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Drehstrommotoren DRS/DRE/DRP / Operating Instructions / 2007-07

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1. BE05 1 BE2 Max braking torque Nm 5 10 20 Braking power W 32 43 Inrush current ratio Ig Iy 4 4 Rated voltage Vp BE05 1 BE2 Vac Vpc Rg Rr Rg Rr 24 23 26 10 0 77 2 35 0 57 1 74 60 57 63 24 4 85 14 8 3 60 11 0 120 111 123 48 19 4 59 0 14 4 44 0 184 174 193 80 48 5 148 36 0 111 208 194 217 90 61 0 187 45 5 139 230 218 243 96 77 0 125 58 0 174 254 244 273 110 97 0 295 72 0 220 290 274 306 125 122 370 91 275 330 307 343 140 154 470 115 350 360 344 379 160 194 590 144 440 400 380 431 180 245 740 182 550 460 432 484 200 310 940 230 690 500 485 542 220 385 1180 290 870 575 543 600 250 490 1480 365 1100 8 4 2 Brake BE5 BE11 BE20 BE5 BE11 BE20 Max braking torque Nm 55 110 200 Braking power W 49 77 100 Inrush current ratio Ip ly 5 7 6 6 7 Rated voltage Vp BES BE11 BE20 Vac Voc Rg Rr Rg Rr Rg Rr 60 57 63 24 2 20 10 5 1 20 7 6 0 8 5 0 120 111 123 48 8 70 42 0 4 75 30 5 3 4 20 0 184 174 193 80 22 0 105 12 0 76 0 8 5 50 4 208 194 217 90 27 5 132 15 1 96 10 6 63 5 230 218 243 96 34 5 166 19 0 121 13 4 79 9 254 244 273 110 43 5 210 24 0 152 16 9 100 6 290 274 306 125 55 0 265 30 0 191 21 2 126 6 330 307 343 140 69 0 330 38 0 240 26 7 159 4 360 344 379 160 87 0 420 4T 5 305 33 7 200 7 400 380 431 180 110 530 60 380 42 4 252 7 460 432 484 200 138 660 76 480 53 3 318 1 500 485 542 220
2. 5 9 5 Encoder connection When connecting encoders to inverters always follow the operating instructions for the relevant inverter Maximum line length inverter encoder 100 m with a capacitance per unit length lt 120 nF km e Core cross section 0 20 0 5 mm Use shielded cable with twisted pair conductors and apply shield over large area on both ends Tothe connection cover of the encoder in the cable gland or in the encoder plug Tothe inverter on the electronics shield clamp or to the housing of the sub D plug Install the encoder cables separately from the power cables maintaining a distance of at least 200 mm 28 Operating Instructions AC Motors DRS DRE DRP Startup 6 Prerequisites for startup 6 Startup 6 1 Prerequisites for startup NOTE e Itis essential to observe the safety notes in section 2 page 6 during installation n case of problems refer to the section Malfunctions page 89 6 1 1 Before startup make sure that The drive is undamaged and not blocked The measures stipulated in section Preliminary work page 13 are performed after extended storage periods All connections have been made properly The direction of rotation of the motor gearmotor is correct motor rotating clockwise U V W to L1 L2 L3 All protective covers have been installed correctly All motor protection equipment is active and set for th
3. 1 Terminal link 4 Terminal board 2 Terminal stud 5 Customer connection 3 Hexagon nut with flange 6 Customer connection with split connection cable NOTE The terminal box must be free of foreign objects dirt and humidity Unused cable entry openings and the terminal box itself must be closed so they are dust and water proof Operating Instructions AC Motors DRS DRE DRP Electrical Installation Connecting the motor 5 7 2 Motor connection terminal board Depending on the electric design the motors are supplied and connected in different ways The terminal links must be arranged according to the wiring diagram and screwed in tightly Observe the tightening torques specified in the following tables Motor size DR 71 DR 100 Terminal stud Tightening torque of Connection at Version Connection Scope of delivery diameter hex nut customer site type cross section M4 1 6 Nm lt 1 5 mm Type la Massive wire Pre assembled terminal Conductor end links sleeve lt 6 mm Type 1b Ring cable lug Pre assembled terminal links lt 6 mm Type 2 Ring cable lug Small connection accesso ries in enclosed bag M5 2 0 Nm lt 10 mm Type 2 Ring cable lug Small connection accesso ries in enclosed bag M6 3 0 Nm lt 16 mm Type 3 Ring cable lug Small connection accesso ries in enclosed ba
4. Gearmotors Industrial Gear Units 1 Drive Electronics Drive Automation 1 Services EURODRIVE run Es A TEN AA QU p e A gt j 3 d y E eee cdd 3 P re E a teca Td AC Motors DRS DRE DRP Edition 07 2007 O 11651814 EN perati Ng nstructions SEW EURODRIVE Driving the world Table of Contents Table of Contents 1 General Information iicet iaa 5 1 1 Structure of the safety notes ssssssssssseee emen 5 1 2 Rights to claim under limited warranty seemm 5 1 3 Exclusion of liability iii eiiiai nenne 5 2 Safety Notes 5 eremo Render O energie 6 2 1 Preliminary information sssssseeee nemen 6 2 2 General information ccceccceeeececeeeeeeeeeeeeeeeeeeaeeaaeaeeeeeeeeeeeeeeseeseeneeaeess 6 2 9 Designated use uni ad tameii 7 O oiu meri EH OE br ete ttes 7 2 5 Installation AA Reh 7 2 6 Electrical connection ooooocccnnnnicnnonocconnccnnnnncnnnnnnnnnnnnnncnnnnnnnnnnnnnnnannnnnnnnnnn 8 2 ODSratlonsscsus A Mau 8 3 Motor Beslgh iere erre aan 9 3 1 Basic design of DR 71 DR 132 sss eee een 9 3 2 Basic design of the DR 160 iiir i erk REEERE EE enne 10 3 3 Basic design of the DR 3 fiiere A a eene ene 11 3 4 Nameplate unit designation sssssssssseeemm 12 4 Mechanical Installation ununnusssnsnnsnnnnnn
5. 35 7 6 Inspection and maintenance for DR71 DR100 brake motors 38 7 7 Inspection and maintenance work on the DR315 motor 54 7 8 Inspection and maintenance for DR315 brake motor 57 Operating Instructions AC Motors DRS DRE DRP Table of Contents 10 11 Technical Data 2 eos elf 68 8 1 Work done working air gap braking torques seeeeeee 68 8 2 Braking torque assignment sssss nee 69 8 3 Operating currents seeseeeeseseseesessesee aa enne tn ndash ahnen 70 84 7 RESISTANCES CR 73 8 5 Brake rectifier combinations 4sennennennennnnnnnnnnnnnnnennnnnnnnnnn en 76 8 6 Brake Control diain e e a Dita 77 8 7 Permitted roller bearing types ssssessen mnn 79 8 8 Lubricant tables enne rentre 80 8 9 Order data for lubricants and anti corrosion agents 80 O A cer tirade dene reni Rote tian iene a enar id nnus 81 91 Wiring daga bici 81 Malfunctions iii ri ri 89 10 1 Motor MalfUNctiONS oooooooccccncnccccccccncnnnononnnnnncnnnnnnnnnnnnnnn meme trnn nennen nnne 89 10 2 Brake malfunctions ooooooooccccnnnnccccccnccncnnnonnononnncnnnnnnnnnnnnnnnnnnn nn nnnnnnnnnnnnnnns 91 10 3 Malfunctions when operated with a frequency inverter 93 10 4 Customer service uuuuennsennssnnnennnnnnnnnn
6. Inspection Maintenance 7 Inspection and maintenance for DR315 brake motor 7 8 4 Setting the working air gap of BE120 BE122 brakes A DANGER Risk of crushing if the drive starts up unintentionally Severe or fatal injuries Isolate the motor and brake from the power supply before starting work safeguarding them against unintentional power up Strictly observe the following instructions Remove forced cooling fan and incremental encoder if installed See sec Preliminary work for motor and brake maintenance page 33 2 Remove fan guard 35 and fan 36 3 Push the rubber sealing collar 66 aside if necessary release the clip Vacuum up the abraded matter Measure the brake disk 68 68b If brake disk lt 12 mm replace brake disk See sec Replacing the brake disk of brakes BE120 BE122 page 63 5 Loosen the setting sleeve 67 by turning it towards the bearing endshield 6 Measure the working air gap A see the following figure use a feeler gauge and measure at three points offset by 120 Operating Instructions AC Motors DRS DRE DRP 61 62 Inspection Maintenance Inspection and maintenance for DR315 brake motor 7 Tighten the hexagon nuts 61 8 For BE 122 in vertical mounting position set the 2 springs of the brake lining to the following value Mounting position men M4 10 0 M2 10 5 M4 49 52b X 90
7. 705 Protection canopy 706 Spacer bolt 707 Hex head screw 715 Hex nut 716 Washer Operating Instructions AC Motors DRS DRE DRP Inspection Maintenance Inspection and maintenance work on the DR315 motor 7 7 2 Inspection steps for DR 315 A DANGER Risk of crushing if the drive starts up unintentionally Severe or fatal injuries Disconnect the motor from the power supply before starting work and protect it against unintentional re start Strictly observe the following instructions Remove forced cooling fan and incremental encoder if installed See sec Preliminary work for motor and brake maintenance page 33 With gearmotors Remove the motor from the gear unit 2 Remove fan guard 35 and fan 36 3 Loosen hex head screws 25 and 19 and remove B side endshield 42 4 Remove machine screws 15 from the flange 7 Remove rotor 1 completely to 9 gether with the flange For gearmotors remove oil flinger 107 Loosen screws 609 and remove rotor from the flange 7 Before disassembly pro tect oil seal seat against damage e g with tape or a protective sleeve Visual inspection Is there any moisture or gear unit oil inside the stator f not continue with 8 fthere is condensation continue with 7 Ifthere is gear oil have the motor repaired by a specialist workshop If there is moisture inside the stator Clean the winding dry
8. By changing the complete magnet only possible for BEO5 and BE1 By changing the brake from motor size DR 90 For the possible braking torque steps please refer to sec Technical Data page 68 Changing the brake spring Risk of crushing if the drive starts up unintentionally Severe or fatal injuries Isolate the motor and brake from the power supply before starting work safeguarding them against unintentional power up Strictly observe the following instructions 48 Remove the following Forced cooling fan and incremental encoder if installed See sec Preliminary work for motor and brake maintenance page 33 Flange cover or fan guard 35 circlip 32 62 and fan 36 Removing the brake cable Size DR 71 DR 132 Remove the terminal box cover loosen the brake cable from the rectifier Size DR 160 Loosen safety screws of the brake plug connector 698 and remove plug connector Remove the rubber sealing collar 66 and the manual brake release Setting nuts 58 conical coil springs 57 studs 56 release lever 53 dowel pin 59 Loosen hex nuts 61 pull off the magnet 54 by approx 50 mm watch the brake cable Change or add brake springs 50 276 Arrange brake springs symmetrically Re install the brake components Except for the fan and the fan guard because the working air gap has to be set first see section Setting t
9. Switch both the DC and AC sides e g through retrofitting the current relay from SR to BSR or the voltage relay from UR to BUR observe wiring diagram Noises in vicinity of brake Gearing wear on the brake disk or the car rier caused by jolting startup Check the project planning replace the brake disk if needed See the following section e Replacing the brake disk of brakes BE05 BE20 page 46 Replacing the brake disk of brakes BE120 BE122 page 63 Have a specialist workshop replace the carrier Pulsating torques due to incorrectly set fre quency inverter Check correct setting of frequency inverter according to oper ating instructions 92 Operating Instructions AC Motors DRS DRE DRP Malfunctions E a 10 Malfunctions when operated with a frequency inverter lt 2 10 3 Malfunctions when operated with a frequency inverter The symptoms described in the Motor Problems section may also occur when the motor is operated with a frequency inverter Please refer to the frequency inverter oper ILL ating instructions for the meaning of the problems that occur and to find information about rectifying the problems 10 4 Customer service Please have the following information to hand if you require the assistance of our cus tomer service Nameplate data complete Type and extent of the problem Time the problem occurred and any accompanying circumstances Assumed cause
10. 10 7 0 N NOINA OD ANAI 1374 024 5 1374 052 0 BE5 260 0 25 0 9 9 0 55 40 28 20 NNO ANA OS 1374 070 9 1374 0717 BE11 640 0 3 10 0 110 80 55 40 NNO ANA I 1374 183 7 1374 184 5 BE20 1000 0 3 12 0 200 150 110 80 w N 1 1374 322 8 1374 248 5 BE120 520 0 4 12 0 1000 800 600 400 AN 1360 877 0 1360 831 2 BE122 520 0 5 12 0 2000 1600 1200 800 PrOoo r 2 90 w8w 0 AN 1360 877 0 1360 831 2 1 When checking the working air gap note Parallelism tolerances on the brake disk may give rise to deviations of 0 15 mm after a test run Operating Instructions AC Motors DRS DRE DRP Technical Data Braking torque assignment 8 2 Braking torque assignment 8 2 1 Motor size DR 71 DR 100 Motor type Brake type Braking torque steps in Nm BE05 1 8 2 5 3 5 5 0 DR 71 BE1 5 0 7 0 10 BE05 1 8 2 5 3 5 5 0 DR 80 BE1 5 0 7 0 10 BE2 7 0 10 14 20 BE1 5 0 7 0 10 DR 90 BE2 7 0 10 14 20 BE5 20 28 40 55 BE2 7 0 10 14 20 DR 100 BE5 20 28 40 55 8 2 2 Motor sizes DR 112 DR 160 Motor type Brake type Braking torque steps in Nm BE5 28 40 55 DR 112 BE11 40 55 BE5 28 40 55 DR 132 BE11 40 55 80 110 BE11 40 55 80 110 DR
11. Is there any moisture or gear unit oil inside the stator If not continue with 8 If there is condensation continue with 7 If there is gear oil have the motor repaired by a specialist workshop If there is moisture inside the stator Clean the winding dry it and check it electrically see sec Preliminary work page 33 10 Replace anti friction bearings 11 44 with permitted anti friction bearing types See sec Permitted anti friction bearing types page 79 Fill bearings about two thirds full with grease See sec Bearing lubrication DR 315 page 31 Important Place sealing ring flanges 608 and 21 on the rotor shaft before mount ing the bearings 11 Assemble the motor by aligning it vertically A side up 12 Insert cup springs 105 and lubricating ring 604 in the bearing bore of the flange 7 Suspend rotor 1 from the B side thread and insert into the flange 7 Attach sealing ring flange 608 on the flange 7 using hex head screws 609 Operating Instructions AC Motors DRS DRE DRP 59 7 Inspection Maintenance Inspection and maintenance for DR315 brake motor 13 Install stator 16 Replace the stator seat sealing Seal the sealing surface with duroplastic sealing compound operating temperature 40 180 C such as Hylomar L Spezial Important Protect winding overhang from damage Screw in the stator 16 and flange 7 with screws 15 14 Bef
