___________________ Introduction Fundamental safety 1 ___________________ instructions SIMOTICS Drive Technology 1FN3 linear motors Operating Instructions 2 ___________________ Description 3 ___________________ Preparations for use 4 ___________________ Mechanical installation 5 ___________________ Connection 6 ___________________ Commissioning 7 ___________________ Operation 8 ___________________ Maintenance Decommissioning and 9 ___________________ disposal A ___________________ Appendix 12/2016 6SN1197-0AF01-0BP1 Legal information Warning notice system This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are graded according to the degree of danger. DANGER indicates that death or severe personal injury will result if proper precautions are not taken. WARNING indicates that death or severe personal injury may result if proper precautions are not taken. CAUTION indicates that minor personal injury can result if proper precautions are not taken. NOTICE indicates that property damage can result if proper precautions are not taken. If more than one degree of danger is present, the warning notice representing the highest degree of danger will be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to property damage. Qualified Personnel The product/system described in this documentation may be operated only by personnel qualified for the specific task in accordance with the relevant documentation, in particular its warning notices and safety instructions. Qualified personnel are those who, based on their training and experience, are capable of identifying risks and avoiding potential hazards when working with these products/systems. Proper use of Siemens products Note the following: WARNING Siemens products may only be used for the applications described in the catalog and in the relevant technical documentation. If products and components from other manufacturers are used, these must be recommended or approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation and maintenance are required to ensure that the products operate safely and without any problems. The permissible ambient conditions must be complied with. The information in the relevant documentation must be observed. Trademarks All names identified by (R) are registered trademarks of Siemens AG. The remaining trademarks in this publication may be trademarks whose use by third parties for their own purposes could violate the rights of the owner. Disclaimer of Liability We have reviewed the contents of this publication to ensure consistency with the hardware and software described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the information in this publication is reviewed regularly and any necessary corrections are included in subsequent editions. Siemens AG Division Digital Factory Postfach 48 48 90026 NURNBERG GERMANY Document order number: 6SN1197-0AF01-0BP1 03/2017 Subject to change Copyright (c) Siemens AG 2012 - 2016. All rights reserved Introduction About these operating instructions These operating instructions describe the motor and explain how to handle the motor from the delivery to the disposal stage. Before you start using the motor, you must read these operating instructions to ensure safe, problem-free operation and to maximize the service life. These operating instructions complement the relevant SIEMENS Configuration Manual. Siemens strives continually to improve the quality of information provided in these operating instructions. If you find any mistakes or would like to offer suggestions about how this document could be improved, contact the Siemens Service Center. Always follow the safety instructions and notices in these operating instructions. The warning notice system is explained on the rear of the inside front. Text features In addition to the notes that you must observe for your own personal safety as well as to avoid material damage, in these operating instructions you will find the following text features: Operating instructions Operating instructions with the specified sequence are designated using the following symbols: The arrow indicates the start of the operating instructions. The individual handling steps are numbered. 1. Execute the operating instructions in the specified sequence. The square indicates the end of the operating instruction. Operating instructions without a specified sequence are identified using a bullet point: Execute the operating instructions. Enumerations Enumerations are identified by a bullet point without any additional symbols. - Enumerations at the second level are hyphenated. 1FN3 linear motors Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 5 Introduction Notes Notes are shown as follows: Note A Note is an important item of information about the product, handling of the product or the relevant section of the document. Notes provide you with help or further suggestions/ideas. Target group These operating instructions are intended for electricians, fitters, service technicians and warehouse personnel. Training The following link provides information on SITRAIN - training from Siemens for products, systems and automation engineering solutions: SITRAIN (http://siemens.com/sitrain) Technical Support Country-specific telephone numbers for technical support are provided on the Internet under Contact: Technical Support (https://support.industry.siemens.com) Recommended additional documents System components Manufacturer's manuals Motor * Configuration Manual * Safety instructions for direct drives Encoder system * User Manual * Operating Instructions Brake * Operating Instructions Sensor module * Manual Drive system * Commissioning Manual * List Manual * Function Manual 1FN3 linear motors 6 Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 Introduction More information Information on the following topics is available under the link: Ordering documentation/overview of documentation Additional links to download documents Using documentation online (find and search in manuals/information) More information (https://support.industry.siemens.com/cs/de/en/view/108998034) Please send any questions about the technical documentation (e.g. suggestions for improvement, corrections) to the following e-mail address: docu.motioncontrol@siemens.com Any manuals or operating instructions that you may have in printed or electronic file form could be of an older product version. You can also request all descriptions and safety instructions from your local Siemens office. My support The following link provides information on how to create your own individual documentation based on Siemens content, and adapt it for your own machine documentation: My support (https://support.industry.siemens.com/My/de/en/documentation) Note If you want to use this function, you must first register. Later, you can log on with your login data. Websites of third parties This publication contains hyperlinks to websites of third parties. Siemens does not take any responsibility for the contents of these websites or adopt any of these websites or their contents as their own, because Siemens does not control the information on these websites and is also not responsible for the contents and information provided there. Use of these websites is at the risk of the person doing so. Internet address for products Products (http://www.siemens.com/motioncontrol) 1FN3 linear motors Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 7 Introduction 1FN3 linear motors 8 Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 Table of contents Introduction ............................................................................................................................................. 5 1 2 3 Fundamental safety instructions ............................................................................................................ 13 1.1 General safety instructions .....................................................................................................13 1.2 Handling electrostatic sensitive devices (ESD) ......................................................................19 1.3 Industrial security ....................................................................................................................20 1.4 Residual risks of power drive systems....................................................................................21 Description ............................................................................................................................................ 23 2.1 Use for the intended purpose .................................................................................................23 2.2 2.2.1 2.2.2 2.2.3 2.2.4 2.2.5 2.2.6 2.2.7 2.2.8 Technical features and ambient conditions ............................................................................25 Directives and standards ........................................................................................................25 Danger from strong magnetic fields ........................................................................................26 Technical features ...................................................................................................................31 Direction of motion of the motor ..............................................................................................32 Environmental conditions for stationary use ...........................................................................32 Degree of protection ...............................................................................................................33 Vibration response ..................................................................................................................34 Noise emission ........................................................................................................................34 2.3 Derating factors .......................................................................................................................35 2.4 Rating plate data (type plate) ..................................................................................................36 2.5 2.5.1 2.5.2 2.5.2.1 2.5.2.2 2.5.3 2.5.3.1 2.5.3.2 2.5.3.3 2.5.4 2.5.4.1 2.5.4.2 Design .....................................................................................................................................37 Motor components ..................................................................................................................37 Scope of delivery ....................................................................................................................39 Linear motors ..........................................................................................................................39 Supplied pictograms ...............................................................................................................40 Cooling ....................................................................................................................................42 Design of the cooling ..............................................................................................................42 Cooling circuits ........................................................................................................................43 Coolants ..................................................................................................................................46 Temperature monitoring and thermal motor protection ..........................................................47 Temperature monitoring circuits Temp-S and Temp-F ...........................................................47 Technical features of temperature sensors ............................................................................50 Preparations for use .............................................................................................................................. 55 3.1 Shipment and packaging ........................................................................................................57 3.2 3.2.1 3.2.2 3.2.3 Transport and storage.............................................................................................................59 Packaging specifications for air transportation .......................................................................60 Environmental conditions for long term storage and transport ...............................................63 Storage ...................................................................................................................................64 1FN3 linear motors Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 9 Table of contents 4 5 6 7 8 9 Mechanical installation .......................................................................................................................... 65 4.1 Safety instructions for mechanical installation ....................................................................... 65 4.2 Specifications for mounting linear motors .............................................................................. 69 4.3 4.3.1 4.3.2 4.3.3 Procedure when installing the motor ..................................................................................... 71 Comply with the installation dimensions ................................................................................ 71 Motor installation procedures ................................................................................................. 72 Assembling individual motor components ............................................................................. 79 4.4 4.4.1 4.4.2 Checking the work carried out ............................................................................................... 88 Smooth running of the slide ................................................................................................... 88 Check of the air gap height .................................................................................................... 89 Connection ........................................................................................................................................... 91 5.1 5.1.1 5.1.2 Connection of the cooling system .......................................................................................... 91 Primary section cooling connection ....................................................................................... 91 Secondary section cooling connection .................................................................................. 93 5.2 5.2.1 5.2.2 5.2.3 5.2.4 5.2.5 5.2.6 5.2.7 5.2.8 Electrical connection .............................................................................................................. 95 Safety instructions for electrical connections ......................................................................... 95 Important information about the electrical connection ........................................................... 98 PIN assignments for the connectors .................................................................................... 100 Terminal panel ..................................................................................................................... 102 Power connection................................................................................................................. 105 Temperature sensor connection .......................................................................................... 105 Motor circuit diagram ........................................................................................................... 108 Shielding, grounding, and equipotential bonding ................................................................. 108 Commissioning ....................................................................................................................................111 6.1 Safety instructions for commissioning ................................................................................. 112 6.2 Checklists ............................................................................................................................. 117 6.3 Checking the insulation resistance ...................................................................................... 119 6.4 Cooling ................................................................................................................................. 120 Operation .............................................................................................................................................121 7.1 Safety instructions for operation .......................................................................................... 121 7.2 Switching off and operating phases ..................................................................................... 123 7.3 Handling faults ..................................................................................................................... 124 Maintenance ........................................................................................................................................127 8.1 Safety instructions for maintenance ..................................................................................... 127 8.2 Inspection and maintenance ................................................................................................ 133 Decommissioning and disposal ............................................................................................................135 9.1 Decommissioning ................................................................................................................. 135 9.2 9.2.1 9.2.2 Disposal ............................................................................................................................... 135 Disposing of secondary sections ......................................................................................... 136 Disposal of packaging .......................................................................................................... 137 1FN3 linear motors 10 Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 Table of contents A Appendix............................................................................................................................................. 139 A.1 Mounting the Hall sensor box ...............................................................................................139 A.2 A.2.1 A.2.2 A.2.3 A.2.4 Manufacturer recommendations ...........................................................................................155 Manufacturers of anti-corrosion agents ................................................................................155 Manufacturers of connectors for cooling...............................................................................155 Manufacturers of plastic hose manufacturers .......................................................................156 Manufacturers of spacer foils ................................................................................................156 A.3 List of abbreviations ..............................................................................................................157 Index................................................................................................................................................... 159 1FN3 linear motors Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 11 Table of contents 1FN3 linear motors 12 Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 Fundamental safety instructions 1.1 1 General safety instructions DANGER Danger to life due to live parts and other energy sources Death or serious injury can result when live parts are touched. * Only work on electrical devices when you are qualified for this job. * Always observe the country-specific safety rules. Generally, six steps apply when establishing safety: 1. Prepare for shutdown and notify all those who will be affected by the procedure. 2. Disconnect the machine from the supply. - Switch off the machine. - Wait until the discharge time specified on the warning labels has elapsed. - Check that it really is in a no-voltage condition, from phase conductor to phase conductor and phase conductor to protective conductor. - Check whether the existing auxiliary supply circuits are de-energized. - Ensure that the motors cannot move. 3. Identify all other dangerous energy sources, e.g. compressed air, hydraulic systems, or water. 4. Isolate or neutralize all hazardous energy sources by closing switches, grounding or short-circuiting or closing valves, for example. 5. Secure the energy sources against switching on again. 6. Ensure that the correct machine is completely interlocked. After you have completed the work, restore the operational readiness in the inverse sequence. WARNING Danger to life through a hazardous voltage when connecting an unsuitable power supply Touching live components can result in death or severe injury. * Only use power supplies that provide SELV (Safety Extra Low Voltage) or PELV(Protective Extra Low Voltage) output voltages for all connections and terminals of the electronics modules. 1FN3 linear motors Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 13 Fundamental safety instructions 1.1 General safety instructions WARNING Danger to life when live parts are touched on damaged motors/devices Improper handling of motors/devices can damage them. For damaged motors/devices, hazardous voltages can be present at the enclosure or at exposed components. * Ensure compliance with the limit values specified in the technical data during transport, storage and operation. * Do not use any damaged motors/devices. WARNING Danger to life through electric shock due to unconnected cable shields Hazardous touch voltages can occur through capacitive cross-coupling due to unconnected cable shields. * As a minimum, connect cable shields and the conductors of power cables that are not used (e.g. brake cores) at one end at the grounded housing potential. WARNING Danger to life due to electric shock when not grounded For missing or incorrectly implemented protective conductor connection for devices with protection class I, high voltages can be present at open, exposed parts, which when touched, can result in death or severe injury. * Ground the device in compliance with the applicable regulations. WARNING Danger to life due to electric shock when opening plug connections in operation When opening plug connections in operation, arcs can result in severe injury or death. * Only open plug connections when the equipment is in a no-voltage state, unless it has been explicitly stated that they can be opened in operation. 