8804 0002 306 0098 HEATSHRINK SHIELD 423 0025 oo 1 _ gS 8 E 55 E Q 8 10 Mme _ 20 50 Powercable __ cable cable FP 0711 FP 09011 FP 1111 FP 1311 CM
25. a holding brake Motor reos Feo reooss rPons reoxr reos Brake torque Nm 1 1 2 4 5 4 5 9 Power W 10 10 11 12 12 18 Inertia 10 0 021 0 021 0 068 0 18 0 18 0 54 Weight kg 0 11 0 11 0 15 0 30 0 30 0 46 Moor 0911 reir Frasi 8019 9 9 Brake torque Nm 18 18 18 36 72 72 Power W 18 24 24 24 26 40 40 Inertia 10 0 54 1 66 1 66 1 66 5 56 11 5 Weight kg 0 46 0 9 0 9 0 9 1 6 2 85 Table 5 Version 11 06 Sheet 20 of 46 XtraforsPrime servomotor MAVILOR Release voltage vs brake air gap and motor temperature voltage release area diagram Worked penetration ASTM D217 Dropping point C 566 Copper strip corrosion 100 C 24h ASTM D4048 Evaporation loss mass 99 C 22h ASTM D972 10 ASTM D6184 98 Oil separation mass 0 C 24h Mod Oxidation stability Mpa 99 C 100h D942 10 um or larger Foreign particles particles cm 75 or larger 125 larger Working stability 01264 01478 63 ASTM D1743 73 0445 38 C 1h Low temperature torque 40 C 52 48h Other greases are available for different temperatures please ask factory for more information Version 11 06 Sheet 21 of 46 SINFRANOR XtraforsPrime servomotor MAVILOR 3 8 Shaft Load Axial force The axial force Fa on the
26. agnets Sinusoidal commutation with encoder or resolver as feedback unit Three phase winding with star connection Compact sizes result in low weight High overload capability peak torque 0 Cogging torque due to it s special construction without slots in the stator High dynamic torque at high speeds Long life span all motor parts except for bearings are free of wear Direct diversion of lost power generated in the stator over the housing to the flange Preloaded grooved ball bearings which are sealed on both sides and greased Complete motor system with stall torque ranging from 0 25 Nm to 75 Nm Connection using two circular plugs or cables 3 2 Definitions Max speed The speed limit 15 fixed by the bus voltage of the drive The value 15 given in RPM Stall torque The torque is given by the motor at very low speed with an increment of the winding temperature 130 C and mounted with a heat sink plate The value is given in Nm Stall current The current is required to achieve the stall torque The value is given in A Peak torque The maximum torque is available without iron saturation torque constant still linear The value is given in Nm Version 11 06 Sheet 11 of 46 SINFRANOR XtraforsPrime servomotor MAVILOR EMF constant Voltage that the motor gives as a generator between two terminals at certain speed the voltage 15 measured in rms value and the speed rad s The value
27. ed lifespan of the bearing As standard 20000 h when the load indicated on the catalogue 15 applied in the middle of the output shaft Excessive radial force can cause premature wear on the bearing or in extreme cases can cause the output shaft to break Version 11 06 Sheet 22 of 46 SINFRANOR XtraforsPrime servomotor MAVILOR When installing drive elements the motor shaft avoid hyperstatic arrangements of the motor shaft bearing The tolerances that occurs cause additional force on the motor shaft bearings This can significantly reduce the bearing lifespan or damage the bearing Shaft Load vs position Radial load FP_0034 Frontal Ball Bearing Radial load FP_0055 Frontal Ball Bearing 3000 rpm 3000 rpm lifetime 20000 hours lifetime 20000 hours Rear Ball Bearing Rear Ball Bearing 15 20 10 5 Distance output shaft between load application point Distance on output shaft between load application point and output flange mm and output flange mm Radial load FP_0105 Frontal Ball Bearing Radial load FP_0207 Frontal Ball Bearing 3000 rpm 3000 rpm lifetime 20000 hours lifetime 20000 hours Rear Ball Bearing Rear Ball Bearing 5 10 Distance on output shaft between load application point Distance on output shaft between load application point and output flange mm and output flange mm Version 11 06 Sheet 23 of 46 XtraforsPrime servomotor
28. et 15 of 46 0609 5500 5 6 4 97 5 12 33 6 0 65 1 13 0 4 1 2 4 0 63 3 53 0 585 1108 0 57 155 8 160 606 4 3 400 400 3314 2500 31 5 13 37 21 50 189 1 36 2 36 0 1 28 2 1 12 01 4 80 1 641 2948 0 25 195 8 360 950 23 2 700 700 0711 6300 6 5 6 82 6 10 39 0 55 0 95 0 2 84 2 4 1 16 6 29 0 845 992 0 44 155 8 200 550 5 6 PTC 500x500 FP 5019 FP 8019 2000 54 5 19 07 46 00 327 1 65 2 86 0 0 8 2 28 3 4 80 2 500 2407 0 20 133 12 700 1500 32 700 700 0911 5000 9 7 99 8 20 54 0 65 1 13 0 2 4 2 29 5 64 0 954 1157 0 38 155 8 200 600 7 500 500 2000 75 22 79 59 00 450 1 9 3 29 0 0 83 2 1 9 7 5 00 2 530 2555 0 13 195 12 700 1600 41 700 700 1111 4600 11 8 14 9 10 66 0 78 1 35 0 1 91 2 07 2 28 4 13 1 084 1340 0 46 F 155 8 200 650 8 3 500 500 1311 4600 13 2 ST 10 75 0 78 1 35 0 1 9 2 2 85 5 14 1 053 1604 0 32 155 8 200 685 9 6 500 500 XtraforsPrime servomotor 230 VAC CHARACTERISTICS SYMBOL UNITS FP 0023 FP 0034 CINFRANOR MAVILOR FP 0055 0105 0207 0307 Speed at 230 10 270001 30000 1 16300 2 11400 8700 6600 Stall Torque 10 Ms Nm 0 24 0 4 0 54 1 2 2 7 Stall Current
