Baumuller DSC Series, Commissioning And Maintenance Instructions

Page 1: ...TAM 00682 1 DSC 045 100 07 2012 Three phase synchronous motor English TAM 00682 DSC 045 100 Three phase synchronous motor Version 07 2012 English Commissioning and Maintenance Instructions ...

Page 2: ... on this documentation together with the unit machine Following the sale of the unit machine this original and all copies are to be passed on to the purchaser Following disposal or any other form of termination of utilization this original and all copies are to be destroyed With the introduction of this documentation corresponding documentation with earlier issue dates is superseded Please note th...

Page 3: ...ex 1 pole assignment main connection and control port 20 8 1 Main connection via plug 20 8 2 Main connection via the terminal box Standard design acc to catalogue 20 8 3 Main connection via the terminal box customer specific design acc to EN 60034 non UL approved 21 8 4 Main and control connection via combination mounting box customer specific design 22 8 5 Fan connection 23 8 6 Control port Resol...

Page 4: ... your attention to the following hazards when using the product Hazards resulting from Lifting and transport Electrical power Moving parts Hot surfaces EMC interference Mechanical overload Thermal overload To avoid damage to persons and property and to minimize residual risks please read all of the safety instructions and in particular those that are marked with a symbol Risk of fatality due to el...

Page 5: ...he electric motor in accordance with its designated use must comply with the safety requirements in the EMC Directive EC The proper installation e g separation of signal lines and power cables screened lines and cables etc is the responsibility of the erector of the installation and the system provider During converter operation the EMC information of the converter encoder and brake manufacturer m...

Page 6: ...ations and changes to the electric motor are not permitted If such modifications changes are necessary please contact the motor manufacturer No safety devices may be dismantled or decommissioned when operating the electric motor 2 Operating conditions 2 1 Product description With its new DSC 45 100 series Baumüller is making the torque motor servo ready In developing this series the focus was on i...

Page 7: ...ur motor Figure 1 Nameplate 1 Motor number 2 Standards and approbation 3 Motor type designation 4 Motor protection class 5 Heat category class of insulation VDE 6 Motor is powered with converter 7 optional Supply voltage of the brakes DC 8 Motor type 3 phase motor 9 Permitted ambient temperature 10 Rated frequency 11 Isolation system UL 12 Motor operating type 13 Rated voltage UN 14 Standstill tor...

Page 8: ...on and fully closed terminal box Cooling process EN 60034 6 IC 410 Standard completely enclosed motor design self cooling without fan IC 416 Option from shaft height 56 completely enclosed motor surface cooled with fan air flow direction from NDE to DE IC 3W7 Option from shaft height 71 completely enclosed motor water cooled Cooling circuit connections towards NDE non drive end Electrical connecti...

Page 9: ...not a standard type as per the technical list or if special contractual arrangements have been made there may technical differences to the information contained in these Commissioning and Maintenance Instructions In this case request the relevant technical supplements 2 5 Transport intermediate storage Water cooled motors To avoid frost damage it must be ensured that there is no coolant in the mot...

Page 10: ...te and therefore have a negative impact on the service life even before the unit has been commissioned Direct exposure to incident solar radiation UV light and ozone also lead to an ageing of the gaskets and must be avoided Please note that the warranty periods commence from the date of delivery For this reason we recommend that storage periods be kept to a minimum Should nevertheless a longer sto...

Page 11: ... This information provides minimum values for the safe heat dissipation via the motor flange surfaces Axis height Steel plate width x height x thickness in mm Mounting surface in m2 45 250 x 250 x 10 0 06 56 100 450 x 400 x 30 0 18 Table 1 Mounting surfaces The heat dissipation conditions approve on larger mounting surfaces An insulated mounting of the motors is not permitted 2 7 Balancing output ...

Page 12: ...end of the shaft used for axial securing of output elements e g belt pulley the maximum tightening torque acc to following table 2 must not be exceeded thread tightening torque in Nm M5 2 2 M8 10 0 M10 19 0 M12 33 0 Table 2 Tightening torque for safety screw S of a belt pulley appropriate measures for securing screw must be applied Vibration The site vibration response of the system which is deter...

Page 13: ...is designed for the ambient conditions and environmental influences on site see Sect 2 4 The compartment in the machine is suitable for the cooling method employed for the electric motor The motor is to be installed in such a way that heat can be adequately dissipated via the housing surface and via the motor flange surface refer to Sect 2 6 The motor can be mounted and operated with the fastening...

Page 14: ...ric motor must be operated via a correspondingly designed converter A direct connection to the three phase mains can destroy the motor Ensure that the phase sequence and the pin assignment are correct Electrical connections protective conductor connections and screen connections when using screened cables must be permanently secure Never touch the contacts of the encoder or thermal sensors with yo...

Page 15: ...the electric motor Work must not be carried out on the electric motor until the motor has come to a standstill is electrically isolated and has cooled down All connections such as screw connections that were loosened when working on the motor must be tightened again prior to commissioning When carrying out work on the motor please observe the technical instructions and notes in the respective sect...

Page 16: ...been checked 5 3 Commissioning operation Note on brake function if present The brake is designed as a holding brake with an emergency stop function power failure emergency stop It must not be used as a working brake Commissioning must be carried out exclusively by qualified personnel Please refer to the commissioning instructions for the converter Checks during commissioning Release the brake if n...

Page 17: ... converter If necessary contact the manufacturer of the motor or converter Have the following information ready nameplate data type and scope of malfunction circumstances leading up to the malfuntion application data torque cycle speed and forces over time ambient conditions The following selection of possible causes can be helpful in the fault rectification process Malfunction Cause Remedy Motor ...