12. Maintenance Inspection and maintenance for DR71 DR100 brake motors 8 With manual brake release Use setting nuts to set the floating clearance s between the conical coil springs pressed flat and the setting nuts see the following figure This floating clearance s is necessary so that the pressure plate can move up as the brake lining wears Otherwise reliable braking is not guaranteed 177241867 Brake Floating clearance s mm BE05 BE1 BE2 1 5 BE5 BE11 BE20 2 9 Install the rubber sealing collar back in place and re install the dismantled parts NOTES The lockable manual brake release type HF is already released if resistance is encountered when operating the grub screw The self reengaging manual brake release type HR can be operated with normal hand pressure n brake motors with self reengaging manual brake release the manual brake release lever must be removed after startup maintenance A bracket is provided for storing the lever on the outside of the motor NOTES Important After replacing the brake disc the maximum braking torque is reached only after several cycles Operating Instructions AC Motors DRS DRE DRP 7 Inspection Maintenance Inspection and maintenance for DR71 DR100 brake motors 7 6 9 Changing the braking torque of BE05 BE20 brakes The braking torque can be changed in steps By the type and number of brake springs
13. Motor size Operating mode con Frequency in Hz Voltage V nection DR 71 DR 160 1 AC A 50 230 277 DR 71 DR 160 1 AC A 60 230 277 DR 71 DR 315 3 ACA 50 346 500 DR 71 DR 315 3 AC HK 60 380 575 DR 71 DR 315 3 AC A 50 200 290 DR 71 DR 315 3 AC A 60 220 330 NOTE For information on how to connect the V forced cooling fan refer to the wiring diagram page 88 Operating Instructions AC Motors DRS DRE DRP 27 5 Electrical Installation Accessory equipment 5 9 4 Encoder overview For notes on connecting the incremental encoders please refer to the wiring diagrams Enco 5 Encoder Installation Power A Wiring Motor size Signal der type type supply diagram ES7S DR 71 DR 132 Encoder Shaft centered DC 7 30 V 1 Vss sin cos 68 169 xx 06 ES7H DR 71 DR 132 Encoder Shaft centered DC 7 0 12 V Hiperface Single 68 170 xx 061 turn AS7H DR 71 DR 132 Encoder Shaftcentered DC 7 0 12 V Hiperface Multi 68 170 xx 06 turn EH7S DR 315 Encoder Shaftcentered DC 10 30 V 1 Vas sin cos 08 259 xx 071 AH7Y DR 315 Encoder Shaft centered DC 9 30 V TTL SSI RS 422 08 259 xx 071 1 xx Placeholder for wiring diagram version NOTES e Maximum oscillation load for encoders x 10 g 100 m s 10 Hz 2 kHz Shock resistance lt 100 g 1 000 m s for DR 71 DR 132 Shock resistance lt 200 g 2 000 m s for the DR 315
14. Operating Instructions AC Motors DRS DRE DRP 93 11 94 a ae Address List Customer service 11 Address List Germany Headquarters Bruchsal SEW EURODRIVE GmbH amp Co KG Tel 49 7251 75 0 Production Ernst Blickle Stra e 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 Compe Central SEW EURODRIVE GmbH amp Co KG Tel 49 7251 75 1710 tence Center Ernst Blickle Stra e 1 Fax 49 7251 75 1711 D 76676 Graben Neudorf sc mitte sew eurodrive de North SEW EURODRIVE GmbH amp Co KG Tel 49 5137 8798 30 Alte Ricklinger Stra e 40 42 Fax 49 5137 8798 55 D 30823 Garbsen near Hannover sc nord sew eurodrive de East SEW EURODRIVE GmbH amp Co KG Tel 49 3764 7606 0 D nkritzer Weg 1 Fax 49 3764 7606 30 D 08393 Meerane near Zwickau sc ost sew eurodrive de South SEW EURODRIVE GmbH amp Co KG Tel 49 89 909552 10 Domagkstra e 5 Fax 49 89 909552 50 D 85551 Kirchheim near M nchen sc sued sew eurodrive de West SEW EURODRIVE GmbH amp Co KG Tel 49 2173 8507 30 Siemensstra e 1 Fax 49 2173 8507 55 D 40764 Langenfeld near D sseldorf sc west sew eurodrive de Electronics SEW EURODRIVE GmbH amp Co KG Tel 49 7251 75 1780 Ernst Blickle Stra e 42 D 76646 Bruchsal Fax 49 7251 75 1769 sc elektronik sew eurodrive de Drive Service Hotline 24 Hour Service 49 180 5 SEWHELP 49 18
15. Pressure plate 50 Brake spring 11 Magnet complete 51 Hand lever 53 Releasing lever 54 Magnet complete 38 70 73 68 56 Stud 57 Conical spring 58 Setting nut 59 Parallel pin 60 Stud 3x 61 Hex nut 65 Pressure ring 66 Rubber sealing collar 67 Counter spring 68 Brake disc 49 718 166 50 54 95 59 53 56 57 58 36 62 35 22 174200971 62 Circlip 70 Driver 71 Key 73 Stainless steel shim plate 95 Sealing ring 718 Damping plate Operating Instructions AC Motors DRS DRE DRP Inspection Maintenance 7 Inspection and maintenance for DR71 DR100 brake motors 7 6 2 Basic design of DR 90 DR 132 brakemotors 2 85 amp 179981963 1 Motor with brake bearing end shield 53 Releasing lever 70 Carrier 22 Hex head bolt 56 Stud 95 Sealing ring 32 Circlip 57 Conical coil spring 550 Pre assembled brake 35 Fan guard 58 Setting nut 900 Screw 36 Fan 59 Parallel pin 901 Gasket 51 Hand lever 62 Circlip Operating Instructions AC Motors DRS DRE DRP 39 40 Inspection Maintenance Inspection and maintenance for DR71 DR100 brake motors 7 6 3 Basic design of DR 160 brakemotor 156 51 36 95 900 550 NARA 527223691 550 Pre assembled brake 698 Plug connector complete only for 1 Motor with brake bearing end shield 55 Closing pi
16. Steinmetz The following figure shows the wiring of the V forced cooling fan for delta Steinmetz con nection PE L1 N U1 V1 W1 523348491 A connection The following figure shows the wiring of the V forced cooling fan for A connection L1 L2 L3 523350155 Aconnection The following figure shows the wiring of the V forced cooling fan for A connection PE L1 L2 L3 U1 V1 W1 a eS SS a E R a L1 L2 L3 523351819 Operating Instructions AC Motors DRS DRE DRP Malfunctions Motor malfunctions 10 Malfunctions 10 1 Motor malfunctions Malfunction Possible cause Remedy Motor does not start up Interruption in supply cable Check the connections and intermediate terminal points correct if necessary Brake does not release See Sec Brake faults page 91 Supply cable fuse has blown Replace fuse Motor protection switch has triggered Check that the motor protection switch is set correctly current specification is on the nameplate Motor contactor does not trip Check motor contactor control Malfunction in control or in the control pro cess Observe the switching sequence correct if necessary Motor does not start or only with difficulty Motor power designed for delta connection but used in star connection Correct the connection from star to delta follow the wiring diagram Motor power design
17. 174 830 95 600 67 2 400 4 575 543 600 250 220 1050 120 760 84 5 504 1 Operating Instructions AC Motors DRS DRE DRP 73 74 Technical Data Resistances 8 4 3 Resistance measurement BE05 BE20 Cut off in the AC circuit Cut off in the DC and AC circuits The following figure shows the resistance measurement for a cut off in the AC circuit RD Rg WH o BU RD Ry WH BU The following figure shows the resistance measurement for a cut off in the AC and DC circuits RD Rg WH O BU RD Ry WH BU BS Accelerator coil RD red TS Coil section WH white Rg Accelerator coil resistance at 20 C Q BU blue R4 Coil section resistance at 20 C Q Vg Rated voltage rated voltage range NOTE For measuring the resistance of the RT coil section or the RB accelerator coil remove the white conductor from the brake rectifier If it remains connected the internal resis tance of the brake rectifier will cause erroneous results Operating Instructions AC Motors DRS DRE DRP Technical Data Resistances 8 44 Brake BE120 BE122 BE120 BE122 Max braking torque Nm 1000 2000 Braking power W 250 250 Inrush current ratio Ip ly 4 9 4 9 Rated voltage Vn BE120 BE122 Vac Voc Rg Rr Rg Rr 230 218 243 7 6 29 5 7 6 29 5 254 244 273 9 5 37 0 9 5 37 0 290 274 306 12 0 46 5
18. 33 34 AB Y EEE d 34 yin EL 33 EFI Sunat a eatae hun 34 ESTE uiuit ala 33 ESTO os er LEE 33 Removing the incremental encoder 33 34 ABT Y 3 eae tete 34 ASTH a d 33 EHI Societe termi eter tete uou 34 ESZH nails niece 33 ES Sumate 33 Operating Instructions AC Motors DRS DRE DRP Index Replacing the brake disk BE05 idad do 46 BEN a Ren den edm 46 BEI ia RR 46 BETO He tee een 63 BE122 a a E e edt 63 BER O 46 BE2O na eti rens 46 BES ise aded np se Rt 46 Retrofitting HR HF manual brake release 53 Rights to claim under limited warranty 5 Roller bearing types sss 79 S Safety Notes aisin or aariaa iea eai Tia Aaien 6 Safety notes Designated USO niaar a ae n rE 7 Electrical connection oooooococccincccccccccononccnnccnnnanons 8 General information ssssssssssss 6 Installation ies ere Een 7 Operation Bun allein 8 Transport ease e getreten ast 7 Set the working air gap BEO5 eoe EAD 45 BELO cti ran 61 Setting the working air gap BEIM As ea ee 45 BE e a 61 A FRETEENETERTEDELERTEHRETLERELUEREEEREERELETERTEERTR 45 BE etra ERR ng 45 Special aspects in switching operation 19 Star connection cocccoconncnconcccocnccnnncnonoronencnnnononos 20 81 Startup ae ee ere eee ea 29 Switching operation 19 T Technical data ooooooooccccccccccccccccnccnnonnononnncnnnnnnnnnnnnnns 68 ME a dan
19. 385 4 red electronic switching AC 42 0 150 V 3 0 BGE 3 825 387 0 blue 825 3854 1 0 BGE 1 5 SR 11 826 761 8 AC 150 500 V BORNE One way rectifier cur 1 0 BGE 1 5 SR 15 826 762 6 BSR rent relay for cut off in the POTETE DC circuit 1 0 BGE 3 SR11 826 761 8 AC 42 0 150 V 2553070 1 0 BGE 3 SR15 826 762 6 825 3854 One way rectifier volt AC 150 500 V 1 0 BGE 1 5 UR 15 826 759 6 BUR age relay for cut off in the ROTO DC circuit AC 42 0 150 V 1 0 BGE 3 UR 11 826 758 8 BS Varistor protection circuit DC 24V 5 0 BS24 8267634 Aqua BSG Electronic switching DC 24 V 5 0 BSG 825 459 1 white Holding Type Function Voltage current Type Fart Color number code IHmax A One way rectifier with BMP electronic switching inte AC 230 0 575 28 BMP 3 1 829 507 7 grated voltage relay for V cut off in the DC circuit Operating Instructions AC Motors DRS DRE DRP 77 Technical Data Brake control 8 6 2 Control cabinet The following tables list the technical data of brake control systems for installation in the control cabinet and the assignments with regard to motor size and connection technol ogy The different housings have different colors color code to make them easier to distinguish Motor size DR 71 DR 160 WS olding Type Function Voltage current Type ER Mie IHmax A aus One way rectifier such as AC 15
20. 90 Base plate 93 Pan head screw 100 Hex nut 103 Stud 106 Oil seal 107 Oil flinger 108 Nameplate 109 Grooved pin 111 Gasket for lower part 112 Terminal box lower part 113 Pan head screw 115 Terminal board 116 Terminal clip Operating Instructions AC Motors DRS DRE DRP 173332747 117 Hex head bolt 118 Lock washer 119 Pan head screw 123 Hex head bolt 129 Screw plug with O ring 131 Gasket for cover 132 Terminal box cover 134 Screw plug with O ring 156 Information sign 262 Terminal clip complete 392 Gasket 705 Protection canopy 706 Spacer 707 Pan head screw 35 36 Inspection Maintenance Inspection and maintenance work on the motor DR71 DR100 7 5 2 Basic design of the DR 160 120 121 127 390 115 113 N SH WSS XS 527322635 1 Rotor 36 Fan 119 Hex head bolt 2 Circlip 41 Spring washer 120 Grounding terminal bottom 3 Key 42 Non drive end bearing shield 121 Grooved pin 4 Key 44 Deep groove ball bearing 122 Lock washer 7 Flange 90 Foot 123 Hex head bolt 9 Screw plug 91 Hexagonal nut 127 Grounding terminal top 10 Circlip 93 Disc 129 Screw plug with O ring 11 Deep groove ball bearing 94 Machine screw 131 Gasket for cover 12 Circlip 100 Hexagonal nut 132 Terminal box cover 14 Disc 103 Stud 134 Screw plug wi
21. Adcock Ingram and Aerodrome Roads http www sew co za Aeroton Ext 2 dross sew co za Johannesburg 2013 P O Box 90004 Bertsham 2013 Capetown SEW EURODRIVE PROPRIETARY LIMITED Tel 27 21 552 9820 Rainbow Park Fax 27 21 552 9830 Cnr Racecourse amp Omuramba Road Telex 576 062 Montague Gardens dswanepoel sew co za Cape Town P O Box 36556 Chempet 7442 Cape Town Operating Instructions AC Motors DRS DRE DRP Address List Customer service South Africa Durban SEW EURODRIVE PROPRIETARY LIMITED Tel 27 31 700 3451 2 Monaceo Place Fax 27 31 700 3847 Pinetown dtait sew co za Durban P O Box 10433 Ashwood 3605 Spain Assembly Bilbao SEW EURODRIVE ESPANA S L Tel 34 94 43184 70 Sales Parque Tecnol gico Edificio 302 Fax 34 94 43184 71 Service E 48170 Zamudio Vizcaya http www sew eurodrive es sew spain sew eurodrive es Sweden Assembly J nk ping SEW EURODRIVE AB Tel 46 36 3442 00 Sales Gnejsvagen 6 8 Fax 46 36 3442 80 Service S 55303 J nk ping http www sew eurodrive se Box 3100 S 55003 J nk ping info sew eurodrive se Switzerland Assembly Basel Alfred Imhof A G Tel 41 61 417 1717 Sales Jurastrasse 10 Fax 41 61 417 1700 Service CH 4142 M nchenstein bei Basel http www imhof sew ch info imhof sew ch Thailand Assembly Chonburi SEW EURODRIVE Thailand Ltd Tel 66 38 454281 Sales 700 456 Moo 7 Donhuaroh Fax 6
22. Heat the motor With hot air or e Via isolation transformer Connect the windings in series see following figure Auxiliary AC voltage supply max 10 96 of the rated voltage with max 20 96 of the rated current Trafo 174065419 The drying process is finished when the minimum insulation resistance has been ex ceeded Check terminal box whether Theinside is clean and dry The connections and fixing parts are free from corrosion Seals and sealing surfaces are ok The cable glands are sound otherwise clean or replace them Operating Instructions AC Motors DRS DRE DRP Mechanical Installation Mechanical installation 4 2 2 Installing the motor Installation in damp locations or in the open The motor or gearmotor may only be mounted or installed in the specified mounting po sition on a level and torsionally rigid support structure that is not subject to shocks Carefully align the motor and the driven machine to avoid placing any unacceptable strain on the output shafts observe permitted overhung load and axial load Do not butt or hammer the shaft end Use an appropriate cover to protect motors in vertical mounting positions from objects or fluids entering protection cowl C Ensure an unobstructed cooling air supply and that air heated by other apparatus cannot be drawn in or reused Balance components for subsequent mounting on the shaft with a half key motor shafts are balanced wit