1FN3 linear motors 14 Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 Fundamental safety instructions 1.1 General safety instructions NOTICE Material damage due to loose power connections Insufficient tightening torques or vibrations can result in loose electrical connections. This can result in damage due to fire, device defects or malfunctions. * Tighten all power connections with the specified tightening torques, e.g. line supply connection, motor connection, DC link connections. * Check all power connections at regular intervals. This applies in particular after transport. WARNING Danger to life through unexpected movement of machines when using mobile wireless devices or mobile phones Using mobile wireless devices or mobile phones with a transmit power > 1 W closer than approx. 2 m to the components may cause the devices to malfunction, influence the functional safety of machines therefore putting people at risk or causing material damage. * Switch the wireless devices or mobile phones off in the immediate vicinity of the components. WARNING Danger of an accident occurring due to missing or illegible warning labels Missing or illegible warning labels can result in accidents involving death or serious injury. * Check that the warning labels are complete based on the documentation. * Attach any missing warning labels to the components, in the national language if necessary. * Replace illegible warning labels. 1FN3 linear motors Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 15 Fundamental safety instructions 1.1 General safety instructions WARNING Danger to life when safety functions are inactive Safety functions that are inactive or that have not been adjusted accordingly can cause operational faults on machines that could lead to serious injury or death. * Observe the information in the appropriate product documentation before commissioning. * Carry out a safety inspection for functions relevant to safety on the entire system, including all safety-related components. * Ensure that the safety functions used in your drives and automation tasks are adjusted and activated through appropriate parameterizing. * Perform a function test. * Only put your plant into live operation once you have guaranteed that the functions relevant to safety are running correctly. Note Important safety notices for Safety Integrated functions If you want to use Safety Integrated functions, you must observe the safety notices in the Safety Integrated manuals. WARNING Danger to life from electromagnetic fields Electromagnetic fields (EMF) are generated by the operation of electrical power equipment, such as transformers, converters, or motors. People with pacemakers or implants are at particular risk in the immediate vicinity of this equipment. * If you have a heart pacemaker or implant, maintain the minimum distance specified in chapter "Correct usage" from such motors. 1FN3 linear motors 16 Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 Fundamental safety instructions 1.1 General safety instructions WARNING Danger to life from permanent-magnet fields Even when switched off, electric motors with permanent magnets represent a potential risk for persons with heart pacemakers or implants if they are close to converters/motors. * If you have a heart pacemaker or implant, maintain the minimum distance specified in chapter "Correct usage". * When transporting or storing permanent-magnet motors always use the original packing materials with the warning labels attached. * Clearly mark the storage locations with the appropriate warning labels. * IATA regulations must be observed when transported by air. WARNING Risk of injury caused by moving parts or parts that are flung out Touching moving motor parts or drive output elements and loose motor parts that are flung out (e.g. feather keys) in operation can result in severe injury or death. * Remove any loose parts or secure them so that they cannot be flung out. * Do not touch any moving parts. * Safeguard all moving parts using the appropriate safety guards. WARNING Danger to life due to fire if overheating occurs because of insufficient cooling Inadequate cooling can cause overheating resulting in death or severe injury as a result of smoke and fire. This can also result in increased failures and reduced service lives of motors. * Comply with the specified coolant requirements for the motor. WARNING Danger to life due to fire as a result of overheating caused by incorrect operation When incorrectly operated and in the case of a fault, the motor can overheat resulting in fire and smoke. This can result in severe injury or death. Further, excessively high temperatures destroy motor components and result in increased failures as well as shorter service lives of motors. * Operate the motor according to the relevant specifications. * Only operate the motors in conjunction with effective temperature monitoring. * Immediately switch off the motor if excessively high temperatures occur. 1FN3 linear motors Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 17 Fundamental safety instructions 1.1 General safety instructions CAUTION Risk of injury due to touching hot surfaces In operation, the motor can reach high temperatures, which can cause burns if touched. * Mount the motor so that it is not accessible in operation. Measures when maintenance is required: * Allow the motor to cool down before starting any work. * Use the appropriate personnel protection equipment, e.g. gloves. 1FN3 linear motors 18 Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 Fundamental safety instructions 1.2 Handling electrostatic sensitive devices (ESD) 1.2 Handling electrostatic sensitive devices (ESD) Electrostatic sensitive devices (ESD) are individual components, integrated circuits, modules or devices that may be damaged by either electric fields or electrostatic discharge. NOTICE Damage through electric fields or electrostatic discharge Electric fields or electrostatic discharge can cause malfunctions through damaged individual components, integrated circuits, modules or devices. * Only pack, store, transport and send electronic components, modules or devices in their original packaging or in other suitable materials, e.g conductive foam rubber of aluminum foil. * Only touch components, modules and devices when you are grounded by one of the following methods: - Wearing an ESD wrist strap - Wearing ESD shoes or ESD grounding straps in ESD areas with conductive flooring * Only place electronic components, modules or devices on conductive surfaces (table with ESD surface, conductive ESD foam, ESD packaging, ESD transport container). 1FN3 linear motors Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 19 Fundamental safety instructions 1.3 Industrial security 1.3 Industrial security Note Industrial security Siemens provides products and solutions with industrial security functions that support the secure operation of plants, systems, machines and networks. In order to protect plants, systems, machines and networks against cyber threats, it is necessary to implement - and continuously maintain - a holistic, state-of-the-art industrial security concept. Siemens products and solutions only represent one component of such a concept. The customer is responsible for preventing unauthorized access to its plants, systems, machines and networks. Systems, machines and components should only be connected to the enterprise network or the internet if and to the extent necessary and with appropriate security measures (e.g. use of firewalls and network segmentation) in place. Additionally, Siemens' guidance on appropriate security measures should be taken into account. For more information about industrial security, please visit: Industrial security (http://www.siemens.com/industrialsecurity). Siemens' products and solutions undergo continuous development to make them more secure. Siemens strongly recommends to apply product updates as soon as available and to always use the latest product versions. Use of product versions that are no longer supported, and failure to apply latest updates may increase customer's exposure to cyber threats. To stay informed about product updates, subscribe to the Siemens Industrial Security RSS Feed at: Industrial security (http://www.siemens.com/industrialsecurity). WARNING Danger to life as a result of unsafe operating states resulting from software manipulation Software manipulations (e.g. viruses, trojans, malware or worms) can cause unsafe operating states in your system that may lead to death, serious injury, and property damage. * Keep the software up to date. * Incorporate the automation and drive components into a holistic, state-of-the-art industrial security concept for the installation or machine. * Make sure that you include all installed products into the holistic industrial security concept. * Protect files stored on exchangeable storage media from malicious software by with suitable protection measures, e.g. virus scanners. 1FN3 linear motors 20 Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 Fundamental safety instructions 1.4 Residual risks of power drive systems 1.4 Residual risks of power drive systems When assessing the machine- or system-related risk in accordance with the respective local regulations (e.g., EC Machinery Directive), the machine manufacturer or system installer must take into account the following residual risks emanating from the control and drive components of a drive system: 1. Unintentional movements of driven machine or system components during commissioning, operation, maintenance, and repairs caused by, for example, - Hardware and/or software errors in the sensors, control system, actuators, and cables and connections - Response times of the control system and of the drive - Operation and/or environmental conditions outside the specification - Condensation/conductive contamination - Parameterization, programming, cabling, and installation errors - Use of wireless devices/mobile phones in the immediate vicinity of electronic components - External influences/damage - X-ray, ionizing radiation and cosmic radiation 2. Unusually high temperatures, including open flames, as well as emissions of light, noise, particles, gases, etc., can occur inside and outside the components under fault conditions caused by, for example: - Component failure - Software errors - Operation and/or environmental conditions outside the specification - External influences/damage 3. Hazardous shock voltages caused by, for example: - Component failure - Influence during electrostatic charging - Induction of voltages in moving motors - Operation and/or environmental conditions outside the specification - Condensation/conductive contamination - External influences/damage 4. Electrical, magnetic and electromagnetic fields generated in operation that can pose a risk to people with a pacemaker, implants or metal replacement joints, etc., if they are too close 5. Release of environmental pollutants or emissions as a result of improper operation of the system and/or failure to dispose of components safely and correctly 6. Influence of network-connected communication systems, e.g. ripple-control transmitters or data communication via the network 1FN3 linear motors Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 21 Fundamental safety instructions 1.4 Residual risks of power drive systems For more information about the residual risks of the drive system components, see the relevant sections in the technical user documentation. 1FN3 linear motors 22 Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 2 Description 2.1 Use for the intended purpose WARNING Risk of death and material damage as a result of incorrect use There is a risk of death, serious injury and/or material damage when direct drives or their components are used for a purpose for which they were not intended. * Only use the motors for industrial or commercial plants and systems. * If, in an exceptional case, the motors are not used in industrial or commercial plants and systems, then ensure that increased requirements (e.g. regarding touch protection) are complied with. * Do not install the motors in hazardous zones if the motors have not been expressly and explicitly designed and authorized for this purpose. Carefully observe any special additional notes provided. * Only use direct drives and their components for applications that Siemens has explicitly specified. * Protect the motors against dirt and contact with aggressive substances. * Ensure that the installation conditions comply with the rating plate specifications and the condition specifications contained in this documentation. Where relevant, take into account deviations regarding approvals or country-specific regulations. * Contact your local Siemens office if you have any questions relating to correct use. * If you wish to use special versions and design versions whose technical details vary from the motors described in this document, then you must contact your local Siemens office. WARNING Danger to life for wearers of active implants due to magnetic and electrical fields Electric motors pose a danger to people with active medical implants, e.g. cardiac stimulators, who come close to the motors. * If you are affected, stay at a minimum distance of 500 mm from the motors (tripping threshold for static magnetic fields of 0.5 mT according to the Directive 2013/35/EU). 1FN3 linear motors Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 23 Description 2.1 Use for the intended purpose WARNING Personal injury and material damage by noncompliance with directive 2006/42/EC There is a risk of death, serious injury and/or material damage if Directive 2006/42/EC is not carefully observed. * The products included in the scope of delivery are exclusively designed for installation in a machine. Commissioning is prohibited until it has been fully established that the end product conforms with Directive 2006/42/EC. * Please take into account all safety instructions and provide these to end users. Please take note of national and international license terms when operating direct motors so that no patent rights are violated. Applications for peak load motors Combined with a drive system with closed-loop control, peak load motors are well suited as direct drives for linear motion, e.g. for: highly dynamic and flexible machine tools Laser machining Handling Applications for continuous load motors Combined with a drive system with closed-loop control, continuous load motors are well suited as direct drives for linear motion, e.g. for: Oscillating motion (e.g. out-of-center machining) Applications with high process forces (e.g. grinding, turning, etc.) Vertical axes without weight compensation, quills Handling, Cartesian robots 1FN3 linear motors 24 Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 Description 2.2 Technical features and ambient conditions 2.2 Technical features and ambient conditions 2.2.1 Directives and standards Standards that are complied with SIMOTICS S, SIMOTICS M, SIMOTICS L, SIMOTICS T, SIMOTICS A motors subsequently called the "SIMOTICS motor series " - comply with the following standards: EN 60034-1 - Rotating electrical machines - Dimensioning and operating behavior EN 60204-1 - Safety of machinery - Electrical equipment of machines; general requirements Where applicable, the SIMOTICS motor series are in conformance with the following parts of IEC / EN 60034: Feature Standard Degree of protection IEC / EN 60034-5 Cooling IEC / EN 60034-6 1) Type of construction IEC / EN 60034-7 Connection designations IEC / EN 60034-8 Noise levels IEC / EN 60034-9 1) Temperature monitoring Vibration severity levels 1) IEC / EN 60034-11 1) IEC / EN 60034-14 Standard component, e.g. cannot be applied to built-in motors Relevant directives The following directives are relevant for SIMOTICS motors. European Low-Voltage Directive SIMOTICS motors comply with the Low-Voltage Directive 2014/35/EU. European Machinery Directive SIMOTICS motors do not fall within the area of validity covered by the Machinery Directive. However, the use of the products in a typical machine application has been fully assessed for compliance with the main regulations in this directive concerning health and safety. European EMC Directive SIMOTICS motors do not fall within the area of validity covered by the EMC Directive. The products are not considered as devices in the sense of the directive. 1FN3 linear motors Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 25 Description 2.2 Technical features and ambient conditions Eurasian conformity SIMOTICS motors comply with the requirements of the customs union Russia/Belarus/Kazakhstan (EAC). China Compulsory Certification SIMOTICS motors do not fall within the area of validity covered by the China Compulsory Certification (CCC). CCC product certification (https://support.industry.siemens.com/cs/products?search=CCC&dtp=Certificate&mfn=ps&o =DefaultRankingDesc&pnid=13347&lc=de-WW) Underwriters Laboratories SIMOTICS motors are generally in compliance with UL and cUL as components of motor applications, and are appropriately listed. Specifically developed motors and functions are the exceptions in this case. Here, it is important that you carefully observe the contents of the quotation and that there is a cUL mark on the rating plate! Quality systems Siemens AG employs a quality management system that meets the requirements of ISO 9001 and ISO 14001. Certificates for SIMOTICS motors can be downloaded from the Internet at the following link: Certificates for SIMOTICS motors (https://support.industry.siemens.com/cs/products?dtp=Certificate&mfn=ps&pnid=13347&lc= de-WW) 2.2.2 Danger from strong magnetic fields Occurrence of magnetic fields Motor components with permanent magnets generate very strong magnetic fields. In the nocurrent condition, the magnetic field strength of the motors comes exclusively from the magnetic fields of components equipped with permanent magnets. Additional electromagnetic fields occur in operation. 1FN3 linear motors 26 Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 Description 2.2 Technical features and ambient conditions Components with permanent magnets For the linear motors described in this manual, the permanent magnets are in the secondary sections. Figure 2-1 Schematic representation of the static magnetic field of a secondary section, depending on distance Risk to persons as a result of strong magnetic fields WARNING Risk of death as a result of permanent magnet fields Even when the motor is switched off, the permanent magnets can put people with active medical implants at risk if they are close to the motor. Examples of active medical implants include: Heart pacemakers, insulin pumps. * As the affected person, maintain a minimum distance of 500 mm from the permanent magnets (trigger threshold for static magnetic fields of 0.5 mT as per directive 2013/35/EU). With regard to the effect of strong magnetic fields on people, the DGUV rule 103-013 "Electromagnetic Fields" of the German Social Accident Insurance applies in Germany. This rule specifies all the requirements that must be observed in the workplace. In other countries, the relevant applicable national and local regulations and requirements must be taken into account. 1FN3 linear motors Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 27 Description 2.2 Technical features and ambient conditions When dealing with magnetic fields, you must consider the requirements of DGUV rule 103013 of the German Social Accident Insurance. CAUTION Handling secondary sections The magnetic fields of the secondary sections are permanent. When you come into direct bodily contact with the secondary sections, a static magnetic flux density of 2 T is not exceeded. * Observe DGUV rule 103-013, 14 "Systems with high static magnetic fields". WARNING Risk of electric shock Voltage is induced at the power connections of the primary section each time a primary section moves with respect to a secondary section - and vice versa. If you touch the power connections you may suffer an electric shock. * Do not touch the power connections. * Connect the motor cable ports correctly, or insulate them properly. 1FN3 linear motors 28 Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 Description 2.2 Technical features and ambient conditions WARNING Danger of crushing by permanent magnets of the secondary section The forces of attraction of magnetic secondary sections act on materials that can be magnetized. The forces of attraction increase significantly close to the secondary section. The trigger threshold of 3 mT for a risk of injury due to attraction and projectile effect is reached at a distance of 150 mm (directive 2013/35/EU). Secondary sections and materials that can be magnetized can suddenly slam together unintentionally. Two secondary sections can also unintentionally slam together. There is a significant risk of crushing when you are close to a secondary section. Close to the secondary section, the forces of attraction can be several kN - example: Magnetic attractive forces are equivalent to a force of 100 kg, which is sufficient to trap a body part. * Do not underestimate the strength of the attractive forces, and work very carefully. * Wear safety gloves. * The work should be done by at least two people. * Do not unpack the secondary section until immediately before assembly. * Never unpack several secondary sections at the same time. * Never place secondary sections next to one another without taking the appropriate precautions. * Never place any metals on magnetic surfaces and vice versa. * Never carry any objects made of magnetizable materials (for example watches, steel or iron tools) and/or permanent magnets close to the secondary section! If tools that can be magnetized are nevertheless required, then hold the tool firmly using both hands. Slowly bring the tool to the secondary section. * Immediately mount the secondary section that has just been unpacked. * Always comply with the specified procedure. * Avoid inadvertently traversing direct drives. * Keep the following tools at hand to release parts of the body (hand, fingers, foot etc.) trapped between two components: - A hammer (about 3 kg) made of solid, non-magnetizable material - Two pointed wedges (wedge angle approx. 10 to 15, minimum height 50 mm) made of solid, non-magnetizable material (e.g. hard wood). 