PDF

engineering
mannesmann
Rexroth
Synchronous Linear Motors LSF

Project Planning Manual, Selction Data and Commissioning
SYSTEM200
Rexroth
DOK-MOTOR*-LSF********-GN02-EN-P Indramat
About this Documentation Synchronous Linear Motors LSF
Title Synchronous Linear Motors LSF
Type of Documentation Project Planning Manual, Selction Data and Commissioning
Document Typecode DOK-MOTOR*-LSF********-GN02-EN-P
Internal File Reference • LSF-EN_Book.doc

• Document Number: 120-1500B310-02-EN
• Material Number: 00288895
Purpose of Documentation This documentation contains …

• Configuration notes
• Selection data of motor-controller combinations
• Assembling and commissing guidelines
For synchronous linear motors LSF
Record of Revisions Description Release Notes

Date
DOK-MOTOR*LSF********-GN01-EN-P 10/00
DOK-MOTOR*LSF********-GN02-EN-P 11/00 Revision
Copyright  2000 Rexroth Indramat GmbH

Copying this document, giving it to others and the use or communication
of the contents thereof without express authority, are forbidden. Offenders
are liable for the payment of damages. All rights are reserved in the event
of the grant of a patent or the registration of a utility model or design (DIN
34-1).
Validity All rights are reserved with respect to the content of this documentation
and the availability of the product.
Published by Rexroth Indramat GmbH

Bgm.-Dr.-Nebel-Str. 2 • D-97816 Lohr a. Main
Telephone 09352/40-0 • Tx 689421 • Fax 09352/40-4885
http://www.rexroth.com/indramat
Dept. ECM1/ECM (SWI/SK)
Note This document has been printed on chlorine-free bleached paper..
DOK-MOTOR*-LSF********-GN02-EN-P
Synchronous Linear Motors LSF Contents I
Contents
1 Introduction 1-1
1.1 About this Document...................................................................................................................... 1-1
1.2 Application Ranges of Linear Direct Drives ................................................................................... 1-1
2 Important directions for use 2-1

2.1 Appropriate use.............................................................................................................................. 2-1
Introduction .............................................................................................................................. 2-1
Areas of use and application.................................................................................................... 2-2
2.2 Inappropriate use ........................................................................................................................... 2-2
3 Safety Instructions for Electrical Drives and Controllers 3-1

3.1 Introduction..................................................................................................................................... 3-1
3.2 Explanations................................................................................................................................... 3-1
3.3 Risks due to Incorrect Utilization.................................................................................................... 3-2
3.4 General Information ....................................................................................................................... 3-3
3.5 Protection Against Touching Electrical Parts ................................................................................. 3-4
3.6 Protective Extra-Low Voltage (PELV) Protects Against Electric Shocks....................................... 3-6
3.7 Protection Against Dangerous Movements.................................................................................... 3-6
3.8 Protection Against Magnetic or Electromagnetic Fields During Operation and Installation .......... 3-8
3.9 Protection Against Touching Hot Parts .......................................................................................... 3-8
3.10 Protection During Handling and Installation................................................................................... 3-9
3.11 Safety in Handling Batteries........................................................................................................... 3-9
3.12 Protection Against Pressurized Pipes.......................................................................................... 3-10
3.13 Safety in Handling Secondary Parts of Synchronous Linear Motors ........................................... 3-11
4 Technology of Synchronous Linear Motors 4-1

4.1 Operational Principle...................................................................................................................... 4-1
4.2 Motor Versions ............................................................................................................................... 4-3
Standard encapsulation for primary part.................................................................................. 4-4
Thermal encapsulation for primary part ................................................................................... 4-5
Secondary part version ............................................................................................................ 4-6
Sizes and feed forces .............................................................................................................. 4-7
4.3 Type Code and Order Designations .............................................................................................. 4-8
5 Specifications 5-1
5.1 Explanation of Specifications ......................................................................................................... 5-1
5.2 LSF040........................................................................................................................................... 5-4
5.3 LSF080........................................................................................................................................... 5-8
II Contents Synchronous Linear Motors LSF
5.4 LSF120......................................................................................................................................... 5-14

5.5 LSF140......................................................................................................................................... 5-22
5.6 LSF160......................................................................................................................................... 5-26
5.7 LSF200......................................................................................................................................... 5-34
5.8 LSF240......................................................................................................................................... 5-42
6 Mounting Sizes and Tolerances 6-1

6.1 Mounting Tolerances...................................................................................................................... 6-1
6.2 Mounting Sizes............................................................................................................................... 6-3
LSF040..................................................................................................................................... 6-3
LSF080..................................................................................................................................... 6-5
LSF120..................................................................................................................................... 6-8
LSF140................................................................................................................................... 6-11
LSF160................................................................................................................................... 6-12
LSF200................................................................................................................................... 6-15
LSF240................................................................................................................................... 6-18
7 Motor - Controller Combinations 7-1

7.1 General Explanations..................................................................................................................... 7-1
Description of the specified variables ...................................................................................... 7-2
7.2 Motor - Controller Combination DIAX04, Single-Arrangement Primary Part ................................. 7-3
Unregulated DC bus; mains connection voltage 3 x AC 400 V ............................................... 7-3
Unregulated DC bus, mains connection voltage 3 x AC 480 V ............................................... 7-5
Connection to regulated DC bus, DC bus voltage 750 V ........................................................ 7-7
7.3 Motor - Controller Combination DIAX04, Parallel-Arrangement Primary Part ............................... 7-9
Unregulated DC bus; mains connection voltage 3 x AC 400 V ............................................... 7-9
Unregulated DC bus, mains connection voltage 3 x AC 480 V ............................................. 7-11
Connection to regulated DC bus, DC bus voltage 750 V ...................................................... 7-12
7.4 Motor - Controller Combination ECODRIVE03, Single-Arrangement Primary Part..................... 7-13
Unregulated DC bus; mains connection voltage 3 x AC 400 V ............................................. 7-13
7.5 Motor - Controller Combination ECODRIVE, Parallel-Arrangement Primary Part....................... 7-15
Unregulated DC bus; mains connection voltage 3 x AC 400 V ............................................. 7-15
8 Motor Sizing 8-1

8.1 General Procedure......................................................................................................................... 8-1
8.2 Basic Formulae .............................................................................................................................. 8-2
General equations of motion.................................................................................................... 8-2
Feed forces .............................................................................................................................. 8-3
Average velocity....................................................................................................................... 8-5
Trapezoidal velocity ................................................................................................................. 8-6
Triangular velocity.................................................................................................................. 8-10
Sinusoidal velocity ................................................................................................................. 8-11
8.3 Duty cycle and Feed Force .......................................................................................................... 8-13
Determining the duty cycle..................................................................................................... 8-13
Synchronous Linear Motors LSF Contents III
8.4 Determining the Drive Power ....................................................................................................... 8-15

Continuous output.................................................................................................................. 8-15
Maximum output .................................................................................................................... 8-16
Cooling capacity..................................................................................................................... 8-17
Regeneration energy ............................................................................................................. 8-17
8.5 Efficiency...................................................................................................................................... 8-18
8.6 Sizing Examples........................................................................................................................... 8-19
Handling axis ......................................................................................................................... 8-19
Machine tool feed axis; sizing via duty cycle ......................................................................... 8-27
9 Configuration and Construction Instructions 9-1

9.1 Requirements on the Machine Design........................................................................................... 9-1
Mass reduction......................................................................................................................... 9-1
Mechanical rigidity ................................................................................................................... 9-1
9.2 Arrangement of Motor Components............................................................................................... 9-3
Single arrangement.................................................................................................................. 9-3
Several motors per axis ........................................................................................................... 9-4
Vertical axes........................................................................................................................... 9-11
9.3 Feed and Attractive Forces .......................................................................................................... 9-12
Attractive forces between primary and secondary part ......................................................... 9-12
Air-gap-related attractive forces between primary and secondary part................................. 9-13
Air-gap-related feed force ...................................................................................................... 9-14
Reduced overlapping of primary and secondary part............................................................ 9-14
9.4 Motor Cooling............................................................................................................................... 9-16
Thermal behavior of linear motors ......................................................................................... 9-16
Cooling concept of LSF synchronous linear motors .............................................................. 9-18
Coolant................................................................................................................................... 9-20
Sizing the cooling circuit ........................................................................................................ 9-23
Liquid cooling system............................................................................................................. 9-27
9.5 Motor Temperature Monitoring Circuit ......................................................................................... 9-33
9.6 Installation Altitude and Ambient Conditions................................................................................ 9-36
9.7 Class of protection ....................................................................................................................... 9-37
9.8 Magnetic Fields ............................................................................................................................ 9-38
9.9 Vibration and Shock ..................................................................................................................... 9-39
9.10 Enclosure Surface........................................................................................................................ 9-40
9.11 Noise Emission ............................................................................................................................ 9-40
9.12 Linear Scale ................................................................................................................................. 9-41
Selection criteria for linear scales .......................................................................................... 9-41
Mounting Linear scales .......................................................................................................... 9-47
9.13 Linear Guides ............................................................................................................................... 9-48
9.14 Braking Systems and Holding Devices ........................................................................................ 9-48
9.15 End Position chock absorber ....................................................................................................... 9-49
9.16 Axis cover systems ...................................................................................................................... 9-50
9.17 Wiper ............................................................................................................................................ 9-51
10 Controlling of Linear Direct Drives 10-1
IV Contents Synchronous Linear Motors LSF
10.1 Drive Controllers, Power Supply Modules and Controls.............................................................. 10-1

Drive controllers and power supply modules ......................................................................... 10-1
Control systems ..................................................................................................................... 10-2
10.2 Shutdown upon EMERGENCY STOP and in the Event of a Malfunction ................................... 10-3
Shutdown by the drive ........................................................................................................... 10-3
Shutdown by master control .................................................................................................. 10-4
Shutdown by mechanical braking devices............................................................................. 10-4
Response to a mains failure .................................................................................................. 10-5
Short-circuit of DC bus........................................................................................................... 10-5
10.3 Maximum Acceleration Changes (Jerk Limitation) ...................................................................... 10-6
10.4 Position and Velocity Resolution.................................................................................................. 10-8
10.5 Load Rigidity............................................................................................................................... 10-10
Static load rigidity................................................................................................................. 10-10
Dynamic load rigidity............................................................................................................ 10-11
11 Handling, Transport, Storage and Inspection 11-1

11.1 Identifying the Motor Components ............................................................................................... 11-1
Primary part............................................................................................................................ 11-1
Secondary part....................................................................................................................... 11-1
11.2 Delivery and Packaging ............................................................................................................... 11-2
11.3 Storage and Transport ................................................................................................................. 11-4
Peculiarities during the transport of secondary parts of synchronous linear motors ............. 11-4
11.4 Checking the Motor Components ................................................................................................ 11-5
Factory checks....................................................................................................................... 11-5
Customer Incoming Inspection .............................................................................................. 11-5
12 Installation and Assembly 12-1

12.1 Basic Requirements ..................................................................................................................... 12-1
12.2 Basic Procedure when Installing the Motor Components ............................................................ 12-1
Installation with a segmented secondary part along the entire motion path.......................... 12-1
Installation with a whole secondary part along the entire travel ............................................ 12-3
12.3 Assembling the Secondary Part Segments ................................................................................. 12-5
12.4 Mounting the Primary Part ........................................................................................................... 12-7
12.5 Liquid Cooling Connection ........................................................................................................... 12-7
12.6 Securing Screws .......................................................................................................................... 12-8
13 Electrical Connection 13-1

13.1 Power Connection........................................................................................................................ 13-1
Primary part connecting cable ............................................................................................... 13-1
Power feeder connection ....................................................................................................... 13-2
Connection at the drive controller .......................................................................................... 13-6
Selection of cable assemblies for the power supply.............................................................. 13-7
13.2 Linear scale Connection............................................................................................................... 13-8
14 Commissioning 14-1
14.1 General Information About Commissioning of Synchronous Linear Motors................................ 14-1
Synchronous Linear Motors LSF Contents V
14.2 Basic Prerequisites ...................................................................................................................... 14-2

Checking all electrical and mechanical components ............................................................. 14-2
Commissioning Tests............................................................................................................. 14-3
14.3 Basic Commissioning Sequence ................................................................................................. 14-4
14.4 Parameter ization ......................................................................................................................... 14-5
Entering motor parameters .................................................................................................... 14-5
Input of linear scale parameters ............................................................................................ 14-9
Input of drive limitations and application-related parameters ................................................ 14-9
14.5 Determining the Polarity of the linear scale ............................................................................... 14-10
14.6 Commutation setting .................................................................................................................. 14-12
Method 1: Measuring the reference between primary and secondary part ......................... 14-14
Method 2: Current flow method............................................................................................ 14-17
14.7 Setting and Optimizing the Control Loop ................................................................................... 14-18
General sequence................................................................................................................ 14-18
Parameter value assignments and optimization of Gantry axes ......................................... 14-20
Estimating the moved mass using a velocity ramp.............................................................. 14-22
15 Maintenance and check of Motor Components 15-1

15.1 General Information ..................................................................................................................... 15-1
15.2 Check of Motor and Auxiliary Components.................................................................................. 15-1
Electrical check of motor components ................................................................................... 15-1
16 Recommended Suppliers of Auxiliary Components 16-1

16.1 Linear scales ................................................................................................................................ 16-1
16.2 Linear Guides ............................................................................................................................... 16-1
16.3 Energy Chains.............................................................................................................................. 16-1
16.4 Cooling Units ................................................................................................................................ 16-2
16.5 Coolant Additives ......................................................................................................................... 16-2
16.6 Coolant Hoses.............................................................................................................................. 16-2
16.7 Axis Cover Systems ..................................................................................................................... 16-3
16.8 End Position Shock absorbers ..................................................................................................... 16-3
16.9 Clamping Elements for Linear Guideways................................................................................... 16-4
16.10External Mechanical Brakes ........................................................................................................ 16-4
16.11Weight Compensation Systems................................................................................................... 16-4
16.12Wipers .......................................................................................................................................... 16-5
17 Applicable Documents 17-1
18 Linear Drive Application Form 18-1
19 Service & Support 19-1

19.1 Helpdesk ...................................................................................................................................... 19-1
19.2 Service-Hotline............................................................................................................................. 19-1
19.3 Internet ......................................................................................................................................... 19-1
19.4 Vor der Kontaktaufnahme... - Before contacting us..................................................................... 19-1
19.5 Kundenbetreuungsstellen - Sales & Service Facilities ................................................................ 19-2
VI Contents Synchronous Linear Motors LSF
20 Index 20-1
Synchronous Linear Motors LSF Introduction 1-1
1 Introduction
1.1 About this Document
This document presents a comprehensive source of information

for the application of linear direct drive systems with synchronous linear
motors (LSF).
This documentation combines the previously available documents
Configuration, Selection Data and Commissioning in one document.
Arrangement of chapters The chapters are arranged in same order in which the product is used.
Important chapters (specifications, mounting sizing, motor-controller
combinations), that are frequently used, are in the front part of the
document.
Orientation Use the Contents and the Index for swift orientation.
1.2 Application Ranges of Linear Direct Drives

New technologies of high economical benefit require numerically
controlled movements with extreme requirements on acceleration,
velocity and accuracy.
Implementing these requirement with conventional NC drive technology

that consist of a rotary electric motor, and subsequently arranged
mechanical transfer elements, such as gearbox, belt drive, ball screws, or
rack-and-pinion drive will either cause tremendous efforts and costs or
simply be impossible.
In many cases, linear direct drive technology is an optimal alternative,

providing significant benefits:
• High velocity and acceleration
• Excellent control quality and positioning behavior
• Direct power transfer - no mechanical transmission elements
(such as ball screw, toothed belt, gear rack, etc.)
• Maintenance-free drive (no wearing parts at the motor)
• Simplified machine structure
• High static and dynamic load rigidity
Due to the direct installation into the machine, there are no wearing
mechanical components, making a power train with no backlash or
minimized backlash possible. This permits very high control qualities with
a gain in the position control loop (KV factor) of more than 20 m/min/mm
to be reached.
In conventional electromagnetic systems, positioning tasks with high feed
rates or highly accelerated short-stroke movements in quick succession
lead to a premature wear of mechanical parts and thus to failures and
significant costs. In these applications Linear direct drives offer decisive
advantages.
1-2 Introduction Synchronous Linear Motors LSF
Starting from the above-mentioned benefits, there are the following

application ranges for linear synchronous direct drives:
• High-speed machining in transfer lines and machining centers

• Grinding, in particular camshaft and crankshaft machining
• Laser machining
• Precision and ultra-precision machining
• Sheet-metal working
• Handling, textile and packaging machines
• Free form surface machining
• Wood machining
• Printed circuit board machining
Due to a practice-oriented combination of motor technology and with

intelligent digital drive controllers with SERCOS interface as the digital
interface to the NC controller, the linear direct drive technique offers new
solutions with significantly improved performance.
The development level of the synchronous linear technique of Rexroth
Indramat permits a very high force density to be implemented.
The spectrum of synchronous linear drives from Rexroth Indramat that is
described below permits drives to be implemented that feature a feed
force between 200 N and 22,000 N per motor and a velocity of more than
600 m/min.
The development stage of Rexroth Indramat‘ s synchronous linear

technology permits a very high force density to be implemented.
As well as feed forces between a forces between 200 N and 22,000 N per
motor and a velocity of more than 600 m/min.
Synchronous Linear Motors LSF Important directions for use 2-1
2 Important directions for use
2.1 Appropriate use
Introduction
Rexroth Indramat products represent state-of-the-art developments and
manufacturing. They are tested prior to delivery to ensure operating safety
and reliability.
The products may only be used in the manner that is defined as
appropriate. If they are used in an inappropriate manner, then situations
can develop that may lead to property damage or injury to personnel.
Note: Rexroth Indramat, as manufacturer, is not liable for any

damages resulting from inappropriate use. In such cases, the
guarantee and the right to payment of damages resulting from
inappropriate use are forfeited. The user alone carries all
responsibility of the risks.
Before using Rexroth Indramat products, make sure that all the pre-
requisites for appropriate use of the products are satisfied:
• Personnel that in any way, shape or form uses our products must first
read and understand the relevant safety instructions and be familiar
with appropriate use.
• If the product takes the form of hardware, then they must remain in
their original state, in other words, no structural changes are permitted.
It is not permitted to decompile software products or alter source
codes.
• Do not mount damaged or faulty products or use them in operation.
• Make sure that the products have been installed in the manner
described in the relevant documentation.
2-2 Important directions for use Synchronous Linear Motors LSF
Areas of use and application

Synchronous linear motors of the LSF series from Rexroth Indramat are
intended to be used as linear servo drive motors.
Drive controller types with different drive power and different interfaces
are available for the application-related utilization of the motors.
Additional sensors (e.g. length measuring systems) must be connected in
order to monitor and control the motors.
Note: The motors may only be used with the accessories and parts
specified in this document. If a component has not been
specifically named, then it may not be either mounted or
connected. The same applies to cables and lines.
Operation is only permitted in the specified configurations and
combinations of components using the software and firmware
as specified in the relevant function descriptions.
Every drive controller has to be programmed before starting it up, making

it possible for the motor to execute the specific functions of an application.
The motors may only be operated under the assembly, installation and
ambient conditions as described here (temperature, protection categories,
humidity, EMC requirements, etc.) and in the position specified.
2.2 Inappropriate use

Using the motors outside of the above-referenced areas of application or
under operating conditions other than described in the document and the
technical data specified is defined as “inappropriate use".
LSF synchronous linear motors must not be used if ...
• they are subject to operating conditions that do not meet the above
specified ambient conditions. This includes, for example, operation
under water, in the case of extreme temperature fluctuations or
extremely high maximum temperatures or if
• Rexroth Indramat has not specifically released them for that intended
purpose. Please note the specifications outlined in the general Safety
Instructions!
Note: LSF synchronous linear motors are not suitable for a direct
operation on the mains.
Synchronous Linear Motors LSF Safety Instructions for Electrical Drives and Controllers 3-1
3 Safety Instructions for Electrical Drives and

Controllers
3.1 Introduction
To avoid personal injuries and/or damage to the equipment, you should
read the following instructions before the system is put into operation for
the first time. These safety instructions must always be observed.
Do not try to install this unit or to put it into operation before you have
thoroughly read all documents provided. You must read these safety
instructions and all other user information before you start working with
the unit. Please contact your Rexroth Indramat sales representative if you
do not have the user information for the unit available. In order to be able
to safely use the unit, request the immediate shipment of these
documents to the person(s) responsible.
These safety instruction must also be passed on when the unit is sold,
rented out and/or passed on.
Inexpert handling of these units, non-

observance of the warnings listed here, and/or
inexpert tampering with the safety devices can
WARNING lead to damage, personal injuries, electric
shock or even death.
3.2 Explanations
The safety instruction describe the following risk classes to ANSI:
Warning symbol with signal Risk class to ANSI

word The risk class describes the risk if the safety
instruction is ignored:
Death or serious injuries will occur.
DANGER
Death or serious injuries may occur.
WARNING
Injuries or damage to equipment may occur.
CAUTION
Figure 3-1: Risk levels (to ANSI)
3-2 Safety Instructions for Electrical Drives and Controllers Synchronous Linear Motors LSF
3.3 Risks due to Incorrect Utilization
High electric voltage and high working current !

Death or serious injuries due to electric shock.
DANGER
Dangerous movements ! Death, serious injuries

or damage due to inadvertent movement of the
motors.
DANGER
High electric voltage due to incorrect

connection ! Death or injuries due to electric
shock.
WARNING
Health hazard for persons with pacemakers,

metallic implants, or hearing aids in the
immediate vicinity of electrical equipment.
WARNING
Hot surfaces on device enclosure possible. Risk

of injury ! Risk of burning !
CAUTION
Risk of injuries due to improper handling.

Injuries caused by squeezing, shearing, cutting,
pushing.
CAUTION
Risk of injuries due to improper handling of

batteries.
CAUTION
3.4 General Information

• Rexroth Indramat GmbH does not assume any liability for damages
that are caused by non-observance of the warnings in these Operating
Instructions.
• Prior to commissioning, you must read the operating, service and
safety instructions. Please inform the supplier if you are not able to
fully understand the documentation in the language provided.
• Proper and safe operation of the unit requires proper and expert
transport, storage, installation, and thorough handling and service.
• Use trained and qualified personnel for handling electrical equipment:
Only adequately trained and qualified personnel should work on this

unit or in its vicinity. Personnel are qualified if they are sufficiently
familiar with mounting, installing and operating the product, and with all
warnings and precautions listed in these Operating Instructions.
In addition, they are trained, instructed or authorized to switch on and
off circuits and devices according to the safety engineering
requirements, to ground them and to label them expediently according
to the working requirements. They must possess an appropriate safety
equipment and be trained in first aid.
• Only use manufacturer-approved accessories and spare parts.
• You must observe the safety regulations of the country in which the
unit is used.
• The units are designed for installation in machines that are employed
in commercial areas.
European countries: EEC Directive 89/392/EWG (Machine Directive)
• The ambient conditions specified in the product documents must be
adhered to.
• Safety-relevant applications are not permitted if they have not been
specified expressively and in detail in the configuration documents,
The following application ranges are excluded, for example: Cranes,
passenger and freight elevators, passenger transport facilities and
vehicles, medical engineering, refineries, transport of hazardous
goods, nuclear areas, use in high-frequency-sensitive areas, mining,
food processing, safety device control (also in machines).
• Commissioning is not permitted until the conformity of the machine in
which the products are installed with the national provisions and the
safety requirements of the applications has been confirmed.
• Operation is only permitted if the national EMC requirements for the
actual application are satisfied.
The instructions for an EMC-compatible installation can be found in
the "EMC for AC Drives and Controllers" document.
Staying within the limits that are required by the national regulations is
within the responsibility of the manufacturer of the system or machine.
European countries: EEC Directive 89/336/EWG (EMC Directive).
USA: See national electrical regulations (NEC), national association of the
manufacturers of electric systems (NEMA), and regional design
requirements. The user must always comply with all above-mentioned
points.
• The specifications, and the connection and installation requirements

can be found in the product documentation. They must always be
adhered to.
3.5 Protection Against Touching Electrical Parts
Note: This section only concerns units and drive components with a
voltage of more than 50 volts.
Touching parts that carry a voltage of more than 50 V can be dangerous

and lead to an electric shock. When an electric unit is used, certain parts
of this unit inevitably carry a dangerous voltage.
High electric voltage ! Risk of death or serious

injuries due to electric shock.
⇒ Only qualified personnel who has been trained for
DANGER working on or with electrical equipment are permitted
to operate, service and/or repair this unit.
⇒ Observe the general installation and safety
regulations for working on power systems.
⇒ Prior to power-up, the firm connection of the
equipment grounding conductor must be established
at all electrical units according to the wiring diagram.
⇒ Operation - even for brief measurement and test
purposes - is only permitted when the equipment
grounding conductor is firmly connected to the
connecting points provided at the components.
⇒ Disconnect the unit from the mains or the voltage
source before you access parts that carry a voltage
of more than 50 V. Secure against reclosing.
⇒ The following points must be observed for electrical
drive and filter components:
Before you access the units, allow for the capacitors
to discharge for five minutes. To exclude any risk,
measure the voltage at the capacitors before you
start working.
⇒ Never touch the electrical connections of the
components when the unit is switched on.
⇒ Prior to power-up, install the shock protection covers
and guards at the units. To avoid contact, safely
cover and protect live parts prior to power-up.
⇒ An RCD protection cannot be used for electrical
drives. The protection against indirect contact must
be established in a different way (e.g. by an
overcurrent protective device according to the
relevant standards).
⇒ With built-in units, the protection against direct
contact with electrical parts must be ensured by an
outer enclosure (e.g. a switchgear cabinet).
European countries: According to EN 50178/ 1998,

Section 5.3.2.3.
USA: See national electrical regulations (NEC), national
association of the manufacturers of electric systems
(NEMA), and regional design requirements. The user
must always comply with all above-mentioned points.
The following points must be observed for electrical drive and filter
components:
High enclosure voltage and high leakage

current ! Death or injuries due to electric shock.
⇒ Prior to power-up, you must first ground the electrical
DANGER equipment and the enclosures of all electrical units
and motors or connect them with the grounding point
via the equipment grounding conductor. This must
also be done for short tests.
⇒ Always connect the equipment grounding conductor
of the electrical equipment and the units firmly with
the supply network. The leakage current is greater
than 3.5 mA.
⇒ Use copper wires of a minimum cross section of 10
2
mm for the full length of this equipment grounding
connection.
⇒ Prior to commissioning - including tests - always
connect equipment grounding conductor or connect
the unit to the ground conductor. Failure to do so
could result in high voltages on the enclosure that
can cause electric shocks.
European countries: EN 50178 / 1998, Section 5.3.2.1.
USA: See national electrical regulations (NEC), national
association of the manufacturers of electric systems
(NEMA), and regional design requirements. The user
must always comply with all above-mentioned points.
3.6 Protective Extra-Low Voltage (PELV) Protects Against

Electric Shocks
All connections and terminals with voltages between 5 and 50 Volt at
Rexroth Indramat products are protective extra-low voltages that have
been designed safe to touch according to the following standards:
• International: IEC 60364-4-41
• European countries in the EEC: EN 50178/1998, Section 5.2.8.1.
High electric voltage due to incorrect

connection ! Death or injuries due to electric
shock.
WARNING ⇒ Only units, electrical components and cables that
feature a protective extra-low voltage (PELV) may be
connected to all connections and terminals with
voltages between 0 and 50 V.
⇒ Only connect voltages and circuits that have a
protective separation to dangerous voltages.
Protective separation can be achieved, for example,
by an isolating transformer, a safe optocoupler, or
mains-free battery operation.
3.7 Protection Against Dangerous Movements

Dangerous movements can be caused by incorrectly controlling a
connected motor. The causes can be of the most different kind:
• Improper or incorrect wiring
• Incorrect handling of the components
• Faults in the sensors and transducers
• Defective components
• Faults in the software
These malfunctions can occur immediately after power-up or after an
undefined time during operation
The monitoring functions in the drive components exclude a malfunction
in the connected drives to the greatest extent possible. With respect to
personal safety - in particular the risk of personal injuries and / or damage
to the equipment - this fact must not solely be relied on. Until the
integrated monitoring functions take effect, you must always reckon with a
wrong drive movement whose extent depends on the type of the controller
and the operating state.
Dangerous movements ! Death, serious injuries,

or damage
⇒ The above-mentioned reasons require personal
DANGER protection to be ensured using monitoring functions
or measures that are on a higher system level.
These are provided by the system builder according
to the specific circumstances of the system and a
risk and fault analysis. The safety regulations valid
for the system are included. Arbitrary movements of
the machine or other malfunctions can occur when
safety devices are switched off, bypassed, or not
activated.
Avoiding accidents, injuries, and / or damages:
⇒ No persons are allowed in the motion range of the

machine or machine parts. Possible measures
against inadvertent access of persons:
- Protective fence
- Protective gate
- Protective cover
- Light barrier
⇒ Sufficient strength of the fences and covers to
withstand the maximum kinetic energy possible.
⇒ Arrange easily accessible EMERGENCY STOP
switches in the immediate vicinity. Check the
function of the EMERGENCY STOP device prior to
commissioning. Do not use the unit if the
EMERGENCY STOP switch does not work properly.
⇒ Protection against inadvertent startup by isolating the
power connection of the drives via the EMERGENCY
STOP circuit or by using a safe starting lockout.
⇒ Before any access or entry into the hazardous area,
you must safely bring the drives to a standstill.
⇒ De-energize the electrical equipment via the mains
switch, and secure against reclosing in the case of:
- Service and repair work
- Cleaning
- Extended interruptions of operation
⇒ Avoid using high frequency equipment, remote
control units and radios in the vicinity of the device
electronics and their connecting cables. If using one
of these units cannot be avoided, test the system in
all normal positions for possible malfunctions before
you put it into operation for the first time. If
necessary, a special EMC test of the system will be
required.
3.8 Protection Against Magnetic or Electromagnetic Fields

During Operation and Installation
Magnetic and electromagnetic fields in the immediate vicinity of energized
conductors and motor permanent magnets can represent a serious
hazard to people with pacemakers, metallic implants, or hearing aids.
Health hazard for persons with pacemakers,

metallic implants, or hearing aids in the
immediate vicinity of electrical equipment.
WARNING ⇒ The access to the following areas is prohibited for
persons with pacemakers and/or metallic implants:
- Areas in which electrical units and parts are
mounted, used, or commissioned.
- Areas in which motor parts with permanent
magnets are stored, repaired, or mounted.
⇒ A doctor must be asked for permission if a person
with a pacemaker must enter such an area. The
noise immunity of pacemakers that have been or are
to be implanted is very different so that there are no
generally valid rules.
⇒ Persons who carry metallic implants or metallic
splinters in their bodies or persons with hearing aids
must consult a doctor before they enter such an
area. Their health can be impaired.
3.9 Protection Against Touching Hot Parts
Hot surfaces on device enclosure possible.

Risk of injury ! Risk of burning !
⇒ Do not touch the enclosure surface in the vicinity of
CAUTION hot heat sources. Risk of burning !
⇒ Prior to accessing the units, allow them to cool down
for 10 minutes after they have been switched off.
⇒ Touching hot parts of the equipment (such as
enclosures that contain heat sinks or resistors) may
lead to burning.
3.10 Protection During Handling and Installation

Improper handling and installation of certain parts and components can,
under adverse conditions, lead to injuries.

Injuries caused by squeezing, shearing, cutting,
pushing.
CAUTION ⇒ Observe the general installation and safety
regulations for handling and installation.
⇒ Use suitable mounting and transport devices.
⇒ Use suitable precautions to avoid jamming and
squeezing.
⇒ Use only adequate tools. Use special tools if
required. .
⇒ Use lifting devices and tools expertly. .
⇒ If necessary, use adequate protective gear (e.g.
protective goggles, safety shoes, safety gloves).
⇒ Do not stay under suspended loads.
⇒ To avoid slipping, remove spilled liquids from the
floor immediately.
3.11 Safety in Handling Batteries

Batteries consist of chemicals that are accommodated in a firm
enclosure. Improper handling can therefore lead to injuries or damage.

⇒ Never try to reactivate empty batteries by heating
them or by using other methods (risk of explosion
and etching).
CAUTION
⇒ Never try to recharge the batteries. They could leak
or explode.
⇒ Never throw batteries in a fire.
⇒ Never take batteries apart.
⇒ Never damage the electrical components that are
installed in the units.
Note: Environmental protection and disposing! Within the legal

provisions, the batteries contained in the product must be
considered as hazardous goods in air, sea, or land transport
(explosion hazard). Dispose of old batteries separately from
the other waste. Observe the national regulations in the
installation country.
3.12 Protection Against Pressurized Pipes

According to the specifications in the configuration documents, certain
motors (ADS, ADM, 1MB etc.) and drive controllers can partly be fed with
externally supplied pressurized media such as compressed air, hydraulic
oil, coolant, and cooling lubricant. Inexpert handling of external supply
systems, supply lines, or connections may lead to injuries or damage to
equipment.
Risk of injuries due to inexpert handling of

pressurized pipes !
⇒ Do not try to separate, open or sever pressurized lines
(explosion hazard)
CAUTION
⇒ Observe the operating instructions of the individual
manufacturers.
⇒ Release pressure and drain medium before you
dismantle a line.
⇒ Use adequate protective gear (e.g. protective goggles,
safety shoes, safety gloves).
⇒ Immediately remove spilled liquids from the floor.
Note: Environmental protection and disposing! The media used for

the operation of the product may not be environmentally
compatible. Dispose of polluting media separately from the
other waste. Observe the national regulations in the installation
country.
3.13 Safety in Handling Secondary Parts of Synchronous

Linear Motors
Secondary parts of LSF synchronous linear motors carry permanent
magnets. These permanent magnets produce a static magnetic field with
the related attractive forces to ferromagnetic objects (such as machine
parts or tools made from steel).
Risk of injuries due to inexpert handling of

secondary parts of synchronous linear motors !
⇒ Persons with pacemakers, metallic implants, or
CAUTION hearing aids must not approach these motor parts or
handle them. A doctor must be consulted if such a
person needs to approach those parts.
⇒ Secondary parts must not be in the vicinity of objects
that could be impaired or destroyed by magnetic
fields (e.g. watches, data carriers, credit cards, etc.).
⇒ Due to the strong force of the secondary parts that
act upon ferromagnetic objects made from iron,
nickel or cobalt (this also applies to the primary part
and the other secondary parts), whose movements
could lead to personal injuries and/or damages to
equipment, the following safety measures must be
observed:
If possible, use non-magnetic tools and wear suitable
protective gloves at all times (protection against
squeezing).
Always use the transport and installation protection
provided when you transport, store and install the
secondary part. If possible, the transport and
installation protection may only be removed after the
pre-installation (i.e. after the secondary part has
safely been mounted in the machine). Without the
transport and installation protection there is the risk
that the secondary part moves in an uncontrolled
way or that parts made from ferromagnetic materials
(such as iron, nickel, cobalt) are attracted in an
uncontrolled way.
⇒ Using a crane for resting ferromagnetic components
or modules (such as machine slide) on the
secondary part is not permitted. With small distances
to the secondary part, the elasticity within the crane
suspension can lead to uncontrolled movements.
Use a rigid jig instead of a crane.
⇒ Only trained and instructed personnel may be used

for the transporting, storing, installing, and
commissioning the linear drives. People working on
the system must be instructed at regular intervals - at
least once a year.
Synchronous Linear Motors LSF Technology of Synchronous Linear Motors 4-1
4 Technology of Synchronous Linear Motors
4.1 Operational Principle

The following figure shows the basic structure of a synchronous linear
motor.
primary part
with three-phase winding
power connection
N S N S N
secondary part
with permanent magnets AUFBAU-LSFEN.FH7
Figure 4-1: Basic structure of a synchronous linear motor
The force of a synchronous linear motor is produced in the same way as

the torque in a rotary synchronous motor. While the primary part (active
part) carries a three-phase winding, the secondary part (passive part)
carries permanent magnets (Figure 4-1).
Primary part and secondary part can both be moved.
Any motion path length can be implemented by connecting several
secondary part segments.
Axis structure The synchronous linear motor is an assembly kit motor. The components
primary and secondary part(s) are delivered individually. Completed by
linear guides and length measuring system, they are installed by the user
in the machine or system.
An axis that is equipped with a synchronous linear motor (Figure 4-2)
usually consists of
• primary part with three-phase winding,
• one or more secondary parts with permanent magnets,
• length measuring system,
• linear guides,
• cable track
• slide or machine structure
4-2 Technology of Synchronous Linear Motors Synchronous Linear Motors LSF
cable track
linear guideways
primary part
slide and/or
machine
structure
linear scale
sec. part ACHSAUFBAU-LSF-EN.FH7
Figure 4-2: Basic structure of a linear motor axis
Figure 4-2 shows the basic structure of an axis that is equipped with a
synchronous linear motor in single arrangement.
In order to multiply the force, two or more primary parts can mechanically
be coupled and arranged in parallel or in series. Please refer to Chapter
for details.
Note: Only primary and secondary part(s) are included in the motor
delivery.
Linear guides, length measuring system and other auxiliary
components must be provided by the user. Please refer to
Chapter 16 (Recommended Suppliers of Auxiliary
Components) for recommendations of proven auxiliary
components.
4.2 Motor Versions

LSF synchronous linear motors from Rexroth Indramat are field-drive
components. With following features:
• Modular system with different motor sizes and lengths for feed forces
up to 22,000 N per motor and velocities of more than 600 m/min.
• Different winding versions for each motor size to achieve optimal

adaptation to different velocity requirements.
• All motor components are completely encapsulated. Cracks in potting

compounds, as well as damaged or corroded magnets are not
possible.
• Different cooling and encapsulation designs of the primary part (see

below: standard and thermal encapsulation).
• IP65 rating (all motor components) Class of protection
• High operational reliability for DC bus voltages up to 750 V
• No mechanical wear
• Integrated temperature sensors protect the motor winding against

thermal overload.
• Highly flexible shielded power cable with strain relief.
Versions of cooling and In order to be able to provide a motor for the most different applications
encapsulation that represents an optimum solution with respect to technical
requirements and costs, primary parts are available that feature different
versions of cooling and encapsulation:
• Standard encapsulation: Stainless steel encapsulation with a liquid

cooling integrated into the back of the motor that removes the power
loss.
• Thermal encapsulation: Aluminum encapsulation with additional

liquid cooling at the back of the motor and at the lateral and end faces
for optimum thermal decoupling against the machine structure.
Standard encapsulation for primary part

Primary parts in standard encapsulation represent an economic solution
of applications with low thermal requirements. The primary parts of the
standard encapsulation version are mainly used in the field of general
automation. Here the electrical motor components are protected by a
stainless steel encapsulation. The cooling system of this motor type is
integrated into the motor. It is primarily used for removing the power loss
and/or for maintaining the specified continuous feed force. It does not
provide any additional thermal decoupling between machine and motor.
Figure 4-3: Primary parts in standard encapsulation (figure with secondary part)
Note: Please refer to Chapter 9.4 Motor Cooling for further

information about liquid cooling.
primary part
integrated fixing boreholes stainless steel
cooling
encapsulation
core stack coolant connection

(standard 1/8")
motor winding
fixing permanent magnets

boreholes secondary part
STANDARDKAPSELUNG-LSF-EN.FH7
Figure 4-4: Sketch of primary part with standard encapsulation (figure with
secondary part)
Main application areas The main application areas of this motor version are general automation
and handling.
Thermal encapsulation for primary part

An additional liquid cooling, that is integrated into the encapsulation and is
used for thermal decoupling against the machine structure, provides a
highly constant temperature at the contact surface. With the thermal
encapsulation version, a maximum temperature rise of 2 Kelvin can be
obtained with respect to the coolant inlet temperature at the contact
surface.
Figure 4-5: Primary parts in thermal encapsulation (figure with secondary part)
Not the entire surface of the primary part is connected with the
attachment surface at the machine side. It merely rests on raised seating
ledges. This offers the following benefits:
• Additional thermal decoupling and additional minimization of heat
infiltration into the machine.
• Simplified machining of the contact surface at the machine side to stay
within the necessary installation tolerances.
Note: Please refer to Chapter 9.4 Motor Cooling for further

information about liquid cooling.
integrated cooling fixing cooling channels primary

(removal of power loss) boreholes (thermal encapsulation)
cooling channels
(thermal coolant connection
encapsulation) (standard 1/4")
motor winding
core stack
labyrinth seal for lateral

protection against chips
fixing permanent magnets
boreholes secondary part
THERMOKAPSELUNG-LSF-EN.FH7
Figure 4-6: Sketch of primary part with thermal encapsulation (figure with
secondary part)
Main application areas The main application areas of this motor version are machine tools and
precision applications, for example.
Secondary part version

