SEW-Eurodrive DR Series Operating Instructions Manual
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SEW-Eurodrive DR Series Operating Instructions Manual

Ac motors, asynchronous servo motors
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Gearmotors \ Industrial Gear Units \ Drive Electronics \ Drive Automation \ Services
A6.C01
AC Motors DR/DV/DT/DTE/DVE,
Asynchronous Servo Motors CT/CV
Edition 08/2004
O
perating Instructions
11291613 / EN

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  • Page 1 Gearmotors \ Industrial Gear Units \ Drive Electronics \ Drive Automation \ Services A6.C01 AC Motors DR/DV/DT/DTE/DVE, Asynchronous Servo Motors CT/CV Edition 08/2004 perating Instructions 11291613 / EN...
  • Page 2 SEW-EURODRIVE – Driving the world...

  • Page 3: Table Of Contents

    Contents 1 Important Notes....................4 2 Safety Notes ...................... 5 3 Motor Design ..................... 6 Basic structure of AC motors ..............6 Nameplate, unit designation ..............7 4 Mechanical Installation ..................9 Before you begin ..................9 Preliminary work..................9 Installing the motor..................

  • Page 4: Important Notes

    Important Notes Important Notes Betriebsanleitung Safety and Always follow the safety and warning instructions in these operating instructions! warning notes Electrical hazard Possible consequences: Severe or fatal injuries. Hazard Possible consequences: Severe or fatal injuries. Hazardous situation Possible consequences: Slight or minor injuries. Harmful situation Possible consequences: Damage to the drive and the environment.

  • Page 5: Safety Notes

    Safety Notes Safety Notes Preface The following safety notes are concerned with the use of motors. If using gearmotors, also refer to the safety notes for gear units in the corresponding operating instructions. Please also consider the supplementary safety notes in the individual sections of these operating instructions.

  • Page 6: Motor Design

    Motor Design Basic structure of AC motors Motor Design The following illustration is intended to explain the general structure. Its only purpose is to facilitate the assignment of components to the spare parts lists. Discrepancies are possible depending on the motor size and version! Basic structure of AC motors 44 41 02969AXX...

  • Page 7: Nameplate, Unit Designation

    Motor Design Nameplate, unit designation Nameplate, unit designation Nameplate Example: DFV 160 M4 /BM brake motor 03214BXX Unit designation Example: DR / DT / DV / DTE / DVE AC (brake) motors DFV 132M2 / BM /TF / AMA1 / EV1T Motor option: 5 V TTL incremental encoder Motor option: AMB1 plug connector...
  • Page 8 Motor Design Nameplate, unit designation Nameplate Example: CT90L4 / BMG / TF / ES1S servo brake motor CT90L4 BMG TF / ES1S 01.3410069302.0001.00 30.5 3000 10.5 230~ BGE 1.5 51358BXX Unit designation Examples: Servo (brake) motors CT / CV CFV 132M4 / BM / TF / EV1S Motor option: Sine/cosine incremental encoder Motor option: TF thermistor sensor Motor option: Brake...

  • Page 9: Mechanical Installation

    Mechanical Installation Before you begin Mechanical Installation It is essential to comply with the safety notes in Section 2 during installation! Before you begin The drive may • The entries on the nameplate of the drive and/or the output voltage of the frequency only be installed inverter match the voltage supply system •...

  • Page 10: Installing The Motor

    Mechanical Installation Installing the motor Drying the motor Heat up the motor • with hot air or • using an isolation transformer – Connect the windings in series (→ following figure) – Auxiliary AC voltage supply max. 10 % of the rated voltage with max. 20 % of the rated current Transformer 01730AEN...

  • Page 11: Installation Tolerances

    Mechanical Installation Installation tolerances Installation in If possible, arrange the terminal box so the cable entries are pointing downwards. damp locations Coat the threads of cable glands and pocket caps with sealant and tighten them well – or in the open then coat them again.

  • Page 12: Electrical Installation

    The motor must only ever be connected as shown in the wiring diagram included with diagrams the motor. Do not connect or start up the motor if this wiring diagram is missing. You can obtain the valid wiring diagram free of charge from SEW-EURODRIVE. Wiring notes Comply with the safety notes during installation.

