En Technical Information PDF

Technical Information
WE CREATE MOTION EN
Imprint
As at:
11th edition, 2019
Copyright
by Dr. Fritz Faulhaber GmbH & Co. KG
Daimlerstr. 23 / 25 · 71101 Schönaich
All rights reserved, including translation rights. No part

of this description may be duplicated, reproduced, stored
in an information system or processed or transferred in any
other form without prior express written permission of
Dr. Fritz Faulhaber GmbH & Co. KG.
This document has been prepared with care.

Dr. Fritz Faulhaber GmbH & Co. KG cannot accept any
liability for any errors in this document or for the
consequences of such errors. Equally, no liability can be
accepted for direct or consequential damages resulting
from improper use of the products.
Subject to modifications.
The respective current version of this document is avail-

able on FAULHABER‘s website: www.faulhaber.com
Contents
DC-Motors DC-Micromotors 4 – 25
Flat DC-Micromotors & DC-Gearmotors
Brushless DC-Motors Brushless DC-Servomotors 26 – 55

Brushless Flat DC-Micromotors & DC-Gearmotors
Motors with integrated Brushless DC-Motors with integrated Speed Controller 56 – 91

Electronics Brushless DC-Servomotors with integrated
Motion Controller
Stepper Motors Stepper Motors 92 – 99
Linear DC-Servomotors Linear DC-Servomotors 100 – 105
Precision Gearheads Precision Gearheads 106 – 111
Linear Components Ball Screws 112 – 119

Lead Screws and Options
Encoders Encoders – 2 Channel 120 – 133

Encoders – 3 Channel
Encoder – Absolute
Drive Electronics Speed Controller 134 – 153

Motion Controller
DC-Motors
WE CREATE MOTION
DC-Micromotors
Magnets:
General information
FAULHABER S/G Page
FAULHABER DC Motors are designed with a variety of
DC-Micromotors Portfolio description 32 – 33
The FAULHABER Winding: different types of magnets to suit the particular perfor-
0615 … S Precious Metal Commutation 0,17 mNm 34 – 35
Originally invented by Dr. Fritz Faulhaber mance of the given motor type. These materials include
1219 …Sr. G and patented Precious Metal Commutation 0,72 mNm 36 – 37
in 1958, the System FAULHABER coreless1516 …(orS ironless) pro- AlNiCo magnets and high performance
Precious Metal Commutation
rare earth types
0,59 mNm 38 – 39
gressive, self-supporting, skew-wound rotor
1624 … S winding is at such asMetal
Precious SmCo and NdFeB.
Commutation 2 mNm 40 – 41
the heart of every System FAULHABER DC…Motor.
2230 S This revo- Precious Metal Commutation 4,7 mNm 42 – 43
Operational Lifetime:
2233 … Sand created
lutionary technology changed the industry Precious Metal Commutation 5,9 mNm 44 – 45
The lifetime of a FAULHABER DC Motor depends mainly
new possibilities for customer application of DC Motors
FAULHABER SR on the operational duty point and the ambient conditions Page
where the highest power, best dynamic performance, in
DC-Micromotors Portfolio description during operation. The total hours of operation can46 there-
– 47
the smallest possible size and weight are required. The
0816 … SR fore vary
Precious Metalgreatly from some hundreds
Commutation 0,7of hours under
mNm 48 – 49
main benefits of this technology include:
1016 … SR extreme
Precious conditions
Metal Commutationto over 25 000 hours under optimal
0,92 mNm 50 – 51
1024 …positioning
■ No cogging torque resulting in smooth SR Precious Metal Commutation
conditions. 1,6 mNm
Under typical load conditions 52 – 53
a FAULHABER
1224 effi
and speed control and higher overall … SR ciency than Precious
DC motor Metalwill
Commutation 1,7 mNm anywhere
have an operational lifetime 54 – 55
other DC motor types 1319 … SR Precious Metal Commutation
between 1 000 to 5 000 hours. 1,4 mNm 56 – 57
1331 … SR Precious Metal Commutation 3,8 mNm 58 – 59
■ Extremely high torque and power1516
in relation
… SR to motor In general the operational lifetime of0,97
a FAULHABER
mNm
DC
60 – 61
size and weight 1524 … SR MotorMetal
Precious is limited by the effects of electrical
Commutation 2,9 mNmand mechanical
62 – 63
1717 load
■ Absolute linear relationship between … SR to speed, wear on
Precious the
Metal commutator and brushes.
Commutation 2,2The
mNmelectrical64
wear
– 65
1724
current to torque, and voltage to speed… SR (sparking)
Precious Metaldepends heavily on the electrical
Commutation 4,5 mNmload and66the– 67
2224 … SR motorMetal
Precious speed. As the electrical load and
Commutation 6,8 speed
mNm increase,68 – the
69
■ Very low rotor inertia which results in superior dynamic
2232 … SR typicalMetal
Precious motor operational lifetime will10normally
Commutation mNm decrease.
70 – 71
characteristics for starting and stopping
FAULHABER CXR The effects of electrical wear are more significant for Page
■ Extremely low torque ripple and EMI motors with precious metal commutation and vary depend-
DC-Micromotors Portfolio description 72 – 73
ing on the nominal voltage of the winding. Where neces-
DC Motor Types: 1336 … CXR Graphite Commutation 3,6 mNm 74 – 75
sary FAULHABER
Commutation DC Motors are therefore fitted with
FAULHABER DC Motors are built with1727
two…different
CXR types Graphite 4,9 mNm 76 – 77
1741 commutation
… CXR integrated
Graphite spark suppression to minimize
Commutation the negative
8,8 mNm 78 – 79
of commutation systems: precious metal and
2237 … CXR effectsCommutation
Graphite of sparking on the operational12lifetime.
mNm 80 – 81
graphite commutation.
2642 … CXR Graphite Commutationwear of the commutation
The mechanical 26 mNm 82 – 83
system is depend-
The term precious metal commutation refers to the ma-
2657 … CXR Graphite
ent onCommutation 40 mNm
the motor speed and will increase with higher84 – 85
terials used in the brushes and commutator which consist
speeds. In general, for applications with higher than speci Page -
ofFAULHABER CR precious metal alloys. This type of
high performance
fied speeds and loads, a longer operational lifetime can be
commutation system is used mainly because
DC-Micromotors of its very
Portfolio description 86 – 87
achieved by graphite commutated motors.19 mNm It is also 88
impor-
small size, very low contact resistance2342
and …theCR very pre- Graphite Commutation – 89
2642 … CR tant not to exceed
Graphite Commutation the load characteristics
32 mNmfor the motor
90 – 91
cise commutation signal. This commutation system is
2657 … CR bearings
Graphite given in the data sheet for continuous
Commutation 51 mNm duty92opera-
– 93
particularly well suited for low current applications such
2668 … CR tion. Doing
Graphite so will also limit the achievable
Commutation 70 mNmmotor lifetime.
94 – 95
as battery operated devices.
3242 … CR Graphite Commutation
Other effects 41 mNm ambient
limiting motor lifetime include 96 con-
– 97
In general, precious metal commutated motors
3257 … CR exhibit the Graphite Commutation 73 mNm 98 – 99
ditions like excessive humidity and temperature, excessive
best overall performance at continuous
3272 … CRwith a load at
duty Graphite Commutation 120 mNm 100 – 101
vibration and shock, and an incorrect or suboptimal mount-
or around the point of maximum nominal
3863 …effi
CR ciency. Graphite Commutation 131 mNm 102 – 103
ing configuration of the motor in the application.
The term graphite commutation refers 3890
to… theCRbrush ma- Graphite Commutation 224 mNm 104 – 105
It is also important to note that the method of driving
terial used in combination
FAULHABER SR-Flat with a copper alloy commutator. Page
and controlling the motor will have a large effect on the
This type of commutation
Flat DC-Micromotors and
system is very robust and is better
Portfolio description 106 – 107
operational lifetime of the motor. For example, for control
suited to dynamic
DC-Gearmotors high power applications
1506 …withSR rapid start / Precious Metal Commutation 0,45 mNm 108 – 109
using a PWM signal, FAULHABER recommends a minimum
stops or periodic overload conditions.1506 … SR IE2-8 with integrated Encoder 0,4 mNm 110 – 111
frequency of 20 kHz.
1512 … SR with integrated Gearhead 30 mNm 112
1512 … SR IE2-8 with integrated Gearhead und Encoder 30 mNm 114 – 115
2607 … SR Precious Metal Commutation 3,4 mNm 116 – 117
2607 … SR IE2-16 with integrated Encoder 2,9 mNm 118 – 119
2619 … SR with integrated Gearhead 100 mNm 120
2619 … SR IE2-16 with integrated Gearhead und Encoder 100 mNm 122 – 123
5
DC-Micromotors
Modifications:
FAULHABER specializes in the configuration of its standard DC-Micromotors
products to fit the customer application. Available modifi-
cations for FAULHABER DC Motors include:
■ Many other nominal voltage types
■ Motor leads (PTFE and PVC) and connectors
Series 0615 ... S
■ Configurable shaft lengths and second shaft ends Values at 22°C and nominal voltage 0615 N
1 Nominal voltage UN
■ Modified shaft dimensions and pinion configurations 2 Terminal resistance R
3 Efficiency, max. Kmax.
such as flats, gears, pulley and eccenters 4 No-load speed n0
5 No-load current, typ. (with shaft ø 0,8 mm) I0
■ Modifications for extreme high and low temperature 6 Stall torque MH
7 F i ti t M
operation
■ Modifications for operation in a vacuum (ex. 10-5 Pa)
■ Modifications for high speed and / or high load Notes on technical datasheet
applications The following values are measured or calculated at
■ Modifications for motors with tighter than standard nominal voltage with an ambient temperature of 22 °C.
electrical or mechanical tolerances Nominal voltage UN [V]
The nominal voltage at which all other characteristics
Product Combinations
indicated are measured and rated.
FAULHABER offers the industry’s largest selection of com-
plementary products tailor made for all of its DC Motors Terminal resistance R [Ω] ±12%
including: The resistance measured across the motor terminals.
The value will vary according to the winding temperature.
■ Precision Gearheads (planetary, spur, and low
(temperature coefficient: α22 = 0,004 K-1).
backlash spur)
This type of measurement is not possible for the graphite
■ High resolution Encoders (Incremental and Absolute) commutated motors due to the transition resistance of the
■ High Performance Drive Electronics (Speed Controllers, brushes.
Motion Controllers) Efficiency ηmax. [%]
The maximum ratio between the absorbed electrical
power and the obtained mechanical power of the motor.
Io· R
= 1– ––––
2
max.
UN
No-load speed no [min-1] ±12%

Describes the motor speed under no-load conditions
at steady state and 22 °C ambient temperature. If not
otherwise defined the tolerance for the no-load speed is
assumed to be ±12%.
UN - (Io · R)
no = –––––––––
2π · kM
No-load current (typical) Io [A]

Describes the typical current consumption of the motor
without load at an ambient temperature of 22 °C after
reaching a steady state condition.
The no-load current is speed and temperature dependent.
Changes in ambient temperature or cooling conditions
will influence the value. In addition, modifications to the
DCM2019_EN-FR-DE-CN.indd 1
6
DC-Micromotors
shaft, bearing, lubrication, and commutation system or Mechanical time constant τm [ms]
combinations with other components such as gearheads or The time required for the motor to reach a speed of 63%
17 mNm
encoders will all result in a change to the no-load current of its final no-load speed, from standstill.
W
of the motor.
R·J
= ––––
m
Stall torque MH [mNm] kM 2
The torque developed by the motor at zero speed (locked
Rotor inertia J [gcm2]
rotor) and nominal voltage. This value may vary due to the
S 003 S 4,5 S The dynamic moment of inertia of the rotor.
3 magnet Vtype and temperature and the temperature of the
4,5
16,2 37,7
50 winding.Ω
48 % Angular acceleration α max. [rad/s2]
100 20 200 20 000 min-¹ The acceleration obtained from standstill under no-load-
3 0,016 0,012 A
4 0,22 0,21 mNm UN – M
MH = kM · ––– conditions and at nominal voltage.
R
2 0,02 0,02 mNm R
840 7 346 4 872 -
min ¹/V
72 0,136 0,205 mV/min-¹ max.
MH
= –––––
9 1,3 Friction mNm/A
1,96 torque MR [mNm] J
49 0,769 0,51 A/mNm
224 91 538 Torque
93 713 losses
min-¹/mNm caused by the friction of brushes, commuta-
39 95
tor and
μH
bearings. This value varies due to temperature. Thermal resistance Rth1; Rth2 [K/W]
10 10 ms
1 0,01 0,01 gcm² Rth1 corresponds to the thermal resistance between the
221 213 ·103rad/s²
winding and housing. Rth2 corresponds to the thermal
MR = kM · Io
K/W
s
resistance between the housing and the ambient air.
Rth2 can be reduced by enabling exchange of heat between
+125) Speed constant
°C kn [min-1/V] the motor and the ambient air (for example, a thermally
+125) °C
The speed variation per Volt applied to the motor coupled mounting configuration, using a heat sink, and /
terminals
mmat constant load. or forced air cooling).
N
N
N no
kn = –––––––– =1
–– Thermal time constant τw1; τw2 [s]
UN – I o · R k E The thermal time constant specifies the time needed for
mm
mm the winding (τw1) and housing (τw2) to reach a temperature
Back-EMF constant kE [mV/min-1]
g equal to 63% of final steady state value.
The constant corresponding to the relationship between
min-¹
the induced voltage in the rotor and the speed of rotation. em
Final
temperature
kE = 2 π · kM
63 % of
final
temperature (t ) Thermal
time constant
7
9
0,16
0,14
Torque constant
0,15
0,092
mNm
A
kM [mNm/A]
00 2 500 2The
500 constant
min-¹ corresponding to
the relationship between
the torque developed by the motor and the current drawn.
e Rth2 value has been reduced by 0%. o th
t
Current constant k I [A/mNm]
Describes the relation of the current in the motor winding
0615N1.5S
Operating temperature range [°C]
0615N1.5S (R -50%)
th2
andoperation
Intermittent the torque developed at the output shaft. Indicates the minimum and maximum standard motor
0,5 Operating point
at nominal value
1 operating temperature, as well as the maximum allowable
kl = –––
kM temperature of the standard motor winding.
Shaft bearings
Slope of n-M curve ∆n/∆M [min-1/mNm]
The bearings used for the DC-Micromotors.
The ratio of the speed variation to the torque variation.
The smaller the value, the more powerful the motor. Shaft load max. [N]
The output shaft load at a specified shaft diameter for the
R –––
Δn = –––
––– 1
·
ΔM kM 2 2π
primary output shaft. For motors with ball bearings the
M [mNm]
load and lifetime are in accordance with the values given
0,2 0,24
Rotor
mple: nominal voltage 1,5V)inductance L [µH] by the bearing manufacturers. This value does not apply to
The inductance measured on the motor terminals at 1 kHz. second, or rear shaft ends.
© DR. FRITZ FAULHABER GMBH & CO. KG
Specifications subject to change without notice. Shaft play [mm]
www.faulhaber.com
The play between the shaft and bearings, including the
additional bearing play in the case of ball bearings.
02.10.18 08:52
7
DC-Micromotors
shaft, bearing,
Housing material
lubrication, and commutation system or Mechanical
Please note, time choosingτma[ms]
whenconstant precious metal commutated
combinations with other
The housing material andcomponents such as gearheads or
the surface protection. The time
motor required
that for the
they exhibit themotor to reach
best overall a speed of
continuous 63%
duty
encoders will all result in a change to the no-load current of its final no-load
performance speed, from
at or around standstill.
the point of highest efficiency.
Mass [g]
of the motor. For continuous duty operating conditions that require the
The typical mass of the motor in its standard configuration. R·J
= its
––––
motor to operate closemto kM 2thermal limits, a DC Motor
Stall torque MH [mNm]
Direction of rotation with graphite commutation is recommended.
The direction of rotation as viewed from the front face. Rotor inertia J [gcm2]
rotor) and nominal voltage. This value may vary due to the For DC Motors with graphite commutation:
Positive voltage applied to the (+) terminal gives clockwise The dynamic moment of inertia of the rotor.
magnet type and temperature and the temperature of the The maximum continuous duty torque (S1 operation) at
rotation of the motor shaft. All motors are designed for
winding. Angular voltage
nominal acceleration α max.in
resulting [rad/s 2
]
a steady state temperature
clockwise (CW) and counter-clockwise (CCW) operation; The acceleration obtained from standstill under no-load-
not exceeding the maximum winding temperature and / or
the direction of rotation is Ureversible. conditions and at nominal voltage.
MH = kM · ––– – MR
N
operating temperature range of the motor. The motor
R
Speed up to n max. [min-1] is rated with a reduction of the Rth2 value of 25% which
MH
max. = –––––
The maximum
Friction torquerecommended
MR [mNm] motor speed for continuous approximates the amount of cooling
J available from a typi-
operation.
Torque lossesThiscaused
value is
bybased on the of
the friction recommended operat-
brushes, commuta- cal mounting configuration of the motor. This value can
ing range
tor and for the standard
bearings. This valuemotorvariesbearings, winding, and
due to temperature. Thermal
be safelyresistance
exceeded R ifth1; Rth2
the motor[K/W] is operated intermittently,
commutation system. All values in excess of this value will R
for corresponds
th1 example, to operation
in S2 the thermal resistance
and/or if morebetween
coolingthe
is
negatively affect theMmaximum achievable operational winding and housing. Rth2 corresponds to the thermal
applied.
R = kM · Io
lifetime of the motor. Rated Current (thermal limit) I N [A]
Speed constant The typical maximum continuous current at steady state
of pole kpairs
n [min /V]
-1
Number the motor and the ambient air (for example, a thermally
The speedthe
variation resulting from the rated continuous duty torque. This
Indicates numberper of Volt
pole applied
pairs of to
thethe motor motor.
standard coupled mounting configuration, using a heat sink, and /
terminals at constant load. value includes the effects of a loss of Km (torque constant)
or forced air cooling).
Magnet material as it relates to the temperature coefficient of the winding
Describes the basic ktype ofnthe 1
magnet
n = –––––––– = ––
o used in the Thermal
as well astime
the thermal τw1; τw2 [s]
constantcharacteristics of the given magnet
UN – I o · R k E The thermal
standard motor. material. Thistime
valueconstant
can be specifi
safely es the timeif needed
exceeded for
the motor
the
is operated (τw1) and housing (τw2) to reach a temperature
windingintermittently, during start / stop, in the ramp
Unspecified
Back-EMF mechanical
constant tolerances:
kE [mV/min -1
]
equal
up phasesto 63% of fi
of the nal steadycycle
operating stateand/or
value.if more cooling
The constant
Tolerances in corresponding
accordance withtoISO
the2768.
relationship between
the induced voltage in the rotor and the speed of rotation. is applied. For certain series and lower voltage types this
≤ 6 = ± 0,1 mm em
current
Final is limited by the capacity of the brush and commu-
≤ 30 = ± 0,2 mm temperature
tation system.
kE = 2 π · kM
≤ 120 = ± 0,3 mm 63 % of
Rated
final
Speed nN [min-1]
The tolerances
Torque ofkvalues
constant not specified are given on request.
M [mNm/A]
The typical speedt at steady stateThermal
temperature ( ) timefrom
resulting
constantthe appli-
The constant corresponding
All mechanical to the to
dimensions related relationship
the motorbetween
shaft are cation of the given rated torque. This value includes the
the effects of motor heating on the slope of the n/M curve.
meatorque developed
sured with an axialbypreload
the motor andshaft
of the the current
toward drawn.
the
Higher speeds can be achieved o th by increasing the input
motor.
Current constant k I [A/mNm]
t
voltage to the motor, however the rated current (thermal
Describes the relation of the current in the motor winding limit) remains
Operating the same.range [°C]
temperature
Rated
and values
the torque for continuous
developed duty
at the output operation
shaft. Indicates the minimum and maximum standard motor
The following values are1 measured or calculated at operating
n [min-1] temperature, as well as the maximum allowable
Continuous operation (R 0%)
kl = –––
th2
nominal voltage with ankMambient temperature of 22 °C. temperature

9 000
of the standard
Watt motor winding.
Continuous operation (R -50%)
Intermittent operation
th2
8 16 24 32 Operating point at nominal value

Rated Torque MN [mNm] Shaft
7 500bearings
n
Slope of n-M curve ∆n/∆M [min-1/mNm] max.

P D
The DC
For ratio of thewith
motors speed variation
precious to the
metal torque variation.
commutation: 6 000 U N
n0
The maximum
The smaller thecontinuous
value, the duty
moretorque
powerful the motor.
at nominal voltage Shaft
4 500
load max. [N]
M M N= D
resulting in steady state The output shaft load at a specified shaft diameter for the
Δn = current
––– R –––
––– 1 and speed not exceeding 3 000
the capacity of the brush
ΔM kand 2 ·
commutation
2π system. The primary output shaft. For motors with ball bearings the
M
1 500
motor is rated without a reduction to the Rth2 value (with-
Rotor inductance L [µH] by the bearing manufacturers. This value does not apply to
out external cooling). This value can be safely exceeded 0 M [mNm]
The inductance measuredintermittently,
on the motorfor
terminals at 1 second,0 or rear
10 shaft20ends. 30
inkHz.
40 50
if the motor is operated example, Recommended operation areas
S2 operation and/or if more cooling is applied. For the Shaft play [mm]
purposes of the rating, certain motors are limited by the The play between
Example: the shaft
Performance and for
diagram bearings, including
rated values the
with
resulting rated speed (< 2 500 min-1) at nominal voltage. additional bearing play in the case of ball
continuous operation (graphite commutation) bearings.
8
DC-Micromotors
Explanations on the performance diagram How to select a DC-Micromotor

The performance diagram shows the range of possible This section provides a very basic step-by-step procedure
operating points of a drive at an ambient temperature of of how to select a DC-Micromotor for an application that
22 °C and includes both the operation in the thermally requires continuous duty operation under constant load
insulated and in the cooled state. The possible speed ranges and ambient conditions. The example describes the calcula-
are shown in dependence on the shaft torque. tions necessary to create a basic motor characteristic curve
The sector shown dashed describes possible operating to describe the behaviour of the motor in the application.
points in which the drive can be engaged in intermittent To simplify the calculation, in this example continuous opera-
operation or with increased cooling. tion and optimum life performance are assumed and the
influence of temperature and tolerances has been omitted.
Continuous torque MD [mNm]
Describes the max. recommended continuous torque in Application data:
the steady-state condition at nominal voltage and with The basic data required for any given application are:
thermal reduction of the Rth 2 value by 25 % for graphite Required torque M
Required speed n
commutation and by 0 % for precious metal commutation. Duty cycle δ
With brush motors, the continuous torque corresponds Available supply voltage, max. U
to the respective rated torque MN. The value is independ- Available current, max. I
Available space, max. diameter/length
ent of the continuous output and can be exceeded if the Shaft load radial/axial
motor is intermittently operated and/or more cooling is Ambient temperature
put to use.
This example is based on the following application data:
Continuous output PD [W]
Output torque M = 3 mNm
Describes the max. possible output in continuous operation Speed n = 5 500 min-1
in the steady-state condition with thermal reduction of the Duty cycle δ = 100 %
Rth 2 value by 50 %. The value is independent of the continu- Supply voltage U = 20 V
Current source, max. I = 0,5 A
ous torque and can be exceeded if the motor is intermit- Space max diameter = 25 mm
tently operated and/or more cooling is put to use. length = 50 mm
Shaft load radial = 1,0 N
axial = 0,2 N
Nominal voltage characteristic curve UN [V] Ambient temperature = 22 °C constant
The nominal voltage curve describes the operating points
at UN in the uncooled and cooled state. In steady-state, the
Preselection
starting point corresponds to the no-load speed n0 of the
The first step is to calculate the power the motor is
drive. Operating points above this curve can be attained by
an increase, operating points below by a reduction of the expected to deliver:
nominal voltage .
P2 = M · 2 π n
P2 = 3 mNm · 5 500 min-1 · 2π = 1,73 W
Second, compare the physical dimensions (diameter and

length) to the motor sizes given in the data sheets. Then,
from the available motor sizes, compare the required
output torque to the diagram for the recommended
areas of operation for the motor types in question. Please
choose a motor type where the required output torque
and speed are well within the limits given in the diagram.
For the best results it is recommended to operate the
motor close to the "operating point at nominal value"
indicated in the diagram. Please note that the diagram in
the data sheet is a representative example regarding one
nominal voltage type and should be used for orientation
purposes only.
9
DC-Micromotors
shaft,
The motor
bearing,
selected
lubrication,
from theand
catalogue
commutation
for this
system
particular
or Mechanical time
Performance constant τmat
characteristics [ms]
nominal voltage (24 V)
application, is with
combinations seriesother
2224components
U 024 SR with theasfollowing
such gearheads or The
A time required
graphic for the
presentation of motor to reach
the motor‘s a speed of 63%
characteristics
characteristics:
encoders will all result in a change to the no-load current of itsbefinal
can no-load
obtained byspeed, from the
calculating standstill.
stall current IH and
of the motor.
Nominal voltage UN = 24 V the torque Mopt. at its point of max. efficiency. All other
R·J
m = ––––
parameters are taken directly
Frame size:
Ø = 22 mm kM 2 from the data sheet of the
L = 24 mm
selected motor.
The
Shafttorque developed by the motorradial
load, max.: at zero =speed
1,5 (locked
N
axial = 0,2 N Rotorcurrent
Stall inertia J [gcm2]
rotor) and nominal voltage. This value
No-load current Io
may vary due to the
= 0,007 A The dynamic moment of inertia of the rotor.
magnet type and temperature and the
No-load speed no temperature of -1the
= 7 800 min UN
Stall torque
winding. M H = 19 mNm IH = –––
Angular acceleration α max. [rad/s2]
R
The acceleration obtained from standstill under no-load-
Optimizing the preselection UN – M
MH = kM · ––– R conditions and 24at V
nominal voltage.
R
To optimize the motor‘s operation and life performance, IH = ––––––– = 0,661 A
36,3 Ω
the required speed n has to be higher than half the no- MH
max. = –––––
Friction torque MR [mNm] J
load speed no at nominal voltage, and the load torque M Torque at max. efficiency
Torque losses caused by the friction of brushes, commuta-
has to be less than half the stall torque MH. Thermal resistance Rth1; Rth2 [K/W]
tor and bearings. This value varies due to temperature.
Mopt. = toMthe
Rth1 corresponds H · Mthermal
R resistance between the
no
n ≥ ––– MH
M ≤ ––– winding and housing. Rth2 corresponds to the thermal
MR 2= kM · Io 2
opt. = 19 by
mNm · 0,2 mNm
From the data sheet for the DC-Micromotor, 2224 U 024 SR Rth2 can beMreduced enabling exchange=of1,95
heat mNm
between
Speed
the constantmeet
parameters kn [min -1
/V]
the above requirements. the motor and the ambient air (for example, a thermally
The speed variation per Volt applied to the motor It is now mounting
coupled possible toconfi
make a graphic
guration, presentation
using and
a heat sink, and /
terminals is higher
at -1constant load. ––––––––––
7 800 min-1 no draw the motor diagram (see diagram 1).
n = 5 500 min = 3 900 min-1 = ––– or forced air cooling).
than 2 2
n
kn = –––––––– = ––
o 1 Thermal time constant τw1; τw2 [s] Diagram 1
is lowerUN – Io · R19 mNm
kE MH The thermal time constant specifies the time needed for
M = 3 mNm –––––––– = 9,5 mNm = –––– P I n
than 2 2
η
the% winding
W
2
and housing (τw2) to reach a temperature
A (τw1)min -1

equal to 63% of final steady state value.
This constant
The DC-Micromotor will be ato
corresponding good
the firelationship
rst choice tobetween
test in this 90 4 0,7 8 000
n o = 7 800 min-1
application.
the induced Should
voltagethe required
in the rotor speed
and then be less than
speed half
of rotation. η max = 80,6 % em
IH = 0,661 A
the no-load speed no, and the load torque M be less than Final
80
3,5
0,6
7 000
temperature tI
half the stall torquekME =H,2the
π · kMmotor with the next higher
70
3 6 000
Ef
fic
ie
nc Cu
rr
en
63 % of
0,5
y
nominal voltage UN should be selected. 60
η
final
2,5 5 000
(t ) Thermal
time constant
Should
Torque the required
constant torque M be compliant but the
kM [mNm/A] temperature
50
0,4
Ou
2 4 000
required
The speed
constant n be less thanto
corresponding half
thethe no-load speed
relationship no, try
between
tpu
t
40
0,3
pow
a lower
the supply
torque voltage by
developed or the
another
motorsmaller frame
and the size motor.
current drawn. 1,5 3 000
Sp
er P
30 ee
d
2
o th n
Should the required speed be well below half the no-load
0,2
t
Current constant k I [A/mNm] 20
1 2 000
Describes the relation torque

speed and or the load M be more
of the current than
in the half winding
motor the stall
10
0,5
0,1
1 000
torque M H, a gearhead or a larger frame size motor has to

and the torque developed at the output shaft. MH = 19 mNm
Indicates the minimum and maximum standard motor
Io M Opt. = 1,95 mNm
be selected. 0 0 0 0
0 2 4 6 8 10 12 14 16 18 20
M
mNm
1 operating temperature, as well as the maximum allowable

MR = 0,2 mNm
kl = –––
kM temperature of the standard motor winding.
Shaft bearings
Slope of n-M curve ∆n/∆M [min-1/mNm]
R –––
Δn = –––
––– 1
·
ΔM kM 2 2π
Shaft play [mm]
10
DC-Micromotors
Calculation of the main parameters Calculation of the operating point at 20 V

In this application the available supply voltage is lower When the torque (M = 3 mNm) at the working point is
than the nominal voltage of the selected motor. taken into consideration I, n, P2 and η can be calculated:
The calculation under load therefore is made at 20 V.
Current at the operating point
No-load speed no at 20 V
U – (Io · R ) ILast = –M + MR
–––––––
no = ––––––––– kM
2 π · kM
inserting the values 3 mNm + 0,2 mNm

ILast = –––––––––––––––––– = 0,11 A
Supply voltage U = 20 V 29,1 mNm / A
Terminal resistance R = 36,3 Ω
No-load current IO = 0,007 A
Torque constant kM = 29,1 mNm / A
Speed at the operating point
U – R · ILast
n = ––––––––––
2π · kM
20 V – (0,007 A · 36,3 Ω)
no = ––––––––––––––––––––––– = 6 481 min-1
2 π · 29,1 mNm / A
20 V – 36,3 Ω · 0,11 A
n = ––––––––––––––––––––– = 5 253 min-1
Stall current IH 2 π · 29,1 mNm / A
IH = –U
–– Output power at the operating point
R
P2 = M · 2 π · n
20 V
–––––
IH = ––– = 0,551 A
36,3 Ω
P2 = 3 mNm · 2π · 5 253 min-1 = 1,65 W
Stall torque MH
MH = kM ––
R (
U –I
o ) Efficiency at the operating point
P2
= ––––
20 V U·I
MH = 29,1 mNm / A · –––––– – 0,007 A = 15,83 mNm
36,3 Ω
1,65 W
= ––––––––––––
Efficiency, max. ηmax. = 75,0 %
20 V · 0,11 A
R 2
max. = 1 – I0 · ––– In this example the calculated speed at the working point
U
is different to the required speed, therefore the supply
2 voltage has to be changed and the calculation repeated.
36,3 Ω
max. = 1 – 0,007 A · –––––– = 78,9 %
20 V Supply voltage at the operating point
The exact supply voltage at the operating point can now
At the point of max. efficiency, the torque delivered is: be obtained with the following equation:
U = R · ILoad + 2π · n · kM
Mopt. = MH · MR
U = 36,3 Ω · 0,11 A + 2π · 5 500 min-1 · 29,1 mNm / A = 20,75 V
inserting the values In this calculated example, the parameters at the operating
Friction torque MR = 0,2 mNm point are summarized as follows:
and
Stall torque with 20 V MH = 15,83 mNm Supply voltage U = 20,75 V
Speed n = 5 500 min-1
Output torque MN = 3 mNm
Mopt. = 15,83 mNm · 0,2 mNm = 1,78 mNm Current I = 0,11 A
Output power P2 = 1,73 W
Efficiency η = 75,7 %
11
DC-Micromotors
shaft, bearing,
Estimating the lubrication,
temperatureand of the
commutation
motor winding
systemin or Motor characteristic
Mechanical curvesτm [ms]
time constant
operation:
combinations with other components such as gearheads or The
For atime required
specifi forthe
c torque, thevarious
motor to reach a speed
parameters of read
can be 63%
To ensurewill
encoders thatall
the
result
motorin aoperates
change within
to the no-load
a permissible
current of
on its final no-load
diagram 2. speed, from standstill.
temperature
of the motor.range, it is necessary to calculate the tem- To simplify the calculation,R the
· J influence of temperature
perature of the winding and housing under load. m = ––––
Stall torque MH [mNm] and tolerances has deliberately
kM 2 been omitted.
First calculate the approximate motor losses using the
following formula: Rotor inertia J [gcm2] Diagram 2
rotor) and nominal voltage. This value may vary due to the P I n
= ltemperature
Load · R The
% dynamic
η 2
moment of inertia of the rotor.
magnet typePLoss
2 W A min
and and the temperature of the
-1
winding.
inserting the values Angular acceleration α max. [rad/s2]
80 3 0,7 7 000
Current lLoad = 0,11 A The acceleration obtained from standstill under no-load- 76 %
Resistance UN – M
MH = kM · ––– R = 36,3 Ω conditions and at nominal voltage.
70
0,6 6 000
R
R 2,5
60 5 500 min-1
0,5 5 000 20,75 V
max.
MH
= –––––
Friction torque
PLoss M R [mNm]
= (0,11 A)2 · 36,3 Ω = 0,44 W 50
2
J
1,73 W
Torque losses caused by the friction of brushes, commuta- 0,4 4 000
Then
tor andmultiply theThis
bearings. value for the
value power
varies due losses by the com-
to temperature. Thermal resistance Rth1; Rth2 [K/W]
40 1,5
bined thermal resistances of the motor to estimate the Rth1 corresponds to the thermal resistance between the
0,3 3 000
30
change in the temperature of the motor due to the load. winding and housing. Rth2 corresponds to the thermal
1
M =k I
R M · o 20
0,2 2 000