23. Remove flange cover or fan guard 35 circlip 32 and fan 36 Loosen brake connector Loosen the bolts 900 and remove the brake from the brake endshield c1 A OO N 900 6 With manual brake release Use setting nuts to set the floating clearance s between the conical coil springs pressed flat and the setting nuts see the following figure This floating clearance s is necessary so that the pressure plate can move up as the brake lining wears Otherwise reliable braking is not guaranteed 353592459 Brake Floating clearance s mm BE120 BE122 2 Operating Instructions AC Motors DRS DRE DRP Align cam of the friction disk and mount the brake to the brake endshield using screw 67 68 8 8 1 Technical Data Work done working air gap braking torques Technical Data Work done working air gap braking torques Brake type Work done until mainte nance 1063 Working air gap mm min 1 max Brake disc mm min Braking torque Nm Braking torque settings Standard Type and number of brake springs Blue Order number of brake springs Standard Blue BE05 120 0 25 0 6 9 0 5 0 3 5 2 5 1 8 2 2 4 WOON 0135 017 X 1374 137 3 BE1 120 0 25 0 6 9 0 10 7 0 5 0 AN 0135 017 X 1374 137 3 BE2 165 0 25 0 6 9 0 20 14
24. SEW EURODRIVE INC Tel 1 856 467 2277 Pureland Ind Complex Fax 1 856 845 3179 2107 High Hill Road P O Box 481 csbridgeport seweurodrive com Bridgeport New Jersey 08014 Dayton SEW EURODRIVE INC Tel 1 937 335 0036 2001 West Main Street Fax 1 937 440 3799 Troy Ohio 45373 cstroy seweurodrive com Dallas SEW EURODRIVE INC Tel 1 214 330 4824 3950 Platinum Way Fax 1 214 330 4724 Dallas Texas 75237 csdallas seweurodrive com Additional addresses for service in the USA provided on request Venezuela Assembly Valencia SEW EURODRIVE Venezuela S A Tel 58 241 832 9804 Sales Av Norte Sur No 3 Galpon 84 319 Fax 58 241 838 6275 Service Zona Industrial Municipal Norte http www sew eurodrive com ve Valencia Estado Carabobo sewventas cantv net sewfinanzas cantv net Operating Instructions AC Motors DRS DRE DRP Index Index A Accessory equipment 26 1AN a O eine HT 28 34 Ambient conditions Ambient temperature oococcccccnccnncnnonnnnccnncnnnnnnnns 19 Hazardous radiation ccceeeeeeeeeeseeeeeeeeeeeees 19 Installation altitude ccccccccccceseseeseeeeeeeeneees 19 y ern e eb Wad nett 28 33 B Bearing lubrication seeeee 31 BE05 uinhaninebelsm en nU HN 41 BET uu an 42 BET ee tec eee E ede e uds 42 BE Dita Rn dado an eru is 58 BET ten een bts 58 BED oso ACID us 41 42 BED ati Era ehe 42 BES same ee an evi ete ai 42 Brake BEOS Rein 41 BEIN e ral een de A
25. again Operating Instructions AC Motors DRS DRE DRP 53 54 Inspection Maintenance Inspection and maintenance work on the DR315 motor 7 7 Inspection and maintenance work on the DR315 motor 7 7 1 Basic design of the DR 315 motor 1 Rotor 2 Circlip 8 Key 4 Key 7 Flange 9 Screw plug 11 Rolling element bearings 15 Machine screw 16 Stator 17 Hexagonal nut 19 Machine screw 21 Oil seal flange 22 Hex head bolt 24 Lifting eyebolt 25 Machine screw 26 Sealing washer 30 Oil seal 31 Key 32 Circlip 35 Fan guard 86 Fan 40 Circlip 42 Non drive end bearing shield 43 Supporting ring 44 Rolling element bearings 90 Foot 93 Disc 94 Machine screw 100 Hex nut 103 Stud 105 Spring washer 106 Oil seal 107 Oil flinger 108 Nameplate 109 Grooved pin 111 Gasket for lower part 112 Terminal box lower part 113 Machine screw 115 Terminal board 116 Serrated lock washer 117 Stud 118 Washer 119 Hex head screw 123 Hex head screw 128 Serrated lock washer 129 Screw plug 351998603 131 Gasket for cover 132 Terminal box cover 134 Screw plug 139 Hex head screw 140 Washer 151 Machine screw 219 Hex nut 250 Oil seal 452 Terminal strip 454 DIN rail 604 Oiling ring 606 Grease nipple 607 Grease nipple 608 Oil seal flange 609 Hex head screw 633 End holder 634 End plate
26. based anti friction bearing grease Motor size DR 315 Motors of size DR 315 can be equipped with a relubrication device Ambient temperature Manufacturer Type DIN designation Motor anti 20 C 80 C Esso Polyrex EM K2P 20 friction bearings 40 C 60 C SKF GXN K2N 40 1 Mineral lubricant mineral based anti friction bearing grease 8 9 Order data for lubricants and anti corrosion agents The lubricants and anti corrosion agents can be ordered directly from SEW EURO DRIVE with the following order number Usage Manufacturer Type quantity Order number Lubricant for anti Esso Polyrex EM 400g 09101470 friction bearings SKF GXN 400 g 09101276 Lubricant tor Kl ber Petamo GHY 133 109 04963458 Sealing rings Anti corrosion agents sew EURODRIVE Noco Fluid 5 59 09107819 and lubricants Operating Instructions AC Motors DRS DRE DRP Appendix Wiring diagrams 9 Appendix 9 1 Wiring diagrams NOTE Connect the motor as shown in the wiring diagram or the assignment diagram included with the motor The following section only gives an overview of the most com mon connection options You can obtain the valid wiring diagrams free of charge from SEW EURODRIVE 9 1 1 Delta and star connection AC motor For all motors with one speed direct on line or A A startup A connection The following figure depicts the A connection fo
27. cable lug 8 Serrated lock washer Operating Instructions AC Motors DRS DRE DRP Electrical Installation Connecting the brake 5 8 Connecting the brake The brake is released electrically The brake is applied mechanically when the voltage is switched off STOP Comply with the applicable regulations issued by the relevant employer s liability insurance association regarding phase failure protection and the associated circuit circuit modification Connect the brake according to the wiring diagram supplied with the brake n view of the DC voltage to be switched and the high level of current load it is essential to use either special brake contactors or AC contactors with contacts in utilization category AC 3 to EN 60947 4 1 5 8 1 Connecting the brake control The DC disk brake is powered from a brake control system with protection circuit It is located in the terminal box IS lower part or must be installed in the control cabinet e Check the cable cross sections braking currents see sec Technical Data Connect the brake control system according to the wiring diagram supplied with the brake For motors in thermal class 180 H install the brake rectifier in the control cabinet Operating Instructions AC Motors DRS DRE DRP 25 Electrical Installation Accessory equipment 5 9 Accessory equipment Connect the accessory equipment only as shown in the wiring diagram
28. cae th D uM 26 82 83 TF temperature sensor sssssssss 26 Ti eet e ei er eee te es 26 82 83 TH winding thermostats sseeseeesss 26 TRANS PO iii D n 7 U Unit designation 444ssssnnnnnnnnennnnnnnnen nennen 12 V V forced cooling fane erranera a 27 Operating Instructions AC Motors DRS DRE DRP Ww Wiring diagram BMP Sd rn een 87 Wiring diagrams sm nn 81 CA in inaaesirhiehe 84 BE cue a aa cb das Ei o A ess 84 BOSGuinoduieeine eit 85 BOR hu as le 86 Delta connection essen 81 Star CONNectiON ccooocococconoocococcncncnononnnnnnnncncnnnns 81 ME es eee dons eed 82 83 M 82 83 105 EURODRIVE SEW EURODRIVE Driving the world Gearmotors Industrial Gear Units Drive Electronics Drive Automation 1 Services m b How we re driving the world With people who think fast and develop the future with you r Lan L Yi With a global presence that offers responsive and reliable solutions Anywhere service network that is always close at hand e With drives and controls that automatically improve your
29. circlip 32 62 and fan 36 Remove the rubber sealing collar 66 and the manual brake release Setting nuts 58 conical coil springs 57 studs 56 release lever 53 Removing the brake cable Size DR 71 DR 132 Remove the terminal box cover loosen the brake cable from the rectifier Size DR 160 Loosen safety screws of the brake plug connector 698 and remove plug connector 4 Loosen hex nuts 61 remove complete magnet 54 replace brake springs 50 276 5 Re install the brake components Except for the fan and the fan guard because the working air gap has to be set first see section Setting the working air gap of the BEO5 BE20 brakes page 45 With manual brake release Use setting nuts to set the floating clearance s between the conical coil springs pressed flat and the setting nuts see the following figure This floating clearance s is necessary so that the pressure plate can move up as the brake lining wears Otherwise reliable braking is not guaranteed 177241867 Brake Floating clearance s mm BE05 BE1 BE2 1 5 BE5 BE11 BE20 2 7 50 Install the rubber sealing collar back in place and re install the dismantled parts Operating Instructions AC Motors DRS DRE DRP Inspection Maintenance Inspection and maintenance for DR71 DR100 brake motors Changing the brake of DR 71 and DR 80 A DANGER Risk of cru
30. coder as example 179980299 1 Rotor 367 Retaining bolt 220 Connection cover 733 Screws 361 Protective cowl Removing AS7 Remove the protective cowl 361 Remove expansion anchor from the cowl grid by unscrewing the screws 733 Unscrew the central retaining screw 367 by about two to three turns and loosen the spread shaft by tapping lightly on the head of the screw Remove the incremental encoder from the bore of the rotor 1 Removing ES7 Remove the protective cowl 361 Unscrew the connection cover 220 and remove it The encoder connection cable need not be disconnected Remove expansion anchor from the cowl grid by unscrewing the screws 733 Unscrew the central retaining screw 367 by about two to three turns and loosen the spread shaft by tapping lightly on the head of the screw Remove the incremental encoder from the bore of the rotor 1 Re assembly Important for re assembly e Apply NOCO fluid to the encoder spigot Tighten the central retaining screw 367 with a tightening torque of to 2 9 Nm Tighten screw 733 in expansion anchor with a tightening torque of max 1 0 Nm Operating Instructions AC Motors DRS DRE DRP 33 7 Inspection Maintenance Preliminary work for motor and brake maintenance 7 4 2 Removing incremental encoder from DR 315 The following figure shows the disassembly of the incremental encoder on the DR 315 35 734 367 2
31. connected with special care to ensure permanent and reli able contact without loose cable ends use assigned terminals for the connection ca bles Ensure a safe connection of the protective earth conductor When the motor is con nected the distances to live and uninsulated parts may not be below the minimum val ues specified in IEC 60664 and in national regulations The minimum distances for low voltage according to IEC 60664 are Rated voltage Vn Distance lt 500 V 3 mm 690 V 5 5 mm Make sure that no foreign matter is left in the terminal box and that it is clean and dry Cable entries which are not used and the terminal box itself have to be sealed dust and watertight Secure keys for test mode without output elements Check whether the brake is functioning correctly before startup when using a low voltage machine with brake Observe the notes in sec Electrical Installation Whenever changes occur in relation to normal operation such as increased tempera tures noise oscillation determine the cause and contact the manufacturer if required Never bypass or disable protection devices not even in test mode If you are in doubt Switch off the motor Regularly clean air ducts in dusty or dirty environments Operating Instructions AC Motors DRS DRE DRP Motor Design Basic design of DR 71 DR 132 3 Motor Design NOTE The following illustration is intended to explain th
32. it and check it electrically see sec Preliminary work page 13 Replace anti friction bearings 11 44 with permitted anti friction bearing types See sec Permitted anti friction bearing types page 79 Fill bearings about two thirds full with grease See sec Bearing lubrication DR 315 page 31 Important Place sealing ring flanges 608 and 21 on the rotor shaft before mount ing the bearings Assemble the motor by aligning it vertically A side up 10 Insert cup springs 105 and lubricating ring 604 in the bearing bore of the flange 7 Suspend rotor 1 from the B side thread and insert into the flange 7 Attach sealing ring flange 608 on the flange 7 using hex head screws 609 Operating Instructions AC Motors DRS DRE DRP 55 56 Inspection Maintenance Inspection and maintenance work on the DR315 motor 11 Install stator 16 Replace the stator seat sealing Seal the sealing surface with duroplastic sealing compound operating temperature 40 180 C such as Hylomar L Spezial Important Protect winding overhang from damage Screw in the stator 16 and flange 7 with screws 15 12 Before mounting the B side endshield 42 screw in the M8 setscrew approximately 200 mm 7 87 in into the oil seal flange 21 13 Mount the B side endshield 42 feed the setscrew in through a bore for the screw 25 Screw in the B side endshield 42 and stator 16 using ma
33. notes in section 2 during installation e Switch contacts in utilization category AC 3 to EN 60947 4 1 must be used for switching the motor and the brake 5 1 Using the wiring diagrams Connect the motor only as shown in the wiring diagram s included with the motor Do not connect or start up the motor if the wiring diagram is missing You can obtain the valid wiring diagrams free of charge from SEW EURODRIVE 5 2 Wiring notes Comply with the safety notes during startup 5 2 1 Protection against interference from brake control systems Brake cables must always be routed separately from other power cables with phased currents unless they are shielded to protect brake control systems against interference Power cables with phased currents are in particular Output cables from frequency inverters and servo controllers soft start units and brake units Supply cables for brake resistors and similar options 5 2 2 Protecting motor protection devices against interference To protect SEW motor protection devices TF temperature sensors TH winding thermo stats against interference Route separately shielded supply cables together with switched mode power lines in one cable Do not route unshielded supply cables together with switched mode power lines in one cable 16 Operating Instructions AC Motors DRS DRE DRP Electrical Installation 5 Special aspects for operation with a frequency inverter 5