Page 18: ... motor has come to a standstill is electrically isolated and has cooled down All connections such as screw connections that were loosened when working on the motor must be tightened again after the inspection and maintenance work When carrying out work on the motor please observe the technical instructions and notes in the respective sections in these Commissioning and Maintenance Instructions Whe...

Page 19: ...proximately 5 000 running hours if present and if no leaks have been detected during previous inspections If an optional brake is fitted it is essential that it is replaced when its wear limits are reached Maintenance work must be carried out by Baumüller or a specialist company commissioned by Baumüller Caution It is imperative on motors that are used for safety related applications to heed the t...

Page 20: ...l sensor and brake Note If the thermal sensor is routed via the encoder channel signals K and K are omitted from the wiring diagrams above 8 2 Main connection via the terminal box Standard design acc to catalogue Use during standstill current I0 36 A Figure 3 pole assignment with thermal sensor and brake Table 4 shows the cable leads of the terminal boxes and the main connector pin assignment toge...

Page 21: ...Terminal box size 56 71 100 Figure 4 pole assignment special variant Table 5 shows the cable leads of the terminal boxes and the main connector pin assignment together with the permissible torque specification On the connections for the cable leads we recommend the use of EMC connectors When tightening the terminal screws it is recommended to hold against the conductor to keep the terminal board f...

Page 22: ... motors not turnable Figure 5 pole assignment of the combination mounting box Outside section Pin B to A shows the pole assignment for the power terminal and PE brake Inside section Pin 1 to 12 shows the pole assignment for resolver and thermal sensor Pin 1 2 3 4 5 6 Signal Sin 1 Sin 2 shield Colour LTN yellow blue Pin 7 8 9 10 11 12 Signal Ref 1 K K Ref 1 Cos 1 Cos 2 Colour LTN black white yellow...

Page 23: ...re 6 pole assignment of the fan 8 6 Control port Resolver Pin Signal Option for allocation KTY on encoder socket View of the contact side of the built in box 1 2 3 4 5 6 7 8 9 10 11 12 cos sin sin cos Ref Ref cos sin sin K cos K Ref Ref Figure 7 pole assignment resolver contactside mounting box ...

Page 24: ...4 5 6 7 8 9 10 11 12 ref cos 485 sin ref sin 485 cos Gnd U ref cos 485 K K sin ref sin 485 cos Gnd U Figure 8 pole assignment SRS SRM 50 8 8 Control port SEK SEL 52 encoder with Hiperface port from SICK Stegmann companies Pin Signal Option for allocation KTY on encoder socket View of the contact side of the built in box 1 2 3 4 5 6 7 8 9 10 11 12 ref cos 485 sin ref sin 485 cos Gnd U ref cos 485 K...

Page 25: ...ock inv 0 V B B Data A A Data inv Figure 10 pole assignment ECN 1313 EQN 1325 8 10 Control port ECN 1325 EQN 1337 M23 encoder with EnDat 2 2 port from Heidenhain companies Pin Signal 5 6 8 7 2 3 9 4 1 View of the contact side of the built in box M23 1 2 3 4 5 6 7 8 9 Clock Clock inv Up 0 V Data Data inv Sensor Up Sensor 0 V Figure 11 pole assignment ECN 1325 EQN 1337 M23 Note For other encoder typ...

Page 26: ...nd outlet on the NDE are supplied as standard with a stainless steel tube Ø8 x 1 without extra termination systems The coolant in accordance with the coolant properties specified in Section 9 6 is permitted to contain corrosion inhibitors and anti bacterial additives The type and volume of these additives is based on the respective manufacturer s recommendations and the prevailing ambient conditio...

Page 27: ...l box Leak test acc to EN 50178 The cooling system is to be checked for leaks before commissioning by pressure testing with coolant water The test pressure must be twice the operating pressure minimum test pressure 1 bar The coolant used does not have to be brought to operating temperature for this purpose Pressure must be maintained until all areas have been tested for leaks minimum test duration...

Page 28: ...rature against ambient temperature and humidity 25 rel humidity 35 rel humidity 45 rel hum idity 55 rel hum idity 65 rel hum idity 75 rel hum idity 85 rel hum idity 10 15 20 25 30 35 40 0 5 10 15 20 25 30 35 40 ambient temperature C min coolant temperature C Figure 12 Determination of the coolant temperature The allowed coolant temperature depends on relative humidity and ambient temperature For e...

Page 29: ...ll coolant should be discharged as a precaution to prevent frost damage Figure 13 Flow chart coolant temperature Start Definition rel humidity Definition of min coolant temperature Section 1 3 2 Twater Tambience 5K Twater Tmin water Section 1 3 2 Derating referred to section 1 2 2 No restrictions 2 point controller Ton 70 C Toff 50 C Twater 25 C Twater 25 C No restrictions Twater 25 C No restricti...

Page 30: ...ternal cooling system Check and switch on if necessary Check water circuit Check and clean if necessary Follow plant supplier s instructions Overpressure in the cooling system Heavily soiled coolant Cooling channels blocked Malfunctions in the external cooling system Filter coolant Check and if necessary clean Follow plant supplier s instructions Table 9 Malfunctions water cooling 9 9 Inspection D...

Page 31: ...el overloaded the system operated the unit with faulty safety devices safety devices that were incorrectly fitted or not fitted safety devices or protective devices not in proper working order not operated the system in the stipulated ambient conditions You have modified the system without the written approval of Baumüller Nürnberg GmbH You have not observed the instructions concerning maintenance...