The secondary part or a secondary part segment consists of a steel base
with an applied permanent magnet. The mounting holes are at the outer
edge alongside the secondary part.
To ensure the best operational reliability possible, the permanent
magnets of the secondary part are protected by an integrated stainless
cover plate against corrosion, external influences (such as cooling
lubricants or oil), and against mechanical damages.
Using a wiper directly on the secondary part is possible (see also Chapter
9.17 Wiper).
Figure 4-7: LSS secondary part
Note: The secondary part version is independent of the primary part

version.
Available lengths of Secondary parts and secondary part segments are available in different
secondary parts lengths between 150 mm and 1200 mm in steps of 150 mm (See also
Chapter 6 Mounting Dimensions).
Required length of the The required length L of the secondary part can be defined with the
secondary part following formula:
L sec ondary part ≥ L travel + L primary part

L: Length
Abb. 4-8: Determining the required secondary part length
Sizes and feed forces

In order to be able to comply with the different feed force requirements,
Rexroth Indramat offers synchronous linear motors in a modular system
with different sizes and lengths.
Sizes The active width of primary and secondary part is used for defining the
size of a linear motor. A linear motor of size 120, for example, has a
laminated core and a magnet 120 mm wide (see also Figure 4-4 and
Figure 4-6).
The LSF modular system includes the following motor sizes:
040 080 120 140 160 200 240
Figure 4-9: Sizes of LSF synchronous linear motors
Lengths Each primary part is graduated in different motor lengths. The primary
part length is identified by the identification letters K, L, M and N for
standard encapsulation or S, T, U and V for thermal encapsulation (see
Figure 4-3).
identification in type code:

K, L, M, N - standard encapsulation
S, T, U, V - thermal encapsulation
Figure 4-10: Different lengths of the primary parts
Note: Please refer to Chapter 6 Mounting Dimensions for details

about sizes and lengths.
Feed forces The following diagram gives an overview of the force spectrum of LSF
synchronous linear motors from Rexroth Indramat.
LSF240
25000
Continous force FdN
22000
LSF200 Maximum Force FMAX
20000 LSF160
16500
LSF140
Feed Forces in N
15700
13200
15000
13200
LSF120
11500
11700 10500 , 9800

lenght of primary
10000 8600 9700 LSF080
7800
6600
7800 5600 7700
6300
5300 4150 5800 3900
6500 4350 4700
5000 4700
3900
5300
3700
3350
3500
LSF040
2150
2650 3800 2550 N/V
2600 2300 1750 1200 M/U
2100 360 L/T
1550 1100 800 240 K/S
0
LSF240 LSF200 LSF160 LSF140 LSF120 LSF080 LSF040
KRAFTSPEKTRUM LSF.XLS
Figure 4-11: Force spectrum of LSF synchronous linear motors
4.3 Type Code and Order Designations

LSF is the generic product name of synchronous linear motors. This
name describes the overall system that consists of primary and
secondary part. Since linear motors are assembly kit motors, primary part
and secondary part have an individual unambiguous type designation.
Synchronous Linear
Motors LSF
primarg part LSP secondary part LSS
standard thermal
encapsulation encapsulation
The following two figures use a typical motor for showing the type code of
primary and secondary part that permits an exact definition of the
individual components (in orders, for example).
Text 1
column 1 2 3 4 5 6 7 8 9 0 1 2 3 4
Example: L S P 0 8 0 K - R U 2 - A N
1. Product group
1.1 LSP . . . . . . . . . . . = LSP
2. Motor size
2.1 80 . . . . . . . . . . . . . . . . . . = 080
3. Encapsulation / motor length

Encapsulation motor length
3.1 Standard encapsul. K L M N
3.2 Thermal encapsul. S T U V
4. Power connection
4.1 bottom right . . . . . . . . . . . . . . . . . . . = RU
5. Length of the power connection

5.1 2m ............................... =2
6. Winding code
6.1 A .................................... =A
6.2 B .................................... =B
6.3 C .................................... =C
7. Cooling
7.1 Liquid cooling (integrated) ................ =N
Permissible combinations
encapsulation / length winding code
standard enc. thermal en. A B C
K S X X X
L T - X X
M U X X -
N V - X -
Example: LSF linear motor
A LSS secondary part

B LSP primary part (depends on version - standard
C encapsulation or thermal encapsulation)
C Power connection bottom right
D D screw mounting (from top)
TYPECODELSP-LSF-EN.FH7
Figure 4-12: Typical LSP primary part type code
Example: L S S 0 8 0 - B 1 - 0 6 0 0 A
1. Product group
1.1 LSS . . . . . . = LSS
2. Motor size
2.1 080 . . . . . . . . . . . = 080
3. Magnet carrier version

3.1 Versions. . . . . . =B
4. Mechanical versions
4.1 Screwed fixing (fromthe top)= 1
5. Length 1
5.1 150...1200 mm (in steps of 150 mm)
e.g.: 600 mm. . . . . . . . . . . . . . .= 0600
6. Cover plate
6.1 With cover plate. . . . . . . . . . . . . . . . . . =A
Note:
1 LSS040 only available in 150 mm and 600 mm length;
TYPECODELSS-LSF-EN.FH7
Figure 4-13: Typical LSS secondary part type code
Synchronous Linear Motors LSF Specifications 5-1
5 Specifications
5.1 Explanation of Specifications

This Chapter specifies all relevant technical motor data in the form of
tables and characteristic curves. The following parameters are taken into
account:
• Size and length of the primary part
• Winding version of the primary part
• Available mains and/or DC bus voltage
Note: Unless specified otherwise, all data and characteristic curves

specified here are related to the following conditions:
• Absolute motor winding temperature 135°C.
• Nominal air gap
• Coolant water, inlet temperature 30°C
Note: The resulting data from certain motor - controller combinations

may differ from the data specified here. See Chapter 7 Motor -
Controller Combination.
Force vs. velocity characteristic curve

The force vs. velocity characteristic curve is specified as a limiting
characteristic curve. The profile and the key data of this characteristic
curve are determined by the level of the DC bus voltage and by the
corresponding motor-related data (such as inductively, resistance, motor
constant). Variations in the DC bus voltage (different drive controllers or
power supply modules and connecting voltages) and different motor
windings produce different characteristic curves (Figure 5-1).
force
Fmax
FdN
1 2 3 4 5
VFMAX VN velocity
F V K E N N L IN -L S F -E N .F H 7
Figure 5-1: Force vs. velocity limiting characteristic curve
The maximum force FMAX is available up to a velocity vFMAX. When the

velocity rises, the available DC bus voltage is reduced by the velocity-
dependent back e.m.f. (electromotive force) of the motor. This leads to a
reduction of the maximum feed force at rising velocity. The characteristic
curves are specified up to the continuous nominal force. The velocity that
belongs to the continuous nominal force is known as nominal velocity vN.
5-2 Specifications Synchronous Linear Motors LSF
The force vs. velocity characteristic curves are specified for the following
controllers, power supply modules and connection voltages:
1. Modular drive controller DDS at power supply units TVD or KVR

with mains connection 3 x AC 400...480V
(DC bus voltage, regulated UDC = 320V)
2. Modular drive controller HDS at power supply units HVE

(DIAX04)
or
Compact drive controller DKCxx.3 (ECODRIVE)
with mains connection 3 x AC 400V
(medium DC bus voltage, unregulated UDC = 540V)

(DIAX04)
or

(DIAX04)
or
5. Modular drive controller HDS at power supply units HVR

(DIAX04)
with mains connection 3 x AC 400...480V
(DC bus voltage, regulated UDC =750V)
Note: The specified characteristic curves can linearly be converted

according to the existing voltages if the connection voltages or
mains voltages are different.
Where power supply modules with unregulated DC bus

voltage are concerned, possible voltage drops must be taken
into account that can be caused by simultaneous acceleration
of several axes.
Parallel connection of two The following interrelations exist for the parallel connection of two primary
primary parts at one drive parts to one drive controller:
controller
• Doubling of currents and feed forces

(unless limited by the drive controller)
• Velocities vFMAX and vNENN as in single arrangement
• Same motor and voltage constant (kiF, kE)
• Halved motor resistances and inductance’s
Fmax parallel
feed force
parallel arrangement
FdN parallel
Fmax single
FdN single
single arrangement
VFMAX VN
velocity
FVKENNLIN1-LSF-EN.FH7
Figure 5-2: Force vs. velocity characteristic curve for single and parallel
connection of primary parts to one drive controller
Note: For the parallel connection of two primary parts to one drive
controller this document specifies the corresponding selection
data for motor - controller combinations and the motor
parameters for commissioning (see Chapter 7 Motor –
Controller Combinations and Chapter 14 Commissioning).
5.2 LSF040
LSP040K primary part
Designation Symbol Unit Data

Primary part type, standard encapsulation LSP040K-RU2-AN LSP040K-RU2-BN LSP040K-RU2-CN
1)
Related secondary part (segments) LSS040-B1-****A LSS040-B1-****A LSS040-B1-****A
2)
Maximum force Fmax N 800
2,3)
Continuous nominal force FdN N 240
4)
Maximum current imax A - 30 -
3,4)
Nominal continuous current idN A - 6.7 -
5)
Maximum velocity at Fmax vFmax m/min - 75...380 -
5)
Nominal velocity vN m/min - 145...700 -
Force constant kiFN N/A - 36 -
6)
Voltage constant KE Vs/m - 45 -
7)
Winding resistance at 20ºC R12 ohms - 7.5 -
7)
Winding inductively L12 mH - 34.7 -
Power connection cross-section APL mm² - 1.0 mm² (INK0653) -
8)
Continuous power loss PvN W 365
9)
Minimum coolant flow Qmin l/min 0.60
10)
Constant pressure loss determination kdp 0.007
11)
Coolant inlet temperature TIN °C 15...40
12)
Attractive force FATT N 1450
Nominal air gap sA mm 1,4 ±0.3
Primary part mass mP kg 2.9
Secondary part mass mS kg/m 8
Maximum winding temperature TWmax °C 155
3)
Thermal time constant Tth min 4.3
Maximum secondary part temperature TSmax °C 70
13)
Perm. ambient temperature Tum °C 0 ... +45
Permissible storage and transport
TL ºC -10 ... +60
temperature
Maximum site altitude 13) m 1000 above sea level
Class of protection IP65
Insulation class to DIN VDE 0530 Part 1 F
Enclosure surface primary part Priming black (RAL 9005)
1) Segment length 150 and 600 mm (see also Chapter 6 Mounting Sizes).
2) The achievable forces depend on the employed drive controller. See Chapter 7 Motor – Controller Combinations.
3) With liquid cooling (coolant: water, inlet temperature 30°C), winding end temperature 135°C, nominal air gap and motor standstill.
4) Specification in peak values.
5) See the force vs. velocity characteristic curves and Chapter 7 Motor – Controller Combinations.
6) Peak value of voltage between phases at 20°C.
7) Between two motor connection wires
8) At continuous nominal force and winding temperature 135°C. Lower continuous forces and winding temperatures result in lower
power losses (see Chapter 8.4 Determining the Drive Power).
9) To maintain the continuous nominal force at coolant temperature rise by 10K. Definition of coolant temperature rise in Chapter 9.4 Motor Cooling.
10) Coolant water. Determining the pressure drop as a function of the coolant flow see Chapter 9.4 Motor Cooling.
11) See also Chapter 9.4 Motor Cooling.
12) Between primary and secondary part at nominal air gap; no current in primary part
13) With different ambient temperatures and / or site altitudes see Chapter 9.6 Site Altitude and Ambient Conditions.
Figure 5-3: Specifications of LSP040K
B winding 900
800
700
600
500
F [N]
400
300
200
100 1 2 3 4 5
0
0 100 200 300 400 500 600 700
v [m/min]
Figure 5-4: Force vs. velocity characteristic curves; LSP040K with B winding
[1] - DDS at TVD or KVR (UDC 320V)

[2] - HDS at HVE or DKCxx.3 with mains connection 3 x AC 400 V (UDC 540V)
[5] - HDS at HVR (UDC 750V)
LSP040L primary part

Primary part type, standard encapsulation LSP040L-RU2-AN LSP040L-RU2-BN LSP040L-RU2-CN
Related secondary part (segments) 1) LSS040-B1-****A LSS040-B1-****A LSS040-B1-****A
2)
2,3)
4)
Nominal continuous current 3,4) idN A - 7,8 -
Maximum velocity at Fmax 5) vFmax m/min - 35...320 -
Nominal velocity 5) vN m/min - 300...750 -
Voltage constant 6) KE Vs/m - 57 -
Winding resistance at 20ºC 7) R12 Ohm - 7,4 -
Winding inductively 7) L12 mH - 38 -
Continuous power loss 8) PvN W 490
Minimum coolant flow 9) Qmin l/min 0,80
Constant pressure loss determination 10) kdp 0,01
Coolant inlet temperature 11) TIN °C 15...40
Attractive force 12) FATT N 2150
Primary part mass mP kg 4,7
Thermal time constant 3) Tth min 5,2
Perm. ambient temperature 13) Tum ºC 0 ... +45
TL ºC -10 ... +60
temperature
Maximum site altitude 13) m 1000 above see level
Insulation class to DIN VDE 0530 part 1 F
1) Segment length 150 and 600 mm (see also Chapter 6 Sizes).
5) See force vs. Velocity characteristic curves and Chapter 7 Motor – Controller Combinations.
8) At continuous nominal force and winding temperature 135°C. Lower continuous forces and winding temperatures results in lower power losses
(see Chapter 8.4 Determining the Drive Power).
10) Coolant water. Determining the pressure drop as a function of coolant flow see Chapter 9.4 Motor Cooling.
12) Between primary and secondary part at nominal air gap; no current in Primary part.
13) With different ambient temperatures and / or altitudes see Chapter 9.6 Site Altitude and Ambient Conditions.
Fig. 5-5: Specifications of LSP040L
B winding 1400
1200
1000
800
F [N]
600
400
200
1 2 3 4 5
0
0 100 200 300 400 500 600 700 800
v [m/min]
Fig. 5-6: Force vs. velocity characteristic curves, LSP040L, B winding
[1] - DDS an TVD or KVR (UDC 320V)

[2] - HDS an HVE or DKCxx.3 with mains connection 3 x AC 400 V (UDC 540V)
[5] - HDS an HVR (UDC 750V)
5.3 LSF080
LSP080K / S primary part
Designation Symb Unit Data
Primary part type, standard encapsulation LSP080K-RU2-Ax LSP080K-RU2-Bx LSP080K-RU2-Cx
Primary part type, thermal encapsulation LSP080S-RU2-AN LSP080S-RU2-BN LSP080S-RU2-CN
1)
2)
2,3)
4)
Maximum current imax A 70 45 40
3,4)
Nominal continuous current idN A 26.8 17.5 15.1
5)
Maximum velocity at Fmax vFmax m/min 155...415 80...265 60...225
5)
Nominal velocity vN m/min 295...760 190...500 160...440
Force constant kiFN N/A 41 63 73
6)
Voltage constant KE Vs/m 53 80 88
7)
Winding resistance at 20ºC R12 ohms 1.5 3.5 4.8
7)
Winding inductively L12 mH 17.0 39.6 53.8
Power connection cross-section APL mm² 2.5 mm² (INK0602) 1.5 mm² (INK0650) 1.0 mm² (INK0653)
8)
9)
10)
Constant to determine the pressure drop kdp Standard encapsulation: 0.023 / thermal encapsulation: 0.034
Primary part mass mP kg Standard encapsulation: 12.0 / thermal encapsulation: 16.0
Secondary part mass mS kg/m 14.6
Thermal time constant 3) Tth min Standard encapsulation: 5.7 / thermal encapsulation: 7.6
Perm. ambient temperature 13) Tum °C 0 ... +45
TL °C -10 ... +60
temperature
Standard encapsulation: Priming black (RAL 9005)
Enclosure surface primary part Thermal encapsulation: Aluminum bare
1) Segment length 150 through 1200 mm at a pitch of 150 mm (see also Chapter 6 Mounting Sizes).
5) See force vs. velocity characteristic curves and Chapter 7 Motor – Controller Combinations.
Figure 5-7: Specifications of LSP080K / S
A winding 2500
2000
1500
F [N]
1000
500
1 2 3 4 5
0
0 100 200 300 400 500 600 700 800
v [m/min]
Figure 5-8: Force vs. velocity characteristic curves, LSP080K/S, A winding
B winding 2500
2000
1500
F [N]
1000
500
1 2 3 4 5
0
0 100 200 300 400 500
v [m/min]
Figure 5-9: Force vs. velocity characteristic curve, LSP080K/S, B winding
C winding 2500
2000
1500
F [N]
1000
500
1 2 3 4 5
0
0 50 100 150 200 250 300 350 400 450
v [m/min]
Figure 5-10: Force vs. velocity characteristic curves, LSP080K/S, C winding

LSP080L / T primary part

Primary part type, standard encapsulation LSP080L-RU2-Ax LSP080L-RU2-Bx LSP080L-RU2-Cx
Primary part type, thermal encapsulation LSP080T-RU2-AN LSP080T-RU2-BN LSP080T-RU2-CN
1)
2)
2,3)
4)
Maximum current imax A - 55 40
3,4)
Nominal continuous current idN A - 20.8 14.5
5)
Maximum velocity at Fmax vFmax m/min - 40...190 5...120
5)
Nominal velocity vN m/min - 130...370 80...250
Force constant kiFN N/A - 84 121
6)
Voltage constant KE Vs/m - 103 150
7)
Winding resistance at 20ºC R12 ohms - 4.0 8.3
7)
Winding inductively L12 mH - 46.7 95.9
Power connection cross-section APL mm² - 1.5 mm² (INK0650) 1.0 mm² (INK0653)
8)
9)
10)
TL °C -10 ... +60
temperature
Figure 5-11: LSP080L / T, specifications
B winding 4000
3500
3000
2500
F [N]
2000
1500
1000
500
1 2 3 4 5
0
0 50 100 150 200 250 300 350 400
v [m/min]
Figure 5-12: Force vs. velocity characteristic curves, LSP080L / T, B winding
C winding 4000
3500
3000
2500
F [N]
2000
1500
1000
500
1 2 3 4 5
0
0 50 100 150 200 250 300
v [m/min]
Figure 5-13: Force vs. velocity characteristic curves, LSP080L / T, C winding
[1] - DDS at TVD or. KVR (UDC 320V)

LSP080M / U primary part

Primary part type, standard encapsulation LSP080M-RU2-Ax LSP080M-RU2-Bx LSP080M-RU2-Cx
Primary part type, thermal encapsulation LSP080U-RU2-AN LSP080U-RU2-BN LSP080U-RU2-CN
1)
2)
2,3)
4)
Maximum current imax A 80 60 -
3,4)
Nominal continuous current idN A 27.9 23.6 -
5)
Maximum velocity at Fmax vFmax m/min 75...245 5...170 -
5)
Nominal velocity vN m/min 175...460 120...355 -
Force constant kiFN N/A 77 91 -
6)
Voltage constant KE Vs/m 91 114 -
7)
Winding resistance at 20ºC R12 ohms 2.1 4.2 -
7)
Winding inductively L12 mH 24.9 38.0 -
Power connection cross-section APL mm² 2.5 mm² (INK0602) 2.5 mm² (INK0602) -
8)
9)
10)
TL °C -10 ... +60
temperature
2) The achievable forces depend on the employed drive controller. See Chapter 7 Motor Controller Combinations.
13) With different ambient temperatures and / or site altitudes see Chapter 9.6 Altitude and Ambient Conditions.
Figure 5-14: Specifications LSP080M / U
A winding 5000
4500
4000
3500
3000
F [N]
2500
2000
1500
1000
500 1 2 3 4 5
0
0 50 100 150 200 250 300 350 400 450 500
v [m/min]
Figure 5-15: Force vs. velocity characteristic curves, LSP080M / U, A winding
B winding 5000
4500
4000
3500
3000
F [N]
2500
2000
1500
1000
500 1 2 3 4 5
0
0 50 100 150 200 250 300 350 400
v [m/min]
Figure 5-16: Force vs. velocity characteristic curves, LSP080M / U, B winding

5.4 LSF120
1)
2)
2,3)
4)
3,4)
5)
Maximum velocity with Fmax vFmax m/min 105...295 50...190 5...115
5)
6)
7)
7)
Power connection cross-section APL mm² 2.5 mm² (INK0602) 1.5 mm² (INK0650) 1.0 mm² (INK0653)
8)
9)
10)
TL °C -10 ... +60
temperature
9) To maintain the continuous nominal force at coolant temperature rise by 10K. Definition of coolant temperature rise in Chapter 9. 4 Motor Cooling.
13) With different ambient temperatures and / or site altitudes see Chapter 9.6 Site Altitude and Conditions.
Figure 5-17: Specifications LSP120K / S
A winding 4000
3500
3000
2500
F [N]
2000
1500
1000
500
1 2 3 4 5
0
0 50 100 150 200 250 300 350 400 450 500 550 600
v [m/min]
Figure 5-18: Force vs. velocity characteristic curves, LSP120K / S, A winding
B winding 4000
3500
3000
2500
F [N]
2000
1500
1000
500
1 2 3 4 5
0
0 50 100 150 200 250 300 350 400
v [m/min]
Figure 5-19: Force vs. velocity characteristic curves, LSP120K / S, B winding
C winding 4000
3500
3000
2500
F [N]
2000
1500
1000
500
1 2 3 4 5
0
0 50 100 150 200 250 300
v [m/min]
Figure 5-20: Force vs. velocity characteristic curves, LSP120K / S, C winding


1)
2)
2,3)
4)
3,4)
5)
5)
6)
7)
7)
Power connection cross-section APL mm² 4 mm² (INK0603) 2.5 mm² (INK0602) 1.5 mm² (INK0650)
8)
9)
10)
Thermal time constant 3) Tth min Standard encapsulation: 6,2 / thermal encapsulation: 7.6
TL °C -10 ... +60
temperature
1) Segment length 150 through 1200 mm at an increment of 150 mm (see also Chapter 6 Mounting Sizes).
Figure 5-21: Specifications LSP120L / T
A winding 6000
5000
4000
F [N]
3000
2000
1000
1 2 3 4 5
0
0 50 100 150 200 250 300 350 400 450
v [m/min]
Figure 5-22: Force vs. velocity characteristic curves, LSP120L / T, A winding
B winding 6000
5000
4000
F [N]
3000
2000
1000
1 2 3 4 5
0
0 50 100 150 200 250 300 350 400
v [m/min]
C winding 6000
5000
4000
F [N]
3000
2000
1000
1 2 3 4 5
0
0 50 100 150 200 250 300
v [m/min]


1)
2)
2,3)
4)
3,4)
5)
5)
6)
7)
7)
Power connection cross-section APL mm² 1.5 mm² (INK0650) 2.5 mm² (INK0602) 10 mm² (INK0605)
8)
9)
10)
TL °C -10 ... +60
temperature
A winding 8000
7000
6000
5000
F [N]
4000
3000
2000
1000
1 2 3 4 5
0
0 50 100 150 200 250
v [m/min]
B winding 8000
7000
6000
5000
F [N]
4000
3000
2000
1000
1 2 3 4 5
0
0 50 100 150 200 250 300
v [m/min]
C winding 8000
7000
6000
5000
F [N]
4000
3000
2000
1000
1 2 3 4 5
0
0 50 100 150 200 250 300 350 400 450 500 550
v [m/min]
Figure 5-28: Force vs. velocity characteristic curves, LSP120M / U, C winding

LSP120N / V primary part

Primary part type, standard encapsulation LSP120N-RU2-Ax LSP120N-RU2-Bx LSP120N-RU2-Cx
Primary part type, thermal encapsulation LSP120V-RU2-AN LSP120V-RU2-BN LSP120V-RU2-CN
1)
2)
2,3)
4)
Maximum current imax A 200 - -
Nominal continuous current 3,4) idN A 54.9 - -
Maximum velocity with Fmax 5) vFmax m/min 60...225 - -
Nominal velocity 5) vN m/min 180...475 - -
Force constant kiFN N/A 71 - -
6)
Voltage constant KE Vs/m 89 - -
7)
Winding resistance at 20ºC R12 ohms 1.1 - -
7)
Winding inductively L12 mH 12.0 - -
Power connection cross-section APL mm² 10 mm² (INK0605) - -
8)
9)
10)


TL °C -10 ... +60
temperature
Figure 5-29: Specifications LSP120N / V
A winding 10000
9000
8000
7000
6000
F [N]
5000
4000
3000
2000
1000 1 2 3 4 5
0
0 50 100 150 200 250 300 350 400 450 500
v [m/min]
Figure 5-30: Force vs. velocity characteristic curves, LSP120N / V, A winding

5.5 LSF140
LSP140L primary part
Primary part type, standard encapsulation LSP140L-RU2-AN LSP140L-RU2-BN LSP140L-RU2-CN
1)
2)
2,3)
4)
3,4)
Nominal continuous current idN A - 18.4 -
5)
Maximum velocity at Fmax vFmax m/min - 10...200 -
5)
Nominal velocity vN m/min - 115...325 -
6)
7)
7)
8)
9)
10)
Constant to determine the pressure drop kdp 0.054
11)
Coolant inlet temperature TIN °C 15...40
12)
3)
Thermal time constant Tth min 7.0
13)
Perm. ambient temperature Tum ºC 0 ... +45
TL ºC -10 ... +60
temperature
Figure 5-31: Specifications LSP140L
B winding 8000
7000
6000
5000
F [N]
4000
3000
2000
1000
1 2 3 4 5
0
0 50 100 150 200 250 300 350
v [m/min]
Figure 5-32: Force vs. velocity characteristic curves, LSP140L, B winding

LSP140N primary part

Primary part type, standard encapsulation LSP140N-RU2-AN LSP140N-RU2-BN LSP140N-RU2-CN
1)
2)
2,3)
4)
Nominal continuous current 3,4) idN A - 28.8 -
Maximum velocity with Fmax 5) vFmax m/min - 5...130 -
Voltage constant 6) KE Vs/m - 171 -
7)
7)
8)
9)
10)
Constant to determine the pressure drop kdp 0.081
Thermal time constant 3) Tth min 4.7
Perm. ambient temperature 13) Tum ºC 0 ... +45
TL ºC -10 ... +60
temperature
2) The achievable forces depend on the employed drive controller. See Chapter 7 Motor – Controller Combintions.
Figure 5-33: Specifications LSP140N
B winding 12000
11000
10000
9000
8000
7000
F [N]
6000
5000
4000
3000
2000
1 2 3 4 5
1000
0
0 50 100 150 200 250 300
v [m/min]
Figure 5-34: Force vs. velocity characteristic curves, LSP140N, B winding

5.6 LSF160
1)
2)
2,3)
4)
3,4)
Nominal continuous current idN A 26.9 21.2 -
5)
Maximum velocity at Fmax vFmax m/min 55...210 30...160 -
5)
Nominal velocity vN m/min 165...410 125...320 -
6)
7)
7)
Power connection cross-section APL mm² 2.5 mm² (INK0602) 1.5 mm² (INK0650) -
8)
9)
10)
12)
3)
Thermal time constant Tth min Standard encapsulation: 7.3 / thermal encapsulation: 8.9
TL °C -10 ... +60
temperature
2) The achievable forces depend on the employed drive controller. See Chapter 7 Motor – Controller Combinations
5) See force vs. velocity characteristic curves and Chapter 7 Motor – Controller Combinations
A winding 6000
5000
4000
F [N]
3000
2000
1000
1 2 3 4 5
0
0 50 100 150 200 250 300 350 400 450
v [m/min]
Figure 5-36: Force vs. velocity characteristic curves, LSP160K / S, A winding
B winding 6000
5000
4000
F [N]
3000
2000
1000
1 2 3 4 5
0
0 50 100 150 200 250 300 350
v [m/min]
Figure 5-37: Force vs. velocity characteristic curves, LSP160K / S, B winding


1)
2)
2,3)
4)
3,4)
5)
5)
6)
7)
7)
Power connection cross-section APL mm² 10 mm² (INK0605) 4 mm² (INK0603) 2.5 mm² (INK0602)
8)
9)
10)
TL °C -10 ... +60
temperature
A winding 8000
7000
6000
5000
F [N]
4000
3000
2000
1000 1 2 3 4 5
0
0 50 100 150 200 250 300 350 400 450 500 550 600 650 700
v [m/min]
B winding 8000
7000
6000
5000
F [N]
4000
3000
2000
1000
1 2 3 4 5
0
0 50 100 150 200 250 300
v [m/min]
C winding 8000
7000
6000
5000
F [N]
4000
3000
2000
1000
1 2 3 4 5
0
0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210
v [m/min]


1)
2)
2,3)
4)
Nominal continuous current 3,4) idN A 46.3 35.4 24.3
Maximum velocity with Fmax 5) vFmax m/min 65...205 35...160 20...90
Nominal velocity 5) vN m/min 155...385 110...285 65...190
6)
7)
7)
Power connection cross-section APL mm² 6 mm² (INK0604) 4 mm² (INK0603) 2.5 mm² (INK0602)
8)
9)
10)
TL °C -10 ... +60
temperature
A winding 11000
10000
9000
8000
7000
6000
F [N]
5000
4000
3000
2000
1000 1 2 3 4 5
0
0 50 100 150 200 250 300 350 400
v [m/min]
B winding 11000
10000
9000
8000
7000
6000
F [N]
5000
4000
3000
2000
1 2 3 4 5
1000
0
0 50 100 150 200 250 300
v [m/min]
C winding 11000
10000
9000
8000
7000
6000
F [N]
5000
4000
3000
2000
1000 1 2 3 4 5
0
0 20 40 60 80 100 120 140 160 180 200
v [m/min]
Figure 5-45: Force vs. velocity characteristic curves, LSP160M / U, C winding


1)
2)
2,3)
4)
Maximum current imax A - 170 110
Nominal continuous current 3,4) idN A - 46.7 31.8
Maximum velocity with Fmax 5) vFmax m/min - 25...120 5...65
Nominal velocity 5) vN m/min - 95...255 50...165
Force constant kiFN N/A - 120 176
6)
Voltage constant KE Vs/m - 141 217
7)
Winding resistance at 20ºC R12 ohms - 1.8 4.2
7)
Winding inductively L12 mH - 27.5 57.1
Power connection cross-section APL mm² - 6 mm² (INK0604) 4 mm² (INK0603)
8)
9)
10)
TL °C -10 ... +60
temperature
B winding 14000
12000
10000
8000
F [N]
6000
4000
2000
1 2 3 4 5
0
0 50 100 150 200 250 300
v [m/min]
Figure 5-47: Force vs. velocity characteristic curves, LSP160N / V, B winding
C winding 14000
12000
10000
8000
F [N]
6000
4000
2000
1 2 3 4 5
0
0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200
v [m/min]
Figure 5-48: Force vs. velocity characteristic curves, LSP160N / V, C winding

5.7 LSF200
1)
2)
2,3)
4)
Maximum current imax A - - 75
3,4)
Nominal continuous current idN A - - 22.0
5)
Maximum velocity with Fmax vFmax m/min - - 5...125
5)
Nominal velocity vN m/min - - 100...265
Force constant kiFN N/A - - 118
6)
Voltage constant KE Vs/m - - 148
7)
Winding resistance at 20ºC R12 ohms - - 3.8
7)
Winding inductively L12 mH - - 50.0
Power connection cross-section APL mm² - - 1.5 mm² (INK0650)
8)
9)
10)
TL °C -10 ... +60
temperature
C winding 7000
6000
5000
4000
F [N]
3000
2000
1000
1 2 3 4 5
0
0 50 100 150 200 250 300
v [m/min]
Figure 5-50: Force vs. velocity characteristic curves, LSP200K / S, C winding


1)
2)
2,3)
4)
6)
7)
7)
8)
9)
10)
TL °C -10 ... +60
temperature
B winding 10000
9000
8000
7000
6000
F [N]
5000
4000
3000
2000
1000 1 2 3 4 5
0
0 50 100 150 200 250
v [m/min]


1)
2)
2,3)
4)
Nominal continuous current 3,4) idN A 51.5 30.5 -
Maximum velocity with Fmax 5) vFmax m/min 15...140 5...65 -
Nominal velocity 5) vN m/min 115...295 55...170 -
6)
7)
7)
Power connection cross-section APL mm² 6 mm² (INK0604) 4 mm² (INK0603) -
8)
9)
10)
TL °C -10 ... +60
temperature
A winding 14000
12000
10000
8000
F [N]
6000
4000
2000
1 2 3 4 5
0
0 50 100 150 200 250 300
v [m/min]
B winding 14000
12000
10000
8000
F [N]
6000
4000
2000
1 2 3 4 5
0
0 20 40 60 80 100 120 140 160 180
v [m/min]


1)
2)
2,3)
4)
Nominal continuous current 3,4) idN A 52.8 47.5 -
Maximum velocity with Fmax 5) vFmax m/min 5...105 5...95 -
Nominal velocity 5) vN m/min 85...240 80...220 -
6)
7)
7)
Power connection cross-section APL mm² 6 mm² (INK0604) 6 mm² (INK0604) -
8)
9)
10)
TL °C -10 ... +60
temperature
A winding 18000
16000
14000
12000
10000
F [N]
8000
6000
4000
2000 1 2 3 4 5
0
0 50 100 150 200 250
v [m/min]
B winding 18000
16000
14000
12000
10000
F [N]
8000
6000
4000
2000 1 2 3 4 5
0
0 50 100 150 200 250
v [m/min]

5.8 LSF240
1)
2)
2,3)
4)
Maximum current imax A 190.0 - 100.0
3,4)
Nominal continuous current idN A 53.4 - 29.6
5)
Maximum velocity with Fmax vFmax m/min 40...175 - 5...75
5)
Nominal velocity vN m/min 140...355 - 60...185
Force constant kiFN N/A 88 - 159
6)
Voltage constant KE Vs/m 110 - 199
7)
Winding resistance at 20ºC R12 ohms 1.2 - 4.0
7)
Winding inductively L12 mH 16.0 - 54.0
Power connection cross-section APL mm² 10 mm² (INK0605) - 2.5 mm² (INK0602)
8)
9)
10)


3) Standard encapsulation: 7.7 / thermal encapsulation: 8.2
Thermal time constant Tth min
TL °C -10 ... +60
temperature
2) The achievable forces depend on the employed drive controller. See Chapter 7 Motor - Controller Combinations.
5) See force vs. velocity characteristic curves and Chapter 7 Motor - Controller Combinations.
A winding 12000
10000
8000
F [N]
6000
4000
2000
1 2 3 4 5
0
0 50 100 150 200 250 300 350 400
v [m/min]
C winding 12000
10000
8000
F [N]
6000
4000
2000
1 2 3 4 5
0
0 20 40 60 80 100 120 140 160 180 200
v [m/min]


1)
2)
2,3)
4)
6)
7)
7)
Power connection cross-section APL mm² - 6 mm² (INK0604) -
8)
9)
10)
TL °C -10 ... +60
temperature
B winding 16000
14000
12000
10000
F [N]
8000
6000
4000
2000 1 2 3 4 5
0
0 20 40 60 80 100 120 140 160 180 200 220 240
v [m/min]


1)
2)
2,3)
4)
Nominal continuous current 3,4) idN A 64.2 53.8 43.0
Maximum velocity with Fmax 5) vFmax m/min 5...100 5...70 5...50
Nominal velocity 5) vN m/min 75...220 55...180 45...150
6)
7)
7)
Power connection cross-section APL mm² 10 mm² (INK0605) 10 mm² (INK0605) 6 mm² (INK0604)
8)
9)
10)
Thermal time constant 3) Tth min Standard encapsulation: 6,2 / thermal encapsulation: 6.5
TL °C -10 ... +60
temperature
A winding 24000
22000
20000
18000
16000
14000
F [N]
12000
10000
8000
6000
4000
1 2 3 4 5
2000
0
0 50 100 150 200 250
v [m/min]
B winding 24000
22000
20000
18000
16000
14000
F [N]
12000
10000
8000
6000
4000
1 2 3 4 5
2000
0
0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190
v [m/min]
C winding 24000
22000
20000
18000
16000
14000
F [N]
12000
10000
8000
6000
4000
1 2 3 4 5
2000
0
0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160
v [m/min]
Figure 5-67: Force vs. velocity characteristic curves, LSP240N / V, C winding

Synchronous Linear Motors LSF Mounting Sizes and Tolerances 6-1
6 Mounting Sizes and Tolerances
6.1 Mounting Tolerances

In order to ensure a constant force along the entire travel length, a
defined air gap height must be guaranteed. For this purpose, the
individual parts of the motor (primary and secondary part) have been
provided with the required tolerances. The distance of the mounting
surface, the parallelism and the symmetry of the primary and secondary
part of the linear motor in the machine must be inside a certain tolerance
along the entire travel length. Any deformations that result from weight,
attractive forces and process forces must be taken into account. A
deviation of the specified nominal air gap may lead
• to a reduction or modification of the specified performance data;

• to a contact between the primary part and the secondary part and
thus to damaged or destroyed motor components.
For the installation of the motors into the machine structure, Rexroth
Indramat specifies a defined installation height including tolerances (see
installation size L1 in Figure 6-1). Thus, the specified size and tolerances
of the air gap are maintained kept to (even if individual motor components
are replaced).
maschine structure
primary part
L2
L1
secondary part
maschine structure
EBMASSE-LSF-EN.FH7
Primary part size Primary part version Secondary part Installation Measurable
version height air gap L2
L1
LSP040, 140 Standard encapsulation LSSxxx-B1-xxxxA 55 +0.1 1.4 ±0.3
LSP080, 120, 160 Standard encapsulation 65+0.1 1.4 ±0.3
LSP200 Standard encapsulation 69+0.1 1.4 ±0.3
LSP240 Standard encapsulation 73 +0.1 1.4 ±0.3
LSP080, 120, 160 Thermal encapsulation 80.5 +0.1 1.4 ±0.3
LSP200 Thermal encapsulation 84.5 +0.1 1.4 ±0.3
LSP240 Thermal encapsulation 88.5 +0.1 1.4 ±0.3
Figure 6-1: Mounting sizes and tolerances
6-2 Mounting Sizes and Tolerances Synchronous Linear Motors LSF
Parallelism and symmetry Figure 6-2 defines the parallelism and symmetry between primary part
between primary part and and secondary part that must be met.
secondary part
0.1/1000
LSP primary part
LSS secondary part(s)
0.5
P A R A L S Y S M-L S F -E N .F H 7
Figure 6-2: Parallelism and symmetry between primary part and secondary part
Note: The specified installation height with the corresponding tolerances

must always be observed.
6.2 Mounting Sizes
LSF040
LSP040, primary part
Z
23 ±2
Ø12.2 ±0.4
2100 +10 A ±2
+0.10
35 - 0.15
C ±0.3 N*100 ±0.1 13.5

B 0.7 B 0.05/100
100 ±0.1
20.5
11+1
PG13.5
24 ±0.1
113 ±1
M6
18
OUTLET G1/8"
10
17 INLET G1/8"
Z
FERRULES connecting cable INK0653
static bending radius: R = 70 mm
100+10 MOTOR TYPE A C N
YE/GN -PE conductor LSP040K-RU2-XN 197 53.75 1
1-U
LSP040L-RU2-XN 272 41,25 2
2-V
x x 3-W
x 5-
6 - PTC SNM.150.D
7-
8 - PTC KTY84 - 130 LSP040KLMNXN-LSF-EN.FH7
Figure 6-3: LSP040 primary part, standard encapsulation
LSS040, secondary part
[(N x 75)+37.5] ±0.1

187.5±0.1
112.5±0.1
37.5 ±0.1 (75) (75)
0.1
see note 1
46.2 +0.5
60 ±0.1
75 ±0.2
X
see note 2
-0.1
L
18.6 +0.3
-0.2 X "L"
name/type mm "N"
LSS040-B1-0150-A 150 1
LSS040-B1-0600-A 600 7
Notes:
1) Cover plate
secondary part delivered with stainless cover plate,
ø 11
ø7
bonded over full length.
2) Fixing screws
1x45° Allen screw M6x16 DIN 912 8.8
+0.1
6 or M6x16 DIN 6912 8.8 (flat-head)
9-0.2
LSS040B1xxxxA-LSF-EN.FH7
Figure 6-4: LSS040 secondary part, version B1
Note: The required length of the secondary part can be determined

as follows:
L: Length
LSF080
LSP080 primary part, standard encapsulation
Z
26 ±2
25
Ø17.8 ±0.6
2100 +10 A ±2
N*100 ±0.1
0.7 B
+0.10
C ±0.3 100 ±0.1 45 - 0.15
B
54.5
PG21
11+1
50 ±0.1
150±1
M6
12 12
OUTLET G1/8" 0.05/100
INLET G1/8" 13.5 18
Z
FERRULES
connecting cable INK0603
100+10 static bending radius: R = 100 mm
MOTOR TYPE A C N
YE/GN - PE CONDUCTOR
1-U LSP080K-RU2-XN 395 47.5 3
2-V
3-W LSP080L-RU2-XN 545 72.5 4
x x
x 5- LSP080M-RU2-XN 695 47.5 6
6 - PTC SNM.150.D
7-
8- PTC KTY84 - 130
LSP080KLMNXN-LSF-EN.FH7
LSP080 primary part, thermal encapsulation
66 ±0,2
C ±0,1 n x 150 ±0,1 contact surfaces
(other surface recessed 35 ±0,5
2100 +2 by 0.5mm)
PG 21
23 ±0,5
ø 17,8 ±0,6
26 ±2
Z
40 ±0,5
71 ±0,5
9 ±0,5
170 ±0,5
90 ±0,1
95 ±0,1
Rz10
Rz10
OUTLET G1/4
INLET G1/4
17
m x M8
max. screw depth 11 mm 60,5 ±0,1
0,05
A -1
DETAIL Z connecting cable INK0603