34. on the nameplate 4 2 Mechanical installation 4 2 1 Preliminary work Motors with rein forced bearing Motor shaft ends must be thoroughly cleaned of anti corrosion agents contamination or similar use a commercially available solvent Do not allow the solvent to penetrate the bearings or shaft seals this could damage the material STOP Motors with reinforced bearing may not be operated without any overhung loads The bearings might be damaged 1 Note that the temperature range of the gear unit may also be restricted see gear unit operating instruc tions Operating Instructions AC Motors DRS DRE DRP 13 14 Mechanical Installation Mechanical installation Long term storage of motors Drying the motor Please note that the grease utilization period of the ball bearings is reduced by 10 96 each year after storage periods exceeding one year e Re lubricate motors with relubrication device that have been stored longer than 5 years before startup Observe the information on the lubrication plate of the motor Check whether the motor has absorbed moisture as a result of being stored for a long time Measure the insulation resistance for this purpose measuring voltage 500 V The insulation resistance see following figure varies greatly depending on the temperature The motor must be dried if the insulation resistance is not adequate MO 0 20 40 60 80 6 173323019
35. repair Severe speed loss under load Motor overload Measure power check project planning and use larger motor or reduce load if necessary Voltage drops Check cross section of supply cable replace with cable of larger cross section if needed Motor heats up excessively measure temperature Overload Measure power check project planning and use larger motor or reduce load if necessary Insufficient cooling Provide for cooling air supply or clear cooling air pas sages retrofit forced cooling fan if necessary Check the air filter clean or replace if necessary Ambient temperature is too high Observe the permitted temperature range reduce the load if necessary Motor in delta connection instead of star connection as provided for Correct the wiring observe the wiring diagram Loose contact in supply cable one phase missing Tighten loose contact check connections observe wiring diagram Fuse has blown Look for and rectify cause see above replace fuse Mains voltage deviates from the rated motor voltage by more than 5 range A 10 range B Adjust motor to mains voltage Rated operation type S1 to S10 DIN 57530 exceeded e g through excessive starting frequency Adjust rated operation type of motor to required operating conditions if necessary call in a specialist to determine correct drive Operating Instructions AC Motors DRS DRE D
36. stator from flanged endshield Visual inspection Is there any moisture or gear unit oil inside the stator If not continue with 7 If there is condensation continue with 5 If there is gear oil have the motor repaired by a specialist workshop If there is moisture inside the stator With gearmotors Remove the motor from the gear unit Motors without a gear unit Remove the A flange Remove the rotor 1 Clean the winding dry it and check it electrically see sec Preliminary work page 13 Replace deep groove ball bearings 11 44 with permitted ball bearings See sec Permitted anti friction bearing types page 79 Replace the shaft sealing A end Replace oil seal 106 B end Replace oil seal 30 Apply grease Kl ber Petamo GHY 133 to the sealing lip Replace the stator seat sealing Seal the sealing surface with duroplastic sealing compound operating temperature 40 180 C such as Hylomar L Spezial For size DR 71 DR 132 Replace gasket 392 10 Install the motor and accessories Operating Instructions AC Motors DRS DRE DRP 37 7 Inspection Maintenance Inspection and maintenance for DR71 DR100 brake motors 7 6 Inspection and maintenance for DR71 DR100 brake motors 7 6 1 Basic design of DR 71 DR 80 brakemotors 1 71 1 Motor with brake bearing end shield 22 Hex head bolt 35 Fan guard 36 Fan 49
37. the stator With gearmotors Remove the motor from the gear unit Motors without a gear unit Remove the A flange Remove the rotor 1 Clean the winding dry it and check it electrically see sec Preliminary work page 13 Operating Instructions AC Motors DRS DRE DRP 43 Inspection Maintenance Inspection and maintenance for DR71 DR100 brake motors 10 Replace deep groove ball bearings 1 1 44 with permitted ball bearings See sec Permitted anti friction bearing types page 79 11 Replace the shaft sealing A end Replace oil seal 106 B end Replace oil seal 30 Apply grease Kl ber Petamo GHY 133 to the sealing lip 12 Replace the stator seat sealing Seal the sealing surface with duroplastic sealing compound operating temperature 40 180 C such as Hylomar L Spezial Forsize DR 71 DR 132 Replace gasket 392 13 Install the motor brake and accessories Operating Instructions AC Motors DRS DRE DRP Inspection Maintenance 7 Inspection and maintenance for DR71 DR100 brake motors 7 6 7 Setting the working air gap of BE05 BE20 brakes A DANGER Risk of crushing if the drive starts up unintentionally Severe or fatal injuries Isolate the motor and brake from the power supply before starting work safeguarding them against unintentional power up Strictly observe the following instructions Remove the following For
38. 0 49 Pressure plate 52b Brake lining only for BE122 68 Brake disc 68b Brake disk only BE122 900 Hexagonal nut 9 Tighten the setting sleeves Against the magnet 68b 68 Until the working air gap is set correctly see sec Technical Data page 68 10 Install the rubber sealing collar back in place and re install the dismantled parts Operating Instructions AC Motors DRS DRE DRP Inspection Maintenance Inspection and maintenance for DR315 brake motor 7 8 5 Replacing the brake disk of BE120 BE122 brakes When fitting a new brake disk thickness lt 12 mm inspect the other removed parts as well and install new ones if necessary A DANGER Risk of crushing if the drive starts up unintentionally Severe or fatal injuries Isolate the motor and brake from the power supply before starting work safeguarding them against unintentional power up Strictly observe the following instructions Remove forced cooling fan and incremental encoder if installed See sec Preliminary work for motor and brake maintenance page 33 2 Remove fan guard 35 circlip 32 and fan 36 3 Loosen plug connector on the magnet 4 Remove the rubber sealing collar 66 and the manual brake release Setting nuts 58 ball cup 255 concave washer 256 conical coil springs 57 studs 56 release lever 53 Loosen hex nuts 61 carefully p
39. 0 500 V 1 5 BMS 1 5 825 802 3 black BG AC 42 150 V 3 0 BMS 3 825 8031 brown One way rectifier with AC 150 0 500 1 5 BME 1 5 825 722 1 red BME electronic switching such V as BGE AC 42 150 V 3 0 BME 3 825 723X blue One way rectifier with AC 150 0 500 15 BMH 1 5 825818X Green BMH electronic switching and V heating function AC 42 150 V 3 BMH 3 8258198 yellow AC 150 0 500 One way rectifier with V ts PME TS 825 685 3 white BMP electronic switching inte grated voltage relay for cut off in the DC circuit Light AC 42 150 V 3 0 BMP 3 826 566 6 se One way rectifier with AC 150 0 500 15 BMK 1 5 826 463 5 Aqua electronic switch mode V i q BMK 24 Vpg control input and separation in the DC cir AC 42 150 V 3 0 BMK 3 8265674 Bright cuit red Brake control unit with BMV p Oone sienna E DOSAV 5 0 BMV5 13000063 white pc Control input and fast cut off Motor size DR 315 Holding Type Function Voltage current Type ean ee IHmax A One way rectifier with BMP electronic switching inte AC 230 0 575 28 BMP 3 1 829 507 7 grated voltage relay for V cut off in the DC circuit 78 Operating Instructions AC Motors DRS DRE DRP Technical Data Permitted roller bearing types 8 7 Permitted roller bearing types 8 7 1 Anti friction bearing types for motor sizes DR 71 DR 160 Drive end bearing Non drive end bearing Motor type IEC motor Gearmotor AC mot
40. 0 28 Key lg Accelerator current brief inrush current ly Holding current r m s value in the supply cable to the SEW brake rectifier la Direct current with direct DC voltage supply VR Rated voltage rated voltage range Operating Instructions AC Motors DRS DRE DRP Technical Data Operating currents 8 3 3 Brake BE120 BE122 The current values Iy holding current listed in the tables are r m s values Use only devices for measuring r m s values The inrush current accelerator current Ig only flows for a short time approx 400 ms when the brake is released Direct voltage supply is not possible BE120 BE122 Max braking torque Nm 1000 2000 Braking power W 250 250 Inrush current ratio Ip ly 4 9 4 9 Rated voltage Vp BE120 BE122 I l Vac Voc acl acl 230 218 243 1 80 1 80 254 244 273 1 60 1 60 290 274 306 1 43 1 43 360 344 379 1 14 1 14 400 380 431 1 02 1 02 460 432 484 0 91 0 91 500 485 542 0 81 0 81 575 543 600 0 72 0 72 Key lg Accelerator current brief inrush current ly Holding current r m s value in the supply cable to the SEW brake rectifier la Direct current with direct DC voltage supply VR Rated voltage rated voltage range Operating Instructions AC Motors DRS DRE DRP Technical Data Resistances 8 4 Resistances 8 4 1 Brake BE05 1 BE2
41. 0 5 7394357 Additional addresses for service in Germany provided on request France Production Haguenau SEW USOCOME Tel 33 3 88 73 67 00 Sales 48 54 route de Soufflenheim Fax 33 3 88 73 66 00 Service B P 20185 http www usocome com F 67506 Haguenau Cedex sew usocome com Production Forbach SEW EUROCOME Tel 33 3 87 29 38 00 Zone Industrielle Technop le Forbach Sud B P 30269 F 57604 Forbach Cedex Assembly Bordeaux SEW USOCOME Tel 33 5 57 26 39 00 Sales Parc d activit s de Magellan Fax 33 5 57 26 39 09 Service 62 avenue de Magellan B P 182 F 33607 Pessac Cedex Lyon SEW USOCOME Tel 33 4 72 15 37 00 Parc d Affaires Roosevelt Fax 33 4 72 15 37 15 Rue Jacques Tati F 69120 Vaulx en Velin Paris SEW USOCOME Tel 33 1 64 42 40 80 Zone industrielle 2 rue Denis Papin F 77390 Verneuil l Etang Fax 33 1 64 42 40 88 Additional addresses for service in France provided on request Operating Instructions AC Motors DRS DRE DRP Address List Customer service Algeria Sales Alger R ducom Tel 213 21 8222 84 16 rue des Fr res Zaghnoun Fax 213 21 8222 84 Bellevue El Harrach 16200 Alger Argentina Assembly Buenos Aires SEW EURODRIVE ARGENTINA S A Tel 54 3327 4572 84 Sales Centro Industrial Garin Lote 35 Fax 54 3327 4572 21 Service Ruta Panamericana Km 37 5 sewar sew eurodrive com ar
42. 1 4949 71 gacar beirut com Lithuania Sales Alytus UAB Irseva Tel 370 315 79204 Naujoji 19 Fax 370 315 56175 LT 62175 Alytus info irseva lt http www sew eurodrive lt Luxembourg Assembly Br ssel CARON VECTOR S A Tel 32 10 231 311 Sales Avenue Eiffel 5 Fax 32 10 231 336 Service B 1300 Wavre http www sew eurodrive lu info caron vector be Malaysia Assembly Johore SEW EURODRIVE SDN BHD Tel 60 7 3549409 Sales No 95 Jalan Seroja 39 Taman Johor Jaya Fax 60 7 3541404 Service 81000 Johor Bahru Johor sales sew eurodrive com my West Malaysia 98 Operating Instructions AC Motors DRS DRE DRP Address List Customer service Mexico Assembly Queretaro SEW EURODRIVE MEXIKO SA DE CV Tel 52 442 1030 300 Sales SEM 981118 M93 Fax 52 442 1030 301 Service Tequisquiapan No 102 http www sew eurodrive com mx Parque Industrial Queretaro scmexico seweurodrive com mx C P 76220 Queretaro Mexico Morocco Sales Casablanca Afit Tel 212 22618372 5 rue Emir Abdelkader Fax 212 22618351 MA 20300 Casablanca ali alami premium net ma Netherlands Assembly Rotterdam VECTOR Aandrijftechniek B V Tel 31 10 4463 700 Sales Industrieweg 175 Fax 31 10 4155 552 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
43. 12 0 46 5 360 344 379 19 1 74 0 19 1 74 0 400 380 431 24 0 93 0 24 0 93 0 460 432 484 30 0 117 0 30 0 117 0 500 485 542 38 0 147 0 38 0 147 0 575 543 600 48 0 185 0 48 0 185 0 Resistance mea surement BE120 BE122 BS Accelerator coil TS Coil section The following figure shows the resistance measurement for BMP 3 1 RD Rg WH Rr BU Rg Accelerator coil resistance at 20 C Q Ry Coil section resistance at 20 C Q Vg Rated voltage rated voltage range NOTE For measuring the resistance of the RT coil section or the RB accelerator coil remove the white conductor from the brake rectifier If it remains connected the internal resis tance of the brake rectifier will cause erroneous results Operating Instructions AC Motors DRS DRE DRP 75 Technical Data Brake rectifier combinations 8 5 Brake rectifier combinations 8 5 1 Brake BE05 1 BE2 BE5 BE11 BE20 The following table shows the standard and optional combinations of brakes and brake rectifiers BE05 BE1 BE2 BE5 BE11 BE20 amp Size 1 5 x x x Ize Size 3 x x x BGE 1 5 x x x BGE BGE 3 x x2 x2 x2 BS BS 24 X X x _ E BMS 1 5 A E E BMS BMS 3 E E BME 1 5 E BME BME 3 A BMH 1 5 3 BMH BMH 3 A n n BMK 1 5 BMK BMK
44. 160 BE20 80 110 150 200 8 2 3 Motor size DR 315 Motor type Brake type Braking torque steps in Nm BE120 400 600 800 1000 DR 315 BE122 800 1200 1600 2000 Operating Instructions AC Motors DRS DRE DRP 69 Technical Data Operating currents 8 3 Operating currents 8 3 1 Brake BE05 1 BE2 The current values ly holding current listed in the tables are r m s values Use only devices for measuring r m s values The inrush current accelerator current Ig only flows for a short time approx 160 ms when the brake is released There is no in creased inrush current if the BG or BMS brake rectifiers are used or if there is a direct DC voltage supply only possible with brakes up to size BE2 BE05 1 BE2 Max braking torque Nm 5 10 20 Braking power W 32 43 Inrush current ratio Ip ly 4 4 Rated voltage Vp BE05 1 BE2 l l l l Vac Voc trae a We ae 24 23 26 10 2 10 2 80 2 75 3 75 60 57 63 24 0 88 1 17 1 57 1 46 120 111 123 48 0 45 0 58 0 59 0 78 184 174 193 80 0 29 0 35 0 38 0 47 208 194 217 90 0 26 0 31 0 34 0 42 230 218 243 96 0 23 0 29 0 30 0 39 254 244 273 110 0 20 0 26 0 27 0 34 290 274 306 125 0 18 0 26 0 24 0 30 330 307 343 140 0 16 0 20 0 21 0 27 360 344 379 160 0 14 0 18 0 19 0 24 400 380 431 180 0 13 0 16 0 17 0 21 460 432 484 200 0 11 0 14 0 15 0 19 500 48