1FN3 linear motors Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 29 Description 2.2 Technical features and ambient conditions First aid in the case of accidents involving permanent magnets Stay calm. Press the emergency stop switch and, where necessary, switch off the main switch if the machine is live. Administer FIRST AID. Call for further help if required. To free jammed body parts (e.g., hands, fingers, feet), pull apart components that are clamped together. - To do this, use a hammer to drive a wedge into the separating rift - Release the jammed body parts. If necessary, call for an EMERGENCY DOCTOR. Material damage caused by strong magnetic fields NOTICE Data loss caused by strong magnetic fields If you are close to a secondary section (< 150 mm) any magnetic or electronic data medium as well as electronic devices that you are carrying can be destroyed. For example, credit cards, USB sticks, floppy disks and watches are at risk. * Do not carry any magnetic/electronic data media and no electronic devices when you are close to a secondary section! 1FN3 linear motors 30 Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 Description 2.2 Technical features and ambient conditions 2.2.3 Technical features Table 2- 1 Standard version of the 1FN3 range of motors: Technical features Technical feature Design Motor type Permanently excited synchronous linear motor Type of construction Individual components Degree of protection according to EN 60034-5 * Primary section: IP65 * Mounted motor: The degree of protection depends on the machine design and must therefore be realized by the machine manufacturer; minimum requirement: IP23 Cooling method Water cooling Thermal motor protection * Maximum pressure in the cooling circuit: 10 bar = 1 MPa * Wiring: with G1/8 pipe thread (in compliance with DIN EN ISO 228-1); special connectors are required to connect hoses/pipes In the primary section: 1x PTC for thermistor triplet with response threshold +120 C (according to DIN 44081/44082) Temperature monitoring In the primary section: 1FN3xxx-xxxxx-xxx1 with 1 x KTY 84 (according to EN 60034-11) 1FN3xxx-xxxxx-xxx3 with 1 x Pt1000 (according to EN 60751) 2nd rating plate Enclosed separately Insulation of motor winding according to EN 60034-1 Temperature class 155 (F) Magnet material Rare earth material Connection, electrical 1FN3050: Signal and power cables with connectors or open ends permanently connected to the motor 1FN3100 ... 1FN3900: Terminal panel with cover integrated in the motor, with metric cable glands for signal and power cables. Additional cover with heavygauge threaded joint for combined lines with 1FN3100-xW ... 1FN3900-xW Encoder system * Not included in the scope of supply * Selection based on application-specific and converter-specific supplementary conditions 1FN3 linear motors Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 31 Description 2.2 Technical features and ambient conditions 2.2.4 Direction of motion of the motor Defining the traversing direction If the primary section is connected to the terminals of the terminal box with the phase sequence U-V-W and is supplied with current by a three-phase system with a clockwise rotating field, the direction of motion of the primary or secondary section is positive. 2.2.5 Environmental conditions for stationary use Based on DIN EN 60721-3-3 (for fixed installation locations that all weather protected) Table 2- 2 Climatic ambient conditions Lower air temperature limit: - 5 C (deviates from 3K3) Upper air temperature limit: + 40 C Lower relative humidity limit: 5% Upper relative humidity limit: 85 % Rate of temperature fluctuations: Max 0.5 K/min Condensation: Not permissible Formation of ice: Not permissible Fixed location: Class 3K3 Devices can only be operated in locations that are fully protected against the weather (in halls or rooms). 1FN3 linear motors 32 Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 Description 2.2 Technical features and ambient conditions Table 2- 3 Biological ambient conditions Fixed location: Table 2- 4 Class 3B1 Chemical ambient conditions Fixed location: Class 3C2 Different to class 3C2: Operating site in the immediate vicinity of industrial plants with chemical emissions Table 2- 5 Mechanically active ambient conditions Fixed location: Table 2- 6 Class 3S1 Mechanical ambient conditions Fixed location: 2.2.6 Class 3M3 Degree of protection NOTICE Damage to the motor caused by pollution If the area where the motor is installed is polluted and dirty, then the motor can malfunction and clog up. * Keep the area where the motor is installed free of all dirt and pollution. Primary section The primary sections satisfy the requirements for IP65 degree of protection in accordance with EN 60529 and EN 60034-5. Secondary sections The secondary sections are protected against corrosion to a large degree via structural measures. Ensure that the air gap remains free of chips. Provide suitable covers for this. As of a distance of 150 mm from the surface of the secondary section, ferromagnetic particles are generally no longer attracted. Avoid using abrasive or aggressive substances (e.g. acids). 1FN3 linear motors Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 33 Description 2.2 Technical features and ambient conditions Installed motor The better the motor installation space is protected against the ingress of foreign particles (especially true for ferromagnetic particles), the longer the motor service life. The space around the motor must be kept free of chips and other foreign bodies. The degree of protection of the installed motor according to EN 60529 and EN 60034-5 is primarily dictated by the machine construction, but must be at least IP23. 2.2.7 Vibration response The vibration response of build-in motors in operation essentially depends on the machine design and the application itself. As a result of an unfavorable machine design, configuration or system settings, resonance points can be excited, so that vibration severity level A according to EN 60034-14 (IEC 60034-14) is not reached. Excessive vibration caused by resonance effects can frequently be avoided by making suitable settings. Contact Mechatronic Support if you require help in applying remedial measures. You can find contact data in the Introduction under "Technical Support". 2.2.8 Noise emission The following components and settings influence the noise levels reached when built-in motors are operational: Machine design Encoder system Storage Controller settings Pulse frequency As a result of unfavorable machine designs, configuration or system settings, measuring surface sound pressure levels of over 70dB (A) can occur. Contact Mechatronic Support if you require help in applying remedial measures. You can find contact data in the Introduction under "Technical Support". 1FN3 linear motors 34 Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 Description 2.3 Derating factors 2.3 Derating factors For installation altitudes above 2000 m above sea level, reduce the voltage stress of the motors according to table "Factors to reduce the maximum DC link voltage" (reciprocal values from EN 60664-1 Table A.2). Table 2- 7 Factors to reduce the maximum DC link voltage Installation altitude above sea level in m up to Factor 2000 1 3000 0.877 4000 0.775 5000 0.656 6000 0.588 7000 0.513 8000 0.444 Reducing the DC link voltage reduces the converter output voltage. The operating range in the F-v diagram is thus also reduced. You can find the F-v diagrams in the associated data sheet. Operation in a vacuum is not permissible due to the low voltage strength and the poor cooling. 1FN3 linear motors Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 35 Description 2.4 Rating plate data (type plate) 2.4 Rating plate data (type plate) The rating plate (type plate) lists the valid technical data for a primary section. A second rating plate is provided separately for a primary section. Data on the rating plate The following data is on the rating plate: Figure 2-2 Examples of rating plates for primary sections Table 2- 8 Elements on the rating plate for primary sections Item Description 1 Motor type 2 Article No. 3 2D code, contains the motor data 4 Thermal class 5 Approvals/conformities 6 Temperature sensors 7 Max. coolant temperature where the rated data are reached 8 Degree of protection 9 Motor version 10 Rated current IN 11 Weight 12 Induced voltage UiN at rated speed vN 13 Maximum permissible rms value of the motor terminal voltage Ua max 14 Rated force FN 15 Options 16 Serial number 1FN3 linear motors 36 Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 Description 2.5 Design 2.5 Design 2.5.1 Motor components Basic characteristics of the motor 1FN3 motors are permanent-magnet synchronous linear motors with a modular cooling concept. Depending on the accuracy requirements, the motor can be optionally operated with a primary section precision cooler and/or a secondary section cooling. To a large extent, the motors are then thermally neutral with respect to the machine itself. The motor is delivered in components (at least primary section and secondary sections) and installed directly in the machine. Due to the series connection of primary and secondary sections, user-defined motor forces and straight traversing paths of various lengths can be achieved. Motor components Motors of the 1FN3 product family consist of the following components: Primary section: - Basic component of the linear motor - With 3-phase winding - Integrated main cooler to dissipate the heat loss Precision cooler (optional): - Additional cooler to minimize the heat transfer to the machine in accordance with the Thermo-Sandwich(R) principle - Recommended for applications with high precision requirements Secondary sections: - Mounted side-by-side these form the reactive part of the motor - Consist of a steel base with attached permanent magnets - The casing provides a large degree of protection against corrosion and external effects Secondary section cover (optional): - Mechanical protection for secondary sections - Stainless steel plate that can be magnetized (thickness d = 0.4 mm) - Adheres to secondary sections - Can be removed without tools if worn - Available as a continuous band or as a segmented cover with fixed lengths 1FN3 linear motors Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 37 Description 2.5 Design Cooling sections with plug-in connector/nipple (optional): - Secondary cooling component - Aluminum rail sections with integrated cooling channels - Are placed under the secondary sections when high machine precision is required Secondary section end pieces (optional): - Secondary cooling component - Used to hold down the integrated secondary section cover - Available in different versions Precision cooler Secondary section cover Cooling section Primary section with main Secondary section Secondary section end (option) cooler Figure 2-3 (option), here as continuous band; alternatively as segmented cover with plug-in connector (option) piece (option) Components of a 1FN3 linear motor 1FN3 linear motors 38 Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 Description 2.5 Design Overview of the connection variants Peak and continuous load motor with two pre-assembled cables with/without connector Peak and continuous load motor with connection cover for two cables Peak load motor with connector cover for one cable or with a fixed cable without a connector 2.5.2 Scope of delivery 2.5.2.1 Linear motors Primary section Primary section One rating plate (attached); additional loose rating plate Accessory pack note (safety accessory pack) Safety warning instructions (pictograms) For the terminal box design: Terminal box accessories (fixing accessories) with connection cover Secondary section Secondary section Accessory pack note (safety accessory pack) Safety warning instructions (pictograms) 1FN3 linear motors Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 39 Description 2.5 Design 2.5.2.2 Supplied pictograms Primary sections To identify hazards, warning signs in the form of permanent adhesive stickers are enclosed with all primary sections in the packaging: Table 2- 9 Warning signs included with primary sections according to BGV A8 and EN ISO 7010 and their meaning Sign Meaning Sign Meaning Warning against hot surface Warning against electric voltage (W017) (W012) The following safety instructions are attached at the signal port of the primary section: Table 2- 10 Safety instructions for temperature protection according to BGV A8 and EN ISO 7010 and their significance Sign Meaning Sign Meaning General warning sign Observe instruction (W001) (M002) Secondary sections To identify hazards, warning and prohibition signs in the form of permanent adhesive stickers are enclosed with all secondary sections in the packaging: Table 2- 11 Warning signs according to BGV A8 and EN ISO 7010 included with secondary sections and their meaning Sign Meaning Sign Meaning Warning: strong magnetic field Warning: hand injuries (W006) (W024) 1FN3 linear motors 40 Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 Description 2.5 Design Table 2- 12 Prohibiting signs according to BGV A8 and EN ISO 7010 included with secondary sections and their meaning Sign Meaning No access for persons with pacemakers or implanted defibrillators Sign Meaning No access for persons with metal implants (P014) (P007) No metal objects or watches (P008) Note Applying the stickers The stickers are not suitable for applying to a secondary section or on the secondary section cover. * Apply the stickers next to the secondary section track in the vicinity of the motor so that they are clearly visible. Note The quality of the label can diminish as result of extreme environmental conditions. Any danger areas encountered during normal operation and when maintaining and servicing the motor must be identified using clearly visible warning and prohibit signs (pictograms) in the immediate vicinity of the danger (close to the motor). The associated texts must be available in the language of the country in which the product is used. 1FN3 linear motors Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 41 Description 2.5 Design 2.5.3 Cooling 2.5.3.1 Design of the cooling Components The cooling system of the motors from the 1FN3 product family can be made up of various components: Primary section main cooler Primary section precision cooler (optional) Secondary section cooling (optional) These components are structurally separated in motors of the 1FN3 product family. They allow the cooling system to be laid out according to the Thermo-Sandwich(R) principle. Structure of a cooling system according to the Thermo-Sandwich(R) principle. In the Thermo-Sandwich(R) principle, components of the cooling system are layered on top of each other. All components are separated by an insulating layer (see the image below). The thermal flow from the primary section into the machine assembly is restricted by this multilayer cooling design: Heat is dissipated in each component of the cooling system. Therefore, the residual amount of heat that ultimately reaches the machine is very low. Figure 2-4 Schematic representation of the Thermo-Sandwich(R) principle 1FN3 linear motors 42 Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 Description 2.5 Design 2.5.3.2 Cooling circuits Cooling circuit requirements Avoid algae growth by using suitable chemical agents and opaque water lines. We recommend that the cooling circuits be designed as closed systems. The maximum permissible pressure is 10 bar. NOTICE Blocked and clogged cooling circuits Cooling circuits can become blocked and clogged as a result of pollution and longer-term deposits. * We recommend that you use a separate cooling circuit to cool the motors. If you use the machine cooling circuits to also cool the motors, you must ensure that the cooling medium fully complies with the requirements listed in this chapter. Also note the maximum non-operational times of cooling circuits corresponding to the coolant manufacturer's data. Interconnecting cooling circuits NOTICE Leaks associated with rigid connections Rigid connections between the cooling circuits can lead to problems with leaks! * Use flexible connections (hoses) when interconnecting cooling circuits. You can connect primary section cooling circuits in parallel to simplify connection systems and piping. In this case, you must carefully take into consideration the temperature and pressure differences between the intake and return. Note Connect the cooling ducts of the primary sections in parallel. This ensures that each primary section is supplied with coolant with the same intake temperature. 1FN3 linear motors Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 43 Description 2.5 Design Example of the interconnection of cooling circuits The following figure shows two examples for the series connection of different cooling circuits: On the left, all cooling circuits of the motor are connected in series. On the right, the cooling circuits of the primary section precision cooler and the primary section main cooler of a motor form a series connection. The resulting cooling circuits are connected in parallel. The secondary section cooling systems of both motors are also connected in series. Figure 2-5 Examples for the interconnection of various different circuits (schematic diagram) Materials used The following table lists the materials that are used for the cooling system in the motors. Table 2- 13 Materials used for the cooling system Precision cooler Main cooler Secondary section cooling 1.4301/1.4305; 1.4541; Viton SF-Cu; 1.4301/1.4305; Viton; AlMgSi0.5 (anodized) ; 1.4305; Viton; Delo 5327 NOTICE Corrosion as a result of unsuitable materials used to connect the cooler Corrosion damage can occur if you use unsuitable materials to connect to the cooler. * We recommend that you use brass or stainless steel fittings when connecting the cooler. 1FN3 linear motors 44 Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 Description 2.5 Design Coolant intake temperature NOTICE Corrosion in the machine Condensation can lead to corrosion in the machine. * Select the intake temperatures so that no condensation forms on the surface of the motor. Condensation does not form if the intake temperature TVORL is higher than the ambient temperature or corresponds to the ambient temperature. The rated motor data refer to operation at a coolant intake temperature of 35 C. If the intake temperature is different, the continuous motor current changes as shown below. Note For a cooler intake temperature of < 35 C, the possible continuous motor current is greater than the rated current IN. Larger cable cross-sections may be required. This means that you must take into account the rated current of the cables. The following diagram shows the dependency of the relative continuous primary section current (IPrimarteil / IN) * 100 on the water intake temperature in the cooling system. Losses due to friction and eddy currents are ignored here. Figure 2-6 Influence of the coolant intake temperature 1FN3 linear motors Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 45 Description 2.5 Design 2.5.3.3 Coolants Provision of the coolant The customer must provide the coolant. The motors are designed for use with an anticorrosion protection agent added to the water. NOTICE Disintegration of O-rings and hoses The use of oil as a coolant can lead to material incompatibilities. O-rings and hoses can disintegrate. * Use water with anti-corrosion protection as coolant. Reason for the use of water with an anti-corrosion agent The use of untreated water may lead to considerable damage and malfunctions due to water hardness deposits, the formation of algae and slime, as well as corrosion, for example: Worsening of the heat transfer Higher pressure losses due to reductions in cross-sectional area Blockage of nozzles, valves, heat exchangers and cooling ducts General requirements placed on the cooling medium The cooling medium must be pre-cleaned or filtered in order to prevent the cooling circuit from becoming blocked. The formation of ice is not permitted! Note The maximum permissible size for particles in the cooling medium is 100 m. Requirements placed on the water Water which is used as basis for the coolant must comply as a minimum with the following requirements: Chloride concentration: c < 100 mg/l Sulfate concentration: c < 100 mg/l 6.5 pH value 9.5 Contact the anti-corrosion agent manufacturer relating to additional requirements! 1FN3 linear motors 46 Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 Description 2.5 Design Requirements placed on the anti-corrosion agent The anti-corrosion agent must fulfill the following requirements: The basis is ethylene glycol (also called ethanediol) The water and anti-corrosion agent do not segregate The freezing point of the water used is reduced to at least -5 C The anti-corrosion agent used must be compatible with the fittings and cooling system hoses used as well as the materials of the motor cooler Check these requirements, especially in regard to material compatibility, with the cooling unit manufacturer and the manufacturer of the anti-corrosion agent! Suitable mixture 25 % - 30 % ethylene glycol (= ethanediol) The water used contains a maximum of 2 g/l dissolved mineral salt and is largely free from nitrates and phosphates Manufacturer recommendations: see appendix 2.5.4 Temperature monitoring and thermal motor protection 2.5.4.1 Temperature monitoring circuits Temp-S and Temp-F The primary sections are equipped with two subsequently described temperature monitoring circuits - Temp-S and Temp-F. Temp-S activates the thermal motor protection when the motor windings are thermally overloaded. In this case the precondition is that Temp-S is correctly connected and evaluated. For a thermal overload, the drive system must bring the motor into a nocurrent condition. Temp-F is used for temperature monitoring and diagnostics during commissioning and in operation. Both temperature monitoring circuits are independent of one another. For example, the SME12x sensor module or the TM120 terminal module evaluates the temperature sensor signals. You can obtain commissioning information from Technical Support. Contact data is provided in the introduction. 1FN3 linear motors Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 47 Description 2.5 Design Temp-S To protect the motor winding against thermal overload, all primary sections are equipped with the following temperature monitoring circuit: 1 x PTC 120 C temperature sensor per phase winding U, V, and W, switching threshold at 120 C The three PTC temperature sensors of this temperature monitoring circuit are connected in series to create a PTC triplet. Figure 2-7 PTC triplet Note Shutdown time If Temp-S responds, and its response threshold is not undershot again in the meantime, then the drive system must shut down (de-energize) the motor within 2 seconds. This prevents the motor windings from becoming inadmissibly hot. NOTICE Motor destroyed as a result of overtemperature The motor can be destroyed if the motor winding overheats. * Connect Temp-S. * Evaluate Temp-S. * Ensure that the shutdown time is not exceeded. Note No temperature monitoring with Temp-S As a result of their non-linear characteristic, PTC temperature sensors are not suitable for determining the instantaneous temperature. 