100 +10
dim.
YE/GN - PE CONDUCTOR type A C n m
1-U
2-V
LSP080S-xxx-xN 390 45 2 6
x x 3-W LSP080T-xxx-xN 540 45 3 8
x 5-
6 - PTC SNM.150.D LSP080U-xxx-xN 690 45 4 10
7-
8 - PTC KTY84 - 130
ferrules
LSP080STUVXN-LSF-DE-LSF-EN.FH7
Figure 6-6: LSP080 primary part, thermal encapsulation
[(N x 75)+37.5] ±0.1

187.5
112.5±0.1
37.5 ±0.1 (75) (75)
0.1
see note 1
86.2 +0.5
100 ±0.1
115 ±0.2
X
see note 2
L -T
18.6 +0.3
-0.2 name/type "L" "T" "N"
mm mm
LSS080-B1-0150-A 150 0.1 1
X LSS080-B1-0300-A 300 0.1 3
LSS080-B1-0450-A 450 0.1 5
LSS080-B1-0600-A 600 0.1 7
LSS080-B1-0750-A 750 0.2 9
LSS080-B1-0900-A 900 0.2 11
LSS080-B1-1050-A 1050 0.2 13
LSS080-B1-1200-A 1200 0.2 15
ø 11
ø7
Notes:
1) Cover plate
Secondary part delivered with stainless cover plate,
1x45° bonded over full length.
6+0.1 2) Fixing screws
9-0.2 Allen screw M6x16 DIN 912 8.8
or M6x16 DIN 6912 8.8 (flat-head)
Figure 6-7: LSS080, secondary part

as follows:
L: Length
LSF120
Z 26 ±2
25
Ø19.8 ±0.6
2100 +10 A ±2
N*100 ±0.1
0.7 B
+0.10
C ±0.3 100 ±0.1 45 - 0.15
B
74.5
PG21
90 ±0.1
190 ±1
11+1
M6
12 12
Z OUTLET G1/8" 0.05/100
FERRULES INLET G1/8" 13.5 18
YE/GN - PE CONDUCTOR MOTOR TYPE A C N

1-U
2-V LSP120K-RU2-XN 395 47.5 3
x x 3-W
x 5- LSP120L-RU2-XN 545 72.5 4
6 - PTC SNM.150.D LSP120M-RU2-XN 695 47.5 6
7-
8- PTC KTY84 - 130 LSP120N-RU2-XN 845 72.5 7
66 ±0,2
C ±0,1 n x 150 ±0,1 contact surfaces 35 ±0,5
(other surfaces recessed
2100 +2 by 0.5mm)
PG 21 23 ±0,5
ø 19,8 ±0,6
26 ±2
Z
40 ±0,5
71 ±0,5
9 ±0,5
130 ±0,1
135 ±0,1
210 ±0,5
Rz10
Rz10
OUTLET G1/4
INLET G1/4
17
m x M8
0,05
A -1

DETAIL Z
100 +10
dim.
1-U
2-V LSP120S-xxx-xN 390 45 2 6
x x 3-W
x LSP120T-xxx-xN 540 45 3 8
5-
7-
8 - PTC KTY84 - 130 LSP120V-xxx-xN 840 45 5 12
ferrules
LSP120STUVXN-LSF-EN.FH7
[(N x 75)+37.5] ±0.1

187.5±0.1
112.5±0.1
37.5 ±0.1 (75) (75)
0.1
see note 1
126.2+0.5
±0.2
±0.1
155
140
X
see note 2
L -T
18.6 +0.3
-0.2 "L" "T"
name/type mm mm "N"
X LSS120-B1-0150-A 150 0.1 1
LSS120-B1-0300-A 300 0.1 3
LSS120-B1-0450-A 450 0.1 5
LSS120-B1-0600-A 600 0.1 7
LSS120-B1-0750-A 750 0.2 9
LSS120-B1-0900-A 900 0.2 11
LSS120-B1-1050-A 1050 0.2 13
LSS120-B1-1200-A 1200 0.2 15
ø 11
ø7
Notes:
1) Cover plate
1x45° Secondary part delivered with stainless cover plate,
6+0.1
9-0.2 2) Fixing screws
Allen screw M6x16 DIN 912 8.8

as follows:
L: Length
LSF140
LSP140, primary part
26 ±2
18
2100 +10 A ±2
Z
+0.10
35 - 0.15
N*100 ±0.1
0.7 B
C ±0.3 100 ±0.1
B
Ø19.8 ±0.6
86
PG21
90±0.1
213±1
11+1
M6
13 17
OUTLET G1/8" 0.05/100
Z
FERRULES connecting cable INK0604 INLET G1/8" 8 9
100+10
1-U
2-V LSP140L-RU2-XN 567 91.25 4
x x 3-W
x LSP140N-RU2-XN 792 53.75 7
5-
6 - PTC SNM.150.D
7-
8 - PTC KTY84 - 130 LSP140LNXN-LSF-EN.FH7
Figure 6-11: LSP140, primary part
Note: The LSP140 primary parts are combined with LSS160

secondary parts (see Figure 6-14: LSS160, secondary part).
LSF160
Z 26 ±2
25
±0.6
Ø19.8
2100 +10 A ±2
N*100 ±0.1
0.7 B
+0.10
C ±0.3 100 ±0.1 45 - 0.15
PG21
94.5
125 ±0.1
230 ±1
+1
11
M6
12 12
OUTLET G1/8" 0.05/100
Z
connecting cable INK0604 INLET G1/8" 13.5 18
FERRULES
100+10
YE/GN - PE CONDUCTOR
1-U MOTOR TYPE A C N
2-V
3-W LSP160K-RU2-XN 395 47.5 3
x x
x 5- LSP160L-RU2-XN 545 22.5 5
6 - PTC SNM.150.D
7- LSP160M-RU2-XN 695 47.5 6
8- PTC KTY84 - 130
LSP160N-RU2-XN 845 22.5 8
66 ±0,2
C ±0,1 n x 150 ±0,1 contact surfaces 35 ±0,5
(other surfaces recessed
2100 +2 by 0.5mm)
PG 21 23 ±0,5
ø 19,8 ±0,6
26 ±2
Z
40 ±0,5
71 ±0,5
9 ±0,5
170 ±0,1
175 ±0,1
250 ±0,5
Rz10
OUTLET G1/4
Rz10
INLET G1/4
17
m x M8
max. insertion depth 11 mm 60,5 ±0,1
0,05
A -1

DETAIL Z
100 +10
dim.
1-U
2-V LSP160S-xxx-xN 390 45 2 9
x x 3-W
x 5- LSP160T-xxx-xN 540 45 3 12
7-
8- PTC KTY84 - 130 LSP160V-xxx-xN 840 45 5 18
ferrules
LSS160 secondary part
[(N x 75)+37.5] ±0.1

187.5±0.1
112.5±0.1
37.5 ±0.1 (75) (75)
0.1
see note 1
166.2+0.5
180 ±0.1
195±0.2
X
see note 2
L -T
18.6 +0.3
-0.2
name/type "L" "T" "N"

mm mm
LSS160-B1-0150-A 150 0.1 1
LSS160-B1-0300-A 300 0.1 3
X LSS160-B1-0450-A 450 0.1 5
LSS160-B1-0600-A 600 0.1 7
LSS160-B1-0750-A 750 0.2 9
LSS160-B1-0900-A 900 0.2 11
LSS160-B1-1050-A 1050 0.2 13
LSS160-B1-1200-A 1200 0.2 15
ø 11
ø7
Notes:
1) Cover plate
Secondary part delivered with stainless cover plate,
1x45° bonded over full length.
6+0.1
2) Fixing screws
9-0.2 Allen screws M6x16 DIN 912 8.8

as follows:
L sec ondray part ≥ L travel + L primary part
L: Length
LSF200
Z 26 ±2
25
Ø19.8 ±0.6
2100 +10 A ±2
N*100 ±0.1
0.7 B
+0.10
C ±0.3 100 ±0.1 45 - 0.15
PG21
114.5
165 ±0.1
270 ±1.0
11+1
M6
12 12
Z 0.05/100
OUTLET G1/8"
FERRULES connecting cable INK0604
static bending radius: R = 110 mm INLET G1/8" 13.5 18
100+10
1-U
2-V LSP200K-RU2-XN 395 47.5 3
x x 3-W
x LSP200L-RU2-XN 545 22.5 5
5-
6 - PTC SNM.150.D LSP200M-RU2-XN 695 47.5 6
7-
8 - PTC KTY84 - 130 LSP200N-RU2-XN 845 22.5 8
66 ±0,2
C ±0,1 n x 150 ±0,1 contact surface 35 ±0,5
(other surcace recessed
2100 +2 by 0.5mm)
PG 21 23 ±0,5
ø 19,8 ±0,6
26 ±2
Z
40 ±0,5
71 ±0,5
9 ±0,5
210 ±0,1
215 ±0,1
290 ±0,5
Rz10
OUTLET G1/4
Rz10
INLET G1/4
17
m x M8
max. insertion depth 11 mm 60,5 ±0,1
0,05
A -1

DETAIL Z
100 +10
dim.
1-U
2-V LSP200S-xxx-xN 390 45 2 9
x x 3-W
x 5- LSP200T-xxx-xN 540 45 3 12
7-
8 - PTC KTY84 - 130 LSP200V-xxx-xN 840 45 5 18
ferrules LSP200STUVXN-LSF-EN.FH7
[(N x 75)+37.5]±0.1
187.5±0.1
112.5±0.1
0.1
37.5 ±0.1 (75) (75)
see note 1
206.2+0.5
220±0.1
235±0.2
X
see note 2
L -T
22.6 +0.3
-0.2

mm mm
LSS200-B1-0150-A 150 0.1 1
LSS200-B1-0300-A 300 0.1 3
X LSS200-B1-0450-A 450 0.1 5
LSS200-B1-0600-A 600 0.1 7
LSS200-B1-0750-A 750 0.2 9
LSS200-B1-0900-A 900 0.2 11
LSS200-B1-1050-A 1050 0.2 13
LSS200-B1-1200-A 1200 0.2 15
ø 11
ø7
Notes:
1) Cover plate
Stainless cover plate stuck along the full length
1x45° is a part of the delivery of the related secondary part
6+0.1 2) Fixing screws

Allen screw M6x16 DIN 912 8.8
13-0.2 or M6x16 DIN 6912 8.8 (flat-head)

as follows:
L: Length
LSF240
26 ±2
Z
25
Ø19.8 ±0.6
2100 +10 A±2
N*100 ±0.1
0.7 B
C ±0.3 100 ±0.1 45 +0.10
- 0.15
Rz10
PG21
134.5
210 ±0.1
310 ±1.0
30±0.1
11+1
INLET G1/8"
OUTLET G1/8"
M6
12 12
Z 0.05/100
FERRULES 13.5 18
MOTOR TYPE A C N
YE/GN - PE CONDUCTOR LSP240K-RU2-XN
1-U
2-V LSP240L-RU2-XN 545 72.5 4
x x 3-W 47.5
x LSP240M-RU2-XN 695 6
5-
6 - PTC SNM.150.D LSP240N-RU2-XN 845 72.5 7
7-
8 - PTC KTY84 - 130 LSP240KLMNXN-LSF-EN.FH7
66 ±0,2
C ±0,1 n x 150 ±0,1 contact surface 35 ±0,5
(other surface recessed
2100 +2 by 0.5mm)
PG 21 23 ±0,5
ø 19,8 ±0,6
26 ±2
Z
40 ±0,5
71 ±0,5
9 ±0,5
250 ±0,1
255 ±0,1
330 ±0,5
110 ±0,1
Rz10
Rz10
OUTLET G1/4
INLET G1/4
17
m x M8
0,05
A -1
DETAIL Z
100 +10
dim.
1-U
LSP240S-xxx-xN
2-V
x x 3-W LSP240T-xxx-xN 540 45 3 16
x 5-
7-
PTC KTY84 - 130 LSP240V-xxx-xN 840 45 5 24
8-
ferrules
[(N x 75)+37.5] ±0.1

187.5±0.1
112.5±0.1
37.5 ±0.1 (75) (75) 0.1
see note 1
246.2 +0.5
275 ±0.2
260 ±0.1
X
see note 2
L -T
26.6 +0.3
-0.2

mm mm
X LSS240-B1-0150-A 150 0.1 1
LSS240-B1-0300-A 300 0.1 3
LSS240-B1-0450-A 450 0.1 5
LSS240-B1-0600-A 600 0.1 7
LSS240-B1-0750-A 750 0.2 9
LSS240-B1-0900-A 900 0.2 11
LSS240-B1-1050-A 1050 0.2 13
LSS240-B1-1200-A 1200 0.2 15
ø 11
ø7
Notes:
1) Cover plate
1x45° Secondary part delivered with stainless cover plate,
6+0.1
2) Fixing screws
17-0.2 Allen screws M6x16 DIN 912 8.8

as follows:
L: Length
Synchronous Linear Motors LSF Motor - Controller Combinations 7-1
7 Motor - Controller Combinations
7.1 General Explanations

This Chapter contains selection data of different motor - controller
combinations for the following controller families:
• DIAX04
• ECODRIVE03
Structure of the selection data The selection data for synchronous linear drives LSF are structured by
• controller family (DIAX or ECODRIVE)
• power supply module / mains connection voltage
• single or parallel arrangement of primary part
List order The individual selection data is sorted according to:
1. Motor type
2. Maximum feed force FMAX
3. Maximum velocity at maximum feed force vFMAX
Primary part versions With identical size, the same data applies to standard encapsulation and
to thermal encapsulation. The motor - controller combination is specified
for both versions at the same time.
Note: The data for motor - controller combinations is specified for

standard and thermal encapsulation at the same time.
Parallel motor arrangement Motor - controller combinations are also specified for parallel motor
arrangements at one drive controller.
Note: For parallel arrangements, the data for parallel motor

arrangement is specified at one drive controller.
Gantry arrangements require selection and planning to be
made for the individual motors.
PWM frequency drive controller The PWM frequency (pulse width modulation) of the drive controller has
an effect on the resulting motor data. The data specified in this document
are related to a PWM frequency of 4 kHz.
7-2 Motor - Controller Combinations Synchronous Linear Motors LSF
Description of the specified variables
FMAX Maximum feed force of the motor; available for a maximum of 400 ms
(see Figure 5-1)
vFMAX Maximum velocity at maximum force FMAX. Velocity up to which the

maximum feed force is available (see Figure 5-1)
PVMAX Electrical maximum power loss of the motor, related to the specified
maximum current at a motor winding temperature of 135°C.
FdN Continuous feed force of the motor (see Figure 5-1), related to:
- Water cooling; coolant water; inlet temperature of 30° C

- Motor winding temperature of 135°C.
- Motor stopped
VN Rated velocity (see Figure 5-1)

Velocity at which the rated force FdN of the motor is available.
PvN Rated power loss of the motor at FdN
EDFMAX Relative duty cycle ED in %, related to the specified maximum and

continuous force (see Figure 8-16)
FKB Short-time operating force

The possible short-time operating force results from the ratio of rated
motor current and the rated current of the drive controller. In periodic duty
operation S6, is can be used with the duty cycle EDFKB. The maximum
duty cycle time corresponds to the thermal time constant of the motor
(see Chapter 5 Specifications).
2
F 
ED FKB ≈  dN  ⋅ 100%
 FKB 
FdN: Rated force of the motor in N
FKB: Possible short-time operating force in N
Figure 7-1: Calculation of the possible duty cycle related to FKB
A short-time operating force that is higher than the rated force of the
motor is only available if the rated current of the drive controller is higher
than the rated current of the motor.
idN Rated current of the motor at rated force FdN
imax Maximum current of the motor at FMAX.
Note: Unless specified differently, currents are always specified as

peak values.
7.2 Motor - Controller Combination DIAX04, Single-

Arrangement Primary Part
Unregulated DC bus; mains connection voltage 3 x AC 400 V
PRIMARY PART
FMAX vFmax PVMAX FdN vN PvN EDFMAX FKB idN iMAX Standard / thermal encapsulation
[N] [m/min] [kW] [N] [m/min] [kW] [%] [N] [A] [A] LSP... Drive controller
800 185 6.6 240 345 0.37 6 360 6.7 30 040K-RU2-BN HDS02.2-W040N
1200 200 11.5 360 535 0.49 4 540 7.8 40 040L-RU2-BN HDS02.2-W040N
2300 290 7.2 1100 510 1.17 16 1100 26.8 70 080K-RU2-AN / 080S-RU2-AN HDS03.2-W075N
2050 205 5.5 900 345 0.86 16 900 15.0 40 080K-RU2-BN / 080S-RU2-BN HDS02.2-W040N
2300 150 7.5 1100 290 1.17 16 1100 15.0 40 080K-RU2-CN / 080S-RU2-CN HDS02.2-W040N
3500 125 11.8 1750 245 1.88 16 2400 20.8 55 080L-RU2-BN / 080T-RU2-BN HDS03.2-W075N
3500 65 12.9 1750 160 1.90 15 1750 14.5 40 080L-RU2-CN / 080T-RU2-CN HDS02.2-W040N
4450 175 11.5 1900 315 1.43 12 1900 25.0 75 080M-RU2-AN / 080U-RU2-AN HDS03.2-W075N
4700 100 14.7 2150 230 2.54 17 2650 23.6 60 080M-RU2-BN / 080U-RU2-BN HDS03.2-W075N
4150 220 8.8 1800 325 1.09 12 1800 25.0 75 120L-RU2-AN / 120T-RU2-AN HDS03.2-W075N
7800 180 33.9 3350 350 2.85 8 3800 54.9 200 120M-RU2-CN / 120U-RU2-CN HDS04.2-W200N
9800 150 42.9 3900 320 3.61 8 4500 54.9 200 120N-RU2-AN / 120V-RU2-AN HDS04.2-W200N
7700 115 22.0 2650 225 1.69 8 3500 18.4 70 140L-RU2-BN HDS03.2-W075N
7700 115 22.0 2650 225 1.69 8 3950 18.4 70 140L-RU2-BN HDS03.2-W100N
11500 60 32.4 4150 175 3.70 11 4750 28.8 90 140N-RU2-BN HDS03.2-W100N
9650 85 22.5 3600 180 2.79 12 3600 25.0 75 140N-RU2-BN HDS03.2-W075N
13200 75 51.8 5600 180 4.36 8 8150 46.7 170 160N-RU2-BN / 160V-RU2-BN HDS04.2-W200N
12200 30 41.0 5250 110 4.11 10 5250 30.0 100 160N-RU2-CN / 160V-RU2-CN HDS03.2-W100N
Figure 7-2: Single arrangement LSF040 / 080 / 120 / 140 / 160 at DIAX04,
unregulated DC bus, mains connection voltage 3 x AC 400V
PRIMARY PART
Figure 7-3: Single arrangement LSF200 / 240 at DIAX04,
Unregulated DC bus, mains connection voltage 3 x AC 480 V
PRIMARY PART
800 325 6.6 240 605 0.37 6 360 6.7 30 040K-RU2-BN HDS02.2-W040N
1200 265 11.5 360 645 0.49 4 540 7.8 40 040L-RU2-BN HDS02.2-W040N
7700 160 22.0 2650 280 1.69 8 3500 18.4 70 140L-RU2-BN HDS03.2-W075N
7700 160 22.0 2650 280 1.69 8 3950 18.4 70 140L-RU2-BN HDS03.2-W100N
11500 100 32.4 4150 215 3.70 11 4750 28.8 90 140N-RU2-BN HDS03.2-W100N
9650 125 22.5 3600 220 2.79 12 3600 25.0 75 140N-RU2-BN HDS03.2-W075N
PRIMARY PART
Connection to regulated DC bus, DC bus voltage 750 V
PRIMARY PART
FMAX vFmax PVMAX FdN vN PvN EDFMAX idN iMAX Standard / thermal encapsulation
[N] [m/min] [kW] [N] [m/min] [kW] [%] FKB [N] [A] [A] LSP... Drive controller
800 380 6.6 240 700 0.37 6 360 6.7 30 040K-RU2-BN HDS02.2-W040N
1200 320 11.5 360 750 0.49 4 540 7.8 40 040L-RU2-BN HDS02.2-W040N
7700 200 22.0 2650 325 1.69 8 3500 18.4 70 140L-RU2-BN HDS03.2-W075N
7700 200 22.0 2650 325 1.69 8 3950 18.4 70 140L-RU2-BN HDS03.2-W100N
11500 130 32.4 4150 255 3.70 11 4750 28.8 90 140N-RU2-BN HDS03.2-W100N
9650 160 22.5 3600 260 2.79 12 3600 25.0 75 140N-RU2-BN HDS03.2-W075N
regulated DC bus, DC bus voltage 750V
PRIMARY PART
regulated DC bus, DC bus voltage 750 V
7.3 Motor - Controller Combination DIAX04, Parallel-

PRIMARY PART
[N] [m/min] [kW] [N] [m/min] [kW] [%] [N] [A] [A] 2 x LSP... Drive controller
1600 185 13.2 480 345 0.73 6 720 13.4 60 040K-RU2-BN HDS03.2-W075N
1600 185 13.2 480 345 0.73 6 720 13.4 60 040K-RU2-BN HDS03.2-W100N
2250 225 20.3 720 535 0.98 5 960 15.6 75 040L-RU2-BN HDS03.2-W075N
2400 200 23.1 720 535 0.98 4 1080 15.6 80 040L-RU2-BN HDS03.2-W100N
11450 155 22.4 4300 235 2.25 10 4300 30.0 100 140L-RU2-BN HDS03.2-W100N
15400 115 44.0 5300 225 3.39 8 7950 36.8 140 140L-RU2-BN HDS04.2-W200N
9000 180 12.6 3600 240 1.56 12 3600 25.0 75 140L-RU2-BN HDS03.2-W075N
23000 60 64.8 8300 175 7.40 11 11250 57.6 180 140N-RU2-BN HDS04.2-W200N
Continued on next page
PRIMARY PART
Figure 7-8: Parallel arrangement LSF040 / 080 / 120 / 140 / 160 / 200 / 240 at
DIAX04, unregulated DC bus, mains connection voltage 3 x AC 400V
PRIMARY PART
1600 325 13.2 480 605 0.73 6 720 13.4 60 040K-RU2-BN HDS03.2-W075N
1600 325 13.2 480 605 0.73 6 720 13.4 60 040K-RU2-BN HDS03.2-W100N
2250 290 20.3 720 645 0.98 5 960 15.6 75 040L-RU2-BN HDS03.2-W075N
2400 265 23.1 720 645 0.98 4 1080 15.6 80 040L-RU2-BN HDS03.2-W100N
11450 205 22.4 4300 290 2.25 10 4300 30.0 100 140L-RU2-BN HDS03.2-W100N
15400 160 44.0 5300 280 3.39 8 7950 36.8 140 140L-RU2-BN HDS04.2-W200N
9000 235 12.6 3600 300 1.56 12 3600 25.0 75 140L-RU2-BN HDS03.2-W075N
23000 100 64.8 8300 215 7.40 11 11250 57.6 180 140N-RU2-BN HDS04.2-W200N
DIAX04, unregulated DC bus, mains connection voltage 3 x AC 480V
Connection to regulated DC bus, DC bus voltage 750 V
PRIMARY PART
[N] [m/min] [kW] [N] [m/min] [kW] [%] FKB [N] [A] [A] 2 x LSP... Drive controller
1600 380 13.2 480 700 0.73 6 720 13.4 60 040K-RU2-BN HDS03.2-W075N
1600 380 13.2 480 700 0.73 6 720 13.4 60 040K-RU2-BN HDS03.2-W100N
2250 350 20.3 720 750 0.98 5 960 15.6 75 040L-RU2-BN HDS03.2-W075N
2400 320 23.1 720 750 0.98 4 1080 15.6 80 040L-RU2-BN HDS03.2-W100N
11450 245 22.4 4300 335 2.25 10 4300 30.0 100 140L-RU2-BN HDS03.2-W100N
15400 200 44.0 5300 325 3.39 8 7950 36.8 140 140L-RU2-BN HDS04.2-W200N
9000 275 12.6 3600 345 1.56 12 3600 25.0 75 140L-RU2-BN HDS03.2-W075N
23000 130 64.8 8300 255 7.40 11 11250 57.6 180 140N-RU2-BN HDS04.2-W200N
Figure 7-10: Parallel arrangement LSF040 / 080 / 120 / 140 / 160 at DIAX04,
regulated DC bus, DC bus voltage 750V
7.4 Motor - Controller Combination ECODRIVE03, Single-

PRIMARY PART
800 185 6.6 240 345 0.37 6 360 6.7 30 040K-RU2-BN DKCxx.3-040-7
1200 200 11.5 360 535 0.49 4 490 7.8 40 040L-RU2-BN DKCxx.3-040-7
2300 290 7.2 1100 510 1.17 16 1350 26.8 70 080K-RU2-AN / 080S-RU2-AN DKCxx.3-100-7
2050 205 5.5 800 365 0.64 12 800 13.0 40 080K-RU2-BN / 080S-RU2-BN DKCxx.3-040-7
2300 150 7.5 1100 290 0.88 12 1100 13.0 40 080K-RU2-CN / 080S-RU2-CN DKCxx.3-040-7
3500 125 11.8 1750 245 1.88 16 2600 20.8 55 080L-RU2-BN / 080T-RU2-BN DKCxx.3-100-7
3500 65 12.9 1750 160 1.53 12 1750 13.0 40 080L-RU2-CN / 080T-RU2-CN DKCxx.3-040-7
4700 165 13.1 2150 305 1.78 14 2450 27.9 80 080M-RU2-AN / 080U-RU2-AN DKCxx.3-100-7
4700 100 14.7 2150 230 2.54 17 3100 23.6 60 080M-RU2-BN / 080U-RU2-BN DKCxx.3-100-7
5150 175 15.6 2300 300 1.78 11 2300 32.0 100 120L-RU2-AN / 120T-RU2-AN DKCxx.3-100-7
7800 180 33.9 3350 350 2.85 8 4250 54.9 200 120M-RU2-CN / 120U-RU2-CN DKCxx.3-200-7
9800 150 42.9 3900 320 3.61 8 5100 54.9 200 120N-RU2-AN / 120V-RU2-AN DKCxx.3-200-7
7700 115 22.0 2650 225 1.69 8 3950 18.4 70 140L-RU2-BN DKCxx.3-100-7
11500 60 32.4 4150 175 3.70 11 4650 28.8 90 140N-RU2-BN DKCxx.3-100-7
13200 75 51.8 5600 180 4.36 8 8200 46.7 170 160N-RU2-BN / 160V-RU2-BN DKCxx.3-200-7
12200 30 41.0 5600 110 4.62 11 5600 31.8 100 160N-RU2-CN / 160V-RU2-CN DKCxx.3-100-7
Figure 7-11:Single arrangement LSF040 / 080 / 120 / 140 / 160 / 200 / 240 at
ECODRIVE03, unregulated DC bus, mains connection voltage
3 x AC 400V
PRIMARY PART
[N] [m/min] [kW] [N] [m/min] [kW] [%] FKB [N] [A] [A] LSP... Drive controller
800 325 6.6 240 605 0.37 6 360 6.7 30 040K-RU2-BN DKCxx.3-040-7
1200 265 11.5 360 645 0.49 4 490 7.8 40 040L-RU2-BN DKCxx.3-040-7
7700 160 22.0 2650 280 1.69 8 3950 18.4 70 140L-RU2-BN DKCxx.3-100-7
11500 100 32.4 4150 215 3.70 11 4650 28.8 90 140N-RU2-BN DKCxx.3-100-7
Figure 7-12: Single arrangement LSF040 / 080 / 120 / 140 / 160 / 200 / 240 at
3 x AC 480V
7.5 Motor - Controller Combination ECODRIVE, Parallel-

PRIMARY PART
1600 185 13.2 480 345 0.73 6 720 13.4 60 040K-RU2-BN DKCxx.3-100-7
2400 200 23.1 720 535 0.98 4 1080 15.6 80 040L-RU2-BN DKCxx.3-100-7
11450 155 22.4 4600 230 2.56 11 4600 32.0 100 140L-RU2-BN DKCxx.3-100-7
23000 60 64.8 8300 175 7.40 11 11950 57.6 180 140N-RU2-BN DKCxx.3-200-7
3 x AC 400V

PRIMARY PART
1600 325 13.2 480 605 0.73 6 720 13.4 60 040K-RU2-BN DKCxx.3-100-7
2400 265 23.1 720 645 0.98 4 1080 15.6 80 040L-RU2-BN DKCxx.3-100-7
11450 205 22.4 4600 285 2.56 11 4600 32.0 100 140L-RU2-BN DKCxx.3-100-7
23000 100 64.8 8300 215 7.40 11 11950 57.6 180 140N-RU2-BN DKCxx.3-200-7
3 x AC 480V
Synchronous Linear Motors LSF Motor Sizing 8-1
8 Motor Sizing
8.1 General Procedure

The sizing of linear drives is mainly determined by the application-related
characteristics of velocity and feed force. The basic sequence of sizing
linear drives is shown in the Figure below.
F force profile
v velocity profile moved mass
friction, machining forces
+
motor mounting position
travel
limit values for:
t - maximum velocity t
- maximum acceleration
F operating points of upplication

F = f(v)
Effective force FEFF Aux. conditions
Installation space
Maximum force FMAX
motor and axis arrangement
Maximum velocity (single, parallel or gantry)
vMAX cooling
ambient conditions
Maximum velocity
at maximum force (coolant lubricants,chips, etc.)
v vFMAX linear scales
guides
Selection of motor or motor controller combination

Selection criteria: limit characteristic of motor
F = f(v)
· All operating points are inside the force- F
velocity characteristic curve of the motor operating pts.
· FMAX £ FMAX,Motor application
F = f(v)
· FEFF £ FdN,Motor
· vMAX £ vMAX,Motor
· vFMAX £ vFMAX,Motor
· Motor version acc. to application v
(cooling, protection rating, etc.)
Drive controller and Machine structure auxiliary components

power supply module - linear scales
- moved masses
- power - attractive forces - cables
- connection voltage - installation space - linear guides
- DC bus voltage - rigidity - shock absorbers, brakes,
counter balance, etc.
DIMALLGEMEIN-LSF-EN.FH7
Figure. 8-1: Basic procedure of sizing linear drives
8-2 Motor Sizing Synchronous Linear Motors LSF
8.2 Basic Formulae
General equations of motion

The variables required for sizing and selecting the motor are calculated
using the equations shown in Figure 8-2.
Note: When linear direct drives are configured, the process-related

feed forces and velocities are used directly and without
conversion for selecting the drive.
s( t )
velocity : v( t ) =
dt
v( t )
acceleration : a( t ) =
dt
force : F( t ) = a( t ) ⋅ m + F0 ( t ) + FP ( t )
T
1
effective force : Feff = ⋅ ∫ F( t )2 dt
T 0
T
1
average velocity : v avg = ⋅ ∫ v( t ) dt
T 0
v(t): Velocity profile vs. time in m/s
s(t): Path profile vs. time in m
a(t): Acceleration profile vs. time in m/s
F(t): Force profile vs. time in N
m: Moved mass in kg
F0(t): Base force in N
FP(t): Process or machining force in N
Feff: Effective force in N
vavg: Average velocity in m/s
t: Time in s
t: Total time in s
Figure 8-2: General equations of motion
In most cases the mathematical description of the required positions vs.

the time is known (NC program, electronic cam disk). Using the
preparatory function, velocity, acceleration, and forces can be calculated.
Standard software (such as MS Excel or MathCad) can be used for
calculating the required variables, even with complex motion profiles.
Note: The following Chapter provides a more detailed correlation for

trapezoidal, triangular or sinusoidal velocity characteristics.
Feed forces
acceleration force : FACC = m ⋅ a
fcb
force due to weight : FW = m ⋅ g ⋅ sin α ⋅ (1 − )
100
frictional force : FF = µ ⋅ (m ⋅ g ⋅ sin α + FATT ) + F0
maximum force : FMAX = FACC + FF + FW + FP
F12 ⋅ t 1 + F22 ⋅ t 2 + ...

effective force : FEFF =
t all
F F ...
1 2
t t ...
1 2
tall FTRAPEZ01-LSF-EN.FH7
FACC: Acceleration force in N

FW : Force due to weight in N
FF : Frictional force in N
F0: Additional frictional or base force in N (e.g. by seals of linear guides)
FMAX: Maximum force in N
FP: Machining force in N
A: Acceleration in m/s²
m: Moved mass in kg
g: Gravitational acceleration (9.81 m/s²)
α Axis angle in degrees (0°:horizontal axis; 90°: vertical axis)
fCB: Weight compensation in %
tall: Total duty cycle time in s
FATT: Attractive force between primary and secondary part in N
µ: Friction coefficient
Figure 8-3: Determining the feed forces
Note: For sizing calculations of linear motor drives, the moved mass
of the motor component must be taken into account (in
particular if the slide masses are relatively small). However,
the moved mass and the attractive force between primary and
secondary part are only known after the motor has been
selected. Thus, first make assumptions for these variables
and verify these values after the motor has been selected.
(1) acceleration (up) : F = FACC + FF + FW

(2) const. velocity (up) : F = FF + FW
(3) deceleration (up) : F = −FACC + FF + FW
(4) acceleration (up) : F = FACC + FF − FW
(5) const. velocity (up) : F = FF − FW
(6) deceleration (up) : F = −FACC + FF − FW
(7) idle time : F = FW

force
velocity
axis arrangement:
horizontal vertical / slanted
up
weight force FW= 0 down
FVTRAPEZ01-LSF-EN.FH7

FW : Force due to weight in N
FF : Frictional force in N
Figure 8-4: Determining the resulting feed forces according to motion type and
direction
Note: With horizontal axis arrangement, the weight is FW = 0.
Further directional base and process forces must be taken into

account.
Average velocity
The average velocity is required for determining the mechanical
continuous output of the drive. Figure 8-2 shows the general way of
determining the average velocity. The following calculation can be used
for a simple determination in trapezoidal or triangular velocity profiles:
v va ve ve
vavgi
vavgi
ve va
vavgi
va
t
ti ti ti
VAVG01-LSF-EN.FH7
va − ve
v avgi =
2
v avg =
∑v avg i ⋅ ti
t all
vavgi: Average velocity for a velocity segment of the duration ti in m/s

va: Initial velocity of the velocity segment in m/s
ve: Final velocity of the velocity segment in m/s
vavg: Average velocity over total duty cycle time in m/s
ti : Duration of velocity segment in s
tall: Total duty cycle time, including breaks and/or downtime, in s
Figure 8-5: Determining the average velocity with triangular or trapezoidal
velocity profile
Trapezoidal velocity
This mode is characteristic for most applications. An acceleration phase
is followed by a movement of constant velocity up to the deceleration
phase.
vc
deceleration
ve
acceleration v = constant
va
t
ta tc tb
VTRAPEZ01-LSF-EN.FH7
Figure 8-6: Trapezoidal velocity profile
Acceleration, initial velocity = 0
• Velocity v ≠ constant
• Initial velocity va = 0
• Acceleration a = constant and positive
vc 2 ⋅ s v2
acceleration : a= = 2 = c
ta ta 2⋅s
2⋅s
final velocity : vc = a ⋅ ta = 2 ⋅ a ⋅ s =
ta
vc v2 a ⋅ t a2
travel : s= ⋅ ta = c =
2 2⋅a 2
vc 2 ⋅ s 2⋅s
time : ta = = =
a vc a
vc: Final velocity in m/s
ta : Acceleration time in s
s: Travel covered during acceleration in m
Figure 8-7: Constantly accelerated movement, initial velocity = 0 (according to
Figure 8-6)
Acceleration, initial velocity ≠ 0
• Initial velocity va ≠ 0
• Acceleration a = constant and positive
v c − v a 2 ⋅ s 2 ⋅ v a v c2 − v a2
acceleration : a= = 2 − =
ta ta ta 2⋅s
2⋅s
velocity : v c = v a + a ⋅ t a = 2 ⋅ a ⋅ s + v a2 = − va
ta
vc + va v 2 − v a2 a ⋅ t a2
travel : s= ⋅ ta = c = va ⋅ ta +
2 2⋅a 2
vc − va 2⋅s 2 ⋅ a ⋅ s + v 2a − v a
time : ta = = =
a vc + va a
va: Initial velocity in m/s
ta : Acceleration time in s
s: Travel covered during acceleration in m
Figure 8-8: Constantly accelerated movement, initial velocity ≠ 0 (according to
Figure 8-6)
Constant velocity
• Velocity v = constant
• Acceleration a = 0
time :
sc
acceleration : vc =
tc
travel : sc = v c ⋅ t c
sc
time : tc =
vc
vc: Constant velocity in m/s
tc: Time during constant velocity in s
sc: Travel covered during constant velocity in m
Figure 8-9: Constant velocity (to Figure 8-6)
Decelerating, final velocity = 0
• Final velocity ve = 0
• Acceleration a = constant and negative
v c 2 ⋅ s v c2
acceleration : a= = 2 =
tb tb 2⋅s
2⋅s
velocity : vc = a ⋅ tb = 2 ⋅ a ⋅ s =
tb
vc v2 a ⋅ t b2
travel : s= ⋅ tb = c =
2 2⋅a 2
vc 2 ⋅ s 2⋅s
time : tb = = =
a vc a
tb : Deceleration time in s
s: Travel covered during deceleration in m
Figure 8-10: Constantly decelerated movement, final velocity = 0
(according to Figure 8-6)
Decelerating, final velocity ≠ 0
• Final velocity ve ≠ 0
• Acceleration a = constant and negative
v c − v e 2 ⋅ v c 2 ⋅ s v 2c − v 2e
acceleration : a = = − 2 =
tb tb tb 2⋅s
2⋅s
velocity : v e = v c − a ⋅ t b = v c2 − 2 ⋅ a ⋅ s = − vc
tb
vc + ve v c2 − v 2e a ⋅ t b2
travel : s= ⋅ tb = = v c ⋅ tb +
2 2⋅a 2
vc − ve 2⋅s v − v 2c − 2 ⋅ a ⋅ s
time : ta = = = c
a vc + ve a
vc: Initial velocity in m/s
ve: Final velocity in m/s
s: Travel covered during deceleration in m
Figure 8-11: Constantly decelerated movement, final velocity ≠0
(according to Figure 8-6)
Triangular velocity
In contrast to the trapezoidal characteristic, this velocity profile does not
have a phase of constant velocity. The acceleration phase is immediately
followed by the deceleration phase. This characteristic can frequently be
found in conjunction with movements of short strokes.
vmax
acceleration deceleration
t
t
VDREIECK01-LSF-EN.FH7
Figure 8-12: Triangular velocity profile
2 ⋅ v max 4 ⋅ sall v max

2
acceleration : a= = =
t t2 s
a⋅t 2 ⋅ sall
velocity : v max = = a ⋅ sall =
2 t
v max ⋅ t v max
2
a ⋅ t2
travel : s all = = =
2 4⋅a 4
2 ⋅ v max 4 ⋅ s all 4 ⋅ s all

time : t= = =
a v max a
vmax: Maximum velocity in m/s
sall: Total motion travel in m
t: Positioning time in s
Figure 8-13: Calculation of triangular velocity profile (according to Figure 8-12)
Sinusoidal velocity
This velocity profile results, for example, from the circular interpolation of
two axes (circular movement) or the oscillating movement of one axis
(grinding, for example).
The specified variables are chiefly the motion travel or the circle diameter
and the period T.
travel profile : s( t ) = r ⋅ sin(ω ⋅ t )
velocity profile : v( t ) = r ⋅ cos( ω ⋅ t ) ⋅ ω
acceleration profile : a( t ) = r ⋅ sin(ωt ) ⋅ ω2
jerk profile r( t ) = r ⋅ cos( ωt ) ⋅ ω3
2⋅π
ω= = 2⋅π⋅f
T
path/stroke v
time t
period T
path/stroke v
time t
period T VSINUS01-LSF-EN.FH7
s(t): Travel profile vs. time in m

v(t): Velocity profile vs. time in m/s
a(t): acceleration profile vs. time in m/s²
3
r(t): jerk profile vs. time in m/s
r: Motion travel in one direction (circle radius) in m
ω:
-1
Angular frequency in s
T: Period in s (time for circular motion or complete stroke)
t: Time in s
f: stroke frequency in Hz
Figure 8-14: Motion profiles of an axis at sinusoidal velocity
The following calculation bases on Figure 8-14:
2
2⋅π
maximum accelerati on : a max = r ⋅ 
 T 
2⋅π
maximum velocity : V max = r ⋅ V max
T
2 ⋅ v max 4 ⋅r
average velocity : v avg = =
π T
accelerati on force : F ACC = a max ⋅ m
2
Facc
effective force : FEFF = + F02
2
vertical axis arrangemen t :