45. 1619 Garin Australia Assembly Melbourne SEW EURODRIVE PTY LTD Tel 61 3 9933 1000 Sales 27 Beverage Drive Fax 61 3 9933 1003 Service Tullamarine Victoria 3043 http www sew eurodrive com au enquires sew eurodrive com au Sydney SEW EURODRIVE PTY LTD Tel 61 2 9725 9900 9 Sleigh Place Wetherill Park Fax 61 2 9725 9905 New South Wales 2164 enquires sew eurodrive com au Townsville SEW EURODRIVE PTY LTD Tel 61 7 4779 4333 12 Leyland Street Fax 61 7 4779 5333 Garbutt QLD 4814 enquires sew eurodrive com au Austria Assembly Wien SEW EURODRIVE Ges m b H Tel 43 1 617 55 00 0 Sales Richard Strauss Strasse 24 Fax 43 1 617 55 00 30 Service A 1230 Wien http sew eurodrive at sew sew eurodrive at Belarus Sales Minsk SEW EURODRIVE BY Tel 375 17 298 38 50 RybalkoStr 26 Fax 375 17 29838 50 BY 220033 Minsk sales sew by Belgium Assembly Br ssel SEW Caron Vector S A Tel 32 10 231 311 Sales Avenue Eiffel 5 Fax 32 10 231 336 Service B 1300 Wavre http www sew eurodrive be info caron vector be Brazil Production Sao Paulo SEW EURODRIVE Brasil Ltda Tel 55 11 6489 9133 Sales Avenida Am ncio Gaiolli 50 Fax 55 11 6480 3328 Service Caixa Postal 201 07111 970 http www sew com br Guarulhos SP Cep 07251 250 sew sew com br Additional addresses for service in Brazil provided on request Bulgaria Sales Sofia BEVER DRIVE GmbH Tel 359 2 9151160 Bogdanovetz Str 1 Fax 359 2 9151166 BG 1606 Sofia bever fastbg net Cameroon Sales
46. 2 Circlip 14 Disc 15 Hex head bolt 16 Stator 17 Hexagonal nut 19 Machine screw 22 Hex head bolt 24 Lifting eyebolt 30 Sealing ring 31 Key 32 Circlip 35 Fan guard 36 Fan 41 Spring washer 42 Non drive end bearing shield 44 Deep groove ball bearing 90 Foot 91 Hexagonal nut 93 Disc 94 Machine screw 100 Hexagonal nut 103 Stud 106 Oil seal 107 Oil flinger ring 108 Nameplate 109 Grooved pin 111 Seal for bottom part 112 Terminal box lower part 113 Bolt 115 Terminal board 117 Hex head bolt 118 Lock washer cS N m A XIII UA WSS y E 527322635 119 Hex head bolt 120 Grounding terminal bottom 121 Grooved pin 122 Lock washer 123 Hex head bolt 127 Grounding terminal top 129 Screw plug with O ring 131 Gasket for cover 132 Terminal box cover 134 Screw plug with O ring 137 Bolt 153 Terminal strip complete 156 Information sign 390 O ring 705 Protection canopy 706 Spacer 707 Hex head bolt 715 Hex head screw Operating Instructions AC Motors DRS DRE DRP Motor Design Basic design of the DR 315 3 3 Basic design of the DR 315 1 Rotor 2 Circlip 8 Key 4 Key 7 Flange 9 Screw plug 11 Rolling element bearings 15 Machine screw 16 Stator 17 Hexagonal nut 19 Machine screw 21 Oil seal flange 22 Hex head bolt 24 ifting eyebolt 25 Mac
47. 20 659 657 748 367 220 407629451 35 Fan guard 659 Screw 220 Encoder 734 Nut 367 Retaining bolt 748 Screw 657 Protective cowl Removing EHT Remove protective cowl 657 by unscrewing the screws 659 e Remove encoder from the fan guard by unscrewing the nut 734 Loosen retaining screw 367 on the encoder 220 and remove 220 encoder from the shaft Removing AHT Remove protective cowl 657 by unscrewing the screws 659 Remove encoder from the fan guard by unscrewing the screws 748 Loosen retaining screw 367 on the encoder 220 and remove 220 encoder from the shaft Re assembly Important for re assembly Apply NOCO fluid to the encoder spigot Tighten retaining screw with the following tightening torques Encoder Tightening torque EHT 0 7 Nm AHT 3 0 Nm 34 Operating Instructions AC Motors DRS DRE DRP Inspection Maintenance Inspection and maintenance work on the motor DR71 DR100 7 5 Inspection and maintenance work on the motor DR71 DR100 7 5 4 Basic design of DR 71 DR 132 1 Rotor 2 Circlip 3 Key 7 Flanged end shield 9 Screw plug 10 Circlip 11 Deep groove ball bearing 12 Circlip 13 Machine screw 16 Stator 22 Hex head bolt 24 Lifting eyebolt 30 Cil seal 32 Circlip 35 Fan guard 36 Fan 41 Equalizing ring 42 Non drive end bearing shield 44 Grooved ball bearing
48. 3 a A BMP 1 5 n BMP BMP 3 BMV BMV 5 BSG BSG X X x BGE 3 SR 11 e e e e e BGE 3 SR 15 BSR BGE 1 5 SR 11 R z BGE 1 5 SR 15 BGE 3 UR 11 E gt _ BUR BGE 1 5 UR 15 n X Standard design x Standard design with brake rated voltage of AC 150 500 V X Standard design with brake rated voltage of AC 24 42 150 V e Optional Not permitted 8 5 2 Brake BE120 BE122 The following table shows the standard and optional combinations of brakes and brake rectifiers BE120 BE122 BMP 3 1 X X Operating Instructions AC Motors DRS DRE DRP Technical Data Brake control 8 6 8 6 1 Motor size DR 71 DR 160 Motor size DR 315 Brake control Wiring space of the motor The following table lists the technical data of brake control systems for installation in the motor wiring space and the assignments with regard to motor size and connection tech nology The different housings have different colors color code to make them easier to distinguish Holding Type Function Voltage current Type slo zu number code IHmax A AC 150 500 V 1 5 Size 1 5 825 384 6 black Size One way rectifier AC 24 500 V 3 0 Size 3 825 386 2 brown AC 150 0 500 BGE One way rectifier with V 1 5 BGE 1 5 825
49. 3 Special aspects for operation with a frequency inverter When motors are powered from inverters you must adhere to the wiring instructions is sued by the inverter manufacturer It is essential to observe the operating instructions for the frequency inverter 5 3 1 Motor on SEW inverter SEW EURODRIVE has tested operation of the motor on SEW frequency inverters The required dialectic strength values of the motors were confirmed and the startup routines adjusted to the motor data You can operate the DR motor with any frequency inverter from SEW EURODRIVE To do so startup the motor according to the operating instruc tions of the frequency inverter 5 3 2 Motor on non SEW frequency inverter Operation of SEW motors on non SEW frequency inverters is permitted if the pulse volt ages indicated in the following figure are not exceeded for the specified rise times N Q Q o 1800 1600 1400 1200 1000 Permitted pulse voltage U V 800 600 0 0 2 04 06 0 8 10 1 2 1 4 Rise time ys 244030091 1 Permitted pulse voltage for DR standard 2 Permitted pulse voltage according to IEC 60 034 17 NOTE The diagram applies to motor operation If the permitted pulse voltage is exceeded limiting measures such as filters chokes or special motor cables have to be used Ask the manufacturer of the frequency inverter in this case Operating Instructions AC M
50. 333 Suhong Middle Road Fax 86 512 62581783 Service Suzhou Industrial Park suzhou sew com cn Jiangsu Province 215021 P R China Additional addresses for service in China provided on request Colombia Assembly Bogot SEW EURODRIVE COLOMBIA LTDA Tel 57 1 54750 50 Sales Calle 22 No 132 60 Fax 57 1 54750 44 Service Bodega 6 Manzana B http www sew eurodrive com co Santaf de Bogot sewcol sew eurodrive com co Croatia Sales Zagreb KOMPEKS d o o Tel 385 1 4613 158 Service PIT Erd dy 4 Il Fax 385 1 4613 158 HR 10 000 Zagreb kompeks net hr Czech Republic Sales Praha SEW EURODRIVE CZ S R O Tel 420 220121234 Business Centrum Praha Fax 420 220121237 Luzna 591 http www sew eurodrive cz CZ 16000 Praha 6 Vokovice sew sew eurodrive cz Denmark Assembly Kopenhagen SEW EURODRIVEA S Tel 45 43 9585 00 Sales Geminivej 28 30 Fax 45 43 9585 09 Service DK 2670 Greve http www sew eurodrive dk sew sew eurodrive dk 96 Operating Instructions AC Motors DRS DRE DRP Address List Customer service Estonia Sales Tallin ALAS KUUL AS Tel 372 6593230 Reti tee 4 Fax 372 6593231 EE 75301 Peetri k la Rae vald Harjumaa veiko soots alas kuul ee Finland Assembly Lahti SEW EURODRIVE OY Tel 358 201 589 300 Sales Vesim entie 4 Fax 358 3 780 6211 Service FIN 15860 Hollola 2 sew sew fi http www sew eurodrive fi Gabon Sales Lib
51. 5 7 Inspection Maintenance Inspection and maintenance for DR315 brake motor 8 With manual brake release Use setting nuts to set the floating clearance s between the conical coil springs pressed flat and the setting nuts see the following figure This floating clearance s is necessary so that the pressure plate can move up as the brake lining wears Otherwise reliable braking is not guaranteed SL 353592459 Brake Floating clearance s mm BE120 BE122 2 9 Install the rubber sealing collar back in place and re install the dismantled parts NOTE Replace setting nuts 58 and hexagon nuts 61 if the removal procedure is repeated 66 Operating Instructions AC Motors DRS DRE DRP Inspection Maintenance Inspection and maintenance for DR315 brake motor Changing the brake DR 315 STOP Make sure that the intended mounting position is permitted according to the data on the nameplate A DANGER Risk of crushing if the drive starts up unintentionally Severe or fatal injuries e Isolate the motor and brake from the power supply before starting work safeguarding them against unintentional power up Strictly observe the following instructions 1 Remove forced cooling fan and incremental encoder if installed See sec Preliminary work for motor and brake maintenance page 33
52. 5 542 220 0 10 0 13 0 13 0 17 575 543 600 250 0 09 0 11 0 12 0 15 Key lg Accelerator current brief inrush current ly Holding current r m s value in the supply cable to the SEW brake rectifier la Direct current with direct DC voltage supply VR Rated voltage rated voltage range Operating Instructions AC Motors DRS DRE DRP Technical Data Operating currents 8 3 2 Brake BE5 BE11 BE20 The current values l4 holding current listed in the tables are r m s values Use only devices for measuring r m s values The inrush current accelerator current lg only flows for a short time approx 160 ms when the brake is released There is no in creased inrush current when brake rectifiers B and BMS are used Direct voltage supply is not possible BE5 BE11 BE20 Max braking torque Nm 55 110 200 Braking power W 49 77 100 Inrush current ratio Ip ly 5 7 6 6 7 Rated voltage Vn BES BE11 BE20 l l l Vac Voc acl acl Arc 60 57 63 24 1 25 2 85 2 77 120 111 123 48 0 64 1 45 1 39 184 174 193 80 0 40 0 92 0 88 208 194 217 90 0 36 0 82 0 78 230 218 243 96 0 33 0 73 0 70 254 244 273 110 0 29 0 65 0 62 290 274 306 125 0 26 0 58 0 55 330 307 343 140 0 23 0 52 0 49 360 344 379 160 0 21 0 47 0 44 400 380 431 180 0 18 0 42 0 39 460 432 484 200 0 16 0 37 0 35 500 485 542 220 0 15 0 33 0 31 575 543 600 250 0 13 0 29
53. 6 38 454288 Service Muang sewthailand sew eurodrive com Chonburi 20000 Tunisia Sales Tunis T M S Technic Marketing Service Tel 216 71 4340 64 71 4320 29 5 Rue El Houdaibiah Fax 216 71 4329 76 1000 Tunis tms tms com tn Turkey Assembly Istanbul SEW EURODRIVE Tel 90 216 4419163 164 3838014 15 Sales Hareket Sistemleri San ve Tic Ltd Sti Fax 90 216 3055867 Service Bagdat Cad Koruma Cikmazi No 3 http www sew eurodrive com tr TR 34846 Maltepe ISTANBUL sew sew eurodrive com tr Ukraine Sales Dnepropetrovsk SEW EURODRIVE Tel 380 56 370 3211 Service Str Rabochaja 23 B Office 409 Fax 380 56 372 2078 49008 Dnepropetrovsk http www sew eurodrive ua sew sew eurodrive ua Sales Kiev SEW EURODRIVE GmbH Tel 380 44 503 95 77 S Oleynika str 21 Fax 380 44 503 95 78 02068 Kiev kso sew eurodrive ua USA Production Greenville SEW EURODRIVE INC Tel 1 864 439 7537 Assembly 1295 Old Spartanburg Highway Fax Sales 1 864 439 7830 Sales P O Box 518 Fax Manuf 1 864 439 9948 Service Lyman S C 29365 Fax Ass 1 864 439 0566 Telex 805 550 http www seweurodrive com cslyman seweurodrive com Operating Instructions AC Motors DRS DRE DRP 11 101 11 102 Address List Customer service USA Assembly San Francisco SEW EURODRIVE INC Tel 1 510 487 3560 Sales 30599 San Antonio St Fax 1 510 487 6381 Service Hayward California 94544 7101 cshayward seweurodrive com Philadelphia PA
54. Box 58 428 Fax 64 9 2740165 Service 82 Greenmount drive http www sew eurodrive co nz East Tamaki Auckland sales sew eurodrive co nz Christchurch SEW EURODRIVE NEW ZEALAND LTD Tel 64 3 384 6251 10 Settlers Crescent Ferrymead Fax 64 3 384 6455 Christchurch sales sew eurodrive co nz Norway Assembly Moss SEW EURODRIVE A S Tel 47 69 241 020 Sales Solgaard skog 71 Fax 47 69 241 040 Service N 1599 Moss http www sew eurodrive no sew sew eurodrive no Peru Assembly Lima SEW DEL PERU MOTORES REDUCTORES Tel 51 1 3495280 Sales S A C Fax 51 1 3493002 Service Los Calderos 120 124 http www sew eurodrive com pe Urbanizacion Industrial Vulcano ATE Lima sewperu sew eurodrive com pe Poland Assembly Lodz SEW EURODRIVE Polska Sp z o o Tel 48 42 67710 90 Sales ul Techniczna 5 Fax 48 42 67710 99 Service PL 92 518 d http www sew eurodrive pl sew sew eurodrive pl Portugal Assembly Coimbra SEW EURODRIVE LDA Tel 351 231 20 9670 Sales Apartado 15 Fax 351 231 20 3685 Service P 3050 901 Mealhada http www sew eurodrive pt infosew sew eurodrive pt Romania Sales Bucuresti Sialco Trading SRL Tel 40 21 230 1328 Service str Madrid nr 4 Fax 40 21 230 7170 011785 Bucuresti sialco sialco ro Operating Instructions AC Motors DRS DRE DRP 11 99 11 Address List Customer service 100 Russia Assembly St Petersburg ZAO SEW EURODRIVE
55. Customer service ooooooccccoconoccnnncnnncnononocononnnnnnnononons 93 D Delta connection oooccccccconocnnoncconononononononennnns 20 81 Design DIRS 100 5 o ae let e terns 9 BDRAB2 22 en 9 DRiSO 55th eto bab caet deed 9 DR QO sa cet si 9 MOtOF nice stes 9 10 11 36 Designated use ssssseee e 7 E A esca n eet iet 28 34 Electrical CONNectiON ooooocococoncoccccncnoncnnnnnnnncnnnns 8 Electrical Installation nenne 16 EM eroe nt hee ete ede ie EE 18 103 104 Index EriGoderz haste o rho deed tabat uius 28 AEVO uie mee Het red 28 f rS 28 EHS 3 tc A 28 ESP teneo ui deutet 28 ES D A AE ILE Se 28 Encoder connection 222224 4444 nnennnenennenn 28 ESYZhb a ee era te Ee 28 33 E Sii augen ann 28 33 Exclusion of liability ooooonnnnncnnnnnnicnnnnnnacccccnnnnanccnnns 5 F Frequency inverter operation nn 17 G General safety notes 6 Grountdirig E 18 I Improving the grounding 244 seen 18 Tats e 0 ee 30 Inspection and maintenance intervals 30 Inspection intervals cecceseeseecceeeeeeeeeeeeeeeeees 30 Inspection Maintenance en 30 instalation eu near 7 15 Electrical har eI 16 Mechanical riri 13 Installation tolerances nn 15 L Long term storage sseee 14 Lubricant tableau ra a edis 80 M Maint