  • Page 13: Improving The Grounding (Emc)

    Special aspects of torque motors and low-speed motors Due to the design of torque motors and low-speed motors, very high induction voltages may be generated when they are switched off. Consequently, SEW-EURODRIVE recommends using the varistor circuit shown below for protection. The size of the varis- tors depends, amongst other factors, on the starting frequency –...

  • Page 14: Special Aspects In Switching Operation

    1000 2000 3000 4000 Hazardous Motors must not be subjected to hazardous radiation. Contact SEW-EURODRIVE if radiation necessary. Operating Instructions – AC Motors DR / DV / DT / DTE / DVE / Asynchrounos Servo Motors CT / CV...

  • Page 15: Connecting The Motor

    Electrical Installation Connecting the motor Connecting the motor In case of operation with electronic control units, it is essential to adhere to the corresponding operating instructions / wiring diagrams! Connecting the • According to the circuit diagram provided motor via •...

  • Page 16: Preparing Motor Sizes 56 And 63 - Knockout

    Electrical Installation Preparing motor sizes 56 and 63 – knockout Preparing motor sizes 56 and 63 – knockout Important: Wear safety glasses – danger of injury from fragments! • Put on the terminal box cover and screw it into place •...

  • Page 17: Single-Phase Version Et56

    Electrical Installation Single-phase version ET56 5.11 Single-phase version ET56 The ET56 single-phase motor is supplied with a running capacitor that is mounted and connected: = 4 µF 1~230 V, 50 Hz = 4 µF 1~230 V, 60 Hz = 20 µF 1~110 V, 60 Hz No full-load startup is possible with the running capacitor alone! The single- phase motor cannot be combined with a TF.
  • Page 18 Electrical Installation Connecting the motor using the IS plug connector Wiring the upper • Loosen the housing cover screws section of the – Remove the housing cover plug connection • Remove the screws from the upper section of the plug connector –...
  • Page 19 Electrical Installation Connecting the motor using the IS plug connector Brake control operation: system BSR – On the side of the variable terminal link as shown in the following figure: Remove only preparing the the bare metal pin of the marked prong horizontally – touch guard! variable terminal link 50429AXX...
  • Page 20 Electrical Installation Connecting the motor using the IS plug connector Installing the plug The housing cover of the IS plug connector can be screwed onto the lower section of connector the plug connector depending on the required position of the cable lead. The upper section of the plug connector shown in the following figure must first be installed in the housing cover so it will match the position of the lower section of the plug connector: •...

  • Page 21: Connect The Motor Using Plug Connectors Ab.., Ad.., Am.., As

    (version 1.1). Switchgear or control units which also have to be certified can be certified connected to SEW-EURODRIVE motors using a pre-fabricated system cable or a carri- er plate (installation integrated in the motor → Fig. B). The ASK1 plug connector with single-clip locking is mounted on the side of the terminal box and is supplied from the Operating Instructions –...
  • Page 22 • For installation integrated in the motor according to the ECOFAST specifica- tion, the customer must obtain the carrier plate from SEW-EURODRIVE by quoting part number 0187 390 3. Carrier plates from other manufacturers do not fit on SEW-EURODRIVE motors.

  • Page 23: Connecting The Brake

    Electrical Installation Connecting the brake 5.15 Connecting the brake The brake is released electrically. The brake is applied mechanically when the voltage is switched off. Comply with the applicable regulations issued by the relevant employer's liability insurance association regarding phase failure protection and the associated circuit/circuit modification! •...

  • Page 24: Accessory Equipment

    Electrical Installation Accessory equipment 5.16 Accessory equipment Connect supplied accessory equipment according to the wiring diagrams included. TF temperature sensor Do not apply voltage! The positive temperature coefficient (PTC) thermistors comply with DIN 44082. Resistance measurement (measuring instrument with V ≤ 2.5 V or I < 1 mA): Standard measured values: 20...500 Ω, thermal resistance >...
  • Page 25 Electrical Installation Accessory equipment VR system ± 20 % • 24 V • Plug connector • Max. connection cross section 3x1 mm • Pg7 cable gland with 7 mm inside diamater The VR forced cooling fan is available for 24 V DC voltage and for 100 ... 240 V AC voltage.
  • Page 26 Electrical Installation Accessory equipment Motor size 132M - 280 V system • 3 x 400 V , 50 Hz • Connection in separate terminal box • Max. connection cross section 4 x 1.5 mm • Cable gland M16x1.5 Refer to the V wiring diagram for information about connecting the V system (order number: 0975 8385).
  • Page 27 Electrical Installation Accessory equipment • Refer to the following wiring diagrams for information about connecting ES1./ES2./EV1./EH1. encoders and AV1Y and AV1H absolute encoders: • Wiring diagrams for ES1./ES2./EV1./EH1. encoders: Order number 0918 6832 • Wiring diagram AV1Y absolute encoder: Order number 0918 6808 •...