1FN3 linear motors 48 Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 Description 2.5 Design Temp-F The Temp-F temperature monitoring circuit comprises an individual temperature sensor. Contrary to Temp-S, this temperature sensor only monitors one phase winding. As a consequence, Temp-F is only used for monitoring the temperature and diagnosing the motor winding temperature. NOTICE Motor destroyed as a result of overtemperature If you use Temp-F for thermal motor protection, then the motor is not adequately protected against destruction as a result of overtemperature. * Evaluate the Temp-S temperature monitoring circuit to implement thermal motor protection. Temp-F as KTY 84 or Pt1000 The 16th digit of the order designation on the rating plate of the primary section indicates whether a KTY 84 or a Pt1000 is installed, see Rating plate data (type plate) (Page 36): 1FN3xxx-xxxxx-xxx1: with KTY 84 1FN3xxx-xxxxx-xxx3: with Pt1000 1FN3 linear motors Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 49 Description 2.5 Design No direct connection of the temperature monitoring circuits WARNING Risk of electric shock when incorrectly connecting the temperature monitoring circuit In the case of a fault, circuits Temp-S and Temp-F do not provide safe electrical separation with respect to the power components. * Use, for example, the TM120 or the SME12x to connect the Temp-S and Temp-F temperature monitoring circuits. You therefore comply with the directives for safe electrical separation according to DIN EN 61800-5-1 (previously safe electrical separation according to DIN EN 50178). Correctly connecting temperature sensors NOTICE Motor destroyed as a result of overtemperature The motor can be destroyed as a result of overtemperature if you do not correctly connect the temperature sensors. * When connecting temperature sensor cables with open conductor ends, pay attention to the correct assignment of conductor colors. 2.5.4.2 Technical features of temperature sensors Technical features of PTC temperature sensors Every PTC temperature has a "quasi-switching" characteristic. The resistance suddenly increases in the vicinity of the response threshold (nominal response temperature NAT). PTC temperature sensors have a low thermal capacity - and have good thermal contact with the motor winding. As a consequence, the temperature sensors and the system quickly respond to inadmissibly high motor winding temperatures. 1FN3 linear motors 50 Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 Description 2.5 Design Table 2- 14 Technical data of the PTC temperature sensors Name Description Type PTC triplet acc. to DIN 44082 Individual PTC temperature sensor according to DIN 44081 Response threshold (nominal response temperature NAT) PTC resistance R (20 C) at the PTC triplet 120 C 5 K See the characteristic if -20 C < T < NAT -20 K R 3 x 250 R 750 Minimum resistance when hot R in the PTC triplet and in the individual PTC temperature sensor See the characteristic if T NAT - 5 K R 3 x 550 R 1650 if T > NAT + 5 K R 3 x 1330 R 3990 if T > NAT + 15 K R 3 x 4000 R 12000 Typical characteristic R() of a PTC temperature sensor according to DIN 44081 1FN3 linear motors Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 51 Description 2.5 Design Technical features of the KTY 84 temperature sensor The KTY 84 has a progressive temperature resistance characteristic that is approximately linear. In addition, the KTY 84 has a low thermal capacity and provides good thermal contact with the motor winding. The KTY 84 has a continuous characteristic. Table 2- 15 Technical data of the KTY 84 PTC thermistor Name Description Type KTY 84 according to EN 60034-11 Transfer range -40 C ... +300 C Resistance when cold (20 C) ca. 580 Resistance when warm (100 C) ca. 1000 Characteristic of a KTY 84 1FN3 linear motors 52 Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 Description 2.5 Design Technical features of the Pt1000 temperature sensor The Pt1000 has a linear temperature resistance characteristic. In addition, the Pt1000 has a low thermal capacity and provides good thermal contact with the motor winding. Table 2- 16 Technical data of the Pt1000 PTC thermistor Name Description Type Pt1000 according to EN 60751 Transfer range 0 C ... +300 C Resistance when cold (20 C) ca. 1080 Resistance when warm (100 C) ca. 1380 Characteristic of a Pt1000 System requirements for the Pt1000 temperature sensor To use the Pt1000 together with the following systems, you will need at least the specified versions: SINAMICS S120 Firmware V4.8 and V4.7 HF17 SINUMERIK V4.8 as well as V4.7 SP2 HF1 and V4.5 SP6 SIMOTION V4.5 (SINAMICS Integrated Firmware V4.8) 1FN3 linear motors Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 53 Description 2.5 Design 1FN3 linear motors 54 Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 Preparations for use 3 WARNING Risk of death and crushing as a result of permanent magnet fields Severe injury and material damage can result if you do not take into consideration the safety instructions relating to the permanent magnet fields of the secondary sections. * Observe the information in Chapter "Danger from strong magnetic fields (Page 26)". Keep these operating instructions so that they are accessible at all times. Please provide these operating instructions to the appropriate personnel. WARNING Incorrect packaging, storage and/or incorrect transport Risk of death, injury and/or material damage can occur if the devices are packed, stored, or transported incorrectly. * Always follow the safety instructions for storage and transport. * When transporting or lifting machines or machine parts with the motors installed, protect the components from moving unintentionally. * Always correctly and carefully carry out storage, transport and lifting operations. * Only use suitable devices and equipment that are in perfect condition. * Only use lifting devices, transport equipment and suspension equipment that comply with the appropriate regulations. * IATA regulations must be observed when components are transported by air. * Mark locations where secondary sections are stored with warning and prohibit signs according to the tables in Chapter "Supplied pictograms". * Observe the warning instructions on the packaging. * Always wear safety shoes and safety gloves. * Take into account the maximum loads that personnel can lift and carry. The motors and their components can weigh more than 13 kg. * Primary sections and secondary sections must always be transported and stored in the packaged condition. - Replace any defective packaging. Correct packaging offers protection against sudden forces of attraction that can occur in the immediate vicinity of a secondary section. Further, when correctly packaged, you are protected against hazardous motion when storing and moving the secondary section. - Only use undamaged original packaging. 1FN3 linear motors Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 55 Preparations for use Checking the delivery for completeness When you take receipt of the delivery, please check immediately whether the items delivered are in accordance with the accompanying documents. Report any apparent transport damage to the delivery agent immediately. Report any apparent defects / missing components to the appropriate Siemens office immediately. Siemens will not accept any claims relating to items missing from the delivery and which are submitted at a later date. 1FN3 linear motors 56 Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 Preparations for use 3.1 Shipment and packaging 3.1 Shipment and packaging When shipping products that contain permanent magnets by sea or road, no additional packaging measures are required for protection against magnetic fields. Dangers are marked as follows on the original packaging of secondary sections: Table 3- 1 Warning signs according to BGV A8 and DIN EN ISO 7010 and their significance Sign Meaning Sign Warning: strong magnetic field Warning: hand injuries (W024) (W006) Table 3- 2 Meaning Prohibit signs according to BGV A8 and DIN EN ISO 7010 and their significance Sign Meaning No access for persons with pacemakers or implanted defibrillators (P007) Sign Meaning No access for persons with metal implants (P014) No metal objects or watches (P008) 1FN3 linear motors Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 57 Preparations for use 3.1 Shipment and packaging Furthermore, the following symbols are marked on the original packaging of primary sections and secondary sections: Table 3- 3 Handling notes and their significance Symbols Meaning Symbols Meaning protect against moisture fragile (ISO 7000, No. 0621) (ISO 7000, No. 0626) top (ISO 7000, No. 0623) Note Original packaging Keep the packaging of components with permanent magnets where possible! When reusing the original packaging do not cover safety instructions that are possibly attached. When required, use transparent adhesive tape for the packaging. Original packaging can also be requested from your local Siemens office. 1FN3 linear motors 58 Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 Preparations for use 3.2 Transport and storage 3.2 Transport and storage Note UN number for permanent magnets UN number 2807 is allocated to permit magnets as hazardous item. NOTICE Damage to the primary section when incorrectly lifted Improper use of lifting equipment and slings can lead to permanent deformation and damage to the primary section. * Always ensure the primary section is horizontal when lifting and transporting it. * To fasten the suspension ropes for lifting the primary section, use - the threaded holes on the top of the primary section - Eye bolts acc. to DIN 580 * To lift and transport in a horizontal position, screw in the eye bolts in diagonally opposing threaded holes of the primary section. Choose the threaded holes with the greatest possible distance from one another. * If the unit must be lifted and transported in a vertical position, you must screw in the eye bolts in adjacent threaded holes directly on a front end of the primary section. * The locating surfaces of the eye bolts must positioned flat and over the whole surface on the top of the primary section. * Observe the specifications for thread depths and screw-in depths in the primary section (Specifications for mounting linear motors (Page 69)). The values cited in this chapter also apply to the eye bolts. If the threaded pins of the eye bolts are too long, you must ensure that the maximum screw-in depth is adhered to, using washers if necessary. * All of the suspension ropes must be the same length. When lifting and transporting in a horizontal position, the taut suspension ropes must form an angle of at least 50 between the rope and the primary section. The center of gravity of the primary section must be centered between the threaded holes that are used and lie vertically under the hook of the crane. * Two suspension ropes and two eyebolts are sufficient to lift and transport the primary section. The primary section may incline to one side during this, however. * If you use four suspension ropes and four eye bolts, the load is optimally distributed, which means that a sideward inclination is ruled out. * The positioning of the primary section with suspension ropes on the provided installation position is not permitted. 1FN3 linear motors Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 59 Preparations for use 3.2 Transport and storage Figure 3-1 3.2.1 Correct lifting of primary sections Packaging specifications for air transportation When transporting products containing permanent magnets by air, the maximum permissible magnetic field strengths specified by the appropriate IATA Packing Instruction must not be exceeded. Special measures may be required so that these products can be shipped. Above a certain magnetic field strength, shipping requires that you notify the relevant authorities and appropriately label the products. Note The magnetic field strengths listed in the following always refer to values for the DC magnetic field specified in the IATA packaging instruction 953. If the values change, then we will take this into account in the next edition. Products whose highest field strength exceeds 0.418 A/m, as determined at a distance of 4.6 m from the product, require shipping authorization. This product will only be shipped with previous authorization from the responsible national body of the country from where the product is being shipped (country of origin) and the country where the airfreight company is based. Special measures need to be taken to enable the product to be shipped. When shipping products whose highest field strength is equal to or greater than 0.418 A/m, as determined at a distance of 2.1 m from the product, you have a duty to notify the relevant authorities and appropriately label the product. When shipping products whose highest field strength is less than 0.418 A/m, as determined at a distance of 2.1 m from the product, you do not have to notify the relevant authorities and you do not have to label the product. 1FN3 linear motors 60 Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 Preparations for use 3.2 Transport and storage To achieve mutual optimal weakening of the magnetic fields (magnetic interference fields) the original and individual packaging of two secondary sections must always be stacked on one another in pairs, alternating according to the following diagram. In each case, edge A-B of the lower individual package must be placed on the edge C-D of the upper individual package. Figure 3-2 Packing for secondary sections and correct stacking The precondition for correctly stacking two secondary sections is an offset within a secondary section pair of less than 1 cm, which must be guaranteed for the complete duration of the air transport. To achieve this, fix the original individual packaging, e.g. using adhesive packaging tape. When required, use transparent adhesive packaging tape in order not to cover any safety instructions. If the individual packages with the secondary sections are not stacked pairwise alternating on top of one another, the magnetic fields strengthen one another. If the offset within a secondary section pair is larger than 1 cm during the complete duration of the air transport, then the magnetic fields also strengthen one another. In bulk packaging, secondary section pairs (each pair stacked alternating, according to the diagram "Packaging for secondary sections and correct stacking") can be arranged as required. 1FN3 linear motors Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 61 Preparations for use 3.2 Transport and storage Table 3- 4 Packaging specifications for 1FN3xxx-xSxxx-xxxx secondary sections not subject to notification and subject to notification and labeling requirements labeling requirements A single secondary section is packaged in its original individual packaging Two secondary sections each are packaged in the original individual packaging and correctly stacked in pairs Secondary sections are packaged in the original individual packaging and cab e arbitrarily arranged subject to authorization X X 2) X 1) 1) If the secondary section is also packed in a ferromagnetic sheet metal case in addition to the original individual packaging, e.g. manufactured out of iron with a thickness of greater than 0.5 mm, then when shipping, you only have to notify the relevant authorities and attach appropriate labels. 2) If an offset within a secondary section pair of less than 1 cm cannot be guaranteed for the duration of the complete air transport, then for transportation you have to notify the relevant authorities and attach appropriate labels. Example 1 Original individual packages with secondary section pairs with the Article number 1FN3xxxxSxxx-xxxx are correctly stacked in new packaging (bulk packaging). The shipment is not subject to notification and labeling requirements Example 2 A maximum of one additional original individual packaging with one secondary section may be added to the new (bulk) packaging from example 1. This individual secondary section can be arbitrarily aligned, a sheet metal case to provide additional shielding is not required. The shipment of the complete new package is then subject to notification and labeling requirements. 1FN3 linear motors 62 Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 Preparations for use 3.2 Transport and storage 3.2.2 Environmental conditions for long term storage and transport Based on DIN EN 60721-3-1 (for long-term storage) and DIN EN 60721-3-2 (for transport) Table 3- 5 Climatic ambient conditions Lower air temperature limit: - 5 C (deviates from 3K3) Upper air temperature limit: + 40 C Lower relative humidity limit: 5% Upper relative humidity limit: 85 % Rate of temperature fluctuations: Max 0.5 K/min Condensation: Not permissible Formation of ice: Not permissible Long-term storage: Class 1K3 and class 1Z1 have a different upper relative humidity Transport: Class 2K2 Storage and transport are only permissible only in locations that are fully protected against the weather (in halls or rooms). Table 3- 6 Biological ambient conditions Long-term storage: Class 1B1 Transport: Class 2B1 Table 3- 7 Chemical ambient conditions Long-term storage: Class 1C1 Transport: Class 2C1 Table 3- 8 Mechanically active ambient conditions Long-term storage: Class 1S2 Transport: Class 2S2 Table 3- 9 Mechanical ambient conditions Long-term storage: Class 1M2 Transport: Class 2M2 1FN3 linear motors Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 63 Preparations for use 3.2 Transport and storage 3.2.3 Storage The motors can be stored for up to two years under the following conditions: Storing indoors Apply a preservation agent (e.g. Tectyl) to bare external components if this has not already been carried out in the factory. Store the motors as described in Section "Ambient conditions for long-term storage and transport". The storage room/area must meet the following conditions: - Dry - Dust-free - Free of vibration - Well ventilated - Protected against extreme weather conditions - The air inside the room or space must be free of any aggressive gases Protect the motor against shocks and humidity. Make sure that the motor is covered properly. Protection against humidity If a dry storage area is not available, then take the following precautions: Wrap the motor in humidity-absorbent material. Then wrap it in foil so that it is air tight. Include several bags of desiccant in the sealed packaging. Check the desiccant and replace it as required. Place a humidity meter in the sealed packaging to indicate the level of air humidity inside it. Inspect the motor on a regular basis. Protecting the cooling system for motors with integrated cooling Before you store the motor after use, perform the following actions: Empty the cooling channels. Blow out the cooling ducts with dry, compressed air so that the cooling ducts are completely empty. Seal the connections of the cooling system. 1FN3 linear motors 64 Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 Mechanical installation 4.1 4 Safety instructions for mechanical installation WARNING Risk of death and crushing as a result of permanent magnet fields Severe injury and material damage can result if you do not take into consideration the safety instructions relating to the permanent magnet fields of the secondary sections. * Observe the information in Chapter "Danger from strong magnetic fields (Page 26)". 1FN3 linear motors Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 65 Mechanical installation 4.1 Safety instructions for mechanical installation WARNING Danger of crushing by permanent magnets of the secondary section The forces of attraction of magnetic secondary sections act on materials that can be magnetized. The forces of attraction increase significantly close to the secondary section. The trigger threshold of 3 mT for a risk of injury due to attraction and projectile effect is reached at a distance of 150 mm (directive 2013/35/EU). Secondary sections and materials that can be magnetized can suddenly slam together unintentionally. Two secondary sections can also unintentionally slam together. There is a significant risk of crushing when you are close to a secondary section. Close to the secondary section, the forces of attraction can be several kN - example: Magnetic attractive forces are equivalent to a force of 100 kg, which is sufficient to trap a body part. * Do not underestimate the strength of the attractive forces, and work very carefully. * Wear safety gloves. * The work should be done by at least two people. * Do not unpack the secondary section until immediately before assembly. * Never unpack several secondary sections at the same time. * Never place secondary sections next to one another without taking the appropriate precautions. * Never place any metals on magnetic surfaces and vice versa. * Never carry any objects made of magnetizable materials (for example watches, steel or iron tools) and/or permanent magnets close to the secondary section! If tools that can be magnetized are nevertheless required, then hold the tool firmly using both hands. Slowly bring the tool to the secondary section. * Immediately mount the secondary section that has just been unpacked. * Always comply with the specified procedure. * Avoid inadvertently traversing direct drives. * Keep the following tools at hand to release parts of the body (hand, fingers, foot etc.) trapped between two components: - A hammer (about 3 kg) made of solid, non-magnetizable material - Two pointed wedges (wedge angle approx. 10 to 15, minimum height 50 mm) made of solid, non-magnetizable material (e.g. hard wood). 1FN3 linear motors 66 Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 Mechanical installation 4.1 Safety instructions for mechanical installation WARNING Electric shock caused by defective cables Defective connecting cables can cause an electric shock and/or material damage, e.g. by fire. * When installing the motor, make sure that the connecting cables - are not damaged, - are not under tension, - do not come into contact with moving parts. * Note the permissible bending radii according to the data in the catalog. * Do not hold a motor by its cables. * Do not pull the motor cables. WARNING Risk of electric shock Voltage is induced at the power connections of the primary section each time a primary section moves with respect to a secondary section - and vice versa. When the motor is switched on, the power connections of the primary section are also live. If you touch the power connections you may suffer an electric shock. * Only mount and remove electrical components if you have been qualified to do so. * Only work on the motor when the system is in a no-voltage condition. * Do not touch the power connections. Correctly connect the power connections of the primary section or properly insulate the cable connections. * Do not disconnect the power connection if the primary section is under voltage (live). * When connecting up, only use power cables intended for the purpose. * First connect the protective conductor (PE). * Attach the shield through a large surface area. * First connect the power cable to the primary section before you connect the power cable to the converter. * First disconnect the connection to the converter before you disconnect the power connection to the primary section. * In the final step, disconnect the protective conductor (PE). 