56. Douala Electro Services Tel 237 33 431137 Rue Drouot Akwa B P 2024 Douala Fax 237 33 431137 Operating Instructions AC Motors DRS DRE DRP 11 95 11 Address List Customer service 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 marketing sew eurodrive ca Vancouver SEW EURODRIVE CO OF CANADALTD Tel 1 604 946 5535 7188 Honeyman Street Fax 1 604 946 2513 Delta B C V4G 1 E2 marketing sew eurodrive ca Montreal SEW EURODRIVE CO OF CANADALTD Tel 1 514 367 1124 2555 Rue Leger Fax 1 514 367 3677 LaSalle Quebec H8N 2V9 marketing sew eurodrive ca Additional addresses for service in Canada provided on request Chile Assembly Santiago de SEW EURODRIVE CHILE LTDA Tel 56 2 75770 00 Sales Chile Las Encinas 1295 Fax 56 2 75770 01 Service Parque Industrial Valle Grande http www sew eurodrive cl LAMPA ventas sew eurodrive cl RCH Santiago de Chile P O Box Casilla 23 Correo Quilicura Santiago Chile China Production Tianjin SEW EURODRIVE Tianjin Co Ltd Tel 86 22 25322612 Assembly No 78 13th Avenue TEDA Fax 86 22 25322611 Sales Tianjin 300457 gm tianjin sew eurodrive cn Service http www sew eurodrive com cn Assembly Suzhou SEW EURODRIVE Suzhou Co Ltd Tel 86 512 62581781 Sales
57. E20 page 46 e Replacing the brake disk of brakes BE120 BE122 page 63 Brake lining worn down Replace entire brake disc See the following section e Replacing the brake disk of brakes BE05 BE20 page 46 e Replacing the brake disk of brakes BE120 BE122 page 63 Incorrect braking torque Check the project planning and change the braking torque if needed see sec Work done working air gap braking torques page 68 by changing the type and number of brake springs See the following section Changing the braking torque of brakes BEO5 BE20 page 48 Changing the braking torque of brakes BE120 BE122 page 65 Byselecting a different brake See section Braking torque assignment page 69 Working air gap so large that setting nuts of the manual brake release come into contact Set the working air gap See the following section Setting the working air gap of brakes BEO5 BE20 page 45 Setting the working air gap of brakes BE120 BE122 page 61 Manual brake release device not set cor rectly Set the setting nuts for the manual brake release correctly See the following section e Changing the braking torque of brakes BE05 BE20 page 48 Changing the braking torque of brakes BE120 BE 122 page 65 Brake locked by manual brake release HF Loosen the setscrew remove if needed Brake is applied with time lag Brake is switched on AC voltage side only
58. G220 0 651 E E EFF I 3 1EC60034 i 16 22 Nm 122 cos p 0 79 A 4 45 2 55 Ins Cl 130 B IP 55 Hz 50 C BGE1 5 kg 41 0188 229 5 Made in Germany ED 3 4 2 Unit designation Example AC motor with feet and brake 186018187 DRE 90 M4 BE2 FI TF ES7S p Motor option sine encoder ES7S Motor option thermal motor protection with thermistor TF IEC motor type Motor with brake BE2 Motor length and number of poles Motor size DR motor series with code letter E type CEMEP EFF1 energy efficient motor or MEPS A2 Operating Instructions AC Motors DRS DRE DRP Mechanical Installation Before you start 4 Mechanical Installation NOTE It is essential to observe the safety notes in section 2 during installation 4 1 Before you start The drive may only be installed when The entries on the nameplate of the drive and or the output voltage of the frequency inverter match the voltage supply system The drive is undamaged no damage caused by transportation or storage tis certain that the following requirements have been met Ambient temperature between 20 C and 40 C 1 No oil acid gas vapors radiation etc Installation altitude max 1000 m above sea level Note the restrictions for encoders Special versions Drive configured in accordance with the ambient conditions STOP Make sure the mounting position corresponds to the information
59. R100 brake motors 7 6 6 Inspection steps for DR 71 DR 160 brakemotors A DANGER Risk of crushing if the drive starts up unintentionally Severe or fatal injuries Isolate the motor and brake from the power supply before starting work safeguarding them against unintentional power up Strictly observe the following instructions Remove forced cooling fan and incremental encoder if installed See sec Preliminary work for motor and brake maintenance page 33 2 Remove fan guard 35 and fan 36 3 Remove stator Size DR 71 DR 132 Remove machine screws 13 from flanged endshield 7 and B side endshield 42 Remove stator 16 from flanged endshield 7 Size DR 160 Loosen hex head screw 19 and remove B side endshield 42 Loosen hex head screw 15 and remove stator from flanged endshield Removing the brake cable Size DR 71 DR 132 Remove the terminal box cover loosen the brake cable from the rectifier Size DR 160 Loosen safety screws of the brake plug connector 698 and remove plug connector 5 Press off the brake from the stator and remove it carefully 6 Pull the stator back by approx 3 to 4 cm 7 Visual inspection Is there any moisture or gear unit oil inside the stator f not continue with 10 If there is condensation continue with 8 If there is gear oil have the motor repaired by a specialist workshop If there is moisture inside
60. RP 10 89 10 90 ES i Malfunctions 2 Motor malfunctions Malfunction Possible cause Remedy Excessively loud Ball bearing compressed contaminated or damaged Re align motor and the driven machine inspect anti fric tion bearing and replace if necessary See sec Permitted anti friction bearing types page 79 Vibration of rotating parts Look for the case possibly an imbalance correct the cause observe method for balancing Foreign bodies in cooling air passages Clean cooling air passages Operating Instructions AC Motors DRS DRE DRP Malfunctions 3 Brake malfunctions lt 10 2 Brake malfunctions Malfunction Possible cause Remedy Brake does not release Incorrect voltage on brake control unit Apply the correct voltage brake voltage specified on the name plate Brake control unit failed Install a new brake control check resistances and insulation of the brake coils see Resistances section for resistance val ues Check switchgear replace if needed Max permitted working air gap exceeded because brake lining worn down Measure and set working air gap See the following section Setting the working air gap of brakes BEO5 BE20 page 45 Sa the working air gap of brakes BE120 BE122 page 61 If the brake disk is too thin replace the brake disk See the following section e Replacing the brake disk o
61. Tel 7 812 3332522 7 812 5357142 Sales P O Box 36 Fax 7 812 3332523 Service 195220 St Petersburg Russia http www sew eurodrive ru sew sew eurodrive ru Senegal Sales Dakar SENEMECA Tel 221 849 47 70 M canique G n rale Fax 221 849 47 71 Km 8 Route de Rufisque senemeca sentoo sn B P 3251 Dakar Serbia Sales Beograd DIPAR d o o Tel 381 11 347 3244 381 11 288 Ustanicka 128a 0393 PC Kosum IV floor Fax 381 11 347 1337 SCG 11000 Beograd dipar yubc net Singapore Assembly Singapore SEW EURODRIVE PTE LTD Tel 65 68621701 Sales No 9 Tuas Drive 2 Fax 65 68612827 Service Jurong Industrial Estate http www sew eurodrive com sg Singapore 638644 sewsingapore sew eurodrive com Slovakia Sales Bratislava SEW Eurodrive SK s r o Tel 421 2 49595201 Rybni na 40 Fax 421 2 49595200 SK 83554 Bratislava sew sew eurodrive sk http sk sew eurodrive com Zilina SEW Eurodrive SK s r o Tel 421 41 700 2513 ul Vojtecha Spanyola 33 Fax 421 41 700 2514 SK 010 01 Zilina sew sew eurodrive sk Bansk Bystrica SEW Eurodrive SK s r o Tel 421 48 414 6564 Rudlovsk cesta 85 Fax 421 48 414 6566 SK 97411 Bansk Bystrica sew sew eurodrive sk Slovenia Sales Celje Pakman Pogonska Tehnika d o o Tel 386 3 490 83 20 Service Ul XIV divizije 14 Fax 386 3 490 83 21 SLO 3000 Celje pakman siol net South Africa Assembly Johannesburg SEW EURODRIVE PROPRIETARY LIMITED Tel 27 11 248 7000 Sales Eurodrive House Fax 27 11 494 3104 Service Cnr
62. al power up Strictly observe the following instructions NOTES The brake of DR 71 DR 80 motor sizes cannot be removed from the motor because the BE brake is directly installed on the brake endshield of the motor The brake of DR 90 DR 160 motor sizes cannot be removed from the motor for replacing the brake disk because the BE brake is pre installed on the brake endshield of the motor with a friction disk Remove the following Forced cooling fan and incremental encoder if installed See sec Preliminary work for motor and brake maintenance page 33 Flange cover or fan guard 35 circlip 32 62 and fan 36 Removing the brake cable Size DR 71 DR 132 Remove the terminal box cover loosen the brake cable from the rectifier Size DR 160 Loosen safety screws of the brake plug connector 698 and remove plug connector 3 Remove the rubber sealing collar 66 4 Loosen hex nuts 61 carefully pull off the magnet 54 brake cable and take out the brake springs 50 Remove the damping plate 718 pressure plate 49 and brake disc 68 and clean the brake components 6 Install a new brake disk 7 Re install the brake components Except for the fan and the fan guard because the working air gap has to be set first see section Setting the working air gap of the BEO5 BE20 brakes page 45 Operating Instructions AC Motors DRS DRE DRP Inspection
63. alperton ie Glasnevin Dublin 11 Israel Sales Tel Aviv Liraz Handasa Ltd Tel 972 3 5599511 Ahofer Str 34B 228 58858 Holon Fax 972 3 5599512 office liraz handasa co il Operating Instructions AC Motors DRS DRE DRP 11 97 11 Address List Customer service Italy Assembly Milano SEW EURODRIVE di R Blickle amp Co s a s Tel 39 02 96 9801 Sales Via Bernini 14 Fax 39 02 96 799781 Service 1 20020 Solaro Milano http www sew eurodrive it sewit sew eurodrive it Ivory Coast Sales Abidjan SICA Tel 225 2579 44 Ste industrielle et commerciale pour l Afrique Fax 225 2584 36 165 Bld de Marseille B P 2323 Abidjan 08 Japan Assembly Iwata SEW EURODRIVE JAPAN CO LTD Tel 81 538 373811 Sales 250 1 Shimoman no Fax 81 538 373814 Service Iwata http www sew eurodrive co jp Shizuoka 438 0818 sewjapan sew eurodrive co jp Korea Assembly Ansan City SEW EURODRIVE KOREA CO LTD Tel 82 31 492 8051 Sales B 601 4 Banweol Industrial Estate Fax 82 31 492 8056 Service 1048 4 Shingil Dong http www sew korea co kr Ansan 425 120 master sew korea co kr Latvia Sales Riga SIA Alas Kuul Tel 371 7139253 Katlakalna 11C Fax 371 7139386 LV 1073 Riga http www alas kuul com info alas kuul com Lebanon Sales Beirut Gabriel Acar amp Fils sarl Tel 961 1 4947 86 B P 80484 961 1 4982 72 Bourj Hammoud Beirut 961 3 2745 39 Fax 961
64. ating Instructions AC Motors DRS DRE DRP Appendix Wiring diagrams 9 1 3 Motor protection using TF or TH with DR315 TF TH The following figures show the connection of the motor protection with TF PTC ther mistor sensors or TH bimetallic thermostats Depending on the design an x pole terminal clip is available for connecting to the trip switch Example TF TH to terminal strip 1 TF 1 1F 1 TH 1 TH Example 2 x TF TH to terminal strip 1 TF 1 TF 2 TF 2 TF 1 TH 1 TH 2 TH 2 TH Operating Instructions AC Motors DRS DRE DRP 83 9 Appendix Wiring diagrams 9 1 4 Brake control BGE BG BSG BUR Brake BE Brake control BGE BG BSG BUR Apply voltage to release the brake see nameplate Contact rating of the brake contactors AC3 according to EN 60947 4 1 The voltage can be distributed as follows Through a separate supply cable From the motor terminal board This does not apply to multi speed and frequency controlled motors BG BGE The following figure shows the wiring for BG and BGE brake rectifiers for the AC side cut off as well as the DC and AC side cut off 242604811 1 Brake coil 84 Operating Instructions AC Motors DRS DRE DRP Appendix Wiring diagrams BSG The following figure shows the DC 24 V connection of the BSG control unit 24VDc 242606475 1 Brake coil BUR STOP Connection to motor terminal board not p
65. ced cooling fan and incremental encoder if installed See sec Preliminary work for motor and brake maintenance page 33 Flange cover or fan guard 21 Push the rubber sealing collar 5 aside if necessary release the clip Vacuum up the abraded matter Measure the brake disk 68 Minimum brake disk thickness see sec Technical Data page 68 Replace brake disk if necessary see sec Replacing the brake disk of brakes BE05 BE20 page 46 Measure the working air gap A see the following figure use a feeler gauge and measure at three points offset by 120 Between the pressure plate 49 and damping plate 718 5 Tighten the hexagon nuts 61 6 Tighten the setting sleeves Until the working air gap is set correctly see sec Technical Data page 68 Install the rubber sealing collar back in place and re install the dismantled parts 179978635 Operating Instructions AC Motors DRS DRE DRP 45 Inspection Maintenance Inspection and maintenance for DR71 DR100 brake motors 7 6 8 Replacing the brake disk of BE05 BE20 brakes When changing a brake disk inspect the other removed parts as well and fit new ones if necessary Risk of crushing if the drive starts up unintentionally Severe or fatal injuries Isolate the motor and brake from the power supply before starting work safeguarding them against unintention