2
Facc + F02up + F02 down
FEFFv =
2
base force up movement : F0 up = F0 + Fw

base force down movement : F0 down = F0 − F w
amax: Maximum acceleration in m/s²

r: Motion travel in one direction or circle radius in m
t: Period in s
m: Moved mass in kg
FEFFv: Effective force at vertical or inclined axis arrangement in N
F0: Base force, e.g., frictional force, in N
FW : Force due to weight in N (according to Figure 8-3 )
Figure 8-15: Calculation formulae for sinusoidal velocity profile
Note: Further directional base and process forces must additionally

be taken into account.
8.3 Duty cycle and Feed Force

The relative duty cycle ED specifies the duty cycle percentage of the load
with respect to a total duty cycle time, including idle time. The thermal
load capacity of the motor limits the duty cycle. Stressing the motor with
rated force is possible over the entire duty cycle time. The duty cycle must
be reduced at F > FdN (Figure 8-16 ) in order to not thermally overload the
motor at higher feed forces.
feed force
in N
max. motor
force
Fmax
Fx
rated
force of motor ON time
FdN in %
EDFmax EDFx ED=100%

EDKENNLIN01-LSF-EN.FH7
Figure 8-16: Correlation between duty cycle and feed force
Determining the duty cycle

The approximate determination of the relative duty cycle EDideal is
performed via the correlation:
 FEFF
2

EDideal =  2  ⋅ 100
 FMAX 
ED: Relative duty cycle in %
Feff: Effective force or rated force in N
FMAX: Maximum feed force
Figure 8-17: Approximate determination of duty cycle ED
Prerequisite: Linear correlation between feed force and current.
For LSF linear motors to Figure 8-17, only an approximate duty cycle
calculation is possible since there is a non-linear correlation between
force and current.
This calculation remains valid for a rough determination of possible duty
cycle at short-time duty forces with FKB ≤ 1.5 FdN.
Note: You must check with Figure 8-18 or Figure 8-19 to exactly
determine the relative duty cycle of LSF linear motors.
The non-linearity of the characteristic curve force vs. current of LSF

synchronous linear motors leads to an increased rise of power loss at
higher feed forces. This increased power loss leads - in particular at a
high percentage of acceleration and deceleration processes - to a
possible duty cycle that is reduced with respect to Figure 8-17.
Use Figure 8-18 or Figure 8-19 to determine exactly the possible relative
duty cycle for LSF synchronous linear motors.
PvN
EDreal = ⋅ 100
PAVG a
EDreal: Possible relative duty cycle in %
PvN: Maximum removable power loss of the motor in W
(continuous power loss see Chapter 5 Specifications)
PAVG a: Average motor power loss in application over a
duty cycle time including idle time in W
Figure 8-18: Determining the duty cycle ED
Prerequisite: Duty cycle time ≤ Thermal time constant of motor
100%
90%
80%
70%
60%
ED
50%
40%
ideal
30%
20%
real (LSF)
10%
0%
1,0 1,2 1,4 1,6 1,8 2,0 2,2 2,4 2,6 2,8 3,0
F / FdN NORMIERTE KENNLINIEN LSF.XLS
Figure 8-19: Duty cycle vs. force for LSF synchronous linear motor
8.4 Determining the Drive Power

To size the power supply module or the mains rating, you must determine
the rated (continuous) and maximum power of the linear drive.
Note: Take the corresponding simultaneity factor into account when

you determine the total power of several drives that are
connected to a single power supply module.
Continuous output
The rated output corresponds to the sum of the mechanical and electrical
motor power.
total rated output : Pc = Pcm + Pce
mechanical rated output : Pcm = Feff ⋅ v avg
2
F 
rated electrical output : Pce =  eff  ⋅ Pvn mit Feff ≤ Fdn
 Fdn 
Pc: Rated power in W
Pcm: Mechanical rated output in W
Pce: Electrical rated power loss of motor in W
Feff: Effective force in N (from application)
vavg: Average velocity in m/s
Fdn: Rated force of the motor in N (see Chapter 5 Specifications)
PvN: Rated power loss of the motor in W (see Chapter 5 Specifications)
Figure 8-20: Rated power of the linear motor
Note: The rated electrical output (see Figure 8-20) is reduced when
the rated force is reduced.
Maximum output
The maximum output is also the sum of the mechanical and electrical
maximum output. It must be made available to the drive during
acceleration and deceleration phase or for very high machining forces, for
example.
total maximum output : Pmax = Pmaxm + Pmaxe
mechanical maximum output : P maxm = Fmax ⋅ v Fmax

Pmax: Total maximum power in W
Pmaxm: Mechanical maximum power in W
Pmaxe: Electrical maximum power in W (see Figure 8-22)
FMAX: Maximum feed force in N
vFmax: Maximum velocity with Fmax in N
Figure 8-21: Maximum power of the linear motor
Note: When the maximum feed force is reduced against the

achievable maximum force of the motor, the electrical
maximum output Pmaxe is reduced too.
To determine the reduced electrical maximum output Pmaxe,
use Figure 8-22.
1,0
0,8
Pv / Pvmax
0,6
0,4
0,2
0,0
0,0 0,1 0,2 0,3 0,4 0,5 0,6 0,7 0,8 0,9 1,0
F / Fmax NORMIERTE KENNLINIEN LSF.XLS
Fmax: Maximum force of the motor in N

f: Maximum force application in N
Pvmax: Maximum power loss of the motor in W
Pv: Power loss of the motor application in W
Figure 8-22: Diagram used for determining the reduced electrical power loss
Note: The maximum power loss is specified in Chapter 7 Motor-

Controller Combinations.
Cooling capacity
The necessary cooling capacity nearly corresponds to the motor’s
electrical continuous power loss.
2
F 
cooling capacity : Pco = Pce =  eff  ⋅ Pvn with Feff ≤ Fdn
 Fdn 
Pco: Required cooling capacity in W
Pce: Electrical power loss of the motor in W
PvN: Rated power loss of the motor in W (see Chapter 5 Specifications)
Figure 8-23: Required cooling capacity of the linear motor
Regeneration energy
Compared with rotary servo motors, the energy of a linear motor fed back
during deceleration is lower. The translatory velocity of a linear motor is
usually much lower than the circumferential speed of a rotary servo
motor.
The regeneration energy of a synchronous linear drive results from the
energy balance during the deceleration process. To size additional brake
resistors or power supply units with feedback capability, it can be
estimated as follows:
2
m ⋅ v2 a 
PR = − v ⋅ FR − 3 ⋅ m ⋅ R12 ⋅  max 
tb  k iFN 
PRavg
1
T
= ⋅ ∫ PR ( t ) dt =
∑P Ri ⋅ t bi
T 0 t all
PR: Regeneration energy during a deceleration phase in W
PRavg: Average regeneration energy over total duty cycle time in W
m: Moved mass in kg
V: Maximum velocity in m/s
FR: Frictional force in N
R12: Winding resistance of the motor at 20°C in ohms
(see Chapter 5 Motor Specifications)
amax: Braking deceleration (negative acceleration) in m/s²
kiFN: Motor constant in N/A
tall: Total duty cycle time in s
Figure 8-24: Regeneration energy of the linear motor
Prerequisite: Velocity-independent friction

Constant deceleration
Final velocity = 0
Note: If the regeneration energy that is determined according to

Figure 8-24 is negative, energy is not fed back. This means
that energy must be supplied to the motor during the
deceleration process.
8.5 Efficiency
The efficiency of electrical machines is the ratio between the motor output
and the power fed to the motor. With linear motors, it is determined by the
application-related traverse rates and forces, and the corresponding
motor losses.
Figure 8-25 and Figure 8-26 can be used for determining and/or
estimating the motor efficiency.
Pmech F⋅v 1
η= = =
Pmech + PV el (F ⋅ v ) + PV el 1 + Pvel
F⋅v
η: Efficiency
Pmech: Mechanical output in W
PVel: Electrical power loss in W
f: Feed force in N
V: Velocity in m/s
Figure 8-25: Determining the efficiency of linear motors
1,0
e ffe c ien c y v s . c o ntin uo u s
0,9 no rm in a l fo rc e F d N
0,8
0,7
0,6 effic ie nc y v s .
M ax im u m fo rce F m ax
0,5
0,4
0,3
0,2
0,1
0,0
0 m /m in 1 00 m /m in 200 m /m in 3 00 m /m in 40 0 m /m in 5 00 m /m in 60 0 m /m in
V e lo c ity W IR K U N G S G R A D LS F .XLS
Figure 8-26: Efficiency vs. velocity for LSF synchronous linear motors
8.6 Sizing Examples
Handling axis
The example of a simple handling axis is used for describing the basic
procedure of sizing a linear drive.
Specifications
The following data is specified:
Slide mass: mS = 65 kg
Maximum velocity possible: 300 m/min
Maximum acceleration possible: 50 m/s²
Axis arrangement: horizontally, primary part moved
Base force through energy chain,
seals, linear guides, etc.: Fzus = 150 N (constant)
Additional process forces: none
Friction coefficient of linear guides: µ = 0.005
Mains connection voltage 3 x AC 400V
Coolant temperature (water): ϑcoolant = 25°C
Required positioning movements:
No. Stroke Positioning Idle time after stroke Comment

time
1 600 mm 0.32 s 0.20 s Moving from start
position to part
pickup
2 -1300 0.50 s 0.20 s Parts transport
mm and deposit
3 700 mm 0.35 s 0.45 s Moving back to
start position
Figure 8-27: Required positioning movements of the handling axis
The mass of the primary part must be taken into account when the feed
forces are determined. The attractive force between primary and
secondary part is required additionally when the frictional force is
determined. The following assumptions are made to start with:
Primary part mass: mP = 26 kg
Attractive force: FATT = 13400 N
Check the calculations again once you have selected the motor.
Calculation
The following velocity and acceleration values are selected in order to

maintain the required positioning times and specified limitations:
No. Stroke Positioning Feed rate acceleration

time
1 600 mm 0.32 s 180 m/min 25 m/s²
2 -1300 mm 0.50 s 220 m/min 25 m/s²
3 700 mm 0.35 s 185 m/min 25 m/s²
Figure 8-28: Selected velocities and accelerations of the handling axis
Note: When you select positioning velocity and positioning

acceleration, you should try to find an optimum ratio for the
motor selection (to reach a minimum effective force, for
example).
Moved total mass m = mS + mP

m = 65 kg + 26 kg
m = 91 kg
Base force F0 = FF + F0
F0 = µ ⋅ (m ⋅ g + FATT ) + F0
F0 = 0.005 ⋅ (91 kg ⋅ 9.81 m/s² + 13400 N) + 150 N
F0 = 222 N
Force due to weight FW = 0 N (horizontal axis)
Acceleration force: FACC = m ⋅ a

FACC = (91 kg) ⋅ 25 m/s²
FACC = 2275 N
Maximum force: FMAX = FACC + F0

FMAX = 2275 N + 222 N
FMAX = 2497 N
Total time or duty cycle time t all = 0.32 s + 0.2 s + 0.5 s + 0.2 s + 0.35 s + 0.45 s
t all = 2.02 s
Velocity and force profile The selected velocities and the determined forces provide the following
velocity and force profile:
2497 N 2497 N 2497 N
180 m/min 185 m/min
force F in N
222 N 0N 222 N 0N 222 N 0N
velocity v in m/min
220 m/min
-2053 N -2053 N -2053 N
0.12 s 0.12 s 0.147 s 0.147 s 0.123 s 0.123 s
0.08 s 0.2 s 0.206 s 0.2 s 0.104 s 0.45 s
time t DIMBSPHDL01-LSF-EN.FH7
Figure 8-29: Velocity and force profile of handling axis
Effective force and average The effective force and the average velocity are determined on the basis
velocity of the force profile:
No. Time ti Force Fi in N Average

in s velocity vavg i
in m/min
1 0.120 2497 Fi = FACC+F0 90
2 0.080 222 Fi = F 0 180
3 0.120 -2053 Fi = FACC-F0 90
4 0.200 0 0
5 0.147 2497 Fi = FACC+F0 110
6 0.206 222 Fi = F 0 220
7 0.147 -2053 Fi = FACC-F0 110
8 0.2 0 0
9 0.123 2497 Fi = FACC+F0 92.5
10 0.104 222 Fi = F 0 185
11 0.123 -2053 Fi = FACC-F0 92.5
12 0.45 0N 0
Figure 8-30: Force profile vs. time to determine the effective force
∑ (F 2
⋅ ti ) v avg =
∑v avg i ⋅ ti
FEFF =
i
t all t all
FEFF = 1424 N v avg = 77.1 m / min
Selection of motor - controller combination

Once the application data has been calculated, an appropriate motor -
controller combination can be selected.
The standard encapsulation motor version and the ECODRIVE controller
family are selected. Using the calculated data, the following combination
is chosen from the selection data for motor - controller combinations (see
Chapter 7 Motor - Controller Combinations):
Motor: LSP120K-RU2-AN
Drive controller: DKCxx.3-100-7
Verification of mass and The mass of the selected primary part LSP120K-RU2-AN is slightly
attractive force smaller that the previously assumed mass. The same applies to the
attractive force. The selected motor is retained within the scope of this
example.
Operating points and Using the profiles of velocity and force (Figure 8-29), the operating points
characteristic curve of the motor of the required feed forces and the necessary velocities can be
determined. These operating points and the characteristics are shown in
the Figure below.
4000
3500
3000
force in N
2500
2000
1500
1000
500
0
0 50 100 150 200 250 300 350 400 450
F-v charact. curve motor
velocity in m/min
working pts. application
DIMBSPHDL02-LSF-EN.FH7
Figure 8-31: Force - velocity diagram of handling axis

(operating points and motor characteristic)
Note: All operating points that are related to force and velocity of the
application must be inside the characteristic curve of the
selected motor - controller combination.
Selecting the secondary part segments

Based on the motion profile, the effective total motion path and,
consequently, the required number and/or length of the secondary part
segments can be determined. The effective total travel is 1300 mm; the
length of the selected primary part is 395 mm.
Required length of the L sec ondary part ≥ L total travel + L primary part
secondary part
L sec ondary part = 1300 mm + 395 mm
L sec ondary part = 1695 mm
Selecting the secondary part Secondary part segments for LSF synchronous linear motors are
segments available in a pitch of 150 mm up to a total length of 1200 mm. Three
secondary part segments of 600 mm each (total length: 1800 mm) are
selected for the handling axis.
Power calculation
Rated mechanical power Pcm = Feff ⋅ v avg

77.1 m / min
Pcm = 1424 N ⋅
60
Pcm = 1830 W
2
F 
Rated electrical power loss Pce =  eff  ⋅ Pvn
 Fdn 
2
 1424 N 
Pce =   ⋅ 1100 W
 1550 N 
Pce = 930 W
Total rated power Pc = Pcm + Pce

Pc = 1830 W + 930 W
Pc = 2760 W
Maximum output mechanical P maxm = Fmax ⋅ v Fmax

220 m / min
P maxm = 2497 N ⋅
60
P maxm = 9.16 kW
Maximum output electrical Figure 8-22 is used for determining the maximum electrical power loss.
The ratio of required maximum force and maximum force of the motor is
2497 N / 3800 N = 0.66 .
Thus, Figure 8-22 shows a reduction factor of 0.28 for the maximum
power loss Together with the specification of the maximum motor power
loss from the selection charts for the motor - controller combination, the
maximum electrical power loss results as
Pmaxe = 0.28 ⋅ Pmax motor

Pmaxe = 0.28 ⋅ 10 kW
Pmaxe = 2.8 kW
Total maximum output Pmax = Pmaxm + Pmaxe

Pmax = 9.16 kW + 2.8 kW
Pmax = 11.96 kW
Cooling capacity Pco = Pce = 930 W
Regeneration energy Figure 8-24 and the motor data in Chapter 5 Specifications are used for
determining the regeneration energy for all deceleration phases.
2
m ⋅ v2 a 
PRi = − v ⋅ FR − 3 ⋅ m ⋅ R12 ⋅  max 
t bi  k iFN 
No. Deceleration time tbi Velocity Acceleration Regeneration energy PRi

1 0.120 s 180 m/min - 25 m/s² -371 W
2 0.147 s 220 m/min - 25 m/s² 314 W
3 0.123 s 185 m/min -25 m/s² -285 W
Figure 8-32: Regeneration energy during deceleration phases
It is obvious that energy is only fed back during a deceleration process

(2). The average regeneration energy over the entire duty cycle time
amounts to:
PRavg =
∑P Ri ⋅ t bi
t all
PRavg = 23 W
Additional braking resistors or a power supply unit with feedback

capability are therefore not required.
Additional capacities for Additional DC bus capacities (capacitors) shall ensure that the axis is
stopping the axis upon a power safely stopped in the event of a power failure. Figure 10-3 is used for
failure determining the required additional capacities in the DC bus. The motor
decelerates at maximum feed force; the minimum DC bus voltage should
be 50V. The maximum velocity of 220 m/min is considered as worst case.
m ⋅ v max F  F 
Cadd = ⋅ 3,5 ⋅ max ⋅ R12 − v max ⋅  R + 0.3 
U2
− UDC min
DC max
2
k iF2  Fmax 
m
91 kg ⋅ 3.67
Cadd = s ⋅ 3,5 ⋅ 3800 N ⋅ 1.6 Ω − 3.67 m ⋅  222 N + 0.3 
(540 V )2 − (50 V )
2
 N
 60 
s  3800 N 
 A
Cadd = 0.0053 F = 5.3 mF
Note: The maximum possible DC bus capacity of the employed

power supply module must be taken into account when
additional capacities are used in the DC bus.
Selection of linear scale

The linear scale can be selected when the effective total travel is known.
An open incremental linear scale of the LIDA187C type is selected for the
handling axis. The selected system has distance-encoded reference
marks.
Motor efficiency
The motor efficiency, related to the continuous output, results as follows:
Pcm 1830 W
ηc = =
Pcm + Pce 1830 W + 930 W
ηc = 0.66
Final overtemperature of the motor
Limit overtemperature of the ϑ wg = ϑ w max − ϑCoolant

motor winding
ϑ wg = 155 K − 25 K
ϑ wg = 130 K
2
Final overtemperature of the F 
motor winding ϑ w =  eff  ⋅ ϑ wg
 Fdn 
2
 1424 N 
ϑw =   ⋅ ϑ wg
 1550 N 
ϑ w = 110 K
Absolute final temperature of the ϑ wabs = ϑ w + ϑ Coolant

motor winding
ϑ wabs = 110 K + 25 K
ϑ wabs = 135 °C
Reaching the final temperature The thermal time constant of the selected motor is Tth = 9.4 min. 98 % of
the final temperature is reached after approximately 4 thermal time
constants (i.e. after 38 minutes).
Note: Additional explanations of the thermal behavior of linear

motors can be found in Chapter 9.4 Motor Cooling .
Machine tool feed axis; sizing via duty cycle

Detailed information of the motion cycle are sometimes not available or
are not exact. This is the case, for example, with flexible small batch
production and frequently changing port programs. Sizing of drives is
performed on the basis of the relative duty cycle of different operating
phases, and based on empirical values from machine manufacturers
and/or machine users.
The following example explains this procedure.
Specifications
The following data is specified:
Slide mass including motor: mS = 440 kg

Velocity rapid traverse: 120 m/min
Velocity machining 15 m/min
Maximum acceleration possible: 15 m/s²
Axis arrangement: horizontally, primary part moved
Motion path 800 mm
Base force : F0 = 600 N (constant)
Maximum machining force: FP = 1200 N
Friction coefficient of linear guides: µ = 0.005
Mains supply voltage 3 x AC 400V
Type of machining / movement Share

Acceleration and deceleration 20 %
Rapid traverse 15 %
Machining process 25 %
Standstill with machining 20 %
Standstill without machining 20 %
Total: 100 %
Figure 8-33: Percentage of individual machining processes and movements
standstill acceleration
without and
machining deceleration
20% 20%
rapid
standstill with
traverse
machining
15%
20%
machining
25%
Figure 8-34: Graphical presentation of the individual operating phases
Calculation
Acceleration force: FACC = m ⋅ a

FACC = 440 kg ⋅ 15 m/s²
FACC = 6600 N
Maximum force: FMAX = FACC + F0

FMAX = 6600 N + 600 N
FMAX = 7200 N
Effective force and average The effective force and the average velocity are determined on the basis
velocity of the specifications for the individual operating phases.
Type of machining / movement EDi Force Fi Average

velocity vavgi
Acceleration and deceleration 20 % 6600 N Fi = FACC ± F0 60 m/min
Rapid traverse 15 % 600 N Fi = F0 120 m/min
Machining process 25 % 1800 N Fi = FP + F0 15 m/min
Standstill with machining 20 % 1200 N F i = FP 0 m/min
Standstill without machining 20 % 0N 0 m/min
Figure 8-35: Percentage of the individual machining processes and/or
movements
EDi
FEFF = ∑ (F 2
⋅
EDi
) v avg = ∑ ( v avgi ⋅ )
i
100 100
FEFF = 3141 N v avg = 54 m / min
Drive selection
The determined data can be used for selecting a motor - controller
combination. The primary part with thermal encapsulation is selected for
machine tool applications.
Primary part: LSP120U-RU2-BN

Fmax: 7800 N FdN: 3350 N
vFmax 750V:140 m/min vNENN 750V: 290 m/min
Secondary part 2 x LSS120-B1-0750A
segments: Total travel + primary part length
≈ 1500 mm
Drive controller: HDS03.2-W100N
Power supply module: HVR ( UDC=750V, with feedback capability)
Linear scale Heidenhain LC481
encapsulated, absolute, ENDAT interface
Determining the cooling capacity
2
F 
Electrical continuous power loss Pco = Pce =  eff  ⋅ Pvn
 Fdn 
2
 3141 N 
Pco =   ⋅ 3050 W
 3350 N 
Pco = 2682 W
Required coolant flow The maximum temperature rise at the contact surface of the primary part
should not exceed 3 K. The necessary coolant flow in l/min is determined
according to Figure 9-35:
Pco ⋅ 25200
Q=
c ⋅ ρ ⋅ ∆Tm
2682 W ⋅ 25200
Q=
J kg
4183 ⋅ 988,3 3 ⋅ 3 K
kg ⋅ K m
l
Q = 5.45
min
Note: The way of determining the drive power and other more
detailed data are not discussed within the scope of this
example.
Synchronous Linear Motors LSF Configuration and Construction Instructions 9-1
9 Configuration and Construction Instructions
9.1 Requirements on the Machine Design

Derived from design and properties of linear direct drives, the machine
design must meet various requirements. For example, the moved masses
should be minimized whilst the rigidity is kept at a high level.
Mass reduction
To ensure a high acceleration capability, the mass of the moved machine
elements must be reduced to a minimum. This can be done by using
materials of a low specific weight (e.g. aluminum or compound materials)
and by design measures (e.g. skeleton structures).
If there are no requirements for extreme acceleration, masses up to
several tons can be moved without any problems. There is no control-
engineering correlation between the moved slide mass and the motor’s
mass, as this is the case with rotary drives.
Mechanical rigidity
In conjunction with the mass and the resulting resonant frequency, the
rigidity of the individual mechanical components within a machine chiefly
determines the quality a machine can reach. The rigidity of a motion axis
is determined by the overall mechanical structure. The goal of the
construction must be to obtain an axis structure that is as compact as
possible.
Natural frequencies The increased loop bandwidth of linear direct drives requires higher
mechanical natural frequencies of the machine structure in order to avoid
the excitation of vibrations.
To ensure an adequate control quality, the lowest natural frequency that
occurs inside the axis should not be less than approximately 200 Hz. The
natural frequencies of axes with masses that are not constantly moving
(e.g. due to workpieces that must be machined differently) change, so
that the natural frequency is reduced with f = 1 / m as the mass
increases.
Mechanically linked axes The elasticity’s of the axes (both, the mechanical and the control-
engineering component) add up. This must be taken into account with
respect to the rigidity of cinematically coupled axes.
If several axes must cinematically be coupled in order to produce path
motions (e.g. cross-table or gantry structure), the mutual effects of the
individual axes on each other should be minimized. Thus, cinematic
chains should be avoided in machines with several axes. Axis
configurations with long projections that change during operation are
particularly critical.
9-2 Configuration and Construction Instructions Synchronous Linear Motors LSF
Reactive forces Initiated by acceleration, deceleration or process forces of the moved

axis, reactive forces can deform the stationary machine base or cause it
to vibrate.
Ds m
STEIFIGKEIT01-LSF-EN.FH7
Figure 9-1: Deformation of the machine base caused by the reactive force during
the acceleration process
m ⋅ a 500kg ⋅ 10m / s 2
∆s = = = 5µm
C base 1000N / µm
∆s: Deformation of displacement of the machine base in µm
m: Mass in kg
a: Acceleration in m/s²
c: Rigidity of the machine base in N/µm
Figure 9-2: Typical calculation of the machine base deformation
Integrating the linear scale The rigidity of the length measuring system integration is particularly
important. Please refer to Chapter 9.12 L for explanations.
Load rigidity Chapter 10.5 Load Rigidity explains the static and dynamic load rigidity of
linear direct drives.
9.2 Arrangement of Motor Components
Single arrangement
The single arrangement of the primary part is the most common
arrangement.
Figure 9-3: Single arrangement of primary parts
The independent operation of two or more primary parts on a secondary

part is possible too (Figure 9-3 right-hand side). In such an arrangement,
the length measuring system can also be equipped with two or more
scanning heads.
Note: Due to the higher sealing lip friction, the number of scanning
heads in encapsulated linear scales is usually limited to two.
Please contact the scale manufacturer for details.
controller drive controller
linear scale
primary part secondary part
3~ EINZELANORDNUNG01-LSF-EN.FH7
Figure 9-4: Controlling a linear motor with single arrangement of the motor
components
Several motors per axis

The arrangement of several motors per axis provides the following
benefits:
• Multiplied feed forces
• With corresponding arrangement, compensation of the attractive
forces "outwards"
Figure 9-5: Arrangement of several motors per axis
Depending on the application, the motors can be controlled in two

different ways:
• Two motors at one drive controller and one linear scale (parallel
arrangement)
• Two motors at two drive controllers and two linear scales (Gantry
arrangement)
Parallel arrangement
The arrangement of two or more primary parts on one drive controller in
conjunction with a linear scale is known as parallel arrangement. Parallel
arrangement is possible if the coupling between the two motors can be
very rigid.
controller drive controller
primary part second. part
mechanically 1 linear scale

rigid coupling
3~
PARALLELANORDNUNG01-LSF-EN.FH7
Figure 9-6: Parallel arrangement of two primary parts on one drive controller in
conjunction with a length measuring system
To ensure successful operation, the axis must fulfill the following

requirements in parallel arrangement:
• Identical primary and secondary parts

• Very rigid coupling of the motors within the axis
• Position offset between the primary parts < 1 mm in feed direction
• Position offset between the secondary parts < 1 mm in feed direction
• Same pole sequence of the secondary parts
• If possible, load stationary and arranged symmetrically with respect to
the motors
position offset between position offset between

the primary parts: the secondary parts
< 1 mm < 1 mm
S primary part 1 second. part N
same pole identification of

power connection the secondary parts at each
in the same direction side (same pole sequence)
S primary part 2 second. part N
PARALLELANORDNUNG02-LSF-DE.FH7
Figure 9-7: Alignment of motor components in parallel arrangement
Note: The mounting holes of the primary parts are used for defining
the correct position of the paralleled motors. In the grid, you
must always use the same hole in either primary part (see
Figure 9-7). An offset of the hole grid between the primary
parts is only permitted in the structures shown in Figure 9-9 or
Figure 9-12.
The face ends of the primary parts may alternatively be used if the
mounting holes cannot be employed as position reference. The motor
parts have the corresponding tolerances.
Parallel arrangement: Double comb arrangement

In a parallel arrangement - also within a Gantry arrangement - the primary
parts in feed direction can mechanically be coupled and be arranged in
the form of a "double comb arrangement" (see Figure 9-5, right-hand
side). In addition to the force multiplication, the attractive forces between
primary and secondary part are compensated towards the outside. With
the corresponding arrangement, the linear guides are not stressed
additionally, and may even be sized smaller.
Note: Double comb arrangement (to Figure 9-5 right-hand side)

does not require a minimum distance to be kept between the
two secondary part mounting surfaces.
Parallel arrangement: Arrangement of primary parts in

succession
In a parallel arrangement - also within a Gantry arrangement - the primary
parts in feed direction can mechanically be coupled and be arranged in
succession (see Figure 9-5 center).
To ensure successful operation, the primary parts must be arranged in a
specific grid. The determination of the grid sizes that must be adhered to
depends on the direction of the cable entry.
Cable entry in the same direction If the primary parts are arranged behind each other with the cable entries
in the same direction (see Figure 9-8), an integer multiple of twice the
electrical pole pitch must be adhered to:
Dxp
S primary part 1 second. part primary part 2 N
PARALLELANORDNUNG03-LSF-EN.FH7
xpmin
Dxp
Figure 9-8: Arrangement of the primary parts behind each other and cable entry
in the same direction
Note: When you determine the correct primary part distance with
cable entries in the same direction according to Figure 9-8,
you must always use the same reference point for both
primary parts (e.g. the same mounting hole (Figure 9-8).
∆x P = n ⋅ 2 ⋅ τ p
∆xP: Required grid spacing between the primary parts in mm
τP: Electrical pole pitch of LSF motors in mm (all sizes: 37.5 mm)
n: Integer factor (depends on mounting distance)
Figure 9-9: Determining the grid distance between the primary parts with cable
entries in the same direction
Minimum distances between According to Figure 9-9 and depending on the size, the following
primary parts minimum distances between the primary parts result at a motor
arrangement with the cable entries in the same direction:
Motor version Overall length Xpmin in mm
Standard encapsulation
K, L,M, N 55 mm + n ⋅ 2 ⋅ τ p
sizes 080, 120, 160, 200, 240
K 28 mm + n ⋅ 2 ⋅ τ p
size 040
L, N 33 mm + n ⋅ 2 ⋅ τ p
size 140
Thermal encapsulation
S, T, U, V 60 mm + n ⋅ 2 ⋅ τ p
sizes 080, 120, 160, 200, 240
Figure 9-10: Distance xpmin to be kept between the two primary parts with cable
entries in the same direction
Cable entries in opposite If the primary parts are arranged behind each other and with cable entries
directions in opposite directions to Figure 9-11, a defined distance must be kept
between the primary parts (as defined in Figure 9-12):
S primary part 1 second. part primary part 2 N
xpmin PARALLELANORDNUNG04-LSF-EN.FH7
Figure 9-11: Arrangement of primary parts behind each other with cable entries
in opposite directions
Note: When you determine the correct primary part distance with
cable entries in opposite directions according to Figure 9-11,
you can only use the distance between the primary part end
faces xpmin as reference point (Figure 9-11).
∆x P = n ⋅ 2 ⋅ τp + x p min
∆xP: Required grid spacing between the primary parts in mm
τP: Electrical pole pitch of LSF motors in mm (all sizes: 37.5 mm)
n: Integer factor (depends on mounting distance)
Figure 9-12: Determining the grid distance between primary parts with cable
entries in opposite directions
Minimum distances between the For a motor arrangement with cable entries at opposite directions, the
primary parts following size-related minimum distances between primary parts result
from Figure 9-12:
Motor version Overall Xpmin in mm

length
K, L,M, N 70 mm + n ⋅ 2 ⋅ τ p
sizes 080, 120, 140, 160, 200, 240
Standard encapsulation in preparation

K
size 040
Thermal encapsulation
S, T, U, V 0 mm + n ⋅ 2 ⋅ τ p
sizes 080, 120, 160, 200, 240
Figure 9-13: Distance xpmin to be kept between two primary parts with cable
entries in the opposite directions
Note: With motor version "thermal encapsulation" and an

arrangement according to Figure 9-11, the primary parts can
be arranged without any distance between the primary parts
(xpmin= 0 mm).
Power cable connection If primary parts with cable entries in opposite direction are arranged in
parallel, the connection of the power cores of the connecting cable at the
drive controller depends on the cable entry.
Connection for arrangement according to Figure 9-8

cable entry in the same direction
Drive controller X5 1 2 3
Primary part 1 1 2 3
cable entries in opposite directions
Figure 9-14: Connection of the cable cores for the parallel arrangement of
primary parts on a drive controller
Note: Please refer to Chapter 13 Electrical Connection for details

about the electrical connection.
Note: The primary part according to Figure 9-11 is always the

reference motor that is used for determining the sensor
polarity and for commutation setting. See also Chapter 14
Commissioning. Ensure that the secondary part is correctly
aligned.
Gantry arrangement
Operation with two linear scales and drive controllers (Gantry
arrangement) should be planned if there are load conditions that are
different with respect to place and time, and sufficient rigidity between the
motors cannot be ensured. This is frequently the case with axis in a
Gantry structure, for example.
Note: Paralleled motors may also be used within a Gantry

arrangement.
controller 2 drive controllers
length measuring system
no mechanically
rigid coupling

3~
GANTRYANORDNUNG01-LSF-EN.FH7
Figure 9-15: Gantry arrangement
With Gantry arrangements is must be remembered that the motors may

be stressed unsymmetrically, although the position offset is minimized.
As a consequence, this permanently existing base load may lead to a
generally higher stress than in a single arrangement. This must be taken
into account when the drive is selected.
Note: The asymmetric stress can be reduced to a minimum by

exactly aligning the length measuring systems and the primary
and secondary parts to each other, and by a drive-internal axis
error compensation.
Vertical axes
Holding brake When linear motors are used in vertical axes, it must be taken into
account that the motor is not self-locking when power is switched off.
Lowering the axis can only be secured by an appropriate holding brake
(see also Chapter 9.14 Braking Systems and Holding Devices).
Weight compensation An additionally used weight compensation ensures that the motor is not
exposed to an unnecessary thermal stress that is caused by the holding
forces and that the acceleration capability of the axis is independent of the
motion direction. The weight compensation can be pneumatic or
hydraulic.
Weight compensation with a counterweight is not suitable since the
counterweight must also be accelerated.
Note: Suitable holding devices must be used for preventing the axis
from sinking after the power has been switched off. These
holding devices can be actuated electrically, pneumatically, or
hydraulically.
Note: Adequate holding devices are integrated in most of today’s

weight compensation systems.
9.3 Feed and Attractive Forces
Attractive forces between primary and secondary part

When it is installed, a synchronous linear motor has a permanently
effective attractive force between primary and secondary part, that results
from its principle. With synchronous linear motors, this attractive force
also exists when the motor is switched off.
primary part
F attractive force
secondary part
ANZKRAFT01-LSF-EN.FH7
Figure 9-16: Attractive force between primary and secondary part
Considering the attractive force These attractive forces must always be taken into account in the
in motor installation mechanical design of the system.
Depending on the motor arrangement, the attractive forces must be
accommodated by linear guides and the slide and machine structure.
With an unfavorable arrangement of the motors, the attractive forces can
cause deformations (deflection) in the machine structure and
unacceptable transverse stress on the linear guides. The following points
should therefore be taken into account during the design integration of the
motors:
• Arrange the linear guides as close to the motor as possible.
• To compensate the attractive forces, you can use the parallel
arrangement shown at the right-hand side in Figure 9-5.
Note: When installed, the attractive force must not reduce the air
gap between primary and secondary part. The mechanical
design must provide sufficient rigidity.
Note: The attractive forces at the nominal air gap are specified in
Chapter 5, Specifications.
Air-gap-related attractive forces between primary and secondary part

The attractive force rises as the distance between primary and secondary
part is reduced.
When the primary part is lowered onto the secondary part, the attractive
forces rise as the air gap decreases.
The curve in the following diagram shows the attractive force as a

function of the air gap.
160%
norminal air gap

140%
attractire force rel. To norminal air gap
120%
100%
80%
60%
40%
20%
0%
0 mm 5 mm 10 mm 15 mm 20 mm 25 mm 30 mm
measurable air gap ANZIEHUNGSKRAFT LSF.XLS
Figure 9-17: Attractive force vs. distance between primary and secondary part
Note: The attractive forces at the nominal air gap are specified in
Chapter 5, Specifications.
Air-gap-related feed force
Air gap tolerances The feed forces detailed in the specifications are related to the specified
rated air gap. The tolerances permissible for the measurable air gap have
a slight effect on the feed forces that can be achieved. The following
diagram shows this relationship:
103%
102%
feed force rel. to nominal air gap
101%
100%
99%
98%
nominal air gap
97%
1,1 mm 1,2 mm 1,3 mm 1,4 mm 1,5 mm 1,6 mm 1,7 mm
measurable air gap LUFTSPALTABHÄNGIGE VORSCHUBKRAFT LSF.XLS
Figure 9-18: Feed force within the air gap tolerance of LSF synchronous linear
motors
Note: Sizes in Figure 9-18 are only valid for LSF synchronous linear
motors; there is no general correlation for other motor types.
Reduced overlapping of primary and secondary part

When moving in the end position range of an axis it can be necessary that
the primary part moves beyond the end of the secondary part. This results
in a partial coverage between primary and secondary part.
primary part
secondary part
s
PRIMPARTOVSEC-LSF-EN.FH7
Figure 9-19: Partial overlapping of primary and secondary part
Feed and attractive forces are reduced if primary and secondary part
overlap each other only partially.
Inception of the force reduction The force reduction does not start immediately. It differs according to the
encapsulation types of the primary parts:
Standard encapsulation: sR = 22.5 mm

Thermal encapsulation: sR = 20.0 mm
The force reduction in the beginning and end areas of the primary part is
the same for all sizes of a given encapsulation type. Outside the
beginning and end areas, the force is reduced linearly as a function of the
reduced coverage area.
The following diagram illustrates the correlation between the coverage
between primary and secondary part and the resulting force reduction.
100 %
90 %
sR
standard encapsulation: sR = 22.5 mm
feed and attractive force as a function
80 % thermal encapsulation: sR = 20 mm
of the coverage factor between
primary and secondary part
70 %
60 %
50 %
40 %
30 %
20 %
10 %
sR
0%
overall length of the primary part PRIMPARTOVSEC02-LSF-EN.FH7
Figure 9-20: Force reduction with partial coverage of primary and secondary part
The partial coverage of primary and secondary part must not be used in
continuous operation since there is an increased current consumption of
the motor. Instabilities in the control loop can be expected from a certain
reduction of the degree of coverage onwards.
Malfunctions and uncontrolled motor

movements due to partial coverage of primary
and secondary part.
WARNING ⇒ Partial coverage of primary and secondary part only
when moving to the end position during a drive error
⇒ Minimum coverage factor 75 %
9.4 Motor Cooling
Thermal behavior of linear motors

Power loss The rated feed force of a synchronous linear motor that can be achieved
is mainly determined by the power loss PV that is produced during the
energy conversion process. The power loss fully dissipates in the form of
heat. Due to the limited permissible winding temperature it must not
exceed a specific value.
Note: The maximum winding temperature of LSF synchronous linear

motors is 155 °C. This corresponds to insulation class F.
Due to the low relative velocities between primary and secondary part, the
total losses of synchronous linear motors are chiefly determined by the
direct load loss of the primary part:
3 2
PV ≈ PVi = ⋅ i ⋅ R12 ⋅ fT
4
PV: Total loss in W
PVi: Direct load losses in W
i: Current in motor cable (peak value) in A
R12: Electrical resistance of the motor at 20°C in Ohms
(see Chapter 5 Specifications)
fT : Factor temperature-related resistance raise
Figure 9-21: Power loss of synchronous linear motors
Note: When you determine the power loss according to Figure 9-

21,you must take the temperature-related rise of the electrical
resistance into account. At a temperature rise of 15 K (from
20°C to 135°C), for example, the electrical resistance goes up
by the factor fT = 1.45.
Thermal time constant The temperature variation vs. the time is determined by the produced
power loss and the heat-dissipation and -storage capability of the motor.
The heat-dissipation and -storage capability of an electrical machine is
(combined in one variable) specified as the thermal time constant.
Note: With liquid cooling systems, the thermal time constant of an

LSF synchronous linear motor is between 5 and 10 minutes
(depending on size).
Figure 9-22 following shows a typical heating and cooling process of an

electrical machine. The thermal time constant is the period within which
63% of the final over temperature is reached. With liquid cooling, the
cooling time constant corresponds to the heating time constant. Thus, the
heating process and the cooling process can both be specified with the
specified thermal time constant (heating time constant) of the motor.
In conjunction with the duty cycle, the correlation to Figure 9-23 and
Figure 9-25 are used for defining the duty type, i.e. according to
DIN VDE 0530.
heating up with initial overtemperature > 0
Overtemperature final overtemperture
heating up with final