∆ T = PLoss · ( Rth1 + Rth2) 0,5 0,11 A
10
0,1 1 000
Speed constant kn [min /V] -1

the motor and the ambient air (for example, a thermally
M
mNm
inserting
The speedthe values per Volt applied to the motor
variation
0 0 0 0
Thermal resistance 1 Rth1 = 5 K/W coupled mounting configuration, using a heat sink, and /
0 2 3 4 6 8 10 12 14 16 18
terminals at constant
Thermal resistance 2 load. Rth2 = 20 K/W or forced air cooling).
no
kn = –––––––– =1
–– Thermal time constant τw1; τw2 [s]
∆ T = 0,44 W U N –K/W
· (5 Io · R + 20
kE K/W) = 11 K The thermal time constant specifies the time needed for
Add the resulting change in temperature ∆T to the ambi- the winding (τw1) and housing (τw2) to reach a temperature
ent temperature to estimate the motor winding tempera- equal to 63% of final steady state value.
ture under load.
the induced voltage in the rotor and the speed of rotation. em
TWinding = ∆T + TAmb Final
temperature
2π+ ·22
E =K
TWinding = k11 kM °C = 33 °C
63 % of
This calculation confirms that the temperature is well final
(t ) Thermal
time constant
Torque constant temperature
within the specifiked
M [mNm/A]
standard operating temperature range
The constant
as well as thecorresponding
maximum winding to the relationship between
temperature.
the torque developed by the motor and the current drawn.
The calculation given above is for the purposes of a quick o th
t
Current constant
estimation k I [A/mNm]
only. The non-linear effects of temperature
Describes the relation
on the resistance of the ofwinding
the current
andin the
the motor winding
resulting torque Operating temperature range [°C]
and the torque developed at the output shaft.
constant (kM) of the motor due to the temperature coef- Indicates the minimum and maximum standard motor
ficient of the magnet material1 used have not been taken operating temperature, as well as the maximum allowable
kl = –––
into account and can have kM a large effect on motor perfor- temperature of the standard motor winding.
mance at higher temperatures. A more detailed calcula-
Shaft bearings
Slope of n-Mbecurve
tion should ∆n/∆Mbefore
performed [min-1/mNm]
operating the motor The bearings used for the DC-Micromotors.
The ratio
close to itsofthermal
the speed variation to the torque variation.
limits.
R –––
Δn = –––
––– 1
·
ΔM kM 2 2π
Shaft play [mm]
12
DC-Micromotors
Basic design
1
6
2
FAULHABER SR
1 End cap
2 Terminals
3 Brushes with brush cover
4 Commutator 8
5 Winding
6 Shaft
7 Housing
8 Magnet with sintered bearing
and retaining ring
9 3
FAULHABER CR
6
1 Graphite brushes
with brush cover and
ball bearing 7
2 Insulating ring
3 Commutator
4 Winding
5 Shaft 8
6 Magnet
7 Magnet cover
8 Housing with ball bearing
9 Terminals
13
Flat DC-Micromotors
Basic design
1
6
FAULHABER SR-Flat
1 End cap with encoder PCB

7
2 Brush cover with sintered bearing
3 Windings and collector
4 Housing with integrated gears
and sintered bearing
5 Intermediate plate with
sintered bearing
6 Output shaft
7 Front cover with bearing
14
Notes
15
DC-Micromotors with
precious metal commutation
Originally invented by Dr. Fritz Faulhaber Sr. and patented in Series
1958, the System FAULHABER coreless (or ironless) progres-
sive, self-supporting, skew wound rotor winding is at the 0615 … S 1219 … G
heart of every System FAULHABER DC Motor. This revolu- 1516 … S 1624 … S
tionary technology changed the industry and created new
2230 … S 2233 … S
possibilities for customer application of DC Motors where
the highest power, best dynamic performance, in the smallest
possible size and weight are required.
Key Features
The main benefits of this technology include no cogging
Motor diameter 6 ... 22 mm
torque resulting in smooth positioning and speed con-
trol, higher overall efficiency than other DC Motor types, Motor length 15 ... 33 mm
extremely high torque and power in relation to motor size Nominal voltage 1,5 ... 40 V
and weight, and a linear relationship between load to speed, Speed up to 24.000 min-1
current to torque, and voltage to speed. The very low rotor Torque up to 5,9 mNm
inertia results in superior dynamic characteristics for starting
Continuous output up to 8 W
and stopping and the motors exhibit extremely low torque
ripple and EMI.
Product Code
22 Motor diameter [mm]

30 Motor length [mm]
T Shaft type
22 30 T 0 1 2 S
012 Nominal voltage [V]
S Product family
WE CREATE MOTION
FAULHABER S/G
Advantages of this series at a glance
Low torque ripple and high efficiency Low current and starting voltage
Wide operating temperature range Compact and lightweight
No cogging torque
DC-Micromotors with
precious metal commutation
These ironless DC motors are the most compact in the indus- Series
try today and most types feature integrated high resolution
encoders for use in highly precise positioning and speed 0816 … SR 1016 … SR
control applications. 1024 … SR 1224 … SR
The commutation system is characterized by its small size, low 1319 … SR 1331 … SR
contact resistance and clean low noise commutation signal. It 1516 … SR 1524 … SR
is ideal for use in battery operated applications where current
1717 … SR 1724 … SR
is at a premium.
2224 … SR 2232 … SR
Combinations with a wide variety of gearheads and control-
lers make it possible to create the best system solution for
even the most challenging applications. Key Features

Motor length 16 ... 32 mm
Nominal voltage 3 ... 36 V
Speed up to 17.000 min-1
Torque up to 10 mNm
Continuous output up to 8,5 W
Product Code

T Shaft type
15 24 T 0 1 2 SR
SR Product family
WE CREATE MOTION
FAULHABER SR
Powerful rare-earth magnets Low torque ripple and high efficiency

Wide operating temperature range: No cogging torque
-30 °C to +85 °C (optional -55 °C to +125 °C) Low current and starting voltage
All-steel housing with Extremely compact and lightweight design
corrosion-resistant coating with integrated encoder
DC-Micromotors with
graphite commutation
The CXR series combines power, robustness and control in a Series
compact form. This is ensured by graphite commutation, high-
quality neodymium magnets and the tried-and-tested winding 1336 … CXR 1727 … CXR
of the FAULHABER rotor. 1741 … CXR 2237 … CXR
The powerful neodymium magnet gives the motors a high 2642 … CXR 2657 … CXR
power density with a continuous torque ranging from 3.6 to
40 mNm. The impressive performance data and the compact
size open up a wide spectrum of possible applications at an Key Features
optimised price/performance ratio. The standard drive can be
combined with high-resolution optical or magnetic encoders
for applications with precise speed control or positioning Motor length 27 ... 57 mm
tasks. A broad and optimally matched selection of gearheads is Nominal voltage 6 ... 48 V
available to extend the range of requirements that this series Speed up to 10.000 min-1
is able to fulfil. Torque up to 40 mNm
Product Code

W Shaft type
26 57 W 024 CXR
CXR Product family
WE CREATE MOTION
FAULHABER CXR
Highly dynamic performance Wide operating temperature range:

due to a low rotor inertia -30°C to +100°C (optional -55°C)
Shockproof all-steel housing with Durable graphite commutation
corrosion-resistant coating No cogging
Powerful rare-earth magnet Very high power density
DC-Micromotors with
graphite commutation
Highly stable and low-wear graphite commutation, extremely Series
powerful neodymium magnets and a particularly high copper
content in the winding of the FAULHABER rotor give the CR 2342 … CR 2642 … CR
series its enormous power. The impressive power range of 19 2657 … CR 2668 … CR
to 224 mNm is ideal for high-performance applications with
3242 … CR 3257 … CR
fast start/stop operation or periodic overload conditions.
3272 … CR 3863 … CR
Thanks to the extremely high power density as well as the
outstanding dynamics with minimal rotor inertia, the CR family 3890 … CR
is the most powerful product family of the entire FAULHABER
DC range. The standard drive can be combined with high-
resolution optical or magnetic encoders for applications with Key Features
precise speed control or positioning tasks. A broad and
optimally matched selection of gearheads is available to
extend the range of requirements that this series is able
to fulfil. Nominal voltage 6 ... 48 V
Torque up to 224 mNm
Product Code

G Shaft type
32 72 G 024 CR
CR Product family
WE CREATE MOTION
FAULHABER CR
Best dynamic performance due Extremely wide operating temperature range

to a low rotor inertia -30 °C to 125 °C (optionally -55 °C, winding
Shockproof all-steel housing with up to 155 °C)
corrosion-resistant coating Durable graphite commutation
Powerful rare-earth magnet No cogging
Highest power density
Flat DC-Micromotors
and DC-Gearmotors
Precious-metal commutated DC-Micromotors with uniquely Series
flat coil technology with three flat, self-supporting copper
windings used in the SR-Flat series form the basis for drive 1506 … SR 1506 … SR IE2-8
systems in applications where space is extremely limited. 1512 … SR 1512 … SR IE2-8
With their powerful rare-earth magnets, the motors deliver a
2607 … SR 2607 … SR IE2-16
continuous output of 0.8 W to 4 W and at the same time have
2619 … SR 2619 … SR IE2-16
only minimal inertia. The motors are available with integrated
gearheads and optical encoders – both with an extremely flat
design matched to the motors. When combined with inte-
grated gearheads and encoders, they provide a very compact Key Features
drive system with increased output torque. Motor diameter 15 ... 26 mm
Product Code

U Shaft type
15 12 U 0 0 6 SR 3 2 4 : 1
SR Product family
324:1 Gearhead reduction
WE CREATE MOTION
FAULHABER SR-Flat
Extremely flat design. Integrated spur gearheads of minimal length

Lengths ranging from 6 mm to 19 mm with high gear ratio are available
4-pole design Available with integrated optical encoders
Minimal moment of inertia
Brushless DC-Motors
WE CREATE MOTION
Brushless DC-Servomotors
For highly dynamic servo applications requiring very high

General information
FAULHABER B-Micro Page
torque in the most compact dimensions, the FAULHABER
Brushless DC-Servomotors Portfolio description 136 – 137
The FAULHABER winding: BX4 and BP4 Series 4-pole, DC-Servomotors are ideal. Their
0308 … B sensorless 18 µNm 138 – 139
Originally invented by Dr. Fritz Faulhaber robust design with very few parts and no glued compo-
0515 …Sr. B and patented sensorless 0,13 mNm 140 – 141
in 1958, the System FAULHABER coreless (or ironless) nents means that they are extremely durable and well
FAULHABER
progressive, B
self-supporting, skew-wound rotor winding is suited for challenging ambient conditions such as extreme
Page
Brushless DC-Servomotors Portfolio description
at the heart of every FAULHABER DC-Motor. This revolu- temperatures and high shock and vibration loads.142 – 143
0620 …
tionary technology changed the industry andB created new with
Theintegrated
FAULHABERHall sensors
BP4 family of 4-pole0,36 mNm brushless
slotless 144 – 145
possibilities for customer application0824 …B
of DC-Motors where with integrated Hall sensors 1,1 mNm
motors are ideal for applications requiring the highest 146 – 147
1028 … B with integrated Hall sensors 2,2
peak torque and extremely dynamic motion control. mNm 148 – 149
the highest power, best dynamic performance, in the
1218 … B with integrated Hall sensors 1,2 mNm 150 – 151
smallest possible size and weight are required. Applied in FAULHABER brushless
1226 … B with integrated Hall sensors flat DC-Micromotors2,6 mNm are 3 phase,
152 – 153
a three phase brushless motor, the winding no longer slotless, axial
1628 … B with integrated Hallflsensors
ux gap motors with a 3,3 rotating
mNm back 154iron.
– 155
rotates but rather becomes the basis2036of …a slotless
B stator. They have a much higher
with integrated Hall sensors efficiency than other
7,2 mNm fl at
156brush-
– 157
The main benefits of this technology2057
include:
…B lessintegrated
with motors Hall
andsensors
their rotating back iron provides 158
20 mNm a high
– 159
2444 …positioning
■ No cogging torque resulting in smooth B and rotor
with inertiaHall
integrated that is ideal for applications
sensors 18 mNmrequiring
160low
– 161
3056ciency
speed control and higher overall effi … B than other with integrated
torque Halland
ripple sensors 33 mNmspeed control.
very precise continuous 162 – 163
brushless motor types 3564 … B with integrated Hall sensors 66 mNm 164 – 165
FAULHABER also offers a range of 2-pole Brushless
4490 … B with integrated Hall sensors 190 mNm 166 – 167
■ Extremely high torque and high performance in relation Motors with a cylindrical rotating back iron sometimes
4490 … BS with integrated Hall sensors 217 mNm 168 – 169
to the size and weight of the motor referred to as ironless external rotor motors. What sets
■ FAULHABER
Absolute linearBHx
relationship between load to speed, the FAULHABER Motor apart is the slotless design which Page
Brushless
currentDC-Servomotors
to torque, and– voltage to Portfolio
speed,description
with a highly eliminates the cogging effect. The high inertia rotor 170 – 171
2sensitive
Pole Technology NEW 1660 … BHS
current / torque behaviour with
makesintegrated
theseHall sensors ideal for continuous
motors 15,9 mNm 172 – 173
duty applica-
NEW 1660 … BHT with integrated Hall sensors 18,7 mNm 174 – 175
■ Extremely low torque ripple
tions requiring very precise speed control. These motors
FAULHABER BX4 also have on-board speed control electronics that can be
Page
Brushless DC-Motor Types: configured for different speed profiles.
Brushless DC-Servomotors – Portfolio description 176 – 177
Whether it’s high torque 4-pole DC-Servomotors, highly
4 Pole Technology 2232 … BX4 with integrated
Sensors: Hall sensors 18 mNm 178 – 179
efficient flat DC-Micromotors, or compact slotless motors,
2250 … BX4 S with
FAULHABER 2-pole or 4-pole DC-Servomotors and180
integrated Hall sensors 18 mNm – 181
Flat
FAULHABER specializes in getting the most performance
2250 … BX4 with integrated Hall sensors 32 mNm 182 – 183
out of the smallest package. Brushless DC-Micromotors come standard with 3 discrete
3242 … BX4 with integrated Hall sensors 53 mNm 184 – 185
digital Hall sensors with a 120° phase shift.
Due to their design FAULHABER Brushless
3268 …DC-Motors
BX4 are with integrated Hall sensors 96 mNm 186 – 187
ideal for heavy duty servo applications with frequent over- 0° 120° 240° 360°
FAULHABER BP4 Page
load conditions as well as for continuous duty applications 1
Brushless DC-Servomotors – Portfolio description 188 – 189
where maximum operational lifetime is required. HA
4 Pole Technology 2264 … BP4 with integrated
0 Hall sensors 59 mNm 190 – 191
FAULHABER high precision 2-pole Brushless DC-Motors are
3274 … BP4 with integrated Hall sensors 162 mNm 192 – 193
three phase slotless motors that have a wide speed and 1
FAULHABER
torque range andB-Flat
are ideal for mid- to high speed applica-
HB
0
Page
Brushless
tions Flat DC-Micromotors
requiring smooth speed andcontrol,
Portfolio
high description
efficiency, and 194 – 195
DC-Gearmotors
long operational lifetimes. 1509 … B with integrated
1 Hall sensors 0,5 mNm 196 – 197
H
1515 … B with integrated
C
Gearhead 30 mNm Digital
198Hall
– 199
FAULHABER BHx motors are three phase slotless brushless 0
2610 … B with integrated Hall sensors 3,1 mNm sensor
200 – 201
motors designed for the very highest2622
power output signal
… B to volume with integrated
S1 Gearhead
S2 S3 S4 S5 100
S6 mNmS1 202motor
2-pole – 203
ratio and peak efficiency for cool operation even at very
high speed. They feature a six phase coil connected for
As an option, most FAULHABER Brushless DC-Servomotors
three phase operation which give the motors a signifi-
are available with analog (linear) Hall sensors.
cant boost in motor performance with no reduction in
efficiency. They are designed for high to very high speed
operation. They are available in high speed (BHS) and high
torque (BHT) versions to maximize the speed or torque
available in a given application.
27
Hall signals HallA – HallC shaft,

Modifibearing,
cations: lubrication, and commutation system or
5 HallA combinations with other
FAULHABER specialises incomponents
the adaptation suchofasitsgearheads
standard or
4.5 HallB
products3,3
encoders for mNm
willcustomer-specifi
all result in a changec applications. Available
to the no-load current
HallC
4
2 Pole Technology modifi
of 17 W for FAULHABER Brushless DC-Servomotors
the cations
motor.
3.5
include:
3 Stall torque MH [mNm]
UA … UC
2.5 ■ Additional
The voltage types
torque developed by the motor at zero speed (locked
2
Series 1628 ... B rotor) and nominal
■ Connecting cables voltage.
(PTFE and ThisPVC)
value may
and vary due to the
plugs
1.5
Values at 22°C and nominal voltage 1628 T magnet type and
■ Configurable shaft temperature
012 B 024 B
lengths and
and the temperature of the
1 Nominal voltage
1 UN 12 24 V second shaft ends
2 Terminal resistance, phase-phase R Analog Hall winding. 4,36 15,2 Ω
0.5 3 Efficiency, max. ηmax. ■ Modified shaft 68dimensions
69 and% pinion configurations
4 No-load speed n0
sensor 30 800 31 600 min-¹
0
5 No-load current, typ. (with shaft ø 1,5 mm) I0 output signal such as flats, gears, pulleys
0,087 MH =0,045
kM · ——and
UN eccenters
A– Co
6 Stall 60°
0° torque 120° 180° 240° 300°MH 360° 2-pole motor 9,79 11 R mNm
7 Friction torque, staticmechanical angle
Absolute C0 ■ Extended temperature
0,148 range
0,148 mNm
8 Friction torque, dynamic CV 5,33·10-6 mNm/min-¹
5,33·10-6
9 Speed constant kn ■ Vacuum
Friction compatibility
torque [mNm]1(e.g.
C2O645 349 10 minPa)
-5 -
¹/V
These 10sensors
Back-EMF can replace the need forka
constant E high resolu- 0,378 0,741 mV/min-¹
11 Torque constant kM TheModifi
■ torque caused
cations forbyhigh
3,61 static mechanical
speed
7,08 and
mNm/A / orfriction of the ball
high load
tion encoder
12 Currentin many applications andkprovide the basic
Notes on technical datasheet
constant
13 Slope of n-M curve
I
Δn /ΔM applications
bearings
0,277
and magnetic
3 195
0,141
hysteresis
2 896
A/mNm
of-¹/mNm
min the stator.
commutation signal for the
14 Terminal inductance, phase-phase Brushless DC-Servomotors
L in 134 517 μH
combination with
15 Mechanical FAULHABER
time constant Motion τControllers. ■ Modifi
Viscous cations18,1
damping for highC16,4
factor shock &msvibration
V [mNm/min ]
-1 loads
The following values are measured or calculated at
m
16 Rotor inertia J 0,54 0,54 gcm²
17 Angular acceleration
In some cases,
nominal voltage, forwithout
example, αmax.
the FAUHABER
integrated BHx family,
drive electronics, ■ Autoclavable
This Motors
factor is made
181 up of204the torque due to the viscous
·103rad/s²
discrete
at 18 sensors
an ambient are replacedofby22a °C.
temperature
Thermal resistance commutation
Rth1 / Rth2 5,6PCB
/ 22,5which friction
■ Modifiofcations
the ballforbearings
motors as well
with as thethan
tighter
K/W Foucault
standard
19 Thermal time constant τw1 / τw2 5,7 / 283 s
provide 20 the halltemperature
Operating signals but range:can, in some cases, also provide currents, caused
electrical by the cyclical
or mechanical changes in the magnetic
tolerances
Nominal –voltage
motor UN [V] -30 ... +125 °C
sinusoidal commutation
– winding, max. permissiblesignals. +125 field of the stator. These losses are °C proportional to the
This is21the voltage
Shaft bearings applied between two winding phases
ball bearings, preloadedProduct Combinations:
22 Shaft load max.: speed of the motor.
using
Magnets:block commutation. This is the voltage at
– with shaft diameter 1,5
which the FAULHABER offers the industry’s largest mm selection of
other data
FAULHABER – sheet
Brushless
radial at 3 parameters
000 min
-
are measured
-¹ (4 mm from mounting flange)
DC-Servomotors are or calculated.
designed
17 with a Speed constant products
complementary kn [min-1/V] tailor madeN
for all of its Brushless
– axial at 3 000 min ¹ (push only) 10 N
Depending
variety of– axial onat the
different required
types
standstill of speed,
(push only) magnets higher
to suit orthelower voltage
20 particular The speed variation
DC-Servomotors per Volt applied
including: N to the motor
23 Shaft play:
performance
can – radialofto
be applied thethegiven
motor motor
within typetheor application
≤ given limits.
0,015 condi- terminals at constant load. mm
– axial = 0 ■ Precision gearheads (planetarymm gearheads, spur gear-
tions. 24
These materials include high performance rare earth
Terminal resistance,
Housing material phase to phase R [ ] ±12 % aluminium, black anodized
heads and zero-backlash n spur gearheads)
1
magnet 25 types
Mass such as SmCo and NdFeB. 30 kn = –––––––– = g––
o
Is the resistance
26 Direction ofbetween
rotation two motor phases without an reversible ■ High resolution Encoders
electronically UN – I o · R k E
27 Speed up to nmax. 70 000 (Incremental
min-¹ and Absolute)
additional
Service 28 life: cable.
Number This
of pole value will vary with the winding
pairs 1
■ High Performance
constant kEDrive Electronics (Speed Controllers,
coefficient: αis
29 Hall sensors digital -1
temperature
Due to30the fact
Magnet (temperature
that motor commutation
material 22 = 0,004
SmCo Kelec-
achieved ). Back-EMF [mV/min -1
]
The Motion Controllers)
constant corresponding to the relationship between
tronically
Efficiency and η max.not [%]mechanically, the operational lifetime of
a Rated values for continuous operation
FAULHABER Brushless DC-Servomotor depends mainly on ■ Integrated drive electronics (Motion and
the induced voltage in the rotor and the speed of rotation. Speed Control)
The maximum
31 Rated torque ratio between the absorbed MN electrical 2,62 2,74 mNm
the
powerlifetime
32 Rated performance
obtained of
current (thermal limit) the motorpower bearings.
IN FAULHABER 0,829 0,442 A
33andRatedthespeed mechanical nN of the motor. 19 130 20 540 min-¹
uses high precision preloaded ball bearings in all of its kE = 2 π · kM
Brushless Io· R in2 diameter and larger.
Note: DC-Servomotors
Rated valuesmax.are 6 mm
= calculated
1– –––– with nominal voltage and at a 22°C ambient temperature. The Rth2 value has been reduced by 25%.
UN
Factors affecting the life of the motor bearings include Torque constant kM [mNm/A]
the static and dynamic -1axial and radial n [min-1] loads, the
bearing The constant corresponding
1628T024B to the relationship between
No-load speedNote: no [min ] ±12 % Watt 1628T024B (R -50%)
th2
ambient thermal conditions,

The diagram indicates the the
recommended motor speed, shock and the torque developed by theoperation
Intermittent motor and the current
speed in relation to the available torque 80 000 4 8 12 16 Operating point
vibrational
at steadyatstate loads, and
andshaft
the output the
22 for precision
°Caambient
given ambient of the shaft
temperature. If not coupling drawn. at nominal value
to the given temperature of 22°C.
application. If operated according
otherwise defi ned the tolerance for the no-loadtospeed the data is Current constant k I [A/mNm]
60 000
sheet Brushless
assumed The diagram
to be ±12%. DC-Servomotors
shows the motor have in a an operational life-
Describes the relation of the current in the motor winding
completely insulated as well as thermally
time many times
coupled that(Rof 50%
condition th2
mechanically
reduced). commutated (brush) and the torque developed at the output shaft.
UN - (Io · R)
no = ––––––––– 40 000
DC-Motors. The nominal voltage (U2)πcurve · k shows UN
N M
the operating point at nominal voltage
kI = ——1
in the insulated and thermally coupled 20 000 kM
No-load current,
condition. Anytyp. Io of
points [A]
operation above
the curve at nominal voltage will require
Describesa the
highertypical
operatingcurrent consumption
voltage. Any points of the motor
0 Slope of n-M curve ∆n/∆M [minM-1/mNm] [mNm]
without load
below at
the an ambient
nominal voltage temperature
curve will of 220 °C after
0,5 1,0 1,5
require less voltage. The2,0ratio2,5of the
3,0 3,5
speed 4,0
variation to the torque variation.
reaching a steady state condition. Recommended operation areas (example: nominal voltage 24V)
The smaller the value, the more powerful the motor.
For notes on technical data and lifetime performance © DR. FRITZ FAULHABER GMBH & CO. KG
Changesrefer toin ambient
“Technical temperature or cooling conditions
Information”. R –––
Δn = ––– 1
Specifications subject to change without notice.
––– ·
Edition 2019
will influence the value. In addition, modifications to the 2π
ΔM kM 2 www.faulhaber.com
BLM_2019-EN,DE,FR,CN.indd 15 02.10.18 16:32

28
shaft, bearing, lubrication, and commutation system or
combinations with other components such as gearheads or
Brushless DC-Servomotors encoders will all result in a change to the no-load current
2 Pole Technology of the motor.

Series 1628 ... B rotor) and nominal voltage. This value may vary due to the
Values at 22°C and nominal voltage 1628 T magnet type and temperature and the temperature of the
1 Nominal voltage UN
2 Terminal resistance, phase-phase R winding.
4 No-load speed n0 UN – C
5 No-load current, typ. (with shaft ø 1,5 mm) I0 MH = kM · —— o
6 Stall torque MH R
7 Friction torque, static C0
Friction torque CO [mNm]

The torque caused by static mechanical friction of the ball
Notes on technical datasheet bearings and magnetic hysteresis of the stator.
The following values are measured or calculated at Viscous damping factor CV [mNm/min-1]
nominal voltage, without integrated drive electronics, This factor is made up of the torque due to the viscous
at an ambient temperature of 22 °C. friction of the ball bearings as well as the Foucault
currents, caused by the cyclical changes in the magnetic
Nominal voltage UN [V]
field of the stator. These losses are proportional to the
This is the voltage applied between two winding phases
speed of the motor.
using block commutation. This is the voltage at which the
other data sheet parameters are measured or calculated. Speed constant kn [min-1/V]
Depending on the required speed, higher or lower voltage The speed variation per Volt applied to the motor
can be applied to the motor within the given limits. terminals at constant load.
Terminal resistance, phase to phase R [ ] ±12 % no
kn = –––––––– =1
––
Is the resistance between two motor phases without an UN – I o · R k E
additional cable. This value will vary with the winding
temperature (temperature coefficient: α22 = 0,004 K-1). Back-EMF constant kE [mV/min-1]
Efficiency η max. [%]
the induced voltage in the rotor and the speed of rotation.
The maximum ratio between the absorbed electrical
power and the obtained mechanical power of the motor.
kE = 2π · kM
Io· R
= 1– ––––
2
max.
UN
Torque constant kM [mNm/A]
No-load speed no [min ] ±12 % -1 The constant corresponding to the relationship between
Describes the motor speed under no-load conditions the torque developed by the motor and the current
at steady state and 22 °C ambient temperature. If not drawn.
otherwise defined the tolerance for the no-load speed is Current constant kI [A/mNm]
assumed to be ±12%. Describes the relation of the current in the motor winding
UN - (Io · R) and the torque developed at the output shaft.
no = –––––––––
2π · kM
kI = ——1
kM
No-load current, typ. Io [A]
Slope of n-M curve Δn/ΔM [min-1/mNm]
Changes in ambient temperature or cooling conditions Δn = –––
––– R –––1
·
will influence the value. In addition, modifications to the ΔM kM 2 2π

29
Terminal inductance, phase to phase L [µH] shaft, play

Shaft bearing,
[mm]lubrication, and commutation system or
The inductance measured between two phases at 1 kHz. combinations
The withthe
play between other
shaftcomponents such
and bearings, as gearheads
including the or
Mechanical time constant τ m [ms] encoders 3,3
additionalwillmNm
bearing play in
all result in athe case oftoball
change thebearings.
no-load current
2 Pole
The time Technology
required by the motor to reach a speed of 63 % Housing 17 W
of the motor.
material
of its final no-load speed, from standstill. The
Stallhousing
torque M material
H [mNm] and the surface protection.
The
Masstorque
[g] developed by the motor at zero speed (locked
R·J
m = –––– rotor) and nominal
Series 1628 ... B kM 2 The average mass ofvoltage.
the basic This
motorvaluetype. may vary due to the
Values at 22°C and nominal voltage 1628 T magnet type and012 temperature
B 024 B and the temperature of the
1 Nominal voltage2 UN Direction of rotation 12 24 V
Rotor inertia
2 Terminal J [gcm
resistance,] phase-phase R winding.
3 Efficiency, max. ηmax. Most motors are4,36 designed
68
15,2
69 for clockwise
Ω
% (CW) and counter
The dynamic moment of inertia of the rotor.
4 No-load speed n0 -clockwise (CCW)30operation;
800 31 600the direction
min-¹
UN A– C of rotation is
5 No-load current, typ. (with shaft ø 1,5 mm) I0 0,087 MH =0,045 kM · —— o
Angular acceleration
6 Stall torque αmax. [rad/s2] MH reversible. The direction
9,79 11 R mNm is given by the exter-
of rotation
7 Friction torque, static C0 0,148 0,148 mNm
The acceleration
8 Friction torque, obtained
dynamic from standstill CV under no-load nal servo amplifi5,33·10
er. -6 5,33·10-6 mNm/min-¹
conditions 9 Speed constant
and at nominal voltage. kn Friction torque CO [mNm]
2 645 1 349 min-¹/V
10 Back-EMF constant kE Please note that0,378 for motors 0,741 withmV/min integrated
-¹ electronics,
11 Torque constant kM The torque caused 3,61by static 7,08 mechanical mNm/A friction of the ball
the direction of rotation may notA/mNm be reversible.
Notes on oftechnical
12 Current constant
13 Slope n-M curve datasheet
max.
MH
= –––––
kI
Δn /ΔM bearings and magnetic
0,277
3 195
0,141
hysteresis
2 896 of-¹/mNm
min the stator.
14 Terminal inductance, phase-phaseJ L Speed up to nmax.134 [min-1] 517 μH
15 Mechanical time constant τm Viscous damping 18,1
factor C0,5416,4
V [mNm/min ]
ms -1
The following values are measured or calculated
16 Rotor inertia J at The maximum recommended
0,54 motor
gcm² speed for continuous
Thermal resistance
17 Angular R
acceleration th 1; Rth 2 [K/W]
nominal voltage, without integrated drive electronics, α This factor is made181 up of204 the torque due
·103rad/s² to theisviscous
operation at a given cooling level. This value based on
max.
R th1 corresponds to the thermal resistance between the

at an ambient
18 Thermal temperature
resistance of 22 °C. R th1 / Rth2 5,6 / 22,5 friction
the of the ball bearings
recommended operating asrange
well as
K/W
for the
theFoucault
standard motor
winding and housing. Rth2 corresponds τto
19 Thermal time constant w1 / τw2 5,7 / 283
the thermal currents, and
caused
s
20 Operating temperature range: bearings theby the cyclical
winding. All changes
higher values in thehave
magnetic
nega-
Nominal –voltage
resistance between
motor UNthe [V] housing and the ambient air.
-30 ... +125 °C
– winding, max. permissible +125 fieldeffects
tive of the on
stator.
the These
maximum losses are°C proportional
achievable to the
service life of the
This is
Rth2 can the
21 be voltage
reduced
Shaft applied between
bearings by enabling exchange of heat two winding phases
between
ball bearings, preloaded
22 Shaft load max.: speed of the motor.
motor.
using
the motor block and
– with
commutation.
shaftthe ambientThis
diameter
is the
air (for voltageaat
example, which the
thermally
1,5 mm
other data
coupled mounting sheet
– radial parameters
at 3 000 min-¹ (4 mm from
confi-
are
guration, measured
mounting
using flange)or calculated.
a heat 17
sink, and / Number of pole kpairs
Speed constant n [min /V]
-1 N
– axial at 3 000 min ¹ (push only) 10 N
Depending
or forced – airon
axial at the required
standstill
cooling). speed, higher or lower
(push only) 20 voltage Indicates
The speedthe numberper
variation of Volt
pole applied
pairsN of to thethestandard
motor motor.
23 Shaft play:
can be applied– radial to the motor within the≤ given limits. 0,015 terminals
Hall sensors at constant load. mm
Thermal –time axial constant τ w1; τ w2 [s] = 0 mm
Terminal
The 24
thermal resistance,
Housing
timematerial phase
constant to phase
specifi es R
the[ ]
time±12 %aluminium,
needed black
for Describes
anodized the type of motor commutation feedback
25 Mass 30 kn = –––––––– = g1
n o
––
Is the
the resistance
winding
26 (τw1)between
Direction of and housing
rotation two (motor phasesa without
τw2) to reach temperature an
electronically reversible components in the standard
U N – I o motor.
· R k E
27 Speed up to nmax. 70 000 min-¹
additional
equal 28 63% cable.
to Number of fiThis
of pole nal value
steadywill
pairs vary
state with the winding
value. 1 Magnet material
coefficient: α22 = 0,004
29 Hall sensors digital -1
temperature
30 Magnet(temperature
material SmCo K ).
Back-EMF
Describes theconstant kE [mV/min
basic type
-1
of the magnet ] used in the
em The constant
standard corresponding
motor. to the relationship between
Final η max. [%]
Efficiency
temperature
Rated values for continuous operation the induced voltage in the rotor and the speed of rotation.
The maximum
31 Rated torque ratio between the absorbed MN electrical Unspecified mechanical 2,62 tolerances:
2,74 mNm
32 Rated current (thermal limit) IN 0,829 0,442 A
power33and Ratedthespeedobtained mechanical power n of the motor. Tolerances in accordance
19 130 20with
540 ISO min 2768.
-¹
63 % of N
kE = 2 π · kM
final (t ) Thermal
time constant ≤ 6 = ± 0,1 mm
temperature
Io· R 2
= calculated
1– ––––
Note: Rated values
max.are with nominal voltage and at a 22°C ambient temperature. The Rth2 value has been reduced by 25%.
UN ≤ 30 = ± 0,2 mm
Torque constant kM [mNm/A]
n [min-1] ≤ 120 = ± 0,3 mm
No-load speed
Note: no [min ] ±12 % -1
o th
The constant corresponding
1628T024B to the relationship between
Watt 1628T024B (R -50%) th2
DescribesThe
the motor
diagram speed
indicates t
under no-load conditions
the recommended The torque
the tolerances of non-specifi
developedIntermittent ed values
by theoperation
motor andarethe
available
currenton
speed in relation to the available torque 80 000 4 8 12 16 Operating point
at steadyatstate andshaft
the output 22 for
°Caambient
given ambient temperature. If not request.
drawn. at nominal value
Operating temperature
temperature of 22°C. range [°C]
otherwise defined the tolerance for the no-load speed is All mechanical
Current constantdimensions
kI [A/mNm] related to the motor shaft are
IndicatesThe
thediagram
minimum and maximum standard
shows the motor in a
60 000 motor
assumed completely
to be ±12%. measured
Describes with
the an axial
relation preload
of the of the
current in shaft toward
the motor the
winding
operating temperature,
insulated as as
wellwell as the maximum allowable
as thermally
coupled condition (R 50% reduced).
th2 motor.
and the torque developed at the output shaft.
temperature of thenstandard UN - (Io ·motor
o = –––––––––
R) winding.
40 000
The nominal voltage (U2N)πcurve
· kM shows UN
Shaft bearings
the operating point at nominal voltage
kI = ——1
in the insulated and thermally coupled 20 000 kM
The bearings
No-load current,used
condition. Any for
typ. the
Io of
points [A] Brushless
operation above DC-Servomotor.
the curve at nominal voltage will require
Describes
Shaft a the
load max.
highertypical
[N] current
operating consumption
voltage. Any points of the motor
0 Slope of n-M curve ∆n/∆M [minM-1/mNm] [mNm]
without
The load
below at
output
the an
shaft ambient
nominal
load
voltage temperature
at a
curve will
specifi ed shaft of 220 °C after
diameter for the
0,5 1,0 1,5
require less voltage. The2,0ratio2,5of the
3,0 3,5
speed 4,0
variation to the torque variation.
primary output shaft. For motors with ball bearings the Recommended operation areas (example: nominal voltage 24V)
The no-load
load and current
lifetime areisinspeed and temperature
accordance
For notes on technical data and lifetime performance
dependent.
with the values given © DR. FRITZ FAULHABER GMBH & CO. KG
Changes
by therefer toin
bearing ambient temperature
manufacturers.
“Technical Information”. Thisorvalue
cooling conditions
does not apply to R –––
Δn = ––– 1
Specifications subject to change without notice.
––– ·
Edition 2019
will influence
second, or rearthe value.
shaft ends. In addition, modifications to the 2π
ΔM kM 2 www.faulhaber.com