66. chine screws 19 and hex nuts 17 Lift the oil seal flange 21 with the setscrew and fasten using 2 screws 25 Remove the setscrew and screw in the remaining screws 25 14 Renew oil seals A end Insert the oil seal 106 and the oil seal 250 for gearmotors With gearmotors fill the space between the two oil seals approx two thirds full with grease Kl ber Petamo GHY 133 B end Insert the oil seal 30 and coat the sealing lip with the same grease 15 Reinstall the fan 36 and fan guard 35 Operating Instructions AC Motors DRS DRE DRP Inspection Maintenance Inspection and maintenance for DR315 brake motor 7 8 Inspection and maintenance for DR315 brake motor 7 8 1 Basic design of the DR 315 brakemotor 1 Motor with brake bearing end shield 53 Release lever 22 Hex head bolt 55 Closing piece 31 Key 56 Stud 82 Circlip 57 Conical spring 85 Fan guard 58 Setting nut 86 Fan 62 Circlip 87 V ring 64 Setscrew 47 O ring 70 Driver Operating Instructions AC Motors DRS DRE DRP 57 255 256 58 353595787 71 Key 255 Ball cup 256 Concave washer 550 Pre assembled brake 900 Bolt 901 Gasket 57 58 Inspection Maintenance Inspection and maintenance for DR315 brake motor 7 8 2 Basic design of BE120 BE122 brakes 28 49 50 52b 54 60 61 Closing cap Pressure plate Brake spring Brake lining onl
67. e general structure lts only purpose is to facilitate the assignment of components to the spare parts lists Discrepancies are possible depending on the motor size and version 3 1 Basic design of DR 71 DR 132 1 Rotor 2 Circlip 8 Key 7 Flanged end shield 9 Screw plug 10 Circlip 11 Deep groove ball bearing 12 Circlip 13 Machine screw 16 Stator 22 Hex head bolt 24 Lifting eyebolt 30 Oil seal 82 Circlip 85 Fan guard 36 Fan 41 Equalizing ring 42 B side endshield 44 Deep groove ball bearing 90 Base plate 93 Pan head screw 100 Hexagonal nut 103 Stud 106 Oil seal 107 Oil flinger ring 108 Nameplate 109 Grooved pin 111 Seal for bottom part 112 Terminal box lower part 113 Pan head screw 115 Terminal board 116 Terminal clip Operating Instructions AC Motors DRS DRE DRP 173332747 117 Hex head bolt 118 Lock washer 119 Pan head screw 123 Hex head bolt 129 Screw plug with O ring 131 Gasket for cover 132 Terminal box cover 134 Screw plug with O ring 156 Information sign 262 Terminal clip complete 392 Gasket 705 Protection canopy 706 Spacer 707 Pan head screw 10 Motor Design Basic design of the DR 160 3 2 Basic design of the DR 160 107 1 Rotor 2 Circlip 3 Key 4 Key 7 Flange 9 Screw plug 10 Circlip 11 Deep groove ball bearing 1
68. e rated motor current There are no other sources of danger present 6 1 2 During startup make sure that The motor is running correctly no overload no speed fluctuation no loud noises etc The correct braking torque is set according to the specific application see section Technical Data page 68 STOP On brake motors with self reengaging manual brake release the lever must be removed after startup A bracket is provided for storing the lever on the outside of the motor Operating Instructions AC Motors DRS DRE DRP 29 7 30 Cd Inspection Maintenance Inspection and maintenance intervals 7 Inspection Maintenance Risk of crushing if the hoist falls Severe or fatal injuries Secure or lower hoist drives danger of falling Isolate the motor and brake from the power supply before starting work safeguarding them against unintentional re start Use only genuine spare parts according to the valid parts list Always install a new brake controller at the same time as replacing the brake coil A CAUTION Before starting work let the motor cool down STOP For assembly the ambient temperature and the oil seals themselves may not be colder than 0 C since the oil seals could be damaged otherwise The drive surfaces can reach high temperatures during operation Danger of burns 7 1 Inspection and maintenance intervals Uni
69. ece 22 Hex head bolt 56 Stud 31 Key 57 Conical coil spring BE20 32 Circlip 58 Setting nut 900 Screw 85 Fan guard 62 Circlip 901 O ring 36 Fan 70 Carrier 51 Hand lever 71 Key 53 Releasing lever 95 Sealing ring Operating Instructions AC Motors DRS DRE DRP Inspection Maintenance Inspection and maintenance for DR71 DR100 brake motors 7 6 4 Basic design of BE05 BE2 brake DR 71 DR 80 42 73 68 67 65 49 718 50 276 54 60 61 66 528377739 42 Brake endshield 61 Hexagonal nut 73 Niro disk 49 Pressure plate 65 Pressure ring 276 Brake spring blue 50 Brake spring standard 66 Rubber sealing collar 718 Dampening plate 54 Magnet complete 67 Counter spring 60 Stud 3x 68 Brake disk Operating Instructions AC Motors DRS DRE DRP 41 Inspection Maintenance Inspection and maintenance for DR71 DR100 brake motors 7 6 5 Basic design of BE1 BE20 brake DR 90 DR 160 702 69 67 68 65 49 718 50 276 54 60 61 66 174202635 49 Pressure plate 65 Pressure ring 276 Brake spring blue 50 Brake spring standard 66 Rubber sealing collar 702 Friction disk 54 Magnet complete 67 Counter spring 718 Dampening plate 60 Stud 3x 68 Brake disk 61 Hexagonal nut 69 Circular spring Operating Instructions AC Motors DRS DRE DRP Inspection Maintenance Inspection and maintenance for DR71 D
70. ection and maintenance for DR71 DR100 brake motors 7 6 10 Retrofitting HR HF manual brake release A DANGER Risk of crushing if the drive starts up unintentionally Severe or fatal injuries Isolate the motor and brake from the power supply before starting work safeguarding them against unintentional power up Strictly observe the following instructions Remove the following Forced cooling fan and incremental encoder if installed See sec Preliminary work for motor and brake maintenance page 33 Flange cover or fan guard 35 circlip 32 62 and fan 36 Installing manual brake release e For size DR 71 DR 132 Remove the sealing ring 95 Screw in studs 56 insert sealing ring for manual brake release 95 and hammer in parallel pin 59 Mount release lever 53 conical coil springs 57 and setting nuts 58 For size DR 160 Screw in studs 56 Mountrelease lever 53 conical coil springs 57 and setting nuts 58 Use setting nuts to set the floating clearance s between the conical coil springs pressed flat and the setting nuts see the following figure This floating clearance s is necessary so that the pressure plate can move up as the brake lining wears Otherwise reliable braking is not guaranteed 177241867 Brake Floating clearance s mm BE05 BE1 BE2 1 5 BE5 BE11 BE20 2 4 Install the removed parts
71. ed for star star connec tion but only connected in star Correct the connection from star to star star follow the wiring diagram Voltage or frequency deviate considerably from setpoint at least while being switched on Provide better power supply system reduce the power supply load Check cross section of supply cable replace with cable of larger cross section if needed Motor does not start in star connection only in delta connection Torque not sufficient in start connection Ifthe delta inrush current is not too high observe the reg ulations of the power supplier start up directly in delta Check the project planning and use a larger motor or spe cial version if necessary consult with SEW EURODRIVE Contact fault on star delta switch Check the switch replace if necessary Check the connections Incorrect direction of rotation Motor connected incorrectly Swap two phases of the motor supply cable Motor hums and has high current consumption Brake does not release See Sec Brake faults page 91 Winding defective Rotor rubbing Send motor to specialist workshop for repair Fuses blow or motor protec tion trips immediately Short circuit in the motor supply cable Rectify short circuit Supply cables connected incorrectly Correct the wiring observe the wiring diagram Short circuit in motor Ground fault on motor Send motor to specialist workshop for
72. enance canis aae aea 30 Maintenance intervals nennen 30 Malfunctions S i e t e aeni es 89 Malfunctions when operated with a frequency inverter sssssseene 93 Mechanical Installation ssesssssss 13 Motor Connect pica ite e ET des 20 DING ir ir dotan 14 Installation ii ti edain 15 Long term Storage ooooccccccococcccccnnnancncninannncnnnnannns 14 Motor connection terminal board 21 Motor Design id 9 Motor design DR 100 oia il 9 DRA near 9 DR 160 5 i Lee 10 36 DR 315 55 sete veneno 11 DR 1 vs REOR esos 9 A iiie tries 9 DREI ries te ett ert oue 9 Motor inspection DE 100 ote ita n Ede EA 37 DR 19325 innu Rumes 37 DR IOO a ans 37 DR nen reed 55 DR lites oe A 37 DE 80 cote NE 37 DR 90 inea t entis edt es 37 Motor malfunctions ooococcococcnnccncnoncnnnnnncncnnnnnns 89 Motor protectiON cooooococononcnconancnononos 16 82 83 TE nn a atat breed dettes 82 83 n BE E EE EE ER ETE EEA 82 83 N Nameplate a rear 12 O Operation with frequency inverter 17 P Preliminary work for motor and brake maintenance cccocccncccccnnnncononononononenenonos 33 R Reinforced bearing nen 13 32 Relubrication ooooooococononcocononononononononnnnonononononos 31 Relubrication periods 24444424 nn 32 Removing the encoder 4
73. ermitted The following figure shows the wiring for the BUR brake control 242608139 1 Brake coil 2 Voltage relay UR11 UR15 UR 11 42 150 V BN UR 15 150 500 V BK Operating Instructions AC Motors DRS DRE DRP 85 9 Appendix Wiring diagrams 9 1 5 BSR brake control Brake BE BSR brake control system Brake voltage Phase voltage The white connecting leads are the ends of a converter loop and depending on the motor connection must be connected to the motor terminal block instead of the A or A bridge Factory wiring A The following figure shows the factory wiring for the BSR brake control Example Motor AC 230 V AC 400 V Brake AC 230 V L1 L2 L3 242599819 1 Brake coil 2 SR11 15 current relay 86 Operating Instructions AC Motors DRS DRE DRP Appendix 9 Wiring diagrams 9 1 6 BMP3 1 brake control in the terminal box Brake BE120 BE122 BMP3 1 brake control Apply voltage to release the brake see nameplate Contact rating of the brake contactors AC3 according to EN 60947 4 1 Separate supply cables are required for the voltage supply BMP3 1 The following figure shows the wiring for the BMP3 1 brake rectifier for the AC side cut off as well as the DC and AC side cut off DC 7 _ AC BMP3 1 365750411 1 Brake coil Operating Instructions AC Motors DRS DRE DRP 87 Appendix Wiring diagrams 9 1 7 V forced cooling fan A
74. f brakes BE05 BE20 page 46 Replacing the brake disk of brakes BE120 BE122 page 63 Voltage drop on supply cable gt 10 Provide correct connection voltage brake voltage specifica tions on the nameplate Check the cross section of the brake supply cable increase cross section if necessary Inadequate cooling brake overheats Provide for cooling air supply or clear cooling air passages check air filter clean or replace if necessary Replace type BG brake rectifier with type BGE Brake coil has interturn fault or short circuit to exposed conductive part Check resistances and insulation of the brake coils see Resistances section for resistance values Replace complete brake and brake control system specialist workshop Check switchgear replace if needed Rectifier defective Replace rectifier and brake coil it may be more economical to replace the complete brake Operating Instructions AC Motors DRS DRE DRP 10 91 10 gt 2 Malfunctions Brake malfunctions Malfunction Possible cause Remedy Brake does not brake Working air gap not correct Measure and set working air gap See the following section Setting the working air gap of brakes BEO5 BE20 page 45 im the working air gap of brakes BE120 BE122 page 61 Ifthe brake disk is too thin replace the brake disk See the following section e Replacing the brake disk of brakes BE05 B
75. f crushing if the drive starts up unintentionally Severe or fatal injuries Isolate the motor and brake from the power supply before starting work safeguarding them against unintentional power up Strictly observe the following instructions oOo N DO FB CO Remove the following Forced cooling fan and incremental encoder if installed See sec Preliminary work for motor and brake maintenance page 33 Flange cover or fan guard 35 circlip 32 62 and fan 36 Removing the brake cable Sizes DR 90 DR 132 Remove the terminal box cover loosen the brake cable from the rectifier Size DR 160 Loosen safety screws of the brake plug connector 698 and remove plug connector Loosen the bolts 900 and remove the brake from the brake endshield Make sure the seal 901 is aligned properly Connect brake cable Align the cam of the friction disc Install seal 95 With manual brake release Use setting nuts to set the floating clearance s between the conical coil springs pressed flat and the setting nuts see the following figure This floating clearance s is necessary so that the pressure plate can move up as the brake lining wears Otherwise reliable braking is not guaranteed 177241867 Brake Floating clearance s mm BE05 BE1 BE2 1 5 BE5 BE11 BE20 2 52 Operating Instructions AC Motors DRS DRE DRP Inspection Maintenance Insp
76. g Motor size DR 112 DR 132 Terminal stud Tightening torque of Connection at Version Connection Scope of delivery diameter hex nut customer site type cross section M5 2 0 Nm lt 10 mm Type 2 Ring cable lug Connection accessories preassembled M6 3 0 Nm lt 16 mm Type 3 Ring cable lug Connection accessories pre assembled Motor size DR 160 Terminal stud Tightening torque of Connection at Version Connection Scope of delivery diameter hex nut customer site type cross section M6 3 0 Nm lt 16 mm Type 3 Ring cable lug Connection accessories preassembled M8 6 0 Nm lt 25 mm Type 3 Ring cable lug Connection accessories pre assembled Motor size DR 315 Terminal stud Tightening torque of Connection at Version Connection Scope of delivery diameter hex nut customer site type cross section 2 M12 15 5 Nm lt 50 mm Connection accessories Type 3 Ring cable lug M16 30 Nm 95 mm preassembled The types printed in bold apply to S1 operation for the standard voltages and standard frequencies according to the data specified in the catalog Deviating types can have dif ferent connections e g different diameters of the terminal studs and or a different scope of delivery Operating Instructions AC Motors DRS DRE DRP 21 5 Electrical Installation Connecting the motor Type 1 a Ifthe cross section of the external connection is x 1 5 mm it can be installed directly under the terminal washer b Ifthe cross