63 % overtemperature = 0
cooling
tth
Time E R WAE R MUNG L S F .XL S
Figure 9-22: Heating up and cooling down of an electrical machine
Heating up
 −
t
 −
t

ϑ( t ) = ϑe ⋅ 1 − e t th 
+ ϑa ⋅ e t th
 
 
ϑe: Final overtemperature in K
ϑa: Initial overtemperature in K
t: Time in min
tth: Thermal time constant in min (see Chapter 5 Specifications)
Figure 9-23: Heating up (overtemperature) of an electrical machine compared
with coolant
Final overtemperature Since the final overtemperature is proportional to the power loss, the
expected final overtemperature ϑe can be estimated according to Figure
9-24:
2
Pce F
ϑe = ⋅ ϑe max = eff 2 ⋅ ϑe max
PvN FdN
Pce: Permanent power loss or average power loss vs. duty cycle time in W
(see Chapter 8.4 Determining the Drive Power, Figure 8-20)
PVN: Nominal power loss of the motor in W
ϑemax: Maximum final overtemperature of the motor in K
Feff: Effective force in N (from application)
Figure 9-24: Expected final overtemperature of the motor
Cooling t
−
ϑ( t ) = ϑe ⋅ e t th
ϑe: Final overtemperature or shutdown temperature in K

t: Time in min
Figure 9-25: Cooling down of an electrical machine
Cooling concept of LSF synchronous linear motors

The request for highest feed forces and minimum installation volume
usually requires linear motors to be equipped with a liquid cooling. The
liquid cooling ensures:
• that the power loss is removed and, consequently, rated feed forces
are maintained;
• that a certain temperature level is maintained at the machine.
The cooling and encapsulation concept of LSF synchronous linear motor

includes two different solutions:
Standard encapsulation The primary parts of the standard encapsulation version are mainly used
in the field of general automation. The liquid cooling system of this motor
type is merely used for removing the power loss and/or for maintaining
the specified rated feed force. It does not provide any additional thermal
decoupling between machine and motor. The maximum temperature of
the contact surface can locally rise up to 60°C. These maximum
temperature gradients can occur independently of the coolant inlet
temperature.
Thermal encapsulation For an optimum thermal decoupling between the motor and the machine
structure, the primary parts of the thermal encapsulation version have an
additional liquid cooling system at the back of the motor and at
longitudinal and front ends. The constant temperature that can easily be
attained and the minimum heat transfer into the machine make the
primary parts of the thermal encapsulation version particularly suitable for
the utilization in machine tools and in other precision applications. Inside
the motor there is already an optimum connection between the internal
cooling circulation used for removing the power loss and the cooling ducts
of the thermal encapsulation. Thus, this motor version too possesses only
two coolant connections.
Not the entire surface of the primary part is connected with the mounting
surface at the machine side. It merely rests on elevated seating ledges.
This provides an additional thermal decoupling and, consequently, further
minimization of the possible heat transfer into the machine (see Figure 9-
26).
Note: Using the thermal encapsulation does not provide any

improved performance data (for the continuous feed force, for
example). The power ratings are identical for both versions.
temperature rise of the attachment surface A

against the coolant inlet temperature
2K A
machine structure
A
air gap (0.5mm)

(additional thermal
decoupling)
seating ledges
Pv
thermal isolation
(not a part of the
secondary part)
machine structure
cooling at machine side (option)

THERMOKAPSELUNG02-LSF-EN.FH7
Figure 9-26: Cooling concept for thermal encapsulation
Secondary parts The secondary version is identical for both primary part versions. The
secondary part does not develop any power loss. With inadvertent
conditions (extended standstill or slow velocity of the primary part together
with a simultaneously acting high continuous force), there can be a heat
transfer by the primary part due to radiation or convection.
Note: The secondary part does not develop any power loss. The
maximum heat infiltration possible of the primary part at
standstill and continuous nominal force is approximately 3 %
of the motor’s nominal power loss.
The heat transfer depends on the ambient temperature and on the

installation conditions in the machine.
To maintain a constant temperature level in the machine, cooling can be
done at the machine side (via two cooling pipes and/or thermal isolators,
for example). See Figure 9-26).
Coolant
The specified motor data and the characteristics of the motor cooling
system /(e.g. continuous feed forces, pressure losses, and flow
characteristics), and all the other specifications in this Chapter are related
to liquid cooling with coolant water. Most cooling devices use water too.
The following coolants can be used:
• Water
• Oil
• Air
Note: The specified motor data and the characteristics of the motor
cooling system /(e.g. continuous feed forces, pressure losses,
and flow characteristics), and all the other specifications in this
Chapter are related to liquid cooling with coolant water.
This data is no longer valid and must again be calculated or determined

empirically if coolants with different material characteristics are used.
An impairment of the thermal decoupling may also have to be taken into
account, if necessary.
The required coolant flow for different coolants can be determined using
Figure 9-32 and Figure 9-33.
Impairing the cooling effect or damaging the

cooling system.
⇒ Adjust coolant and flow to the required motor
WARNING performance data
⇒ With coolant water use anticorrosion agent and
observe the specified mixture
⇒ Only use approved anticorrosion agents
⇒ Do not use cooling lubricants from machining
process
⇒ Filter the coolant
⇒ Do not use flowing water
⇒ Use a closed cooling circuit
⇒ Adhere to the specified inlet temperatures
⇒ Do not exceed the maximum pressure
⇒ Motor operation not without liquid cooling
Coolant additives
Corrosion protection and chemical stabilization requires a suitable
additive to be added to the cooling water. The corrosion protection agent
must be suitable for a mixed installation (steel/iron, aluminum, copper,
and brass). The required mix (according to the manufacturer’s
specifications) must be adhered to and/or verified. Larger differences can
lead to changes in the stability of the emulsion, the behavior towards
sealant, and the corrosion protection capability.
Watery solutions Watery solutions ensure a reliable corrosion protection without any
significant changes of the physical properties of the water. According to
the water endangering classes, the recommended additives do not
contain any water-endangering substances.
Emulsion with corrosion Corrosion protective oils for coolant circuits contain emulsifiers that
protection oil provide for a fine distribution of the oil in the water. The oily components
of the emulsion protect the metallic surfaces of the coolant channels
against corrosion and cavitation. An oil contents between 0.5 and 2 per
cent per volume is a well-proven mix. An oil contents of approximately 5
per cent per volume is necessary if the corrosion protective oil is
supposed to lubricate coolant pump in addition to the corrosion protection
(observe the requirements of the pump manufacturers)
Designation Manufacturer
1%...3% solutions
Aquaplus 22 Petrofer, Hildesheim
Varidos 1+1 Schilling Chemie, Freiburg
33% solutions
Glycoshell Deutsche Shell Chemie GmbH, Eschborn
Tyfocor L Tyforop Chemie GmbH, Hamburg
OZO Frostschutz Deutsche Total GmbH, Düsseldorf
Aral Kühler-Frostschutz A ARAL AG, Bochum
BP antifrost X 2270 A Deutsche BP AG, Hamburg
Emulgierbares Mineralölkonzentrat
Shell Donax CC (WGK: 3) Shell, Hamburg
Figure 9-27: Recommended coolant additives
Coolant temperature
Temperature range The permissible temperature range of the coolant is 15...40°C. The
coolant temperature must never be outside this range. A higher
temperature will lead to a stronger reduction of the continuous feed force.
A lower temperature may lead to a destruction of the motor (due to high
temperature gradients).
Reduction of the continuous feed force or

destruction of the motor.
⇒ Keep coolant with in permissible temperature range.
WARNING
Condensation All the motor components of the LSF synchronous linear motors are of
protection rating IP65. Thus, their design protects them against
condensation.
Continuous feed force vs. The specification of the rated feed force in the technical motor
coolant temperature specifications is related to a coolant inlet temperature of 30°C.
If the inlet temperature is different, there is a minor change of the
continuous feed force according to Figure 9-28:
105%
Confinuous feed force
100%
95%
15 °C 20 °C 25 °C 30 °C 35 °C 40 °C
Cooling water inlet temperature KMTEMPERATUR LSF.XLS
Figure 9-28: Continuous feed force vs. coolant inlet temperature
Maximum pressure
With all motor versions, the maximum system pressure via the internal
system circulation of the motor is 30 bar.
Operation of LSF synchronous linear motors without

liquid cooling
In certain exceptions it can be necessary or possible, to do without a
liquid cooling. Depending on the size, this results in a reduction of the
continuous nominal force to approximately 20 ... 25%. It does not reduce
the maximum force of the motors.
Depending on the load, the temperature at the contact surface of the
primary part may rise up to 140°C.
Drastic reduction of the rated feed force and

significant heating and stress of the machine
structure if synchronous linear motors are used
WARNING without liquid cooling.
⇒ Provide liquid cooling
⇒ The reduction of the rated force and the heating of
the machine structure (stress due to expansion)
must be included in the sizing and design of axes
that are used without liquid cooling.
Sizing the cooling circuit
Pv
Q
T1, p1 T2, p2
KUEHLUNG01-LSF-EN.FH7
Q: Flow quantity
T1: Coolant inlet temperature
T2: Coolant outlet temperature
p 1: Inlet pressure
p 2: Outlet pressure
Figure 9-29: Liquid-cooled component
Coolant temperature rise

∆T = T2 − T1
T1: Coolant inlet temperature in K
T2: Coolant outlet temperature in K
∆T: Coolant temperature rise in K
Figure 9-30: Coolant temperature rise in K
Pressure drop
∆p = p1 − p 2
p 1: Inlet pressure
p 2: Outlet pressure
∆p: Pressure drop
Figure 9-31: Pressure drop across traversed component
Design criteria Related to the motor, two basic application-related requirements must be
distinguished when the cooling circuit of LSF synchronous linear motors is
sized.
1. Liquid cooling is only used for removing the power loss and thus for
maintaining the specified rated forces (e.g. for the standard
encapsulation motor version).
2. At the same time, liquid cooling shall ensure a defined temperature

level at the contact surface (e.g. for the thermal encapsulation motor
version).
Flow quantity
Coolant flow to maintain the The coolant flow required to maintain the rated feed force is defined in
rated feed force Chapter 5 Specifications.
The specification of this value is based on a rise of the coolant
temperature by 10 K.
Figure 9-32 and Figure 9-33 are used to determine the necessary coolant
flow at different temperature rises and / or different coolants:
Pco ⋅ 60000
Q=
c ⋅ ρ ⋅ ∆T
Q: Rated coolant flow in l/min
Pro: Power loss to be removed in W
c: Specific heat capacity of the coolant in J / kg ⋅ K
ρ: Density of the coolant in kg/m³
∆T: Coolant temperature rise in K
Figure 9-32: Coolant flow required for removing a given power loss
Coolant Specific heat capacity c Density ρ in kg/m³

in J / kg ⋅ K
Water 4183 998.3
Thermal oil
1000 887
(example)
Air 1007 1.188
Figure 9-33: Substance values of different coolants at 20°C
Reducing the rated feed force To estimate the reduction of the rated feed force when you employ a
with coolants different than coolant that is different than water at the same flow quantity, use Figure
water and identical flow quantity 9-34.
c x ⋅ ρx
k cred = ⋅ 100%
c w ⋅ ρw
kcred: Reduction factor "rated feed force" related to water in per cent
cw: Specific heat capacity of water in J / kg ⋅ K
ρw: Density of water in kg/m³
cx: Specific heat capacity of the employed coolant in J / kg ⋅ K
ρx: Density of employed coolant in kg/m³
Figure 9-34: Reduced rated feed force when a coolant different than water is
used at the same flow quantity
Maintaining a constant If you want to ensure a defined temperature level at the contact surface of
temperature level at thermal the primary part of the thermal encapsulation motor version, you must use
encapsulation the formula in Figure 9-35 to determine the coolant flow that is necessary
for maintaining a maximum coolant temperature rise. It is taken into
account, that only a part of the power loss remains to be removed via the
thermal encapsulation. ∆Tm is the temperature at the contact surface of
the primary part.
Note: A defined temperature level at the contact surface can only be

maintained with the thermal encapsulation motor version.
Pco ⋅ 25200
Q=
c ⋅ ρ ⋅ ∆Tm
Q: Required coolant flow in l/min
Pco: Power loss to be removed in W
c: Specific heat capacity of the coolant in J / kg ⋅ K
ρ: Density of the coolant in kg/m³
∆Tm: Contact surface temperature rise in K
Figure 9-35: Coolant flow required for maintaining a constant temperature level at
the motor contact surface in the case of thermal encapsulation
Prerequisite: Q ≥ Qmin (see Chapter 5 Specifications)
Pressure drop
The flow resistance at the pipe walls, curves, and changes of the cross-
section produces a pressure drop along the traversed components
(Figure 9-29).
The pressure drop ∆p rises as the flow quantity rises (Figure 9-36).
pressure drop Dp
flow quantity Q KUEHLUNG02-LSF-EN.FH7
Figure 9-36: Pressure drop vs. flow quantity; general representation
Pressure drop across the motor On the basis of the constant for determining the pressure drop kdp, that is
cooling system explained in Chapter 5 Specifications, the pressure drop across the
internal motor cooling circuit can be determined as follows:
∆p m = k dp ⋅ Q1.75
∆pm: Pressure drop across the internal motor cooling circuit in bar
Q: Flow quantity in l/min
kdp: Constant for determining the pressure drop (see Chapter 5
Specifications)
Figure 9-37: Determining the pressure drop vs. the flow quantity
Note: The constant for determining the pressure drop kdp combines
interrelations of the cooling circuits of the individual motor
types and the coolant. It is only valid for the coolant water.
Overall pressure drop The pressure drop across the overall system is determined by the sum of
a series of partial pressure drops (Figure 9-38). Usually, the pressure
drop across the internal motor cooling system is relatively small.
heat removal device Dpp Dpa

Q
coolant connections
lines
Dpw
upstream
coolant
heat heat
transfer heat exchanger motor Dpm transfer
coolant
pump
Dpp
container
Figure 9-38: Block diagram of a liquid-cooled motor with heat removal facility
Note: The overall pressure drop of the cooling system is determined

by various partial pressure drops (motor, feeders, connectors,
etc.). This must be taken into account when the cooling circuit
is sized.
Note: With all motor versions, the maximum system pressure via the
internal system circulation of the motor is 30 bar.
Cooling capacity
The specifications that are needed for determining the cooling capacity
which is required for a synchronous linear motor can be found in Chapter
8.4 Determining the Drive Power.
Liquid cooling system

Machines and systems can require liquid cooling for one or more working
components. If several liquid-cooled drive components exist, they are
connected to the heat removal device via a distribution unit.
heat removal device

heat motor
output
coolant lines
motor 1
upstream
coolant
motor 2
heat removal device
main distributor
motor 3
heat
output motor 4
control cabinet air
cooler
control
cabinet
coolant temperature
controller
distributor
Figure 9-39: Block diagram of cooling systems with one and more drive
components
Heat removal device The heat removal device carries off the total heat that was fed into the
liquid into a higher-level coolant. It provides a temperature-controlled
coolant and thus maintains a required temperature level at the
components that are to be cooled.
There are three different types of heat removal devices (Figure 9-40).
They are identified by the type of the heat exchanger between the
different media:
1. Air-to-liquid cooling unit

2. Liquid-to-liquid cooling unit
3. Cooling unit
A heat removal device includes a heat exchanger, a coolant pump

container and a coolant container (Figure 9-38).
1 1
2 2
air-liquid cooling unit liquid-liquid cooling unit
1 coolant pump
5 6
2 coolant container
3 air-liquid heat exchanger

7
4 liquid-liquid heat exchanger
5 air-cooled condenser
1
2
6 compressor
7 vaporizer
cooling unit
Figure 9-40: Heat removal devices
Air-to-liquid cooling unit Liquid-to-liquid cooling Cooling unit

unit
Coolant temperature control
Low (±5 K) Low (±5 K) Good (±1 K)
accuracy
Upstream coolant circuit
No Yes No
required
Heating of ambient air Yes No Yes
Power loss recovery No Yes No
Size of the cooling unit Small Small Large
Dependent of ambient
Yes No No
temperature
Environment-damaging
No No Yes
coolant
Comments on utilization Particularly suitable for This cooler type is Particularly suitable for high
criteria stand-alone machines that particularly suitable for requirements on the thermal
do not have an upstream systems with existing stability (high-precision
coolant circuit available and central feedback cooler. applications, for example).
do not have to fulfill high It does not fulfill high
requirements on the stability requirements on the stability
of the coolant temperature. of the coolant temperature.
Figure 9-41: Overview of the heat removal devices according to utilization criteria
Coolant lines
The coolant lines are a major part of the cooling system. They have a
great influence on the system’s operational safety and pressure drop. The
lines can be made up as hoses or pipes.
Laying flexible coolant lines The coolant lines of linear motor drives with moved primary parts must be
within the energy chain laid within a flexible energy chain.
The continuous bending strain of the coolant lines must always be taken
into account when they are sized and selected.
Further optional components
• Distributions
• Coolant temperature controller
• Flow monitor
A message is output when the flow drops below a selectable minimum
flow quantity.
• Level monitor
Chiefly minimum-maximum level monitor to check the coolant level in
the coolant container.
• Overflow valve
• Safety valve
Opens a connection between the coolant inlet and the contained when
a certain pressure is reached.
• Coolant filter (100 µm)
• Coolant headings
To provide coolant of a correct temperature, in particular for coolant
temperature control
• Throttles and shut-off valves
Circuit types
The two possible ways of connecting hydraulic components
(series/parallel connection) show significant differences with respect to:
• Pressure drop of the entire cooling system
• Capacity of the coolant pump
• Temperature level and controllability of the individual components that
are to be cooled
Parallel connection
Q1 PV1 J1
Q2 PV2 J2
SQ SQ
J1 J
Q3 J3
PV3
Dp
Figure 9-42: Parallel connection of liquid-cooled drive components
The parallel connection is characterized by nodes in the hydraulic system.

The sum of the coolant streams flowing into a node is equal to the sum of
the coolant streams flowing out of this node. Between two nodes, the
pressure difference (pressure drop) is the same for all intermediate
cooling system branches.
Q = Q1 + Q 2 ... + Qn
∆p = ∆p1 = ∆p 2 = ∆p n
∆p: Pressure drop
Q: Flow quantity
Figure 9-43: Pressure drop and flow quantity in the parallel connection of
hydraulic components
When several working components are cooled, a parallel connection is

advantageous for the following reasons:
• The individual components that are to be cooled can be cooled at the
individually required flow quantity. This means a high thermal
operational reliability.
• Same temperature level at the coolant entry of all components (equal
machine heating)
• Same pressure difference between coolant entry and outlet of all
components (no high overall pressure required).
Series connection
J < J1 < J2 < J 3
Q, J PV1 J1 PV2 J2 PV3 J3
Dp1, DJ1 Dp2, DJ2 Dp3, DJ3
Dp
Figure 9-44: Series connection of liquid-cooled drive components
In series connection, the same coolant stream flows through all

components that are to be cooled. Each component has a pressure drop
between coolant inlet and coolant outlet. The individual pressure drops
add up to the overall pressure drop of the drive components.
Series connection does not permit any individual selection of the flow
quantity required for the individual components to be made. It is only
expedient if the individual components that are to be cooled need
approximately the same flow quantity and bring about only a small
pressure drop or if they are installed very far away from the heat removal
device.
Q = Q1 = Q 2 = Qn
∆p = ∆p1 + ∆p 2 ... + ∆pn

∆p: Pressure drop
Q: Flow quantity
Figure 9-45: Pressure drop and flow quantity in the parallel connection of
hydraulic components
The following disadvantages of series connection must always be taken

into account:
• The required system pressure corresponds to the sum of all pressure
drops of the individual components. This means a reduced hydraulic
operational safety due to a high system pressure.
• The temperature level of the coolant rises from one component to the
next. Each power loss contribution to the coolant rises its temperature
(inhomogeneous machine heating)
• Some components may not be cooled as required since the flow
quantity cannot be selected individually.
Combination of series and Combining series and parallel connections of the drive components that
parallel connection are to be cooled permits the benefits of both connection types to be used.
Q1 J1
PV1
Q2 J2
SQ PV2 SQ
J0 J
Q3 PV3 J3
Q4
PV4 J4 PV5 J5 PV6 J6
Dp
Figure 9-46: Combination of series and parallel connection
9.5 Motor Temperature Monitoring Circuit

In their standard configuration, primary parts of LSF synchronous linear
motors are equipped with built-in motor protection temperature sensors.
Each motor phase contains one out of three ceramic PTC thermistors that
are connected in series. They ensure safe thermal monitoring of the
motor in all operating phases. These temperature sensors (in the text
below: motor protection temperature sensor) have a switching
characteristic (Figure 9-50). They are interpreted in all drive controllers
from Rexroth Indramat.
Furthermore, all primary parts are equipped with an additional
temperature sensor for external temperature measurement. This sensor
(in the text below: temperature measurement sensor) possesses a nearly
linear characteristic curve (Figure 9-51).
lead identification
PTC
8 (-)
KTY84-130
sensor external temperature measurement
J 7 (+) no connection to drive controller
PTC
6
PTC SNM.150.DK.***
motor protection temperatute sensor
J 5 connected to drive controller
M 2
3~ power connection
1
GNYE
TEMPSENS01-LSF-EN.FH7
Figure 9-47: Arrangement of temperature sensors of LSF synchronous linear

motors
Motor protection temperature

Type PTC SNM.150.DK.***
sensor
Rated response temperature ϑNAT 150 °C
Resistance at 25°C ≈ 100...250 ohms
Figure 9-48: Motor protection temperature sensor
Note: For the parallel arrangement of two or more primary parts, the
motor protection temperature sensors of all primary parts are
connected in series. Please refer to Chapter 13 Electrical
Connection for details.
Sensors for external Type KTY84-130

temperature measurement
Resistance at 25°C 577 ohms
Resistance at 100°C 1000 ohms
Continuous current at 100°C 2 mA
Figure 9-49: Temperature measurement sensor
Note: Ensure the correct polarity when the sensor is used externally
(Figure 9-47).
100000
Motor protection temperature sensors
connecting cores 5 and 6
norminal responce temperature 150°C
temperature sensor resistance in ohms
10000
1000 4 primary parts in series
2 primary parts in series
1 temperature sensor (1 primary part)
100
0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170
motor winding temperature in °C TEMPERATURSENSOREN LSF.XLS
Figure 9-50: Characteristic curve of the motor protection temperature sensors

(PTC)
1500
1400
temperature sensor resistance in ohms
1300
1200
1100
1000
900
800
temperature measuring sensor KTY84-130

700 connecting cores 7 (+) und 8 (-)
600
500
10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170
motor winding temperature in °C
Figure 9-51: Characteristic curve of the temperature measurement sensor

KTY84-130 (PTC)
A polynomial of degree 3 proves sufficient for describing the resistance

characteristic of the sensor used for temperature measurement (KTY84-
130). Below, this is specified for determining a temperature from a given
resistance, and vice versa.
Temperature vs. resistance

Tw = A ⋅ RKTY + B ⋅ RKTY + C ⋅ RKTY + D
3 2
Tw: Winding temperature of the motor in °C

RKTY: Resistance of the temperature sensor in ohms
-8
A: 3.039 ·10
-4
B: -1.44 ·10
C: 0.358
D: -143.78
Figure 9-52: Polynomial used for determining the temperature with a known
sensor resistance (KTY84)
Resistance vs. temperature

RKTY = A ⋅ Tw + B ⋅ Tw + C ⋅ Tw + D
3 2
Tw: Winding temperature of the motor in °C

RKTY: Resistance of the temperature sensor in ohms
-6
A: 1.065 ·10
B: 0.011
C: 3.93
D: 492.78
Figure 9-53: Polynomial used for determining the sensor resistance (KTY84) with
a known temperature
9.6 Installation Altitude and Ambient Conditions

Installation altitude and ambient The specified technical motor data is valid under the following conditions:
temperature
Ambient temperature: + 5 ... + 45° C

Installation altitude: up to 1000 m above sea level
Different conditions lead to a departing of the data according to the

following diagrams. If different ambient temperatures and higher
installation altitudes occur at the same time, both utilization factors must
be multiplied.
utilization capability vs. utilization capability

ambient temperature 1 vs. installation altitude
as 1000 m
1 0,8
utilization factor fH
utilizaion factor fT
0,8 0,6
0,6
40 45 50 55 0 1000 2000 3000
ambient temperature in °C installation altitude above
sea level in m
UMGEBHOE-LSF-EN.FH7
Figure 9-54: Utilization factor vs. ambient temperature and installation altitude
Note: When liquid cooling is defined, the specifications of the

utilization vs. installation altitude or ambient temperature are
related to the entire drive (that consists of motor, drive
controller and power supply), not just to the motor.
Ambient conditions All motor components are equipped with IP65 rating (see also Chapter
9.7 Protecting Rating). No additional protective measures are required
when the unit is used accorching to the appropriate use and the specified
class of protection.
Note: Synchronous linear motors cannot be used together with

aggressive substances, such as concentrated acids.
Note: It must be ensured that the secondary part is not located in the
immediate chip area of the machine. Suitable covers must be
provided.
Chip attraction Ferromagnetic chips are basically not attracted at a distance of

approximately 100 mm from the surface of the secondary part.
9.7 Class of protection

The design of the LSF synchronous linear motors corresponds to the
class of protection defined in DIN VDE 0470 Part 1 Issue 11/1992
(EN 60 529):
Motor components Class of protection

Standard encapsulation primary part
IP 65
Thermal encapsulation primary part
Secondary part segment
Figure 9-55: Class of protection of LSF synchronous linear motors
The class of protection rating is described by the letters IP (International

Protection) and two code numbers for the degree of protection.
The first figure describes the degree of protection against touch and the
penetration of foreign bodies. The second figure describes the degree of
protection against water.
First figure Degree of protection

Protection against the penetration of dust (dust-proof);
6
full touch guard
Second figure Degree of protection
Protection against a water jet from a nozzle that is
5 directed against the enclosure from any direction (jet
water).
Figure 9-56: IP class of protection
Note: The tests for the second figure are performed with fresh water.
A higher protection rating may be necessary if cleaning is
performed at a high pressure and/or if cleansers, solvents,
coolant lubricants etc. are used.
Personal injuries, damaging or destroying

motor components !
⇒ Use the LSF synchronous linear motors only in
WARNING environments for which the specified class of
protection proves sufficient.
9.8 Magnetic Fields

The secondary parts of synchronous linear motors that are equipped with
permanent magnets, are not provided with a magnetic screen.
To be able to assess EMC problems (e.g. the influence on inductive
switches or inductive measuring systems), chip attraction, and for human
protection, the values of the magnetic induction as a function of the
distance to the secondary part are specified below.
The representation distinguishes between ferromagnetic materials (e.g.
steel) and non-ferromagnetic materials (e.g. air), and between different
directions.
0,8 T
direction 1
0,7 T
0,6 T
0 0
induction B
0,5 T
0 direction 2
3
tion
0,4 T
1 c
dire
0,3 T
1: direction 1, ferromagnetic material
2 2: direction 1, non-ferromagnetic material
0,2 T 3: direction 2 and 3, areas of both materials
0,1 T
0,0 T
0 mm 10 mm 20 mm 30 mm 40 mm 50 mm 60 mm 70 mm 80 mm 90 mm
distance to secondary part INDUKTIONSVERTEILUNG LSS-en.XL
Figure 9-57: Magnetic induction in ferromagnetic and non-ferromagnetic

materials vs. the distance to the secondary part
Note: Secondary parts of synchronous linear motors generate a

static magnetic field.
Chip attraction Ferromagnetic chips are not attracted at a distance of approximately 100
mm from the surface of the secondary part.
Note: It must be ensured that the secondary part is not located in the
immediate chip area of the machine. Suitable covers must be
provided.
9.9 Vibration and Shock

According to IEC 721-3-3 Issue 1987 or EN 60721-3-3 Issue 06/1994,
LSF synchronous linear motors are approved for the utilization in areas
that are exposed to vibration and/or shock as given in Figure 9-58 and
Figure 9-59. LSF motors and may be used in stationary weather-proof
operation corresponding to Class 3M5:
Parameter Unit Maximum

value
Amplitude of deflection at 2 ... 9 Hz mm 0.3
Amplitude of acceleration at 9 ... 200 Hz m/s² 1
Figure 9-58: Limit data for sinusoidal vibrations
Parameter Unit Maximum

value
Total shock response spectrum Type II
(to IEC721-1 Issue 1990;
Table 1, Section 6)
Reference acceleration, m/s² 250
in IEC 721: peak acceleration
Duration ms 6
Figure 9-59: Limit data for shock
Motor damage and loss of warranty !

⇒ A motor that is used outside of specified operating
conditions can be damaged. Furthermore, any
warranty claim becomes void.
WARNING
⇒ It must be ensured that the limits shown in Figure 9-
58 and Figure 9-59 are not exceeded during storage,
transport and operation of the motors.
9.10 Enclosure Surface

The following table shows the condition of the enclosure surface when
delivered.
Motor component Layout of enclosure / enclosure Comments

surface
Varnish resistant to weather,
Stainless steel V4A
Primary part, standard encapsulation yellowing, chalking, thinned acids,
black priming (RAL 9005)
and thinned lyes
Aluminum, bright
Primary part, thermal encapsulation active side (towards the air gap):
V4A
Cover plate V4A
Secondary part segments
magnet base carrier C45, chromatic
Figure 9-60: Layout of enclosure surface
Note: The surface of motor components may be painted with

additional varnish.
9.11 Noise Emission

The noise emission of synchronous linear drives can be compared with
conventional inverter-operated feed drives.
Experience has shown that the noise generation chiefly depends on
• the employed linear guides (velocity-related travel noise),

• the mechanical design (following cover, etc.), and
• the settings of drive and controller (e.g. switching frequency).
A generally valid specification is therefore not possible.
9.12 Linear Scale

A linear scale is required for measuring the position and the velocity.
Particularly high requirements are placed upon the linear scale and its
mechanical connection.
Note: The linear scale is not a part of the delivery from Rexroth
Indramat. The machine manufacturer must provide and install
it (see also Figure 9-66)
measuring
model
principle
linear scale incremental,

ensapsulated
open systems integrated into incremental distance-encoded absolute
systems
linear guides reference marks
Figure 9-61: Classification of linear scales
Peculiarities of synchronous The principle of a synchronous linear motor requires that the position of
linear motors the primary part, with respect to the secondary part, be obtained
immediately after power-up and/or after a malfunction (pole position
recognition). Using an absolute linear scale is the optimum solution here.
Selection criteria for linear scales

Depending on the operating conditions, open or encapsulated linear
scales with different measuring principles and signal periods can be used.
The selection of a suitable linear scales mainly depends on:
• the maximum feed rate (model, signal period)

• the maximum travel (measuring length, model)
• if applicable, utilization of coolant lubricants (model)
• produced dirt, chips etc. (model)
• the accuracy requirements (signal period)
Models
Open model Encapsulated model Measuring system

integrated in rail guides
Benefits:
- High traverse rates - Easy installation - Combined guidance and

- No friction - High protection rating measurement
- High accuracy - Incremental and absolute - No additional installation required
measurement available - Highest protection rating
- High traverse rates
- Little space required
Disadvantages:
- Low protection rating - Maximum velocity - No absolute measurement

- Currently no absolute measurement currently 120 m/min systems available
systems available
- More complicated mounting and
adjustment
Figure 9-62: Benefits and disadvantages of different linear scales models
Open model If there are no dirt, chips etc. in a machine or system and if coolant
lubricants will never be used, employing an open linear scale is
recommended. Thus, open linear scale are frequently used for handling
axes, precision and measuring machines, and in the semiconductor
industry.
Encapsulated model Encapsulated systems should be employed if chips are produced and/or
coolant lubricants are used. To achieve highest operational reliability, an
encapsulated system can have additional sealing air. Thus, encapsulated
linear scales are chiefly used at chip-producing machine tools.
Measuring system integrated in The ball and roller rail guides from Rexroth Star are available with an
rail guides integrated inductive linear scales. The system consists of a separate
scanner (read head) and a material measure that is integrated into the
rail. The material measure is accommodated in a groove of the guide rail,
and is protected by a tightly welded stainless steel tape. The read head is
attached directly to the guide carriage.
The system is insensitive against soiling (e.g. dust, chips, coolant, etc.)
and magnetic fields. Due to the little space required, the compact and
robust device (measuring system and guides) permits simplified
structures compared with an externally attached measuring system.
There are no costs for material and installation of external systems.
Measuring principles
Absolute scales The benefits of an absolute linear scales result from the fact that a high
availability and operational reliability of the axis of motion and,
consequently, of the entire system is guaranteed:
Benefits
• Monitoring and diagnosis functions of the electronic drive system are
possible without any additional wiring
• No axis travel limit switches required
• The maximum available motor force is available at any point of the
travel immediately after power-up.
• No referencing required
• Easy commissioning of horizontal and vertical axes
• Pole position recognition only required for initial commissioning
Disadvantages
• Maximum measuring length is limited (3040 mm)
• Only encapsulated systems available
Note: An ENDAT interface is required if absolute linear scales are

used.
Using an absolute linear scales makes it possible that the pole position
recognition of the motor need only be performed once for initial
commissioning. This drive-internal procedure is possible without
activating the power (i.e. without moving the axis). This provides
advantages when commissioning vertical axes, in particular.
Rexroth Indramat recommends the absolute linear scales LC181 and
LC481 from Heidenhain. Both systems are equipped with an ENDAT
interface.
Figure 9-63: Absolute encapsulated length measuring system LC181
Incremental scales When an incremental linear scales is used together with a synchronous
linear motor, the pole position must be measured upon each power-up.
This is done using a drive-internal procedure that must be executed
whenever the axis is switched on. The motor force can only build up
afterwards.
Note: With incremental linear scales, the drive-internal pole position

recognition procedure must be executed upon each power-up.
Pole position recognition requires the primary part to be
moved !
Benefits
• Depending on the model, travels up to 30 m (or unlimited distance)
possible
• High feed rate possible
• Different signal periods and, consequently, different position
resolutions possible.
Disadvantages
• Pole position must be measured upon each power-up
• Pole position recognition requires the primary part to be moved
• Pole position recognition is not possible for vertical axes
• Pole position recognition is not possible for securely braked axes or for
axes at the hard stop
• Pole position recognition of Gantry axes may cause problems
• Reference point interpretation and homing switch are required
• Safety limit switch is required
Incremental linear scales with Incremental linear scales with distance-encoded reference marks offer
distance-encoded reference the benefit of a simplified and, even more important, shortened
marks referencing. With such a system, referencing requires the axis merely to
be moved by several centimeters (depends on model).
Note: Distance-encoded scales do not perform absolute

measurement. Pole position recognition must also be
performed upon each power-up (like in incremental systems
that are not distance-encoded).
Figure 9-64: Open incremental linear scales LIDA185C with distance-encoded

reference marks
Maximum permissible velocity and acceleration
Maximum permissible feed rate One limitation factor of the maximum permissible feed rate of a length
measuring system are the sealing lips and the guides of the scan carriage
on the glass rule. Currently, the velocity of an encapsulated system is
limited to 120 m/min.
The other limitation factor of the maximum permissible feed rate is the
frequency limit of the output signals (manufacturer’s specifications) or the
maximum permissible input frequency of subsequent circuits (drive
controller).
v max = fmax ⋅ Signal ⋅ period ⋅ 60

vmax: Maximum feed rate in m/min
Signal period: Signal period of linear scale in mm
fmax: Maximum input frequency of scale interface
DAG 1 Vpp: 150kHz
DLF 1 Vpp: 500kHz
Figure 9-65: Maximum traverse rate of linear scale related to the maximum input
frequency of the scale interface
Maximum permissible The very rigid internal structure of open linear scales permits maximum
acceleration in the measuring acceleration values in the measuring direction of up to 200m/s². To permit
direction relatively high attachment tolerances, the scan carriage of encapsulated
linear scales cannot rigidly be connected with the mounting foot.
Encapsulated linear scales systems for linear motors, however, are
comparatively rigid and may be used for maximum accelerations in the
measuring direction between 50 m/s² and 100 m/s² (depending on the
length measuring system employed).
Note: Please refer to the documents from the corresponding

manufacturer for detailed and updated information.
Positions resolution and positioning accuracy

To reach a high resolution of the linear scale, an interpolation of the
sinusoidal input signal of the linear scale is performed in the drive
controller (Figure 10-9. Depending on the maximum travel range and on
the signal period, a drive-internal position resolution of less than 1 mm is
possible (see also Chapter 10.4 Position and Velocity Resolution)
Note: The drive-internal position resolution does not correspond to

the positioning accuracy. The absolute positioning accuracy is
depending on the entire drive system, including mechanical
systems.
Measuring system cables

Ready-made cables from Rexroth Indramat are available for the electrical
connection between the output of the linear scale and the input of the
scale interface. To ensure maximum transmission and scale interference
safety, you should preferably use these ready-made cubes.
Recommended linear scales for linear motors

Manufacturer Signal Model Output Measuring Max. meas. Maximum velocity P-0-0074 Reference marks
type period signals principle length in m/min
in mm in mm
(S-0-
0116)
Heidenhain absolute none
0.016 encapsulated sine 1 Vpp 3040 120 8
LC 181 ENDAT (absolute)
Heidenhain absolute none
0.016 encapsulated sine 1 Vpp 2040 120 8
LC 481 ENDAT (absolute)
Heidenhain one
0.02 encapsulated sine 1 Vpp incremental 2040 120 2
LS 486 (center meas. length)
Heidenhain
0.02 encapsulated sine 1 Vpp incremental 2040 120 2 distance-encoded
LS 486C
Heidenhain one
LS 186 (center meas. length)
Heidenhain
LS 186C
Heidenhain
0.04 encapsulated sine 1 Vpp incremental 30040 120 2 selectable by masks
LB 382
Heidenhain
LB 382C
Heidenhain
0.004 encapsulated sine 1 Vpp incremental 3040 60 2 selectable by magnets
LF 183
Heidenhain
LF 183C
Heidenhain one
LF 481 (center meas. length)
Heidenhain
LF 481C
Heidenhain
0.04 open sine 1 Vpp incremental 30040 480 2 selectable by magnets
LIDA 185
Heidenhain
0.04 open sine 1 Vpp incremental 30040 480 2 distance-encoded
LIDA 185C
Heidenhain
LIDA 187
Heidenhain
LIDA 187C
Renishaw
RG 2
Heidenhain one
0.004 open sine 1 Vpp incremental 3040 120 2
LIF 181R (center meas. length)
Heidenhain
LIF 181C
Heidenhain LIP one
0.002 open sine 1 Vpp incremental 420 60 2
481R (center meas. length)
integrated in one
Rexroth Star
1.000 rail sine 1 Vpp incremental 4000 600 2 (position to customer
IML
guides request)
P-0-0074: "Sensor type 1" drive parameter

S-0-0116: "Sensor 1 resolution" drive parameter
Figure 9-66: Recommended linear scales for linear motors
Note: To ensure maximum interference immunity, Indramat

recommends the voltage interface with 1Vpp.
Note: Please refer to the documents from the corresponding

manufacturer for detailed and updated information.
Mounting Linear scales
Elasticity the coupling to the With linear drives, the mounting of the measuring system to the machine
machine can limit the bandwidth of the position control loop. As a consequence for
the design, this means that the coupling between the scan unit and the
rule of an open linear scale, or between the rule enclosure of an
encapsulated linear scale, and the machine - with respect to the natural
frequency - must be significantly higher than the one of the linear scale.
The natural frequencies of today’s encapsulated linear scales are 2kHz
and higher.
It must also be ensured that the linear scales is not attached to vibrating
machine components. In particular, attaching the system in the vicinity of
vibration maximal must be avoided.
Mounting method In order to minimize the moved masses and to obtain the highest rigidity
in the measuring direction, the scanner unit should always be moved if
possible.
Open linear scales systems The user should provide an encapsulation if an open linear scale is
employed despite adverse ambient conditions (chips, dust, etc.). It must
also be noted that the scanning head must be adjusted when the open
linear scale is installed. Corresponding adjustment possibilities must be
provided in the design (please note the manufacturer’s specifications).
Encapsulated linear scales To obtain relatively high installation tolerances, the scan carriage of
encapsulated linear scale is connected with the mounting base via a
coupling that is very rigid in the measuring direction and slightly flexible
perpendicularly to the measuring direction. If the rigidity of this coupling in
the measuring direction is too weak, there are low natural frequencies in
the feedback of the position and velocity control loop, that can limit the
bandwidth. The encapsulated linear scales that are recommended for
linear motors usually possess a natural frequency in the measuring
direction that is above 2 kHz. Thus, the natural frequency of the linear
scale in the measuring direction can be neglected with respect to the
mechanical natural frequencies of the machine.
Parallel arrangement of motors If several motors on an axis are used with a single linear scale, the
with one linear scale system motors should be positioned as symmetrically as possible.
Gantry axes With a Gantry axis, where each motor or pair of motors is assigned to a
linear scale stem, the distance between motor and linear scale should be
as small as possible. The accuracy of the linear scale as such and with
respect to each other should be less than 5 µm/m. Drive-internal axis
error compensations can minimize remaining misalignments between the
linear scales.
9.13 Linear Guides