1FN3 linear motors Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 67 Mechanical installation 4.1 Safety instructions for mechanical installation CAUTION Sharp edges and falling objects Sharp edges can cause cuts and falling objects can injure feet. * Always wear safety shoes and safety gloves! 1FN3 linear motors 68 Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 Mechanical installation 4.2 Specifications for mounting linear motors 4.2 Specifications for mounting linear motors General rules When you fasten primary sections and secondary sections on the machine construction, you must observe the following: Use screws of property class 10.9. Use only new, unused screws. Ensure that the mounting surfaces are free of oil and grease and are clean and unpainted. Maintain the optimal surface roughness depth Rz of the screw connection surface. Rz lies between 10 and 40 m. Minimize the number of joints. This keeps the settling effect for the material and the screws low. Note the presets for the thread depths and screw-in depths in the primary section. Tighten the fixing screws using torque control. If you cannot tighten the fixing screws using torque control, at least use a calibrated torque wrench with a short wrench insert. Note the tightening torques specified in the table below. Tighten the screws gradually, with no jerky movements. Select a long terminal length lk/d > 5 for securing the screws. Alternatively, secure the screws with Loctite 243, for example. Tightening torques for screws of property class 10.9 Applicable for screws of property class 10.9 Friction value tot = 0.1 M5 M6 M8 7.6 Nm 13.2 Nm 31.8 Nm Thread depth and screw-in depths in the primary section The following drawings schematically illustrate the minimum permissible and maximum screw-in depth of the fixing screws in the screwed-in state, with and without the use of a precision cooler. For selecting the screw length, a good range is thus made available to the machine manufacturer. The selection of the length of the fixing screws while taking all of the design tolerances into consideration is the responsibility of the machine manufacturer. The machine manufacturer must ensure that the minimum screw-in depth is reached and the maximum screw-in depth is not exceeded. 1FN3 linear motors Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 69 Mechanical installation 4.2 Specifications for mounting linear motors Figure on the left: Primary section with precision cooler, figure on the right: Primary section without precision cooler Fixing screw Maximum screw-in depth Slide Precision cooler Primary section The minimum screw-in depth as per the installation drawing of the primary section in the configuration manual under "Screw-in depth MP" Figure 4-1 Schematic diagram for the screw-in depths in the primary section Screw-in depths for the secondary section installation Minimum permissible screw-in depth The minimum permissible screw-in depths for the most commonly used materials for a machine bed are listed below. For different materials, you must determine the screw-in depth according to VDI Directive 2230. Table 4- 1 Minimum permissible screw-in depths Material Screw-in depth EN GJL-250 1.4 * d EN GJL-300 1.3 * d EN GJS-600-3 0.7 * d G-ALZN10Si8Mg 2.8 * d St 37 1.8 * d St 50 1.3 * d Maximum screw-in depth The maximum screw-in depth is at the discretion of the machine manufacturer. The maximum screw-in depth is specified by the threaded holes in the customers machine bed. 1FN3 linear motors 70 Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 Mechanical installation 4.3 Procedure when installing the motor 4.3 Procedure when installing the motor Installing a linear motor is subdivided into the following steps: 1. Check the installation dimension before installing motors 2. Clean the mounting surfaces for motor parts and the machine. 3. Installing primary sections, secondary sections and components 4. Checking the motor installation 4.3.1 Comply with the installation dimensions Installation dimensions for the motor installation The following figure shows the installation dimensions for the motor installation. The associated values are specified in the following table. Figure 4-2 Installation dimensions for the motor installation 1FN3 linear motors Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 71 Mechanical installation 4.3 Procedure when installing the motor Peak load motor: Installation dimensions Table 4- 2 Dimensions for the air gap and installation dimensions for installing the motor, according to figure above Installation dimension with precision cooler and with secondary section cooler Installation dimension with precision cooler and without secondary section cooler Installation dimension without precision cooler and without secondary section cooler Installation dimension without precision cooler but with secondary section cooler h M1 h M2 h M3 h M4 in mm in mm in mm in mm in mm 1FN3050 1FN3100 63.4 60.4 48.5 51.1 +0.3 1FN3150 65.4 62.4 50.5 53.5 +0.3 1FN3300 79.0 76.0 64.1 67.1 +0.3 1FN3450 81.0 78.0 66.1 69.1 +0.3 1FN3600 86.0 -- -- 74.1 +0.3 1FN3900 88.0 -- -- 76.1 +0.3 1FN3..-xW Tolerance of the installation dimensions Continuous load motor: Installation dimensions Table 4- 3 Dimensions for the air gap and installation dimensions for installing the motor, according to figure above Installation dimension with precision cooler and with secondary section cooler Installation dimension with precision cooler and without secondary section cooler Installation dimension without precision cooler and without secondary section cooler Installation dimension without precision cooler but with secondary section cooler h M1 h M2 h M3 h M4 in mm in mm in mm in mm in mm 1FN3050 1FN3100 74.3 71.3 59.4 62.4 +0.3 1FN3150 76.3 73.3 61.4 64.4 +0.3 1FN3300 92.9 89.9 78 81 +0.3 1FN3450 94.9 91.9 80 83 +0.3 1FN3600 99.9 -- -- 88 +0.3 1FN3900 101.9 -- -- 90 +0.3 1FN3..-xN 4.3.2 Tolerance of the installation dimensions Motor installation procedures There are three different procedures for installing a linear motor in a machine: Assembly with divided secondary section track Assembly by introducing the slide Assembly through the mounting of the motor components 1FN3 linear motors 72 Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 Mechanical installation 4.3 Procedure when installing the motor Motor assembly with divided secondary section track One prerequisite for this type of assembly is that the entire secondary section track can be divided into two sections. In this case, the two sections must at least be as long as the slide. Procedure 1. Mount the slide together with the linear guide and the primary section. 2. Push the slide to one side. Mount the secondary section on the other side. Align the secondary section track. Tighten the fixing screws according to the specifications. WARNING Risk of crushing when moving the primary section onto the secondary section track (step 3) When moving the primary section onto the secondary section track (Step 3), drawing forces towards the secondary section will occur for a short time. Danger of crushing! * Make sure that your fingers do not reach into the danger zone! 3. Push the slide over the mounted secondary section track. The attraction forces are taken up by the linear guides. 1FN3 linear motors Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 73 Mechanical installation 4.3 Procedure when installing the motor 4. Mount the remaining secondary section track. Align the track as well. Tighten the fixing screws according to the specifications. Motor assembly through the insertion of the slide This type of assembly is only intended for setting up motors in a double-sided arrangement. WARNING Risk of crushing as result of attractive forces In this procedure, pulling forces towards the stationary motor component occur. There is a risk of crushing! * Ensure that the slide plate is guided through the threading unit before the magnetic forces of attraction take effect. Slide the movable part of the motor into the stationary housing with the already assembled motor parts, see the following figure. Normally, for this you will need a threading unit to be provided by the customer. 1FN3 linear motors 74 Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 Mechanical installation 4.3 Procedure when installing the motor Figure 4-3 Insertion of the secondary section with a double-sided motor Motor assembly through the mounting of the motor components If other assembly methods are not possible, this complex method is applied. Application example The secondary section track is shorter than twice the length of the primary section. The primary section together with the slide cannot be shifted to the side far enough so that all of the secondary sections can be easily screwed into place. 1FN3 linear motors Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 75 Mechanical installation 4.3 Procedure when installing the motor For this installation technique, you must place a non-magnetic foil between the primary section and secondary section track. This foil prevents the primary section from lying directly on the secondary section track and causing physical damage. WARNING High forces of attraction when the placing the primary section onto the secondary section When the primary section is being mounted, high attraction forces (up to 40 kN) act in the direction of the secondary section track. There is a risk of crushing! * For this type of installation, a forcing assembly is required that allows the primary section to be lowered in a controlled fashion. * The stiffness of the forcing plate and the length of the jack screws must be selected in such a way that the primary section is held at a height of at least 50 mm before touching down. * The high forces of attraction must be taken into account with sufficient reserve when dimensioning the screws. Procedure 1. Mount the secondary section track according to Chapter "Assembling individual motor components (Page 79)". 2. Place the primary section with a forcing assembly on the secondary section track as follows. WARNING Danger of crushing when mounting the primary section on the secondary section! When you are placing the primary section on the secondary section, there is a risk of crushing due to the high forces of attraction. * Never place the primary section directly onto the secondary section. * Always place a distance foil manufactured out of non magnetizable material between the primary section and secondary section. 1FN3 linear motors 76 Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 Mechanical installation 4.3 Procedure when installing the motor Forcing plate Primary section End support block Figure 4-4 Forcing assembly Mount the primary section on the forcing plate of a forcing assembly. You can use the factory-made fastening drill-holes for this purpose. Screw the jack screws into the forcing plate. Ensure that the jack screws protrude evenly from the forcing plate. There must be a minimum distance of 50 mm between the nonmagnetic counter-bearing blocks and the forcing plate. Place a spacer foil between the primary section and the secondary section track. This spacer foil must be thinner than the required air gap. This is necessary to ensure that the spacer foil can be removed at the end of the assembly without any effort. The forcing assembly must ensure that the primary section can be lowered onto the secondary section track (covered with the spacer foil) in a controlled fashion. Further, it must be lowered in parallel with the secondary section track and centered. 1FN3 linear motors Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 77 Mechanical installation 4.3 Procedure when installing the motor Screw back the jack screws in steps to lower the primary section onto the secondary section track, in parallel and centered with it. Then completely remove the forcing assembly from the primary part. Jack bolt Forcing plate Primary section Spacer foil Secondary section End support block (aluminum/brass) 3. Mount the primary section on the slide. Secure the slide on the guides. Push the slide over the primary section. When doing this, the mounting holes of the primary section and slide must be fully aligned. The fixing screws are initially screwed through the slide into the primary section and tightened by hand. By uniform and alternating tightening of the mounting screws, the primary section is lifted from the secondary section track. Then remove the spacer foil from the air gap without applying any force. 1FN3 linear motors 78 Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 Mechanical installation 4.3 Procedure when installing the motor 4.3.3 Assembling individual motor components Assembly of the secondary sections Use the fixing screws to force-fit the secondary sections to the machine bed. You screw in the optional installable cooling profiles together with secondary sections between the secondary sections and the machine bed. The mounting dimensions without secondary section cooling are reduced by the height of the cooling sections. Note Hole in the machine bed The shaft of the bolts, which are used to attach the secondary section to the machine base may not reach the thread. * If necessary, you must lower the relevant hole in the machine bed. There is a letter N on each secondary section. Ensure that the letter N on each of the secondary sections is pointing in the same direction, as shown in the following figure. Figure 4-5 Position of the "N" mark on 1FN3 secondary sections Screw on the secondary sections in the prescribed order as per the following figure. Figure 4-6 Screwed joint sequence of 1FN3 secondary sections 1FN3 linear motors Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 79 Mechanical installation 4.3 Procedure when installing the motor WARNING There is a high risk of crushing fingers etc. when handling unpacked secondary sections! Secondary sections and materials that can be magnetized can suddenly slam together unintentionally. Two secondary sections can also unintentionally slam together. * Heed the warning information "Risk of crushing caused by permanent magnets of the secondary section" in Chapter "Safety instructions for mechanical installation (Page 65)". Assembly of the secondary section cooling system If you use secondary section cooling, you must install the cooling profiles and the secondary section end pieces prior to assembly of the secondary sections. To attach the secondary section end pieces, you must remove the wedges. The mounting screws for the wedges are standard steel socket head cap screws (hex socket, DIN 7984 M3x6). You can also use stainless steel fillister-head screws (Phillips head H1, DIN 7985 M3x8). The respective number of screws for each option is specified in the following table. To mount the secondary section end pieces, use the same screws as for mounting the secondary sections. Table 4- 4 Number of mounting screws for the wedge of the secondary section end pieces 1FN3... 050 100 150 300 450 600 900 Combi adapter 4 6 6 6 8 -- -- Combi end piece 4 6 6 6 8 -- -- Combi distributor 4 6 6 6 8 10 14 Cover end piece 2 5 5 6 7 -- -- If you use the cooling profiles with plug-in connector, you must proceed as follows: 1. At first, only fix the cooling sections with a few screws so that all threads in the machine bed are visible. Do not tighten the screws, because you will have to remove them again later. 2. Slide the secondary section end piece No. 1 without wedge axially onto the plug-in connectors of the cooling sections. 3. Screw in the fixing screws of the secondary section end piece No. 1. Do not tighten the fixing screws. 4. Slide the secondary section end piece No. 2 without wedge axially onto the plug-in connectors of the cooling sections. 5. Screw in the fixing screws of the secondary section end piece No. 2. Do not tighten the fixing screws. 6. Tighten the fixing screws of the secondary section end pieces. 1FN3 linear motors 80 Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 Mechanical installation 4.3 Procedure when installing the motor 7. Check the cooling circuit for leaks, if applicable (pressure check at a maximum of 10 bar). 8. Check again whether all threads in the machine bed are visible. 9. Remove the screws that were used for fastening. NOTICE Damage to the plug-in connectors If you remove the fastening screws too early, the plug-in connectors may become deformed and thus overstressed, especially if the secondary section track is set up vertically. The reason for this is the dead weight of the cooling profiles. * At a vertically arranged secondary section track, remove the screws used to position the heatsink profiles only step by step. 10.Screw the secondary sections together with the heatsink profiles. 11.If the cover band is not used as a secondary section cover, mount the wedges of the secondary section end pieces. The following figure shows the correct position for fixing cooling sections and combidistributors. Figure 4-7 Position of the heatsink profiles and combi distributors (illustration without fastening screws) Assembly of the secondary section cover The secondary section cover protects the secondary section track. The installation method depends on the type of cover. The following two variants are available: Continuous cover band Segmented cover 1FN3 linear motors Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 81 Mechanical installation 4.3 Procedure when installing the motor Cover band If fine dust or the like can accumulate in the spaces of the segmented cover, the use of a cover band is advantageous. NOTICE Loss of functionality and motor wear due to contamination in the motor compartment Contamination in the motor compartment can cause the motor to stop functioning or cause wear and tear. The use of scrapers to keep the air gap free is not sufficient and therefore not recommended. * Use suitable measures to protect the motor compartment from contamination independently of the use of a cover band. Covering long secondary section tracks with cover bands is more complicated than with segments. If the traversing distance of the axis is greater than twice the slide length, proceed as follows: 1. Mount the primary section under the slide. 2. Push the slide to one side of the traversing path. 3. Mount the secondary sections on the other side up to the center of the traversing path. 4. Mark the length of the mounted secondary sections plus the required clamping length on the cover band. 5. From the mark, slide the cover band under the primary section to the side without secondary sections. 6. Starting from the mark, place the other half of the cover band onto the secondary sections. 7. Push the slide over the covered secondary sections. The magnetic forces are taken up by the guides. 8. Carefully lift the cover band from the machine frame. 9. Mount the remaining secondary sections located under the cover band. 10.Place the second half of the secondary section cover onto the secondary section track. 11.Lock both ends on the secondary section end pieces using the wedges. The following work steps are required for the following conditions: The traversing path of the axis is less than twice the slide length. Accessibility for installing the secondary section cover is limited. 1FN3 linear motors 82 Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 Mechanical installation 4.3 Procedure when installing the motor Segmented cover The following work steps are required before you can install the segmented cover: 1. Mount the secondary sections with the slide plate removed. 2. Starting from one end, place the magnetic secondary section cover on the secondary sections. 3. Secure both ends of the secondary section cover on the secondary section end pieces with a wedge. 4. Place the primary section with spacer and forcing assembly on the secondary section track. 5. Mount the slide onto the guide. 6. Align the slide over the mounting holes of the primary section. 7. Remove the primary section from the secondary section track using the forcing assembly. 8. Mount the primary section securely on the slide. To install the segmented cover, carry out the following work steps: 1. Mount the first segment of the cover as follows: Place the end of the first segment starting from the top in a 45 angle, flush to the outer edge of the last secondary section. Then lower the segment in alignment with the secondary section track. When you sense the magnetic attraction, let loose of the segment. The segment generally assumes the correct position on its own. 2. Check for correct position: If the first segment of the cover reaches to the middle of a secondary section, the position is correct. 3. Mount all other segments the same way as the first segment. The following figures show Steps 1 and 3. 1FN3 linear motors Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 83 Mechanical installation 4.3 Procedure when installing the motor Figure 4-8 Mounting of the first segment of the segmented secondary section cover Figure 4-9 Mounting of a further segment of the segmented secondary section cover Note Arranging segments of the cover If you arrange the butt joints of the cover segments so that they are offset from the butt joints of the secondary sections, the secondary section track will be better protected against dust. The segments of the cover also align better. 