  • Page 28: Startup

    Startup Prerequisites for startup Startup Prerequisites for startup It is essential to comply with the safety notes in Sec. 2 during startup! Before startup, • The drive is undamaged and not blocked make sure that • The measures stipulated in the "Preliminary work" section are performed after extended storage •...

  • Page 29: Altering The Blocking Direction On Motors With A Backstop

    Startup Altering the blocking direction on motors with a backstop Altering the blocking direction on motors with a backstop 50447AXX [1] Fan guard [5] Felt ring [9] Wedge element train [2] Fan [6] Circlip [10] Equalizing ring [3] Hexagon socket head cap [7] Threaded hole screw [8] Carrier...
  • Page 30 Startup Altering the blocking direction on motors with a backstop Do not start up the motor in the blocking direction (note the phase angle when connecting). Note the direction of rotation of the output shaft and the number of stages when mounting the motor on a gear unit.

  • Page 31: Malfunctions

    Malfunctions Motor Malfunctions Malfunctions Motor Malfunctions Problem Possible cause Remedy Motor does not start up Interruption in connecting harness Check connections, correct if necessary → Sec. "Brake Problems" Brake does not release Fuse blown Replace fuse Motor protection has tripped Check motor protection for correct setting, correct error if necessary.

  • Page 32: Brake Problems

    Malfunctions Brake problems Brake problems Problem Possible cause Remedy Brake does not release Incorrect voltage on brake control unit Apply correct voltage Brake control unit failed Install a new brake control system, check internal resis- tance and insulation of brake coil, check switchgear Max.

  • Page 33: Inspection / Maintenance

    Inspection / Maintenance Inspection and maintenance intervals Inspection / Maintenance • Use only genuine spare parts in accordance with the valid parts list! • Always install a new brake control system at the same time as replacing the brake coil! •...

  • Page 34: Preliminary Work For Motor And Brake Maintenance

    Inspection / Maintenance Preliminary work for motor and brake maintenance Preliminary work for motor and brake maintenance Isolate the motor and brake from the power supply before starting work, safeguarding them against unintentional power-up! Removing the EV1. incremental encoder / AV1H absolute encoder 369 251 232 EV1.
  • Page 35 Inspection / Maintenance Preliminary work for motor and brake maintenance Incremental encoder ES1. Removing / ES2. / EH1. 54196AXX [220] Encoder [361] Protective canopy [367] Retaining screw [733] Retaining screw for torque arm • Remove the protective canopy [361]. • Unscrew the retaining screws [733] for the torque arm.
  • Page 36 Inspection / Maintenance Preliminary work for motor and brake maintenance Removing the proximity sensor NV1. / NV2. 01114CXX Caution! It is essential for the fan wheel to be stationary! • Disconnect plug • Pull off the fan guard including NV1. / NV2. Do not tilt it, in order to avoid damaging the proximity switch.

  • Page 37: Inspection / Maintenance On The Motor

    Inspection / Maintenance Inspection / maintenance on the motor Inspection / maintenance on the motor Example: Motor DFT90 11 12 54008AXX 1 Circlip 8 Circlip 16 V-ring 2 Oil-flinger ring 9 Rotor 17 Fan 3 Oil seal 11 Ball bearing 18 Circlip 4 Screw plug 12 Equalizing ring...
  • Page 38 Inspection / Maintenance Inspection / maintenance on the motor Sequence Isolate the motor and brake from the supply, safeguarding them against uninten- tional power-up! 1. Remove the forced cooling fan and encoder, if installed (→ Sec. "Preliminary work for motor and brake maintenance") 2.