30
Rated values for continuous duty operation Explanations on the performance diagram
The following values are measured at nominal voltage, The performance diagram shows the range of possible
without integrated drive electronics, at an ambient tem- operating points of a drive at an ambient temperature
perature of 22 °C. of 22 °C and includes both the operation in the thermally
insulated and in the cooled state. The possible speed
Rated Torque MN [mNm]
ranges are shown in dependence on the shaft torque.
The maximum continuous duty torque (S1 Operation) at
nominal voltage resulting in a steady state temperature The sector shown dashed describes potential operating
not exceeding either the maximum winding temperature points in which the drive can be engaged in intermittent
and/or operating temperature range of the motor. The operation or with increased cooling.
motor is specified with a 25 % reduction of the Rth2 value, Continuous torque MD [mNm]
which roughly corresponds to the cooling of the motor in Describes the max. continuous torque in the steady state
a typical installation situation. This value can be exceeded at nominal voltage and with a thermal reduction of the
if the motor is operated intermittently, for example, in S2 Rth 2 value by 50 %. The continuous speed decreases linearly
mode and/or if more cooling is applied. vis-à-vis the continuous torque. The continuous torque is
independent of the continuous output power and can be
Rated Current (thermal limit) IN [A] exceeded if the motor is operated intermittently, for exam-
The typical maximum continuous current at steady state ple, in S2 operation and/or if more cooling is applied.
resulting from the rated continuous duty torque. This
value includes the effects of a loss of kM (torque constant) Continuous output power PD [W]
as it relates to the temperature coefficient of the wind- Describes the max. possible output power in continuous
ing, losses due to the effects of the dynamic coefficient of operation in steady state with a thermal reduction of the
friction which include the Foucault (eddy current) losses, Rth 2 value by 50 %. The value is independent of the con-
as well as the thermal characteristics of the given magnet tinuous torque, responds linearly to the cooling factor and
material. This value can be exceeded if the motor is oper- can be exceeded if the motor is operated intermittently, for
ated intermittently, in start/stop mode, in the starting example, in S2 operation and/or if more cooling is applied.
phase and/or if more cooling is used. Nominal voltage curve UN [V]
Rated Speed nN [min ] -1 The nominal voltage curve describes the operating points
The typical speed at steady state resulting from the appli- at UN in the uncooled and cooled state. In steady state, the
cation of the given rated torque. This value includes the starting point corresponds to the no-load speed n0 of the
effects of motor losses on the slope of the n/M curve. drive. Operating points above this curve can be attained by
an increase, operating points below by a reduction of the
nominal voltage.
n [min-1] Continuous operation (Rth2 0%)
Watt Continuous operation (Rth2 -50%)
35 000 6 12 18 24 Operating point
at nominal value
30 000
nmax.
25 000
PD
20 000
15 000
10 000
UN
5 000 n0 MN MD
0 M [mNm]
0 2 4 6 8 10 12 14 16 18 20 22
Recommended operation areas
Example: Power diagram for rated values at continuous

operation.
31
Basic design
5
FAULHABER B
1 Rear cover with bearing

2 PCB 6
3 Winding
4 Magnet
7
5 Shaft
6 Stator laminations
FAULHABER BHx
6
1 Rear cover
2 PCB
3 Intermediate bearing flange
4 Winding with PCB
5 Stator laminations with housing 7
6 Magnet
7 Bearing flange
32
Basic design
FAULHABER BX4 5
1 Rear cover
2 PCB 6
3 Winding with Hall sensors
4 Stator laminations with housing 7
5 Magnet
6 Shaft
7 Bearing flange
2
3
7
FAULHABER BP4
1 Bearing flange
2 Winding PCB
3 Hall connection PCB
4 Stainless steel housing
5 Winding with stator laminations 8
6 Shaft
7 4 Pole magnet
8 Front bearing flange
33
Brushless Flat DC-Micromotors
Basic design
1
FAULHABER B-Flat
1 End cap with ball bearing

2 Hall Sensor PCB
3 Rotor and output shaft
4 Stator Winding
5 Rotor, Back-Iron and Magnet
34
Notes
35
2 Pole Technology, sensorless
The brushless, sensorless DC-Servomotors can be used even Series
in the most challenging applications where space is extremely
limited. After many years of development and experience 0308 … B 0515 … B
in microsystem technology, FAULHABER has succeeded in
reducing the size of all components and modules to a mini-
mum in order to provide reliable drive functions even with Key Features
the smallest of dimensions. The brushless DC-Servomotors
are sensorless and available with matching, highly compact
gearheads for increasing the output torque, and speed Motor length 8 ... 15 mm
controllers. The brushless DC-Servomotors provide a techno- Nominal voltage 3 ... 6 V
logy basis that can be modified for projects according to the Speed up to 96.000 min-1
requirements of the individual customer. Torque up to 0,13 mNm
Product Code

G Shaft type
05 15 G 0 0 6 B
B Product family
WE CREATE MOTION
FAULHABER B-Micro
Extremely compact design. 2-pole design with medium to high speeds

Diameters ranging from 3 mm to 5 mm Matching, highly compact gearheads available
For applications where space is very limited Matching speed controllers available
2 Pole Technology
The original FAULHABER brushless DC servomotors. Series
These ironless slotless motors are built for use in highly
challenging areas of application and environmental conditions 0620 … B 0824 … B
from the vacuum of space to medical device technology. 1028 … B 1218 … B
They are precise, have extremely long operational lifetimes,
1226 … B 1628 … B
and are highly reliable. They are available with a wide variety
2036 … B 2057 … B
of complementary products such as high resolution encoders
and precision gearheads. For maximum integration and 2444 … B 3056 … B
reduction of size the standard digital hall sensors in the 3564 … B 4490 … B
motors can be replaced with optional analog (linear) hall 4490 … BS
sensors which can eliminate the need for an encoder in
most applications.
Key Features

Product Code

K Shaft type
35 64 K 0 2 4 B
B Product family
WE CREATE MOTION
FAULHABER B
High density ironless system FAULHABER winding Extremely smooth speed control
Digital or analog hall sensors available Sensitive positioning control
2 Pole Technology
The BHx series uses 2-pole brushless technology based on Series
an innovative and robust design to deliver high power in a
compact size. These motors come in 2 distinct versions to 1660 … BHS 1660 … BHT
support a wide variety of different application needs: the
BHT variant is dedicated to high torque for large impulsive
cycles, and the BHS model is focused on very high speed Key Features
for continuous use.
Motor diameter 16 mm
BHx series is capable of driving variable load with minimum
Motor length 60 mm
speed fluctuation to guarantee smooth behavior at constant
speed. Furthermore their low inertia and short response time
provide also high dynamics. Those characteristics make BHx Speed up to 97.000 min-1
series ideal for both-high speed operation and fast accurate Torque up to 18,7 mNm
positioning, especially in intermittent operation when Continuous output up to 96 W
combined with integrated high resolution encoder. BHx series
exhibits low vibration level and low noise to reduce human
fatigue and stress inside application environment. Their high
efficiency minimizes heat generation and helps to increase
comfort when used as handtools.
Product Code

S Shaft type
16 60 S 024 BHT
BHT Product family
WE CREATE MOTION
FAULHABER BHx
Large power up to 96 W in small diameter Very dynamic and responsive with low inertia
High speed close to 100‘000 min-1 (BHS version) Low vibration and low noise, suitable for handtools
Huge impulsive torque > 30 mNm (BHT version) Optional integrated encoder
4 Pole Technology
From dynamic start/stop operation to speed control and high- Series
precision, integrated position control in confined installation
spaces – the flexible BX4 modular system can be combined 2232 … BX4 2250 … BX4 S
with a wide variety of gearhead and lead screw attachments 2250 … BX4 3242 … BX4
and offers customised solutions for a broad range of differ-
3268 … BX4
ent applications.
The long service life, high torque and an innovative as well

as compact design are further outstanding features of this Key Features
4-pole product family.
Smooth running, low vibration and low noise mean that
these motors can be used in sensitive markets, e.g. medical
technology, in addition to market sectors such as automation
technology, robotics and machine construction. Speed up to 29.000 min-1
Torque up to 96 mNm
Product Code

S Shaft type
22 50 S 0 2 4 BX4
BX4 Product family
WE CREATE MOTION
FAULHABER BX4
High torque and speed rigidity Versions with integrated Speed or

thanks to 4-pole technology Motion Controllers available
Position control in extremely confined High reliability and long service life
installation spaces thanks to optional Dynamically balanced rotor, quiet running
analogue Hall sensors
Modular, diameter-compliant mounting
concept for high-resolution magnetic and
optical encoders
4 Pole Technology
The four-pole brushless DC-Servomotors of the BP4 Series
series are characterised by their extremely high torques,
despite the compact 22 mm and 32 mm diameter 2264 ... BP4 3274 ... BP4
design and low weight. At the heart of the motors lies
innovative winding technology that not only allows a
very high copper content in the stator, but also has a Key Features
high electrical and geometric winding symmetry.
This minimises losses and maximises efficiency. The BP4
series is overload-resistant and suitable for applica- Motor length 64 ... 74 mm
tions involving high power where the lowest possible Nominal voltage 12 ... 24 V
total weight and smallest possible installation space are Speed up to 34.500 min-1
required, and also for dynamic start/stop operation. Torque up to 162 mNm
Product Code

W Shaft type
2264 W 0 2 4 B P 4
BP4 Product family
WE CREATE MOTION
FAULHABER BP4
High-power motors with maximum torque Fully integrated analogue Hall sensors and
Continuous output from 133 W to 150 W matching encoders, gearheads and controllers
are available
Outstanding ratio of torque to weight and size
For dynamic start/stop operation
Very high efficiency of up to 91 %
and DC-Gearmotors
The four-pole brushless DC-Servomotors, which have uniquely Series
flat coil technology with three flat, self-supporting copper
windings and are used in the B-Flat series, form the basis for 1509 … B 1515 … B
drive systems in applications where space is extremely limited. 2610 … B 2622 … B
With their powerful rare-earth magnets, the motors deliver a
continuous output of 1.5 W to 9 W and at the same time have
only minimal inertia. In combination with the integrated gear- Key Features
heads in extremely flat design, the motors provide a very com-
pact drive system with increased output torque. Due to the Motor diameter 15 ... 26 mm
electronic commutation of the drives, the service life is many Motor length 9 ... 22 mm
times longer compared to mechanically commutated motors. Nominal voltage 6 ... 12 V
Product Code

T Shaft type
26 10 T 0 1 2 B
B Product family
WE CREATE MOTION
FAULHABER B-Flat
Extremely flat design. Integrated spur gearheads

Lengths ranging from 9 mm to 22 mm of minimal length with high
4-pole design gear ratio are available
Electronic commutation using Precise speed control

three digital Hall sensors
Brushless Flat DC-Servomotors
2 FAULHABER BXT
Housing (for BXT H) 1
Rotor with shaft and ball bearing 2
1 Stator with PCB 3
Front flange with ball bearing 4
General Information Note

The FAULHABER BXT motors are ideally suited for With the unhoused BXT R motors, the rotor
applications with low to medium speed that require turns freely. The BXT R motors may only be operated
a high torque in short design, high efficiency and long in a suitable environment. Dirt and humidity could
service life. penetrate the motor and reduce the service life.
If hair or clothing become caught in the rotor,
Versions
there is a risk of injury.
The FAULHABER BXT brushless flat DC-servomotors are
available in versions with and without housing. The
unhoused BXT R models are particularly recommended An innovative winding technology is used with the
for speed-controlled applications in which high powers iron-core BXT motors that enables an exceptionally high
are transformed, as the heat is optimally dissipated. The copper fill factor of the stators. Torques far above the
housed version BXT H is particularly recommended for what is typical for this drive class are thereby achieved.
positioning applications, as it can be combined with a
wide variety of optical and magnetic encoders.
The housings of the BXT H serve as protection against
touching as well as dirt, are diameter-compliant and thus
just as compact as the unhoused BXT R motors.
48
The main advantages of the BXT motors are: Product combinations
■ Power in new dimensions: extremely high torque
FAULHABER offers the industry’s largest selection
in relation to the size and weight of the motor of complementary products tailor-made for all of its
■ The design enables the construction of compact
brushless flat DC-servomotors. FAULHABER BXT
motors for space-critical applications DC-servomotors are available with:
■ Precision gearheads (planetary gearheads)
■ Very good synchronisation properties thanks
to the multipole basic design ■ High resolution encoders (incremental encoders)
Unlike motors with an ironless, self-supporting ■ Powerful Drive Electronics (Speed Controller,
FAULHABER winding, motors with an iron-core winding Motion Controller)
have a cogging torque. Through the targeted design of
Modifications
the pole shoes, the cogging torque of the BXT motors is,
FAULHABER specialises in the adaptation of its
however, reduced to a minimum. The adjustment of the
standard products for customer-specific applications.
operating points of the iron-core motors is dependent
The following options are available for the FAULHABER
on the control, since the motors do not have a linear
BXT brushless flat DC-servomotor:
relationship of load to speed due to inductance.
■ Connecting cables (PTFE and PVC) and plugs
Sensors
■ Configurable shaft lengths and second shaft ends
FAULHABER BXT DC-servomotors are equipped standard
with 3 digital Hall sensors with a phase shift of 120°. ■ Modified shaft dimensions and pinion configurations
Due to the motors’ high number of poles with 14 such as flats, gears, pulleys and eccenters
individual magnets, seven electrical commutation
cycles occur within a motor revolution.
Service life
Due to the fact that motor commutation is achieved
electronically and not mechanically, the service life of a
FAULHABER brushless DC-servomotor depends mainly on
the service life of the motor bearings. FAULHABER uses
high-precision, pre-loaded ball bearings in each of its
brushless DC-servomotors with diameters of 6 mm and up.
Factors affecting the life of the motor bearings include
the static and dynamic axial and radial bearing loads, the
ambient thermal conditions, the speed, vibrational and
shock loads, and the precision of the shaft coupling to
the given application. If brushless DC-servomotors are
operated according to the data sheet, their service life
exceeds that of mechanically commutated (brushed)
DC motors many times over.
49
shaft, bearing, and lubrication or combinations with other

Brushless Flat DC-Servomotors components such as gearheads or encoders will all result in
External rotor technology, without housing a change to the no-load current of the motor.
Starting torque MA [mNm]

Maximum torque that the motor can produce at room
Series 2214 ... BXT R temperature and nominal voltage for a short time during
Values at 22°C and nominal voltage 2214 S startup. This value can change due to possible current
UN
1 Nominal voltage
2 Terminal resistance, phase-phase R
limits in the control electronics.
4 No-load speed n0 UN – C
MA = kM · ——
5 No-load current, typ. (with shaft ø 3 mm) I0 o
R
6 Starting torque MA
7 Speed constant kn
8 Back EMF constant kE Speed constant kn [min-1/V]
The speed variation per Volt applied to the motor
Notes on technical data sheet terminals at constant load.
The following values are measured or calculated at nomi- no

kn = –––––––– =1
––
UN – I o · R k E
nal voltage and an ambient temperature of 22°C.
Nominal voltage UN [V] Generator voltage constant kE [mV/min-1]
This voltage is applied between two motor phases. This The constant corresponding to the relationship between
is the voltage at which other data sheet parameters are the induced voltage in the rotor and the speed of rotation.
measured or calculated. Depending on the required
kE = 2π · kM
speed, higher or lower voltage at the motor can be
applied within the given limits.
Slope of the n/M characteristic curve Δn/ΔM [min-1/mNm]
Terminal resistance, phase to phase R [ ] ±12 % The calculated ratio of the speed change to torque
Is the resistance between two motor phases without an change at room temperature and ideal control. The
additional cable. This value will vary with the winding smaller the value, the more powerful the motor.
temperature (temperature coefficient:
α22 = 0,004 K-1). Δn = –––
––– R –––1
·
ΔM kM 2 2π
Efficiency η max. [%]
The maximum ratio between the absorbed electrical Terminal inductance, phase to phase L [μH]
power and the obtained mechanical power of the motor. The inductance measured between two phases at a
sinusoidal measurement frequency of 1 kHz.
Io· R
= 1– ––––
2
max.
UN Mechanical start time constant τ m [ms]
The time required by the motor to reach a speed of 63 %
No-load speed no [min-1] ±12 % of its final no-load speed, from standstill.
at steady state and 22 °C ambient temperature. If not R·J
= ––––
m
kM 2
otherwise defined the tolerance for the no-load speed is
assumed to be ±12%.
UN - (Io · R)
no = –––––––––
2π · kM
No-load current, typ. Io [A]


Changes in ambient temperature or cooling conditions
will influence the value. In addition, modifications to the
50
20181114_BXT_DE_EN_FR.indd 3 05.02.19 10:24
Rotor inertia J [gcm2] Unspecified mechanical tolerances:
The moment of inertia of the rotor. Tolerances in accordance with ISO 2768.
Angular acceleration αmax. [rad/s2] ≤ 6 = ± 0,1 mm
The acceleration obtained from standstill under no-load ≤ 30 = ± 0,2 mm

conditions and at nominal voltage. ≤ 120 = ± 0,3 mm
MA The tolerances of non-specified values are available on

max. = –––––
J request.
Operating temperature range [°C] All mechanical dimensions related to the motor shaft are
Indicates the minimum and maximum standard measured with an axial preload of the shaft toward the
motor operating temperature, as well as the maximum motor.
allowable temperature of the standard motor winding.
Rated values for continuous duty operation
Shaft bearing
The bearings used for the brushless DC-motors. The following values are measured at nominal voltage, on
an aluminium flange (Ø 70 mm x 3 mm) and at an ambient
Shaft load, max. permissible [N]
temperature of 22 °C at the recommended operating point.
Max. permissible shaft load of the output shaft with
specified shaft diameter. The values for load and Rated torque MN [mNm]
service life of motors with ball bearings are based Maximum continuous torque (S1 mode) at nominal
on manufacturer specifications. voltage at which in the steady state condition the tempe-
Shaft play [mm] rature does not exceed the maximum permissible winding
The play between the shaft and bearings, including temperature and/or the operating temperature range
the additional bearing play in the case of ball bearings. of the motor. Motor mounted on an aluminium flange
(Ø 70 mm x 3 mm), which approximates the amount of
Housing material cooling available in a typical mounting configuration
The housing material and the surface protection. of the motor. This value can be exceeded if the motor is
Mass [g] operated intermittently, for example, in S2 mode and/or
The average mass of the basic motor type. if more cooling is applied.
Direction of rotation
Rated current (thermal limits) IN [A]
Most motors are designed for clockwise (CW) and
The typical maximum continuous current at steady state
counter -clockwise (CCW) operation. The direction of
resulting from the rated continuous duty torque. This
rotation is specified by the external control electronics.
value takes into account the influence of heating. This
Speed up to nmax. [min-1] applies to a lower torque constant kM and the increased
The maximum recommended speed for continuous resistance of the winding. Furthermore, the losses from
operation. This value is based on the recommended the effects of the dynamic coefficient of friction – inclu-
operating range of the standard motor bearing and of ding the eddy current losses – are taken into considera-
the winding. All higher values have a negative impact tion. This value can be exceeded if the motor is operated
on the maximum achievable service life of the motor. intermittently, in start/stop mode, in the starting phase
Number of pole pairs and/or if more cooling is used.
Indicates the number of pole pairs of the standard motor. Rated speed nN [min-1]
Hall sensors Typical rated speed in the steady state condition which is
Describes the type of motor commutation feedback determined from the given rated torque. This value takes
components in the standard motor. into account the effects that motor losses have on the
slope of the n/M characteristic curve.
Magnet material
Describes the basic type of the magnet used in the
standard motor.
51
Nominal slope of the n/M

Explanations on the performance diagram
characteristic curve [min-1/mNm]
An approximation of the current slope at the specified The performance diagrams show the range of possible
rated values. This value is derived from the torque and measured operating points of a drive at an ambient
speed values when idling with respect to the rated values. temperature of 22°C and include both the operation on
the plastic as well as aluminium flange. The possible speed
n o – nN
––––––––
MN ranges are shown in dependence on the shaft torque.
The sector shown dashed describes potential operating
points in which the drive can be engaged in intermittent
operation or with increased cooling. The characteris-
n [min-1] Plastic flange
Metal flange tics of the performance diagram of the housed (BXT H)
Watt
12 000 30 60 90 120
Operating point
and unhoused (BXT R) series are different. As the speed
at nominal value
increases, the cooling factor improves for the open series
10 000
(BXT R), which results in an increased torque. As the speed
8 000
increases further, this effect is dampened by the different
UN
6 000 speed-dependent components of the friction.
4 000
2 000 Describes the max. recommended continuous torque in the
0 M [mNm] steady state condition at nominal voltage and operation
0 15 30 45 60 75 90 105 120 135 150 175 on an aluminium flange. The continuous torque is indepen-
Recommended operation areas (example: nominal voltage 24V)
dent of the continuous output power and can be exceeded
if the motor is operated intermittently, for example, in S2
Example: Performance diagram for rated values with
operation and/or if more cooling is applied.
continuous operation. (BXT R)
Describes the max. possible output power in continuous
n [min-1] Plastic flange operation in steady state condition with operation on an
Metal flange
Watt
Intermittent operation aluminium flange. The value is independent of the contin-
12 000 30 60 90 120 Operating point
at nominal value uous torque and can be exceeded if the motor is operated
10 000 intermittently, for example, in S2 operation and/or if more
8 000 cooling is applied.
UN
6 000
Nominal voltage characteristic curve UN [V]
4 000 The nominal voltage curve describes the operating points
2 000 at UN. In steady state, the starting point corresponds to
0 M [mNm]
the no-load speed n0 of the drive. Operating points above
0 15 30 45 60 75 90 105 120 135 150 175 this curve can be attained by an increase, operating
Recommended operation areas (example: nominal voltage 24V)
points below this curve by a reduction of the nominal
voltage.
continuous operation. (BXT H)
52
Notes
53
Brushless flat motors
with External rotor technology
The external rotor motors of the BXT series set new Series
standards: thanks to innovative winding technology and
optimum design, the BXT motors deliver a torque of 2214 … BXT R 2214 … BXT H
up to 134 mNm. The ratio of torque to weight and size is 3216 … BXT R 3216 … BXT H
unmatched. The iron-core motors with 14 high-performance
4221 … BXT R 4221 … BXT H
rare earth magnets on the rotor and 12 teeth on the stator
are just 14 mm, 16 mm and 21 mm long, making them suitable
for applications that require a short drive solution with high
Key Features
torque. Combined with optical and magnetic encoders,
gearheads and controls, the result is a compact drive system. Motor diameter 22 ... 42 mm
Product Code

G Shaft type
42 21 G 024 BXT R
BXT Product family
R Open construction
WE CREATE MOTION
FAULHABER BXT
External rotor motors Flat design for space-critical applications.

with very high torque Length range of 14 to 21 mm.
Continuous output up to 100 W Matching optical and magnetic encoders,
Outstanding ratio of torque gearheads and controls available
to weight and size 14-pole construction
Motors with integrated Electronics
WE CREATE MOTION
Speed Control Systems
Connection
FAULHABERvariants
BRC Page
Brushless DC-Motors with Portfolio description
Brushless DC-Servomotors 214 – 215
integrated Speed Controller 1525 … BRC with
with integrated
integrated Speed Controller
Speed Controller 1,9 mNm 216 – 217
1935 … BRC with integrated Speed Controller 4,4 mNm 218 – 219
3153 … BRC with integrated Speed Controller 36,5 mNm 220 – 221
FAULHABER BX4 SC Page

Series 22xx…BX4 SC
Brushless DC-Servomotors with Portfolio description 222 – 223
integrated Speed Controller – 2232 … BX4 SC with integrated Speed Controller 17,5 mNm 224 – 225
4 Pole Technology 2250 … BX4 S SC with integrated Speed Controller 13,3 mNm 226 – 227
2250 … BX4 SC with integrated Speed Controller 25 mNm 228 – 229
3242 … BX4 SC with integrated Speed Controller 60 mNm 230 – 231
3242 … BX4 SCDC with integrated Speed Controller, 2-wire Series 32xx…BX4
45 mNm SC 232 – 233
3268USB
… BX4 SC with integrated Speed Controller 99 mNm 234 – 235
3268 … BX4 SCDC with integrated Speed Controller, 2-wire 60 mNm 236 – 237
FAULHABER B-Flat SC Page

Brushless Flat DC-Micromotors and Portfolio description 238 – 239
DC-Gearmotors with integrated 2610 … B SC with integrated Speed Controller 3,12 mNm
Series 26xx…B SC 240 – 241
Speed Controller 2622 … B SC with integrated Speed Controller 100 mNm 242 – 243
FAULHABER B Cx Page
integrated Motion Controller 3564 ... B Cx with integrated Motion Controller 71 mNm 262 – 263
Series 1525/1935/3153…BRC
FAULHABER BX4 CxD/Cx Page

Speed Control Systems can be adapted to the application
General Information
integrated Motion Controller – 2232 ... BX4 CxD with integrated Motion Controller 16 mNm 266 – 267
via the FAULHABER Motion Manager software. The type
4 Pole Technology 2250 ... BX4 CxD with integrated Motion Controller 25 mNm 268 – 269
FAULHABER Speed Control Systems are 3242highly dynamic
... BX4 Cx andintegrated
with scalingMotion
of the setpoint input, the67operating
Controller mNm mode and
270 – 271
drive systems with controlled speed. 3268
The ...drive electron-
BX4 Cx the control parameters
with integrated Motion Controllercan be adjusted. The
96 mNm USB program-
272 – 273
ics are already integrated and matched to the respective ming adapter for Speed Controllers is used for configu-
FAULHABER MCS
motor. ration, and a contacting board is used for connectingPage
the
Brushless DC-Servomotors with Portfolio description ribbon cables. 274 – 275
The compact integration of the Speed Controller as well
integrated Motion Controller MCS 3242 ... BX4 RS/CO with integrated Motion Controller 76 mNm 276 – 277
as the flexible connection possibilities open
MCS 3242a...wide
BX4 ETrange with integrated Motion Controller 76 mNm 278 – 279
of applications in areas such as laboratory technology Interfaces – discrete I/O
MCS 3268 ... BX4 RS/CO with integrated Motion Controller 96 mNm 280 – 281
and equipment manufacturing, automation technology,
MCS 3268 ... BX4 ET ■ Analog
with integrated input
Motion as setpoint input for96setting
Controller mNm the speed via
282 – 283
pick-and-place machines and machine tools,
MCS orBP4
3274 ... pumps.
RS/CO with PWM or Motion
integrated analog voltage value
Controller 160 mNm 284 – 285
MCS 3274
The integration of the control electronics ... BP4 ET
in space- with integratedinput
■ Digital Motionas
Controller
switching input for160 mNm
defi 286direc-
ning the – 287
optimised add-on systems reduces space requirements tion of rotation of the motor
and simplifies installation and start-up. ■ Digital output, can be programmed either as frequency
The integrated electronics facilitate speed control by output or as error output
means of a PI controller with external setpoint input.
The direction of rotation can be changed via a separate Note
switching input; the speed signal can be read out via the
frequency output. Device manuals for installation and start-up, as well as the
The motors can optionally be operated as a voltage con- "FAULHABER Motion Manager" software, are available on
troller or in fixed speed mode. request or on the Internet under www.faulhaber.com.
57
8000
7000
Brushless DC-Servomotors 6000
with integrated Speed Controller UN
Speed [min-1]
5000
4 Pole Technology Operation point
4000
Peak torque
3000
3242 ... BX4 SC 2000
Values at 22°C and nominal voltage 3242 G 1000

Power supply electronic UP
Power supply motor Umot 0
Nominal voltage for motor UN 0 25 50 75 100 125 150 175 200
Torque [mNm]
No-load speed (at UN) n0
Peak torque (S2 operation for max. 3s/2s) Mmax.
Torque constant kM
PWM switching frequency fPWM Example: 3242...BX4 SC
Torque constant km [mNm/A]

Notes on technical data sheet Constant that describes the ratio between motor torque
and current input.
The following data sheet values of the Speed Control Sys-
Starting torque [MA]
tems are measured or calculated at nominal voltage and at
Load torque with which the motor starts at room tempera-
an ambient temperature of 22°C.
ture and nominal voltage. This value can change depend-
Power supply for electronics Up [V DC] ing on the magnet type and magnet temperature as well
Describes the range of the permissible supply voltage for as the winding temperature.
the control electronics.
PWM switching frequency ƒPWM [kHz]
Power supply for motor Umot [V DC] Pulse width modulation describes the change of the elec-
Describes the range of the permissible supply voltage for trical voltage between two values. The motors integrated
the base motor integrated in the complete system. in the SCS have a low electrical time constant. To keep the
losses associated with PWM low, a high switching fre-
Motor nominal voltage UN [V]
quency is necessary.
The voltage applied between two winding phases. This is
the voltage at which the data sheet parameters are mea- Electronics efficiency η [%]
sured or calculated. Depending on the required speed, a Ratio between consumed and delivered power of the
higher or lower voltage can be applied within the permis- control electronics.
sible range of the supply voltage.
Standby current for the electronics Iel [A]
No-load speed n0 [min-1] Describes the additional current consumption of the
Describes the motor speed when idling and in the steady- complete system that can be attributed to the integrated
state condition at nominal voltage. electronics.
Peak torque Mmax. [mNm] Speed range [min-1]
Specifies the torque that the drive can reach in S2 oper- Describes the maximum no-load speed for continuous
ation (cold start without additional cooling) at nominal operation in the steady-state condition at elevated nom-
voltage and nominal conditions under constant load for inal voltage. Depending on the required speed, higher
the time specified in the data sheet without exceeding or lower voltage can be applied within the given system
the thermal limit. Unless otherwise defined, the value limits.
that applies for the peak torque is equal to two times the Mounting of the system on a plastic flange according to
continuous torque. installation type IM B 5.
Shaft bearings
The bearings used for the brushless DC motors.
MCS 2019 EN-DE-FR-CN_SCS-MCS-Motoren_dff.indd 13 03.10.18 10:38

58
Shaft load, max. permissible [N] Rated current IN [A]

Max. permissible shaft load of the output shaft with spec- Typical maximum continuous current in the steady-state
ified shaft diameter. The values for load and service life condition which results from the rated torque in contin-
of motors with ball bearings are based on manufacturer uous operation. This value can be exceeded if the drive is
specifications. This value is not applicable for a possibly operated intermittently, in start/stop mode, in the starting
available rear or second shaft end. phase and/or if more cooling is used.
Shaft play [mm] Rated speed nN [min-1]

Clearance between the shaft and bearing including the Typical rated speed in the steady-state condition which is
additional bearing clearance in the case of ball bearings. determined from the given rated torque.
Operating temperature range [°C] This value takes into account the effects that motor losses
Shows the minimum and maximum operating temperature have on the slope of the n/M characteristic curve.
of the complete system under nominal conditions.
Housing material n [min-1] Plastic flange

Watt Metal flange
Housing materials and, if necessary, surface treatment. 8 000
10 20 30
intermittent operation
Operating point at rated values
7 000
n0@ 30V
Mass [g] 6 000
The typical mass of the standard system may vary due to 5 000
n0 @ UN
the different component variants. 4 000 PD
3 000
Length dimensions without mechanical tolerance specifi-
2 000 MN =MD
cations:
1 000
Tolerances according to ISO 2768:
0 M [mNm]
≤ 6 = ± 0.1 mm 0 10 20 30 40 50 60 70 80 90
≤ 30 = ± 0.2 mm
≤ 120 = ± 0.3 mm
The tolerances of non-specified values are available on continuous operation.
request.
All mechanical dimensions of the motor shaft are mea- Explanations on the Performance Diagram
sured with an axial shaft load in the direction of the
The performance diagram shows the possible operating
motor.
points of the servo-drives.
Rated Values for Continuous Operation Operating points in the dark blue area are reached con-
tinually in the case of pure flange mounting (IM B5) on a
The following values are measured at nominal voltage, plastic flange (approx. 100mm x 100mm x 10mm) and at
an ambient temperature of 22°C and with mounting type an ambient temperature of 22°C.
IM B 5.
Operating points in the light blue area up to PD are
Mounting type IM B 5 defines the flange mounting of the reached continually in the case of pure flange mounting
drive without mounting feet with two bearing plates, free (IM B5) on an aluminium flange (approx. 100mm x 100mm
front shaft end and mounting flange close to the bearing. x 10mm) and at an ambient temperature of 22°C.
Rated torque MN [mNm] The maximum achievable speed depends on the motor
Maximum continuous torque (S1 mode) at nominal volt- supply voltage. At nominal voltage, the maximum achiev-
age at which in the steady-state condition the tempera- able operating points are those on the nominal voltage
ture does not exceed the maximum permissible winding line through the no-load point and nominal point.
temperature and/or the operating temperature range of Speeds above the nominal voltage line are reached at an
the motor. The motor is fastened to a metal flange here, increased supply voltage.
which approximates the amount of cooling available from
In this case, the maximum voltage for the electronics or
a typical mounting configuration of the motor. This value
motor supply must never be exceeded.
can be exceeded if the motor is operated intermittently,
for example, in S2 mode and/or if more cooling is applied. The possible speed ranges are shown in dependence on
the shaft torque.
59
Shaft
The sector
load,shown
max. permissible
dashed describes
[N] possible operating Rated current IN [A]
pointspermissible
Max. in which the
shaft
drive
load
canofbe
the
engaged
output in
shaft
intermittent
with spec- Typical maximum continuous current in the steady-state
operation
ifi ed shaft or
diameter.
with increased
The values
cooling.
for load and service life condition which results from the rated torque in contin-
of motors with ball bearings are based on manufacturer uous operation. This value can be exceeded if the drive is
specifications. This value is not applicable for a possibly operated intermittently, in start/stop mode, in the starting
Describes the max. recommended continuous torque in
available rear or second shaft end. phase and/or if more cooling is used.
the steady-state condition at nominal voltage and mount-
Shaft
ing onplay [mm]
an aluminium flange. With Speed Control Systems, Rated speed nN [min-1]
Clearance
the between
continuous thesimultaneously
torque shaft and bearing includingto
corresponds thethe Typical rated speed in the steady-state condition which is
additional
rated bearing clearance in the case of ball bearings.
torque. determined from the given rated torque.
Here, the speed
Operating is linearrange
temperature to the[°C]
continuous torque. The This value takes into account the effects that motor losses
continuous
Shows the minimum and maximumofoperating
torque is independent the continuous
temperature have on the slope of the n/M characteristic curve.
output
of the complete system under nominalthe
power and can be exceeded if motor is oper-
conditions.
ated intermittently, for example, in S2 operation and/or if
Housing
more material
cooling is applied. n [min-1] Plastic flange
Watt Metal flange
Housing materials and, if necessary, surface treatment. 8 000
10 20 30
Continuous output power PD [W] 7 000
n0@ 30V
Mass [g] the max. possible output power in continuous
Describes 6 000
The typicalinmass
operation of the standard
steady-state system
condition withmay vary due
mounting on to 5 000
n0 @ UN
thealuminium
an different component
flange. Thevariants.
value is independent of the 4 000 PD
continuous torque, responds linearly to the cooling factor 3 000