29. evel For different ambient temperatures the following derating curves should be used Other conditions please ask factory gt 00334 Version 11 06 Sheet 34 of 46 0609 CINFRANOR XtraforsPrime servomotor FP 0409 LLLI TAT TTT ET _ _ i EI ss pz NENNEN TES E T LLL 0911 0711 EA E E e d FP 1311 FP 1111 EN EP LLL LLLI 3314 FP 1714 Sheet 35 of 46 Version 11 06 SINFRANOR XtraforsPrime servomotor MAVILOR FP 5019 FP 8019 Derating Curve Derating Curve 40 20 0 20 40 60 80 100 120 140 Temp 2 1 1 1 1 1 1 1 1 1 1 J 40 20 0 20 40 60 80 100 120 140 7 2 Mechanical envir
30. forsPrime servomotors conform to keyway form 1 according to DIN 6885 1 Form A Shaft keys used conforms to DIN 6885 4 Balancing motors with keyways 1s done using the half key convention according to ISO 2372 The end of the shaft has a threaded centre hole which can be used to mount drive elements with shaft end disks The shaft key can be deflected during heavy reverse operation In extreme cases this can cause the output shaft to break Smooth output shaft should be used preferably 4 4 Optional flange mounting The NEMA mounting flange is an option available for other configuration contact factory Version 11 06 Sheet 28 of 46 XtraforsPrime servomotor MAVILOR 5 Codification XtraforsPrime CODIFICATION 8 TORQUE FRAME SPECIFICATION STANDARD 003 REDUCED TOLERANCES DIN 42955 1 00 105 2 0 2 70 4 50 06 90 110 110 11 TWO ROTATEABLE 90 CONNECTORS without plugs 6 110 CONNECTIONING FOR OPTION 6 without plugs 140 EM CONNECTION FWO STRAIGHT CONNECTORS without plugs Sal een ne 9 400 VAC 560 VDC 230 VAC 320 VDC 34 VAC 48 VDC VOLTAGE SPECIAL N esep RESOLVER 278 Transmitter Speed 1 INCREMENTAL SinCos 512 ppr INCREMENTAL SinCos
31. onmental conditions According to IEC 68 2 6 the XtraforsPrime servomotors may be operated permanently installed and weather protected under following conditions 7 2 1 Vibration Shock Sinusoidal vibrations 50 m s from 10 to 500 Hz EN 60068 2 6 Shocks 15 during 11 ms EN 60068 2 27 7 2 2 Enclosure Protection IP Class The type of protection 1s defined by the identification symbol IP International Protection and two code numbers specifying the degree of protection The first code number defines the degree of protection against contact and penetration of foreign particles The second code number defines the degree of protection against water The protection classes according to IEC 529 apply to XtraforsPrime servomotor The degree of protection of the motor is IP 65 the Viton joint used is to prevent against the most usual fluids water and cooling fluids for other type of fluids contact the manufacturer In the case of vertical installation positions shaft up dirt and fluids can enter the motor interior more easily causing malfunctions or failures In those cases a sealing ring on the shaft is recommended The installation position and the protection class of the motors should be taken into account when planning the system 7 3 Balancing XtraforsPrime servomotor motors are dynamically balanced according to DIN ISO 2372 Group K Veff max 4 5 mm s Version 11 06 Sheet 36 of 46 SINFRANOR Xtrafors
32. ording to the relevant guidelines e g line cross section fuse protective ground connection High voltage and High discharge current Danger to life or severe bodily harm by electric shock Version 11 06 Sheet 7 of 46 SINFRANOR XtraforsPrime servomotor MAVILOR 2 6 Protection against Touching Electrical Parts Before turning on a servo drive make sure that the housing is properly connected to ground PE rail The ground connection must be made even when testing the servo drive or when operating it for a short time Before turning the device on make sure that all voltage carrying parts are securely covered During operation all covers and switching cabinet doors must remain closed Control and high power contacts can have voltage applied even when the motor is not turning Touching the contacts when the device is switched on is not permitted Before working on servo drives they must be disconnected from the power mains and prevented from being switched on again The servo drives are labelled with the following warning High electrical voltage due to wrong connections Danger to life or bodily harm by electric shock 2 7 Protection against Dangerous Movements Dangerous movements can be caused by faulty control of the connected motors Some common examples are Improper or wrong wiring of cable connections incorrect operation of the equipment components wrong input of parameters before operation malfunction