  • Page 39: Inspection / Maintenance Of The Bmg02 Brake

    Inspection / Maintenance Inspection / maintenance of the BMG02 brake Inspection / maintenance of the BMG02 brake Measure the The status of the brake disk is ascertained by measuring the brake disk thickness. Install brake disk a new BMG02 brake once the brake disk thickness reaches the minimum value (→ fig- thickness, install ure below).

  • Page 40: Inspection / Maintenance Of The Brake Br03

    Inspection / Maintenance Inspection / maintenance of the brake BR03 Inspection / maintenance of the brake BR03 50067AXX 1 Carrier 7 Brake disk 13 Hand lever 2 Clip 8 Pressure plate with stud 14 Releasing lever 3 Circlip 9 Damping plate 15 Sealing washer 4 Friction plate 10 Brake springs...
  • Page 41 Inspection / Maintenance Inspection / maintenance of the brake BR03 Inspect brake The working air gap cannot be adjusted and can only be measured by means of the BR03, measure stroke of the pressure plate when the brake is released. the working air 1.
  • Page 42 Inspection / Maintenance Inspection / maintenance of the brake BR03 8. Reassemble the removed parts. Connect the complete new brake (replaced if the working air gap ≥ 0.8 mm) to the motor (→ following figure) – Make sure the gearing of the brake disk engages in the gearing of the carrier and that the plug on the motor end fits into the socket on the brake end.
  • Page 43 Inspection / Maintenance Inspection / maintenance of the brake BR03 11.Design with manual brake release: – Put on the conical coil springs [17] and releasing lever [14], install the self locking counter nuts [16] – With manual brake release: Use setting nuts to set the floating clearance "s" between the conical coil springs (pressed flat) and the setting nuts (→...

  • Page 44: Inspection / Maintenance For Bmg05-8, Bm15-62 Brakes

    Inspection / Maintenance Inspection / maintenance for BMG05-8, BM15-62 brakes Inspection / maintenance for BMG05-8, BM15-62 brakes BM(G)05-08 brakes 12 13 01955AXX Motor with brake bearing end shield 10a Stud (3 pcs.) 15 Release lever with hand lever Carrier 10b Counter spring 16 Stud (2 pcs.) Circlip 10c Pressure ring...
  • Page 45 Inspection / Maintenance Inspection / maintenance for BMG05-8, BM15-62 brakes BM15-62 brake 01956AXX Motor with brake bearing end shield Pressure plate 14 Dowel pin Carrier Damping plate (BMG only) 15 Release lever with hand lever Circlip 10a Stud (3 pcs.) 16 Stud (2 pcs.) Niro disk (BMG only) 10b Counter spring...
  • Page 46 Inspection / Maintenance Inspection / maintenance for BMG05-8, BM15-62 brakes BMG05-8, BM15-62 brakes, set the working air gap 1. Isolate the motor and brake from the supply, safeguarding them against unintentional power-up. 2. Remove the following: – If installed, forced cooling fan, tacho/encoder (→ Sec. "Preliminary work for motor and brake maintenance") –...
  • Page 47 Inspection / Maintenance Inspection / maintenance for BMG05-8, BM15-62 brakes Changing the BMG05-8, BM15-62 brake discs When fitting a new brake disk (in BMG05-4 ≤ 9 mm; in BMG62 ≤ 10 mm) inspect the other removed parts as well and install new ones if necessary. 1.
  • Page 48 Inspection / Maintenance Inspection / maintenance for BMG05-8, BM15-62 brakes Change braking The braking torque can be changed in steps (→ Sec. "Technical Data") torque of BMG05- • by installing different brake springs 8, BM15-62 • by changing the number of brake springs •...