Length dimensions without mechanical tolerance specifi-
and can be exceeded if the motor is operated intermit- 2 000 MN =MD
cations:
tently, for example, in S2 operation and/or if more cooling 1 000
is applied. 0 M [mNm]
≤ 6 = ± 0.1 mm 0 10 20 30 40 50 60 70 80 90
Nominal voltage curve UN [V]
≤ 30 = ± 0.2 mm
The nominal voltage curve describes the possible contin-

≤ 120 = ± 0.3 mm
uous operating points at UN. In steady state, the starting Example: Performance diagram for rated values with
The tolerances
point of non-specifi
corresponds ed values
to the no-load speedare
n0 available on
of the drive. continuous operation.
request.
Operating points above this curve can be attained by an
increase,
All operating
mechanical points below
dimensions of the by a reduction
motor shaft areofmea-
the Explanations on the Performance Diagram
nominal
sured withvoltage.
an axial shaft load in the direction of the
motor.
Note
Rated Values for Continuous Operation Operating points in the dark blue area are reached con-
Easy commissioning
The following with the new
values are measured at nominal voltage, plastic flange (approx. 100mm x 100mm x 10mm) and at
Motion
an ambient Manager 6.of 22°C and with mounting type
temperature an ambient temperature of 22°C.
IM B 5.
Depending on the cooling factor, operating point and Operating points in the light blue area up to PD are
Mountingtemperature,
ambient type IM B 5 defi nesbe
it may thenecessary
flange mounting
to adjust of
thethe reached continually in the case of pure flange mounting
drive without
current mounting
limitation feet with
parameters usingtwo
thebearing plates,
operating soft-free (IM B5) on an aluminium flange (approx. 100mm x 100mm
front shaft
ware. end and manual
See technical mountingforfldetails.
ange close to the bearing. x 10mm) and at an ambient temperature of 22°C.
Rated torque MN [mNm] The maximum achievable speed depends on the motor
Maximum continuous torque (S1 mode) at nominal volt- supply voltage. At nominal voltage, the maximum achiev-
age at which in the steady-state condition the tempera- able operating points are those on the nominal voltage
ture does not exceed the maximum permissible winding line through the no-load point and nominal point.
temperature and/or the operating temperature range of Speeds above the nominal voltage line are reached at an
the motor. The motor is fastened to a metal flange here, increased supply voltage.
which approximates the amount of cooling available from
In this case, the maximum voltage for the electronics or
a typical mounting configuration of the motor. This value
for example, in S2 mode and/or if more cooling is applied. The possible speed ranges are shown in dependence on
the shaft torque.
60
Basic design
FAULHABER BRC 5
1 Rear cover 6
2 Drive Electronics
3 Housing with ball bearing 7
4 Winding
5 Magnet
6 Shaft
8
7 Rotor back-iron
8 Washer with ball bearing
FAULHABER BX4 SC
1 Motor
2 Housing
3 Mounting flange
4 Electronics PCB
5 End cap
61
Basic design
FAULHABER BRC 5
1 Rear cover 6
2 Drive Electronics
3 Housing with ball bearing 7
FAULHABER
4 Winding B-Flat SC
5 Magnet
1
6 Shaftcap
End
8
2
7 Rotor back-iron
Electronics PCB
3
8 Washer(Front)
Motor with ball bearing
FAULHABER BX4 SC
1 Motor
2 Housing
3 Mounting flange
4 Electronics PCB
5 End cap
62
Notes
63
Brushless DC-Motors with
The efficient motor series with continuously smooth running Series
impresses with an extraordinarily long service life. In optimised
continuous operation, the motors of the BRC family convince 1525 … BRC 1935 … BRC
with their high-performance bearings and cogging-free 3153 … BRC
running in the linear speed and torque range. The brushless
motors with integrated speed controller operate with precise
speed control. Key Features
This allows the operating point and the operating behaviour
to be precisely controlled by means of corresponding software.
Measuring 15 to 31 mm in diameter, these motors are suitable
for installation in extremely confined spaces and – thanks to Nominal voltage 6 ... 24 V
their robust design – also for applications with high loads. The Speed up to 25.000 min-1
motors can be operated reversibly in a clockwise or anti-clock- Torque up to 5,9 mNm
wise direction, depending on the required control mode. The Continuous output up to 17,5 W
frequency output of these motors enables precise reproduc-
tion and determination of the speed of the motor.
Product Code

K Shaft type
31 53 K 012 BRC
BRC Product family
WE CREATE MOTION
FAULHABER BRC
Programmable motor characteristics through No cogging

integrated speed controller Wide, more linear speed/torque range
Outstanding reliability, long service life Smooth running
Dynamically balanced rotor, quiet running
Brushless DC-Servomotors with
The drives with integrated speed controller combine the Series
advantages of brushless DC-Servomotors with diameter-
compliant control electronics installed in the mounted motor 2232 … BX4 SC 2250 … BX4S SC
unit measuring just 18mm in length. 2250 … BX4 SC 3242 … BX4 SC
Combinable with various precision gearheads, they can be 3242 … BX4 SCDC 3268 … BX4 SC
used in a wide variety of market sectors such as laboratory 3268 … BX4 SCDC
technology, equipment manufacturing, automation technol-
ogy or machine construction. The default factory preconfigu-
ration in combination with the Motion Manager allows quick Key Features
and easy commissioning of the system.
The selectable Hall sensor type (digital/analogue) ensures
Motor length 49,6 ... 85,4 mm
optimum coverage over a wide speed range. The integrated
current limitation matched to the respective type protects the Nominal voltage 12 ... 24 V
motor against overloading and therefore against potential Speed up to 14.000 min-1
destruction. The two-wire version SCDC allows brushed DC- Torque up to 99 mNm
Motors to be replaced easily in certain applications. Continuous output up to 53 W
Product Code

S Shaft type
22 32 S 0 2 4 BX4 SC
BX4 Product family
SC Integrated Speed Controller
WE CREATE MOTION
FAULHABER BX4 SC
High torque and speed rigidity thanks to Simple and convenient programming using the
4-pole technology Motion Manager and programming adapter
Speed control in tight installation spaces; thanks High reliability and long service life
to optional analogue Hall sensors, also available Dynamically balanced rotor, quiet running
in the low speed range from 50 min-1
Modular, diameter-compliant mounting concept
with integrated current limitation
and DC-Gearmotors with
The brushless DC-Servomotors with integrated electronics Series
are based on the motors of the B-Flat series. In the case of
the B-Flat series, the four-pole brushless DC-Servomotors 2610 … B SC 2622 … B SC
with their uniquely flat coil technology with three flat, self-
supporting copper windings form the basis for drive systems
in applications where installation space is extremely limited. Key Features
As an integrated electronic actuation unit, a speed controller
Motor diameter 26 mm
is already available for these motors. What makes this speed
controller so special is that it is fully integrated on the motor Motor length 10,4 ... 22 mm
circuit board and does not increase the length of the motor in Nominal voltage 6 ... 12 V
any way. In combination with the extremely flat, integrated Speed up to 13.000 min-1
gearheads, these motors provide an extremely compact drive Torque up to 100 mNm
system with increased output torque.
Product Code

S Shaft type
26 22 S 0 1 2 B SC 8:1
B Product family
SC Integrated Speed Controller
8:1 Gearhead reduction
WE CREATE MOTION
FAULHABER B-Flat SC
Extremely flat design. Lengths ranging from Easy to use

10 mm to 22 mm with speed controller Integrated spur gearheads of minimal
already integrated length with high gear ratio are available
4-pole design Precise speed control
Motion Control Systems
Feature Comparison
Generation V3.0
General Information
A new generation of integrated Motion Controllers for
The space-optimized FAULHABER Motion Control systems applications that go beyond the features and performance
are available in various series. The different variants are offered by the V2.5 series.
suitable for a variety of market segments and the flexible
■ More power
connection possibilities open a wide range of applications
■ Faster control
in areas such as equipment manufacturing, pick-and-place
machines and machine tools, robotics or special machinery ■ New operating modes
construction. They can be put into operation easily and ■ Flexible use of the I/Os for setpoints and actual values
quickly via Motion Manager, which is available for down- ■ Additional I/Os and interfaces
load at no charge.
■ Sequential programs can be programmed in BASIC for
Generation V2.5 simple, local automation in all interface technologies
■ Proven technology for BL motors in various sizes and ■ Expanded diagnostic functions
performance classes
■ Simple start-up via Motion Manager beginning with ver-
■ Very simple configuration and start-up sion 6.0
■ Numerous configuration options
■ Successfully used in medical and laboratory technology,
equipment manufacturing, automation, medical tech-
nology and aerospace
Generation V2.5 Generation V3.0

Voltage ranges ■ Motor: max. 30V ■ Motor: max. 50V
■ Electronics: max. 30V, optionally separated ■ Electronics: max. 50V, separated standard
PWM switching frequency 78 kHz 100 kHz
Peak torque Up to 190 mNm Up to 320 mNm
Motor types 22xx BX4 CxD 32xx BX4 RS / CO / ET
32xx BX4 Cx 3274 BP4 RS / CO / ET
3564 B Cx
Inputs/outputs DigIn: max. 3 DigIn: 3
DigOut: max. 1 DigOut: 2
AnIn: 1 AnIn ±10V: 2
(not all I/Os available depending on wiring) (standard)
Communication ■ RS232 ■ RS232
■ CANopen ■ EtherCAT
■ CANopen with FAULHABER CAN ■ CANopen
■ USB
Controller Position, speed, current limiting Position, speed, current / torque
Operating modes ■ Depending on the interface variant, ■ Profile Position mode (PP) and Profile Velocity mode
position, speed and current control (PV), taking into account profile settings
with setpoint input via the interface or analog (RS ■ Cyclic Synchronous Position, speed or torque (CSP, CSV
and CF) or CST)
■ Analog input for position, speed, torque or voltage
(APC, AVC, ATC, volt)
Profile operation Linear trapezoidal profiles in all operating modes Linear or sin² speed
in PP and PV modes
Autonomous processes Available in the versions with RS232 interface. Up to eight sequential programs in all versions,
with optional password protection
Protection class n/a IP 54 (optionally with shaft seal)
70
Motion Control Systems V2.5
Connection variants
Brushless DC-Servomotors with integrated

Motion Controller and RS232 or CAN interface.
Series 32xx...BX4 CS/CC/CO
CANopen
USB
RS232
Series 3564...B CS/CC/CO
Series 22xx...BX4 CSD/CCD/COD
Features Benefits
FAULHABER Motion Control Systems of generation V2.5 are ■ Compact construction
highly dynamic positioning systems. The drive electronics ■ Modular design, various performance ratings
are already integrated and matched to the motor. The func- ■ Minimal wiring required
tion of the Motion Control Systems is completely identical ■ Parametrization via “FAULHABER Motion Manager“
to the external MCBL 300x FAULHABER Motion Controllers software
of generation V2.5. ■ Wide range of accessories
In addition to use as a servo drive with controlled position, ■ Adapter for connection to USB interface
the speed can also be controlled. Via an integrated cur- ■ Simple start-up
rent control, the torque is limited and the drive protected
against overload.
Motion Control Systems of generation V2.5 are available

Product code
with RS232 or with CAN interface and, as a result, can also
be integrated in networks. In addition to operation on a PC,
the systems can also be operated on all common industrial
controls.
The integration of the motor and control electronics

reduces space requirements and simplifies installation and
start-up. 3268 motor series 3268 G 024 BX4 CS
G shaft type
024 nominal voltage
BX4 electronic commutation brushless
CS Serial interface RS232
71
Configuration, networking, interfaces
Operating modes Options

Positioning operation Separate supply of power to the motor and electronic
The drive moves to the preset target position and, in doing actuator is optional (important for safety-critical appli-
so, maintains the specified limits for speed and position. cations). Third Input is not available with this option.
The dynamics of the control can be adapted to a wide Depending on the drive, additional programming adapters
range of loads. Limit switches can be evaluated directly. and connection aids are available. The modes and param-
The position can be initialised via limit switches or a refer- eters can be specially pre-configured on request.
ence switch.
Interfaces – discrete I/O
Speed control
The drive controls the the preset target speed via a PI Setpoint input
speed controller without lasting deviation. Depending on the operating mode, setpoints can be input
via the command interface, via an analog voltage value, a
Current control PWM signal or a quadrature signal.
Protects the drive by limiting the motor current to the set
Error output (Open Collector)
peak current. By means of integrated thermal models, the
Configured as error output (factory setting). Also usable
current is limited to the continuous current if necessary.
as digital input, free switch output, for speed control or
Motion profiles signaling an achieved position.
Acceleration and brake ramp as well as the maximum
Additional digital inputs
speed can be preset in speed and positioning operation.
For evaluating reference switches.
Autonomous operation
In version RS, freely programmable processes can be stored Networking
in the Motion Controller. Operation is then also possible
FAULHABER Motion Control Systems of generation V2.5
without RS232 interface.
are available in all three networking variants.
Protective features
RS – systems with RS232 interface
■ Protection against ESD Ideal for equipment manufacturing and for all applications
■ Overload protection for electronics and motor in which the controller is also to be used without a higher
■ Self-protection from overheating level controller. Using Net mode, it is also possible to oper-
ate multiple RS controllers on an RS232 interface.
■ Overvoltage protection in generator mode
Operating modes (CS and CC versions) CC – CANopen with FAULHABER CAN

Combines communication via the CANopen protocol
■ Position control
with the operating modes familiar from the RS version.
– with setpoint input via the interface
The assignment of the PDOs is fixed; the FAULHABER
– with analog setpoint
commands are sent exclusively via one of the PDOs.
– gearing mode
– stepper motor operation Ideal for use in equipment manufacturing if multiple
Motion Controllers are operated on one PC.
■ Speed control
– with setpoint input via the interface CO – CANopen acc. to CiA 402
– with analog setpoint The ideal variant for the operation of a FAULHABER
■ Torque control Motion Controller on a PLC – directly via the CANopen
– with setpoint input via the interface interface or via a gateway on, e.g., Profibus/ProfiNET or
– with analog setpoint on EtherCAT.
■ Operation as Servo Amplifier in voltage controller mode
Operating modes (CO and CC versions)

■ Profile Position mode (PP)
■ Profile Velocity mode (PV)
■ Homing mode
72
The CO version is particularly suitable for users who
Interfaces – Bus Connection
already use various CANopen devices or operate the
Version with RS232 Motion Controllers on a PLC. With dynamic PDO mapping
For coupling to a PC with a transfer rate of up to it is possible to achieve highly efficient networking on the
115 kbaud. Multiple drives can be connected to a single CAN.
controller using the RS232 interface. As regards the control
computer, no special arrangements are necessary. The CC / CO comparison
interface also offers the possibility of retrieving online CC CO
operational data and values. NMT with node guarding • •
A comprehensive ASCII command set is available for Baud rate 1 Mbit max., LSS 1 Mbit max., LSS
programming and operation. This can be preset from the
EMCY object • •
PC using the “FAULHABER Motion Manager“ software or
from another control computer.
SYNCH object • •
Server SDO 1x 1x
Additionally, there is the possibility of creating complex
processes from these commands and storing them on the PDOs 3 x Rx 4 x Rx
3 x Tx 4 x Tx
drive. Once programmed as a speed or positioning each with static each with dynamic
controller via the analog input, as step motor or electronic mapping mapping
gear unit, the drive can operate independently PDO ID fixed adjustable
of the RS232 interface. Configuration Motion Manager Motion Manager
from V5
Versions with CAN CC or CO
Trace PDO3 (fixed) Any PDO
Two controller versions with a CANopen interface are
Standard operating • •
available for optimal integration within a wide range of modes
applications. CANopen is the perfect choice for network- - Profile Position Mode
ing miniature drives because the interface can also be - Profile Velocity Mode
integrated into small electronics. Due to their compact size - Homing
and efficient communication methods, they are the ideal Ext. operating modes FAULHABER -
channel
solution for complex fields of application such as industrial
automation. Both versions support the CANopen communication
profile to CiA 301 V4.02. The transfer rate and node
CC version: CANopen with FAULHABER channel
number are set via the network in accordance with the
The CC version supports not only CiA 402 standard operat-
LSS protocol conforming to CiA 305 V1.11.
ing modes but also a special FAULHABER Mode. Via PDO2,
operator control is thus analogous to that of the RS232 For this purpose, we recommend using the latest version
version. Extended operating modes such as operation with of the FAULHABER Motion Manager.
analog setpoint input or the stepper or gearing mode are
also supported. Note
The CC version is therefore particularly suitable for users Device manuals for installation and commissioning,
who are already familiar with the RS232 version and wish to communication and function manuals as well as the
exploit the benefits of CAN in networking. “FAULHABER Motion Manager” software are available on
request or on the Internet under www.faulhaber.com.
CO version: pure CANopen
The CO version provides the CiA 402 standard operating
modes. All the parameters are directly stored in the object
directory. Configuration can therefore be performed with
the help of the FAULHABER Motion Manager or by apply-
ing available standardized configuratons tools common to
the automation market.
73
General Information Modifications and accessories

System description FAULHABER specialises in the adaptation of its standard
The drive systems integrate a brushless DC servomotor, a products for customer-specific applications. The follow-
high-resolution encoder and a Motion Controller in a com- ing standard options and accessory parts are available for
pact, complete drive unit. FAULHABER Motion Control Systems:
Due to the fact that motor commutation is achieved ■ Configurable shaft lengths
electronically and not mechanically, the service life of a ■ Modified shaft dimensions and pinion configurations
FAULHABER Motion Control Systems depends mainly on such as flats, gears, pulleys and eccenters
the service life of the motor bearings.
■ Modifications for applications with higher speeds and/
FAULHABER uses high-precision, preloaded ball bearings or higher loads
in all of its systems with integrated Motion Controller.
■ Customized special configuration and firmware
Factors affecting the life of the motor bearings include
the static and dynamic axial and radial bearing loads, the ■ Separate voltage supply for motor and electronics
ambient thermal conditions, the speed, vibrational and ■ Configuration and connection adapter
shock loads, and the precision of the shaft coupling to the
given application.
torque in the most compact dimensions, the integrated
FAULHABER BX4 Series 4-pole, DC-Servomotors are ideal.
Their robust design with very few parts and no glued
components means that they are extremely durable and
well suited for harsh ambient conditions such as extreme
temperatures and high vibration and shock loads.
Thanks to their robust construction and their compact
design, the FAULHABER Motion Control Systems of the
V2.5 generation are perfectly suited for use in automation
applications.
74
8000
7000
Motion Control Systems 6000
Speed [min-1]
5000
V2.5, 4-Quadrant PWM UN
Operation point
4000
with RS232 or CANopen interface
3000
Peak torque
2000
3242 ... BX4 Cx 1000

Values at 22°C and nominal voltage 3242 G
0
Power supply electronic UB/UEL 0 25 50 75 100 125 150 175 200
Power supply motor 1) --/UB Torque [mNm]
Nominal voltage for motor UN
Example: 3242...BX4 Cx
Explanatory Notes for Data Sheets Torque constant km [mNm/A]

Constant that describes the ratio between motor torque
The following data sheet values of the Motion Control Sys- and current input.
an ambient temperature of 22°C. PWM switching frequency ƒPWM [kHz]
In their standard version, MCSs of generation V2.5 do not Pulse width modulation describes the change of the elec-
have separate supply inputs for motor and electronics, trical voltage between two values. The motors integrated
but can optionally be equipped with these inputs (via 3rd in the MCS have a low electrical time constant. To keep the
input). losses associated with PWM low, a high switching fre-
Power supply for electronics UB /UEL [V DC]
Describes the range of the permissible supply voltage for Electronics efficiency η [%]
the integrated control electronics. Ratio between consumed and delivered power of the
control electronics.
Power supply for motor -- /UB [V DC]
Describes the range of the permissible supply voltage for Standby current for the electronics Iel [A]
the base motor integrated in the complete system. Describes the additional current consumption of the
complete system that can be attributed to the integrated
Motor nominal voltage UN [V] electronics.
The voltage applied between two winding phases. This is
the voltage at which the data sheet parameters are mea- Speed range [min-1]
sured or calculated. Depending on the required speed, a Describes the maximum no-load speed for continu-
higher or lower voltage can be applied within the permis- ous operation in the steady-state condition at elevated
sible range of the supply voltage. nominal voltage (30 V). Depending on the required speed,
higher or lower voltage can be applied within the given
No-load speed n0 [min-1] system limits.
Describes the motor speed when idling and in the steady- Mounting of the system on a plastic flange according to
state condition at nominal voltage and sinus commutation. installation type IM B 5.
Peak torque Mmax. [mNm] Shaft bearings
Specifies the torque that the drive can reach in S2 opera- The bearings used for the brushless DC motors.
tion (cold start without additional cooling) at nominal
voltage and nominal conditions under constant load for Shaft load, max. permissible [N]
the time specified in the data sheet without exceeding Max. permissible shaft load of the output shaft with speci-
the thermal limit. Unless otherwise defined, the value fied shaft diameter. The values for load and service life
that applies for the peak torque is equal to two times the of motors with ball bearings are based on manufacturer
continuous torque. specifications. This value is not applicable for a possibly
available rear or second shaft end.

75
Shaft play [mm] Rated Values for Continuous Operation

Clearance between the shaft and bearing including the
additional bearing clearance in the case of ball bearings. The following values are measured at nominal voltage,
an ambient temperature of 22°C and with mounting type
IM B 5.
Shows the minimum and maximum operating temperature
of the complete system under nominal conditions. Mounting type IM B 5 defines the flange mounting of the
drive without mounting feet with two bearing plates, free
Housing material front shaft end and mounting flange close to the bearing.
Housing materials and, if necessary, surface treatment.
Rated torque MN [mNm]
Mass [g] Maximum continuous torque (S1 mode) at nominal volt-
The typical mass of the standard system may vary within age at which in the steady-state condition the tempera-
the individual interface variants due to the different com- ture does not exceed the maximum permissible winding
ponent variants. temperature and/or the operating temperature range of
Length dimensions without mechanical tolerance specifi- the motor. The motor is fastened to a metal flange here,
cations: which approximates the amount of cooling available
Tolerances according to ISO 2768: from a typical mounting configuration of the motor. This
value can be exceeded if the motor is operated intermit-
≤ 6 = ± 0.1 mm
tently, for example, in S2 mode and/or if more cooling is
≤ 30 = ± 0.2 mm applied.
≤ 120 = ± 0.3 mm
Rated current IN [A]
The tolerances of non-specified values are available on
Typical maximum continuous current in the steady-state
request.
condition which results from the rated torque in continu-
All mechanical dimensions of the motor shaft are mea- ous operation. This value can be exceeded if the drive is
sured with an axial shaft load in the direction of the operated intermittently, in start/stop mode, in the starting
motor. phase and/or if more cooling is used.
Rated speed nN [min-1]

Typical rated speed in the steady-state condition which is
determined from the given rated torque.
This value takes into account the effects that motor losses
have on the slope of the n/M characteristic curve.
n [min-1] Plastic flange

Watt Metal flange
8 000 intermittent operation
10 20 30 Operating point at rated values
7 000
n0@ 30V
6 000
n0 @ UN
5 000
4 000 PD
3 000
2 000 MN =MD
1 000
0 M [mNm]
0 10 20 30 40 50 60 70 80 90

continuous operation.
76
Explanations on the Performance Diagram Continuous output power PD [W]
The possible speed ranges are shown in dependence on operation in steady-state condition with mounting on
the shaft torque. an aluminium flange. The value is independent of the
continuous torque, responds linearly to the cooling factor
and can be exceeded if the motor is operated intermit-
tently, for example, in S2 operation and/or if more cooling
Operating points in the dark blue area are reached con- is applied.
plastic flange (approx. 100mm x 100mm x 10mm) and at Nominal voltage curve UN [V]
an ambient temperature of 22°C. The nominal voltage curve describes the possible continu-
ous operating points at UN. In steady state, the starting
Operating points in the light blue area up to PD are point corresponds to the no-load speed n0 of the drive.
reached continually in the case of pure flange mount- Operating points above this curve can be attained by an
ing (IM B5) on an aluminium flange (approx. 100mm x increase, operating points below by a reduction of the
100mm x 10mm) and at an ambient temperature of 22°C. nominal voltage.
The maximum achievable speed depends on the motor
supply voltage. At nominal voltage, the maximum Easy commissioning with the new
achievable operating points are those on the nominal Motion Manager 6.
voltage line through the no-load point and nominal
point.
Depending on the cooling factor, operating point and
Speeds above the nominal voltage line are reached at an ambient temperature, it may be necessary to adjust the
increased supply voltage. current limitation parameters using the operating soft-
In this case, the maximum voltage for the electronics or ware. See technical manual for details.
The sector shown dashed describes possible operating
operation or with increased cooling.

Describes the max. recommended continuous torque in the
steady-state condition at nominal voltage and mounting
on an aluminium flange. With Motion Control Systems,
the continuous torque simultaneously corresponds to the
rated torque.
Here, the speed is linear to the continuous torque. The
continuous torque is independent of the continuous
output power and can be exceeded if the motor is oper-
ated intermittently, for example, in S2 operation and/or if
more cooling is applied.
77
Basic design
FAULHABER B Cx
1 Heat sink/cover
2 Thermal conduction pad
3 Thermal protection
4 Motion Controller
with power stage
5 Housing
6 Analog Hall sensors
7 Brushless DC-Servomotors
FAULHABER BX4 CxD/Cx

7
1 End cover
2 Thermal coupling pad
3 PCB with flexboard
4 Flange, electronics side
5 Flange, motor side
6 Housing
7 Brushless DC-Servomotors
78
Supported as communication interfaces are – depending on

the device – RS232 or CANopen and optionally EtherCAT. All
functions of the drive are available here without limitation
via all interfaces.
FAULHABER Motion Control Systems of generation V3.0 are

available in three motor variants and are, thus, perfectly
scalable:
■ MCS 3242 ... BX4

■ MCS 3268 ... BX4
■ MCS 3274 ... BP4
The possible applications are diverse: from laboratory auto-

mation to industrial equipment manufacturing, automation
technology and robotics to aerospace.
The electrical connection of the systems is established via

M12 plugs and extension cables. The flange profile is identi-
cal for all sizes.
Features Benefits
■ Perfectly scalable thanks to various sizes
FAULHABER Motion Control systems of generation V3.0 are
highly dynamic positioning systems in three motor designs ■ Very dynamic control
for use in combination with matched gearheads and ball ■ Various setpoint interfaces
screws from the FAULHABER product portfolio. The motor ■ Stand-alone operation possible in all variants
parameters are preconfigured ex works. Adaptation to ■ Connection via standard M12 plugs
the path is performed during commissioning using the ■ Fast feedback with status LEDs
FAULHABER Motion Manager from version 6.0.
■ Commissioning with the free FAULHABER
Motion Manager from version 6.0
In addition to use as a servo drive with controlled position,
the speed or current can also be controlled. The actual ■ Configuration via programming adapter
values for speed and position are ascertained via the inte-
grated encoders. Limit switches and reference switches can
be directly connected. Product code
The control setpoints can be preset via the communication
interface, via the analogue input or a PWM input or can
come from internally stored sequential programs.
MCS Motion Control System MCS 3268 G 024 BX4 ET

3268 Motor series
G Type of drive
024 Nominal voltage - motor
BX4 Brushless electronic commutation
ET EtherCAT interface
79
Cyclic Synchronous Position (CSP) / Cyclic Synchronous

Error handling Diagnosis Velocity (CSV) / Cyclic Synchronous Torque (CST)
For applications in which a higher-level controller per-
Device control Motor control forms the path planning, even synchronised for multiple
axes. The setpoints for position, speed and current are
Object dictionary
constantly updated. Typical update rates are in the range

+ of a few milliseconds. Cyclic modes are, thus, primarily
suited for combination with EtherCAT. CANopen can also
–
be used.
Analogue Position Control (APC) / Analogue Velocity

Control (AVC) / Analogue Torque Control (ATC)
Hardware driver For applications in which the setpoints of the control
are specified as an analogue value or, e.g., via a directly
connected reference encoder. These operating modes are
Operating modes therefore particularly well suited for stand-alone opera-
tion without higher-level master.
Motor control
Current, speed and position of the drive can be controlled Voltage controller (voltage mode)
via the controller cascade. By means of the optional pilot In the voltage controller, only a current limiting control-
paths, even the fastest movements can be reliably con- ler is used. All control loops are closed by a higher-level
trolled in a reproducible manner. Adjustable filters enable system. The setpoint can be set via the communication
adaptation to a wide range of encoders and loads. system or via an analogue input.
Motion profiles Interfaces – discrete I/O

Acceleration and brake ramp as well as the maximum Three digital inputs for connecting limit and reference
speed can be preset in speed and positioning operation in switches or for connecting a reference encoder. The logic
the Profile Position Mode (PP) and Profile Velocity Mode levels are switchable.
(PV) operating modes. Two analogue inputs (±10V) are available that can be
freely used as setpoint or actual value.
Autonomous operation
Up to eight sequential programs written in BASIC can be Two digital outputs are available that can be freely used as
stored and executed directly on the controller. One of error output, for direct actuation of a holding brake or as
these can be configured from the autostart application. flexible diagnosis output.
Access protection can be activated.
Options
Protection and diagnostic functions
FAULHABER Motion Control systems of generation V3.0 All controllers can optionally be equipped with an Ether-
protect motors and electronics against overload by means CAT interface.
of thermal models. The supply voltage is monitored and For highly dynamic applications, the use of a braking chop-
can also be used in regenerative operation. External per can help to dissipate recovered energy.
devices are thereby protected against overvoltage during
dynamic operation.
Profile Position Mode (PP) / Profile Velocity Mode (PV)

For applications in which only the target of the movement
is specified for the controller. The acceleration and brake
ramp as well as a possible maximum speed are taken into
account via the integrated profile generator. Profile-based
movements are, thus, suited for a combination with stand-
ard networks, such as RS232 or CANopen.
80
Networking General Information
RS – systems with RS232 interface System description
Ideal for device construction and for all applications in The drive systems integrate a brushless DC servomotor,
which the Motion Controller is to be operated on an a high-resolution encoder and a Motion Controller in a
embedded controller. Using Net mode, it is also possible compact, complete drive unit.
to operate multiple RS controllers on an RS232 interface. Due to the fact that motor commutation is achieved
The transmission rate can lie between 9600 baud and 115 electronically and not mechanically, the lifetime of a
kbaud. FAULHABER Motion Control System depends mainly on
CO – CANopen acc. to CiA 402 the lifetime of the motor bearings.
The ideal variant for the operation of a FAULHABER FAULHABER uses high-precision, preloaded ball bearings
Motion Controller on a PLC – directly via the CANopen in all of its systems with integrated Motion Controller.
interface or via a gateway on, e.g., Profibus/ProfiNET or on Factors affecting the life of the motor bearings include
EtherCAT. Dynamic PDO mapping as well as node guarding the static and dynamic axial and radial bearing loads, the
or heartbeat are supported. Refresh rates for setpoint and ambient thermal conditions, the speed, vibrational and
actual values are typically from 10 ms here. shock loads, and the precision of the shaft coupling to
the given application.
ET – EtherCAT
Motion Controller with direct EtherCAT interface. The con-
torque in the most compact dimensions, the integrated
trollers are addressed via CoE via the CiA 402 servo drive
4-pole DC-Servomotors, FAULHABER BX4 / BP4 series are
profile. Ideal in combination with a high-performance
ideal. Their robust design with very few parts and no
industrial controller that also performs path planning and
glued components means that they are extremely dura-
interpolation of the movement for multiple axes. Refresh
ble and well suited for harsh ambient conditions such
rates for setpoint and actual values from 0.5 ms are sup-
as extreme temperatures and high vibration and shock
ported.
loads.
All described operating modes and functions are available Thanks to their robust construction, their compact design
independent of the used communication interface. and the connection concept with industrial-grade stand-
ard cables, the new FAULHABER Motion Control Systems
Note are perfectly suited for use in automation applications.
Device manuals for installation and commissioning, Modifications and accessories
communication and function manuals as well as the FAULHABER specialises in the adaptation of its standard
“FAULHABER Motion Manager” software are available products for customer-specific applications. The follow-
on request or on the Internet under www.faulhaber.com. ing standard options and accessory parts are available for
FAULHABER Motion Control Systems:
■ Industrial-grade connection and interface cables with
plugs
■ Configurable shaft lengths
■ Modified shaft dimensions and pinion configurations
such as flats, gears, pulleys and eccenters
■ Modifications for applications with higher speeds and/
or higher loads
■ Adaptation of the protection classification via shaft
seals
■ Connection and configuration adapter
■ Customized special configuration and firmware
81
8000
7000
Motion Control Systems 6000
5000
Speed [min-1]
V3.0, 4-Quadrant PWM UN
4000
with RS232 or CANopen interface Operation point
3000
2000
Peak torque
MCS 3242 ... BX4 RS/CO 1000
Values at 22°C and nominal voltage MCS 3242G
0
0 25 50 75 100 125 150 175 200
Power supply motor Umot Torque [mNm]
Nominal voltage for motor UN
Example: MCS 3242...BX4
Explanatory Notes for Data Sheets Torque constant km [mNm/A]

Constant that describes the ratio between motor torque
The following data sheet values of the Motion Control Sys- and current input.
an ambient temperature of 22°C. PWM switching frequency ƒPWM [kHz]
Motion Control Systems generally feature separate supply Pulse width modulation describes the change of the elec-
inputs for motor and electronics with the same ground trical voltage between two values. The motors integrated
connection; if necessary, these inputs can also be used as a in the MCS have a low electrical time constant. To keep the
common supply. losses associated with PWM low, a high switching fre-
Power supply for electronics Up [V DC]
Describes the range of the permissible supply voltage for Electronics efficiency η [%]
the integrated control electronics. Ratio between consumed and delivered power of the
Power supply for motor Umot [V DC]
Describes the range of the permissible supply voltage for Standby current for the electronics Iel [A]
the base motor integrated in the complete system. Describes the additional current consumption of the
complete system that can be attributed to the integrated
Nominal voltage UN [V] electronics.
The voltage applied between two winding phases by
means of block commutation. This is the voltage at which Shaft bearings
the data sheet parameters are measured or calculated. The bearings used for the brushless DC motors.
Depending on the required speed, a higher or lower volt- Shaft load, max. permissible [N]
age can be applied within the permissible range of the Max. permissible shaft load of the output shaft with
supply voltage. specified shaft diameter. The values for load and lifetime
No-load speed n0 [min-1] of motors with ball bearings are based on manufacturer
Describes the motor speed when idling and in the steady- specifications. This value is not applicable for a possibly
state condition at nominal voltage and sinus commutation. available rear or second shaft end.
Peak torque Mmax. [mNm] Shaft play [mm]

Specifies the torque that the drive can reach in S2 opera- Play between the shaft and bearing including the
tion (cold start without additional cooling) at nominal additional bearing clearance for ball bearings.
voltage and nominal conditions under constant load for Operating temperature range [°C]
the time specified in the data sheet without exceeding Shows the minimum and maximum operating temperature
the thermal limit. Unless otherwise defined, the value that of the complete system under nominal conditions.
applies for the peak torque is twice the continuous torque.