Depending on the motor arrangement, the attractive, feed and process
forces and the velocities of more than 600 m/min that can be reached
today stress the linear guides. The employed linear guides must be able
to handle:
• the attractive force between primary and secondary part and

• the machining and acceleration forces.
Depending on the application, the following linear guides are employed:
• Ball or roller rail guides

• Slideways
• Hydrostatic guides
• Aerostatics guides
The following requirements should be taken into account when a suitable

linear guide system is selected:
• High accuracy and no backlash

• Low friction and no stick-slip effect
• High rigidity
• Steady run, even at high velocities
• Easy mounting and adjustment
9.14 Braking Systems and Holding Devices

The following systems can be used as braking systems and/or holding
devices for linear motors:
• External braking devices
• Clamping elements for linear guides
• Holding brakes integrated in the weight compensation
See also Chapter 16 Recommended Suppliers of Auxiliary Components.
Note: Information about controlling the holding brake can be found in

10.2 Shutdown upon EMERGENCY STOP and in the Event of
a malfunction and in the corresponding description of functions
of the drive controller.
Note: Additional information about shutting down linear motors can

be found in the Chapters 9.15 End Position and 10.2
Shutdown upon EMERGENCY STOP and in the Event of a
Malfunction.
9.15 End Position chock absorber

Where linear drives with frequently high traverse rates and accelerations
are concerned, uncontrolled movements (such as coasting after a mains
failure) can not always safely be avoided.
Suitable energy-absorbing end position shock absorber must be provided
in order to protect the machine during uncontrolled coasting of an axis.
Damage on machine or motor components

when driving against hard stop !
⇒ Use suitable energy-absorbing end position shock
WARNING absorber
⇒ Adhere to the specified maximum decelerations
Note: The necessary spring excursion of the shock absorbers must

be taken into account when the end position shock absorber
are integrated into the machine (in particular when the total
travel path is determined).
Maximum deceleration when Given by the type of attachment and by the type of the primary part
driving against end stop (number of mounting screws, attractive force, mass, etc.), there is a
maximum deceleration in the movement onto an end stop. If
this maximum deceleration is exceeded, this can lead to loosening the
primary part and to damaging of motor components.
The maximum permissible deceleration upon moving against end stop is
300 m/s².
Note: Using a suitable end stop shock absorber, the maximum

permissible deceleration for moving against a end stop must
be delimited to 300 m/s².
Braking distance to be kept With the known maximum deceleration of 300 m/s² and the maximum
when driving against end stop possible velocity, the minimum spring excursion can be calculated as
follows:
2
v max
smin =
2158
smin : Minimum braking distance in mm
vmax : Maximum possible velocity in m/min
Figure 9-67: Braking distance to be kept when driving against end stop
9.16 Axis cover systems

Depending on the application, design, operational principle and features
of synchronous linear motors the following requirements on axis cover
systems apply:
• High dynamic properties (no overshoot, little masses)

• Accuracy and smooth run
• Protection of motor components against chips, dust and contamination
with ferromagnetic parts.
• Resistance to oils and coolant lubricants
• Robust ness and wear resistance
The following axis cover systems can be used:
• Bellow covers
• Telescopic covers
• Roller covers
If possible, a suitable axis cover system should be configured during the

early development process of the machine or system - supported by the
corresponding specialized suppliers (see 16 Recommended Suppliers of
Auxiliary Components).
9.17 Wiper
A wiper, that is used for removing chips, can be employed directly on the
secondary part. The following points must be taken into account when a
suitable wiper system is selected and used.
Secondary part segments If possible, a wiper should be used on whole secondary part segments. If
more than one secondary part segment is used, joints between the
secondary part segment must be taken into account (destruction of wiper
or of secondary parts). In this case, a defined distance (smaller than the
gap between the primary and the secondary part) between wiper and
secondary part or a wiper in the form of a hard brush can help.
Ferromagnetic chips The secondary part attracts ferromagnetic chips at a distance of less than
approximately 100 mm. These attractive forces must be taken into
account when ferromagnetic chips are removed.
Temperature produced by If the utilization of the wiper causes a significant rise of the temperature
friction on the secondary part surface, it must be ensured that this temperature
does not exceed the limit of 70°C.
Mounting the wiper The wiper should be mounted to the machine structure. Mounting the
wiper in additional holes directly on the primary part is not permitted.
Damage or destruction of motor components by

inappropriate utilization of a wiper on the
secondary part !
WARNING ⇒ If possible, utilization only on whole secondary part
segments
⇒ Take slight height differences of the secondary part
segments into account
⇒ Take temperature rises due to friction into account
⇒ Mounting the wiper in additional holes directly on the
primary part is not permitted
Synchronous Linear Motors LSF Controlling of Linear Direct Drives 10-1
10 Controlling of Linear Direct Drives
10.1 Drive Controllers, Power Supply Modules and Controls

The following diagram shows a complete linear direct drive that consists
of synchronous linear motor, length measuring system, drive controller,
and master control.
master control
act. pos. values,

communication
power,
sensor signals
Motor
motor
3~
linear scale
drive controller
ðabsolute ENDAT
ðcurrent control ðincremental
ðvelocity control ðdistance-encoded
ðspeed control
ðfine interpolation
ANTRSYST01-LSF-EN.FH7
Figure 10-1:Linear direct drive
Drive controllers and power supply modules

To control LSF synchronous linear motors, different digital drive
controllers and power supply modules are available. These drive systems
are configurable and of a modular or compact structure.
Note: The drive controllers and the related firmware for the LSF
synchronous linear motors are the same as for the rotary
drives from Rexroth Indramat.
Functionality The drive controllers from Rexroth Indramat meet all requirements for the
operation of synchronous linear motors. These includes:
• Drive-internal position and velocity control without contouring error
• Drive-internal fine interpolation
• High contour accuracy at high velocity
• High position resolution in the drive: < 0.001 µm
• Simple axis-specific compensation algorithms
(e.g. frictional torque compensation, backlash compensation)
• Filter functions to reduce mechanical feedback (low-pass filter, band-
stop filter)
• Jerk limitation
• Easy implementation of Gantry axes
10-2 Controlling of Linear Direct Drives Synchronous Linear Motors LSF
• Absolute and incremental position measurement with automatic pole

position recognition
• Safety functions
• Automatic control loop adjustment (ECODRIVE03 only)
• Commissioning and diagnosis directly via NC or NC-independently via
PC (DriveTop)
• Rapid initial commissioning and easy re-commissioning
Models The modular structure of the DIAX04 drive family permits several drive
controllers to be used at one power supply module.
Compact units of the ECODRIVE03 drive family contain power supply
module and drive controller in a single unit. Compact units from Rexroth
Indramat can directly be connected to the mains.
Configuration A configured drive controller consists of the following components:

• Base unit
• Drive firmware
• Control communication module (e.g. SERCOS interface module)
• Position interface (length measuring system interpretation)
• Additional card(s) for enhanced functions (optional)
Drive controllers and interfaces The operation of the LSF synchronous linear motor is possible with
following drive controller product families:
Drive family DIAX04 ECODRIVE03 POWERDRIVE

Model modular compact modular
Drive controllers HDS DKCxx.3 HDS, HDD
Type current 40...300 A 40...200 A 40...300 A
Power supply module HVE, HVR integrated HVE, HVR
DC bus voltage 540...750 V 540...650 V 540...750 V
Interfaces SERCOS interface SERCOS interface PWM
ANALOG interface ANALOG interface
parallel interface parallel interface
Profibus
Interbus
CANopen
DeviceNet
Figure 10-2: Drive controllers for LSF synchronous linear motors
Control systems
A master control is required for generating defined movements. Rexroth
Indramat offers different control systems for various functionality’s and
drive interface.
10.2 Shutdown upon EMERGENCY STOP and in the Event of a

Malfunction
The shutdown of an axis that is equipped with synchronous linear motors
can be initiated by
• EMERGENCY STOP,
• drive fault (e.g. response of the sensor monitoring function), or
• mains failure.
For the options of shutting down synchronous linear motors in the event
of a malfunction, distinction must be made between
• shutdown by the drive,
• shutdown by a master control, and
• shutdown by a mechanical braking device.
Shutdown by the drive

Shutdown by the drive is possible as long as there is no fault or
malfunction in the drive system. The shutdown possibilities depend on the
occurred drive error and on the selected error response of the drive.
Certain faults (interface faults or fatal faults) lead to a force disconnection
of the drive.
Death, serious injuries or damage to equipment

may result from an uncontrolled coasting of a
switched-off linear drive !
WARNING ⇒ Construction and design according to the safety
standards
⇒ Protection of people by suitable barriers and
enclosures
⇒ Using external mechanical braking facilities
⇒ Using suitable energy-absorbing end position shock
absorbers
The parameter values of the drive response to interface faults and non-
fatal faults cannot be selected. The drive switches off at the end of each
fault response.
The following fault responses can be selected:
1. Setting velocity command value to zero

2. Setting force command value to zero
3. Setting velocity command value to zero with command value ramp
and filter
4. Retraction
Note: Please refer to the corresponding firmware function

description for additional information about the reaction to
faults and the related parameter value assignments.
Shutdown by master control

Shutdown via control functions
Shutdown by the master control should be performed in following steps:
1. The machine PLC or the machine I/O level reports the fault to the
CNC control.
2. The CNC control shuts down the drives via a ramp in the fastest
possible way.
3. The CNC control causes the power at the power supply module to be
shut down.
Drive initiated by the control shutdown

The shutdown via drive functions should be performed in following steps:
1. The machine I/O level reports the fault to the CNC control or the PLC.
2. The CNC control or the PLC resets the drive enabling signal (RF) of
the drives. If SERCOS interface is employed, it deactivates the "E-
STOP" input at the SERCOS interface module.
3. The drive responds with the selected error response.
4. The power at the power supply module must be switched off 500 ms
after the drive enabling signal (RF) has been reset or the "E-Stop"
input has been deactivated.
Note: The delayed power shutdown ensures the safe shutdown of

the drive by the drive controller. With an undelayed power
shutdown, the drive coasts in an uncontrolled way once the
DC bus energy has been used up.
Shutdown by mechanical braking devices

Shutdown by mechanical braking devices should be activated
simultaneously with switching off the power at the power supply module.
Integration into the holding brake control of the drive controllers is
possible too. The following must be observed:
• Braking devices with electrical 24V DC control (electrically un-locking)
and currents < 2 A can directly be triggered.
• Braking devices with electrical 24V DC control and currents > 2A can
be triggered via a suitable contractor.
Once the drive enabling signal has been removed, the holding brake
control has the following effect:
• Fault reaction "0", "1", or "3":
The holding brake control drops to 0 V once the velocity is less than 10
mm/min or a time of 400 ms has elapsed.
• Fault reaction "2"
The holding brake control drops to 0 V immediately after the drive

enabling signal has been removed.
Response to a mains failure

In order to be able to shut down the linear drive as fast as possible in the
event of a mains failure,
• either an uninterruptible power supply or
• additional DC bus capacities, and/or
• mechanical braking facilities
must be provided.
Determining the required Additional capacities in the DC bus represent an additional energy store
additional DC bus capacitor that can supply the brake energy required in the event of a mains failure.
Note: Internal control circuits are also supplied by the DC bus;

external backup is not necessary.
The additional capacity required for a shutdown upon a mains failure can
be determined as follows:
m ⋅ v max F  F 
C add = ⋅ 3,5 ⋅ max ⋅ R12 − v max ⋅  R + 0.3 
U 2
− UDC min
DC max
2
k iF2  Fmax 
Cadd: Required additional DC bus capacitor in mF
m: Moved mass in kg
UDCmax: Maximum DC bus voltage in V
UDCmin: Minimum DC bus voltage in V
Fmax: Maximum braking force of the motor in N
kiF: Motor constant (force constant) in N/A
R12: Winding resistance at 20°C
FR: Frictional force in N
Figure 10-3: Determining the required additional DC bus capacitor
Prerequisite: - final velocity = 0

- velocity-independent friction
- constant deceleration
- winding temperature of 135°C
Note: The existing and the maximum possible DC bus capacity of

the employed power supply module must be taken into
account when additional capacities are used in the DC bus. Do
not initiate a DC voltage short-circuit when additional
capacitors are employed.
Short-circuit of DC bus
Power supply modules from Rexroth Indramat permit the DC bus to be
shorted when the power is switched off, which also establishes a short-
circuit between the motor phases. When the motor moves, this causes a
braking effect according to the principle of the eddy-current brake.
However, the obtained braking force is not very high and depends on the
velocity. The DC bus short-circuit can therefore only be used to support
existing mechanical braking devices.
10.3 Maximum Acceleration Changes (Jerk Limitation)
Rate of current and force rise The maximum rate of current and force rise is determined by the available
DC bus voltage and the motor inductance. As shown in Figure 10-4, with
highly dynamic movements and short strokes, the motor inductance
should be low and the DC bus voltage as high as possible.
di UDC
=
dt L 12
dF UDC
= ⋅ k iF
dt L 12
UDC: DC bus voltage in V
L12: Winding inductance in H
i: Current in A
t: Time in s
Figure 10-4: Maximum rate of current and force rise
The acceleration change per time unit (derivative of the acceleration) is

known as jerk (Figure 10-7).
velocity
da
=¥
dt
RUCKBEGR01-LSF-EN.FH7
acceleration
Figure 10-5: Acceleration and velocity without jerk limitation
Note: The drive controller or the master control must delimit the
maximum jerk when direct drives are employed (acceleration
ramp with da/dt ≠ ∞, Figure 10-6).
velocity
da
¹¥
dt
RUCKBEGR02-LSF-EN.FH7
acceleration
Figure 10-6: Acceleration and velocity with jerk limitation
Maximum jerk The maximum jerk is determined by the maximum rate of current rise, by
the moved mass and by the motor constant:
da UDC ⋅ k iF
rmax = =
dt L 12 ⋅ m
m: Moved mass in kg
UDC: DC bus voltage in V
L12: Winding inductance in H
a: Acceleration in m/s²
t: Time in s
Figure 10-7: Maximum jerk (acceleration change)
10.4 Position and Velocity Resolution
Drive-internal position resolution and positioning

accuracy
In linear direct drives, a linear scale is used for measuring the position.
The linear scale for linear motors supply sinusoidal output signals. The
length of such a sine signal is known as the signal period. It is mainly
specified in mm or µm.
With the drive controllers from Rexroth Indramat, the sine signals are
amplified again in the drive (see Figure 10-9). The drive-internal
amplification also depends on the maximum travel area and the signal
n
period of the length measuring system. It always employs 2 vertices (e.g.
2048 or 4096).
sp
fint = 231 ⋅ rounded to 2n
x max
fint: Multiplication factor (S-0-0256, Multiplication 1)
s p: Linear scale signal period in mm (S-0-0116 Resolution of encoder 1)
xmax: Maximum travel (S-0-0278, Maximum travel)
Figure 10-8: Multiplication factor
Dxd
signal period
INTPOLSIN-LSF-EN.FH7
Figure 10-9: Drive-internal multiplication and/or interpolation of the measuring

system signals
With a known signal period and a drive-internal multiplication, the drive-

internal position resolution results as:
sp
∆x d =
fint
∆xd: Drive-internal position resolution
s p: Linear scale signal period (S-0-0116, Resolution of encoder 1)
fint: Multiplication factor (S-0-0256, Multiplication 1)
Figure 10-10: Drive-internal position resolution
Note: The drive-internal position resolution is not identical to the

attainable positioning accuracy.
The following diagram shows the correlation between maximum travel

and drive-internal position resolution for different signal periods.
1 0 0 ,0 n m
1 00 0 µm
drive-internal position resolution in nm
1 0 ,0 n m
1 0 0 µm
4 0 µm
1 ,0 n m
20 µm
1 6 µm
4 µm
0 ,1 n m
1 mm 10 m m 100 m m 1000 m m 10000 m m 100000 m m
m a x im u m tra ve l ra n g e in m m
Figure 10-11: Drive-internal position resolution, depending on the maximum

travel range and the signal period of the length measuring system
Prerequisite: Preferred weighting (position data with 4 fractional part

digits)
Attainable positioning accuracy The attainable positioning accuracy depends on the mechanical and
control-engineering overall system. It is not identical to the drive-internal
position resolution.
Using empirical values, the attainable positioning accuracy can be
estimated as follows:
∆x abs = ∆x d ⋅ 30...50
∆xd: Drive-internal position resolution
∆xabs: Positioning accuracy
Figure 10-12: Estimating the attainable positioning accuracy
Prerequisite: Optimum controller setting
Note: The positioning accuracy that can be expected can not be

better than the smallest position command increment of the
master control.
Velocity resolution
The resolution of the velocity (velocity quantization) is proportional to the
position resolution (see Figure 10-8) and inversely proportional to the
sample time tAD from:
∆x d
∆v d =
t AD
∆vd: Velocity resolution in m/s
∆xd: Drive-internal position resolution (see Figure 10-10)
tAD: Sample time in s (DIAX04: 250µs, ECODRIVE03: 500µs)
Figure 10-13: Velocity resolution
10.5 Load Rigidity

The elastic deformability resistance of a structure against an external
force is known as rigidity. It is usually specified in N/µm. The reciprocal
value of the rigidity is known as elasticity.
An important factor for controlled electrical drives is the so called load
rigidity, distinguished in static and dynamic load rigidity
Static load rigidity

The static load rigidity of a linear direct drive only depends on the
maximum motor force and the drive-internal position resolution:
Fmax
c stat =
∆x D
cstat: Static load rigidity in N/µm
∆xd: Drive-internal position resolution in µm (Figure 10-10)
Figure 10-14: Static load rigidity of linear direct drives
Note: The rigidity of the machine structure must be taken into

account when the static load rigidity of a linear direct drive is
rated.
∆x D
dstat =
Fmax
dstat: Static elasticity in µm/N
∆xd: Drive-internal position resolution in µm (Figure 10-10)
Figure 10-15: Static elasticity of linear direct drive
Dynamic load rigidity
Dynamic load rigidity and elasticity are frequency-dependent variables.

The dynamic load rigidity of a linear direct drive only depends on the
controller settings (current, velocity and position controller) and on the
moved masses (Figure 10-17). The maximum elasticity (or the minimum
rigidity) is in the area of the natural frequency of the control loop.
In a simplified form, the figure below shows a typical elasticity frequency
response.
0.1
.
0.01
G S( ω )
µm
N
1 .10
3
1 .10
4
1 .10
3
1 10 100
ω
2 .π
Figure 10-16: Typical elasticity frequency response of a linear direct drive
Estimating the dynamic load Despite the frequency sensitivity, a sufficiently exact estimate of the
rigidity dynamic rigidity can be made for the area below the natural frequency of
the control loop:
0.06 ⋅ k p ⋅ k iF ⋅ (1 + 0.0167 ⋅ k v ⋅ Tn )
c dyn =
 −D⋅
π

 e 1−D 2 
Tn ⋅ 1 + 
 1 − D2 
 
with
1 0.06 ⋅ k p ⋅ k iF ⋅ Tn
D= ⋅
2 m ⋅ (1 + 0.0167 ⋅ k v ⋅ Tn )
cdyn: Dynamic load rigidity in N/µm
D: Attenuation
k p: Proportional gain of velocity controller in A⋅min/m
kv: Proportional gain of position controller (Kv factor) in m/min⋅mm
Tn: Integral time of velocity controller in ms
m: Moved total mass in kg
Figure 10-17: Estimating the dynamic load rigidity
1
ddyn =
c dyn
cdyn: Dynamic load rigidity in N/µm
ddyn: Dynamic elasticity in µm/N
Figure 10-18: Determining the dynamic elasticity
1 1000 ⋅ k p ⋅ k iF ⋅ (60 + k v ⋅ Tn )
ω0 = ⋅
2⋅π m ⋅ Tn
ω0: Natural frequency in Hz
k p: Proportional gain of velocity controller in A⋅min/m
kv: Proportional gain of position controller (Kv factor) in m/min⋅mm
Tn: Integral time of velocity controller in ms
m: Moved total mass in kg
Figure 10-19: Determining the controller's natural frequency
Synchronous Linear Motors LSF Handling, Transport, Storage and Inspection 11-1
11 Handling, Transport, Storage and Inspection
11.1 Identifying the Motor Components
Primary part
There is one type plate on the end face of the primary part at which the
power and coolant connections can be found. Another rating plate is
added to the primary part. The user may stick this type plate onto the
machine or use it in a different way. The rating plate of the primary part
contains the following data:
PRIMARY PART OF MOTOR

Part No. Build Week 1 Rated current (Peak) (A)
Type code
2 Rated force (N)
S.No. Primary part mass
3 Installation class
4 Class of protection
INN 13.01-42-10
Made in Germany
I.CI. 3
1 5 mm IP 4
5 Pole pitch
2
Typenschild-Primärteil-en.fh7
Figure 11-1: Contents primary part type plate
The type plate permits unambiguous identification of the primary part.
Secondary part
There is no space on the secondary part where a type plate could be
attached. Upon delivery, two identical type plates are enclosed to the
secondary part. To ensure a safe and permanent identification of the type,
a type code and the serial number can be found directly on the secondary
part.
Type code and serial number are always located between the first two
mounting holes, starting from the end face that begins with a north pole.
mark "N" mark "S"
for north pole for south pole
N S
LSS secondary part
LSS120-B1-0300A
N 0123456 S
type code and

serial number
LSSKENNZ-LSF-EN.FH7
Figure 11-2: Location of type code and serial number of LSS secondary part
Note: Independent from of its length, each secondary part

possesses its own magnetic north pole and, at the opposite
end face, a magnetic south pole. Accordingly, the end faces of
the secondary parts are marked N (north pole) and S (south
pole) (Figure 11-2).
11-2 Handling, Transport, Storage and Inspection Synchronous Linear Motors LSF
Type plate The type plate of the secondary part contains the following data:
SECONDARY PART OF MOTOR 1 Class of protection

Part No. Build Week
Type code 2 Secondary part mass
S.No. 2 kg
INN 13.01-42-50
Made in Germany
IP 1
Figure 11-3: Contents secondary part type plate
The type plate and the type code permit an unambiguous identification of
the secondary part.
11.2 Delivery and Packaging
Primary part
The primary parts are packed individually in wooden crates. For
identification purposes, the type name of the primary part shows on the
packaging.
Secondary parts
The secondary parts are packed individually in wooden crates. For
identification purposes, the type name of the secondary part shows on the
packaging.
Risk of injuries and / or damage when handling

secondary parts of synchronous linear motors !
⇒ Strictly observe and adhere to the warnings and
CAUTION safety instructions.
⇒ Do not remove the transport and installation
protection from the secondary part when you unpack
the unit. If possible, the transport and installation
protection should only be removed after the
secondary parts have been installed in the machine.
Transport and installation In addition to the packaging, each secondary part possesses transport
protection and installation protection that is approximately 500 mm thick and made
from Polystyrene or a similar material. The transport and installation
protection is connected with the secondary part and must not be removed
when the unit is unpacked.
transport and installation protection made from

non-ferromagnetic material, height approx. 50 mm
secondary
part
TUMSLSS-LSF-EN.FH7
Figure 11-4: Transport and installation protection of LSS secondary parts
Risk of injuries and damaging or destroying

component when you loosen the transport and
installation protection during the lifting process
CAUTION !
⇒ Do not lift the secondary part at the transport- and
installation protection !
⇒ Do not remove the transport and installation
protection from the secondary part when you unpack
the unit. If possible, the transport and installation
protection should only be removed after the
secondary parts have been installed in the machine.
Warnings on the packaging of The packaging of the secondary parts carries the following warnings:
the secondary parts
Figure 11-5: Warning label on the packaging of LSS secondary parts
Note: The self-sticking warning label shown in Figure 11-5 (sizes

approximately 110 mm x 150 mm) can be ordered from
Rexroth Indramat (parts number 00278745).
11.3 Storage and Transport

When stored, the components (i.e. primary and secondary parts) of
synchronous linear motors must be supported at full length. This must
also be ensured for short-time storage.
The permissible storage and transport temperature is -10...+60°C. Heavy
or periodic temperature variations during transport end storage are not
permitted.
+60° C
-10° C
LAGKOMP-LSF-EN.FH7
Figure 11-6: Storing linear motor components
Inappropriate handling during storage or

transport can damage or destroy the motor
components.
CAUTION ⇒ Use the original packaging for permanent storage.
⇒ Short-term storage during installation according to
Figure 11-6
⇒ Do not throw parts
⇒ Adhere to permissible transport and storage
temperatures
⇒ Remove the transportation and installation protection
only during or after the installation in the machine.
Peculiarities during the transport of secondary parts of synchronous

linear motors
The secondary parts of synchronous linear motors, that are equipped with
permanent magnets, are not provided with a magnetic screen. The safety
instructions specified in Chapter 3.13 Safety in Handling Secondary Parts
of Synchronous Linear Motors must always be observed.
Air freight
Possible interference with on-board aircraft

electronics by magnetic fields !
⇒ Observe the transport and packing regulations (IATA
CAUTION 902)
11.4 Checking the Motor Components
Factory checks
Electrical checks The Rexroth Indramat linear motors undergo the following electrical
checks at the factory:
• High-voltage test acc. to EN 60034-1/2.95 (VDE 0530 Part 1)

• Insulation resistance test acc. to EN 60204-1
• Verification of the specified electrical characteristics
Mechanical checks The Rexroth Indramat linear motor components undergo the following
mechanical checks:
• Form and location tolerances acc. to ISO 1101

• Construction and fits acc. to DIN 7157
• Surface structure acc. to DIN ISO1302
• Thread test acc. to DIN 13 Part 20
• Leak test of the cooling circuit
Note: Each motor is accompanied by a corresponding test

certificate.
EMC radio interference The linear motor components from Rexroth Indramat have been
suppression subjected to an EMC type test and have been certified as complying.
EN 55011 Limit Class B, VDE 0875 Part 11.
Customer Incoming Inspection
You must contact Rexroth Indramat if you wish to perform a high-voltage

incoming inspection at the customer site.
Inappropriate performed high-voltage tests can

destroy motor components !
⇒ Contact Rexroth Indramat before carrying out tests.
CAUTION
Synchronous Linear Motors LSF Installation and Assembly 12-1
12 Installation and Assembly
12.1 Basic Requirements

The following basic requirements must be fulfilled when the synchronous
linear motor components are installed:
• The required mounting sizes are observed (Figure 6-1)
• The machine structure fulfills the installation requirements (rigidity,
attractive force, feed force and acceleration forces, etc.)
• The machine structure is prepared for the installation of all
components
• The installation is performed by skilled personnel
• Observing the risk and safety instructions is ensured
12.2 Basic Procedure when Installing the Motor Components

The installation of the motor into the machine structure depends on the
type of the secondary part arrangement. Thus, it can be performed in
different ways:
• Installation with a segmented secondary part along the entire travel
• Installation with a whole secondary part along the entire travel
Note: The procedures described here are merely suggestions.

Depending on the application, they may be performed in a
different way.
Installation with a segmented secondary part along the entire motion

path
With a segmented secondary part, the installation can be performed as it
is shown in Figure 12-1. Only some secondary parts are installed in this
process. The primary part can therefore be rested on the machine base.
Never place the primary part directly onto the

secondary part.
⇒ Due to the high attractive forces, lifting the primary
WARNING part off the secondary part is very difficult (device
required).
Next, the primary part can be installed in the previously installed slide.
Subsequently, the slide and the installed primary part can be pushed
along the installed secondary parts. Next, the remaining secondary parts
can be installed.
12-2 Installation and Assembly Synchronous Linear Motors LSF
STEP 1 slide
secondary part segment 1

primary part
machine bed
total travel
STEP 2
slide
secondary part segment 1 primary part secondary part segment 2
machine bed
total travel
MOTEINBAU01-LSF-EN.FH7
Figure 12-1: Installation of the linear motor components with segmented

secondary part
Unpredictable slide movement

⇒ Protection against uncontrolled movements caused
by the only partial coverage of primary and
secondary parts (forces in feed direction).
CAUTION
Installation with a whole secondary part along the entire travel

With a whole secondary part along the entire travel, the primary part can
be preinstalled on the slide before the slide is installed. Using a suitable
device, the slide and the preinstalled primary part can be lowered onto the
machine bed after the secondary part has been installed.
slide
primary part
secondary part guide carriage lowering using

device
machine bed
total travel
Figure 12-2: Installing the linear motor components with a whole secondary part
along the entire travel
When the primary part is lowered onto the

secondary part, the attractive forces rise as the
air gap decreases.
CAUTION ⇒ Observe the explanations in Chapter 9.3 Feed and
Attractive Forces.
⇒ Never use a crane for lowering the primary part onto
the secondary part (elasticity / attractive force).
Note: The device used for lowering the primary part or the slide is
not a part of the delivery from Rexroth Indramat.
Resting the primary part on the installed secondary part - also using an
appropriate device - and fixing it with the mounting screws in the slide is
another option. In this case, a non-ferromagnetic distance plate (plastic,
wood, etc.) must be placed between the primary and the secondary part
so that the primary part does not rest directly on the secondary part. The
thickness of the distance plate should be such (< nominal air gap) that
moving the slide is possible after the primary part has been screwed to
the slide.
The thickness of the distance plates must be such that the primary part
need not or only a short way be lifted with the mounting screws.
Example Measurable air gap: 1.4 mm

Thickness of the distance plate: 1.35 ... 1.39 mm
Tighten the mounting screws of the primary part according to the

description in Chapter 12.4 Mounting the Primary Part.
STEP 1 primary part

slide
secondary part
loweing using
device
machine bed
total travel
STEP 2
non-ferromagnetic
slide primary part distance plate
secondary part
machine bed
total travel
STEP 3
non-ferromagnetic
primary part distance plate
secondary part slide
machine bed
total travel
Figure 12-3: Installing the linear motor components with a whole secondary part
along the entire travel
When the primary part is lowered onto the

secondary part, the attractive forces rise as the
air gap decreases.
CAUTION ⇒ Observe the explanations in Chapter 9.3 Feed and
Attractive Forces
⇒ Never use a crane for lowering the primary part onto
the secondary part (elasticity / attractive force).
12.3 Assembling the Secondary Part Segments
Injuries and/or damaging motor components

only after the secondary parts have been installed.
WARNING
The secondary parts are screwed to the machine structure. The tightening
torque values of the mounting studs are specified below.
Secondary part size Screw size Tightening torque
LSS040
LSS080
LSS120
M6 10 Nm
LSS160
LSS200
LSS240
Figure 12-4: Tightening torque for the mounting studs at the secondary parts of
synchronous linear motors
Segmented secondary part When several secondary part segments are used along the entire motion
travel, the pole sequence must be observed (as shown in the Figure
below) when the segments are lined up.
N SN SN S
LSS120-B1-0150A LSS120-B1-0300A LSS120-B1-0150A

N 0123456 SN 0123456 SN 0123456 S
correct butt-mounting
S 0123456 N
N S LSS120-B1-0300A N S
LSS120-B1-0150A S N LSS120-B1-0150A
N 0123456 S N 0123456 S
incorrect butt-mounting MOTEINBAU04-LSF-EN.FH7
Figure 12-5: Lining up several secondary part segments
Malfunction or uncontrolled movements of the

motor with a resulting risk of injuries or
damage.
WARNING ⇒ Correct line-up of the secondary part segments
Risk of injuries or damage due to attractive or

repulsive forces when the secondary part
segments are lined up!
WARNING ⇒ Protection against uncontrolled movements
only during or after the installation in the machine.
Depending on the size, the attractive or repulsive forces in lining up the

secondary part segments can be up to approximately 300N.
N S N S
F
LSS120-B1-0150A LSS120-B1-0150A
N 0123456 S N 0123456 S
attractive force with correct butt-mounting
S 0123456 N
N S LSS120-B1-0150A
F LSS120-B1-0150A S N F
N 0123456 S
S 0123456 N
LSS120-B1-0150A N S
F S N
N LSS120-B1-0150A
0123456 S F
repulsive force with incorrect butt-mounting

Figure 12-6: Attractive and repulsive forces in lining up the secondary part
segments
12.4 Mounting the Primary Part
mounting screws
slide
... ...
8 1 4 5
primary part
... ...
6 3 2 7
Figure 12-7: Tightening sequence of the primary part mounting screws
Installation sequence:
1. Use the screws 1, 2, 3... n to fix the primary part until it rests against
the slide.
2. Tighten the screws 1, 2, 3 ...n at rated torque:
Primary part
Versions Screw size Rated torque
size
LSP040
LSP080
Standard
LSP120 M6 10 Nm
encapsulation
LSP140
LSP160
LSP200
Thermal encapsulation M8 25 Nm
LSP240
Figure 12-8: Rated torque values for the mounting screws of the primary parts
Note: The screwed contact surface between primary part and

machine structure must be free of oil and grease.
12.5 Liquid Cooling Connection

The liquid cooling connects directly to the primary part via standard
threads:
• Standard encapsulation: G1/4
• Thermal encapsulation: G1/8
Note: The maximum screw-in depth of the liquid cooling connection

is 10 mm for all motor sizes and versions.
12.6 Securing Screws

General Information LOCTITE is a plastic adhesive that is applied to the installation
components in a liquid form. The adhesive remains liquid as long as it is
in contact with oxygen. Only after the parts have been mounted, it
converts from its liquid state into hard plastic. This chemical conversion
takes place under exclusion of air and the produced metallic contact. The
result is a form-locking connection that is impact- and vibration-resistant.
The hardening accelerator Activator 7649 reduces the hardening time of
the adhesive.
Gluing Procedure
1. Clean metal chips and coarse dirt from threaded hole and screw or
grub screw.
2. Use LOCTITE rapid cleanser 7061 to clean oil, grease, and dirt
particles from threaded hole and screw/grub screw. The threads must
be absolutely free from rust.
3. Spray LOCTITE Activator into the threaded hole and let dry.
4. Use LOCTITE adhesive to moisten the same threaded hole in its
entire thread length thinly and evenly.
5. Screw in the matching screw / grub screw.
6. Allow join to harden. Hardening times see Figure 12-9.
Securing screwed connections using LOCTITE in tapped

blind holes
The adhesive must always be dosed into the tapped hole, never on the
screw. This prevents that the compressed air extrudes the adhesive when
the screw or grub screw is screwed in.
Hardened Hard to the Hard to the

touch without touch with
activator activator 7649
LOCTITE 243 ≈ 12 h 15 to 30 min 10 to 20 min
LOCTITE 620 ≈ 24 h 1 to 2 h 15 to 30 min
Note: All values refer to the hardening time at room temperature. The times are shorter
when heat is added.
Figure 12-9: Hardening times of LOCTITE adhesive
Note: LOCTITE 620 is heat-resistant up to 200 °C, LOCTITE 243 up

to 150 °C.
Detach the connection To detach the connection, use a wrench for unscrewing the screw or grub
screw in the traditional way. The breakaway torque of LOCTITE 620 is 20-
45 Nm, to one of LOCTITE 243 is 14-34 Nm (to DIN 54 454). Blowing hot
air on the screw connection reduces the breakaway torque.
Once the screw/grub screw has been turned out, the residuals of the
adhesive must be removed from the threaded hole (re-cutting the thread,
for example).
Note: The German version of this Chapter was checked by LOCTITE Germany for
correctness and was approved for publication.
Synchronous Linear Motors LSF Electrical Connection 13-1
13 Electrical Connection
13.1 Power Connection
Primary part connecting cable

The primary parts of LSF synchronous linear motors feature a highly
flexible and fully screened connecting cable. This connecting cable is
fixed to the primary part; it is 2 meters long.
1-U
2000 +10 100 +10
2-V
3-W
5-
PTC SNM.150.DK300
6-
primary part power cable 7-
PTC KTY84-130
8-
GE/GR
screwed conduit entry ferrules
PANSCHLKAB-LSF-EN.FH7
Figure 13-1: Primary part connecting cable
The following table lists the technical specifications of connecting cables

for individual motor sizes.
Motor size Type of Power lead Sensor lead Diameter Static bending
connecting cable cross-section cross-section radius
LSF040 INK0653 1.0 mm² 0.75 mm² 12.2 mm 70 mm
LSF080 INK0603 4.0 mm² 1.0 or 1.5 mm² 17.8 mm 100 mm
Figure 13-2: Specifications of the data used at the primary parts
Installing the primary part The connecting cable of the primary part ends with connecting ferrules
connecting cable (Figure 13-1).
The connecting cable that is fixed to the primary part must not be
exposed to any dynamic bending force. Thus, the primary part cable must
not be laid in a moved energy chain.
It is recommended to lay this cable rigidly to
• a flanged box,
• a plug-in connector, or
• a terminal box (cannot be delivered by Rexroth Indramat).
From this connecting point, cables can be used for feeding the power
through the energy chain or the machine structure. These cables are
available from Rexroth Indramat as ready-made cables.
13-2 Electrical Connection Synchronous Linear Motors LSF
drive controller
connection point
- flange socket
- coupling
- terminal box motor
energy chain
ongoing primary part
power cable connecting cable
MOTORANSCHL-LSF-EN.FH7
Figure 13-3: Laying the primary part connecting cable
Dynamic bending stress can damage the

connecting cable and, consequently, the motor.
⇒ Do not lay the primary part cable in a moved energy
WARNING chain.
⇒ Lay the power cable that runs onwards from a
connecting point to the energy chain
Note: The primary part connecting cables are sized for the highest
type current of a motor size. Under certain circumstances, the
cross-section of the continuing power cable may be smaller
(see Figure 13-9).
Power feeder connection

Below are the connecting diagrams for the above-mentioned connecting
types.
Connection via flange socket or

coupling flange socket coupling power connector
PTC
8 G G 8
J 7 F F 7
PTC
6 H H 6 motor temperature
sensor (connection
J 5 E E 5 to drive controller)
3 C C 3
M 2 B B 2
3~
1 A A 1
GNYE D D GNYE
ELCON01-LSF-EN.FH7
Figure 13-4: Electrical connection when a flanges socket or plug-in coupling is

used
Terminal box connection

terminal box
PTC
8 8
J 7 7
PTC
6 6 motor temperature
sensor (connection
J 5 5 to drive controller)
3 W 3
M 2 V 2
3~
1 U 1
GNYE GNYE
ELCON02-LSF-EN.FH7
Figure 13-5: Electrical connection when a terminal box is used
Wiring methods and cable cross-sections
Parallel motor connection With a parallel motor connection at a drive controller, there are the
following possibilities of building the continuing power cable:
• Laying a common cable of a larger cross-section (Figure 13-8)

