Baumuller DSD2 Series, Commissioning And Maintenance Instructions

Page 1: ...TAM 00699 1 DSD2 045 132 04 2018 Three phase synchronous motor English TAM 00699 DSD2 045 132 Three phase synchronous motor Version 04 2018 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are to be destroyed With the introduction of this documentation corresponding documentation with earlier issue dates is superseded Please note th...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: ...d Control terminal 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 22 8 4 Main and control connection via combination mounting box customer specific design 23 8 5 Fan cooling fan connections via connection socket or terminal box 24 8 6 Co...

Page 4: ...on 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 Please read all the safety instructions and in particular those which are marked with a symbol to avoid injury to people and damage to property and to minimize residual risks Risk of fatality due to electric...

Page 5: ...the conformity of the finished product with this directive has been established refer to EN 60204 1 Electrical Equipment of Machines EU EMC Directive When the electric motor is used as intended its operation must comply with the safety requirements laid down in the EMC Directive 2014 30 EU Proper installation e g physical isolation of signal and power cables shielded wiring and cable etc is the re...

Page 6: ...ons unauthorized modifications 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 The DSD2 series electric motors are 8 pole three phase synchronous motors with rare earth magnets Th...

Page 7: ...te from your motor Type plate data Figure 1 Type plate 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 v...

Page 8: ...with terminal box size 45 100 IP 54 size 132 Caution All specified protection classes are only achieved in the event of completely assembled plug connectors mains and control connections and fully closed terminal box Cooling method EN 60034 6 IC 410 Standard completely enclosed motor design surface cooled no fan size 45 100 IC 416 Optional from shaft height 56 completely enclosed motor design surf...

Page 9: ...ention If the electric motor supplied is not a standard type as per the technical documentation or if special contractual arrangements have been made there may be technical differences to these Commissioning and Maintenance Instructions In this case request the related technical supplements 2 5 Transport bearing lock intermediate storage Water cooled motors To avoid frost damages it must be ensure...

Page 10: ...mmissioned 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 are kept to a minimum Should nevertheless a longer storage be necessary the environmental conditions acc to DIN EN 60721 3 1 class 1K2 1M1 have t...

Page 11: ...nting surface based on their axis height are listed in table 1 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 m 2 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 insulate...

Page 12: ... 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 M16 80 0 M20 160 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 w...

Page 13: ...designed for the ambient conditions and environmental influences on site comp Section 2 4 the mounting space in the machine is suitable for the cooling method employed for the electric motor The motor has to mounted in such a way as to guarantee sufficient waste heat removal via the housing and motor flange surfaces during air cooling the incoming air and the outgoing air must be able to flow free...

Page 14: ...lectrical plants must be observed Attention The safety regulations for work on electrotechnical systems in accordance with EN 50110 1 must be followed Isolate Secure against unintentional restarting Verify safe isolation from the supply Earthing and short circuiting Safeguard or cover adjacent live parts The electric motor must be operated by a correspondingly designed converter A direct connectio...

Page 15: ... 8 2 table 4 8 3 table 5 the protection type is maintained Note All lead ins that are not used must be closed off with the sealing caps The sealing elements must be fully functional and undamaged when closing the terminal box 5 Commissioning operation 5 1 Safety instructions Working on the electric motor Work must not be carried out on the electric motor until the motor has come to a standstill an...

Page 16: ...n made correctly The protective conductor system is correct and its functionality has been checked The cables are not in contact with the surface of the motor The drive is not blocked release brake if present Emergency stop functions have been checked Fan is connected properly and its function has been checked 5 3 Commissioning operation Notes on the brake function if present The brake is designed...

Page 17: ...en electrically isolated and secured Observe the 5 safety rules for Isolation see Section 4 Beware of hot surfaces In case of malfunctions in operation always Refer to the operating instructions for the machine system Refer to the operating instructions for the converter If necessary contact the manufacturer of the motor or converter Have the following information ready Type plate data Type and sc...

Page 18: ...te Clean motor surface airways Check and clean or replace if required Check motor has been installed in acc with Sections 2 6 and 3 Have repaired by the motor manufacturer Current consumption too high motor torque too low Indexing angle incorrect Check indexing angle and adjust if necessary Table 3 Malfunctions 6 Inspection and maintenance Working on the electric motor Work must not be carried out...

Page 19: ... reached The maintenance work is to be undertaken by Baumüller or a specialist organization authorized by Baumüller The independent maintenance works of an operator are the following The cleaning of the motor surfaces and of the air channels The replacement or cleaning of the filter mats when using dust filters as at motor size 132 Dust filters should generally be cleaned or replaced after 100 ope...