82
Speed range [min-1] Rated Values for Continuous Operation
Describes the maximum no-load speed for continuous
operation in the steady-state condition at elevated The following values are measured at nominal voltage, an
nominal voltage (30 V). Depending on the required speed, ambient temperature of 22°C and with assembly method
higher or lower voltage can be applied within the given IM B 5.
system limits.
Assembly method IM B 5 defines the flange mounting of
Mounting of the system on a plastic flange according to the drive without mounting feet with two bearing plates,
assembly method IM B 5. free front shaft end and mounting flange close to the
Housing material bearing.
Housing materials and, if necessary, surface treatment. Rated torque MN [mNm]
Protection classification Maximum continuous torque (S1 mode) at nominal volt-
Defines the level of protection of the housing against age at which in the steady-state condition the tempera-
contact, foreign bodies and water. The codes that follow ture does not exceed the maximum permissible winding
designation IP indicate the level of protection a housing temperature and/or the operating temperature range of
offers against contact or foreign bodies (first digit) and the motor. The motor is fastened to a metal flange here,
humidity or water (second digit). which approximates the amount of cooling available
from a typical mounting configuration of the motor. This
Maintenance measures are to be performed in defined
value can be exceeded if the motor is operated intermit-
time intervals due to additional protective measures such
tently, for example, in S2 mode and/or if more cooling is
as shaft seals > see device manual for details.
applied.
Mass [g]
Rated current IN [A]
The typical mass of the standard system may vary within
Typical maximum continuous current in the steady-state
the individual interface variants due to the different
condition which results from the rated torque in continu-
component variants.
ous operation. This value can be exceeded if the drive is
Length dimensions without mechanical tolerance operated intermittently, in start/stop mode, in the starting
specifications: phase and/or if more cooling is used.
Rated speed nN [min-1]
≤ 6 = ± 0.1 mm Typical rated speed in the steady-state condition which is
≤ 30 = ± 0.2 mm determined from the given rated torque.
≤ 120 = ± 0.3 mm This value takes into account the effects that motor losses
The tolerances of non-specified values are available on have on the slope of the n/M characteristic curve.
request.
All mechanical dimensions of the motor shaft are meas- n [min-1] Plastic flange
Watt Metal flange
ured with an axial shaft load in the direction of the motor. 8 000
10 20 30
7 000
n0@ 30V
6 000
n0 @ UN
5 000
4 000 PD
3 000
2 000 MN =MD
1 000
0 M [mNm]
0 10 20 30 40 50 60 70 80 90

continuous operation.
83
Explanations on the Performance Diagram Nominal voltage curve UN [V]

The nominal voltage curve describes the possible conti-
The possible speed ranges are shown in dependence on nuous operating points at UN. In steady state, the starting
the shaft torque. The performance diagram shows the point corresponds to the no-load speed n0 of the drive.
possible operating points of the servo-drives. Operating points above this curve can be attained by an
increase, operating points below by a reduction of the
Operating points in the dark blue area are reached conti-
nominal voltage.
nually in the case of pure flange mounting (IM B5) on a
plastic flange (approx. 100mm x 100mm x 10mm) and at
an ambient temperature of 22 °C. Easy commissioning with the new
Motion Manager 6.
Operating points in the light blue area up to PD are rea-
ched continually in the case of pure flange mounting (IM Depending on the cooling factor, operating point and
B5) on an aluminium flange (approx. 100mm x 100mm x ambient temperature, it may be necessary to adjust the
10mm) and at an ambient temperature of 22 °C. current limitation parameters using the operating soft-
The maximum achievable speed depends on the motor ware. See technical manual for details.
supply voltage. At nominal voltage, the maximum achie-
vable operating points are those on the nominal voltage
line through the no-load point and nominal point.
Speeds above the nominal voltage line are reached at
an increased supply voltage. In this case, the maximum
voltage for the electronics or motor supply must never
be exceeded.
The sector shown dashed describes possible operating
operation or with increased cooling.

Describes the max. recommended continuous torque in the
steady-state condition at nominal voltage and mounting
on an aluminium flange. With Motion Control Systems,
the continuous torque simultaneously corresponds to the
rated torque.
Here, the speed is linear to the continuous torque. The
continuous torque is independent of the continuous
output power and can be exceeded if the motor is opera-
ted intermittently, for example, in S2 operation and/or if
more cooling is applied.

operation in steady-state condition with mounting on an
aluminium flange. The value is independent of the conti-
nuous torque, responds linearly to the cooling factor and
for example, in S2 operation and/or if more cooling is
applied.
84
Notes
85
Brushless DC-Servomotor with
integrated Motion Controller
The 3564…B Cx series stands out first and foremost due to its Series
extremely constant speed control coupled with very smooth-
running operation. 3564 … B Cx
These features make the servo-drive with compact integrated

Motion Controller ideal for use in vibration-sensitive applica-
tions, e.g. in optics, in welding and balancing machines used Key Features
in special machinery construction as well as in measuring or Motor diameter [] 40 x 54 mm
weighing systems. Integrated current control limits the torque
Motor length 84 mm
of the drive if necessary, reliably protecting the drive against
Nominal voltage 24 V
overload.
The interface (RS232 or CANopen) allows simple connection to
Torque up to 71 mNm
networks. The integration of motor and control electronics in
a single unit minimises both space and wiring requirements,
thereby simplifying installation and commissioning. The con-
trol electronics are already perfectly matched to the motor
when the unit leaves the factory. Programming is simple and
convenient using the Motion Manager.
Product Code

K Shaft type
35 64 K 0 2 4 B CS
B Product family
CS Integrated Motion Controller,
RS232 interface
WE CREATE MOTION
FAULHABER B Cx
Wide speed range from 1 to 14,000 min-1 Simple and convenient programming using the
RS232 or CANopen interface, Motion Manager and programming adapter
adapter for connection to USB interface Minimal wiring requirements
Compact mounting concept with Smooth running operation
integrated current limitation
The highly dynamic positioning systems of generation V2.5 are Series
available in two motor diameters with integrated, diameter-
compliant Motion Controllers or with mounted, highly com- 2232 … BX4 CxD 2250 … BX4 CxD
pact Motion Controllers. The different versions with their 3242 … BX4 Cx 3268 … BX4 Cx
high torque, outstanding volume/performance ratio as well as
highly dynamic control characteristics are suitable for a wide
variety of market sectors, e.g. medical and laboratory techno- Key Features
logy, automation technology, robotics or special machinery
construction. Integrated current control limits the torque of Motor diameter Ø 22; [] 40 x 54 mm
the drive if necessary, reliably protecting the drive against Motor length 50 ... 90 mm
overload. Nominal voltage 12 ... 24 V
The interface (RS232 or CANopen) allows simple connection to Speed up to 11.300 min-1
networks. The integration of motor and control electronics in Torque up to 96 mNm
a single unit minimises both space and wiring requirements, Continuous output up to 48 W
thereby simplifying installation and commissioning. The con-
trol electronics are already perfectly matched to the motor
when the unit leaves the factory. Programming is simple and
convenient using the Motion Manager.
Product Code

S Shaft type
22 32 S 0 2 4 BX4 CS D
BX4 Product family
CS Integrated Motion Controller,
RS232 interface
WE CREATE MOTION D Diameter-compliant
FAULHABER BX4 CxD/Cx
Wide speed range from 1 to 11,300 min-1 Simple and convenient programming using the
RS232 or CANopen interface, Motion Manager and programming adapter
adapter for connection to USB interface Minimal wiring requirements
Compact mounting concept with Smooth running operation
integrated current limitation
The motion control systems of the most recent generation V3.0 Series
are available in three performance classes with a continuous
torque of 76 to 160 mNm. The drives comprise a brushless MCS3242 … BX4 RS/CO MCS3242 … BX4 ET
DC-Servomotor, a high-resolution actual value encoder and a MCS3268 … BX4 RS/CO MCS3268 … BX4 ET
Motion Controller in a complete, compact drive unit. The large
MCS3274 … BP4 RS/CO MCS3274 … BP4 ET
number of different communication interfaces, the highly
dynamic controllability, the robust design with protection class
IP 54 as well as the industry standard connection concept via
Key Features
M12 connectors enable use in industrial environments ranging
from automation technology and industrial special machinery Motor diameter [] 42 x 50 mm
construction to robotics and aerospace. Motor length 75 ... 100 mm
In combination with precision gearheads or high-quality lead Nominal voltage 24 V
screw systems, this results in complete system solutions for a Speed up to 11.600 min-1
wide variety of different applications. The systems can be used Torque up to 160 mNm
with any of the interface variants, both as stand-alone axes or
in slave mode at various master controls. Furthermore, flexible
usage possibilities are supported by various libraries and appli-
cation notes that are available for download on the home page.
All features of the drives are available here without restriction
via all of the standard interfaces.
Product Code
MCS Motion Control System

3242 Motor series
G Shaft type
MCS 32 42 G 024 BX4 ET

BX4 Product family
ET EtherCAT interface
WE CREATE MOTION
FAULHABER MCS
Maximum torque in compact installation space Standardised plug and connection cable concept
Interfaces: RS232, CANopen, EtherCAT, Can be universally used in slave
configuration via USB or stand-alone operation
Optionally available with protection class IP 54 Extensive protective and diagnostic functions,
Simple and convenient programming using the local status LEDs
Motion Manager and programming adapter
Stepper Motors
WE CREATE MOTION
Stepper Motors
Residual torque is useful to hold a position without

any current to save battery life or to reduce motor
temperature.
Stepper Motors
Two phase, 24 steps per revolution Rotor inertia [kgm2]
PRECIstep® Technology This value represents the inertia of the complete rotor.
Resonance frequency (at no load) [Hz]
The step rate at which the motor at no load will demon-
Series AM2224 strate resonance. The resonance frequency is load depend-
AM2224 ... 1000
Current Vo ent. For the best results the motor should be driven at a
1 Nominal current per phase (both phases ON) 1)
2 Nominal voltage per phase (both phases ON) 1)
1,0
– 1
higher frequency or in half-step or microstepping mode
outside of the given frequency.
3 Phase resistance (at 20°C) 0,9
0,9
4 Phase inductance (1kHz)
5 Back EMF amplitude 38 Electrical time constant [ms]
Is the time needed to establish 67% of the max. possible
Notes on technical datasheet phase current under a given operation point.
Nominal current per phase [A] Ambient temperature range [°C]

The current supplied to both phases windings at an ambi- Temperatures at which the motor can operate.
ent temperature of 20 °C that will not exceed the thermal Winding temperature tolerated max. [°C]
limits of the motor. Maximum temperature supported by the winding and the
Nominal voltage per phase [V] magnets.
The voltage necessary to reach the nominal current per Thermal resistance R th1; R th2 [K/W]
phase, measured at an ambient temperature of 20 °C. R th1 corresponds to the value between the coil and the
Phase resistance 1) [⍀] housing R th2 corresponds to the value between the
The winding resistance per phase at an ambient tempera- housing and the ambient air R th2 can be reduced by enab-
ture of 20 °C. Tolerance +/- 12%, steady state. ling exchange of heat between the motor and the ambient
air (for example using a heat sink or forced air cooling).
Phase inductance [mH]
The winding inductance per phase measured at 1kHz. Thermal time constant τw1; τw2 [s]
The thermal time constant specifies the time needed for
Back-EMF amplitude 1) [V/k step/s]
the winding respectively the housing to reach a tempera-
The amplitude of the back-EMF measured at 1000 steps/s.
ture equal to 63% of the final value.
Holding torque (at nominal current in both phases) [mNm]
Shaft bearings
Is the torque of the motor at nominal current with two
Self lubricating sintered sleeve bearings or preloaded ball
phases ON.
bearings are available.
Holding torque (at twice the nominal current) [mNm]
Shaft load, max. radial [N]
Is the torque of the motor at 2 x nominal current with two
The maximum recommended radial shaft load for all bear-
phases ON. The magnetic circuit of the motor will not be
ing types.
affected by this boost current, however, to avoid thermal
overload the motor should only be boosted intermittently. Shaft load, max. axial [N]
Ideally, the duty cycle should be reduced to 25% to avoid The maximum recommended axial shaft load for all bearing
damage to the motor. types. For ball bearings this value corresponds to the axial
preload. If this value is exceeded, reversible shaft displace-
Step angle (full step) [degree] ment of ~200μm may occur. To avoid irreversibly damaging
Number of angular degrees the motor moves per full-step. the motor, the maximum axial load should always remain
Angular accuracy [% of full step] under the maximal push force the motor can generate with
The percentage position error per full step, at no load, a mounted lead screw. Please refer to the datasheet of the
with identical phase current in both phases. This error is linear components.
not cumulative between steps. Shaft play max., radial [μm]
Residual torque, max. [mNm] 1)
The maximum clearance between shaft and bearing tested
The maximum torque applied to the shaft to rotate the with the indicated force to move the shaft.
shaft without current to the motor.
93
AM2224_PCS.indd 1 18.09.18 11:23
Stepper Motors
Shaft play max., axial [µm] Load (mNm)

Represents the maximum axial play tested with the 1.25
indicated force. 1
Mass [g] 0.75

Is the motor weight in grams.
0.5
1)
These parameters are measured during final inspection on 100 %
of the products delivered. 0.25
0
0 500 1000 1500 2000 2500 3000 3500
-0.25
How to select a Stepper Motor -0.5
The selection of a stepper motor requires the use of -0.75

T (ms)
published torque speed curves based on the load parameters.
It is not possible to verify the motor selection mathematically
without the use of the curves. 2. Verification of the motor operation.
To select a motor the following parameters must be The highest torque/speed point for this application is
known: found at the end of the acceleration phase. The top speed
is then n = 5000 min-1, the torque is M = 1 mNm.
■ Motion profile
Using these parameters you can transfer the point into
■ Load friction and inertia the torque speed curves of the motor as shown here with
■ Required resolution the AM1524 curves.
■ Available space To ensure the proper operation of the motor in the appli-
■ Available power supply voltage cation, it is highly recommended to use a safety factor
of 30% during the torque calculation. The shown example
1. Definition of the load parameters at the motor shaft assures that the motor will correctly fulfil the requested
The target of this step is to determine a motion profile application conditions.
needed to move the motion angle in the given time frame The use of a higher supply voltage (typically 3 to 5 x higher
and to calculate the motor torque over the entire cycle than the nominal voltage) provides a higher torque at
using the application load parameters such as friction and higher speed (please refer to graph).
load inertia.
In case that no solution is found, it is possible to adapt
The motion and load profiles of the movement used in this the load parameters seen by the motor by the use of a
example are shown below. reduction gearhead.
Depending on the motor size suitable for the application
it is required to recompute the load parameters with the
motor inertia as well. Electronic settings
In the present case it is assumed that a motor with an out- 5 x Nominal voltage *
2.5 x Nominal voltage *
side diameter of maximum 15 mm is suitable and the data
1 x Nominal voltage
has been computed with the inertia of the AM1524.
Torque [mNm] * Nominal current limiting
5
Speed (min-1)
6000 4
5000
3
4000
3000
2
2000
1
1000
0 0
0 500 1000 1500 2000 2500 3000 3500 0 2 500 5 000 7 500 10 000 12 500 15 000 17 500 Speed [min-1]
T (ms) 1 000 2 000 3 000 4 000 5 000 6 000 7 000 Speed [steps/s]
94
3. Verification of the resolution The two major advantages provided by microstep opera-
It is assumed that the application requires a 9° angular tion are lower running noise and higher resolution, both
resolution. depending on the number of microsteps per full step
The motor selected, the AM1524, has a full step angle limited by the capability of the controller.
of 15° which is not suitable in full step mode. It can be As explained above, one electrical cycle or revolution of
operated either in half-step, which reduces the step angle the field vector (4 full steps) requires the driver to provide
to 7,5°, or in micro stepping. With micro stepping, the a number of distinct current values proportional to the
resolution can be increased even higher whereas the pre- number of microsteps per full step.
cision is reduced because the error angle without load of For example, 8 microsteps require 8 different values which
the motor (expressed in % of a full-step) remains the same in phase A would drop from full current to zero following
independently from the number of microsteps with which the cosine function from 0° to 90°, and in phase B would
the motor is operated. rise from zero to full following the sine function.
For that reason the most common solution for adapting These values are stored and called up by the program
the motor resolution to the application requirements is controlling the chopper driver. The rotor target position is
the use of a gearhead or a lead-screw where linear motion determined by the vector sum of the torques generated in
is required. phase A and B:
4. Operation at low speed
All stepper motors exhibit a resonance frequency. MA = k · IA = k · Io · cos ϕ
These are typically below 200Hz. When operating at this
frequency stepper motors will exhibit uncontrolled per- MB = k · IB = k · Io · sin ϕ
turbations in speed, direction of rotation and a reduced
torque. Thus, if the application requires a speed lower or where M is the motor torque, k is the torque constant
equal to the resonance frequency, it is recommended to and Io the nominal phase current.
drive the motor in microstepping mode where the higher
the microstepping rate, the better performance can be For the motor without load the position error is the same
achieved. This will greatly decrease the effects of the reso- in full, half or microstep mode and depends on distortions
nant frequency and result in smoother speed control. of the sinusoidal motor torque function due to detent
torque, saturation or construction details (hence on the
General application notes actual rotor position), as well as on the accuracy of the
phase current values.
In principle each stepper motor can be operated in
three modes: full step (one or two phases on), half step 5. Verification in the application
or microstep. Any layout based on such considerations has to be verified
Holding torque is the same for each mode as long as dis- in the final application under real conditions.
sipated power (I2R losses) is the same. The theory is best Please make sure that all load parameters are taken into
presented on a basic motor model with two phases and account during this test.
one pair of poles where mechanical and electrical angle
are equal.
■ In full step mode (1 phase on) the phases are successive-

ly energised in the following way:
1. A+ 2. B+ 3. A– 4. B–.
■ Half step mode is obtained by alternating between
1-phase-on and 2-phases-on, resulting in 8 half steps
per electrical cycle: 1. A+ 2. A+B+ 3. B+ 4. A–B+
5. A– 6. A–B– 7. B– 8. A+B–.
■ If every half step should generate the same holding
torque, the current per phase is multiplied by √2 each
time only 1 phase is energised.
95
Stepper Motors
Two phase
2 6
3
7
4
5
8
Stepper Motor
10
1 Retaining ring
2 Washer
3 PCB
4 Ball bearing
11
5 Rear cover / stator
6 Coil, Phase A
7 Inner stator 9
8 Rotor
9 Magnets 13
10 Shaft
4
11 Housing
12 Coil, Phase B
13 Front cover / stator
12
Features Benefits
2
PRECIstep® stepper motors are two phase multi-polar ■ Cost effective positioning drive without 1
an encoder
motors with permanent magnets. The use of rare-earth
■ High power density
magnets provides an exceptionally high power to volume
■ Long operational lifetimes
ratio. Precise, open-loop, speed and position control can
■ Wide operational temperature range
be achieved with the application of full step, half step, or
microstepping electronics. ■ Speed range up to 16 000 min-1 using a current
mode chopper driver
The rotor consists of an injection moulded plastic support ■ Possibility of full step, half step and microstep operation
and magnets which are assembled in a 10 or 12 poles
configuration depending on the motor type. The large
magnet volume helps to achieve a very high torque
density. The use of high power rare-earth magnets also
enhances the available temperature range of the motors Product code
from extremely low temperatures up to 180 °C as a
special configuration. The stator consists of two discrete
phase coils which are positioned on either side of the
rotor. The inner and outer stator assemblies provide the
necessary radial magnetic field.
AM1524 Motor series

2R Bearing type AM1524 2R 0075 57
0075 Coil type
57 Motor execution
96
Stepper Motors
Two phase with Disc Magnet
1
4
2
Stepper Motor
6
1 Retaining ring
2 PCB
3 Rear cover / stator
4 Coil
5 Housing 7
6 Sleeve
8
7 Disc Magnet
8 Shaft
9 Front cover
9
10 Sintered bearing
10
Features Benefits
The rotor consists of a thin magnetic disc. The low rotor ■ Extremely low rotor inertia
inertia allows for highly dynamic acceleration. The rotor ■ High power density
disc is precisely magnetized with 10 poles which helps the ■ Long operational lifetimes
motor achieve a very high angular accuracy. The stator ■ Wide operational temperature range
consists of four coils, two per phase, which ■ Ideally suited for micro-stepping applications
are located on one side of the rotor disc and provide the
axial magnetic field.
Special executions with additional rotating back-iron

are available for exceptionally precise micro-stepping
performance.
Product code
DM1220 Motor series

DM1220 2 R 0 3 3 0 5 1
2R Bearing type
0330 Coil type
51 Motor execution
97
Stepper Motors
Reluctant torque [mNm]

Holding force generated by the attraction of the magnets
to the stator structure.
Stepper Motors
Two phase with Disc Magnet, Friction torque [mNm]
100 steps per revolution, microstepping motor Friction from the bearing system.
Thermal resistance Rth [°C/W]
Rth corresponds to the value between the coil and the
Series DM40100R ambient air. It can be reduced by enabling exchange
Winding
of heat between the motor and the ambient air
1 Phase resistance (at 20°C) ± 14%
± 20%
(for example using a heat sink or forced air cooling).
2 Phase inductance
3
4
Nominal current (1 phase ON)
Boosted current (1 phase ON)
typ.
typ.
Thermal time constant τw [s]
5 Induced voltage at 600 min-1 ± 10% The thermal time constant specifies the time needed
6 Torque constant ± 10%
for the winding respectively the housing to reach
Notes on technical datasheet a temperature equal to 63% of the final value.
Recommended ambient temperature range [°C]
Phase resistance 1) [⍀]
Temperatures at which the motor can operate.
The winding resistance per phase at an ambient tem-
perature of 20 °C. Tolerance +/- 14%, steady state. Max temperature for coils [°C]
Maximum temperature supported by the winding.
Phase inductance [mH]
The winding inductance per phase measured at 1kHz. Number of pole pairs
Number of pole pairs inside the motor.
Nominal current [A]
The current supplied per phase, one phase at a time, at Phase shift [°]
an ambient temperature of 20 °C that will not exceed the Electrical phase shift between phase A and phase B.
thermal limits of the motor. Tolerance +/- 5%.
Boosted current [A] Phase fluctuation, max [°]
Maximum current which can be supplied per phase, Max. fluctuation of the phase shift between
one phase at a time for a short period of time to avoid the two phases over the full revolution.
exceeding the thermal capacity of the motor. Maximum speed [min-1]
Induced voltage 1) [VDC] Maximum recommended speed.
The amplitude of the back-EMF measured at 600 rpm. Rotor inertia [kgm2]
Torque constant [mNm/A] This value represents the inertia of the complete rotor.
Torque increase per additional Amps provided to the Mass [g]
motor in the plateau regime and without saturation Is the motor weight in grams.
of the magnetic circuit. Electrical time constant [ms]
Static torque (at nominal current) [mNm] Is the time needed to establish 67% of the max. possible
Torque of the motor at nominal current phase current under a given operation point.
with one phase ON. Max angular acceleration [rad/s2]
Boosted static torque [mNm] Maximum acceleration the motor can reach in boosted
Torque obtained when supplying the motor with the mode and without any load.
boosted current. Be careful, this mode should be used Insulation voltage [VDC]
with low duty cycle only to prevent exceeding the thermal Test voltage applied between the motor windings and
limits of the motor. motor flanges during the insulation test.
1)
These parameters are measured during final inspection on 100%
of the products delivered.
98
Stepper Motors
Two phase with Disc Magnet
1
3
5
6
7
Stepper Motor
Ø 40 – 52 mm
1 Front flange
2 ½ stator
3 Phase A & B cables
4 Phase A & B windings
5 Disc magnet
6 Shaft
7 Phase A & B cables
8 ½ stator
2
9 Rear flange 4
Features Benefits
The Large Disc Magnet stepper motors are two phase ■ Very high acceleration / change of direction capability
multi-polar motors with permanent magnets. The use ■ High power density
of rare-earth magnets provides an exceptionally high ■ Long operational lifetimes
power to volume ratio. Their rotor design with very low ■ Short and light motors
inertia consists in a very thin magnetic disc magnetized ■ High pull-in
in 25 pole pairs mounted on the motor shaft. ■ Possibility of full step, half step and microstep operation
■ High reliability
These motors have specifically been designed for appli-
cations requiring very fast acceleration or change of
directions. Their short length and light weight allow
them to be used in highly integrated systems. The high
number of steps and micro stepping capability makes
them perfectly suitable for very precise positioning. Product code
Combining them with an encoder enables to further
improve their positioning capabilities and minimize
power consumption and heating.
Finally their very low inertia makes it possible to start

from the first step with a rather high speed, reducing
further time needed for the acceleration ramp.
DM52100R Motor series
DM52100R 2 R 5 3 0 0 00
2R Bearing type
5300 Coil type
00 Motor execution
99
Linear DC-Servomotors
WE CREATE MOTION
Force constant kF [N/A]

Linear DC-Servomotors the motor force delivered and the motor line current with
sine wave commutation.
with Analog Hall Sensors
Terminal resistance, phase-phase R [ ] ±12%
The resistance measured between two motor phases.
This value is directly influenced by the coil temperature
LM 1247 ... 11 (temperature coefficient: α 22 = 0,0038 K-1).
Values at 22°C
Continuous force
LM 1247 ... 11
Fe max. 3,6
Terminal inductance, phase-phase L [μH]
Peak force Fp max. 10 The inductance measured between two phases at 1 kHz.
Continuous current Ie max. 0,5
Peak current Ip max. 1,6 Stroke length smax. [mm]
Back-EMF constant kE 5,2
The datasheet parameters are only valid if the rod move-
ment is within the given stroke range, smax.. Aligning the
Notes
N t on ttechnical
h i ld datasheet
t h t
rod and stator axial centres, the allowed movement is
All values at 22 °C. therefore half the overall stroke length.
Continuous force Fe max. [N] Repeatability σ r [μm]

The maximum force delivered by the motor at the thermal The typical measured difference when repeating several
limit in continuous duty operation and with a reduced times the same movement under the same conditions.
thermal resistance Rth2 by 55%. Measurements done with FDS MC (-01, 11 versions) and
3rd party sin/cos motion controller (-02, 12 versions).
Fe max. = kF · Ie max. Accuracy σ a [μm]
The typical positioning error. This value corresponds to the
Peak force Fp max. [N] difference between the set position and the exact meas-
The maximum force delivered by the motor at the ured position of the system. Measurements done with FDS
thermal limit in intermittent duty operation (max. 1 s, MC (-01, 11 versions) and 3rd party sin/cos motion controller
10% duty cycle) and with a reduced thermal resistance (-02, 12 versions).
Rth2 by 55%.
Acceleration ae max. [m/s2]
The maximum theoretical no-load acceleration from stand-
Fp max. = kF · Ip max.
still in continuous duty operation.
Continuous current Ie max. [A] Fe max.
ae max. = –––––
The maximum motor current consumption at the thermal mm
limit in continuous duty operation and with a reduced
thermal resistance Rth2 by 55%. Speed ve max. [m/s]
The maximum theoretical no-load speed from standstill,
T125 – T22 2 considering a triangular speed profile and maximum stroke
Ie max. = ––––––––––––––––––––––––––––––––––––– · –––
R · (1 + 22 · (T125 – T22 )) · (Rth 1 + 0,45·R th 2 ) 3 length.
Peak current Ip max. [A] ve max. = ae max. · s max.

The maximum motor current consumption at the
thermal limit in intermittent duty operation (max. 1 s, Thermal resistance Rth 1; Rth 2 [K/W]
10% duty cycle) and with a reduced thermal resistance Rth1 corresponds to the value between coil and housing.
Rth2 by 55%. Rth2 corresponds to the value between housing and
Back-EMF constant kE [V/m/s] ambient air.
The constant corresponding to the relationship between The listed values refer to a motor totally surrounded by air.
the induced voltage in the motor phases and the linear Rth2 can be reduced with a heat sink and/or forced air cooling.
motion speed.
2 · kF
kE = ——––
6
101
Thermal time constant τw1; τw2 [s] where:

The thermal time constant of the coil (τw1) and housing
(τw2), respectively. Fe : Continuous force delivered by motor [N]
Operating temperature range [°C] Fext : External force [N]

The minimum and maximum permissible operating
Ff : Friction force Ff = m · g · ⋅ cos ( ) [N]
temperature values of the motors.
Fx : Parallel force Fx = m · g · sin ( ) [N]
Rod weight mm [g]
The typical weight of the rod (cylinder with magnets). m: Total mass (incl. rod) [kg]
Total weight mt [g] g: Gravity acceleration [m/s2]
The typical total weight of the linear DC-Servomotor.
a: Acceleration [m/s2]
Magnetic pitch τ m [mm]
The distance between two equal poles.
Rod bearings Speed profiles
The material and type of bearings.
Shifting any load from point A to point B is subject to the
Housing material laws of kinematics.
The material of the motor housing. Equations of a uniform straight-line movement and
Direction of movement uniformly accelerated movement allow definition of the
The direction of movement is reversible, determined by various speed vs. time profiles.
the control electronics. Prior to calculating the continuous duty force delivered by
the motor, a speed profile representing the various load
Force calculation movements needs to be defined.
To move a mass on a slope, the motor needs to deliver Triangular speed profile
a force to accelerate the load and overcome all forces The triangular speed profile simply consists of an accelera-
opposing the movement. tion and a deceleration time.
Fext Speed (m/s)
t The shaded area equals

the movement length
Fe during time t.
m
Ff
Fg Fy t/2 t/2 Time (s)
Fx
11 11 vv2 2
Displacement: ss ==______· ·vv· t· t==______· ·aa· ·tt2 2==____
____ [m]
[m]
The sum of forces shown in above figure has to be equal to: 22 44 aa
ΣF=m·a [N] Speed: v= 2·

s
___
a·t
= ________ = a·s [m/s]
t 2
Entering the various forces in this equation it follows that:

s s v v 2v 2
v ____
Acceleration: a =a 4= ·4____
· ____
= 2= ·2____
· = = ________ [m/s
[m/s2 2]
]
Fe - Fext - Ff - Fx = m · a [N] t 2t2
t t s s
102
Trapezoidal speed profile Speed (m/s)
The trapezoidal speed profile, acceleration, speed and
deceleration, allow simple calculation and represent
typical real application cases.
2
1 3 Time (s)
Speed (m/s)
t1 = td /3 t2 = td /3 t3 = td /3
4
t The shaded area equals td = 100 ms t4 = 100 ms
the movement length
during time t.
Unit 1 2 3 4
s (displacement) m 0,005 0,01 0,005 0

v (speed) m/s 0 ... 0,3 0,3 0,3 ... 0 0
t/3 t/3 t/3 Time (s) a (acceleration) m/s2 9,0 0 –9,0 0
t (time) s 0,033 0,033 0,033 0,100
2 2 1 1 v2 v2 Calculation example
Displacement: s =s ___=· ___
v ··tv=· t______ · a ·· ta2·=t 22 =· ____
= ______ 2 · ____ [m][m] Speed and acceleration of part 1
3 3 4,5 4,5 a a
s 20 · 10-3
vmax. = 1,5 · ___ = 1,5 · _________________
= 0,3 m/s
s s a · at · t a · as · s t 100 · 10-3
Speed: = 1,5
v =v1,5 · ___· ___ = =_________
= ________
= ________ _________ [m/s]
[m/s]
t t 3 3 2 2 s 20 · 10-3
a = 4,5 · ___ = 4,5 · ____________________
= 9 m/s2
s s v v v v 2 2 t2 (100 · 10-3) 2
Acceleration: = 4,5
a =a4,5 = 3=· 3___· =___2=· 2____· ____
· ___· ___ [m/s
[m/s 2 2]
]
t2 t2 t t s s Force definition
Assuming a total mass of 500 g and a friction coefficient of
0,2, the following forces result:
How to select a linear DC-Servomotor Forward Backward
Force Unit Symbol 1 2 3 4 1 2 3 4
This section describes a step-by-step procedure to select a
Friction N Ff 0,94 0,94 0,94 -0,94 0,94 0,94 0,94 0,94
linear DC-Servomotor.
Parallel N Fx 1,71 1,71 1,71 1,71 -1,71 -1,71 -1,71 -1,71
Speed profile definition Acceleration N Fa 4,5 0 -4,5 0 4,5 0 -4,5 0
To start, it is necessary to define the speed profile of the Total N Ft 7,15 2,65 -1,85 0,77 3,73 -0,77 -5,27 -0,77
load movements.
Movement characteristics are the first issues to be con- Calculation example
sidered. Which is the maximum speed? How fast should Friction and acceleration forces of part 1
the mass be accelerated? Which is the length of movement Ff = m · g · μ · cos (∝) = 0,5 · 10 · 0,2 · cos (20º) = 0,94 N
the mass needs to achieve? How long is the rest time?
Fa = m · a = 0,5 · 9 = 4,5FaN= m · a = 0,5 · 9 = 4,5 N
Should the movement parameters not be clearly defin-
ed, it is recommended to use a triangular or trapezoidal
Motor selection
profile.
Now that the forces of the three parts of the profile
Let’s assume a total mass of 500 g that needs to be moved are known, requested peak and continuous forces can
20 mm in 100 ms on a slope having a rising angle of 20° be calculated in function of the time of each part.
considering a trapezoidal speed profile.
The peak force is the highest one achieved during the
motion cycle.
Fp = max. ( | 7,15 | , | 2,65 | , | -1,85 | , | 0,77 | , | 3,73 | , | -0,77 | , | -5,27 | , | -0,77 | ) = 7,15 N
103
The continuous force is represented by the expression: Motor characteristic curves

Motion profile:
Σ (t · Ft2 ) Trapezoidal (t1 = t2 = t3), back and forth
Fe = _______________
= ...
2 · Σt Motor characteristic curves of the linear DC-Servomotor
with the following parameters:
2 2
0,033 · 7,15 + 0,033 · 2,65 + 0,033 · (–1,85) + 0,1 · 0,77
2 2 Displacement distance: 20 mm
2 2 2 2
+ 0,033 · 3,73 + 0,033 · ( –0,77) + 0,033 · (–5,27) + 0,1 · (–0,77) Friction coefficient: 0,2
Fe = ________________________________________________________________________________________
= 2,98 N
2 · (0,033 + 0,033 + 0,033 + 0,1) Slope angle: 20°
Rest time: 0,1 s

With these two values it is now possible to select the
suitable motor for the application.
Load (incl. rod) [kg] External force [N]
Linear DC-Servomotor LM 1247–020–11
smax. = 20 mm ; Fe max. = 3,6 N ; Fp max. = 10,7 N 2,5 2,5
2,0 2,0
Coil winding temperature calculation
To obtain the coil winding temperature, the continuous
motor current needs to be calculated. 1,5 1,5
For this example, considering a force constant kF equal

to 6,43 N/A, gives the result: 1,0 1,0
F e 2,98
Ie = = _________ = 0,46 A
_____ 0,5 0,5
kf 6,43
0
0 0,05 0,10 0,15 0,20 0,25 0,30 Speed
With an electrical resistance of 13,17 , a total thermal [m/s]
resistance of 23,2 °C / W (Rth1 + Rth2) and a reduced ther- LM 1247–020–11
mal resistance Rth2 by 55% (0,45 · Rth2), the resulting coil