  • Page 49: Inspection / Maintenance Of The Bmg61/122 Brake

    Inspection / maintenance of the BMG61/122 brake Inspection / maintenance of the BMG61/122 brake BMG61/122 brakes with encoder mounting are only used as a holding brake. Maintenance work is only allowed to be performed by SEW-EURODRIVE. BMG61/122 brakes 54318AXX Brake end shield...
  • Page 50 Inspection / Maintenance Inspection / maintenance of the BMG61/122 brake BMG61/122 brake without encoder mounting, set the working air gap 1. Isolate the motor and brake from the supply, safeguarding them against unintentional power-up. 2. Remove the following: – Remove the forced cooling fan, if installed (→ Sec. "Preliminary work for motor and brake maintenance") –...
  • Page 51 Inspection / Maintenance Inspection / maintenance of the BMG61/122 brake BMG 61/122 brake without encoder mounting, change the brake disc When fitting a new brake disk (≤ 12 mm), inspect the other removed parts as well and install new ones if necessary. 1.

  • Page 52: Technical Data

    Technical Data Work done, braking torque BMG02 Technical Data Work done, braking torque BMG02 Brake For motor size Work done until Thickness of brake Braking torque Type maintenance disk [mm] max. [Nm] DT56 BMG02 ET56 Information for ordering a replacement BMG02 Brake Voltage Braking torque...

  • Page 53: Work Done, Working Air Gap, Braking Torques Of Bmg05-8, Br03

    Technical Data Work done, working air gap, braking torques of BMG05-8, BR03, BC, Bd Work done, working air gap, braking torques of BMG05-8, BR03, BC, Bd Brake Work done Working air gap Braking torque settings type until motor [mm] Braking Type and no.

  • Page 54: Work Done, Working Air Gap, Braking Torques Of Bm15 - 62

    Technical Data Work done, working air gap, braking torques of BM15 - 62 Work done, working air gap, braking torques of BM15 - 62 Brake Work done Working air gap Braking torque settings type until motor [mm] Braking Type and no. of Order number of maintenanc size...

  • Page 55: Operating Currents

    Technical Data Operating currents Operating currents The current values I (holding current) specified in the tables are r.m.s. values. Use only units to measure the r.m.s. values. The inrush current (acceleration current) I only flows for a short time (max. 120 ms) when the brake is released or during voltage dips below 70 % of rated voltage.
  • Page 56 Technical Data Operating currents BMG 05 - BMG 4 brake BMG05 BMG1 BMG2 BMG4 Motor size 71/80 90/100 Max. braking torque [Nm] Braking power [W] Inrush current ratio I Rated voltage V BMG05 BMG 1 BMG 2 BMG 4 1.38 1.54 1.77 2.20...
  • Page 57 Technical Data Operating currents BMG 8 - BM 32/62 brake BMG8 BM 15 BM30/31; BM32/62 Motor size 112/ 132S 132M-160M 160L-225 Max. braking torque [Nm] Braking power [W] Inrush current ratio I Rated voltage V BMG8 BM 15 BM 30/31; BM 32/62 2.77 4.15 4.00...
  • Page 58 Technical Data Operating currents BMG61, BMG122 brake BMG61 BMG122 Motor size 250M...280S Max. braking torque [Nm] 1200 Braking power [W] Inrush current ratio I Rated voltage V BMG61/122 208 (194-217) 1.50 230 (218-243) 1.35 254 (244-273) 1.20 290 (274-306) 1.10 318 (307-343) 1.00 360 (344-379)

  • Page 59: Permitted Ball Bearing Types

    Technical Data Permitted ball bearing types Permitted ball bearing types Drive-end bearing Non drive-end bearing (AC motor, brakemotor) (foot-mounted, flange-mounted, gearmotors) Motor type Flange- Gearmotor Foot- AC motor Brake motor mounted motor mounted motor DT56 6302-2Z-J 6001-2RS-J 6001-2RS-J DFR63 6203-2Z-J 6303-2Z-J 6202-2Z-J 6202-2RS-J-C3...

  • Page 60: Appendix

    Appendix Appendix 10.1 Index of changes The following additions and changes have been made since the last edition of the "DR/ DV/DT/DTE/DVE AC Motors, CT/CV Asynchronous Servomotors" operating instruc- tions (publication number: 10567917, Edition 02/2003): General updates and revisions. Motor design •...