• Laying two separate parallel cables
(Figure 13-7)
The second possibility may have the advantage of smaller bending radii.
The total cross-section of the parallel cables must correspond to the
increased cross-section for parallel motor connections.
Power connection for single drive controller

arrangement
connection point motor
energy chain
MOTORANSCHL01-LSF-EN.FH7
Figure 13-6: Power connection for single arrangement
Power connection for parallel drive controller

arrangement, separate power
cables
connection point motor 1

connection
point
connection point motor 2
energy chain
Figure 13-7: Power connection for parallel arrangement, separate power cables
Power connection for parallel drive controller

arrangement, common power
cable of larger cross-section
motor 1
motor 2
connection
energy chain point
Figure 13-8: Power connection for parallel arrangement, common power cable of
larger cross-section
Cable cross-section Figure 13-9 is used for selecting the correct cable cross-section, that
depends on the wiring method:
Motor type Motor chain current Primary part connection to Primary part connection
LSP... in A (r.m.s. value) Figure 13-6 and Figure 13-7 to Figure 13-8
040K-...-B. 4.7 1.0 mm² (INK0653) 1.0 mm² (INK0653)
040L-...-B 5.5 1.0 mm² (INK0653) 1.0 mm² (INK0653)
080K-...-A. 080S-...-A. 18.7 2.5 mm² (INK0602) 6 mm² (INK0604)
080K-...-B. 080S-...-B. 13.1 1.5 mm² (INK0650) 4 mm² (INK0603)
080K-...-C. 080S-...-C. 10.8 1.0 mm² (INK0653) 4 mm² (INK0603)
080L-...-B. 080T-...-B. 14.4 1.5 mm² (INK0650) 4 mm² (INK0603)
080L-...-C. 080T-...-C. 10.5 1.0 mm² (INK0653) 2.5 mm² (INK0602)
080M-...-A. 080U-...-A. 21.1 2.5 mm² (INK0602) 10 mm² (INK0605)
080M-...-B. 080U-...-B. 15.9 2.5 mm² (INK0602) 6 mm² (INK0604)
120K-...-A. 120S-...-A. 19.0 2.5 mm² (INK0602) 10 mm² (INK0605)
120K-...-B. 120S-...-B. 12.4 1.5 mm² (INK0650) 4 mm² (INK0603)
120K-...-C. 120S-...-C. 8.2 1.0 mm² (INK0653) 2.5 mm² (INK0602)
120L-...-A. 120T-...-A. 25.9 4 mm² (INK0603) 16 mm² (INK0606)
120L-...-B. 120T-...-B. 19.7 2.5 mm² (INK0602) 10 mm² (INK0605)
120L-...-C. 120T-...-C. 15.2 1.5 mm² (INK0650) 6 mm² (INK0604)
120M-...-A. 120U-...-A. 15.2 1.5 mm² (INK0650) 6 mm² (INK0604)
120M-...-B. 120U-...-B. 19.8 2.5 mm² (INK0602) 10 mm² (INK0605)
120M-...-C. 120U-...-C. 40.3 10 mm² (INK0605) 25 mm² (INK0607)
120N-...-A. 120V-...-A. 38.8 10 mm² (INK0605) 25 mm² (INK0607)
140L-...-B. 13.2 1.5 mm² (INK0650) 4 mm² (INK0603)
140N-...-B. 20.4 2.5 mm² (INK0602) 10 mm² (INK0605)
160K-...-A. 160S-...-A. 19.0 2.5 mm² (INK0602) 10 mm² (INK0605)
160K-...-B. 160S-...-B. 15.6 1.5 mm² (INK0650) 6 mm² (INK0604)
160L-...-A. 160T-...-A. 40.9 10 mm² (INK0605) 25 mm² (INK0607)
160L-...-B. 160T-...-B. 24.0 4 mm² (INK0603) 10 mm² (INK0605)
160L-...-C. 160T-...-C. 18.2 2.5 mm² (INK0602) 6 mm² (INK0604)
160M-...-A. 160U-...-A. 33.7 6 mm² (INK0604) 16 mm² (INK0606)
160M-...-B. 160U-...-B. 24.7 4 mm² (INK0603) 10 mm² (INK0605)
160M-...-C. 160U-...-C. 17.0 2.5 mm² (INK0602) 6 mm² (INK0604)
160N-...-B. 160V-...-B. 32.5 6 mm² (INK0604) 16 mm² (INK0606)
160N-...-C. 160V-...-C. 22.8 4 mm² (INK0603) 10 mm² (INK0605)
200K-...-C. 200S-...-C. 15.6 1.5 mm² (INK0650) 6 mm² (INK0604)
200L-...-B. 200T-...-B. 21.2 2.5 mm² (INK0602) 10 mm² (INK0605)
200M-...-A. 200U-...-A. 36.4 6 mm² (INK0604) 25 mm² (INK0607)
200M-...-B. 200U-...-B. 21.5 4 mm² (INK0603) 10 mm² (INK0605)
200N-...-A. 200V-...-A. 37.3 6 mm² (INK0604) 25 mm² (INK0607)
200N-...-B. 200V-...-B. 33.6 6 mm² (INK0604) 16 mm² (INK0606)
240L-...-A. 240T-...-A. 37.8 10 mm² (INK0605) 25 mm² (INK0607)
240L-...-C. 240T-...-C. 20.9 2.5 mm² (INK0602) 10 mm² (INK0605)
240M-...-B. 240U-...-B. 35.4 6 mm² (INK0604) 25 mm² (INK0607)
240N-...-A. 240V-...-A. 45.4 10 mm² (INK0605) 25 mm² (INK0607)
240N-...-B. 240V-...-B. 38.0 10 mm² (INK0605) 25 mm² (INK0607)
240N-...-C. 240V-...-C. 30.4 6 mm² (INK0604) 16 mm² (INK0606)
Figure 13-9: Required lead cross-sections, depending on motor type,
arrangement and connection method
Connection at the drive controller

This chapter describes the connection of power supply and temperature
monitoring at the drive controller.
The following overview shows the connection and terminal names of
power connection and motor temperature monitoring circuit.
Drive controller Terminal block name Terminal name of Terminal block Terminal name of
of power connection power connection name of motor motor temperature
temperature monitoring circuit
monitoring circuit
HDS0x.x
DKCxx.x 1 and 2
X5 A1, A2, A3 X6
1 (TM+), 2(TM-)
DKR0x.x
Figure 13-10: Drive controller terminal names
Single arrangement
drive controller
TM+
BR+
TM-
0VB
BR-
UB
X5 X6
4
7
A1 A2 A3
XS1
motor cable
screen connection
GNYE
1
M
3
temperature sensor
motor motor protection (PTC)
ELCON03-LSF-EN.FH7
Figure 13-11: Connection at the drive controller – primary part single

arrangement
Parallel arrangement
drive controller
TM+
BR+
TM-
0VB
BR-
UB
X5 X6
7
A1 A2 A3
XS1
motor cable
screen connection
GNYE
motor 1 motor 1
GNYE
1
3
5
6
M M
3 3
temperature sensor temperature sensor
motor protection (PTC) motor protection (PTC)
ELCON04-LSF-EN.FH7
Figure 13-12: Connection at the drive controller – primary part parallel

arrangement
Power cable connection If primary parts with cable entries in the opposite direction are arranged in
depending on primary part parallel, the connection of the power leads of the connecting cable at the
alignment at parallel drive controller depends on the cable entry.
arrangement
cable entry in the same direction
cable entry in opposite directions
Figure 13-13: Connection of the cable leads for the parallel arrangement of
primary parts on a drive controller
Selection of cable assemblies for the power supply
Selection of cable assemblies Power cable assemblies are selected by the documentation “Connecting
Cables for DIAX04, ECODRIVE03 and POWERDRIVE”.
13.2 Linear scale Connection

The length measuring system is connected via a cable assembly.
At the drive controller, connection is made at the high-resolution position
interface DAG (absolute length measuring systems with ENDAT
interface) or at the DLF (incremental length measuring systems).
high-resolution position interface connecting cable for scan head
DAG02.1
DAG oder DLF (part of the length measuring systems,
(plug-in card in the drive controller) supplied by the measuring system manufacturer)
connector or
X23
coupling
cable assembly
(available from Rexroth Indramat)
material measure scan head
ELCON05-LSF-EN.FH7
Figure 13-14: Length measuring system connection
The following table gives an overview of the cable assemblies that can be
used for connecting the length measuring system.
Measuring system type Absolute, ENDAT Incremental

Output variable Voltage: Voltage:
Signal shape Sine Sine
Signal amplitude 1Vpp 1Vpp
Position interface DAG DLF
Cable assembly
(Rexroth Indramat),
version with
DIAX04 male IKS4142 IKS4384
connector IKS4001 IKS4002
DKCxx.3 male
connector
DIAX04 female - IKS4383
connector - IKS4389
DKCxx.3 female
connector
Figure 13-15: Length measuring system connection components
Note: Please refer to the "List of Preferred DIAX04 and

ECODRIVE03 Connecting Cables" document for detailed
descriptions.
Synchronous Linear Motors LSF Commissioning 14-1
14 Commissioning
14.1 General Information About Commissioning of

Synchronous Linear Motors
In some points, commissioning of linear motors is different than
commissioning of rotary servo motors. These points are discussed in this
chapter.
Note: Any further and more detailed information can be found in the
corresponding description of functions of the drive controller.
The following points, in particular, must be observed when synchronous

linear motors are commissioned:
Parameters Synchronous linear motors are assembly kit motors whose individual
components are - completed by a sensor system - installed directly into
the machine by the machine manufacturer. This is why assembly kit
motors do not possess a data memory that provides motor parameters,
standard controller settings, etc. During commissioning, all the
parameters must be entered or loaded manually into the drive. The
DriveTop commissioning program provides all the Rexroth Indramat
motor parameters.
Controller optimization The procedure used for optimizing the controllers (current, velocity and
position controllers) of linear direct drives corresponds to the one used for
rotary servo drives. Merely the setting limits are higher with linear drives.
The kV factors of linear direct drives, for example, can be up to ten times
higher than the ones of rotary servo drives. This requires a corresponding
machine structure, however (see Chapter 9.1 Requirements Placed Upon
the Machine Structure).
Moved masses With regulated rotary servo drives, there are control-related restrictions in
the relationship of the moments of inertia of motor and load. Where direct
drives with linear motors are concerned, there are no such restrictions:
The moved foreign mass is independent of the motor’s own mass.
Encoder polarity The polarity of the actual velocity (linear scale) must agree with the
motor's force polarity. This correlation must be established before
commutation setting is performed.
Commutation setting The principle of a synchronous linear motor requires that the position of
the primary part, with respect to the secondary part, be obtained
immediately after power-up and/or after a malfunction. This is called pole
position recognition or commutation setting. Thus, commutation setting is
the process of establishing a position reference with respect to the
electrical and/or magnetic model of the motor. Commutation setting is
only possible after the motor components and the length measuring
system have been installed. The commutation setting method depends on
the measuring principle of the linear scale.
14-2 Commissioning Synchronous Linear Motors LSF
14.2 Basic Prerequisites

Successful commissioning requires the following prerequisites to be
provided:
• Observing the safety instructions and notes
• Verifying the safe function of electrical and mechanical components
• Providing the necessary tools
• Observing to the commissioning sequence that is described below
Checking all electrical and mechanical components
Prior to commissioning, all electrical and mechanical components must

be checked. Particular attention must be paid to the following points:
• Ensure the safety of man and machine

• Proper installation of the motor
• Correct power connection at the motor
• Correct connection of the linear scale
• Proper function of existing safety limit switch, door switches, etc.
• Proper function of the EMERGENCY STOP chain
• Machine structure and/or mechanical structure in a proper and
complete state
• Suitable end position shock absorbers are available and functional
• Correct connection and function of the motor cooling system
• Proper connection and function of drive controller and controller
Faults or malfunctions of mechanical or

electrical components may cause death,
serious injuries, or damage.
WARNING ⇒ The faults of mechanical or electrical components
must be eliminated before commissioning is
continued.
Risk of injuries, death or damage due to non-

observance of warnings and safety instructions.
⇒ Observe the warnings and safety instructions.
WARNING ⇒ Commissioning by trained personnel only
⇒ Observe to the commissioning sequence described
below
Commissioning Tests
DriveTop commissioning Commissioning can be performed directly via an NC terminal or using

software special commissioning software. Amongst other things, the DriveTop
commissioning software permits menu-controlled, application- and motor-
specific parameter value assignments of the drives to be performed.
PC A standard Windows PC is required for commissioning using DriveTop.
Commissioning via NC When commissioning is performed via the NC controller, the access to all
drive parameters and functionality’s must be ensured.
Oscilloscope An oscilloscope is required for drive optimization. It is used for

representing the signals that can be output via the adjustable analog
outputs of the drive controller. Representable signals are, for example,
command and actual values of velocity, position or current, lag error,
intermediate link performance, etc.
Multimeter A multimeter that is able to measure voltage, current, and resistance can
prove helpful during troubleshooting and for checking components.
14.3 Basic Commissioning Sequence

The following flow chart represents the basic commissioning sequence of
LSF synchronous linear motors. The individual points are explained in the
following chapters.
Verification:
Necessary information,
parameters and aids
- power connection - safety end switch
- measuring system connection - motor cooling
- motor parameters
- mechanical system - controller function
- end position dampers - drive control function - constant focommutation
- E STOP function setting kmx
error ? Yes eliminate error
No
parameter value assignments
initial load drive parameter

Yes
commissioning default values
No
enter parameters for

enter/load motor
length measuring
parameters
system
enteapplication-related
enter drive limitation
parameters
position sensor type

determine sensor polarity
No parameter S-0-0277 Bit 3 = 1
polarity Fsoll = vist?
............1001
commutation setting Yes
set and optimize

control loop
system is operational!
Figure 14-1: Basic commissioning sequence for synchronous linear drives
14.4 Parameter ization

With DriveTop, entering or editing certain parameters and executing
commands during the commissioning process is done inside menu-driven
dialogs or in list representations. Optionally, it can also be performed via
the control terminal.
Entering motor parameters
Note: The motor parameters are specified by Rexroth Indramat.

They must not be changed by the user. Commissioning is not
possible if these parameters are not available. In this case,
you must get into contact with your Rexroth Indramat Sales
and Service Facility.
Injuries and mechanical damage if the motor is

switched on immediately after the motor
parameters have been entered. Entering the
WARNING motor parameters does not make the motor
operational.
⇒ Do not switch on the motor immediately after the
motor parameters have been entered.
⇒ Enter the parameters for the linear scale.
⇒ Check and adjust the measuring system polarity.
⇒ Perform commutation setting.
The motor parameters can be entered in the following way:
• Use DriveTop to load all the motor parameters.

• Enter the individual parameters manually via the controller.
• With series machines, load a complete parameter record via the
controller or DriveTop.
The following overview shows the motor parameters that are required for
commissioning and for the operation of synchronous linear motors.
Parameter number Name Typical UNIT Comment

value
P-0-4014 Motor type 3 - Synchronous linear motor = 3
(Figure 14-3 and Figure 14-4)
S-0-0109 Motor peak current 100 A Corresponds to maximum motor
current
S-0-0111 Motor standstill current 30 A Corresponds to continuous motor
current
P-0-0018 Number of pole pairs/pole pair 75.0 mm (Figure 14-3 and Figure 14-4)
width
S-0-0106 Current controller proportional gain 20.0 V/A P component of the current controller
1 (Figure 14-3 and Figure 14-4)
S-0-0107 Current controller Integral time 1 2.0 ms I component of the current controller
P-0-4047 Motor inductivity 23.0 mH Motor inductivity
(see Specifications)
P-0-4048 Winding resistance 1.5 ohms Winding resistance
(see Specifications)
S-0-0201 Motor warning temperature 145 °C Temperature at which a warning is
generated at the drive. Fixed to 145°C;
cannot be changed by the user.
S-0-0204 Motor shutdown temperature 155 °C Temperature at which the motor is
switched off. Fixed to 155°C; cannot be
changed by the user.
P-0-0051 Torque/force constant 90 N/A Corresponds to the motor constant
kiFN; input only necessary for automatic
control loop setting (ECODRIVE03).
P-0-4005 EMF constant 85 Vs/m EMF constant of the motor; no input
required.
Figure 14-2: Motor parameters of the LSF synchronous linear motor
Input required
Input not required
Note: Depending on the combination with an appropriate drive

controller, maximum current and continuous current of the
motor can be reduced.
The following tables show the required motor parameters for LSF
synchronous linear motors in single arrangement and in parallel
arrangement at a control unit.
LSF motor parameters, primary part single arrangement
Motor type P-0-4014 S-0-0109 S-0-0111 P-0-0018 S-0-0106 S-0-0107 P-0-0051

LSP... in A in A in mm in V/A ms in N/A
040K-...-B. 3 30 6.7 75 29 5.0 36
040L-...-B. 3 40 7.8 75 32 5.0 46
080K-...-A. 080S-...-A. 3 70 26.8 75 15 5.0 41
080K-...-B. 080S-...-B. 3 45 17.5 75 33 5.0 63
080K-...-C. 080S-...-C. 3 40 15.1 75 45 5.0 73
080L-...-B. 080T-...-B. 3 55 20.8 75 39 5.0 84
080L-...-C. 080T-...-C. 3 40 14.5 75 80 5.0 121
080M-...-A. 080U-...-A. 3 80 27.9 75 21 5.0 77
080M-...-B. 080U-...-B. 3 60 23.6 75 32 5.0 91
120K-...-A. 120S-...-A. 3 80 25.8 75 17 5.0 60
120K-...-B. 120S-...-B. 3 60 18.0 75 37 5.0 86
120K-...-C. 120S-...-C. 3 35 10.7 75 90 5.0 145
120L-...-A. 120T-...-A. 3 115 34.9 75 19 5.0 73
120L-...-B. 120T-...-B. 3 90 28.7 75 26 5.0 89
120L-...-C. 120T-...-C. 3 65 21.6 75 45 5.0 118
120M-...-A. 120U-...-A. 3 75 21.9 75 48 5.0 153
120M-...-B. 120U-...-B. 3 90 28.4 75 29 5.0 118
120M-...-C. 120U-...-C. 3 200 54.9 75 11 5.0 61
120N-...-A. 120V-...-A. 3 200 54.9 75 10 5.0 71
140L-...-B. 3 70 18.4 75 21 5.0 144
140N-...-B. 3 90 28.8 75 24 5.0 144
160K-...-A. 160S-...-A. 3 100 26.9 75 22 5.0 78
160K-...-B. 160S-...-B. 3 70 21.2 75 36 5.0 99
160L-...-A. 160T-...-A. 3 200 57.8 75 9 5.0 64
160L-...-B. 160T-...-B. 3 95 33.9 75 33 5.0 109
160L-...-C. 160T-...-C. 3 75 25.7 75 52 5.0 144
160M-...-A. 160U-...-A. 3 165 46.3 75 14 5.0 94
160M-...-B. 160U-...-B. 3 150 35.4 75 20 5.0 123
160M-...-C. 160U-...-C. 3 100 24.3 75 43 5.0 179
160N-...-B. 160V-...-B. 3 170 46.7 75 23 5.0 120
160N-...-C. 160V-...-C. 3 110 31.8 75 48 5.0 176
200K-...-C. 200S-...-C. 3 75 22.0 75 42 5.0 118
200L-...-B. 200T-...-B. 3 100 30.0 75 35 5.0 130
200M-...-A. 200U-...-A. 3 130 51.5 75 17 5.0 103
200M-...-B. 200U-...-B. 3 100 30.5 75 45 5.0 174
200N-...-A. 200V-...-A. 3 200 52.8 75 20 5.0 125
200N-...-B. 200V-...-B. 3 160 47.5 75 24 5.0 139
240L-...-A. 240L-...-A. 3 190 53.4 75 13 5.0 88
240L-...-C. 240L-...-C. 3 100 29.6 75 45 5.0 159
240M-...-B. 240U-...-B. 3 175 50.0 75 22 5.0 126
240N-...-A. 240V-...-A. 3 200 64.2 75 19 5.0 134
240N-...-B. 240V-...-B. 3 175 53.8 75 27 5.0 160
240N-...-C. 240V-...-C. 3 145 43.0 75 36 5.0 200
Figure 14-3: LSF motor parameters, single arrangement
LSF motor parameters, primary part parallel arrangement
Motor type P-0-4014 S-0-0109 S-0-0111 P-0-0018 S-0-0106 S-0-0107 P-0-0051

2 x LSP... in A in A in mm in V/A ms in N/A
040K-...-B. 3 60 13.4 75 15 5.0 36
040L-...-B. 3 80 15.6 75 16 5.0 46
080K-...-A. 080S-...-A. 3 140 53.6 75 8 5.0 41
080K-...-B. 080S-...-B. 3 90 35.0 75 17 5.0 63
080K-...-C. 080S-...-C. 3 80 30.2 75 23 5.0 73
080L-...-B. 080T-...-B. 3 110 41.6 75 20 5.0 84
080L-...-C. 080T-...-C. 3 80 29.0 75 40 5.0 121
080M-...-A. 080U-...-A. 3 160 55.8 75 11 5.0 77
080M-...-B. 080U-...-B. 3 120 47.2 75 16 5.0 91
120K-...-A. 120S-...-A. 3 160 51.6 75 9 5.0 60
120K-...-B. 120S-...-B. 3 120 36.0 75 19 5.0 86
120K-...-C. 120S-...-C. 3 70 21.4 75 45 5.0 145
120L-...-A. 120T-...-A. 3 230 69.8 75 10 5.0 73
120L-...-B. 120T-...-B. 3 180 57.4 75 13 5.0 89
120L-...-C. 120T-...-C. 3 130 43.2 75 23 5.0 118
120M-...-A. 120U-...-A. 3 150 43.8 75 24 5.0 153
120M-...-B. 120U-...-B. 3 180 56.8 75 15 5.0 118
120M-...-C. 120U-...-C. 3 400 109.8 75 6 5.0 61
120N-...-A. 120V-...-A. 3 400 109.8 75 5 5.0 71
140L-...-B. 3 140 36.8 75 11 5.0 144
140N-...-B. 3 180 57.6 75 12 5.0 144
160K-...-A. 160S-...-A. 3 200 53.8 75 11 5.0 78
160K-...-B. 160S-...-B. 3 140 42.4 75 18 5.0 99
160L-...-A. 160T-...-A. 3 400 115.6 75 5 5.0 64
160L-...-B. 160T-...-B. 3 190 67.8 75 17 5.0 109
160L-...-C. 160T-...-C. 3 150 51.4 75 26 5.0 144
160M-...-A. 160U-...-A. 3 330 92.6 75 7 5.0 94
160M-...-B. 160U-...-B. 3 300 70.8 75 10 5.0 123
160M-...-C. 160U-...-C. 3 200 48.6 75 22 5.0 179
160N-...-B. 160V-...-B. 3 340 93.4 75 12 5.0 120
160N-...-C. 160V-...-C. 3 220 63.6 75 24 5.0 176
200K-...-C. 200S-...-C. 3 150 44.0 75 21 5.0 118
200L-...-B. 200T-...-B. 3 200 60.0 75 18 5.0 130
200M-...-A. 200U-...-A. 3 260 103.0 75 9 5.0 103
200M-...-B. 200U-...-B. 3 200 61.0 75 23 5.0 174
200N-...-A. 200V-...-A. 3 400 105.6 75 10 5.0 125
200N-...-B. 200V-...-B. 3 320 95.0 75 12 5.0 139
240L-...-A. 240L-...-A. 3 380 106.8 75 7 5.0 88
240L-...-C. 240L-...-C. 3 200 59.2 75 23 5.0 159
240M-...-B. 240U-...-B. 3 350 100.0 75 11 5.0 126
240N-...-A. 240V-...-A. 3 400 128.4 75 10 5.0 134
240N-...-B. 240V-...-B. 3 350 107.6 75 14 5.0 160
240N-...-C. 240V-...-C. 3 290 86.0 75 18 5.0 200
Figure 14-4: LSF motor parameters, parallel arrangement
Input of linear scale parameters
Sensor type The type of the linear scale must be defined. The parameter P-0-0074,
sensor type 1 is used for this purpose (see also Figure 9-66).
Sensor type P-0-0074

Incremental measuring system, e.g.
LS486 in conjunction with high- 2
resolution DLF position interface
Absolute encoder with ENDAT
interface, e.g. LC181 in conjunction
8
with high-resolution DAG position
interface
Figure 14-5: Encoder type definition
Signal period Linear scale for linear motors generate and interpret sinusoid signals. The
sine signal period must be entered in the parameter S-0-0116, sensor 1
resolution.
Note: The values that must be entered for parameter S-0-0116,

sensor 1 resolution, are specified in Figure 9-66. The values
for linear scale that are not shown in this figure must be
obtained directly from the manufacturer.
Input of drive limitations and application-related parameters
Drive limitations The possible selectable drive limitations include:
• Current limitation
• Force limitation
• Velocity limitations
• Travel range limits
Application-related parameters The application-related drive parameters include, for example, the
parameters of the drive fault reaction.
Note: Detailed information can be found in the description of function

of the employed drive controller and/or firmware.
14.5 Determining the Polarity of the linear scale

In order to avoid direct feedback in the velocity control loop, the effective
direction of the motor force and the count direction of the linear scales
must be the same.
Different effective directions of motor force and

count direction of linear scale cause
uncontrolled movements of the motor upon
WARNING power-up.
⇒ Protection against uncontrolled movements.
⇒ Adjust effective direction of motor force equal to
linear scale count direction.
Effective direction of motor To set the correct sensor polarity:

force
The effective direction of the motor force is always positive in the
direction of the cable connection of the primary part.
force direction
+
LSS second. part(s) LSP primary part
GEBPOL01-LSF-EN.FH7 power connection
Figure 14-6: Effective direction of the motor force
Effective direction motor force = When the primary part is moved in the direction of the cable connection,
linear scale count direction the count direction of the linear scale must consequently be positive:
force direction
+
power connection
GEBPOL02-LSF-EN.FH7
count direction
+
Figure 14-7: Effective direction motor force = linear scale count direction
Note: The adjustment of the sensor polarity is only performed with

respect to the primary part (cable connection). The installation
direction or the pole sequence of the secondary part does not
have any influence on the selection of the sensor polarity.
The sensor polarity is selected via the parameter
S-0-0277, Position feedback type 1 (bit 3)
Position, velocity and force data must not be inverted when the linear
scale count direction is set:
S-0-0085, Force polarity parameter: 0000000000000000

S-0-0043, Velocity polarity parameter: 0000000000000000
S-0-0055, Position polarities: 0000000000000000
The process-related axis count direction is set as required after sensor

polarity and commutation have been set.
14.6 Commutation setting

Setting the correct commutation angle is a prerequisite for maximum and
constant force development of the synchronous linear motor.
This procedure ensures that the angle between the current vector of the
primary part and the flux vector of the secondary part is always 90°. The
motor supplies the maximum force in this state.
Adjustment procedures Three different commutation setting procedures have been implemented
in the firmware. The figure below shows the correlation between the
employed linear scale and the method that is to be used.
Commutation setting of
synchronous linear motors
absolute measuring
incremental
ENDAT principle of linear scale
initial
Yes No
commissioning
Procedure 1 Procedure 2 Procedure 3
Measuring the refernece Current flow methode by Current flow method

between primary and secondary starting the P-0-0524 command Automatic execution after
part and starting the P-0-0524 controller enabling signal is set
command
Only for initial Only for initial
commissioning and sensor commissioning and sensor always after power-up
replacement replacement
Õ no controller enabling Õ with controller Õ with controller
Õ Õ Õ
signal enabling signal anabling signal
no axis movment axis movement axis movement
Figure 14-8: Commutation setting method for synchronous linear motors
Note: Method 2 and 3 cannot be employed for:
- vertical axes without weight compensation
- jammed or blocking axes
Malfunction in controlling motors and moved

elements!
Commutation setting must always be performed
DANGER in the following cases:
⇒ Initial commissioning
⇒ Modification of the mechanical attachment of the
linear scale
⇒ Replacement of the linear scale
⇒ Modification of the mechanical attachment of the
primary and/or secondary part
Malfunction and / or uncontrolled motor

movement due to error in commutation setting!
⇒ Effective direction of motor force = linear scale count
WARNING direction
⇒ Adhering to the described setting procedures
⇒ Correct motor and sensor parameters
⇒ Expedient parameter values must be assigned for
current and velocity control loop
⇒ Correct connection of motor power cable
⇒ Protection against uncontrolled movements
Motor connection The individual phases of the motor power connection must correctly be
assigned. See also Chapter 13 Electrical Connection.
Parameter verification To ensure a correct commutation setting, the following parameters should
be checked again and, if necessary, set to the values specified below:
Ident number Description Value

S-0-0085 Torque/force polarity parameter 0000000000000000
S-0-0043 Velocity polarity parameter 0000000000000000
S-0-0055 Position polarity 0000000000000000
P-0-4014 Motor type 3 (synchronous linear
motor)
P-0-0018 Number of pole pairs/pole pair Figure 14-3 and Figure 14-4
width
S-0-0116 S-0-0116, sensor 1 resolution Figure 9-66
Figure 14-9: Parameters that must be checked prior to commutation setting
Method 1: Measuring the reference between primary and secondary part

If this procedure is used for commutation setting, the relative position of
the primary part with respect to the secondary part must be determined.
The benefit of this procedure is that the commutation setting requires
neither the power to be switched on nor the axes to be moved.
Commutation setting need only be performed during the first-time
commissioning.
Note: This procedure requires an absolute linear scale with ENDAT

interface.
Measuring the relative position Depending on the accessibility of primary and secondary part in the
between primary and secondary machine or system, the relative position between primary and secondary
part part can be measured in different ways:
e g
d f
LSS secondary part(s) LSP primary part
KOMMUT01-LSF-EN.FH7 lp power connection
Figure 14-10: Measuring the relative position between primary and secondary
part
Note: From now on, the position of the primary part must not be
changed until the commutation setting procedure is
terminated.
Calculation of P-0-0523, The input value for P-0-0523, that is required for calculating the
commutation setting measured commutation offset, is determined from the measured relative position of
value the primary part with respect to the secondary part (Figure 14-10,
distance d, e, f, or g, depending on accessibility), and a motor-related
constant kmx (Figure 14-11 and Figure 14-13).
Reference point 1 : P − 0 − 0523 = d − k mx
Reference point 2 : P − 0 − 0523 = e − k mx − 37.5 mm
Reference point 3 : P − 0 − 0523 = − f − lp − k mx
Reference point 4 : P − 0 − 0523 = 37.5 mm − g − lp − k mx

P-0-0523: Commutation setting measured value in mm
d: Relative position reference position 1 in mm (Figure 14-10)
e: Relative position reference position 2 in mm (Figure 14-10)
f: Relative position reference position 3 in mm (Figure 14-10)
g: Relative position reference position 4 in mm (Figure 14-10)
kmx: Motor constant for commutation setting in mm
l p: Length of primary part in mm
Figure 14-11: Calculation of P-0-0523, commutation setting measured value
Note: Ensure that the sign is correct when you determine P-0-0523,
commutation setting measured value.
If P-0-0523 is determined with a negative sign, this must be
entered when the setup procedure is started.
Motor constant for commutation The motor constants for setting the commutation offset kmx depend on the
setting kmx orientation of primary and secondary part:
arrangement A
N S
N S
power connection
arrangement B
power connection
N S
LSS second. part(s) LSP connection
N S
KOMMUT02-LSF-EN.FH7
Figure 14-12: Possible arrangements between primary and secondary part
Arrangement A Arrangement B
(to Figure 14-12) (to Figure 14-12)
kmx in mm kmx in mm
Standard encapsulation 75.5 mm
38 mm
sizes 080, 120, 160, 200, 240
Standard encapsulation 104 mm
66 mm
size 040
Standard encapsulation 75.5 mm
38 mm
size 140
Thermal encapsulation 75.5 mm
38 mm
sizes 080, 120, 160, 200, 240
Figure 14-13: Motor constants for commutation setting kmx
Example 1, reference point (Figure 14-10):

d = 100 mm , kmx = 38.0 mm
P-0-0523 = d - kmx = 100 mm - 38.0 mm = 62 mm
Example 2, reference point (Figure 14-10):
d = 0 mm, kmx = 38.0 mm
P-0-0523 = d - kmx = 0 mm - 38.0 mm = - 38.0 mm
Example 3, reference point ö (Figure 14-10):
g = 180 mm , kmx = 38.0 mm , lp = 540 mm
P-0-0523 = 37.5 mm - g - lp - kmx = 37.5 mm -180 mm - 540 mm - 38 mm

P-0-0523 = 720.5 mm
Activation of commutation Prerequisites:

setting command 1. During the subsequent adjustment procedure, the drive must be in the
A0-13 state (ready for power connection).
2. The position of the primary part and/or the slide must not have changed
since the relative position of the primary part with respect to the
secondary part has been measured.
Once the determined value P-0-0523, commutation setting measured

value, has been entered, the command P-0-0524, D300 commutation
setting command must be started. The commutation offset is calculated in
this step.
Note: If the drive is in control mode when the command is started,

the commutation offset is determined using the current flow
method (see method 2).
The command must subsequently be cleared.
Method 2: Current flow method
This method is used for the following configurations:
• Synchronous linear motors with absolute linear scale.

In first-time commissioning, as an alternative of method 1
• Synchronous linear motor with incremental linear scale
Upon the first-time commissioning of the axis, the parameters P-0-

0560, commutation setting current and P-0-0562, commutation setting
period duration are determined automatically and stored in the drive.
A new commutation setting must be performed whenever the axis is
restarted. This is done using method 3. The parameter values for P-0-
0560 and P-0-0562, that were determined during first-time
commissioning, are used as the start values for this procedure.
Note: With first-time commissioning of the axis, the parameters P-0-

0560, commutation setting current and P-0-0562,
commutation setting period duration may also be set
individually by the user.
14.7 Setting and Optimizing the Control Loop
General sequence
The control loop settings in a digital drive controller are significant to the
characteristics of the servo axis. The control loop structure consists of a
cascaded position, velocity and current controller. The corresponding
mode defines the active controllers.
Note: Defining the control loop settings requires the corresponding

expertise.
The procedure used for optimizing the control loops (current, velocity and
position controllers) of linear direct drives corresponds to the one used for
rotary servo drives. Merely the setting limits are higher with linear drives.
setting and optimizing control loop of

synchronous linear drives
set current controller

(part of motor parameter)
optimize velocity controller
filtering mechanical
yes set rejection frequency
resonance vibrations
re-optimize velocity controller
no
optimize position controller
set and optimize acceleration

precontrol
Figure 14-14: Setting and optimizing the control loop of synchronous linear drives
Note: More detailed information can be found in the corresponding

description of functions of the drive controller.
Automatic control loop setting Drive controllers of the ECODRIVE03 series are able to perform
automatic control loop adjustment.
Filtering mechanical resonance Digital drives from Rexroth Indramat are able to provide a narrow-band
vibrations suppression of vibrations that are produced due to the power train
between motor and mechanical axis system. This results in increased
drive dynamic at a good stability.
The position or velocity feedback in the closed control loop excites the
mechanical system of the slide that is moved by the linear drive to
perform mechanical vibrations. This behavior, that is known as "Two-
masses vibration", is mainly in the frequency range between 400 and 800
Hz. It depends on the rigidity of the mechanical system and the spatial
expansion of the system.
In most cases, this "Two-masses vibration" has a clear resonant
frequency that can selectively be suppressed by a rejection filter in the
drive.
When the mechanical resonant frequency is suppressed, improving the
dynamic properties of the velocity control loop and of the position control
loop with may be possible, compared with close-loop operation without
the rejection filter.
This leads to an increased profile accuracy and to smaller cycle times for
positioning processes at a sufficient distance to the stability limit.
Rejection frequency and bandwidth of the filter can be selected. The
highest attenuation takes effect at the rejection frequency. The bandwidth
defines the frequency range at which the attenuation is less than -3dB. A
higher bandwidth leads to less attenuation of the rejection frequency!
damping in dB bandwidth frequency f

0
-3
rejection frequency fsperr
SPERRFILTER-LSF-EN.FH7
Figure 14-15: Amplitude frequency curve rejection filter vs. bandwidth, qualitative
Parameter value assignments and optimization of Gantry axes

Prerequisites:
• Õ The parameter seffings of the axes are identical
• Õ Parallelism of the guides of the Gantry axes
• Õ Parallelism of the linear scale
• Õ In the controller, the axes are registered as individual axes
Note: Drive-internal axis error compensation procedures can be

used for compensating the misalignments between two linear
scales as or the mechanical system. Please refer to the
corresponding description of functions of the drive controller
for a description of the operational principle and the parameter
settings.
actual position value 1 actual position value 2
Dx
length meas. system 1
length meas. system 2

ACHSKOMP-LSF-EN.FH7
Figure 14-16: Possible misalignment with the linear scale of a Gantry axis
Parameter settings
When using Gantry axes, you must ensure that the parameter settings of
the following parameters are identical:
• Motor parameters
• Polarity parameters for force, velocity and position
• Control loop parameters
We have:
k v1 = k v 2
k p1 = k p 2
kv: Position controller kv factor S-0-0104
k p: Velocity controller proportional gain S-0-0100
Figure 14-17: Proportional gains in the position and velocity control loop of both
axes
Velocity controller integral time The following possibilities must be taken into account for the velocity
(integral part) controller integral time (integral part):
Possibility 1 Possibility 2 Possibility 3 Possibility 4

Alignment of length
linear scale and ideal not ideal not ideal not ideal
guides
Integral part in both axes in both axes in one axis only in no axis
Behavior of the axes Since both motors Both axes work The axis without Both axes permit a
follow the position against each other integral-part permits a continuous position
command value until there is an continuous position offset. The magnitude
ideally, there will not equalization via the offset. The magnitude of the position offset
be a distortion of the mechanical coupling of the position offset depends on the
mechanical system. or until the maximum depends on the proportional gains in
current of one or both rigidity of the the position and
drive controller(s) has mechanical coupling velocity control loop.
been reached and a of both axes and of
control effect is no the proportional gains
longer possible. in the position and
velocity control loop.
Figure 14-18: Parameter ization of the velocity controller integral time S-0-0101
for Gantry axes
Optimization The previously described procedure must be followed for optimizing the
position and velocity loop.
Note: Any parameter modifications that are made during the

optimization of Gantry axes must always be made in both axes
simultaneously. If this is not possible, the parameter changes
should be made during optimization in smaller subsequent
steps in both axes.
Estimating the moved mass using a velocity ramp

Sometimes, the exact moving mass of the machine slide is not known.
Determining this mass can be made difficult by moving parts, additionally
mounted parts, etc.
The procedure explained below permits the moving axis mass to be
estimated on the basis of a recorded velocity ramp. This permits, for
example, the acceleration capability of the axis to be estimated.
Preparation This procedure requires the oscillographic recording of the following

parameters:
• S-0-0040, actual velocity value

• S-0-0080, torque/force command value
You can either use an oscilloscope or the oscilloscope function of the

drive in conjunction with DriveTop or NC.
S-0-0040,
actual velocity value
dv
dt
F acc
acceleration deceleration t
F dec
S-0-0080,
force command value
ERMITTLGMASSE-LSF-EN.FH7
Figure 14-19: Oscillogram of velocity and force
F + FDEC  dt
m = 30 ⋅ FdN ⋅  ACC ⋅
 100%  dv
m: Moved axis mass in kg
FdN: Rated force of the motor in N
FACC: Force command value during acceleration in %
FDEC: Force command value during deceleration in %
dv: Velocity change during const. acceleration in m/min
dt: Time change during const. acceleration in s
Figure 14-20: Determining the moved axis mass on the basis of a recorded
velocity ramp
Prerequisites: 1. Correct parameter settings of the rated motor

current (basis of representation S-0-0080)
2. Frictional force not directional
3. Recording of dv and dt at constant

acceleration
4. Do not perform at maximum motor force to

avoid non-linearities
Note: Due to possible direction-related force variations, this procedure

can not or only conditionally be used for vertical axes.
Synchronous Linear Motors LSF Maintenance and check of Motor Components 15-1
15 Maintenance and check of Motor Components
15.1 General Information

The motor components of the LSF synchronous linear motors need no
maintenance. Due to external influence, the motor components can be
damaged during operation. There should be a preventive maintenance of
the linear motor components within the service intervals of the machine or
system.
15.2 Check of Motor and Auxiliary Components

The following points should be observed during the preventive check of
motor and auxiliary components:
• Scratches on primary and secondary part

• Chips in the air gap between primary and secondary part
• Tightness of liquid cooling, hoses, and connections
• State of power and sensor cables in the energy chain
• State of linear scale (soiled, for example)
• State of guides (e.g. wear of linear guides)
Electrical check of motor components
The electrical defect of a primary part can be checked by measuring

electrical characteristics. The following variables are relevant:
• Resistance between motor connecting wires 1-2, 2-3 and 1-3
• Inductance between motor connecting wires 1-2, 2-3 and 1-3
• Insulation resistance between motor connecting wires and ground.
Resistance and inductance The measured values of resistance and inductance can be compared with
the values specified in Chapter 5 Specifications. The individual values of
resistance and inductance measured between the connections 1-2, 2-3
and 1-3 should be identical - within a tolerance of ± 5 %. There can be a
phase short circuit, a fault between windings, or a short circuit to ground if
one or more values differ significantly. The primary part must be replaced
in this case.
Insulation resistance The insulation resistance - measured between the motor connecting
leads and ground - should be at least 1 MΩ. The primary part should be
replaced if the measured value is lower.
Note: If there are any doubts during the electrical verification, please
consult Rexroth Indramat Service.
15-2 Maintenance and check of Motor Components Synchronous Linear Motors LSF
Synchronous Linear Motors LSF Recommended Suppliers of Auxiliary Components 16-1
16 Recommended Suppliers of Auxiliary Components
16.1 Linear scales
DR. JOHANNES HEIDENHAIN GmbH

Dr.-Johannes-Heidenhain-Strasse 5 • D-83301 Traunreut
Phone: +49 (0) 8669 31 0
Fax: +49 (0) 8669 50 61
E-Mail: verkauf@heidenhain.de
Internet: http://www.heidenhain.de/
Renishaw GmbH
Karl-Benz Strasse 12 • D-72124 Pliezhausen
Phone: +49 (0) 712 797 960
Fax: +49 (0) 712 788 237
E-Mail: germany@renishaw.com
Internet: http://www.renishaw.com/encoder/
Rexroth Star
Ernst-Sachs-Str. 90 • D-97419 Schweinfurt
Phone: +49 (0) 9721 937 0
Fax: +49 (0) 9721 937 350
E-Mail: info@rexroth-star.com
Internet: http://www.rexroth.com/rexrothstar
16.2 Linear Guides