Load curve
temperature is:
Allows knowing the maximum applicable load (incl. rod)
for a given speed with 0 N external force.
3 ) 2· ( 1 – α22 · T22) + T22
R · (Rth1 + 0,45 · Rth2) · (Ie · _____
2 The graph shows that a maximum load (incl. rod) ( ) of
Tc (I) = = ...
______________________________________________________________________________
0,87 kg can be applied at a speed of 0,11 m/s.
1 – α22 · R · ( Rth1 + 0,45 · Rth2) · (Ie · ) 3
_____ 2
2
External force curve
Allows knowing the maximum applicable external force
3 ) · ( 1 - 0,0038 · 22) + 22
2 for a given speed with a load of 0,5 kg.
13,17 · (3,2 + 0,45 · 20,0) · (0,46 · _____
Tc (I) = 2 = 85,26 °C
_____________________________________________________________________________________________ The graph shows that the max. achievable speed ( )
3 2 without external forces, but with a load of 0,5 kg is 0,31 m/s.
1 – 0,0038 · 13,17 ( 3,2 + 0,45 · 20,0) · (0,46 · ) _____
2 Therefore, the maximum applicable external force ( )
at a speed of 0,3 m/s is 0,5 N.
The external peak force ( ) is achieved at a speed
of 0,17 m/s, corresponding to a maximum applicable
external force of 2,27 N.
104
7
8
3
Linear DC-Servomotor
4
5
1 Sleeve bearings
6
2 Bearing support
3 Coil
4 Housing
5 PCB
6 Hall sensors
7 Cable 9
8 Cover
9 Forcer rod
Features Benefits
FAULHABER technology combines the speed and ■ High dynamics
robustness of a pneumatic system with the flexibil- ■ Excellent force to volume ratio
ity and reliability features of an electro-mechanical ■ No residual force present
linear motor. The innovative design with a 3-phase ■ Non-magnetic metal housing
self-supporting coil and non-magnetic metal housing ■ Compact and robust construction
offers outstanding performance. ■ No lubrication required
■ Simple installation and configuration
The absence of residual static force and the excellent
relationship between the linear force and current
make these motors ideal for use in micro-positioning
applications. Position control of the Linear DC-Servo-
motor is made possible by the built-in Hall sensors.
Product code
Performance lifetime of the Linear DC-Servomotors is
mainly influenced by the wear of the sleeve bearings,
which depends on operating speed and applied load
of the cylinder rod.
LM Linear Motor
L M 12 4 7 – 0 2 0 – 1 1
12 Motor width [mm]
020 Stroke length [mm]
11 Sensors type: linear
105
Precision Gearheads
WE CREATE MOTION
Precision Gearheads
General information
Precision Gearheads Input speed Page
03A The recommended
Planetary Gearheads maximum input speed for continuous
0,88 mNm 340
Life performance operation serves as a guideline. It is possible
06A Planetary Gearheads 25 mNm to operate 341
The operational lifetime of a reduction gearhead and the gearhead
06/1 Planetary Gearheadsat higher speeds. However,
25 mNmto obtain 342
motor combination is determined by:08/1 optimum
Planetary life performance in applications
Gearheads 60 mNmthat require343con-
■ Input speed 08/2 Spur Gearheads
tinuous 15 mNm
operation and long life, the recommended 344
speed
■ Output torque 08/3 Spur Gearheads,
should zero backlash
be considered. 15 mNm 345
10/1 Planetary Gearheads 0,1 Nm 346
■ Operating conditions 12/3 BallGearheads
Spur bearings 0,03 Nm 347
■ Environment and Integration into12/4 other systems RatingsGearheads
Planetary on load and lifetime, if not stated,
0,3 Nm are according348
12/5
Since a multitude of parameters prevail in any application, to the
Spur information
Gearheads, from the ball bearing
zero backlash 0,03 Nmmanufacturers.
349
13A Planetary Gearheads 0,18 Nm 350
it is nearly impossible to state the actual lifetime that can Operating temperature range
14/1 Planetary Gearheads 0,3 Nm 351
be expected from a specific type of gearhead or motor- Standard range as listed on the data sheets.
gearhead combination. A number of15/5 options to the Special
Spur executions for extended temperature
Gearheads 0,1 Nm range 353
standard reduction gearheads are available
15/5 S to increase available
Spur Gearheadson request. 0,1 Nm 354
life performance: ball bearings, all metal
15/8 gears, reinforced Spur Gearheads, zero backlash 0,1 Nm 355
Reduction ratio
lubrication etc. 15/10 Planetary Gearheads 0,35 Nm 356
The listed ratios are nominal values only, the exact ratio
16A Spur Gearheads 0,03 Nm 357
Bearings – Lubrication 16/5 for Gearheads
Spur each reduction gearhead can be calculated
0,1 Nm by means358of
Gearheads are available with a range16/5 of Sbearings to meet the Gearheads
Spur stage ratio applicable for each type. 0,1 Nm 359
various shaft loading requirements: sintered
16/7 sleeve bear- Planetary Gearheads
Output torque 0,3 Nm 360
ings, ball bearings and ceramic bearings.
16/8 Where indicated, Spur Gearheads, zero backlash
Continuous operation.
0,1 Nm 361
ball bearings are preloaded with spring 17/1washers of limited Planetary Gearheads 0,55 Nm 362
The continuous torque provides the maximum load pos-
20/1R
force to avoid excessive current consumption. Planetary Gearheads 0,8 Nm 363
22E sible applied
Planetary Gearheadsto the output shaft; exceeding
0,6 Nm this value364 will
A higher axial shaft load or shaft pressfi t force than speci-
22EKV reduce the service
Planetary Gearheads life. 1,2 Nm 365
fied in the data sheets will neutralise22F
the preload on the Intermittent
Planetary operation.
Gearheads 1 Nm 366
ball bearings. 22/2 Spur Gearheads 0,1 Nm
The intermittent torque value may be applied for a short 367
The satellite gears in the 38/1-2 Series22/5
Planetary Gearheads Spur Gearheads, zero backlash 0,1 Nm
period. It should be for short intervals only and not exceed 368
are individually supported on sintered 22/7
sleeve bearings. Planetary Gearheads
5% of the continuous duty cycle. 0,7 Nm 369
23/1gears are indivi-
In the 38A and 44/1 Series, the satellite Planetary Gearheads 0,7 Nm 370
26A Direction
Planetary of rotation, reversible
Gearheads 1 Nm 371
dually supported on needle or ball bearings.
26/1 All gearheads
Planetary Gearheadsare designed for clockwise
3,5 Nmand counter-372
All bearings are lubricated for life. Relubrication
26/1R is not Planetary
clockwise Gearheads 3,5 Nm
rotation. The indication refers 373
to the direction
necessary and not recommended. The30/1 use of non-approved Planetary Gearheads
of rotation as seen from the shaft end,4,5 Nm
with the motor374
lubricants on or around the gearheads 30/1orS motors can Planetary
runningGearheads
in a clockwise direction. 4,5 Nm 375
negatively influence the function and life expectancy.
32ALN Backlash
Planetary Gearheads 4,5 Nm 377
The standard lubrication of the reduction gears is such as
32/3 Backlash
Planetary is defined by the amount by7 which
Gearheads Nm the width378
to provide optimum life performance at minimum cur-
32/3R Planetary
of a toothGearheads
space exceeds the width of 7 Nm 379
the engaging tooth
rent consumption at no-load conditions. For extended life
38A Planetary
on the Gearheads
pitch circle. Backlash is not to 20
beNmconfused with380
performance, all metal gears and heavy 38/1 duty lubrication Planetary Gearheads
elasticity or torsional stiffness of the 10 Nm
system. 381
are available. Specially lubricated gearheads
38/1 S are available Planetary Gearheads
The general purpose of backlash is to10prevent Nm 382
gears from
for operation at extended temperature 38/2environments and Planetary Gearheads 10 Nm 383
jamming when making contact on both sides of their teeth
under vacuum. 38/2 S Planetary Gearheads 10 Nm 384
simultaneously. A small amount of backlash is desirable
44/1 Planetary Gearheads 16 Nm 385
Notes on technical datasheet to provide for lubricant space and differential expansion
between gear components. The backlash is measured on
Unspecified tolerances
the output shaft, at the last geartrain stage.
Tolerances in accordance with ISO 2768 medium.
≤ 6 = ± 0,1 mm
≤ 30 = ± 0,2 mm
≤ 120 = ± 0,3 mm
107
Precision Gearheads
Zero Backlash Gearheads How to select a Precision Gearhead

The spur gearheads, series 08/3, 12/5, 15/8, 16/8 and 22/5,
with dual pass geartrains feature zero backlash when pre- This section gives an example of a step-by-step procedure
loaded with a FAULHABER DC-Micromotor. on how to select a reduction gearhead.
Preloaded gearheads result in a slight reduction in overall
Application data
efficiency and load capability.
The basic data required for any given application are:
Due to manufacturing tolerances, the preloaded gear-
Required torque M [mNm]
heads could present higher and irregular internal friction Required speed n [min-1]
torque resulting in higher and variable current consump- Duty cycle δ [%]
Available space, max. diameter/length [mm]
tion in the motor. Shaft load radial/axial [N]
However, the unusual design of the FAULHABER zero
backlash gearheads offers, with some compromise, an The assumed application data for the selected example are:
excellent and unique product for many low torque, Output torque M = 120 mNm
high precision postioning applications. Speed n = 30 min-1
Duty cycle δ = 100%
The preloading, especially with a small reduction ratios, Space dimensions, max. diameter = 18 mm
is very sensitive. This operation is achieved after a defined length = 60 mm
Shaft load radial = 20 N
burn-in in both directions of rotation. For this reason, axial = 4N
gearheads with pre-loaded zero backlash are only available
To simplify the calculation in this example, the duty cycle is
when factory assembled to the motor.
assumed to be continuous operation.
The true zero backlash properties are maintained with
new gearheads only. Depending on the application, a slight Preselection
backlash could appear with usage when the gears start A reduction gearhead which has a continuous output
wearing. If the wearing is not excessive, a new preload torque larger than the one required in the application
could be considered to return to the original zero backlash is selected from the catalogue.
properties. If the required torque load is for intermittent use, the
selection is based on the output torque for intermittent
Assembly instructions operation.
It is strongly recommended to have the motors and The shaft load, frame size and overall length with the
gearheads factory assembled and tested. This will assure motor must also meet the minimum requirements.
perfect matching and lowest current consumption. The product selected for this application is the planetary
The assembly of spur and hybrid gearheads with motors gearhead, type 16/7.
requires running the motor at very low speed to ensure
Output torque, continuous operation Mmax. = 300 mNm
the correct engagement of the gears without damage. Recommended max. input speed for
– Continuous operation n ≤ 5 000 min-1
The planetary gearheads must not be assembled with – Shaft load, max. radial ≤ 30 N
the motor running. The motor pinion must be matched axial ≤5N
with the planetary input-stage gears to avoid misalign-
Calculation of the reduction ratio
ment before the motor is secured to the gearhead.
To calculate the theoretical reduction ratio, the recom-
When face mounting any gearhead, care must be taken mended input speed for continuous operation is divided
not to exceed the specified screw depth. Driving screws by the required output speed.
beyond this point will damage the gearhead. Gearheads
with metal housing can be mounted using a radial set Recommended max. input speed
iN =
required output speed
screw.
From the gearhead data sheet, a reduction ratio is selected
which is equal to or less than the calculated one.
For this example, the reduction ratio selected is 159 : 1.
108
Calculation of the input speed ninput
ninput = n · i [min-1]
ninput = 30 · 159 = 4 770 min-1
Calculation of the input torque Minput
M · 100
Minput = ––––––– [mNm]
i·
The efficiency of this gearhead is 60%, consequently:
Minput = 120 · 100

–––––––– = 1,26 mNm
159 · 60
The values of
Input speed ninput = 4 770 min-1
and
Input torque Minput = 1,26 mNm
are related to the motor calculation.
The motor suitable for the gearhead selected must be

capable of producing at least two times the input torque
needed.
For this example, the DC-Micromotor type 1624 E 024 S
supplied with 14 V DC will produce the required speed and
torque.
For practical applications, the calculation of the ideal
motor-gearhead drive is not always possible.
Detailed values on torque and speed are usually not
clearly defined.
It is recommended to select suitable components based
on a first estimation, and then test the units in the applica-
tion by varying the supply voltage until the required speed
and torque are obtained.
Recording the applied voltage and current at the point of
operation, along with the type numbers of the test assem-
bly, we can help you to select the ideal motor-gearhead.
The success of your product will depend on the best
possible selection being made!
For confirmation of your selection and peace of mind,
please contact our sales engineers.
109
Precision Gearheads
Planetary Gearheads 1
Planetary Gearhead 7
1 Motor flange
2 Screws 8
3 Washer
9
4 Satellite gears
10
5 Planet carrier
6 Sun gear
7 Satellite gear shafts
11
8 Output shaft
9 Washer
10 Sintered bearing
11 Housing / ring gear 10
12 Retaining ring 9
12
Features Benefits
Their robust construction make the planetary gearheads, ■ Available in all plastic or metal versions
in combination with FAULHABER DC-Micromotors, ideal ■ Use of high performance plastic and ceramic materials
for high torque, high performance applications. ■ Available with a variety of shaft bearings including
sintered, ceramic, and ball bearings
In most cases, the geartrain of the input stage is made of
plastic to keep noise levels as low as possible at higher ■ Modified versions for extended temperature and special
environmental conditions are available
speed. All steel input gears as well as a modified lubri-
■ Custom modifications available
cation are available for applications requiring very high
torque, vacuum, or higher temperature compatability.
For applications requiring medium to high torque

FAULHABER offers planetary gearheads constructed of
high performance plastics. They are ideal solutions for
applications where low weight and high torque density Product code
play a decisive role. The gearhead is mounted to the
motor with a threaded flange to ensure a solid fit.
All metal planetary

gearhead series 12/4 26 Outer diameter [mm]
2 6 A 6 4 :1
A Version
64:1 Reduction ratio
110
Precision Gearheads
Spur Gearheads
3
4
5
6
Spur Gearhead
8
1 Housing
2 Screws
2
3 End plate
4 Intermediate plate
9
5 Gear wheel
6 Sleeve
7 Dowel pin 7
8 Output shaft
10
9 Front cover
11
10 Spacer ring
12
11 Ball bearing
13
12 Spring washer 14
13 Washer
14 Retaining ring
Features gear passes to each other and locking them in place on

A wide range of high quality spur gearheads are avail- the motor pinion gear. They are ideal for positioning
able to compliment FAULHABER DC-Micromotors. applications with a very high resolution and moderate
The all metal or plastic input-stage geartrain assures torque. Zero backlash gearheads can only be delivered
extremely quiet running. The precise construction of the preloaded from the factory.
gearhead causes very low current consumption in the
motor, giving greater efficiency. The gearhead is sleeve Benefits
mounted on the motor, providing a seamless in-line fit. ■ Available in a wide variety of reduction ratios
The FAULHABER Spur Gearheads are ideal for high including very high ratios
precision, low torque and low noise applications. ■ Zero backlash versions are available
■ Available with a variety of shaft bearings including
Zero Backlash Spur Gearhead sintered, ceramic, and ball bearings
1
1 Motor pinion
Dual-pass geartrain
Product code
2
input stage
3 Zero backlash preloaded
engagement
2 3 3 2
FAULHABER offers a special version of a spur gearhead

with zero backlash. These gearheads consist of a dual pass
spur geartrain with all metal gears. The backlash is reduc- 22 Outer diameter [mm]
/5 Version 2 2 /5 3 7 7 :1
ed to a minimum by counter-rotating the two individual 377:1 Reduction ratio
111
Linear Components
WE CREATE MOTION
Ball Screw
Technical information
General information
Function: Spindle Drive
Ball screws convert rotational movements into an axial
Ball screw
movement. Ball screws, which are designed as a recirculat-
ing ball screw, have a very high level of efficiency in com-
parison with planetary screw drives (such as trapezoidal
screws or metric screws) due to the lower rolling friction Series BS22-1.5
that occurs. In addition, the superior manufacturing pre-
Screw length, standard
cision enables a very low axial play, accompanied by a Stroke, standard
very high positioning accuracy. Pitch Ph
Mean actual travel deviation e0a:
In addition to the ball screw, the BS product series also in-
cludes both the bearing and the coupling to the motor.
The duplex bearing used in this case – a pair of angular ball
bearings with backlash-free mounting – enables the ab- Notes on technical datasheet
sorption of axial tensile and compressive forces. The high- Ball screw length, standard [mm]
precision pin coupling transmits the motor torque to the Designates the length of the ball screw between the front
screw virtually backlash-free. of the housing and the end of the ball screw.
Mounting Stroke [mm]
A number of threaded holes are provided on the front of Maximum path which the ball screw nut may axially travel.
the housing for the purpose of attaching the motor-screw The metric fastening thread of the ball screw nut can pro-
combination. trude beyond the raceway area of the ball screw.
Because of the high-precision raceways and the low- Pitch Ph [mm]
backlash or backlash-free adjustment, the ball screw nut Axial displacement when rotating the ball screw by 360°
cannot compensate for radial deviations between screw relative to the ball screw nut.
axis and any additional guides of an attachment to the
Average actual travel deviation, max. permissible ep [μm]
nut. A radial decoupling element must be provided here
The averaged deviation of the actual travel from the ideal
if necessary. This relates to deviations of the radial distance
nominal travel is called the average actual travel deviation
(misalignment) and angular deviations (tipping) of the
e0a. This is limited by the value ep over the entire travel
guides.
(e0a ≤ ep).
In order to reduce radial forces on the bearing, it is re-
commended that the screw is supported by an additional Tolerance of travel variation Vup [μm]
bearing. In parallel with the average actual travel deviation, short-
wave travel variations can occur. The bandwidth, represen-
Handling
ted as a blue band in the following, is limited by the value
The ball raceways on the ball screws are exposed. For this
of the tolerance of travel variation vup.
reason, the screw drives have to be protected against dirt
and contamination. The ball screw nut must never, either
in operation or during mounting, be moved out beyond
the raceway area of the ball screw.
Tolerance of travel
Travel deviation
variation vup
Mean travel
deviation e0a
e0a ≤ ep
Total travel
BS22-1.5_Spindel.indd 1
113
Ball Screw
Effi ciency η max. [%]

Calculations The theoretical
Direction of rotation
service life is calculated as follows:
Describes the ratio between the power input and power Direction of rotation of the ball screw, observed from the
3
output of the
Calculation of ball screw at
the motor axialtorque
drive load Fm max.
The minimum required motor drive torque can be derived
direction of the ballL screw.
rev = ( )
CWith
am a right-hand
· 10 6 thread the
F m of the drive shaft (= rotating
clockwise direction of rotation
as follows clockwise) results in an increase in the distance between
η max drive and ball screwL nut. L rev
h =
F m · P h · 100 n m · 60
Mmot =
2π · η Recommended values
3
( )
Efficiency η [%]
The maximum permissible valuesC am for3 continuous operation

Required motor torque Mmot [mNm] L s = Ph · · 10
in order to obtain an optimal F mservice life are listed below.
Continuous axial load Fm [N]
Pitch Ph [mm] The values are mathematically independent of each other.
Efficiency η [%] Service life in revolutions Lrev [rev]
Continuous axial load Fm max. [N]
Service life in hours Lh [h]
Designates
Service life inthe maximum recommended
meters Ls axial load during
[m]
Calculation of the motor drive speed Dynamic axialoperation.
continuous load capacity Cam [N]
Axial load Fm [N] Fm max
v · 60 Intermittent
Average motoraxial
speedload Fp max. [N] nm [min-1]
nm o t = Pitch Ph [mm]
Designates the maximum permissible axial load. The motor
Ph
Please observe the dependence of the efficiency on the current must be limited if necessary in order to prevent
axial load, especially for small axial loads. exceeding of the permissible loading.
Required motor speed nmot [min ]
-1
Linear speedtemperature range [C°] v

Operating [mm/s]
Pitch Ph [mm] Rotational speed, max. [min-1]
Designates the maximum and minimum permissible operat- Designates the maximum permissible rotational speed.
ing temperature of the ball screw.
Calculation of the theoretical lifetime Linear speed, max. [mm/s]
Axial load capacity, dynamic Cam [N] Designates the maximum permissible linear speed. This
The service life depends on the following factors:
Parameter for calculating the theoretical service life. This results from the product of the maximum permissible rota-
corresponds
■ Axial loadto a constant axial load in a constant direc- tional speed and the pitch Ph.
t■ion, at which
Linear speeda theoretical service life of 10 revolutions is
6
achieved. This is based on a life expectancy of 90%.

■ Operating conditions
Axial load capacity, static Coa [N]
■ Environment and installation in other systems
Maximum permissible axial loading of the ball screw nut.
As a very
Unless large
specifiednumber of parameters
otherwise, come
this is also the into play
maximum per-
in any application,
missible a precise
axial loading service
of the ball lifeTo
screw. defi nition exceed-
prevent is not
possible.
ing of the permissible loading, the motor current must be
limited
As if necessary.
a non-binding reference value a theoretical service life
can
Max.bepermissible
calculatedshaft
on the basis ofradial
loading, standard
Frs maxISO
[N] 3408:
Maximum
The permissible
theoretical serviceradial
life isloading of defi
generally the ball
ned screw.
by theThis
is dependent on the acting lever arm.
number of revolutions. Alternatively, it can also be speci-
fi ed in nut,
Screw hours or as
axial travel.
play [µm]It is based on a life expectancy
of 90%.
Maximum axial displacement of the ball screw nut in
relation to the ball screw, if these are not twisted towards
each other. This is determined using an axial test force of
3.5 N.
Max. permissible nut loading, radial Frn max [N]
Maximum permissible radial loading of the ball screw nut.
114
Ball Screw
Calculations The theoretical service life is calculated as follows:

3
Calculation of the motor drive torque
The minimum required motor drive torque can be derived
Lrev = ( )
C am
Fm
· 10 6
as follows
L rev
Lh =
F · P · 100 n m · 60
Mmot = m h
2π · η
3
Required motor torque

Continuous axial load
Mmot
Fm
[mNm]
[N]
L s = Ph · ( )
C am
Fm
· 10 3
Pitch Ph [mm]
Efficiency η [%] Service life in revolutions Lrev [rev]
Service life in hours Lh [h]
Service life in meters Ls [m]
Calculation of the motor drive speed Dynamic axial load capacity Cam [N]
v · 60 Average motor speed nm [min-1]
nm o t = Pitch Ph [mm]
Ph
Required motor speed nmot [min-1]

Linear speed v [mm/s]
Pitch Ph [mm]
Calculation of the theoretical lifetime

The service life depends on the following factors:
■ Axial load
■ Linear speed
■ Operating conditions
■ Environment and installation in other systems
As a very large number of parameters come into play

in any application, a precise service life definition is not
possible.
As a non-binding reference value a theoretical service life
can be calculated on the basis of standard ISO 3408:
The theoretical service life is generally defined by the
number of revolutions. Alternatively, it can also be speci-
fied in hours or as travel. It is based on a life expectancy
of 90%.
115
Ball Screw
1
Ball Screw
1 Motor
2 Motor flange
3
Clutch housing with duplex ball bearings
4 Spindle thread
5 Spindle nut with fastening screw thread
Features Benefits
Thanks to their high-precision mechanical design, ■ Long service life
FAULHABER ball screws are ideally suited for positioning ■ High efficiency
tasks requiring a high degree of accuracy. Combinations
■ Variable length
with DC-Micromotors with high-resolution encoders, in-
■ Customized versions with special lubrication for
tegrated Motion Controllers or Stepper Motors represent
extended application areas
a superior system solution for the most demanding appli-
■ High positioning accuracy thanks to considerably
cations in optical systems, special machine construction,
reduced play
automation or medical technology.
Compact design in conjunction with numerous modifi-

cation options translates into the perfect drive solution
for a wide range of applications.
Product code
BS Ball screw
B S 2 2-1.5
22 Coupling diameter [mm]
1.5 Pitch [mm]
116
Lead screws parameters

Resolution (travel/step) Lead Screw
A lead screw combined with a PRECIstep® stepper motor Linear actuation for positioning tasks
can achieve a positioning with a resolution of 10μm. PRECIstep® Technology
The resolution of the position depends on the pitch and
number of steps per revolution: Series M2 x 0,2 x L1
Nominal diameter 2,0
Ph
P= Pitch 0,2
n Material Stainless stee
With Ph the pitch of the screw and n the number of steps

per revolution of the motor.
Driving the motor with half-stepping or microstepping Backdriving
will improve the resolution up to a certain extent. Backdriving the motors while applying an axial load on
The resolution must be balanced with another parameter: the lead screws is impossible. The pitch vs. diameter ratio
the precision. does not allow it.
Precision Force vs speed curves

The motor step angle accuracy is one parameter, together The force that a linear system can provide depends on the
with the axial play between the nut and the lead screw, type of screw and stepper motor selected. Torque vs speed
influencing the precision of the linear displacement. It curves for each solution are provided in this catalogue.
varies between ±3 and ±10% of a full step angle depend- Those curves do already consider a 40% safety factor on
ing on the motor model (see line 9 on motor datasheet) the motor torque as well as a conservative lead screw
and remains the same with microstepping. It is however efficiency in the calculation.
not cumulative. Tip for bearings
Axial play Ideally, the application should handle radial loads and the
An axial play up to 30μm is measured with optional nuts lead screw only axial loads. If it is not the case, it is possible
offered in this catalogue. However, it is possible to negate to get lead screws with a tip suitable for bearing at its
the axial play by implementing a preloading system in front end in order to handle radial loads. With this con-
the design of the application (for instance with a spring figuration, a special care to the alignment of the motor
mechanism). and bearing must be paid to not deteriorate the thrust
The “zero” axial play between the lead screw and motor force achievable. Optional mating ball bearings are avail-
housing is ensured thanks to a preload of the motor ball able in the dedicated datasheet for options.
bearings (in standard configuration: spring washer on rear Nut
ball bearing). An axial play up to 0.2 mm will occur if the Optional nuts offered in this catalogue are shaped with a
axial load on the lead screw exceeds the ball bearing pre- flat in order to prevent its rotations in the application.
load. Alternatively, tapped holes on the application are a
This does not cause any damage to the motor and is convenient solution since metric taps are readily available.
reversible. This occurs only while pulling on the shaft.
On request, customization can overcome this limitation.
To avoid irreversibly damaging the motor, the maximum
axial load should always remain under the maximal push
force the motor can generated with a mounted lead screw.
LSM2,0_PCS.indd 1
117
Lead Screws
1 Stepper motor
2 Lead screw
3
Nut
Features Benefits
Stepper motors can be used for more than just a rotation. ■ Cost effective positioning drive without encoder
When combined with lead screws, they provide a high ■ High accuracy
accuracy linear positioning system that provides the
■ Wide range of lead screws available
benefits of a stepper (open loop control, long life, high
■ Short lead time for standard length
torque density, etc.).
■ Flexibility offered by optional nuts and ball bearings
The lead screws available on stepper motors are all based
■ Custom length on request
on metric dimensions (M1.2 up to M3) and specifically
designed to be assembled with PRECIstep® stepper motors.
The technique used to produce the thread ensures a very
high precision and consistency of quality. A large choice
of standard lengths is available from stock and customi- Product code
zation is possible on request.
Such a combination is ideal for any application such as

requiring accurate linear movement or lens adjustment
(zoom, focus), microscope stages or medical syringes.
A M 1 5 2 4 2R 0 0 7 5 5 5 M3 x 15
AM1524 Motor series M3 Screw type

2R Bearing type 15 Length (mm)
0075 Winding type
55 Motor execution
118
Notes
119
Encoders
WE CREATE MOTION
Encoders
under “Controller combinations”. If this option is selected,

General
Encodersinformation
– 2 Channel Page
no encoder is needed. The space and cost advantages
PA2-50 optical 418 – 420
FAULHABER Motors are available with a variety of sensors make analog Hall sensors the preferred solution for most
PA2-100 optical 421 – 423
and encoders for providing solutionsIE2-16
to a wide range of positioning applications with Brushless DC-Motors. When
magnetic 424 – 426
drive applications – from speed control to high-precision
IE2-400
selecting this option, it is recommended that the 428
magnetic
sensors
– 429
positioning. IE2-1024 be operated
magnetic with FAULHABER Controllers, which are– 432
430
IEH2-4096 perfectly designed for the analog Hall signals. 433 – 435
magnetic
Sensors and encoders PE22-120 optical 436 – 437
FAULHABER Motors are offered in combination
HEDS 5500 with sen- Functionality
optical 438 – 439
sors and encoders. An encoder is a sensor for angle meas-
Encoders
urement that –
is 3 Channel
usually used for speed or position control. Measurement principle Page
HXM3-64Hall sensor
The term sensor refers to digital or analog The FAULHABER Sensors and Encoders are based 440
magnetic on – 442
HEM3-256-W are usually
which, in the FAULHABER Brushless DC-Motors, magnetic or optical measurement principles.
magnetic 443 – 445
mounted directly on the motor circuit IEM3-1024
board. Digital Hall magnetic 446 – 448
Magnetic encoders are especially insensitive to dust,
IE3-1024 magnetic 449 – 452
sensors are used primarily for the commutation of the humidity and thermal and mechanical shock. In magnetic
IE3-1024L magnetic, Line Driver 453 – 456
Brushless DC-Motors and for simple speed control. Almost encoders, sensors are used that determine the changes of
IEH3-4096 magnetic 457 – 459
all FAULHABER Brushless DC-Motors IERS3-500
are equipped stand- the magnetic field. The magnetic field is changed460
optical by–the
462
ard with three integrated digital HallIERS3-500L
sensors. movement of
optical, Line Driver a magnetic object. This can be the magnet
463 – 465
IER3-10000 of the motor or an additional sensor magnet with466
optical a – 469
0° 120° 240° IER3-10000L
360° defi ned measuring
optical, Line Driver element that is secured to the470 – 473of
shaft
1
HEDL 5540 the motor.
optical, With encoders, an additional sensor magnet
Line Driver 474 – 475is
HA
usually necessary.
Encoders
0
– Absolute Page
In the case of integrated digital or analog Hall sensors, the
1 AESM-4096 magnetic
movement of the rotor magnet of the motor can 476 be –meas-
478
HB
AES-4096 magnetic 479 – 481
0 ured directly. With the integrated Hall sensors, an addi-
tional sensor magnet is therefore normally not necessary.
1
HC
Digital Hall Optical encoders are characterised by a very high position
0
sensor accuracy and repeatability and a very high signal quality
output signal
2-pole motor
due to the precise measuring element. Furthermore, they
S1 S2 S3 S4 S5 S6 S1
are insensitive to magnetic interference. In optical encod-
ers, a code disc with a measuring element is used that is
In addition, analog Hall sensors are generally available as attached to the shaft of the motor. A distinction is made
an option. between reflective and transmissive optical encoders. With
Hall signals HallA – HallC
reflective encoders, the light from an LED is reflected back
5 HallA to the code disc by a reflective surface and collected by
4.5 HallB photodetectors. Reflective optical encoders are especially
4
HallC
compact since the LED, the photodetectors and the elec-
3.5 tronics can be mounted on the same circuit board or even
3 on the same chip. FAULHABER therefore primarily uses
UA … UC
2.5
reflective optical encoders. With transmissive encoders,
2
the light from the LED passes through slits in the code disc
1.5
and is collected by photodetectors on the other side of the
1
Analog code disc.
0.5
Hall sensor
0 output signal
0° 60° 120° 180° 240° 300° 360° 2-pole motor
Absolute mechanical rotational angle
Due to the higher resolution, the analog Hall sensors can

also be used for precise speed or position control, making
them an especially economical, lightweight and compact
alternative to encoders. The option for analog Hall sensors
can be found directly in the data sheets of the motors
121
Encoders
Moving Element Signal processing and interpolation

Depending on the measurement principle and dimen- In addition to the sensors for signal acquisition, the
sional constraints different moving elements are applied FAULHABER Encoders also include electronic components
in different types of FAULHABER Encoders. The moving for signal processing. These process the signals from the
element has a significant impact on the accuracy and reso- sensors and generate the standardised output signals of
lution of the encoder. In general, the higher the physical the encoders. In many cases, the signals are also interpo-
(native) resolution of the moving element, the higher the lated, i.e., multiple signal periods are generated by inter-
resolution and accuracy of the encoder as a whole. polating a single physically measured signal period. The
In magnetic encoders, simple, two-pole sensor magnets physical resolution of the measuring element can thereby
and magnetic rings are used. The magnetic rings have be increased many times over.
several signal periods per revolution through the use of
a special tooth structure or targeted magnetisation. The Characteristic encoder features
number of signal periods corresponds to the physical reso-
The quality of an encoder is largely determined by the
lution of the magnetic rings.
resolution and the accuracy.
Resolution
The resolution is the number of edges or steps that an
N
S S N encoder produces within a revolution. The resolution is
N S S S N
determined from the physical resolution of the moving
N S N
S element and the interpolation of the physical signal via
the electronics. Due to the large amount of information
Two-pole sensor Multi-pole Magnetic ring with that is made available per motor revolution, a high resolu-
magnet with one magnetic ring tooth structure tion offers various advantages for a drive system:
signal period with multiple with multiple
signal periods signal periods ■ Smoother speed control and lower audible noise
■ Operation at lower speed
In optical encoders, moving elements in the form of code
A high resolution in excess of 4 000 edges or steps is rele-
discs are used. With reflective encoders, these consist of a
vant if the motor is used as a direct drive for positioning or
series of surfaces that alternately reflect or absorb light.
if the motor is operated at very low speeds.
With transmissive encoders, the code discs consist of a
series of bars and slits. The number of reflective surfaces
or slits corresponds to the physical resolution. In general,
0° 360°
optical encoders can have a significantly higher native Low resolution
resolution than magnetic encoders.
0° 360°
Higher resolution
Distribution of encoder edges during rotation of the motor shaft
Accuracy
Independent of the resolution, the accuracy also plays an
important role. The accuracy is determined by the physical
Code disc for reflective Code disc for transmissive resolution of the moving element and the precision with
encoders with high number encoders with high number
of signal periods of signal periods which not only the moving element and the encoder are
manufactured, but the entire drive system as well. If an
encoder has a high accuracy, it always transmits the signals
at the same spacing for each and every motor revolution
and thus has a high signal quality.
122
For encoders with at least two channels, the state of
channel A or channel B changes every 90 °e due to the
0° 360° phase offset. The edges, i.e., the state change of the
Low signal quality
encoder channels, are evaluated for determining the
position. Because four edges occur per pulse, the resolu-
0° 360° tion of the FAULHABER Incremental Encoders is four times
High signal quality
their pulse number. Thus, an encoder with 10 000 pulses
Distribution of encoder edges during rotation of the motor shaft per revolution, for example, has 40 000 edges per revolu-
tion, which corresponds to a very high angular resolution
The most important parameter for the signal quality of the
of 360°/40 000 = 0,009°.
FAULHABER Encoders is the phase shift tolerance (∆ ). If
the phase shift tolerance is low, the encoder transmits uni-
Amplitude
C
form signals. While FAULHABER magnetic encoders have a
high signal quality with a phase shift tolerance of approxi-
mately 45 °e, FAULHABER optical encoders demonstrate an A
especially high signal quality with a phase shift tolerance
of approximately 20 °e . Optical encoders are generally
more accurate than magnetic encoders.
Detailed information for the calculation of the phase shift B
tolerance can be found in the chapter “Notes on technical
data sheet” under the heading “phase shift”. Angle
A high accuracy or a high signal quality has multiple

advantages for a drive system: An incremental encoder does not measure absolute posi-
tions, but rather relative positions. Incremental encoders
■ Exact determination of the position and, thus, accurate determine a position relative to another reference posi-
positioning tion. For this purpose, the signal edges must be counted
■ Smoother speed control and lower audible noise forward or backward by the motor control using a square
counter according to their edge sequence. This position
A high accuracy is relevant above all if the motor is used as
value is lost if the power supply is interrupted. A position-
a direct drive and exact positioning is necessary.
ing system must therefore move to a defined reference
To position a drive system precisely, a highly accurate position during commissioning or after a power interrup-
encoder is not enough. Tolerances in the entire drive tion to initialise the position counter (homing). For the
system must be taken into account, such as the concen- determination of the reference position, an external addi-
tricity tolerance of the motor shaft. The accuracy and the tional sensor, such as a reference switch or limit switch, is
phase shift tolerance of the FAULHABER Encoders is there- usually used.
fore determined in combination with the FAULHABER
To determine the reference position with an especially
Motors. The specified position accuracy and repeatability
high level of accuracy, the FAULHABER 3 Channel Encoders
is the system accuracy that a FAULHABER Motor-Encoder
have an additional channel – the index. Here, a single
combination actually achieves in an application.
index pulse is generated once per revolution. External
reference switches or limit switches can have a comparably
Output signal
high position error due to environmental influences and
Incremental encoder can sometimes trigger a little earlier, sometimes a little
Incremental encoders transmit a specific number of uni- later. To nevertheless accurately determine the reference
formly distributed pulses per revolution. All FAULHABER position, the drive system can move back after the limit
Incremental Encoders have at least two channels: A and switch until the first signal edge of the index pulse occurs.
B. Both channels supply a square wave signal, shifted by This point can then be used as an exact reference position.
90 °e with respect to one another, i.e., one quarter cycle C. The index pulse has a width of 90 °e and always occurs
Through the shift of the pulses, the direction of rotation at defined states of channels A and B. For longer travel
of the motor can be determined. distances and multiple revolutions of the encoder, the
The highest angular resolution of incremental encoders index pulse can also be used to verify the counted number
is not determined by the number of pulses per revolution of edges.
but rather the total number of signal edges.
123
Encoders
reference motion is, therefore, not necessary if positioning

Amplitude
within one or one half revolution of the motor shaft.
A
The resolution of an absolute encoder is defined via the
number of steps per revolution and is specified in bits.
Absolute encoders generate a serial code from multiple
bits. The FAULHABER Absolute Encoders support the SSI
B Interface with BISS-C Protocol. BISS-C supports communica-
tion with clock speeds of up to 2 MHz. Here, the absolute
position value (DATA) is transferred in synch with a cycle
(CLK) specified by the controller.
I
CLK
Angle
Timeout
DATA Ack Start CDS D11 D10 D0 Res. Res. CRC5 CRC4 CRC0 Stop
Absolute encoder Data Range
Unlike the incremental encoder, an absolute encoder Interface protocol (BISS-C) of an absolute encoder
determines absolute positions, not relative positions. After
switching on the absolute encoder, an absolute return
value is available for each position of the motor shaft. A Line Driver
distinction is made between single turn and multi turn Some of the FAULHABER Incremental Encoders are
encoders. The FAULHABER Absolute Encoders are single equipped with a Line Driver. The Line Driver generates an
– – –
turn encoders. additional differential signal A, B and I for all channels,
A, B and I. Electromagnetic interference can thereby be
With the single turn encoders, each position of the
eliminated during signal transmission. Especially if the
motor shaft corresponds to a specific return value. After
encoder signals must be transmitted over long distances of
a complete revolution of the motor shaft, the signals
5 m and more and for position control, the use of a Line
repeat. Thus, the single turn encoder supplies no absolute
Driver is therefore recommended.
information about the number of completed revolutions.
Positioning over more than one revolution is, however, still On the control side, these differential signals must be
possible with the single turn encoder. Like with the incre- combined again with a receiver module. The Line Drivers
mental encoder, this is performed by counting the number from FAULHABER are TIA-422 compatible. TIA-422, also
of revolutions forward or backward using a counter on the known as EIA-422 or RS-422, is an interface standard for
motor control. For travel distances greater than one motor cable-based differential, serial data transfer.
revolution, referencing is therefore necessary after a
Amplitude
power interruption. No referencing is necessary for travel A
distances of less than one motor revolution.