  • Page 61: Index

    Index 10.2 Index Extended storage of motors ........9 Absolute encoder, removal ........34 Forced cooling fan..........24 Altering the blocking direction ......29 V ..............26 AM................21 VR..............25 Ambient temperature..........14 VS ..............24 Anti-friction bearings for motors ......59 Frequency inverter ..........12 AS ................21 ASK1 ..............21 Gas..............
  • Page 62 Index Working air gap Operating currents ..........55 BM15-62, BMG61/122 ........54 BM02, BR03 ..........55 BMG05-8, BC, Bd ......... 53 BMG05 - BMG4 ..........56 BMG61, BMG122 ..........58 BMG8 - BMG32/62 ........57 Operation with Frequency inverter .......12 Overivew of encoders ..........26 Permitted ball bearing types.........59 Plug connector AM ..............21 AS..............21...
  • Page 63 Address List Address List Germany Headquarters Bruchsal SEW-EURODRIVE GmbH & Co KG Tel. +49 7251 75-0 Production Ernst-Blickle-Straße 42 Fax +49 7251 75-1970 Sales D-76646 Bruchsal http://www.sew-eurodrive.de P.O. Box sew@sew-eurodrive.de Postfach 3023 · D-76642 Bruchsal Service Central SEW-EURODRIVE GmbH & Co KG Tel.
  • Page 64 Electro-Services Tel. +237 4322-99 Rue Drouot Akwa Fax +237 4277-03 B.P. 2024 Douala Canada Assembly Toronto SEW-EURODRIVE CO. OF CANADA LTD. Tel. +1 905 791-1553 Sales 210 Walker Drive Fax +1 905 791-2999 Service Bramalea, Ontario L6T3W1 http://www.sew-eurodrive.ca l.reynolds@sew-eurodrive.ca Vancouver SEW-EURODRIVE CO.
  • Page 65 Address List China Assembly Suzhou SEW-EURODRIVE (Suzhou) Co., Ltd. Tel. +86 512 62581781 Sales 333, Suhong Middle Road Fax +86 512 62581783 Service Suzhou Industrial Park suzhou@sew.com.cn Jiangsu Province, 215021 P. R. China Colombia Assembly Bogotá SEW-EURODRIVE COLOMBIA LTDA. Tel. +57 1 54750-50 Sales Calle 22 No.
  • Page 66 Tel. +972 3 5599511 Ahofer Str 34B / 228 Fax +972 3 5599512 58858 Holon lirazhandasa@barak-online.net Italy Assembly Milano SEW-EURODRIVE di R. Blickle & Co.s.a.s. Tel. +39 2 96 9801 Sales Via Bernini,14 Fax +39 2 96 799781 Service I-20020 Solaro (Milano) sewit@sew-eurodrive.it...
  • Page 67 Service NL-3044 AS Rotterdam http://www.vector.nu Postbus 10085 info@vector.nu NL-3004 AB Rotterdam New Zealand Assembly Auckland SEW-EURODRIVE NEW ZEALAND LTD. Tel. +64 9 2745627 Sales P.O. Box 58-428 Fax +64 9 2740165 Service 82 Greenmount drive sales@sew-eurodrive.co.nz East Tamaki Auckland Christchurch SEW-EURODRIVE NEW ZEALAND LTD.
  • Page 68 Tel. +381 11 3046677 Kajmakcalanska 54 Fax +381 11 3809380 SCG-11000 Beograd dipar@yubc.net Singapore Assembly Singapore SEW-EURODRIVE PTE. LTD. Tel. +65 68621701 ... 1705 Sales No 9, Tuas Drive 2 Fax +65 68612827 Service Jurong Industrial Estate sales@sew-eurodrive.com.sg Singapore 638644...
  • Page 69 Jurastrasse 10 Fax +41 61 41717-00 Service CH-4142 Münchenstein bei Basel http://www.imhof-sew.ch info@imhof-sew.ch Thailand Assembly Chon Buri SEW-EURODRIVE (Thailand) Ltd. Tel. +66 38 454281 Sales Bangpakong Industrial Park 2 Fax +66 38 454288 Service 700/456, Moo.7, Tambol Donhuaroh sewthailand@sew-eurodrive.co.th Muang District...
  • Page 72 Internet, available Anywhere. today. around the clock. SEW-EURODRIVE GmbH & Co KG P.O. Box 3023 · D-76642 Bruchsal / Germany Phone +49 7251 75-0 · Fax +49 7251 75-1970 sew@sew-eurodrive.com → www.sew-eurodrive.com...

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