Rexroth Star
Phone: +49 (0) 9721 937 0
Fax: +49 (0) 9721 937 350
16.3 Energy Chains

igus GmbH
Spicher Strasse 1a • D-51147 Köln
Phone: +49 (0) 2203 9649 0
Fax: +49 (0) 2203 9649 222
E-Mail: info@igus.de
Internet: http://www.igus.de/
KABELSCHLEPP GMBH
Marienborner Strasse 75 • 57074 Siegen
Phone: +49 (0) 271 5801 0
Fax: +49 (0) 271 5801 220
E-Mail: info@kabelschlepp.de
Internet: http://www.kabelschlepp.de/
16-2 Recommended Suppliers of Auxiliary Components Synchronous Linear Motors LSF
16.4 Cooling Units

SCHWÄMMLE GmbH & Co KG
Dieselstrasse 12-14 • D-71546 Aspach
Phone: +49 (0) 7191 9242 0
Fax: +49 (0) 7191 225 10
E-Mail: info@schwaemmle-gmbh.de
Internet: http://www.schwaemmle-gmbh.de/
Universal Hydraulik GmbH

Siemensstrasse 33 • D-61267 Neu-Anspach
Phone: +49 (0) 6081 9418 0
Fax: +49 (0) 6081 9602 20
E-Mail:
Internet: http://www.universalhydraulik.com/
16.5 Coolant Additives

See Figure 9-27
16.6 Coolant Hoses

Polyflex AG
Dorfstrasse 49 • CH-5430 Wettingen
Phone: +44 (0) 56-4241088
Fax: +44 (0) 56-4241114
E-Mail:
Internet: http://www.polyflex.ch/
igus GmbH
Spicher Straße 1a • D-51147 Köln
Phone: +49 (0) 2203 9649 0
Fax: +49 (0) 2203 9649 222
E-Mail: info@igus.de
Internet: http://www.igus.de/
Rexroth Mecman
Postfach 910762 • D-30427 Hannover
Phone: +49 (0) 511 2136 0
Fax: +49 (0) 511 2136 269
E-Mail: infomaster@rexroth-mecman.se
Internet: http://www.rexroth.com/rexrothmecman
Synchronous Linear Motors LSF Recommended Suppliers of Auxiliary Components 16-3
16.7 Axis Cover Systems

Möller Werke GmbH
Möller Balg
Kupferhammer • D-33649 Bielefeld
Phone: +49 (0) 521 4477 0
Fax: +49 (0) 521 4477 333
E-Mail: info@moellerbalg.de
Internet: http://www.moellerflex.de/
HCR-Heinrich Cremer GmbH

Oppelner Str. 37 • D-41199 Mönchengladbach
Phone: +49 (0) 2166 964900
Fax: +49 (0) 2166 609157
E-Mail: info@hcr.de
Internet: http://www.hcr.de/
Gebr. HENNIG GmbH

Postfach 1137 • 85729 Ismaning
Phone: +49 (0) 89 96096 0
Fax: +49 (0) 89 96096 120
E-Mail: HENNIGGMBH@aol.com
Internet: http://www.hennig-gmbh.de/
16.8 End Position Shock absorbers

ACE Stoßdämpfer GmbH
Postfach 1510 • D-40740 Langenfeld
Herzogstrasse 28 • D-40764 Langenfeld
Phone: +49 (0) 2173 92 26 10
Fax: +49 (0) 2173 92 26 19
E-Mail: info@ace-ace.de
Internet: http://www.ace-ace.de/
Rexroth Mecman
Postfach 910762 • D-30427 Hannover
Phone: +49 (0) 511 2136 0
Fax: +49 (0) 511 2136 269
E-Mail: infomaster@rexroth-mecman.se
Internet: http://www.rexroth.com/rexrothmecman
Metal Braid Shock Absorbers Rhodius GmbH

Treuchlinger Str. 23 • D-91781 Weißenburg
Phone: +49 (0) 9141 919 0
Fax: +49 (0) 9141 919 45
E-Mail: rhodius@rhodius.com
Internet: http://www.rhodius.com/
16-4 Recommended Suppliers of Auxiliary Components Synchronous Linear Motors LSF
16.9 Clamping Elements for Linear Guideways

Rexroth Star
Phone: +49 (0) 9721 937 0
Fax: +49 (0) 9721 937 350
16.10 External Mechanical Brakes

Kendrion Binder Magnete GmbH
Mönchweilerstr. 1 • D-78048 Villingen-Schwenningen
Phone: +49 (0) 7721 877 455
Fax: +49 (0) 7721 877 462
E-Mail:
Internet: http://www.binder-magnete.de/
16.11 Weight Compensation Systems

Pneumatic Ross Europa GmbH
Robert-Bosch-Str. 2 • D-63225 Langen
Phone: +49 (0) 6103 7597 0
Fax: +49 (0) 6103 7469 40
E-Mail:
Internet:
Hydraulic Rexroth Hydraulics

Jahnstr. 3-5 • D-97816 Lohr am Main
Phone: +49 (0) 9352 18 0
Fax: +49 (0) 9352 18 2598
E-Mail:
Internet: http://www.rexroth.com/
16.12 Wipers
Hunger DFE GmbH
Dichtungs- und Führungselemente
Alfred-Nobel Str. 26 • D-97080 Würzburg
Phone: +49 (0) 931 900 97 0
Fax: +49 (0) 931 900 97 30
E-Mail: info@hunger-dichtungen.de
Internet: http://www.hunger-dichtungen.de/
HME Dichtungssysteme
Richthofenstr. 31 • D - 86343 Königsbrunn
Phone: +49 (0) 8231 9623 0
Fax: +49 (0) 8231 865 16
E-Mail: hme@hme-seals.de
Internet: http://www.hme-seals.de/
Synchronous Linear Motors LSF Applicable Documents 17-1
17 Applicable Documents
All product documents for drive controllers, controllers, motors, cables
etc. are available on a common CD-ROM:
German Electronic Documentation System

Control and Drive Systems
DOK-GENERAL-CONTR*DRIVE-GNxx-DE-D0600
Order no.: 00281882
English Electronic Documentation System

Control and Drive Systems
DOK-GENERAL-CONTR*DRIVE-GNxx-EN-D0600
Order no.: 00281883
17-2 Applicable Documents Synchronous Linear Motors LSF
Synchronous Linear Motors LSF Linear Drive Application Form 18-1
18 Linear Drive Application Form

Rexroth Indramat
Fax: .............................................................. Date: ..........................
Contact person: ..............................................................
1. User information
Company ........................................................ Name ............................................................
Street ........................................................ Department ............................................................
Post code ........................................................ Telephone ............................................................
Town ........................................................ Fax ............................................................
e-mail ............................................................
Please: r call back r size drive r send proposal r ..................................................
2. General information about the application
Brauch r Machine tool r Automation r Packaging r Printing
r ........................................................................................................................
Type of application ...........................................................................................................................
...........................................................................................................................
Axis designation ...........................................................................................................................
Axis setup r Single axis r Compound of ............ axes within the system
r Linear drives only r Rotary and linear drives
Quantity ........................... per year

3. Mechanical and cinematic requirements
Installation position r Horizontal r Vertical r Slant, axis angle: ............degrees
Moved motor component r Primary part moves r Secondary part moves
Moved mass ....................... kg (incl. guides, power feeders, etc.)
Maximum Maximum
....................... m/min ....................... m/s²
velocity acceleration
Base force ....................... N (friction, energy supply, etc.)
Machining force ....................... N (detailed specifications see 5.)
18-2 Linear Drive Application Form Synchronous Linear Motors LSF
4. Ambient conditions
Ambient temperature ....................... °C
Machined material r Steel / cast iron r Light metal r Plastic r Wood

r Other:......................................... r None (handling only)
Dirt and aggressive r Chips r Dust

media
r Oil or lubricants: ............................................................................
r Other: ...............................................................................................
Protection of r Bellows r Telescopic cover r Wiper on secondary part

motor components
r Other: ................................................................................................
5. Thermal conditions and cooling
r Liquid cooling Coolant and additives: .............................................................................
Inlet temperature, minimum: ..................°C maximum: ......................°C
Max. flow quantity: ...............l/min Max. system pressure: .............bar
Maximum heating of the machine structure: ........... K r Not relevant
Maximum coolant temperature rise: ....................... K r Not relevant
Additional cooling at machine r Yes r No
r Air cooling, natural convection (Reducing the continuous forces to approximately 25 %)
6. Drive and control
Drive series r ECODRIVE03 r DIAX04 r POWERDRIVE
Mains voltage r 1 x 230 V r 3 x 400 V r 3 x 480 r ................................
Drive interface / bus r SERCOS interface r ANALOG ±10V r Parallel interface

system
r Profibus r Interbus r CANopen r DeviceNet r PWM
r ..................................................................................................................
Control r MTC200 r MTA200 r CLC / VISUALMOTION r CLC / SYNAX
r ...............................................:..................................................................
7. Linear scale
Measuring principle and r absolute ENDAT

interface
r incremental, sine signals 1 VSS
r incremental, sine signals 1 VSS, distance-encoded reference marks
Model r open r encapsulated r integrated in linear guides
Positioning accuracy ......................... µm
Synchronous Linear Motors LSF Linear Drive Application Form 18-3
8. Motion profile
Specification of motion r Not required; drive selection data exist (see 8.1)
profile r Strokes, positioning and idle times, maximum velocity and
acceleration as specified under item 3 (see 8.2)
r Sketch of velocity profile v(t) and process forces FP(t) (see 8.2 and 8.3)
r Operating phases and duty cycles (see 8.4)
r Equation of motion for s(t) and / or v(t) (see 8.5)
r s(t) and / or v(t) can be specified in digital form:
r MathCad r Excel r ASCII r ...........................

8.1 Data for motor selection exists:
Fmax: .............. N FEFF / FdN: .............. N vFmax: .............. m/min vmax: .............. m/min
8.2 Specification of strokes, position and idle times
Positioning Positioning
Stroke Travel time Idle time Stroke Travel time Idle time
1 8
2 9
3 10
4 11
5 12
6 13
7 14
8.3 Sketch of velocity profile and process forces
time in ......
time in ......
18-4 Linear Drive Application Form Synchronous Linear Motors LSF
8.4 Specification of operating phases and related duty cycle

EDi Force Fi
Acceleration, deceleration at .............m/s² ............. % .............. N
Acceleration, deceleration at .............m/s² and machining ............. % .............. N
Rapid traverse at v = constant = ............ m/min ............. % .............. N
Machining at v = ............ m/min ............. % .............. N
Standstill with machining ............. % .............. N
Standstill without machining ............. % .............. N
................................................................................ ............. % .............. N
Total: 100 %
8.5 Equation of motion for s(t) or v(t)
Equation of motion,
e.g.: s( t ) = r ⋅ sin( ω ⋅ t )
Explanation:
9. Miscellaneous / comments / sketches
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
Synchronous Linear Motors LSF Service & Support 19-1
19 Service & Support
19.1 Helpdesk
Unser Kundendienst-Helpdesk im Hauptwerk Lohr Our service helpdesk at our headquarters in Lohr am
am Main steht Ihnen mit Rat und Tat zur Seite. Main, Germany can assist you in all kinds of inquiries.
Sie erreichen uns Contact us
- telefonisch: +49 (0) 9352 40 50 60 - by phone: +49 (0) 9352 40 50 60

über Service-Call Entry Center Mo-Fr 07:00-18:00 via Service-Call Entry Center Mo-Fr 07:00 am -6:00 pm
- per Fax: +49 (0) 9352 40 49 41 - by fax: +49 (0) 9352 40 49 41
- per e-Mail: service@indramat.de - by e-mail: service@indramat.de
19.2 Service-Hotline
Außerhalb der Helpdesk-Zeiten ist der Service After helpdesk hours, contact our service
direkt ansprechbar unter department directly at
+49 (0) 171 333 88 26 +49 (0) 171 333 88 26

oder +49 (0) 172 660 04 06 or +49 (0) 172 660 04 06
19.3 Internet
Weitere Hinweise zu Service, Reparatur und Additional notes about service, repairs and training
Training finden Sie im Internet unter are available on the Internet at
www.indramat.de www.indramat.de
Außerhalb Deutschlands nehmen Sie bitte zuerst Please contact the sales & service offices in your
Kontakt mit Ihrem lokalen Ansprechpartner auf. Die area first. Refer to the addresses on the following
Adressen sind im Anhang aufgeführt. pages.
19.4 Vor der Kontaktaufnahme... - Before contacting us...

Wir können Ihnen schnell und effizient helfen wenn For quick and efficient help, please have the
Sie folgende Informationen bereithalten: following information ready:
1. detaillierte Beschreibung der Störung und der 1. Detailed description of the failure and
Umstände. circumstances.
2. Angaben auf dem Typenschild der betreffenden 2. Information on the type plate of the affected
Produkte, insbesondere Typenschlüssel und products, especially type codes and serial
Seriennummern. numbers.
3. Telefon-/Faxnummern und e-Mail-Adresse, 3. Your phone/fax numbers and e-mail address,
unter denen Sie für Rückfragen zu erreichen so we can contact you in case of questions.
sind.
19-2 Service & Support Synchronous Linear Motors LSF
19.5 Kundenbetreuungsstellen - Sales & Service Facilities

Verkaufsniederlassungen sales agencies
Niederlassungen mit Kundendienst offices providing service
Deutschland – Germany vom Ausland: (0) nach Landeskennziffer weglassen!

from abroad: don’t dial (0) after country code!
Vertriebsgebiet Mitte
Germany Centre SERVICE SERVICE SERVICE
Rexroth Indramat GmbH CALL ENTRY CENTER HOTLINE ERSATZTEILE / SPARES

Bgm.-Dr.-Nebel-Str. 2 MO – FR MO – FR verlängerte Ansprechzeit
97816 Lohr am Main von 07:00 - 18:00 Uhr von 17:00 - 07:00 Uhr - extended office time -
from 5 pm - 7 am ♦ nur an Werktagen
Kompetenz-Zentrum Europa from 7 am – 6 pm + SA / SO - only on working days -
♦ von 07:00 - 18:00 Uhr
Telefon: +49 (0)9352 40-0 Tel. +49 (0) 9352 40 50 60 Tel.: +49 (0)172 660 04 06 - from 7 am - 6 pm -
Telefax: +49 (0)9352 40-4885 service@indramat.de oder / or
Tel.: +49 (0)171 333 88 26 Tel. +49 (0) 9352 40 42 22
Vertriebsgebiet Süd Gebiet Südwest Vertriebsgebiet Ost Vertriebsgebiet Nord

Germany South Germany South-West Germany East Germany North
Rexroth Indramat GmbH Mannesmann Rexroth AG Rexroth Indramat GmbH Mannesmann Rexroth AG
Ridlerstraße 75 Vertrieb Deutschland – VD-BI Beckerstraße 31 Vertriebsniederlassung Region Nord
80339 München Geschäftsbereich Rexroth Indramat 09120 Chemnitz Gesch.ber. Rexroth Indramat
Regionalzentrum Südwest Walsroder Str. 93
Ringstrasse 70 / Postfach 1144 30853 Langenhagen
70736 Fellbach / 70701 Fellbach
Telefon: +49 (0)89 540138-30
Telefax: +49 (0)89 540138-10 Tel.: +49 (0)711 57 61–100 Telefon: +49 (0)371 35 55-0 Telefon: +49 (0) 511 72 66 57-0
indramat.mue@t-online.de Fax: +49 (0)711 57 61–125 Telefax: +49 (0)371 35 55-333 Telefax: +49 (0) 511 72 66 57-95
Vertriebsgebiet West Vertriebsgebiet Mitte Vertriebsgebiet Ost Vertriebsgebiet Nord

Germany West Germany Centre Germany East Germany North
Mannesmann Rexroth AG Mannesmann Rexroth AG Mannesmann Rexroth AG Rexroth Indramat GmbH

Vertrieb Deutschland Gesch.ber. Rexroth Indramat GB Rexroth Indramat GmbH Kieler Straße 212
Regionalzentrum West Lilistraße 14-18 Holzhäuser Str. 122 22525 Hamburg
Borsigstrasse 15 63067 Offenbach 04299 Leipzig
40880 Ratingen
Telefon: +49 (0)2102 409-0 Telefon: +49 (0) 69 82 00 90-0 Telefon: +49 (0)341 86 77-0 Telefon: +49 (0) 40 81 955 966
Telefax: +49 (0)2102 409-406 Telefax: +49 (0) 69 82 00 90-80 Telefax: +49 (0)341 86 77-219 Telefax: +49 (0) 40 85 418 978
Europa – Europe vom Ausland: (0) nach Landeskennziffer weglassen, Italien: 0 nach Landeskennziffer mitwählen
from abroad: don’t dial (0) after country code, Italy: dial 0 after country code
Austria - Österreich Austria - Österreich Belgium - Belgien Denmark - Dänemark

Mannesmann Rexroth Ges.m.b.H. Mannesmann Rexroth G.m.b.H. Mannesmann Rexroth N.V.-S.A. BEC AS
Gesch.ber. Rexroth Indramat Gesch.ber. Rexroth Indramat Gesch.ber. Rexroth Indramat Zinkvej 6
Hägelingasse 3 Industriepark 18 Industrielaan 8 8900 Randers
1140 Wien 4061 Pasching 1740 Ternat
Telefon: +43 (0)1 9852540-400 Telefon: +43 (0)7221 605-0 Telefon: +32 (0)2 5830719 Telefon: +45 (0)87 11 90 60
Telefax: +43 (0)1 9852540-93 Telefax: +43 (0)7221 605-21 Telefax: +32 (0)2 5830731 Telefax: +45 (0)87 11 90 61
indramat@rexroth.be
Czech Republic - Tschechien England Finland - Finnland France - Frankreich

Mannesmann-Rexroth, spol.s.r.o. Mannesmann Rexroth Ltd. Rexroth Mecman Oy Mannesmann Rexroth S.A.
Hviezdoslavova 5 Rexroth Indramat Division Rexroth Indramat division Division Rexroth Indramat
627 00 Brno Broadway Lane, South Cerney Ansatie 6 Parc des Barbanniers
Cirencester, Glos GL7 5UH 017 40 Vantaa 4, Place du Village
92632 Gennevilliers Cedex
Telefon: +420 (0)5 48 126 358 Telefon: +44 (0)1285 863000 Telefon: +358 (0)9 84 91-11 Telefon: +33 (0)141 47 54 30
Telefax: +420 (0)5 48 126 112 Telefax: +44 (0)1285 863030 Telefax: +358 (0)9 84 91-13 60 Telefax: +33 (0)147 94 69 41
Hotline: +33 (0)608 33 43 28
France - Frankreich France - Frankreich Hungary - Ungarn Italy - Italien

Mannesmann Rexroth S.A. Mannesmann Rexroth S.A. Mannesmann Rexroth Kft. Mannesmann Rexroth S.p.A.
Division Rexroth Indramat Division Rexroth Indramat Angol utca 34 Divisione Rexroth Indramat
270, Avenue de Lardenne 91, Bd. Irène Joliot-Curie 1149 Budapest Via G. Di Vittoria, 1
31100 Toulouse 69634 Vénissieux – Cedex 20063 Cernusco S/N.MI
Telefon: +33 (0)5 61 49 95 19 Telefon: +33 (0)4 78 78 53 65 Telefon: +36 (1) 364 00 02 Telefon: +39 02 2 365 270
Telefax: +33 (0)5 61 31 00 41 Telefax: +33 (0)4 78 78 53 62 Telefax: +36 (1) 383 19 80 Telefax: +39 02 700 408 252378
Italy - Italien Italy - Italien Italy - Italien Italy - Italien

Mannesmann Rexroth S.p.A. Mannesmann Rexroth S.p.A. Mannesmann Rexroth S.p.A. Mannesmann Rexroth S.p.A.
Divisione Rexroth Indramat Divisione Rexroth Indramat Divisione Rexroth Indramat Divisione Rexroth Indramat
Via Borgomanero, 11 Via del Progresso, 16 (Zona Ind.) Via Mascia, 1 Viale Oriani, 38/A
10145 Torino 35020 Padova 80053 Castellamare di Stabia NA 40137 Bologna
Telefon: +39 011 7 50 38 11 Telefon: +39 049 8 70 13 70 Telefon: +39 081 8 71 57 00 Telefon: +39 051 34 14 14
Telefax: +39 011 7 71 01 90 Telefax: +39 049 8 70 13 77 Telefax: +39 081 8 71 68 85 Telefax: +39 051 34 14 22
Netherlands - Niederlande/Holland Netherlands - Niederlande/Holland Norway - Norwegen Poland - Polen

Rexroth B.V. Rexroth Hydrocare B.V. Rexroth Mecman AS Mannesmann Rexroth Sp.zo.o.
Kruisbroeksestraat 1 Kruisbroeksestraat 1 Rexroth Indramat Division Biuro Poznan
(P.O. Box 32) (P.O. Box 32) Berghagan 1 or: Box 3007 ul. Dabrowskiego 81/85
5281 RV Boxtel 5281 RV Boxtel 1405 Ski-Langhus 1402 Ski 60-529 Poznan
Telefon: +31 (0)411 65 19 51 Telefon: +31 (0)411 65 19 51 Telefon: +47 (0)64 86 41 00 Telefon: +48 061 847 67 99
Telefax: +31 (0)411 65 14 83 Telefax: +31 (0)411 67 78 14 Telefax: +47 (0)64 86 90 62 Telefax: +48 061 847 64 02
indramat@hydraudyne.nl
Rumania - Rumänien Russia - Russland Spain - Spanien Spain - Spanien

Mannesmann Rexroth Sp.zo.o. Tschudnenko E.B. Mannesmann Rexroth S.A. Goimendi S.A.
Str. Drobety nr. 4-10, app. 14 Arsenia 22 Divisiòn Rexroth Indramat División Rexroth Indramat
70258 Bucuresti, Sector 2 153000 Ivanovo Centro Industrial Santiga Parque Empresarial Zuatzu
Obradors s/n C/ Francisco Montagne no.2
08130 Santa Perpetua de Mogoda 20018 San Sebastian
Barcelona
Telefon: +40 (0)1 210 48 25 Telefon: +7 093 223 96 33 Telefon: +34 9 37 47 94 00 Telefon: +34 9 43 31 84 21
+40 (0)1 210 29 50 oder/or +7 093 223 95 48 Telefax: +34 9 37 47 94 01 - service: +34 9 43 31 84 56
Telefax: +40 (0)1 210 29 52 Telefax: +7 093 223 46 01 Telefax: +34 9 43 31 84 27
- service: +34 9 43 31 84 60
satindramat-goimendi@adegi.es
Sweden - Schweden Slowenia - Slowenien Switzerland East - Schweiz Ost Switzerland West - Schweiz West
Rexroth Mecman Svenska AB Rexroth Indramat Mannesmann Rexroth Schweiz AG Mannesmann Rexroth Suisse SA
Rexroth Indramat Division elektromotorji d.o.o. Gesch.ber. Rexroth Indramat Département Rexroth Indramat
Varuvägen 7 Otoki 21 Gewerbestraße 3 Rue du village 1
125 81 Stockholm 64 228 Zelezniki 8500 Frauenfeld 1020 Renens
Telefon: +46 (0)8 727 92 00 Telefon: +386 64 61 73 32 Telefon: +41 (0)52 720 21 00 Telefon: +41 (0)21 632 84 20
Telefax: +46 (0)8 647 32 77 Telefax: +386 64 64 71 50 Telefax: +41 (0)52 720 21 11 Telefax: +41 (0)21 632 84 21
Turkey - Türkei
Mannesmann Rexroth Hidropar A..S.
Fevzi Cakmak Cad No. 3
34630 Sefaköy Istanbul
Telefon: +90 212 541 60 70
Telefax: +90 212 599 34 07
Africa, Asia, Australia – incl. Pacific Rim

vom Ausland: (x) nach Landeskennziffer weglassen!
from abroad: don’t dial (x) after country code!
Australia - Australien Australia - Australien China China

AIMS - Australian Industrial Mannesmann Rexroth Pty. Ltd. Shanghai Mannesmann Rexroth Mannesmann Rexroth (China) Ldt.
Machinery Services Pty. Ltd. No. 7, Endeavour Way Hydraulics & Automation Ltd. 15/F China World Trade Center
Unit 3/45 Horne ST Braeside Victoria, 31 95 Wai Gaoqiao Free Trade Zone 1, Jianguomenwai Avenue
Campbellfield , VIC 3061 Melbourne No.122, Fu Te Dong Yi Road Beijing 100004, P.R.China
Melbourne Shanghai 200131 - P.R.China
Telefon: +61 (0)3 93 59 02 28 Telefon: +61 (0)3 95 80 39 33 Telefon: +86 21 58 66 30 30 Telefon: +86 10 65 05 03 80
Telefax: +61 (0)3 93 59 02 86 Telefax: +61 (0)3 95 80 17 33 Telefax: +86 21 58 66 55 23 Telefax: +86 10 65 05 03 79
mel@rexroth.com.au
China China Hongkong India - Indien

Mannesmann Rexroth (China) Ldt. Mannesmann Rexroth (China) Ldt. Rexroth (China) Ldt. Mannesmann Rexroth (India) Ltd.
A-5F., 123 Lian Shan Street Guangzhou Repres. Office 1/F., 19 Cheung Shun Street Rexroth Indramat Division
Sha He Kou District Room 1014-1016, Metro Plaza, Cheung Sha Wan, Plot. A-58, TTC Industrial Area
Dalian 116 023, P.R.China Tian He District, 183 Tian He Bei Rd Kowloon, Hongkong Thane Turbhe Midc Road
Guangzhou 510075, P.R.China Mahape Village
Navi Mumbai - 400 701
Telefon: +86 411 46 78 930 Telefon: +86 20 8755-0030 Telefon: +852 22 62 51 00
Telefax: +86 411 46 78 932 +86 20 8755-0011 Telefax: +852 27 41 33 44 Telefon: +91 (0)22 7 61 46 22
Telefax: +86 20 8755-2387 Telefax: +91 (0)22 7 68 15 31
India - Indien Indonesia - Indonesien Japan Japan
Mannesmann Rexroth (India) Ltd. PT. Rexroth Wijayakusuma Rexroth Automation Co., Ltd. Rexroth Automation Co., Ltd.
Rexroth Indramat Division Jl. Raya Bekasi Km 21 Service Center Japan Rexroth Indramat Division
Plot. 96, Phase III Pulogadung Yutakagaoka 1810, Meito-ku, 1F, I.R. Building
Peenya Industrial Area Jakarta Timur 13920 NAGOYA 465-0035, Japan Nakamachidai 4-26-44, Tsuzuki-ku
Bangalore - 560058 YOKOHAMA 224-0041, Japan
Telefon: +81 (0)52 777 88 41
Telefon: +91 (0)80 8 39 73 74 Telefon: +62 21 4 61 04 87 +81 (0)52 777 88 53 Telefon: +81 (0)45 942 72 10
Telefax: +91 (0)80 8 39 43 45 +62 21 4 61 04 88 +81 (0)52 777 88 79 Telefax: +81 (0)45 942 03 41
Telefax: +62 21 4 60 01 52 Telefax: +81 (0)52 777 89 01
Korea South Africa - Südafrika Taiwan Thailand

Mannesmann Rexroth-Korea Ltd. TECTRA Automation (Pty) Ltd. Rexroth Uchida Co., Ltd. NC Advance Technologies Co. Ltd.
Rexroth Indramat Division 28 Banfield Road,Industria North No.17, Lane 136, Cheng Bei 1 Rd., 59/76 Moo 9
1500-12 Dadae-Dong- Saha-Ku RSA - Maraisburg 1700 Yungkang, Tainan Hsien Soi Ramintra 34
Pusan, 604-050 Taiwan, R.O.C. Ramintra Road, Tharang, Bangkhen
Telefon: +27 (0)11 673 20 80
Republic of South Korea Bangkok 10220
Telefax: +27 (0)11 673 72 69 Telefon: +886 (0)6 25 36 565
Telefon: +82 (0)51 26 00 741 Telefax: +886 (0)6 25 34 754 Telefon: +66 2 943 70 62
Telefax: +82 (0)51 26 00 747 +66 2 943 71 21
gyhan@rexrothkorea.co.kr Telefax: +66 2 509 23 62
sonkawin@hotmail.com
Nordamerika – North America

USA USA Central Region - Mitte USA Southeast Region - Südwest USA SERVICE-HOTLINE
Hauptniederlassung - Headquarters
Mannesmann Rexroth Corporation Mannesmann Rexroth Corporation
Mannesmann Rexroth Corporation Rexroth Indramat Division Rexroth Indramat Division
- 7 days x 24hrs -
Rexroth Indramat Division Central Region Technical Center Southeastern Technical Center
5150 Prairie Stone Parkway Auburn Hills, MI 48326 3625 Swiftwater Park Drive
Hoffman Estates, IL 60192-3707 Suwanee, Georgia 30174
+1-800-860-1055
Competence Centre America
Telefon: +1 248 3 93 33 30 Telefon: +1 770 9 32 32 00
Telefon: +1 847 6 45 36 00 Telefax: +1 770 9 32 19 03
Telefax: +1 248 3 93 29 06
Telefax: +1 847 6 45 62 01
service@indramat.com
USA Northeast Region – Nordost USA Northeast Region – Nordost Canada East - Kanada Ost Canada West - Kanada West
Mannesmann Rexroth Corporation Mannesmann Rexroth Corporation Basic Technologies Corporation Basic Automation Burnaby
Rexroth Indramat Division Rexroth Indramat Division Burlington Division 5345 Goring St.
Charlotte Regional Sales Office Northeastern Technical Center 3426 Mainway Drive Burnaby, British Columbia
14001 South Lakes Drive 99 Rainbow Road Burlington, Ontario Canada V7J 1R1
Charlotte, North Carolina 28273 East Granby, Connecticut 06026 Canada L7M 1A8
Telefon: +1 704 5 83 97 62 Telefon: +1 905 335 55 11 Tel. +1 604 205-5777
+1 704 5 83 14 86 Telefon: +1 860 8 44 83 77 Telefax: +1 905 335-41 84 Fax +1 604 205-6944
Telefax: +1 860 8 44 85 95 dave.gunby@basic.ca
Südamerika – South America

Argentina - Argentinien Argentina - Argentinien Brazil - Brasilien Brazil - Brasilien
Mannesmann Rexroth S.A.I.C. NAKASE Mannesmann Rexroth Mannesmann Rexroth

Division Rexroth Indramat Servicio Tecnico CNC Automação Ltda. Automação Ltda.
Acassusso 48 41/7 Calle 49, No. 5764/66 Divisão Rexroth Indramat Divisão Rexroth Indramat
RA - 1605 Munro (Buenos Aires) RA - 1653 Villa Balester Rua Georg Rexroth, 609 R. Dr.Humberto Pinheiro Vieira, 100
Prov. - Buenos Aires Vila Padre Anchieta Distrito Industrial
Telefon: +54 (0)11 4756 01 40
BR - 09951-270 Diadema-SP BR - 89220-390 Joinville - SC
Telefax: +54 (0)11 4762 6862 Telefon: +54 (0) 11 4768 36 43
mannesmann@mannesmannsaic.com.ar
[ Caixa Postal 377 ] [ Caixa Postal 1273 ]
Telefax: +54 (0) 11 4768 24 13 [ BR-09901-970 Diadema-SP ]
nakase@usa.net Tel./Fax: +55 (0)47 473 58 33
nakase@infovia.com.ar Telefon: +55 (0)11 4075 90 60 Mobil: +55 (0)47 974 66 45
+55 (0)11 4075 90 70 prochnow@zaz.com.br
Telefax: +55 (0)11 4075 35 52
awittwer@rexroth.com.br
Mexico
Mannesmann Rexroth Mexico S.A.

de C.V.
Calle Neptuno 72
Unidad Ind. Vallejo
MEX - 07700 Mexico, D.F.
Telefon: +52 5 754 17 11
+52 5 754 36 84
+52 5 754 12 60
Telefax: +52 5 754 50 73
+52 5 752 59 43
Notizen - Notes
Synchronous Linear Motors LSF Index 20-1
20 Index
A
Ambient conditions 9-36
Appropriate use
Introduction 2-1
Arrangement of the motor components
Single arrangement 9-3
Attractive force 9-12
Auxiliary components
Suppliers 16-1
Axis angel 8-3
Axis cover systems 9-50
Bellows covers 9-50
Shade covers 9-50
Suppliers 16-3
Telescopic covers 9-50
Axis structure 4-1
B
Brakes 9-11, 9-48
Suppliers 16-4
C
Check of motor components
Customer side 15-1
Chip attraction 9-36, 9-38
Commissioning 14-1
Aids 14-3
Mass determination 14-22
Parameter value assignments 14-5
Prerequisites 14-2
Sequence 14-4
Commutation setting 14-1, 14-12
Condensation 9-22
Connection
Length measuring system 13-8
Liquid cooling 12-7
Power cable 13-1
Continuous feed force 7-2
Controller optimization 14-1
Controls 10-1
Coolant flow quantity 9-23
Coolant hoses
Suppliers 16-2
Cooling 9-17
Coolant 9-20
Coolant additives 9-21
Coolant flow quantity 9-23
Coolant lines 9-29
Coolant temperature 9-21
Cooling capacity 9-26
Cooling unit 9-27
Liquid cooling connection 12-7
Maximum pressure of coolant circuit 9-22
Power loss 9-16
Pressure drop 9-25
Secondary parts 9-19
Sizing the cooling circuit 9-23
Standard encapsulation 9-18
Thermal encapsulation 9-18
Cooling concept LSF 9-18
Cooling units
Suppliers 16-2
20-2 Index Synchronous Linear Motors LSF
D
Delivery 11-2
Documentation
About this document 1-1
Documents
Applicable 17-1
Drive controllers 10-1
Motor c controller combinations 7-1
Drive power 8-15
DriveTop 14-3
E
Efficiency 8-18
Electrical connection
Power connection 13-1
Wiring methods and cable cross-sections 13-3
EMERGENCY STOP 10-3
Enclosure surface 9-40
Encoder polarity 14-1
End position damper 9-49
End position Shock absorbers
Suppliers 16-3
Energy chains
Suppliers 16-1
F
Factory checks 11-5
Feed force 9-12
Final overtemperature 9-17
Force
Acceleration force 8-3
Attractive force 8-3
Effective force 8-3
Force due to weight 8-3
Frictional force 8-3
Machining force 8-3
Reactive forces 9-2
Force spectrum 4-8
G
Gantry axes 14-20
H
Handling 11-1
Heating up 9-17
I
Identifying the motor components 11-1
Inappropriate use 2-2
Consequences, Discharge of liability 2-1
Installation height 6-1
Insulation class 9-16
Insulation resistance 15-1
J
Jerk limitation 10-6
L
Attachment 9-47
Measuring principles 9-43

Positioning accuracy 9-45
Recommendations 9-46
Length measuring systems
Measuring system cables 9-45
Models 9-42
Permissible velocity and acceleration 9-45
Selection criteria 9-41
Linear drive appliction form 18-1
Linear guides
Suppliers 16-1
Linear guideways 9-48
Linear scales 16-1
Load rigidity
dynamic 10-11
static 10-10
M
Magnetic fields 9-38
Mains failure 10-5
Malfunction 10-3
Maximum current 7-2
Maximum feed force 7-2
Maximum power loss 7-2
Maximum velocity 7-2
Mechanical design
Mass reduction 9-1
Mechanically linked axes 9-1
Rigidity 9-1
Motor component arrangement
Double comb arrangement 9-6
Gantry arrangement 9-10
Vertical axes 9-11
Motor component insection
Customer side 11-5
Motor component installation
Basic procedure 12-1
Primary part 12-7
Secondary part segments 12-5
Securing screws 12-8
Motor components arrangement
Parallel arrangement 9-4
Motor parameters 14-5, 14-6, 14-7, 14-8
Motor sizing
Average velocity 8-5
Equations of motion 8-2
Feed forces 8-3
Sinusoidal velocity 8-11
Trapezoidal velocity 8-6
Triangular velocity 8-10
Motor Sizing 8-1
Motor versions
Standard encapsulation for primary part 4-3, 9-18
Thermal encapsulation for primary part 4-3, 4-5, 7-1, 9-18
Mounting sizes
LSF040 6-3
LSF080 6-5
LSF120 6-8
LSF140 6-11
LSF160 6-12
LSF200 6-15
LSF240 6-18
Mounting Sizes 6-1
Mounting tolerances 6-1
N
Natural frequencies 9-1
Noise emission 9-40
Nominal continuous current 7-2
Nominal velocity 7-2
O
ON time and feed force 8-13
Operational Principle 4-1
Order Designations 4-8
P
Packaging 11-2
Parameters 14-1
Polarity of the length measuring system 14-10
Position resolution 10-8
Positioning accuracy 10-8
Power
Continuous output 8-15
Cooling capacity 8-17
Maximum output 8-16
Regeneration energy 8-17
Power loss 9-16
Pressure drop 9-23, 9-25
Protection rating 9-37
PWM frequency 7-1
R
Rating plate 11-1
Resonant frequency 14-19
S
Safety Instructions 3-1
Secondary part version 4-6
Setting and optimizing the control loop 14-18
Shock 9-39
Shock absorber 9-49
Short-circuit of DC bus 10-5
Short-time operating force 7-2
Shutdown 10-3
Site altitude 9-36
Sizes 4-7
Sizing examples 8-19
Specifications 5-1
LSF040 5-4
LSF080 5-8
LSF120 5-14
LSF140 5-22
LSF160 5-26
LSF200 5-34
Standard encapsulation for primary part 4-4
Storage 11-4
T
Temperature monitoring 9-33
Thermal time constant 9-16
Transport 11-4
Type Code 4-8
U
Use See appropriate use and inappropriate use
V
Velocity resolution 10-8
Vertical axes 9-11, 14-12
Vibration 9-39
W
Warnings 11-3
Weight compensation 8-3, 9-11
Weight compensation systems
Suppliers 16-4
Winding temperature 9-16
Wiper 9-51
Wipers
Suppliers 16-5
00288895
Printed in Germany

PDF

Hochgeladen von

Dokumentinformationen

Originaltitel

Copyright

Verfügbare Formate

Dieses Dokument teilen

Dokument teilen oder einbetten

Freigabeoptionen

Stufen Sie dieses Dokument als nützlich ein?

Sind diese Inhalte unangemessen?

Copyright:

Verfügbare Formate

PDF

Hochgeladen von

Copyright:

Verfügbare Formate

engineering

Synchronous Linear Motors LSF

Title Synchronous Linear Motors LSF

Type of Documentation Project Planning Manual, Selction Data and Commissioning

Document Typecode DOK-MOTOR*-LSF********-GN02-EN-P

Internal File Reference • LSF-EN_Book.doc

Purpose of Documentation This documentation contains …

For synchronous linear motors LSF

Record of Revisions Description Release Notes

Copyright  2000 Rexroth Indramat GmbH

Published by Rexroth Indramat GmbH

Note This document has been printed on chlorine-free bleached paper..

2 Important directions for use 2-1

3 Safety Instructions for Electrical Drives and Controllers 3-1

4 Technology of Synchronous Linear Motors 4-1

5.4 LSF120......................................................................................................................................... 5-14

6 Mounting Sizes and Tolerances 6-1

7 Motor - Controller Combinations 7-1

8 Motor Sizing 8-1

8.4 Determining the Drive Power ....................................................................................................... 8-15

9 Configuration and Construction Instructions 9-1

10 Controlling of Linear Direct Drives 10-1

10.1 Drive Controllers, Power Supply Modules and Controls.............................................................. 10-1

11 Handling, Transport, Storage and Inspection 11-1

12 Installation and Assembly 12-1

13 Electrical Connection 13-1

14.2 Basic Prerequisites ...................................................................................................................... 14-2

15 Maintenance and check of Motor Components 15-1

16 Recommended Suppliers of Auxiliary Components 16-1

17 Applicable Documents 17-1

18 Linear Drive Application Form 18-1

19 Service & Support 19-1

1.1 About this Document

This document presents a comprehensive source of information

1.2 Application Ranges of Linear Direct Drives

Implementing these requirement with conventional NC drive technology

In many cases, linear direct drive technology is an optimal alternative,

Starting from the above-mentioned benefits, there are the following

• High-speed machining in transfer lines and machining centers

Due to a practice-oriented combination of motor technology and with

The development stage of Rexroth Indramat‘ s synchronous linear

2 Important directions for use

2.1 Appropriate use

Note: Rexroth Indramat, as manufacturer, is not liable for any

Areas of use and application

Every drive controller has to be programmed before starting it up, making

2.2 Inappropriate use

3 Safety Instructions for Electrical Drives and

Inexpert handling of these units, non-

Warning symbol with signal Risk class to ANSI

Death or serious injuries will occur.

Death or serious injuries may occur.

Injuries or damage to equipment may occur.

3.3 Risks due to Incorrect Utilization

High electric voltage and high working current !

Dangerous movements ! Death, serious injuries

High electric voltage due to incorrect

Health hazard for persons with pacemakers,

Hot surfaces on device enclosure possible. Risk

Risk of injuries due to improper handling.

Risk of injuries due to improper handling of

3.4 General Information

Only adequately trained and qualified personnel should work on this