Unlike single turn encoders, multi turn encoders also cap- __
A
ture the number of travelled revolutions by means of an
additional sensor and an electronic memory element or via B
__
a gearhead. Thus, multi turn encoders supply an absolute B
return value over multiple revolutions of the motor shaft
within a defined maximum amount of revolutions that
I
can be captured by the electronic memory element or the __
I
gearhead. Referencing is generally not necessary if the
maximum amount of revolutions is not exceeded.
Angle
The analog Hall sensors, which are mounted directly in
the FAULHABER Brushless DC-Motors as an option, supply
absolute return values within one revolution of the motor
shaft in combination with the motors with 2-pole tech-
nology and absolute return values within half of a revolu-
tion of the motor shaft in combination with motors with
4-pole technology. When using the analog Hall sensors, a
124
CMOS and TTL
The FAULHABER Encoders are normally compatible with
the CMOS and TTL standard. This means that the “low” Encoders
logic state is typically at 0V and the “high” logic state at magnetic Encoder, digital outputs,
5V. It is important to note that the tolerances indicated in 2 channels, 16 - 4096 lines per revolution
the controller specification must be observed.
Integrated solutions Series IEH2-4096

-16 -32
Lines per revolution N 16 32
Many FAULHABER Encoders are highly integrated into Frequency range, up to 1) f 5 10
Signal output, square wave 2
the existing geometry of the motor. By integrating the Supply voltage UDD 4,5 ... 5,5
solutions in the motor, they are especially lightweight, Current consumption, typical 2)
Output current, max. 3)
IDD
IOUT
typ. 15, max.
2,5
compact and economical. Phase shift channel A to B 4) ) 90 ± 45
For the Brushless DC-Motors, these include the integrated

digital and analog Hall sensors and encoders IEM3-1024 Notes on technical data sheet
and AESM-4096. The outer dimensions of the motors are
Lines per revolution (N)
not affected by these solutions.
Specifies how many pulses are generated at the incre-
For the DC-Micromotors of the FAULHABER SR series, mental encoder outputs per channel on each motor shaft
the following integrated encoders are available, which revolution. Through the phase offset of encoder channels
lengthen the motors by just 1,4 – 1,7 mm: IE2-16, IE2-400, A and B, four edges are available per line. Thus, the resolu-
IE2-1024, IEH2-4096 and IEH3-4096. tion of the incremental encoder is four times the number
In combination with the Flat DC-Micromotors, the FAUL- of pulses. If, for example, an encoder has 1 024 lines per
HABER SR-Flat series includes integrated encoders that revolution, the resolution is 4 096 edges per revolution.
lengthen the motors by just 2,3 mm: IE2-8 and IE2-16.
Steps per revolution
The value for “steps per revolution” specifies the number
of position values per motor shaft revolution. The value
is generally used with absolute encoders and corresponds
to the resolution or number of edges for incremental
encoders.
Resolution
Number of binary bits of the output signal. The steps per
revolution of an absolute or incremental encoder corre-
spond to the resolution of 2number of bits.
Frequency range, up to (f)

Indicates the maximum encoder frequency. This is the
maximum frequency at which the encoder electronics can
switch back and forth between the low and high signal
level. The maximum achievable operating speed (n) for
the encoder can be derived from this value and the pulse
number (N). If this frequency range and the resulting
speed are exceeded, the result may be the transmission of
incorrect data or the premature failure of the encoder. For
very high-speed applications, it may be necessary to select
a correspondingly low pulse number.
60 . f
n=
N
ENCODER 2019 EN,DE,FR,CN 15
125
Amplitud
A
Φ
B
Po
Encoders I
Drehrichtung
P
Amplitude
A
Φ
Signal output Permissible deviation ∆P0:
With incremental encoders, square wave signals are B
output. 2 channel encoders have two channels: AΔand Φ P
Φ = B.
90° – 180° ≤ 45° Δ P0 = 90° – 0 * 180° ≤ 45°
3 channel encoders have an additional index channel. P * P
Po
I
C Phase shift, channel A to B ( )
Amplitude
P
The phase shift (in °e) in between output signals A and B is
Drehrichtung
referred to as phase shift and is ideally 90 °e.
S S S S The phase shift tolerance (∆ ) is the deviation of two
A
successive edges at outputs A and B from the ideal value
Φ of 90 °e.
Permissible deviation ∆ :
B
Φ P0
Po ΔΦ = 90° – 180° ≤ 45° Δ P0 = 90° – 180° ≤
P * P *
I
Logic state width (S)
Distance of two adjacent edges (in °e) between the two
Angle
channels A and B. There are four logic state widths (S) per
cycle. Ideally, a logic state width is 90 °e.
With absolute encoders, a digital word is output.
FAULHABER Encoders use a SSI Interface with BISS-C Cycle (C)
Protocol. SSI is an interface for absolute encoders with The duration of a total period (in °e) on channel A or B.
which absolute position information is made available Normally, a cycle is 360 °e.
via serial data transfer.
Signal rise/fall time, max. (tr/tf)
Supply voltage (UDD) Maximum time for changing from the lower to the higher
Defines the range of supply voltage necessary for the signal level or vice versa. This describes the edge steepness
encoder to function properly. To avoid damaging the of the encoder signals. CLOAD specifies the maximum per-
encoder, this range must always be adhered to. missible load of the signal line at which the edge steepness
is still reached.
Current consumption (IDD)
Indicates the current consumption of the encoder at the Clock frequency, max. (CLK)
given operating voltage. Normally, typical and partial Maximal permissible clock frequency for reading the BISS-C
maximum values are specified. Protocol.
Output current, max. (IOUT) Input - low / high level (CLK)

Indicates the maximum allowable output current at the The level of the CLK input signal must lie in the specified
signal outputs. If necessary, this value should be aligned value range in order to ensure reliable signal detection.
with the controller that is used.
Setup time after power on, max.
Pulse width (P) Maximum time to availability of the output signals, as of
Width of the output pulse (in °e) of encoder channels A when supply voltage is applied.
and B. It is ideally 180 °e.
Timeout
Index pulse width (P0) Refers to the time after which communication is termi-
The index pulse width specifies the width of the index nated by the encoder, when the master is no longer trans-
pulse (in °e) and is ideally 90 °e. mitting a clock rate.
The index pulse width error (∆P0) is the deviation from the
ideal value of 90 °e.
126
Inertia of sensor magnet / code disc (J)
Indicates the amount by which the rotor inertia of the
motor is increased by the sensor magnet or the code disc.
Operating temperature range

Indicates the minimum and maximum permissible operat-
ing temperature for encoder operation.
Accuracy
Indicates the average position error of the encoder in
mechanical degrees (°m). This describes the extent to
which the current position of the encoder can deviate
from the target position.
Repeatability
Indicates the average repeatability error of the encoder in
mechanical degrees (°m). This describes the average devia-
tion of multiple position values for the encoder when posi-
tioning at the same position multiple times. Repeatability
shows how precisely a certain position can be reached
when repeatedly moving to the same position.
Hysteresis
Indicates the dead angle during a change in direction in
which no information related to the position is output.
Edge spacing, min.

The minimum spacing between two successive edges of
channels A and B. For a reliable evaluation of the square
wave signal, a controller that is able to detect this mini-
mum edge spacing is required. If no information on the
minimum edge spacing is available, this can also be deter-
mined as an approximate value.
1 ΔΦ
Tmin = · 1–
f·4 90°
Mass
The typical mass of the encoder, including housing and
adapter flange with standard cable without connector.
127
Encoders
How to select an appropriate sensor DC-Motors

This chapter describes how a suitable sensor is selected for Commutation
FAULHABER Motors. Which sensors can be used depends The commutation of DC-Motors with precious metal or
primarily on the selected motor technology. A distinction is graphite brushes is mechanical and therefore requires
to be made between: neither a sensor nor a motor control.
■ DC-Motors Speed and position control
■ Brushless DC-Motors For some applications, the DC-Motors are operated with-
■ Stepper Motors out a sensor and without a controller. In these cases, a
■ Linear DC-Servomotors
specific voltage is applied to the motors at which a specific
speed is produced when operated at a constant load.
Depending on the motor technology, the sensor is neces-
sary not only for speed or position control, but also for the A controller is necessary in order to regulate the speed.
commutation of the motors. Simple speed control is possible by measuring the back
electromotive force (EMF). For precise speed control, an
encoder is necessary. For position control, an encoder is
Commutation Speed control Position control absolutely required.
For DC-Motors, a large selection of incremental encoders is
DC-Motors
available.
Sensors ■ encoders ■ encoders
Without mechanical back-EMF
sensors
■ ■
Brushless DC-Motors
Brushless DC-Motors
Commutation
Sensors Block commuta- ■ integrated ■ integrated The Brushless DC-Motors are electronically commutated.
tion: digital Hall analog Hall
■ integrated sensors sensor For their operation, a controller is therefore always neces-
digital Hall ■ integrated ■ encoders sary.
sensors analog Hall
sensors Most of the FAULHABER Brushless DC-Motors are
Sinus commuta-
tion: ■ encoders equipped with three digital, integrated Hall sensors that
■ integrated determine the position of the motor shaft and supply a
analog Hall commutation signal.
sensors
■ encoders The exception here are motors for simple speed applica-
tions, which can be commutated with the help of the back
Without Block commuta- ■ back-EMF
sensors tion: electromotive force (EMF). Here, the controller evaluates
■ back-EMF the zero crossing of the back-EMF and then commutates
Stepper Motors the motor after a speed-dependent delay. The zero cross-
Sensors ■ encoders ■ encoders ing of the back-EMF cannot be evaluated while the motor
Without ■ stepper mode ■ stepper mode ■ stepper mode is at a standstill and, thus, the position of the rotor cannot
sensors be detected. When starting, it is therefore possible that
the motor first moves in the wrong direction.
If digital Hall sensors are selected or in sensorless oper-
Sensors ■ integrated ■ integrated
analog Hall analog Hall ation with back-EMF, the Brushless DC-Motors are block
sensors sensors commutated. With block commutation, the voltage
characteristics of the three 120° offset windings are block
shaped. The windings are abruptly switched every 60°. The
FAULHABER Speed Controllers use this commutation form.
128
For position control, encoders or integrated Hall sensors
+ are needed. Almost all FAULHABER Brushless DC-Motors
UA 0 Angle are offered with integrated analog Hall sensors as an
– option. For most applications, operation with the analog
0° 60° 120° 180° 240° 300° 360°
Hall sensors is recommended. Encoders are needed if the
+ application requires a higher resolution or accuracy or if
UB 0 Angle the motor is operated at very low speeds.
– For the Brushless DC-Motors, a large selection of incremen-
0° 60° 120° 180° 240° 300° 360°
tal and absolute encoders is available.
+
UC 0 Angle Stepper Motors

–
0° 60° 120° 180° 240° 300° 360° The control of stepper motors in full step, half step and
micro step operation enables exact speed and position
A better running smoothness with a lower torque ripple is control in an open control loop. As a result, sensors are
achieved through sinus commutation. not generally needed in the application – a decisive cost
With sinus commutation, the phase voltages have advantage of stepper motors. A closed control loop is,
a sinusoidal characteristic. The FAULHABER Motion however, often required during development for verify-
Controllers use this commutation form as standard. For ing the function. The FAULHABER product range includes
sinus commutation, analog Hall sensors or encoders are an optical encoder for stepper motors: PE22-120. Other
required. combinations of stepper motors with encoders are possible
on request.
+
UA 0 Angle
–
The linear DC-Servomotors are equipped with analog Hall
0° 60° 120° 180° 240° 300° 360°
sensors. By integrating sensors in the motor, this solution is
+ very compact, lightweight and economical. As a result, an
UB 0 Angle additional encoder is not necessary.
–
0° 60° 120° 180° 240° 300° 360°
UC 0 Angle
–
0° 60° 120° 180° 240° 300° 360°
Speed and position control

For speed control, digital Hall sensors are generally used.
The back electromotive force is only suitable for simple
speed control at higher speeds. Analog Hall sensors or an
encoder are necessary if the drive system is operated at
low speeds or a very high running smoothness is required.
129
Encoders
Optical Encoders
1 3
Optical Encoder 6
1 Cover
2 Encoder circuit board
with LED and photo sensor
7
3 Adapter flange
4 Housing
5 Code disc
6 Hub
7 Motor
Function Features and benefits

Encoders of the IER3-10000 (L) series consist of a high- ■ Very high resolution of up to 40 000 edges per revolution
(corresponds to a 0,009° angle resolution)
resolution code disc that is attached to the motor shaft,
■ Very high position accuracy, repeatability and high signal
a light source and a photo sensor with interpolator and
quality
driver stages. The light from the light source is reflected or
■ Various resolutions available as standard feature
absorbed by the code disc. The reflected light is collected
■ Insensitive to magnetic interference
by the photo sensor and the signal processed into a
high-resolution encoder signal. With this, two square wave
signals that are phase-shifted by 90 °e, as well as an index
signal to display output shaft rotation, are available at the
outputs. A Line Driver is also available as an option.
The high-precision optical encoders are ideally suited for

position control. Product code
IER encoder series

I E R 3 – 6800 L
3 3 channel
6800 lines per revolution
L with integrated Line Driver
130
Encoders
Magnetic Encoders
1
Magnetic Encoder 7
1 Screws
2 Cover
3 Encoder circuit board with chip
8
4 Adapter flange
5 Screws for intermediate flange
6 Intermediate flange
7 Sensor magnet
8 Motor

Encoders of the IE3-1024 (L) series consist of a diametric- ■ Compact modular system
and robust housing
ally magnetized, two-pole sensor magnet which is
■ Various resolutions available as standard feature
fastened to the motor shaft. A special angle sensor for
■ Index channel for referencing a rotation
detecting the motor shaft position is positioned in an
of the drive shaft
axial direction in relation to the sensor magnet. The
■ Also available as Line Driver version
angle sensor comprises all necessary functions, such as
■ Standardized electronic encoder interface
Hall sensors, an interpolator and driver stages. Analog
■ Flexible customer-specific modifications including custom
signals of the sensor magnets are detected by the Hall resolution, direction of rotation, index pulse width and
sensors and, after suitable amplification, passed along to index position are possible
the interpolator. By means of a special processing algo-
rithm, the interpolator generates the high-resolution
encoder signal. Product code
With this, two square wave signals that are phase-shifted
by 90 °e, as well as an index signal to display output shaft
rotation are available at the outputs.
IE encoder series
IE3 – 1024 L
3 3 channel
L with integrated Line Driver
131
Encoders
Integrated Magnetic Encoders
4
3
Integrated Magnetic
Encoder 1
1 Motor
2 Magnet wheel
3 Brushes
4 Brush cover
5 Sensor electronics
6 Flat cable
7 Cover

The encoders of the IEH2-4096 and IEH3-4096 series consist ■ Extremely compact
of a multi-part magnetic ring, which is attached to the ■ High resolution of up to 16 384 edges per revolution
(corresponds to a 0,022° angle resolution)
rotor, and an angle sensor. The angle sensor comprises all
■ No pull-up resistors are necessary at the outputs because
necessary functions, such as Hall sensors, an interpolator
there are no open collector outputs
and driver stages. Analog signals of the sensor magnets
■ Symmetric switching edges, CMOS and TTL-compatible
are detected by the Hall sensors and, after suitable ampli-
■ Different resolutions, according to encoder type,
fication, passed along to the interpolator. from 16 to 4 096 lines, are available for standard delivery
By means of a special processing algorithm, the interpo- ■ High signal quality
lator generates the high-resolution encoder signal. With
this, two square wave signals that are phase-shifted by
90 °e, with up to 4 096 lines per revolution, as well as one
additional index signal are available at the outputs. Product code
The encoder is integrated in the motors of the SR series
and lengthens these by just 1,4 mm.
IEH encoder series

I E H 2 – 4096
2 2 channel
132
Encoders
Absolute Encoders 1
8
Absolute Encoder
1 Cover with encoder PCB

2 Sensor magnet
3 Encoder flange
4 Flat cable 10
5 Ball bearing
6 Magnet
7 Shaft 4
8 Winding
9 Ball bearing
10 Housing with stator laminations

Encoders of the AESM-4096 series consist of a diametrically ■ Minimal wiring requirement
magnetized, two-pole sensor magnet which is fastened to ■ Absolute angle information directly after power-on
the motor shaft. A special angle sensor for detecting the ■ No referencing necessary
motor shaft position is positioned in an axial direction in ■ Enhanced control characteristics even at low rotational
speeds
relation to the sensor magnet. The angle sensor comprises
all necessary functions, such as Hall sensors, an inter- ■ Flexible customisation of resolution and direction of
rotation is possible
polator and driver stages. The analog signal of the sensor
magnet detected by the Hall sensors is processed, after
appropriate amplification, by a special algorithm to pro-
duce a high-resolution encoder signal. At the output there
is absolute angle information available with a resolution
of 4 096 steps per revolution. This data can be queried by Product code
a SSI Interface with BISS-C Protocol. The absolute encoder
is ideal for commutation, speed control and position con-
trol.
AESM encoder series

A E S M – 4096
4096 steps per revolution
133
Drive Electronics
WE CREATE MOTION
Speed Controller
Connection variants
Speed Controller Page
DC-Micromotor with encoder and
SC 1801 P for DC and Brushless Motors
programming adapter1 (optional)
A 490 – 491
SC 1801 F for DC and Brushless Motors 1A 492 – 493
SC 1801 S for DC and Brushless Motors 1A 494 – 495
SC 2402 P for DC and Brushless Motors 2A 496 – 497
To customer
SC 2804 S
application for DC and Brushless Motors 4A 498 – 499
SC 5004 P for DC and Brushless Motors 4A 500 – 501
Speed Brushless DC-Servomotor with digital
SC 5008 S forController
DC and Brushless Motors 8A 502 – 503
or analog Hall sensors
Motion Controller Page

MCDC 3002 P for DC-Micromotors 2A 510 – 511
MCDC 3002 S for DC-Micromotors 2A 512 – 513
MCDC 3003 P for DC-Micromotors 3 A without Hall
Brushless DC-Servomotor 514 – 515
sensors
MCDC 3006 S for DC-Micromotors (sensorless operation)6 A 516 – 517
MCBLUSB
3002 P for Brushless DC-Motors 2A 518 – 519
interface
MCBL 3002 F for Brushless DC-Motors 2A 520 – 521
MCBL 3002 S for Brushless DC-Motors 2A 522 – 523
MCBL 3003 P for Brushless DC-Motors 3A 524 – 525
MCBL 3006 S for Brushless DC-Motors Brushless DC-Servomotor 6 A with 526 – 527
absolute encoder (AES)
MCBL 3002 P AES for Brushless DC-Motors with AES 2A 528 – 529
MCBL 3002 F AES for Brushless DC-Motors with AES 2A 530 – 531
MCBL 3002 S AES for Brushless DC-Motors with AES 2A 532 – 533
MCBL 3003 P AES for Brushless DC-Motors with AES 3A 534 – 535
MCBL 3006 S AES for Brushless DC-Motors with AES 6A 536 – 537
MCLM 3002 P for Linear DC-Servomotors 2A 538 – 539
MCLM 3002 F for Linear DC-Servomotors 2A 540 – 541
General Information MCLM 3002 S The
for different
Linear sizes as well as the flexible
DC-Servomotors 2 A connection542possi-
– 543
MCLM 3003 P bilities
for Linear open a wide range of applications
DC-Servomotors 3 A in areas 544
such as
– 545
MCLM dynamic
FAULHABER Speed Controllers are highly 3006 S speed laboratory
for technology and equipment6 Amanufacturing,
Linear DC-Servomotors auto-
546 – 547
controllers for controlling: MC 5004 P mation
for technology,
DC, Brushless and Linearpick-and-place
Motors machines
4A and machine
554 – 555
NEW MC 5004 P STO for Brushless
tools, and Linear Motors
or pumps. 4A 556 – 557
■ DC-Motors with and without incremental
MC 5005 Sencoder for DC, Brushless and Linear Motors 5A 558 – 559
MC sensors
■ BL motors with analog or digital Hall 5010 S for DC, Brushless and Linear Motors 10 A 560 – 561
MCST 3601 for Stepper Motors 1A 566 – 567
■ BL motors with AES absolute encoder
■ BL motors with digital Hall sensors and
incremental encoders
Depending on the size and delivery state, different motor Product code
and sensor combinations can be operated on the Speed
Controller.
DC sensorless
DC + encoder
BL sensorless
BL + D-Hall
BL + A-Hall
Controller
BL + AES
SC 1801 • • • • (2) (2)

SC 2402/2804 • • • • (1) (2) (2)
SC 5004/5008 - • - • (1) (2) (2) SC Speed Controller SC 28 04 S 3530
28 Max. supply voltage (28V)
04 Max. continuous output current (4A)
1) Optionally also available with additional incremental encoder input S Housing with screw terminal
2) Optionally available 3530 Operating mode (brushless motor with
digital Hall sensors)
135
Speed Controller
Connection variants
General Information
programming adapter (optional)
FAULHABER Speed Controllers can be adapted to the
application via the FAULHABER Motion Manager software.
The type and scaling of the setpoint input, the operating
To customer
mode and the control parameters can be adjusted.
application
The
USB programming adapter for Speed Controllers is used for
Speed Controller Brushless DC-Servomotor with digital
configuration.
or analog Hall sensors
Speed Controllers are available with or without housing.
The variants with housing are connected via screw termi-
nals; the unhoused circuit-board variants can be directly
plugged into a master board. Brushless DC-Servomotor without Hall sensors
(sensorless operation)
USB
Interfaces – discrete I/O interface
■ Analog input as set value input for setting the speed via
PWM or analog voltage value
■ Digital input as switching input for defining the direc-
tion of rotation of the motor
■ Digital output, can be programmed either as frequency
output or as error output
Note
Device manuals for installation and start-up, as well as the The different sizes as well as the flexible connection possi-
General Information
"FAULHABER Motion Manager" software, are available on bilities open a wide range of applications in areas such as
request or on the Internet under www.faulhaber.com. Not laboratory technology and equipment manufacturing, auto-
FAULHABER Speed Controllers are highly dynamic speed
all Speed Controllers are suitable for all operating modes. mation technology, pick-and-place machines and machine
controllers for controlling:
Detailed information on the individual operating modes tools, or pumps.
canDC-Motors
■ be found with
in theand withoutdata
respective incremental
sheets asencoder
well as in the
technical
■ manual.
BL motors with analog or digital Hall sensors
■ BL motors with AES absolute encoder
Benefits
■ BL motors with digital Hall sensors and
Compact design
■ incremental encoders
■ Scalable in current and voltage
Depending on the size and delivery state, different motor Product code
■ Simple
and sensorwiring
combinations can be operated on the Speed
■ Adapted versions for connecting different motors
Controller.
■ Integrated current limiting (motor protection)
DC sensorless
■ Controller setting can be configured in combination

DC + encoder
BL sensorless
BL + D-Hall
BL + A-Hall
with Motion Manager via programming adapters

Controller
BL + AES
■ Extensive range of supported DC-micromotors and

brushless DC-servomotors
SC 1801 • • • • (2) (2)

SC 2402/2804 • • • • (1) (2) (2)
SC 5004/5008 - • - • (1) (2) (2) SC Speed Controller SC 28 04 S 3530
1) Optionally also available with additional incremental encoder input S Housing with screw terminal
2) Optionally available 3530 Operating mode (brushless motor with
digital Hall sensors)
136
Speed Controller
Description & Operating Modes
Operating modes DC-Motors without encoder

In the "sensorless DC motors" configuration, the motors
The speed is controlled via a PI controller with variable are operated with speed control whereby, depending on
parameters. the load condition, either the back electromotive force
(EMF) or IxR compensation is used for speed actual value
Depending on the version, the speed is determined via the
acquisition.
connected sensor system or sensorless from the motor
Matching to the respective motor type is required for this
current. operating mode.
Setpoint specification can be performed using an analog A number of other parameters can also be changed using
value or a PWM signal. The direction of rotation is changed the "FAULHABER Motion Manager" software:
via a separate switching input; the speed signal can be read
out via the frequency output. ■ Controller parameters
■ Output current limiting
The motors can optionally be operated as a voltage control-
ler or in fixed speed mode. ■ Fixed speed
BL motors with digital or analog Hall sensors ■ Encoder resolution

In the "BL motors with Hall sensors" configuration, the ■ Speed setpoint specification via analog or PWM signal
motors are operated with speed control, whereby the
■ Maximum speed or maximum speed range
signals from the Hall sensors are used for commutation and
determination of the actual speed.
BL motors without Hall sensors (sensorless mode)
No Hall sensors are used in this configuration; instead, the Protective functions
back-EMF of the motor is used for commutation and speed
FAULHABER Speed Controllers determine the temperature
control.
of the motor winding from the motor load characteristic.
BL motors with absolute encoder Dynamically, a peak current which is typically 2 times
This mode can only be selected in combination with the larger than the continuous current is available as a result;
appropriate hardware. with a continuously higher load, the current is limited to
In this configuration, the encoder outputs an absolute the set continuous current.
position. This is used for commutation as well as for speed
control. Owing to the high resolution of the encoder, it is In the case of frequent reversing operation with large
possible to achieve low speeds in this mode. connected masses, it is recommended to use a Motion Con-
troller.
BL motors with digital Hall sensors and
brake/enable input
In this configuration, the motors are operated with speed Special functions
control. The additional brake and enable inputs enable
For special applications, special functions such as ramps,
easier connection of the control to e.g. PLCs or safety
switchable fixed speeds or more complex processes can be
circuits.
implemented ex works depending on the additional
BL motors with digital Hall sensors and encoder inputs. This allows FAULHABER Speed Controllers to be
In this configuration, the Hall sensors output the informa- optimally adapted to the requirements of the specific
tion for commutation. The speed is controlled according to application.
the signal from the incremental encoder.
For this reason, it is also possible to achieve extremely low
speeds with a high-resolution encoder.
DC-Motors with encoder
In the "DC motors with encoder" configuration, the
motors are operated with speed control. An incremental
encoder is required as a speed actual value encoder.
137
Speed Controller
Description & Operating Modes
Max. peak output current Imax. [A]

Describes the current that the controller can reach in S2
operation (cold start without additional cooling) at nomi-
Speed Controllers nal conditions under constant load for the time specified
2-Quadrant PWM configurable via PC in the data sheet without exceeding the thermal limit.
Unless otherwise defined, the value that applies for the
peak current is equal to two times the continuous current.
SC 1801 P Standby current for the electronics Iel [A]

Values at 22°C
SC 1801 P
4 ... 18
Describes the additional current consumption of the con-
Power supply motor Umot 1,8 ... 18 trol electronics.
PWM switching frequency 1) fPWM 96
Efficiency electronic K 95
Shows the minimum and maximum operating temperature
Notes on technical data sheet under nominal conditions.
The following data sheet values of the Speed Controllers Housing material
are measured or calculated at an ambient temperature of Housing materials and, if necessary, surface treatment.
22°C.
Mass [g]
Speed Controllers generally feature separate supply inputs The typical mass of the standard controller may vary due
for motor and electronics with the same ground con- to the different components.
nection; if necessary, these inputs can also be used as a
common supply. Note
Power supply for electronics Up [V DC] Speed range
Describes the range of the permissible supply voltage for The speed that can be reached in combination with a
the control electronics. motor depends on the available voltage, the respective
motor type and the maximum processing speed of the
Power supply for motor Umot [V DC]
selected speed controller.
Describes the range of the permissible supply voltage of
the connected motor. The maximum speed range refers to motors with one pole
pair. On motors with a larger number of pole pairs, the
PWM switching frequency ƒPWM [kHz] speed range decreases accordingly.
Pulse width modulation describes the change of the elec-
trical voltage between two values. The motors connected Maximum speed with number of pole pairs 1
to the SCs have a low electrical time constant. To keep the Maximum
=
losses associated with PWM low, a high switching fre- speed Number of pole pairs of
quency is necessary. the connected motor
Electronics efficiency η [%]

Ratio between consumed and delivered power of the
Max. continuous output current Icont [A]

Describes the current that the controller can continuously
deliver to the connected motor at 22°C ambient tempera-
ture without additional cooling.
Steuerungen_2019_EN,DE,FR,.indd 1 26.09.18 14:50

138
Motion Controllers
Feature Comparison
■ Numerous configuration options

General Information
■ Successfully used in medical and laboratory technology,
FAULHABER Motion Controllers are highly dynamic equipment manufacturing, automation, medical tech-
positioning systems, available in housed and unhoused nology and aerospace
variants and control DC, LM or BL motors. The Motion ■ Also available in very small sizes
Controllers are configured here via the FAULHABER
Motion Manager. Generation V3.0
The drives can be operated in the network via the A new generation of controllers for applications that go
CANopen or EtherCAT fieldbus interface (only MC V3.0). beyond the features and performance offered by the V2.5
In smaller setups, networking can also be performed via controller series.
the RS232 interface. The Motion Controllers operate in the ■ More power, faster control, new operating modes
network in principle as a slave; master functionality for ■ One controller for all motor types and encoder systems
actuating other axes is not provided. ■ Flexible use of the I/Os for setpoints and actual values
After basic commissioning via Motion Manager, the ■ Additional I/Os and interfaces
controllers can alternatively also be operated without
■ Sequential programs can be programmed in BASIC for
communication interface.
simple, local automation in all interface technologies
Generation V2.5 ■ Expanded diagnostic functions
■ Proven technology for BL, DC and LM motors
■ Simple start-up via Motion Manager beginning with
■ Very simple configuration and start-up version 6.0
Generation V2.5 Generation V3.0

MCxx 3002 MCxx 3003/06 MC 5004 MC 5005/10
Voltage ranges ■ Motor: max. 30V ■ Motor: max. 50V
■ Electronics: max. 30V, optionally separated ■ Electronics: max. 50V, separated standard
Continuous current 2A 3 / 6A 4A 5 / 10A

Peak current 3A 10A 12A 15 / 30A
Motor types ■ MCDC: DC + Encoder ■ DC motors with pos. / speed sensor
■ MCBL: BL + A-Hall ■ BL motors with pos. / speed sensor
■ MCLM: LM + A-Hall
■ MCBL AES: BL + AES Encoder ■ LM motors with pos. / speed sensor
Speed and see motor types ■ DC motors: incremental1), AES Encoder1), SSI encoder1),
position sensors analog value (potentiometer/tachometer)
■ BL/LM motors: D-Hall, D-Hall + Encoder1), A-Hall, AES
encoder1), SSI encoder1), analog value (potentiometer/
tachometer)
Inputs/outputs MCDC: MCBL/MCLM: DigIn: 8 DigIn: 3
DigIn: max. 5 DigIn: max. 3 DigOut: 3 DigOut: 2
DigOut: max. 1 DigOut: max. 1 AnIn ±10V: 2 AnIn ±10V: 2
AnIn ±10V: 1 AnIn ±10V: 1
Optional connection of a second reference encoder Optional connection of a second reference encoder
(Gearing mode). Not all I/Os available depending on (Gearing mode).
wiring.
Communication RS232 or CANopen USB, RS232 and/or CANopen, EtherCAT
Controller Position, speed, current limiting Position, speed, current / torque
with and without Line driver
Operating ■ Depending on the interface variant, position, ■ Profile Position mode (PP) and Profile Velocity
modes speed and current control with setpoint input mode (PV), taking into account profile settings
via the interface or analog (RS and CF) ■ Cyclic Synchronous Position, speed
or torque (CSP, CSV or CST)
■ Analog input for position, speed, torque or
voltage (APC, AVC, ATC, volt)
Profile operation Linear trapezoidal profiles in all operating modes Linear or sin² speed in PP and PV modes
Autonomous processes Available in the versions with RS232 interface Up to eight sequential programs in all versions,
with optional password protection
1)
139
Motion Controllers
Connection variants
programming adapter (optional)
Brushless DC-Servomotor
with analog Hall sensors
Motion Controller
Linear DC-Servomotor
CANopen with analog Hall sensors
USB
RS232