1FN3 linear motors 84 Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 Mechanical installation 4.3 Procedure when installing the motor This offset is achieved when the cover segments at the ends of the secondary section track have a (n+0.5) length instead of the integral length of the secondary sections, see following figure. Example: Segment position of the segmented secondary section cover If you want to dismantle the segmented secondary section cover, you must raise the segments on one side transversely to the traversing direction as per the following figure. Figure 4-10 Demounting a segment of the segmented secondary section cover 1FN3 linear motors Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 85 Mechanical installation 4.3 Procedure when installing the motor Assembling the primary section Force fit the primary section and screw it on to the back of the primary section via the threaded holes. Make sure that the terminal end of the primary section usually points in the same direction as the north pole mark "N" on the secondary sections. NOTICE Damage to motor components due to incorrect screw-in depths Incorrect screw-in depths of the fixing screws can damage components of the motor. In addition, incorrect screw-in depths of the fixing screws can lead to an insufficiently rigid connection of the motor components on the machine construction. This gives rise to very disadvantageous characteristics. * Observe the minimum permissible screw-in depth and the maximum screw-in depth of the fixing screws. Assembling of the Hall sensor box NOTICE Uncontrolled traversing movements due to incorrect installation of the Hall sensor box Incorrect installation of the Hall sensor box can lead to uncontrolled traversing movements of the motor. The machine can also become damaged. * Starting at a certain minimum distance, the distance between the primary section and the Hall sensor box can only be increased by the integer multiple of the pole pair width 2M. The count factor NP is specified in the drawings. The exact installation dimensions of the Hall sensor box can be found in the annex in Chapter "Mounting the Hall sensor box (Page 139)". The cable outlet direction and position of the Hall sensor within the Hall sensor box are permanently assigned to one another. Therefore, be sure to follow the respective installation diagrams when installing the Hall sensor box with regard to position and alignment with the primary section. Note If several primary sections are operated on one drive system, the master is always to be used as reference for the Hall sensor box. Place the holding fixture for the Hall sensor box so that a distance of x = 35 mm between the top edge of the Hall sensor box and the bottom edge of the primary section is maintained, see following figure. 1FN3 linear motors 86 Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 Mechanical installation 4.3 Procedure when installing the motor Figure 4-11 Specified dimension for mounting the Hall sensor box (HSB) The Hall sensor box cable is trailable and may therefore be integrated into tow chains. 1FN3 linear motors Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 87 Mechanical installation 4.4 Checking the work carried out 4.4 Checking the work carried out WARNING Risk of electric shock Voltage is induced at the power connections of the primary section each time a primary section moves with respect to a secondary section - and vice versa. If you touch the power connections you may suffer an electric shock. * Do not touch the power connections. * Connect the motor cable ports correctly, or insulate them properly. 4.4.1 Smooth running of the slide Checking the smooth running of the slide The motor assembly must be specially checked for the smooth running of the slide. Remove all tools and objects from the traversing range. Clean the magnetic surface with a cloth before moving the slide. If the guidance system is precisely aligned, it must be possible to move the moving part of the motor with a force that remains constant over the entire traversing range. A slight fluctuation in force is permissible. The force fluctuation results from the system-related residual force of the linear motor. If excessive sluggishness results locally, check the air gap and the alignment of the guidance system. Note Increased shifting force or force ripple When checking the smooth running of the slide, ensure that the power connections of the motor cable are not connected to the drive. In addition, the power connections must not be "short-circuited". In these cases, a greater shifting force or force ripple occurs. 1FN3 linear motors 88 Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 Mechanical installation 4.4 Checking the work carried out 4.4.2 Check of the air gap height Note Installation dimension and air gap The installation dimension must lie within the specified tolerances along the entire traversing path. If the installation dimension matches, the correct air gap height will automatically result. If, however, the installation dimension matches, but the correct air gap height does not result, there is generally an installation error. A correct air gap height is critical for keeping the electrical characteristics of the motor in accordance with the data sheet. After the installation, use tear-resistant spacer foil with a constant thickness as an aid in checking to ensure that a minimum air gap height has been complied with. * For secondary section with cover sheet: Foil thickness 0.5 mm * For secondary section without cover sheet: Foil thickness 1.0 mm You can find the manufacturer's recommendation for spacer foil in the annex. 1. Slide the spacer foil into the air gap between the primary and secondary sections. The spacer foil must not jam. It must be easily moveable along the entire length of the air gap by hand with minimal use of force. 2. Slide the primary section over a section of the secondary section track that has not yet been checked. Repeat the check. 3. Repeat this procedure until the entire length of the secondary section track has been checked. NOTICE Air gap height is too small If the check determines that an air gap height is too small, then the prescribed installation dimensions were not complied with or there is an installation error. The machine must not be put into operation. * Ensure that the installation dimensions of the machine are within tolerance. 1FN3 linear motors Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 89 Mechanical installation 4.4 Checking the work carried out 1FN3 linear motors 90 Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 Connection 5.1 5 Connection of the cooling system Connection system Please note the following for the connection of the cooling system: All connections should be flexible (hoses) All material used must be resistant to the local environmental conditions All materials must be compatible Manufacturer's information regarding mounting are to be observed. 5.1.1 Primary section cooling connection Preconditions for the connection All cooling connections of the primary section main cooler and primary section precision cooler have a G1/8 cylindrical pipe thread according to DIN ISO 228-1. Suitable connectors are required for connecting the hoses. NOTICE Never use any used connection parts and components Faulty and used connection parts and components can result in pressure losses and leaks. * Use only new, unused connection parts and components * Check the compatibility of the materials of the connection parts and components and seals with respect to one another and the coolant used. Properties and attributes of the sealants used: Viton: resistant to temperature and glycol Perbunan: up to water temperatures of 80 C Ethylene-propylene: resistant to temperature and glycol 1FN3 linear motors Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 91 Connection 5.1 Connection of the cooling system Note Recommended manufacturers Manufacturers of connection parts and components for cooling 1FN3 motors are recommended in the Appendix. Installing The connection parts and components can generally be installed using standard tools. Recess at the machine slides If the connection assembly of the primary section in the traversing direction protrudes over the primary section, a recess must be machined at the machine slides above the cooling connections so that the connection components can be used. See figure below. Figure 5-1 Example of a cooling connection with recess at the machine slides 1FN3 linear motors 92 Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 Connection 5.1 Connection of the cooling system 5.1.2 Secondary section cooling connection Connection options For 1FN3 motors, secondary section end pieces can be used for the intake and return lines of the secondary section cooling system. As an alternative, if the continuous secondary section cover band is not used, the plastic hoses can be connected directly to the cooling sections using hose connector nipples. Properties of the plastic hose The plastic hoses must be resistant to the cooling medium, flexible and abrasion resistant. Note Recommended manufacturers Recommended manufacturers of plastic hoses are listed in the appendix Connection via secondary section end pieces To connect plastic hoses to secondary section end pieces, screwed connectors with screwed nipples and reinforcing sleeves can be used. However, the plastic hoses can also be attached with hose clamps over the hose connector nipples. For this connection, be sure to note the maximum outer diameter (12 mm) and the maximum square span (width across flats 10) of the screwed joint or the screwed nipple: If larger screw joints or screwed nipples are used, the connection point of the secondary section must be fitted with corresponding cutouts. Screwed nipples can be sealed to the end piece by using an axial-acting O-ring, a sealing ring or a thread sealer. It is recommended to use conical nipples. Note Recommended manufacturers Recommended manufacturers of screwed connections with nipples and reinforcing sleeves are listed in the appendix. 1FN3 linear motors Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 93 Connection 5.1 Connection of the cooling system Position of the connections for secondary section end pieces G 1/8 threaded connectors are used to connect the secondary section cooling system. These are located on the front faces of the secondary section end pieces. For models with combi distributors, the intake is located on one side of the secondary section track and the runback on the opposite side, see also the following figure. Figure 5-2 Position of the connection elements of the secondary section cooling system with combi distributor (face view) For models with combi adapter / combi end piece, the cooling medium intake and runback are located on the combi adapter, see following figure. Figure 5-3 Position of the connection elements of the secondary section cooling system with combi adapter (face view) Table 5- 1 Connector dimensions of the secondary section cooling system with combi adapter (available only for 1FN3050...450) Motor type bKP3 [mm] 1FN3050 40 1FN3100 40 1FN3150 100 1FN3300 50 1FN3450 100 Direct connection To connect plastic hoses directly, cooling sections with hose connector nipples can be ordered from Siemens. The inside diameter of the hose should be 5 mm. Hose and hose connector nipple are connected with a hose clamp. 1FN3 linear motors 94 Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 Connection 5.2 Electrical connection 5.2 Electrical connection 5.2.1 Safety instructions for electrical connections NOTICE Destruction of the motor if it is directly connected to the three-phase line supply The motor will be destroyed if it is directly connected to the three-phase line supply. * Only operate the motors with the appropriately configured converters. WARNING Risk of electric shock If you connect the voltage to the primary section as individual component, then there is a risk of electric shock as there is no touch protection. * Only connect a voltage if the motor component is installed in the assembled machine. WARNING Risk of electric shock due to incorrect connection If you incorrectly connect the motor this can result in death, serious injury, or extensive material damage. The motors require an impressed sinusoidal current. * Connect the motor in accordance with the circuit diagram provided in this documentation. * Refer also to the documentation for the drive system used. 1FN3 linear motors Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 95 Connection 5.2 Electrical connection WARNING Risk of electric shock Voltage is induced at the power connections of the primary section each time a primary section moves with respect to a secondary section - and vice versa. When the motor is switched on, the power connections of the primary section are also live. If you touch the power connections you may suffer an electric shock. * Only mount and remove electrical components if you have been qualified to do so. * Only work on the motor when the system is in a no-voltage condition. * Do not touch the power connections. Correctly connect the power connections of the primary section or properly insulate the cable connections. * Do not disconnect the power connection if the primary section is under voltage (live). * When connecting up, only use power cables intended for the purpose. * First connect the protective conductor (PE). * Attach the shield through a large surface area. * First connect the power cable to the primary section before you connect the power cable to the converter. * First disconnect the connection to the converter before you disconnect the power connection to the primary section. * In the final step, disconnect the protective conductor (PE). 1FN3 linear motors 96 Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 Connection 5.2 Electrical connection WARNING Electric shock caused by high leakage currents When touching conductive parts of the machine, high leakage currents can result in an electric shock. * For high leakage currents, observe the increased requirements placed on the protective conductor. The requirements are laid down in standards DIN EN 61800-5-1 and DIN EN 60204-1. * For high leakage currents, attach warning symbols to Power Drive System . WARNING Risk of electric shock as a result of residual voltages There is a risk of electric shock if hazardous residual voltages are present at the motor connections. Even after switching off the power supply, active motor parts can have a charge exceeding 60 C. In addition, even after withdrawing the connector 1 s after switching off the voltage, more than 60 V can be present at the free cable ends. * Wait for the discharge time to elapse. No direct connection of the temperature monitoring circuits WARNING Risk of electric shock when incorrectly connecting the temperature monitoring circuit In the case of a fault, circuits Temp-S and Temp-F do not provide safe electrical separation with respect to the power components. * Use, for example, the TM120 or the SME12x to connect the Temp-S and Temp-F temperature monitoring circuits. You therefore comply with the directives for safe electrical separation according to DIN EN 61800-5-1 (previously safe electrical separation according to DIN EN 50178). 1FN3 linear motors Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 97 Connection 5.2 Electrical connection Correctly connecting temperature sensors NOTICE Motor destroyed as a result of overtemperature The motor can be destroyed as a result of overtemperature if you do not correctly connect the temperature sensors. * When connecting temperature sensor cables with open conductor ends, pay attention to the correct assignment of conductor colors. 5.2.2 Important information about the electrical connection The 1FN3050 motors either have a permanently connected combination cable or two separate permanently connected cables for the power connection and the signal connection. There is a choice of 0.5 m length and preassembled connectors (size 1 or M17) or 2 m length and open conductor ends for these cables. The 1FN3100 to 1FN3900 motors are provided with separate cables for the power connection and signal connection. To connect these motors, use the connection cover with metric cable glands directly on the integrated terminal panel. Peak load motors from this series are also available with a combination cable. Connect the combination cable via a connection cover with PG cable gland on the terminal panel. Connect the power cables at the points provided in the power module. Connect the signal cables at the points provided in a sensor module. When connecting cables with open conductor ends, ensure there is correct shielding and grounding. General notes for routing electric cables Drives with linear motors are subject to a high dynamic load. It must be ensured that vibration is not transferred to the connectors by suitably routing the cables or by providing strain relief close to the connector (distance < 10 Dmax). Dmax is the maximum cable diameter (see Catalog). Using the cables in the cable carrier Note When laying cables, carefully observe the instructions given by the cable carrier manufacturer! 1FN3 linear motors 98 Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 Connection 5.2 Electrical connection To maximize the service life of the cable carrier and cables, cables in the carrier made from different materials must be installed in the cable carrier with spacers. The chambers must be filled evenly to ensure that the position of the cables does not change during operation. The cables should be distributed as symmetrically as possible according to their mass and dimensions. If possible, use only cables with equal diameters in one chamber. Cables with very different outer diameters should be separated by spacers. The cables must not be fixed in the carrier and must have room to move. It must be possible to move the cables without applying force, in particular in the bending radii of the carrier. The specified bending radii must be adhered to. The cable fixings must be attached at both ends at an appropriate distance away from the end points of the moving parts in a dead zone. A tension relief must be installed at least at the ends of the cable carrier. Be sure to mount the cables along the casing without crushing them. The cables are to be taken off the drum free of twists, i.e. roll the cables off the drum instead of taking them off in loops from the drum flange. Number of conductors and cable cross-sections Cables that are connected to the motor must have four conductors for the power cable / four conductors for the signal cable. The cross-section for each of the signal cable conductors is 0.5 mm2. The cross-section of the power cable conductors is based on the rated current of the motor. The rated current of the motor must be less than the current carrying capacity of the cable according to DIN EN 60204-1 (laying system C). The table below specifies the maximum permissible rated current of the motor for different cross-sections of the power cable conductors. Table 5- 2 Maximum permissible rated current with different cross-sections of the power cable conductors Power cable conductor cross-section 2.5 mm2 4 mm2 6 mm2 10 mm2 16 mm2 25 mm2 Maximum permissible rated current 21 A 28 A 36 A 50 A 66 A 84 A Note Connection of large cable cross-sections Connecting cables with conductor cross-sections of more than 16 mm2 is not possible at the motor terminal panel. If the rated current of a motor requires power conductors with a crosssection of 25 mm2, please contact your local Siemens office. 1FN3 linear motors Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 99 Connection 5.2 Electrical connection 5.2.3 PIN assignments for the connectors PIN assignments of the plug-in connectors for combination cables Figure 5-4 PIN assignments of the plug-in connectors for combination cables Connect the cables at the motor end with EMC-compliant metallic PG cable glands. This allows cable connections with low bending radii in all directions. 1FN3 linear motors 100 Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 Connection 5.2 Electrical connection Pin assignment of the plug-in connectors for separate cables Figure 5-5 PIN assignments of the plug-in connectors for signal cables 1FN3 linear motors Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 101 Connection 5.2 Electrical connection Figure 5-6 5.2.4 PIN assignments of the plug-in connectors for power cables Terminal panel Terminal panel Note Preassemble the cables before installing If the primary section is already installed, the terminal panel may be difficult to access. * Install the cables in the connection frame before installing the primary section in the machine. 1FN3 linear motors 102 Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 Connection 5.2 Electrical connection The following figures show the terminal assignment of the terminal panel for various peak load motor types. The terminal panel of peak load and continuous load motors is identical. The only difference is that the dimensions of the casing are larger on the continuous load motor. However, this is of no significance for the electrical connection. With the EN 60034-8:2002 standard the terminal markings have changed. For the old terminal markings, see Appendix. Figure 5-7 Terminal panel for the motors 1FN3100 to 1FN3150 1FN3 linear motors Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 103 Connection 5.2 Electrical connection Figure 5-8 Terminal panel for the motors 1FN3300 to 1FN3900 The supplied screws and the tightening torques are listed in following table. Table 5- 3 Connection cover screws supplied and tightening torques Motor type 1FN3... Screw compliant with DIN EN ISO 4762 Tightening torque 100, 150 M4x20-A2 2.2 Nm 300, 450, 600, 900 M5x20-A4 3.4 Nm 1FN3 linear motors 104 Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 Connection 5.2 Electrical connection Disassembly of the connection cover NOTICE Damage to the seal The seal can be damaged during disassembly of the connection cover. * When unscrewing the connection cover, take care that the seal stays completely in the groove in the connection cover. * Carefully remove the seal from the motor if necessary. Then press the seal back into the groove of the connection cover. 5.2.5 Power connection Table 5- 4 5.2.6 Conductor assignment for power cables with open conductor ends Color/identification Connection green/yellow PE black / U / L1 / C / L+ U black / V / L2 V black / W / L3 / D / L- W Temperature sensor connection Note Observe the polarity Carefully note the polarity when connecting the KTY. The following shows various connection variants for the temperature sensors. These illustrations apply to the operation of 1FN3 linear motors with the SINAMICS S120 drive system. The IDs A, B or C are used to identify the conductor assignments of the temperature sensor cables in the following tables. 