Page 20: ...e standstill current I0 of the motor determines the size of the built in box Size 1 I0 to 20 A Size 1 5 I0 to 36 A Figure 2 Main connection with thermal sensor and brake Note If the temperature sensor is wired ideally via the encoder cable then the signals K and K are omitted in the above diagrams 8 2 Main connection via the terminal box Standard design acc to catalogue Use during standstill curre...

Page 21: ...e 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 free from torsion forces Terminal box size Cable entries Number of main connection terminals Terminal torques in Nm 156 1 x M40 1 x M25 3 x M6 3 0 196 1 x M50 1 x M25 3 x M8 6 ...

Page 22: ...ogether 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 free from torsion forces Terminal box size Cable leads Number of main connection terminals Torques for terminals in Nm 56 1 x M20 1 x M16 3 x M4 1 2 1 x M25 1 x ...

Page 23: ...e 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 yello...

Page 24: ... terminal box 24V DC Variante 115V AC Variante 230V AC Variante Figure 6A Pole assignment fan connection via a plug fan at the sizes 56 to 100 Figure 6B Terminal assignment fan connection via the terminal box fan motor at the size 132 Figure 6C Pole assignment fan connection via connector axially integrated fan at a size of 132 ...

Page 25: ...os sin sin cos ref ref cos sin sin K or R2 cos K or R1 ref ref Figure 7 pole assignment resolver 8 7 Control terminal SRS SRM 50 absolute value encoder with Hiperface terminal of SICK Stegmann 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 485 sin sin 485 cos GND U cos 485 K or R1 K or R2 Sin sin 485 cos GND U Figu...

Page 26: ... cos 485 K or R1 K or R2 sin sin 485 cos GND U Figure 9 pole assignment SEK SEL 52 8 9 Control terminal ECN 1313 EQN 1325 encoder with EnDat 2 1 port of Heidenhain 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 13 14 15 16 17 Up 0 V Up Clock Clock inv 0 V B B Data A A Data inv Up 0 V K or R1 K or R2 Up Clock Clock inv ...

Page 27: ... lead for the temperature sensor via the encoder cable see the enclosed wiring diagram or technical documentation for the pin assignment The encoder from Section 8 7 to 8 10 are components susceptible to ESD The technical data contains specifications of the encoder manufacturer for which we assume no liability for the correctness 8 11 Brake connection at the size 132 Pole assignment of connector v...

Page 28: ...cally threaded holes G1 2 Wetted materials in the motor Aluminum coated by cathodic dip coating at size 56 diversions are of galvanized steel or brass NBR seals Size 71 and 100 are made of stainless steel Aluminum coated by cathodic dip coating at size 132 connections are of galvanized steel NBR seals The cooling system for water cooled DSD2 motors is made of stainless steel The two water connecti...

Page 29: ...are supposed to be used The coolant pipes should not exert compression tension forces or torsional strain on the motor connections The connection must be made by specially trained personnel During this process the motor must disconnected and electrically isolated When coupling and uncoupling the coolant pipes make sure that coolant does not enter the motor s terminal box Leak test acc to EN 50178 ...

Page 30: ...0 65 7 6 stainless steel tube Ø8 x 1 DSD2 071LO W 5 0 8 8 6 stainless steel tube Ø8 x 1 DSD2 100SO W 5 0 55 8 6 stainless steel tube Ø8 x 1 DSD2 100MO W 5 0 65 9 6 stainless steel tube Ø8 x 1 DSD2 100LO W 5 0 85 10 6 stainless steel tube Ø8 x 1 DSD2 100BO W 5 1 0 12 6 stainless steel tube Ø8 x 1 DSD2 132KO W 15 0 35 3 6 Internal thread G1 2 DSD2 132MO W 15 0 35 4 6 Internal thread G1 2 DSD2 132LO ...

Page 31: ...mm 0 1 Table 8 Coolant consistency Clean water that is free of dirt and suspended matter must be used as a coolant 9 7 Min coolant temperature against ambient temperature and humidity Figure 12 Determination of the coolant temperature The allowed coolant temperature depends on relative humidity and ambient temperature For example with an ambient temperature of 25 C and a relative humidity of 65 th...

Page 32: ...for longer time the cooling must be stopped to avoid condensation If ambient temperatures of 3 C may occur during a longer motor standstill coolant should be discharged as a precaution to prevent frost damage Figure 13 Flow chart coolant temperatur 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...

Page 33: ...xternal cooling system Check and switch on if required Check water circuit Check and clean if required Check and clean if required 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 clean if required Follow plant supplier s instructions Table 9 Malfunctions wate...

Page 34: ...ersonnel overloaded the system operated the system with o faulty safety devices o safety devices that were incorrectly fitted or not fitted o safety devices or protective devices that are not in 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 concer...