33. que calculations 40 Version 11 06 Sheet 3 of 46 SINFRANOR XtraforsPrime servomotor MAVILOR Version 11 06 Sheet 4 of 46 SINFRANOR XtraforsPrime servomotor MAVILOR 1 Introduction to the Product The XtraforsPrime servomotor is a new product generation that resumes all the knowhow and the new technologies of Mavilor and the group Infranor The improvement can be found in the design in the harmony with the drives the performances and optional solutions Version 11 06 Sheet 5 of 46 CINFRANOR XtraforsPrime servomotor MAVILOR 2 Safety Guidelines 2 1 Appropriate use Servo motors have been designed developed and manufactured for conventional use in the industry They were not designed developed and manufactured for any use involving serious risks or hazards that could lead to death injury serious physical damage or loss of any kind without the implementation of exceptionally stringent safety precautions Synchronous servomotors are precision motors They are not intended to be connected directly to a rotary current power supply system They have to be operated only by a particular electronic power stage A direct connection to a main supply will lead to the destruction of the motor Personnel that in any way uses our products must first read and understand the relevant safety instructions and be familiar with appropriate use Do not mount damaged or faulty products or use them in operation Make sure that
34. safety guards use protective coverings install light curtains or light barriers Fences and coverings must be strong enough to resist maximum possible momentum especially if there is a possibility of loose parts flying off Mount the emergency stop switch in the immediate reach of the operator Verify that the emergency stop works before starting up Do not operate the machine if the emergency stop 15 not working Isolate the drive power connection by means of an emergency stop circuit or use a starting lockout to prevent unintentional start Make sure that the drives are brought to a safe standstill before accessing or entering the danger zone Safe standstill can be achieved by switching off the power supply contactor or by safe mechanical locking of moving parts Secure vertical axes against falling or dropping after switching off the motor power by for example mechanically securing the vertical axes adding an external braking arrester clamping mechanism ensuring sufficient equilibration of the vertical axes The standard equipment motor brake or an external brake controlled directly by the drive controller is not sufficient to guarantee personal safety 2 8 Protection against Contact with Hot Parts Surface of machine housing could be extremely hot Danger of injury Danger of burns Do not touch housing surfaces near sources of heat After switching off the equipment wait at least ten 10 minutes to allo
35. the products have been installed in the manner described in the relevant documentation Servo motors can have bare parts with voltages applied e g terminals or hot surfaces Additional sources of danger result from moving machine parts Improperly removing the required covers inappropriate use incorrect installation or incorrect operation can result in severe personal injury or damage to property 2 2 Explanations The safety instructions describe the following degrees of hazard seriousness in compliance with ANSI Z535 4 The degree of hazard seriousness informs about the consequences resulting from noncompliance with the safety instructions Signal Word DANGER indicates imminently hazardous A 87 14 situation which if not avoided will result in death serious injury This signal word is to be limited to the most extreme situations WARNING indicates potentially hazardous Situation which if not avoided could result in death or serious injury CAUTION indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury It may also be used to alert against unsafe practices Version 11 06 Sheet 6 of 46 SINFRANOR XtraforsPrime servomotor MAVILOR 2 3 Hazards by Improper Use High voltage and High discharge current Danger to A DAN life or severe bodily harm electric shock E Dangerous movements Danger to severe bodily A DAN 5
36. w it to cool down before touching it Do not touch hot parts of the equipment such as housings with integrated heat sinks and resistors 2 9 Protection during Handling and Mounting Under certain conditions incorrect handling and mounting of parts and components may cause injuries Risk of injury due to improper handling Bodily harm caused by crushing shearing cutting and mechanical shock Observe general installation and safety instructions with regard to handling and mounting Use appropriate mounting and transport equipment Take precautions to avoid pinching and crushing Use only appropriate tools If specified by the product documentation special tools must be used Version 11 06 Sheet 9 of 46 SINFRANOR XtraforsPrime servomotor MAVILOR Use lifting devices and tools correctly and safely For safe protection wear appropriate protective clothing e g safety glasses safety shoes and safety gloves Never stand under suspended loads Clean up liquids from the floor immediately to prevent slipping Version 11 06 Sheet 10 of 46 XtraforsPrime servomotor MAVILOR 3 Technical Data 3 1 General Description The three phase synchronous motors from the XtraforsPrime are permanently excited electronically commutated synchronous motors for applications that require excellent dynamic characteristics and positioning precision as well as compact size and reduced weight NdFeB permanent m

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