1FN3 linear motors Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 105 Connection 5.2 Electrical connection Identification for cables with open conductor ends or ring-type lugs Identification for plug connections Figure 5-9 Connection variants for temperature sensors for the SINAMICS S120 drive system 1FN3 linear motors 106 Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 Connection 5.2 Electrical connection Table 5- 5 Conductor assignments of the temperature sensor cables - Table A Conductor color Interface White -1R2: -KTY or Pt1000 black +1R1: +KTY or Pt1000 red 1TP1: PTC Yellow 1TP2: PTC Applies to permanently connected combination cable with open conductor ends for 1FN3050 Table 5- 6 Conductor assignments of the temperature sensor cables - Table B Conductor color Interface White -1R2: -KTY or Pt1000 Brown +1R1: +KTY or Pt1000 Green 1TP1: PTC Yellow 1TP2: PTC Applies to cable 6FX8002-2SL01-..., 6FX8002-2SL02-..., 6FX8002-2SL20-... and permanently connected sensor cable with open conductor ends for 1FN3050 Table 5- 7 Conductor assignments of the temperature sensor cables - Table C Conductor color Pin White 1 Brown 2 Green 3 Yellow 4 Gray 5 Pink 6 Green/yellow Applies to cable 6FX8002-2SL00-...; the conductor colors also apply for cable 6FX8002-1BD00-... (sold by the meter) 1FN3 linear motors Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 107 Connection 5.2 Electrical connection 5.2.7 Motor circuit diagram The circuit diagram of the primary section looks like this: Figure 5-10 5.2.8 Circuit diagram for primary section Shielding, grounding, and equipotential bonding Important notes regarding shielding, grounding and equipotential bonding Correct installation, correctly connecting cable shields and protective conductors is very important, not only for the safety of personnel but also for the effect on interference emission and interference immunity. WARNING Risk of electric shock! Hazardous touch voltages can be present at unused cores and shields if they have not been grounded or insulated. * Connect the cable shields to the respective housings through the largest possible surface area. Use suitable clips, clamps or screw couplings to do this. * Connect unused conductors of shielded or unshielded cables and their associated shields to the grounded enclosure potential at one end as minimum. Alternatively: Insulate unused conductors of shielded or unshielded cables and their associated shields. The insulation must be able to withstand the rated voltage. Further, unshielded or incorrectly shielded cables can lead to faults in the drive - particularly the encoder - or in external devices, for example. 1FN3 linear motors 108 Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 Connection 5.2 Electrical connection Electrical charges that are the result of capacitive cross coupling are discharged by connecting the cores and shields. NOTICE Device damage as a result of leakage currents for incorrectly connected protective conductor High leakage currents may damage other devices if the motor protective conductor is not directly connected to the power module. * Connect the motor protective conductor (PE) directly at the power unit. NOTICE Device damage as a result of leakage currents for incorrect shielding High leakage currents may damage other devices if the motor power cable shield is not directly connected to the power module. * Connect the power cable shield at the shield connection of the power module. Note Apply the EMC installation guideline of the converter manufacturer. For Siemens converters, this is available under document order No. 6FC5297-AD30-0P. 1FN3 linear motors Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 109 Connection 5.2 Electrical connection 1FN3 linear motors 110 Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 Commissioning 6 The subsequent information refers to commissioning the hardware components. Siemens provides commissioning support through its Technical Support organization. The motor can only be commissioned when it has been installed and integrated in a functioning system. The commissioning documentation of all the system components must be taken into account for the commissioning. 1FN3 linear motors Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 111 Commissioning 6.1 Safety instructions for commissioning 6.1 Safety instructions for commissioning WARNING Risk of death and crushing as a result of permanent magnet fields Severe injury and material damage can result if you do not take into consideration the safety instructions relating to the permanent magnet fields of the secondary sections. * Observe the information in Chapter "Danger from strong magnetic fields (Page 26)". WARNING injury and material damage if EMC safety requirements are not observed Risk of death, serious personal injury, and/or material damage can occur if a machine that does not fulfill the recognized EMC safety requirements is commissioned. * Plants and machines with converter-fed low-voltage three-phase motors must fulfill the protection requirements of EMC Guideline 2014/30/EU. * The plant engineer is responsible for ensuring that installation is carried out in an EMCcompliant manner. Use shielded signal and power cables. Apply the EMC installation guideline of the converter manufacturer. For Siemens converters, this is available under document order No. 6FC5297-AD30-0P. WARNING Danger of severe injuries caused by unexpected movements of the motor Unexpected movements of the motor may cause death, serious injury (crushing) and/or property damage. * Never stay in the traversing range while the machine is switched on. * Keep persons away from the traversing areas where there is a danger of crushing. * Ensure the free axis travel path. * Check before switching on the commutation! Also observe the instructions of the drive system being used. * Limit the motor currents. * Set the speed limit to small values. * Monitor the end positions of the motor. 1FN3 linear motors 112 Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 Commissioning 6.1 Safety instructions for commissioning WARNING Risk of electric shock Voltage is induced at the power connections of the primary section each time a primary section moves with respect to a secondary section - and vice versa. When the motor is switched on, the power connections of the primary section are also live. If you touch the power connections you may suffer an electric shock. * Only mount and remove electrical components if you have been qualified to do so. * Only work on the motor when the system is in a no-voltage condition. * Do not touch the power connections. Correctly connect the power connections of the primary section or properly insulate the cable connections. * Do not disconnect the power connection if the primary section is under voltage (live). * When connecting up, only use power cables intended for the purpose. * First connect the protective conductor (PE). * Attach the shield through a large surface area. * First connect the power cable to the primary section before you connect the power cable to the converter. * First disconnect the connection to the converter before you disconnect the power connection to the primary section. * In the final step, disconnect the protective conductor (PE). 1FN3 linear motors Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 113 Commissioning 6.1 Safety instructions for commissioning WARNING Risk of electric shock as a result of residual voltages There is a risk of electric shock if hazardous residual voltages are present at the motor connections. Even after switching off the power supply, active motor parts can have a charge exceeding 60 C. In addition, even after withdrawing the connector 1 s after switching off the voltage, more than 60 V can be present at the free cable ends. * Wait for the discharge time to elapse. WARNING Incorrect commutation Incorrect commutation can result in uncontrolled motor movements. * When installing and replacing an encoder, ensure the correct commutation setting. * Only carry out the associated work if you have been appropriately trained. WARNING Fire hazard resulting from hot surfaces Touching the surfaces of the motors may result in burns. The surface temperature of the motors can be more than 100 C (212 F). * Ensure that the cooling system is functioning perfectly. * Never touch the motor during or immediately after use. * Attach the "Hot Surface Do Not Touch" (W017) warning sign close to the source of danger where it can be easily seen. 1FN3 linear motors 114 Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 Commissioning 6.1 Safety instructions for commissioning NOTICE Thermal damage to temperature-sensitive parts Some parts of the electrical motor enclosure can reach temperatures that exceed 100 C. If temperature-sensitive parts, for instance electric cables or electronic components, come into contact with hot surfaces then these parts can be damaged. * Ensure that no temperature-sensitive parts come into contact with hot surfaces. NOTICE Motor destroyed as a result of overheating The motor may overheat without temperature protection and be destroyed. * Check whether the temperature protection is effective before switching on the DC link voltage for the first time! NOTICE Demagnetization of permanent magnets If, during operation, the maximum permissible temperature of the secondary sections exceeds 70 C, then there is a risk that the permanent magnets will be demagnetized. * Ensure that the temperature of the secondary sections when operational does not exceed 70 C! 1FN3 linear motors Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 115 Commissioning 6.1 Safety instructions for commissioning NOTICE Damaged main insulation In systems where direct drives are used on controlled infeeds, electrical oscillations can occur with respect to ground potential. These oscillations are, among other things, influenced by: * The lengths of the cables * The rating of the infeed/regenerative feedback module * The type of infeed/regenerative feedback module (particularly when an HFD commutating reactor is already present) * The number of axes * The size of the motor * The winding design of the motor * The type of line supply * The place of installation The oscillations lead to increased voltage loads and may damage the main insulation! * To dampen the oscillations we recommend the use of the associated Active Interface Module or an HFD reactor with damping resistor. For specific details, refer to the documentation of the drive system being used or contact your local Siemens office. Note Use an Active Interface Module or the matching HFD line reactor Please note the following when connecting the motor to a SINAMICS S120 drive system: The corresponding Active Interface Module or the appropriate HFD line reactor must be used to operate the Active Line Module controlled infeed unit. 1FN3 linear motors 116 Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 Commissioning 6.2 Checklists 6.2 Checklists Checklists for commissioning linear motors Before starting any work, get to know and understand the safety notes and observe the following checklists. Table 6- 1 Checklist (1) - general checks Check OK Are all of the necessary components of the configured drive line-up available, correctly dimensioned, installed and connected? Are the manufacturer documentation for the system components (e.g. drive system, encoder, cooling system, brake) and the Configuration Manual "SIMOTICS L-1FN3 linear motors" available? If the 1FN3 linear motor is to be fed from a SINAMICS S120 drive system: Is the following, current SINAMICS documentation available? * SINAMICS S120 Commissioning Manual * Getting Started S120 * S120 Function Manual * S120/150 List Manual If the 1FN3 linear motor is to be fed from a SINAMICS S120 drive system: Was the Chapter "Checklists for commissioning SINAMICS S" in the SINAMICS S120 Commissioning Manual carefully observed? If the 1FN3 linear motor is to be fed from a SINAMICS S120 drive system: Is the motor type to be commissioned known? (e.g. 1FN3_ _ _ - _ _ _ _ _ - _ _ _ _) If the 1FN3 linear motor is to be fed from a SINAMICS S120 drive system: If it involves a "third-party motor", are the following motor data known as a minimum? (A "third-party motor" is a motor that is not (yet) saved as standard in the Siemens commissioning software.) * Rated motor current * Motor rated velocity * Motor pole distance * Motor force constant * Maximum motor speed * Maximum motor current * Motor limit current * Motor weight * Phase resistor of the motor winding is cold * Phase inductance of winding Are the environmental conditions in the permissible range? 1FN3 linear motors Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 117 Commissioning 6.2 Checklists Table 6- 2 Checklist (2) - checks regarding the mechanical system Check OK Is the motor correctly mounted according to the Siemens specifications and ready to be powered up? Is the axis free to move over the complete traversing range? Has the air gap height between the secondary section track and the primary section been checked? If a motor holding brake is being used, is this functioning correctly? Does the weight balance required for a suspended axis exist? Has the encoder been correctly mounted and adjusted according to the manufacturer's data? Are mechanical limit stops in place and tightly bolted to both ends of the traversing path? Are moving supply lines correctly routed in a tow chain assembly? Has the cooling system required according to the manufacturer's data been connected and is it functioning correctly? Does the coolant meet the requirements stated in chapter "Coolant"? Were the cooling circuits purged before being filled with coolant? Is it ensured that the permissible cooling circuit pressure stated in chapter "Technical features" in the operating instructions will not be exceeded? Have measures been taken to relieve strain on the cables? Table 6- 3 Checklist (3) - checks regarding the electrical system Check OK Has all wiring work been successfully completed? Is the protective conductor correctly connected? Is the ground of the motors directly connected to the ground of the power modules (short distance to avoid high discharge currents)? Are all connectors correctly plugged in and screwed in place? Are the motors connected with shielded power cables? Are the power cable shields connected as closely as possible to the terminal box across a wide area? Are all cable shields connected to the respective housings through the largest possible surface area? Have the control cables been connected in accordance with the required interface configuration and the shield applied? Have the motor power cables been correctly connected to the Motor Module(s) with the UVW phase sequence (clockwise rotating field)? Do the temperature monitoring circuits fulfill the specifications of protective separation? Before commissioning and switching on the DC link voltage for the first time, have you checked the temperature monitoring circuits to ensure that they correctly trip? Has the encoder been correctly connected? Have the digital and analog signals been routed using cables that are separate from the power cables? Has the distance from power cables been observed? Have you ensured that temperature-sensitive components (electric cables, electronic components) are not placed on hot surfaces? Have the line-side and motor-side power cables been dimensioned and routed in accordance with the environmental and routing conditions? Have the maximum permissible cable lengths between the frequency converter and the motor (depending on the type of cables used) been observed? 1FN3 linear motors 118 Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 Commissioning 6.3 Checking the insulation resistance 6.3 Checking the insulation resistance Notes for checking the insulation resistance WARNING Risk of electric shock If you check the insulation resistance using high voltage on a plant/machine equipped with direct drives or directly at the motors, this can damage the motor insulation! Examples necessitating that the insulation resistance is checked include the installation test, preventive maintenance and troubleshooting. * Only use test equipment that is in compliance with DIN EN 61557-1, DIN EN 61557-2 and DIN EN 61010-1 or the corresponding IEC standards. * The test may only be carried out with a maximum direct voltage of 1000 V for a maximum time of 60 s! * Measure the test voltage with respect to ground or the motor housing. * If a higher DC or AC voltage is necessary to test the machine/plant, you must coordinate the test with your local Siemens office! * Carefully observe the operating instructions of the test equipment! Always proceed as follows when testing the insulation resistance of individual motors: 1. Connect all winding and temperature sensor connections with each other; the test voltage must not exceed 1000 VDC, 60 s with respect to PE connection. 2. Connect all temperature sensor connections to the PE connection and all winding connections with each other; the test voltage must not exceed 1000 VDC, 60 s, winding with respect to PE connection. Each insulation resistance must be at least 10 M, otherwise the motor insulation is defective. WARNING Risk of death due to electric shock! During and immediately after the measurement, in some instances, the terminals are at hazardous voltage levels, which can result in death if touched. * Never touch the terminals during or immediately after measurement. 1FN3 linear motors Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 119 Commissioning 6.4 Cooling 6.4 Cooling WARNING Risk of burning when touching hot surfaces There is a risk of burning when touching hot surfaces immediately after the motor has been operational. * Wait until the motor has cooled down. WARNING Danger to life when the cooling system bursts The motor will overheat if it is operated without cooling. When cooling water enters the hot motor, this immediately and suddenly generates hot steam that escapes under high pressure. This can cause the cooling water system to burst, resulting in death, severe injury and material damage. * Never operate the motor without cooling. * Only commission the cooling water circuit when the motor is in a cool condition. CAUTION Risk of burns when hot cooling water escapes There is a risk of burns caused by escaping hot cooling water and steam if you open the cooling circuit of a motor that was previously in operation. * Do not open the motor cooling circuit until the motor has cooled down. 1FN3 linear motors 120 Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 7 Operation 7.1 Safety instructions for operation WARNING Danger to persons in areas with rotary and crushing motion Machine parts driven by the linear motors can cause significant injury, e.g. through crushing. This is as a result of the very high speeds and acceleration rates - as well as low friction and self clamping. * Keep persons away from the axis traversing parts and areas where there is a danger of crushing. NOTICE Material damage caused by incorrect operation Improper operation can lead to serious material damage. * Only operate the motor at locations equipped with full weather protection: The environment must be dry and protected against heat and cold. * Keep the area where the motor is installed free of all foreign bodies. Foreign bodies include metal chips, particles, liquids, oils, screws, tools, etc. * Ensure that the motor cooling system functions perfectly. * Only operate the motor in conjunction with effective temperature protection. 1FN3 linear motors Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 121 Operation 7.1 Safety instructions for operation WARNING Faults while the motor is operational Examples of possible faults that can cause malfunctions: * Higher power consumption * Changed temperatures * Vibration * Unusual noise * Unusual smells * Response of the monitoring devices Faults while the motor is operational can result in death, severe injury or material damage. * Immediately inform the maintenance personnel. * If in doubt, shut down the motor immediately, taking into account the plant-specific safety regulations. 1FN3 linear motors 122 Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 Operation 7.2 Switching off and operating phases 7.2 Switching off and operating phases During downtimes, deposits must not be produced that can block the cooling system. Check with the manufacturer of the coolant as to how long it can remain in the cooling system. 1FN3 linear motors Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 123 Operation 7.3 Handling faults 7.3 Handling faults If there are deviations from normal operation or if faults occur, initially proceed according to the following list. In this regard, observe the relevant chapters in the documentation associated with the components of the complete drive system. WARNING Risk to life as a result of non-functioning protective devices Protective devices that are not functioning can result in death, serious injury or material damage. * Do not deactivate protective devices. This also applies to test operation. * Only work with protective devices that are fully functional. NOTICE Damage to the machine caused by faults * Resolve the cause of the fault as specified in the remedial measures section. Repair any damage to the machine/motor. Table 7- 1 Possible faults Fault Motor blocked Cause of the fault (see following table) A B C D Noise during operation D High temperature rise during no-load operation D F G D F G High temperature rise when under load A E Uneven running Axis is sluggish Water is leaking K H E J K L N 1FN3 linear motors 124 Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 Operation 7.3 Handling faults Table 7- 2 No. Key to causes of faults and remedial measures Cause of fault How to remedy the problem A Overloading Reduce load B Interrupted phase in the supply cable Check frequency converter and supply cables C Interrupted phase in the supply cable after switching on Check frequency converter and supply cables D Motor commutation is faulty Check the commutation, if required re-adjust the commutation angle offset E Winding short-circuit or phase short-circuit in the primary section winding Measure the winding resistances and insulation resistances, motor replacement after consultation with the manufacturer F Cooling water not connected / switched off Check cooling water connection / switch on cooling water / check cooler Water connection / pipes defective Locate leaks and seal as necessary, or consult the manufacturer Cooling water flow rate too low Check cooling water flow rate according to data sheet specification G Intake temperature too high Set correct intake temperature H Insufficient shielding for motor and/or encoder cable Check the shielding and grounding J Drive controller gain too high Adjust the controller K Motor components are rubbing Determine cause and adjust components Foreign bodies in the air gap Consult the manufacturer Guide rail is tight Check that the guide rails are not distorted and are parallel to one another Poor alignment Align machine guides M Shocks from coupled machine Check coupled machine N Cooling water pipes/water connection defective Locate leaks and seal as necessary, or consult the manufacturer L If the fault still cannot be resolved after applying the measures specified above, please contact the manufacturer or your local Siemens office. 