Features Benefits
FAULHABER Motion Controllers of generation V2.5 are ■ Compact design
highly dynamic positioning systems for controlling
■ Can be controlled either via RS232
different motors and sensor systems:
or CAN interface
■ MCDC 300x: DC-Motors with incremental encoder ■ Minimal wiring requirements
■ MCBL 300x: BL-motors with analog Hall signals ■ Configurable using the “FAULHABER Motion
■ MCLM 300x: LM-motors with analog Hall signals
Manager” software and USB interface
■ Extensive range of accessories
■ MCBL 300x AES: BL-motors with absolute encoder
■ Simple start-up
In addition to use as a servo drive with controlled posi-
tion, the speed can also be controlled. Via the integrated
Product code
current control, the torque is limited and the electronics or
the connected motor protected against overload.
Motion Controllers of generation V2.5 are available in var-

ious sizes and performance classes as well as with RS232 or
with CAN interface and, as a result, can also be integrated
in networks. In addition to operation on a PC, the systems
can also be operated on all common industrial controls.
The Motion Controllers are available with or without hous-

ing. The variants with housing are connected via screw ter-
MC Motion Controller MC BL 30 06 S CO
minals; the unhoused circuit-board variants can be directly BL For Brushless DC-Motors
plugged into a master board. 30 Max. supply voltage (30 V)
06 Max. continuous output current (6 A)
S Housing with screw terminal
CO CAN interface
140
Motion Controllers

Positioning operation Separate supply of power to the motor and electronic
The drive moves to the preset target position and, in doing actuator is optional (important for safety-critical applica-
so, maintains the specified limits for speed and position. tions).
The dynamics of the control can be adapted to a wide Third input is not available with this option. Depending on
range of loads. Limit switches can be evaluated directly. the controller, additional programming adapters and
The position can be initialised via limit switches or a refer- connection aids are available. The modes and parameters
ence switch. can be specially pre-configured on request.
Speed control
Interfaces – discrete I/O
The drive controls the preset target speed via a PI speed
controller without lasting deviation. Setpoint input
Current control Depending on the operating mode, setpoints can be input
Protects the drive by limiting the motor current to the set via the command interface, via an analog voltage value, a
peak current. By means of integrated thermal models, the PWM signal or a quadrature signal.
current is limited to the continuous current if necessary. Error output (Open Collector)
Motion profiles Configured as error output (factory setting). Also usable
Acceleration and brake ramp as well as the maximum as digital input, free switch output, for speed control or
speed can be preset in speed and positioning operation. signaling an achieved position.
Autonomous operation Additional digital inputs

In version RS, freely programmable processes can be stored For evaluating reference switches.
in the Motion Controller. Operation is then also possible
without RS232 interface.
Interfaces – position encoder
Depending on the model, one of the listed interfaces
Protective features
for the position and speed sensor is supported.
■ Protection against ESD
■ Overload protection for electronics and motor Analog Hall signals
Three analog Hall signals, offset by 120°, in Brushless
■ Self-protection from overheating
DC-Motors and Linear DC-Servomotors.
■ Overvoltage protection in generator mode
Incremental encoder
Operating modes (RS and CF versions) In DC-Micromotors and as additional sensors for Brushless
■ Position control DC-Motors.
– with analog setpoint Absolute encoder
– gearing mode Serial SSI port, matching Brushless DC-Servomotors with
– stepper motor operation AES encoders.
■ Speed control
■ Torque control
Operating modes (CO and CF versions)

■ Homing mode
141
Motion Controllers
Versions with CAN CF or CO

Networking
Two controller versions with a CANopen interface are
Positioning operation
FAULHABER Motion Controllers of generation V2.5 are Separate
available supply of power
for optimal to the motor
integration withinand electronic
a wide range of
available
The drive in
moves
all three
to the
networking
preset target
versions.
position and, in doing actuator is optional
applications. CANopen (important for safety-critical
is the perfect applica-
choice for network-
so, maintains the specified limits for speed and position. tions).
ing miniature drives because the interface can also be
RS – systems with RS232 interface
The dynamics of the control can be adapted to a wide Third inputinto
integrated is not available
small with this
electronics. Dueoption.
to theirDepending on
compact size
Ideal for equipment manufacturing and for all applications
range of loads. Limit switches can be evaluated directly. the
and controller, additional programming
efficient communication adapters
methods, they are theandideal
in which the controller is also to be used without a higher
The position can be initialised via limit switches or a refer- connection
solution foraids are available.
complex The modes and
fields of application suchparameters
as industrial
level controller. Using Net mode, it is also possible to oper-
ence switch. can be specially pre-configured on request.
automation.
ate multiple RS controllers on an RS232 interface.
Speed control CFInterfaces
version: CANopen with I/O
FAULHABER channel
CF – CANopen with FAULHABER CAN – discrete
The drive controls the preset target speed via a PI speed The CF version supports not only CiA 402 standard operat-
Combines communication via the CANopen protocol
controller without lasting deviation. ing modes
Setpoint but also a special FAULHABER Mode. Via PDO2,
input
with the operating modes familiar from the RS version.
operator control
Depending on theis operating
thus analogous
mode,tosetpoints
that of the
canRS232
be input
The assignment
Current control of the PDOs is fixed; the FAULHABER
version.
via Extended interface,
the command operatingvia
modes such asvoltage
an analog operation with
value, a
commands
Protects thearedrive
sent
byexclusively
limiting the
viamotor
one ofcurrent
the PDOs.
to the set
analogsignal
PWM setpoint
or ainput or the signal.
quadrature stepper or gearing mode are
peak for
Ideal current.
use inByequipment
means of integrated
manufacturingthermal models, the
if multiple also supported.
current is
Motion limited toare
Controllers theoperated
continuouson current
one PC.if necessary. Error output (Open Collector)
The CF version is therefore particularly suitable for users
Motion profilesacc. to CiA 402 Configured as error output (factory setting). Also usable
CO – CANopen who are already familiar with the RS232 version and wish
Acceleration and for
brake as digital input, free switch output, for speed control or
The ideal variant theramp as wellofasa the
operation maximum
FAULHABER to exploit the benefits of CAN in networking.
speed can be preset in speed and positioning operation. signaling an achieved position.
Motion Controller on a PLC – directly via the CANopen
CO version: CANopen
interface
Autonomousor via a gateway on, e.g., Profibus/ProfiNET or
operation Additional digital inputs
The CO version provides the CiA 402 standard operating
on EtherCAT.
In version RS, freely programmable processes can be stored For evaluating reference switches.
modes. All the parameters are directly stored in the object
in the Motion Controller. Operation is then also possible directory. Configuration can therefore be performed with
Interfaces
without RS232–interface.
Bus Connection Interfaces – position encoder
the help of the FAULHABER Motion Manager or by apply-
Depending
ing available onstandardized
the model, one ofguratons
confi the listed interfaces
tools common to
Version with
Protective RS232
features
for the position and
the automation market. speed sensor is supported.
ForProtection
■ coupling to a PC with
against ESD a transfer rate of up to
115 kbaud. Multiple drives can be connected to a single The CO Hall
Analog version is particularly suitable for users who
signals
■ Overload protection for electronics and motor
controller using the RS232 interface. As regards the control already use various CANopen
Three analog Hall signals, devices
offset or operate
by 120°, the
in Brushless
■ Self-protection from overheating Motion Controllers on a PLC. With dynamic PDO mapping
computer, no special arrangements are necessary. The DC-Motors and Linear DC-Servomotors.
■ Overvoltage
interface protection
also offers in generator
the possibility mode online
of retrieving it is possible to achieve highly efficient networking on the
operational data and values. Incremental
CAN. encoder
Operating modes (RS and CF versions) In DC-Micromotors and as additional sensors for Brushless
A comprehensive ASCII command set is available for
■ Position control DC-Motors.
programming
– with setpointand input
operation.
via the This can be preset from the
interface
PC –using the “FAULHABER
with analog setpoint Motion Manager“ software or Absolute encoder
from another
– gearing modecontrol computer. Serial SSI port, matching Brushless DC-Servomotors with
Additionally, there operation
– stepper motor is the possibility of creating complex AES encoders.
processes from
■ Speed control
these commands and storing them on the
drive. Once programmed
– with setpoint input via as the
a speed or positioning
interface
controller via the analog
– with analog setpoint input, as step motor or electronic
gear unit, the drive can operate independently
■ Torque control
of the RS232 interface.
Operating modes (CO and CF versions)

■ Homing mode
142
Motion Controllers
CF / CO comparison
CF CO
NMT with node guarding • •
Baud rate 1 Mbit max., LSS 1 Mbit max., LSS
EMCY object • •
SYNCH object • •
Server SDO 1x 1x
PDOs 3 x Rx 4 x Rx
3 x Tx 4 x Tx
each with static each with dynamic
mapping mapping
PDO ID fixed adjustable
Configuration Motion Manager Motion Manager
from V5
Trace PDO3 (fixed) Any PDO
Standard operating • •
modes
- Profile Position Mode
- Profile Velocity Mode
- Homing
Ext. operating modes FAULHABER -
channel
Both versions support the CANopen communication profile

to CiA 301 V4.02. The transfer rate and node number are
set via the network in accordance with the LSS protocol
conforming to CiA 305 V1.11.
For this purpose, we recommend using the latest version
of the FAULHABER Motion Manager.
Note
Device manuals for installation and commissioning,
communication and function manuals as well as the
“FAULHABER Motion Manager” software are available on
request or on the Internet under www.faulhaber.com.
143
Motion Controllers
Configuration, networking, interfaces

Motion Controllers nal conditions under constant load for the time specified
V2.5, 4-Quadrant PWM in the data sheet without exceeding the thermal limit.
with RS232 or CAN interface Depending on the size and version, the value is up to three
times higher for the ratio of peak current to continuous
current.
MCDC 3002 P
Values at 22°C
Power supply electronic
MCDC 3002 P
UB/UEL 8 ... 30
Standby current for the electronics Iel [A]
Power supply motor 1) --/UB 0 ... 30 Describes the additional current consumption of the con-
PWM switching frequency fPWM 78,12
Efficiency electronic K 95 trol electronics.

Notes on technical data sheet Shows the minimum and maximum operating temperature
under nominal conditions.
The following data sheet values of the Motion Controllers
of generation V2.5 are measured or calculated at an ambi- Housing material
ent temperature of 22°C. In their standard version, the Housing materials and, if necessary, surface treatment.
Motion Controllers do not have separate supply inputs
Mass [g]
for motor and electronics, but can optionally be equipped
The typical mass of the standard controller may vary
with these inputs (via 3rd input).
within the individual interface variants due to the differ-
Power supply for electronics UB /UEL [V DC] ent components.
Describes the range of the permissible supply voltage for
the control electronics. Note
Power supply for motor -- /UB [V DC] Speed range
Describes the range of the permissible supply voltage of The speed that can be reached in combination with a
the connected motor. motor depends on the available voltage, the respective
PWM switching frequency ƒPWM [kHz] selected motion controller.
Pulse width modulation describes the change of the
The maximum speed range refers to motors with one pole
electrical voltage between two values. The motors con-
pair. On motors with a larger number of pole pairs, the
nected to the MCs have a low electrical time constant. To
speed range decreases accordingly.
keep the losses associated with PWM low, a high switching
frequency is necessary.
Maximum speed with number of pole pairs 1
Maximum
Electronics efficiency η [%] =
speed Number of pole pairs of
Ratio between consumed and delivered power of the
the connected motor


144
Motion Controller
FAULHABER Motion Controllers of generation V3.0 are

available in three sizes and three power classes:
■ MC 5004 – with a continuous current of up to 4 A, can be
plugged directly into a motherboard and offers most I/Os
■ MC 5005 – with a continuous current of up to 5 A, is the
ideal partner for most motors from the FAULHABER product
portfolio
■ MC 5010 – with a continuous current of up to 10 A, is also
suitable for applications with higher power requirements.
Especially well suited for use in combination with the highly
dynamic BL motors.
The possible applications are diverse: from laboratory auto-

mation to industrial equipment manufacturing, automation
technology and robotics to aerospace.
The connection to the motors is established via pre-

configured plugs or extension cables, which are available
for all supported motors as options or as accessories.
Features Benefits
■ One controller for all motor types and encoder types
FAULHABER Motion Controllers of generation V3.0 are
highly dynamic, optimally tuned positioning controllers for ■ Very dynamic control
use in combination with DC-micromotors as well as BL and ■ Ideally matched to FAULHABER DC, BL and LM motors
LM DC-servomotors from FAULHABER’s line of motors. The ■ Various setpoint and actual value interfaces
motor type can be configured during commissioning using ■ Stand-alone operation possible in all variants
the FAULHABER Motion Manager from version 6.0.
■ Connection via simple plug concept
In addition to use as a servo drive with controlled position, ■ Fast feedback with status LEDs
the speed or current can also be controlled. The actual ■ Commissioning with the free FAULHABER Motion Manager
values for speed and position can be ascertained here using from version 6.0
a number of supported sensor systems. Limit switches and ■ Extensive mounting accessories available
reference switches can be directly connected.
The control setpoints can be preset via the communication Product code
interface, via the analogue input or a PWM input or can
come from internally stored sequential programs.
Supported as communication interfaces are – depending

on the device – USB and RS232, CANopen and, optionally,
EtherCAT. All functions of the drive are available here with-
out limitation via all interfaces.
MC Motion Controller MC 50 05 S RS
50 Max. supply voltage (50 V)
05 Max. continuous output current (5 A)
S Housing with plug-in connections
RS RS232 interface
145
Motion Controller
Networking The drives

Cyclic Synchronous
can be operated
Position in
(CSP)
the/network
Cyclic Synchronous
via the CAN-
Error handling Diagnosis Velocity
open or (CSV)
EtherCAT
/ Cyclic
fieldbus
Synchronous
interface.
Torque
In smaller
(CST)setups,
RS – systems with RS232 interface For applications
networking can in
also
which
be performed
a higher-level
via the
controller
RS232 per-
inter-
Ideal for device construction and for all applications in forms the path planning, even synchronised for multiple
face.
Device control Motor control
which the Motion Controller is to be operated on an axes. The setpoints for position,
operatesspeed
in theand current
in are
Object dictionary
The Motion Controller network prin-

embedded controller. Using Net mode, it is also possible constantly updated. Typical update rates are in the
ciple as a slave; master functionality for actuating other range
to operate multiple RS controllers
+ on an RS232 interface. of a few
axes milliseconds.
is not provided. Cyclic modes are, thus, primarily
The transmission rate can lie between 9600 baud and suited for combination with EtherCAT. CANopen can also
– After basic commissioning via the Motion Manager, the
115 kbaud. be used.
CO – CANopen acc. to CiA 402 communication
Analogue Position interface.
Control (APC) / Analogue Velocity
The ideal variant for the operation of a FAULHABER Control
The (AVC) / Analogue
controllers of the MCTorque Control
5004 series can(ATC)
be plugged into
Motion Controller on a PLC – directly
Hardware via the CANopen
driver For
a applications via
motherboard in which the setpoints
the 50-pin connector of strip.
the control
For this
interface or via a gateway on, e.g., Profibus/ProfiNET or on are specifiFAULHABER
purpose, ed as an analogue
offers avalue or, e.g., viafor
motherboard a directly
connect-
EtherCAT. Dynamic PDO mapping as well as node guarding connected
ing reference
up to four encoder. These operating modes are
controllers.
orOperating
heartbeat are supported. Refresh rates for setpoint and therefore particularly
modes The controllers of thewell suitedand
MC 5005 for MC
stand-alone opera-
5010 series are
actual values are typically from 10 ms here. tion without higher-level master.
secured to a flat base plate via the mounting holes. With
Motor control
ET – EtherCAT optional accessories,
Voltage mode (VOLT) mounting is also possible on a DIN
Current, speed and position of the drive can be controlled
Motion Controllercascade.
with direct EtherCAT interface. The rail.
In the voltage mode, only a current limiting controller is
via the controller By means of the optional pilot
controllers are addressed via CoE via the CiA 402 servo used.
paths, even the fastest movements can be reliably con- ModifiAll control
cations and loops are closed by a higher-level system.
accessories
drive
trolledprofi
in ale. Ideal in combination with a high-perfor- The
reproducible manner. Adjustable filters enable FAULHABER specialises via
setpoint can be set theadaptation
in the communication
of itssystem or
standard
mance industrial controller that
adaptation to a wide range of encoders also performs path
and loads. via an analogue input.
products for customer-specific applications. The follow-
planning and interpolation of the movement for multiple
ing standard
Interfaces optionsI/O
– discrete and accessory parts are available for
Motion
axes. profiles
Refresh rates for setpoint and actual values from
FAULHABER
Three Motion
to eight digitalController
inputs for MC V3.0: limit and
connecting
Acceleration
0.5 and brake ramp as well as the maximum
ms are supported.
speed can be preset in speed and positioning operation in reference
■ switches
Connection or for connecting
cables a reference
the supply and encoder.
motor side
the Profile Position
Interfaces – BusMode (PP) and Profile Velocity Mode
Connection The logic levels
■ Adapter sets are
for switchable.
encoders
(PV) operating modes. Two analogue
■ Connector sets inputs (±10V) are available that can be
Configuration freely used as setpoint or actual value.
Autonomous
All operationof generation V3.0 are equipped
Motion Controllers ■ Motherboard MC 5004
Up toaeight sequentialThis
programs written in BASIC Two to three digital outputs are available that can be
with USB interface. is intended primarily ascan
a be ■ Programming adapter
stored and executed directly freely used as error output, for direct actuation of a
confi guration interface. Via aonUSBtheto
controller.
RS232 orOne USB of
to ■ Starter kits or as flexible diagnosis output.
theseconverter,
can be confi gured from holding brake
CAN the drives can the autostart application.
alternatively likewise be
Access protection canrestriction.
be activated. ■ Customized special configuration
confi gured without Interfaces – position encoder
and firmware
All described
Protection andoperating modes
diagnostic and functions are avail-
functions FAULHABER Motion Controllers of generation V3.0
able independent of the used communication interface. support all sensor systems typically used on micro motors
FAULHABER Motion Controllers of generation V3.0 protect Functional safety
The interfaces
motors can also against
and electronics be usedoverload
in parallel, thereby
by means ofallow- for position and speed as well as analogue or digital Hall
ing a drive
thermal to beThe
models. integrated in an industrial
supply voltage interface
is monitored via
and can STO – Safe
signals, Torque Off
incremental encoders with and without Line Driver
the
also CANopen
be used inor EtherCAT interface,
regenerative operation.while diagnostics
External devicesare The products
or protocol-basedof the
AESMCor5004 P STO series have a function
SSI encoders.
evaluated
are therebywith the trace
protected function
against via the USB
overvoltage interface.
during dynamic which safely shuts down the torque via a certified inte-
operation. Options
grated safety circuit.
General Information Disconnection through
All controllers can two redundant
optionally be equippedoptocoupler inputs
with an Ether-
Profile Position Mode (PP) / Profile Velocity Mode (PV) ensures operation up to safety integrity level SIL3 as
System description
For applications in which only the target of the movement CAT interface.
defined by IEC 61800-5-2 and performance level PL e as
The products
is specifi ed forofthe
the MC 5004,The
controller. MCacceleration
5005 and MC 5010
and brake For highly dynamic applications, the use of a braking
defined by EN ISO 13849-1. Signalling and visualisation is
series
ramp asarewell
variants of the FAULHABER
as a possible maximum speedMotion
are Controllers
taken into chopper can help to dissipate recovered energy.
via local LEDs as well as two separate outputs for status
with andvia
account without housing profi
the integrated and control eitherProfi
le generator. DC, le-based
LM or and error reporting.
BL motors. The
movements are,Motion Controllers
thus, suited are configured
for a combination withhere
stand-
The corresponding EC type examination is available for
via
ard the FAULHABER
networks, such asMotion
RS232 Manager.
or CANopen.
download at www.faulhaber.com.
146
Motion Controller
Networking The drives can be operated in the network via the CAN-
open or EtherCAT fieldbus interface. In smaller setups,
RS – systems with RS232 interface networking can also be performed via the RS232 inter-
Ideal for device construction and for all applications in face.
which the Motion Controller is to be operated on an The Motion Controller operates in the network in prin-
embedded controller. Using Net mode, it is also possible ciple as a slave; master functionality for actuating other
to operate multiple RS controllers on an RS232 interface. axes is not provided.
The transmission rate can lie between 9600 baud and
After basic commissioning via the Motion Manager, the
115 kbaud.
CO – CANopen acc. to CiA 402 communication interface.
The ideal variant for the operation of a FAULHABER The controllers of the MC 5004 series can be plugged into
Motion Controller on a PLC – directly via the CANopen a motherboard via the 50-pin connector strip. For this
interface or via a gateway on, e.g., Profibus/ProfiNET or on purpose, FAULHABER offers a motherboard for connect-
EtherCAT. Dynamic PDO mapping as well as node guarding ing up to four controllers.
or heartbeat are supported. Refresh rates for setpoint and
The controllers of the MC 5005 and MC 5010 series are
actual values are typically from 10 ms here.
secured to a flat base plate via the mounting holes. With
ET – EtherCAT optional accessories, mounting is also possible on a DIN
Motion Controller with direct EtherCAT interface. The rail.
controllers are addressed via CoE via the CiA 402 servo
Modifications and accessories
drive profile. Ideal in combination with a high-perfor-
FAULHABER specialises in the adaptation of its standard
mance industrial controller that also performs path
products for customer-specific applications. The follow-
planning and interpolation of the movement for multiple
ing standard options and accessory parts are available for
axes. Refresh rates for setpoint and actual values from
FAULHABER Motion Controller MC V3.0:
0.5 ms are supported.
■ Connection cables for the supply and motor side
Interfaces – Bus Connection ■ Adapter sets for encoders
■ Connector sets
Configuration
All Motion Controllers of generation V3.0 are equipped ■ Motherboard MC 5004
with a USB interface. This is intended primarily as a ■ Programming adapter
configuration interface. Via a USB to RS232 or USB to ■ Starter kits
CAN converter, the drives can alternatively likewise be
■ Customized special configuration
configured without restriction.
and firmware
All described operating modes and functions are avail-
able independent of the used communication interface. Functional safety
The interfaces can also be used in parallel, thereby allow-
ing a drive to be integrated in an industrial interface via STO – Safe Torque Off
the CANopen or EtherCAT interface, while diagnostics are The products of the MC 5004 P STO series have a function
evaluated with the trace function via the USB interface. which safely shuts down the torque via a certified inte-
grated safety circuit.
General Information Disconnection through two redundant optocoupler inputs
ensures operation up to safety integrity level SIL3 as
System description defined by IEC 61800-5-2 and performance level PL e as
The products of the MC 5004, MC 5005 and MC 5010 defined by EN ISO 13849-1. Signalling and visualisation is
series are variants of the FAULHABER Motion Controllers via local LEDs as well as two separate outputs for status
with and without housing and control either DC, LM or and error reporting.
BL motors. The Motion Controllers are configured here
The corresponding EC type examination is available for
via the FAULHABER Motion Manager.
download at www.faulhaber.com.
147
Motion Controller

Motion Controllers nal conditions under constant load for the time specified
V3.0, 4-Quadrant PWM in the data sheet without exceeding the thermal limit.
with RS232, CANopen or EtherCAT interface
Unless otherwise defined, the value that applies for the
peak current is equal to three times the continuous cur-
rent.
MC 5004 P
Values at 22°C MC 5004 P
Power supply electronic UP 12 ... 50 Standby current for the electronics Iel [A]
Power supply motor
PWM switching frequency
Umot
fPWM
0 ... 50
100
Describes the additional current consumption of the con-
Efficiency electronic
M ti t t t
K
I
95
4
trol electronics.

Explanatory Notes for Data Sheets Shows the minimum and maximum operating temperature
under nominal conditions.
The following data sheet values of the Motion Controllers
are measured or calculated at an ambient temperature of Mass [g]
22°C. The typical mass of the standard controller may vary
within the individual interface variants due to the differ-
Motion Controllers of generation V3.0 generally feature –
ent components.
with the same ground connection – separate supply inputs
for motor and electronics; if necessary, these inputs can
also be used as a common supply. Note
Speed range
Power supply for electronics Up [V DC]
The speed that can be reached in combination with a
Describes the range of the permissible supply voltage for
motor depends on the available voltage, the respective
the control electronics.
Power supply for motor Umot [V DC] selected motion controller.
Describes the range of the permissible supply voltage for The maximum speed range refers to motors with one pole
the motors connected to the MCs. pair. On motors with a larger number of pole pairs, the
PWM switching frequency ƒPWM [kHz] speed range decreases accordingly.
Pulse width modulation describes the change of the
electrical voltage between two values. Bell-type arma- Maximum speed with number of pole pairs 1
Maximum
ture motors have a low electrical time constant. To keep =
speed Number of pole pairs of
the losses associated with PWM low, a high switching the connected motor
frequency is necessary. In generation V3.0, this value
is fixed at 100 kHz. Through the type of pulse pattern
generation (centre aligned), the switching frequency Manuals/Software
effective at the motor is twice as high.
Device manuals for installation and commissioning,
Electronics efficiency η [%] communication and function manuals as well as the
Ratio between consumed and delivered power of the “FAULHABER Motion Manager” software are available
control electronics. on request or on the Internet under www.faulhaber.com.


148
Motion Controller
Software
FAULHABER Motion Manager The software is characterised by the following features:

■ Start-up support wizards
The powerful 'FAULHABER Motion Manager' software is
available for commissioning and configuring drive systems ■ Access to connected devices via Node-Explorer
with motion and speed controllers. ■ Configuration of drive functions and controller
Motion Manager generally supports interfaces RS232, USB parameters using convenient, coordinated dialogues
and CANopen. Depending on the connected device, it may, for the respective device family
however, be necessary to use an interface adapter, e.g., ■ Context-sensitive online help
during the configuration of a Motion Control System via ■ Only for Motion Controllers:
USB.
– Graphical analysis tools for drive behaviours and
The graphical user interface makes uniform and intuitive controller setting
procedures possible independent of the device family and
– Macro function for execution of program sequences
interface used.
– Development environment for sequential pro-
grammes and Visual Basic Script programmes
Supported Motion Controllers Speed Controller
Interfaces Motion Control Speed Control New features in Motion Manager 6:
Systems Systems ■ Completely revised user interface with window docking
function
RS232 • •
■ Node-Explorer with integrated project management
USB • •
■ Support for the MC V3.0 family Motion Controller
CANopen •
– Controller configuration with route identification
– Expanded graphical analysis options
– Further tools for operation and controller tuning
149
Motion Controller
Software
“FAULHABER Motion Manager” for Microsoft Windows

can be downloaded from www.faulhaber.com free of
charge.
Commissioning and Configuration

FAULHABER Motion Manager can be used to easily access
settings and parameters of the connected controller.
Wizards assist during the commissioning of a controller.
Drive units detected on the selected interfaces are dis-
played in the device explorer.
The current interface and display settings can be saved in
project files.
Sequential programs for saving and execution can be cre-
ated, edited, transferred and executed on the devices. Pos-
sibilities for error detection and monitoring the program
flow are also available.
The operation of a controller and the execution of motion
tasks are performed via:
■ Graphical operating elements
■ Command entries
■ Macro functions
■ Programming of sequences via
Visual Basic Script (VBScript)
FAULHABER Motion Manager The software is characterised by the following features:
Control parameters such as setpoints and actual values can ■ Start-up support wizards
The powerful 'FAULHABER Motion Manager' software is
be recorded in Logger or Recorder mode via a graphical ■ Access to connected devices via Node-Explorer
available for commissioning and configuring drive systems
analysis function. Additional tools are available for the
with motion and speed controllers. ■ Configuration of drive functions and controller
creation and optimisation of control parameters.
Motion Manager generally supports interfaces RS232, USB parameters using convenient, coordinated dialogues
and CANopen. Depending on the connected device, it may, for the respective device family
however, be necessary to use an interface adapter, e.g., ■ Context-sensitive online help
during the configuration of a Motion Control System via ■ Only for Motion Controllers:
USB.
– Graphical analysis tools for drive behaviours and
The graphical user interface makes uniform and intuitive controller setting
procedures possible independent of the device family and
– Macro function for execution of program sequences
interface used.
– Development environment for sequential pro-
grammes and Visual Basic Script programmes
Supported Motion Controllers Speed Controller
Interfaces Motion Control Speed Control New features in Motion Manager 6:
Systems Systems ■ Completely revised user interface with window docking
function
RS232 • •
■ Node-Explorer with integrated project management
USB • •
■ Support for the MC V3.0 family Motion Controller
CANopen •
– Controller configuration with route identification
– Expanded graphical analysis options
– Further tools for operation and controller tuning
150
Stepper motors Motion Controller
Connection variants
Standard cable with

Molex connector
Flex PCB adapter
Motion Controller Wires plugged to the

connecting terminal
USB
Features Benefits
FAULHABER stepper motor motion controllers are highly ■ Fully programmable via software
dynamic positioning systems tailored specifically to the (Graphic User Interface)
requirements of micro stepper motor operations. ■ USB interface

■ 9V…36VDC / 50mA to 1.1A
In addition to be able to control the whole FAULHABER
■ Microstepping up to 1/256
stepper motor range, the controllers are capable of
■ 4 GPI and 7 GPO
managing three axes positioning (requires 2 additional
■ Can be used as step/direction driver only
boards). Reference search and encoder management
■ Reference input (for homing functions)
functions are part of the numerous features offered by the
■ Compatible with LabView
controllers.
■ Board size: 68mm x 47.5mm
A complete IDE is included, allowing the user to benefit
from the full range of functionalities, through a very com-
Product Code
prehensive and user friendly interface.
The integrated systems require less space, as well as

making installation much simpler thanks to their reduced
wiring.
MC Motion Controller
MC ST 36 01
ST Stepper Motor
151
Main characteristics Special functions

Motion controller Speed profiles
■ Motion profile calculation in real-time Motors movements are realized using user definable speed
■ On the fly alteration of motor parameters profiles. The latter can be setup using a complete param-
(e.g. position, velocity, acceleration) eter calculator interface, helping the user to find the most
suited speed values.
■ High performance microcontroller for overall system
control and serial communication protocol handling StallGuard™
Stall detection feature allows the controller to react in
Bipolar stepper motor driver
case of step losses, and can also be used to detect any
■ Up to 256 microsteps per full step
motor hard stop reach.
■ High-efficient operation, low power dissipation
■ Dynamic current control
CoolStep™
Current flowing to the motor is automatically adapted in
■ Integrated protection
case of load variation. This feature allows a reduced power
Software consumption of the whole system.
■ TMCL™: standalone operation or remote controlled
Homing
operation
Reference search process can be done automatically by
■ PC-based application development software TMCL™ – the controller on startup. The user can setup the way to
IDE available for free. perform the operation (direction, switches number, origin
location, etc.).
Operating modes
Interfaces
Standalone
A program is stored in the controller board memory, and ■ USB device interface (on-board mini-USB connector)
starts when the system is powered ON. The software is
■ 6x open drain outputs (24V compatible)
able to react with external stimulus, such as digital I/Os,
encoders, sensors, etc. Standard processor instructions list ■ REF_L / REF_R / HOME switch inputs (24V compatible
as well as complete list of motor positioning control func- with programmable pull-ups)
tions are available for the programmer. ■ 1x S/D input for the on-board driver (on-board motion
controller can be deactivated)
Direct mode
■ 2x step / direction output for two separate external
Using IDE “direct mode” functions, the user is able to send
drivers (in addition to the on-board)
instructions to the board one by one, through USB link.
Status information and position/speed values can be read ■ 1x encoder input for incremental a/b/n encoder
in real time by the user, thanks to dedicated GUI. ■ 3x general purpose digital inputs (24V compatible)
Remote software ■ 1x analog input (0 .. 10V)

The controller can be remotely controlled through USB Please note: Not all functions are available at the same
link, by any user developed software. Labview and C++ time as connector pins are shared.
libraries are available to be used with the controller.
Notes
Device manuals for installation and start up, communi-
cation and function manuals, and the “TMCL™ – IDE”
software are available on request and on the Internet at
www.faulhaber.com.
152
Software
TMCL™ – IDE Startup and configuration

The high-performance software solution “TMCL™ – IDE”
Drivers and libraries are automatically installed together
enables users to control and configure the stepper motors
with the TMCL™-IDE software. Connected controller
controller, through USB interface.
device is immediately detected and recognized by the soft-
“TMCL™ – IDE” software and lots of program ware. The graphical user interface can be used to read out,
examples can be downloaded free of charge from change and reload configurations. Individual commands or
www.faulhaber.com. complete parameter sets and program sequences can be
entered and transferred to controller.
Operation of drives is also supported by several wizards,
helping user to easily setup all the parameters.
Quickstart, hardware and firmware complete user manuals
are also available for the user and can be downloaded free
of charge from www.faulhaber.com. Please refer to the
Quickstart manual before first use.
153
More information
faulhaber.com
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faulhaber.com/youtubeEN
faulhaber.com/linkedin
faulhaber.com/instagram
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Technical Information

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The respective current version of this document is avail-

Brushless DC-Motors Brushless DC-Servomotors 26 – 55

Motors with integrated Brushless DC-Motors with integrated Speed Controller 56 – 91

Stepper Motors Stepper Motors 92 – 99

Linear DC-Servomotors Linear DC-Servomotors 100 – 105

Precision Gearheads Precision Gearheads 106 – 111

Linear Components Ball Screws 112 – 119

Encoders Encoders – 2 Channel 120 – 133

Drive Electronics Speed Controller 134 – 153

No-load speed no [min-1] ±12%

No-load current (typical) Io [A]

nominal voltage with ankMambient temperature of 22 °C. temperature

8 16 24 32 Operating point at nominal value

The bearings used for the DC-Micromotors.

Explanations on the performance diagram How to select a DC-Micromotor

P2 = 3 mNm · 5 500 min-1 · 2π = 1,73 W

Second, compare the physical dimensions (diameter and

Back-EMF constant kE [mV/min-1]

Describes the relation torque

torque M H, a gearhead or a larger frame size motor has to

1 operating temperature, as well as the maximum allowable

Calculation of the main parameters Calculation of the operating point at 20 V

inserting the values 3 mNm + 0,2 mNm

resistance between the housing and the ambient air.

Speed constant kn [min /V] -1

1 End cap with encoder PCB

22 Motor diameter [mm]

Advantages of this series at a glance

Motor diameter 8 ... 22 mm

15 Motor diameter [mm]

Advantages of this series at a glance

Powerful rare-earth magnets Low torque ripple and high efficiency

26 Motor diameter [mm]

Advantages of this series at a glance

Highly dynamic performance Wide operating temperature range:

32 Motor diameter [mm]

Advantages of this series at a glance

Best dynamic performance due Extremely wide operating temperature range

15 Motor diameter [mm]

Advantages of this series at a glance

Extremely ﬂat design. Integrated spur gearheads of minimal length

For highly dynamic servo applications requiring very high

Hall signals HallA – HallC shaft,

ambient thermal conditions,

BLM_2019-EN,DE,FR,CN.indd 15 02.10.18 16:32

Stall torque MH [mNm]

Friction torque CO [mNm]

BLM_2019-EN,DE,FR,CN.indd 15 02.10.18 16:32

Terminal inductance, phase to phase L [µH] shaft, play

R th1 corresponds to the thermal resistance between the

BLM_2019-EN,DE,FR,CN.indd 15 02.10.18 16:32

Example: Power diagram for rated values at continuous

1 Rear cover with bearing

1 End cap with ball bearing

05 Motor diameter [mm]

Advantages of this series at a glance

Extremely compact design. 2-pole design with medium to high speeds

Motor diameter 6 ... 44 mm

35 Motor diameter [mm]

Advantages of this series at a glance