1FN3 linear motors Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 125 Operation 7.3 Handling faults 1FN3 linear motors 126 Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 8 Maintenance 8.1 Safety instructions for maintenance WARNING Risk of injury as a result of inadvertent traversing motions If, with the motor switched on, you work in the traversing range of the motor, and the motor undesirably moves, this can result in death, injury and/or material damage. * Always switch off the motor before working in the traversing range of the motor. Ensure that the motor is in a completely no-voltage condition. 1FN3 linear motors Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 127 Maintenance 8.1 Safety instructions for maintenance WARNING Risk of death and crushing as a result of permanent magnet fields Severe injury and material damage can result if you do not take into consideration the safety instructions relating to the permanent magnet fields of the secondary sections. * Observe the information in Chapter "Danger from strong magnetic fields (Page 26)". WARNING Danger of crushing by permanent magnets of the secondary section The forces of attraction of magnetic secondary sections act on materials that can be magnetized. The forces of attraction increase significantly close to the secondary section. The trigger threshold of 3 mT for a risk of injury due to attraction and projectile effect is reached at a distance of 150 mm (directive 2013/35/EU). Secondary sections and materials that can be magnetized can suddenly slam together unintentionally. Two secondary sections can also unintentionally slam together. There is a significant risk of crushing when you are close to a secondary section. Close to the secondary section, the forces of attraction can be several kN - example: Magnetic attractive forces are equivalent to a force of 100 kg, which is sufficient to trap a body part. * Do not underestimate the strength of the attractive forces, and work very carefully. * Wear safety gloves. * The work should be done by at least two people. * Do not unpack the secondary section until immediately before assembly. * Never unpack several secondary sections at the same time. * Never place secondary sections next to one another without taking the appropriate precautions. * Never place any metals on magnetic surfaces and vice versa. * Never carry any objects made of magnetizable materials (for example watches, steel or iron tools) and/or permanent magnets close to the secondary section! If tools that can be magnetized are nevertheless required, then hold the tool firmly using both hands. Slowly bring the tool to the secondary section. * Immediately mount the secondary section that has just been unpacked. * Always comply with the specified procedure. * Avoid inadvertently traversing direct drives. * Keep the following tools at hand to release parts of the body (hand, fingers, foot etc.) trapped between two components: - A hammer (about 3 kg) made of solid, non-magnetizable material - Two pointed wedges (wedge angle approx. 10 to 15, minimum height 50 mm) made of solid, non-magnetizable material (e.g. hard wood). 1FN3 linear motors 128 Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 Maintenance 8.1 Safety instructions for maintenance WARNING Risk of burning when touching hot surfaces There is a risk of burning when touching hot surfaces immediately after the motor has been operational. * Wait until the motor has cooled down. WARNING Danger to life when the cooling system bursts The motor will overheat if it is operated without cooling. When cooling water enters the hot motor, this immediately and suddenly generates hot steam that escapes under high pressure. This can cause the cooling water system to burst, resulting in death, severe injury and material damage. * Never operate the motor without cooling. * Only commission the cooling water circuit when the motor is in a cool condition. CAUTION Risk of burns when hot cooling water escapes There is a risk of burns caused by escaping hot cooling water and steam if you open the cooling circuit of a motor that was previously in operation. * Do not open the motor cooling circuit until the motor has cooled down. WARNING Risk of electric shock due to incorrect connection There is a risk of electric shock if direct drives are incorrectly connected. This can result in death, serious injury, or material damage. * Motors must always be precisely connected up as described in these instructions. * Direct connection of the motors to the three-phase supply is not permissible. * Consult the documentation of the drive system being used. 1FN3 linear motors Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 129 Maintenance 8.1 Safety instructions for maintenance WARNING Risk of electric shock Voltage is induced at the power connections of the primary section each time a primary section moves with respect to a secondary section - and vice versa. When the motor is switched on, the power connections of the primary section are also live. If you touch the power connections you may suffer an electric shock. * Only mount and remove electrical components if you have been qualified to do so. * Only work on the motor when the system is in a no-voltage condition. * Do not touch the power connections. Correctly connect the power connections of the primary section or properly insulate the cable connections. * Do not disconnect the power connection if the primary section is under voltage (live). * When connecting up, only use power cables intended for the purpose. * First connect the protective conductor (PE). * Attach the shield through a large surface area. * First connect the power cable to the primary section before you connect the power cable to the converter. * First disconnect the connection to the converter before you disconnect the power connection to the primary section. * In the final step, disconnect the protective conductor (PE). 1FN3 linear motors 130 Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 Maintenance 8.1 Safety instructions for maintenance WARNING Risk of electric shock as a result of residual voltages There is a risk of electric shock if hazardous residual voltages are present at the motor connections. Even after switching off the power supply, active motor parts can have a charge exceeding 60 C. In addition, even after withdrawing the connector 1 s after switching off the voltage, more than 60 V can be present at the free cable ends. * Wait for the discharge time to elapse. WARNING Risk of injury when carrying out disassembly work Risk of death, serious personal injury and/or material damage when carrying out disassembly work. * When disassembling, observe the information in Chapter "Decommissioning". The motors have been designed for a long service life. Carefully ensure that maintenance work is correctly performed, e.g. removing chips and particles from the air gap. For safety reasons it is not permissible to repair the motors: WARNING Risk of injury when changing safety-relevant motor properties Changing safety-relevant motor properties may result in death, serious injury and/or material damage. Examples of changed safety-relevant motor properties: Damaged insulation does not protect against arcing. There is a risk of electric shock! Damaged sealing no longer guarantees protection against shock, ingress of foreign bodies and water, which is specified as IP degree of protection on the rating plate. Diminished heat dissipation can result in the motor being prematurely shut down and in machine downtime. * Do not open the motor. 1FN3 linear motors Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 131 Maintenance 8.1 Safety instructions for maintenance Note If incorrect changes or corrective maintenance are carried out by you or a third party on the contractual objects, then for these and the consequential damages, no claims can be made against Siemens regarding personal injury or material damage. Siemens service centers are available to answer any questions you may have. Siemens Service Center addresses can be found at http://www.siemens.com/automation/service&support CAUTION Sharp edges and falling objects Sharp edges can cause cuts and falling objects can injure feet. * Always wear safety shoes and safety gloves! 1FN3 linear motors 132 Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 Maintenance 8.2 Inspection and maintenance 8.2 Inspection and maintenance Performing maintenance work on the motor Note It is essential that you observe the safety information provided in this documentation. As a result of their inherent principle of operation, linear motors are always wear-free. To ensure that the motor functions properly and remains free of wear, the following maintenance work needs to be carried out: Regularly check that the traversing paths are free Regularly clean the motor space and remove foreign bodies (e.g. chips) Regularly check the condition of the motor components. Check the current consumption in the defined test cycle (compare with values of the reference travel) Intervals between maintenance Since operating conditions differ greatly, it is not possible to specify intervals between maintenance work. Indications that maintenance work is required Dirt in the motor cabinet Distinctive changes in the behavior of the machine Unusual sounds emitted by the machine Problems with positioning accuracy Higher current consumption Test and replacement intervals of the cooling medium The test and replacement intervals for the cooling medium should be agreed with the manufacturers of the anti-corrosion agent and the cooling system. 1FN3 linear motors Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 133 Maintenance 8.2 Inspection and maintenance 1FN3 linear motors 134 Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 Decommissioning and disposal 9.1 9 Decommissioning Sequence when decommissioning and disassembling the motor WARNING Risk of injury and material damage Injury can occur if you do not observe the specified sequence when decommissioning and disassembling the motor. Further, motor components could be damaged or destroyed. * Comply with the specified sequence when carrying out decommissioning work. * Dismantle the motors by carrying out the work steps of the respective procedure for installing the motor in the reverse order. 1. Bring the motor into a no-voltage condition. Wait until the DC link of the power unit has been discharged. 2. Allow the motor to cool down for at least 30 min. 3. Switch off the cooling. Reduce the pressure to 0 bar. 4. Disconnect the power and signal cables. 5. If necessary, properly isolate the power connections. Any movement of primary sections respective to secondary sections can lead to induced voltages. 6. Disconnect the coolant lines. 7. Drain the coolant from the motor and dispose of it correctly. 8. Remove chips, dirt, foreign particles, etc. from the motor. 9. Remove the primary sections. Observe the respective installation procedures. When installing with a divided secondary section track, you must first slide the primary section on one end of the secondary section track, for example. Then you can dismantle the secondary sections that are not covered. Then you have to move the primary section to the end without secondary section and remove the remaining secondary section track. Only then can you disassemble the slide together with the linear guide and the primary section. 10.Pack the motor components in the original packaging. 11.Correctly store the motor components. 1FN3 linear motors Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 135 Decommissioning and disposal 9.2 Disposal 9.2 Disposal The product must be disposed of in the normal recycling process in compliance with national and local regulations. WARNING Injury or material damage if not correctly disposed of If you do not correctly dispose of direct drives or their components (especially components with permanent magnets), then this can result in death, severe injury and/or material damage. * Ensure that direct drives and their associated components are correctly disposed of. Main constituents of a proper disposal procedure Complete demagnetization of the components that contain permanent magnets Components that are to be recycled should be separated into: - Electronics scrap (e.g. encoder electronics, Sensor Modules) - Electrical scrap (e.g. motor windings, cables) - Scrap iron (e.g. laminated cores) - Aluminum - Insulating materials No mixing with solvents, cold cleaning agents, or residue of paint, for example 9.2.1 Disposing of secondary sections WARNING Risk of death and crushing as a result of permanent magnet fields Severe injury and material damage can result if you do not take into consideration the safety instructions relating to the permanent magnet fields of the secondary sections. * Observe the information in Chapter "Danger from strong magnetic fields (Page 26)". 1FN3 linear motors 136 Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 Decommissioning and disposal 9.2 Disposal Demagnetization of the secondary sections Disposal companies specialized in demagnetization use special disposal furnaces. The insides of the disposal furnace consist of non-magnetic material. The secondary sections are put in the furnace in a solid, heat-resistant container (such as a skeleton container) made of non-magnetic material and left in the furnace during the entire demagnetization procedure. The temperature in the furnace must be at least 300 C during a holding time of at least 30 minutes. Escaping exhaust must be collected and made risk-free without damaging the environment. 9.2.2 Disposal of packaging Packaging materials and disposal The packaging and packing aids we use contain no problematic materials. With the exception of wooden materials, they can all be recycled and should always be disposed of for reuse. Wooden materials should be burned. Only recyclable plastics are used as packing aids: Code 02 PE-HD (polyethylene) Code 04 PE-LD (polyethylene) Code 05 PP (polypropylene) Code 04 PS (polystyrene) 1FN3 linear motors Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 137 Decommissioning and disposal 9.2 Disposal 1FN3 linear motors 138 Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 A Appendix A.1 Mounting the Hall sensor box Mounting the Hall sensor box onto the peak load motors 1FN3050 - 1FN3150 Figure A-1 Hall sensor box (HSB) with straight cable outlet for motors 1FN3050, 1FN3100 and 1FN3150 1FN3 linear motors Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 139 Appendix A.1 Mounting the Hall sensor box Figure A-2 Hall sensor box (HSB) with lateral cable outlet for motors 1FN3050, 1FN3100 and 1FN3150 1FN3 linear motors 140 Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 Appendix A.1 Mounting the Hall sensor box Mounting the Hall sensor box onto the continuous load motors 1FN3050 - 1FN3150 Figure A-3 Mounting the Hall sensor box (HSB) with straight cable outlet for motors 1FN3050-xN ... 150-xN 1FN3 linear motors Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 141 Appendix A.1 Mounting the Hall sensor box Figure A-4 Mounting the Hall sensor box (HSB) with lateral cable outlet for motors 1FN3050-xN ... 150-xN 1FN3 linear motors 142 Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 Appendix A.1 Mounting the Hall sensor box Mounting the Hall sensor box onto the peak load motors 1FN3300 - 1FN3450 Figure A-5 Hall sensor box (HSB) with straight cable outlet for motors 1FN3300 and 1FN3450 1FN3 linear motors Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 143 Appendix A.1 Mounting the Hall sensor box Figure A-6 Hall sensor box (HSB) with lateral cable outlet for motors 1FN3300 and 1FN3450 1FN3 linear motors 144 Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 Appendix A.1 Mounting the Hall sensor box Mounting the Hall sensor box onto continuous load motors 1FN3300 - 1FN3450 Figure A-7 Mounting the Hall sensor box (HSB) with straight cable outlet for motors 1FN3300-xN ... 450-xN 1FN3 linear motors Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 145 Appendix A.1 Mounting the Hall sensor box Figure A-8 Mounting the Hall sensor box (HSB) with lateral cable outlet for motors 1FN3300-xN ... 450-xN 1FN3 linear motors 146 Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 Appendix A.1 Mounting the Hall sensor box Mounting the Hall sensor onto the peak load motor 1FN3600 Figure A-9 Hall sensor box (HSB) with straight cable outlet for 1FN3600 motors 1FN3 linear motors Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 147 Appendix A.1 Mounting the Hall sensor box Figure A-10 Hall sensor box (HSB) with lateral cable outlet for 1FN3600 motors 1FN3 linear motors 148 Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 Appendix A.1 Mounting the Hall sensor box Mounting the Hall sensor box onto the continuous load motor 1FN3600 Figure A-11 Mounting the Hall sensor box (HSB) with straight cable outlet for 1FN3600-xN motors 1FN3 linear motors Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 149 Appendix A.1 Mounting the Hall sensor box Figure A-12 Mounting the Hall sensor box (HSB) with lateral cable outlet for 1FN3600-xN motors 1FN3 linear motors 150 Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 Appendix A.1 Mounting the Hall sensor box Mounting the Hall sensor box onto the peak load motor 1FN3900 Figure A-13 Hall sensor box (HSB) with straight cable outlet for 1FN3900 motors 1FN3 linear motors Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 151 Appendix A.1 Mounting the Hall sensor box Figure A-14 Hall sensor box (HSB) with lateral cable outlet for 1FN3900 motors 1FN3 linear motors 152 Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 Appendix A.1 Mounting the Hall sensor box Mounting the Hall sensor box to the continuous load motor 1FN3900 Figure A-15 Mounting the Hall sensor box (HSB) with straight cable outlet for 1FN3900-xN motors 1FN3 linear motors Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 153 Appendix A.1 Mounting the Hall sensor box Figure A-16 Mounting the Hall sensor box (HSB) with lateral cable outlet for 1FN3900-xN motors 1FN3 linear motors 154 Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 Appendix A.2 Manufacturer recommendations A.2 Manufacturer recommendations Information regarding third-party products Note Recommendation relating to third-party products This document contains recommendations relating to third-party products. Siemens accepts the fundamental suitability of these third-party products. You can use equivalent products from other manufacturers. Siemens does not accept any warranty for the properties of third-party products. A.2.1 Manufacturers of anti-corrosion agents TYFOROP CHEMIE GmbH Anti-corrosion protection: www.tyfo.de Tyfocor Clariant Produkte (Deutschland) GmbH Anti-corrosion protection: www.clariant.de Antifrogen N A.2.2 Manufacturers of connectors for cooling Rectus GmbH www.rectus.de 1FN3 linear motors Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 155 Appendix A.2 Manufacturer recommendations A.2.3 Manufacturers of plastic hose manufacturers Festo AG & Co. KG www.festo.com Rectus GmbH www.rectus.de A.2.4 Manufacturers of spacer foils SAHLBERG GmbH & Co. KG www.sahlberg.de 1FN3 linear motors 156 Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 Appendix A.3 List of abbreviations A.3 List of abbreviations AAA - abbreviations CE Communaute Europeene DIN Deutsches Institut fur Normung (German standards organization) EC European Community EMC Electromagnetic compatibility EN European standard HFD High-frequency damping HSB Hall sensor box HW Hardware IATA International Air Transport Association IEC International Electrotechnical Commission IP International Protection or Ingress Protection; type of protection fur electric devices according to DIN EN 60529 ISO International Standardization Organization KTY Temperature sensor with progressive, almost linear characteristic PDS Power drive system PE Protective earth PELV Protective extra low voltage PLC Programmable logic controller Pt Platinum resistance thermometer PTC Temperature sensor with positive temperature coefficient SMC Sensor Module Cabinet SME Sensor Module External SSI Synchronous serial interface SW Software Temp-F Circuit for monitoring the temperature of the motor winding Temp-S Temperature monitoring circuit for switching off the drive at overtemperature TM Terminal Module 1FN3 linear motors Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 157 Appendix A.3 List of abbreviations 1FN3 linear motors 158 Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 Index A D Accidents First aid, 30 Anti-corrosion protection, 47 Assembly Secondary section, 79 Secondary section cooling, 80 Decommissioning, 135 Degree of protection, 31 Installed motor, 34 Primary section, 33 Direction of motion, 32 Dismantling, 135 Secondary section cover, 85 Disposal, 136 C Cable Cable laying regulations, 99 Cable carrier, 99 Certificates EAC, 26 EC Declaration of Conformity, 26 UL and cUL, 26 Check Motor assembly, 88 Commissioning, 111 Connection Cooling, 91 Electrical, 108 Coolant Provision, 46 Water properties, 46 Cooling, 42 Connection, 91 Cooling circuits, 43 Maintenance, 133 Parallel connection, 43 Cooling medium Anti-corrosion agent properties, 47 General properties, 46 Cooling method, 31 E Evaluation Temp-F, Temp-S, 47 F Faults, 124 G Grounding, 108 H Hall sensor box Holding fixture, 86 Hotline, 6 I IATA, 60 Incorrect commutation, 114 Insulation resistance, 119 Intake temperature, 45 1FN3 linear motors Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1 159 Index M S Magnetic fields First aid in the case of accidents, 30 Occurrence, 26 Strength, 29, 66, 128 Motor Circuit diagram, 108 Components, 37 Disposal, 136 Motor assembly Check, 88 Motor circuit diagram, 108 Motor installation, 71 Procedures, 72 Motor type, 31 Mounting Primary section, 86 Secondary section cover, 81 Mounting system General rules, 69 Screw-in depth, 69 Screws, 80 Tightening torques, 69 Safety instructions Commissioning, 112 Disassembly, 131 Disposal, 136 Electrical connection, 95 Maintenance, 127 Mechanical installation, 65 Operation, 121 Packaging, 55 Storage, 55 Transport, 55 Secondary section Assembly, 79 Secondary section cooling Assembly, 80 Secondary section cover, 81 Secondary section end piece, 94 Shielding, 108 Siemens Service Center, 6 Storage, 55 N Technical Support, 6 Temperature monitoring, 31 Thermal motor protection, 31 Thermo-sandwich, 42 Thermo-Sandwich, 42 Third-party products, 155 Training, 6 Transport, 55 Type of construction, 31 Noise emission, 34 P Packaging, 55, 57, 137 Pin assignment of the plug-in connectors for separate cables, 101 PIN assignments of the plug-in connectors for combination cables, 100 Power connection, 105 Primary section Mounting, 86 PTC temperature sensor, 48 R T U Use for the intended purpose, 23 V Vibration response, 34 Rating plate, 36 Rating plate data, 36 1FN3 linear motors 160 Operating Instructions, 12/2016, 6SN1197-0AF01-0BP1