77. h a half key Existing condensation drain holes are sealed with closing plugs Drain holes can be opened if required to drain the condensation but have to be closed again be cause open drain holes make higher protection ratings ineffective If using brake motors with manual brake release screw in either the hand lever with self reengaging manual brake release or the setscrew with lockable manual brake re lease If possible arrange the terminal box so that the cable entries are pointing downwards Coat the threads of cable glands and filler plugs with sealing compound and tighten them well then coat them again Seal the cable entry well Clean the sealing surfaces of the terminal box and the terminal box cover carefully be fore re assembly gaskets have to be glued in on one side Replace brittle gaskets Restore the anticorrosive coating if necessary Check the degree of protection 4 2 3 Installation tolerances Shaft end Flanges Diameter tolerance according to EN 50347 Centering shoulder tolerance according to EN SO j6 with lt 28 mm 50347 ISO k6 with Y gt 38 mm up to x 48 mm SOj6 with Y x 250 mm ISO m6 for Y gt 55mm ISO h6 for 2 300 mm Center bore in accordance with DIN 332 shape DR Operating Instructions AC Motors DRS DRE DRP 15 5 Electrical Installation Using the wiring diagrams 5 Electrical Installation NOTES e Itis essential to observe the safety
78. he relubrication period of the bearings for e 20 C 40 C ambient temperature 4 pole speed and normal load can be determined from the table below Higher speeds loads or ambient temperatures cause shorter relubrication periods Horizontal mounting position Vertical mounting position Motor type Duration Quantity Duration Quantity DR 315 NS 5 000h 50g 3 000 h 70g DR 315 ERF NS 3 000 h 50g 2 000 h 70g 7 3 Reinforced bearing STOP In option ERF reinforced bearing cylindrical roller bearings are used on the A side Do not operate them without any overhung loads since otherwise they might be damaged The reinforced bearing is only offered with option NS relubrication to optimize lubrica tion of the bearings Please observe the notes on bearing lubrication in sec Bearing lubrication of the DR 315 page 31 Operating Instructions AC Motors DRS DRE DRP Inspection Maintenance 7 Preliminary work for motor and brake maintenance 7 4 Preliminary work for motor and brake maintenance A DANGER Risk of crushing if the drive starts up unintentionally Severe or fatal injuries Before starting work isolate the motor and brake from the power supply e Safeguard them against unintentional power up 7 4 1 Removing the incremental encoder from DR 71 DR 132 The following figure shows how to remove an encoder using the ES7 incremental en
79. he working air gap of the BEO5 BE20 brakes page 45 Operating Instructions AC Motors DRS DRE DRP Inspection Maintenance Inspection and maintenance for DR71 DR100 brake motors 7 With manual brake release Use setting nuts to set the floating clearance s between the conical coil springs pressed flat and the setting nuts see the following figure This floating clearance s is necessary so that the pressure plate can move up as the brake lining wears Otherwise reliable braking is not guaranteed 177241867 Brake Floating clearance s mm BE05 BE1 BE2 1 5 BE5 BE11 BE20 2 8 Install the rubber sealing collar back in place and re install the dismantled parts NOTE Replace setting nuts 58 and hexagon nuts 61 if the removal procedure is repeated Operating Instructions AC Motors DRS DRE DRP 49 7 Inspection Maintenance Inspection and maintenance for DR71 DR100 brake motors Changing the magnet Risk of crushing if the drive starts up unintentionally Severe or fatal injuries Isolate the motor and brake from the power supply before starting work safeguarding them against unintentional power up Strictly observe the following instructions Remove the following Forced cooling fan and incremental encoder if installed See sec Preliminary work for motor and brake maintenance page 33 Flange cover or fan guard 35
80. hine screw 26 Sealing washer 30 Oil seal 31 Key 32 Circlip 35 Fan guard 36 Fan 40 Circlip 42 Non drive end bearing shield 43 Supporting ring 44 Rolling element bearings 90 Foot 93 Disc 94 Machine screw 100 Hex nut 103 Stud 105 Spring washer 106 Oil seal 107 Oil flinger 108 Nameplate 109 Grooved pin 111 Gasket for lower part 112 Terminal box lower part 113 Machine screw 115 Terminal board 116 Serrated lock washer 117 Stud 118 Washer 119 Hex head screw 123 Hex head screw 128 Serrated lock washer 129 Screw plug Operating Instructions AC Motors DRS DRE DRP 351998603 131 Gasket for cover 132 Terminal box cover 134 Screw plug 139 Hex head screw 140 Washer 151 Machine screw 219 Hex nut 250 Oil seal 452 Terminal strip 454 DIN rail 604 Oiling ring 606 Grease nipple 607 Grease nipple 608 Oil seal flange 609 Hex head screw 633 End holder 634 End plate 705 Protection canopy 706 Spacer bolt 707 Hex head screw 715 Hex nut 716 Washer 11 12 Motor Design Nameplate unit designation 3 4 Nameplate unit designation 3 4 4 Nameplate Example DRE gearmotor with a brake SEW EURODRIVE 76646 Bruchsal Germany RF47 DRE90M4BE2 TF Z C 01 300123456 0002 06 1425 88 kw 1 181 O V 230 400 A Y V 220 240 A 380 415 Y IM M1 rpm UBR 220 240 AC Nm 20 V TA CLPCCV
81. neral information Never install damaged products or take them into operation Submit a complaint to the shipping company immediately in the event of damage Low voltage machines have dangerous live and rotating parts as well as hot surfaces All work related to transportation putting into storage setup mounting connection star tup maintenance and repair may only be carried out by qualified personnel observing The relevant detailed operating instruction s and wiring diagrams The warning and safety signs on the motor gearmotor The specific regulations and requirements for the system The national regional regulations governing safety and the prevention of accidents Removing covers without authorization improper use as well as incorrect installation or operation may result in severe injuries to persons or damage to machinery Consult the documentation for additional information Operating Instructions AC Motors DRS DRE DRP Safety Notes Designated use 2 3 2 4 2 5 Designated use Transport Installation The electric motors are intended for industrial systems The use in potentially explosive atmospheres is not permitted unless the unit has been designed expressly for this pur pose Air cooled variants are designed for ambient temperatures of 20 C to 40 C and alti tudes of x 1 000 m above sea level Please take into account deviating specifications on the nameplate The conditions where the
82. nnnnnnnnnnnnnnnnnnnannannnnnnnnnnnnnnnnnnan nn 13 4 1 Before YOU Sta id e e tala do E Eee eg 13 4 2 Mechanical installatiOD oooonnoninninnnnnnncnncnnncnnncnnnnnnnonnnnnnnncnnnnnnnnnnnannnnnns 13 5 Electrical Installation ecrire trina trece tinere reete dr 16 5 1 Using the wiring diagrams sssee nme 16 9 2 Wiringinotes e e re c EE e t eid 16 5 3 Special aspects for operation with a frequency inverter 17 5 4 Improving the grounding EMO sssssee enne 18 5 5 Special aspects in switching operation sesssssee 19 5 6 Ambient conditions during operation ssseeee 19 5 Connecting the Motor arraine ieia ea AA nennen enne 20 5 8 Connecting the brake ssssssssesssseeeeeee enne 25 5 9 Accessory equipmient iue ti ed tell ed eee ceci lads it 26 6 cStart p oco eue Uh It nee tiere T 29 6 1 Prerequisites for startup sssssssssssssseeeene me 29 7 Inspection Maintenance uuunusssennnnnnsnannnnnnnnnnnnnnnnnnnnnanmannnnnnnnnnnnnnnnnnnnn nn 30 7 1 Inspection and maintenance intervals sssssssssseseee 30 7 2 Bearing l bricatiom 4 48 e eat iin 31 Ta Reinforced bearirig i HERE CHR ERR RUE ER ELE EHE 32 7 4 Preliminary work for motor and brake maintenance een 33 7 5 Inspection and maintenance work on the motor DR71 DR100
83. nnnnnnnnnnnnnnnnnnnnnnnennnnnnnnnnnnnnnnnn nnns 93 Address Listin aa Eee deta area 94 eiii a A da 103 Operating Instructions AC Motors DRS DRE DRP General Information Structure of the safety notes 1 General Information 1 1 Structure of the safety notes The safety notes in these operating instructions are designed as follows Pictogram NST NE DT Type and source of danger Possible consequence s if the safety notes are disregarded Measure s to prevent the danger Pictogram Signal word Meaning Consequences in case of disregard Example A DANGER Imminent danger Severe or fatal injuries A WARNING Possible dangerous situation Severe or fatal injuries General danger AN CAUTION Possible dangerous situation Minor injuries Specific danger e g electric shock STOP Possible damage to property Damage to the drive system or its environ D NOTE Useful information or a tip Simplifies the handling of the drive system 1 2 Rights to claim under limited warranty A requirement of fault free operation and fulfillment of any rights to claim under limited warranty is that you adhere to the information in the operating instructions Conse quently read the operating instructions before you start working with the unit Make sure that the operating instructions are available to persons responsible for the plant and its operation as well as to person who work independentl
84. or Brakemotor DR 71 6204 2Z J C3 6303 2Z J C3 6203 2Z J C3 6203 2RS J C3 DR 80 6205 2Z J C3 6304 2Z J C3 6304 2Z J C3 6304 2RS J C3 DR 90 DR 100 6306 2Z J C3 6205 2Z J C3 6205 2RS J C3 DR 112 DR 132 6308 2Z J C3 6207 2Z J C3 6207 2RS J C3 DR 160 6309 2Z J C3 6209 2Z J C3 6209 2RS J C3 8 7 2 Anti friction bearing types for motor size DR 315 Drive end bearing Non drive end bearing Motor type IEC motor Gearmotor IEC motor Gearmotor DR 315K 6319 J C3 6319 J C3 DR 315S 6319 J C3 6319 J C3 DR 315M 6322 J C3 6322 J C3 DR 315L Motor with rein forced bearing Drive end bearing Non drive end bearing Motor type IEC motor Gearmotor DR 315K 6319 J C3 DR 315S NU319E 6319 J C3 DR 315M 6322 J C3 DR 315L Operating Instructions AC Motors DRS DRE DRP Technical Data Lubricant tables 8 8 Lubricant tables 8 8 1 Lubricant table for roller bearings Motor size DR 71 The bearings are 2Z or 2RS closed bearings and cannot be regreased DR 160 Ambient temperature Manufacturer Type DIN designation 20 C 80 C Esso Polyrex EM K2P 20 Motor anti o gt i 2 friction bearings 20 C 100 C Kl ber Barrierta L55 2 KX2U 40 C 60 C Kyodo Yushi Multemp SRL K2N 40 1 Mineral lubricant mineral based anti friction bearing grease 2 Synthetic lubricant synthetic
85. ore mounting the brake endshield 42 screw in the M8 setscrew approximately 200 mm 7 87 in into the oil seal flange 21 15 Mount the brake endshield 42 feed the setscrew in through a bore for the screw 25 Screw in the brake endshield and stator 16 using machine screws 19 and hex nuts 17 Lift the oil seal flange 21 with the setscrew and fasten using 2 screws 25 Remove the setscrew and screw in the remaining screws 25 16 Renew oil seals A end Insert the oil seals 106 and the oil seal 250 for gearmotors Fill the space between the two oil seals approx two thirds full with grease Kl ber Petamo GHY 133 B end Insert the oil seal 30 and coat the sealing lip with the same grease This applies to gearmotors only 17 Align cam of the friction disk and mount the brake to the brake endshield using screw 900 18 With manual brake release Use setting nuts to set the floating clearance s between the conical coil springs pressed flat and the setting nuts see the following figure This floating clearance s is necessary so that the pressure plate can move up as the brake lining wears Otherwise reliable braking is not guaranteed S lt _ 353592459 Brake Floating clearance s mm BE120 BE122 2 19 Reinstall the fan 36 and fan guard 35 20 Install the motor and accessories 60 Operating Instructions AC Motors DRS DRE DRP
86. otors DRS DRE DRP 17 18 Electrical Installation Improving the grounding EMC 5 4 Improving the grounding EMC For improved low impedance grounding at high frequencies we recommend using the following connections 5 4 1 Size DR 71 DR 132 Size DR 71 DR132 1 x self tapping screw DIN 7500 M5 x 12 e 1x disk ISO 7090 e 1x serrated lock washer DIN 6798 176658571 1 Use the pre cast bore at the terminal box brake motor 2 Bore in stator housing with 4 6 and tmax 11 5 5 4 2 Size DR 160 DR 315 Size DR 160 Size DR 315 1x hex head screw ISO 4017 M8 x 20 e 1x disk ISO 7090 e 1 x serrated lock washer DIN 6798 1 x hex head screw ISO 4017 M12 x 30 1 x disk ISO 7090 1 x serrated lock washer DIN 6798 1 Using the grounding screw on the terminal box 370040459 Operating Instructions AC Motors DRS DRE DRP Electrical Installation 5 Special aspects in switching operation 5 5 Special aspects in switching operation When the motors are used in switching operation possible interference of the switch gear must be excluded by ensuring suitable wiring According to EN 60204 electrical equipment of machines motor windings must have interference suppression to protect the numerical or programmable logic controllers As it is primarily switching operations that cause interference SEW EURODRIVE recommends installing protective circuitry in the switching device
87. pa feet nen 42 BE Maita det lo co 42 O 58 BELL ra a RN 58 BE2 4 tee nei 41 42 A e ted es des 42 E 42 Braking torque breakdown ss 69 Braking tOUS Se a r E RA 68 Operating currents ssseee 70 RESISTANCES Li RR ae 73 Work One coca tii dl 68 Working air gap seem 68 Brake connection rn 25 Brake CONtrol oococccocoonnccnnccconoconencncconononnn 16 25 77 BG diana tese ee tapes 84 BGE m A A T cs 84 BMBP31 Enea lia een 87 BSG wake fi ae nen eee ae us 84 BOR Asa aes da a ML I 86 BUR Sia RT alla 84 Control Cabinet ccccccccccccnncnonococcnnanonononononanonos 78 Motor wiring space sse 77 Brake malfunctions esses 91 Brake rectifier combinations 76 Operating Instructions AC Motors DRS DRE DRP Brakemotor inspection DR 100 5 een 43 DR Olite dz 43 DRAG raa tt Sete Ava 43 A elie el eee Inn 59 A tia eos 43 DR 80 2 cete uenia 43 A tia to OL t TENERE 43 Braking torque breakdown ssssssssss 69 C Changing the braking torque BED tee E eA 48 BEI da ttr desto tieu 48 BEI xni oda AS 48 BE120 niin e E 65 BE 122 iut uelint o iS 65 BEZ nettes 48 BE20 55 dre een ern tee 48 BED Tte TR 48 Configuration DRi160 HDD 10 36 DR Bi banc 11 DR dar MEE 9 Connecting the motor uuesssssnnenennsssnnnnnnnnn nn 20 Connection A a E 20 DUAN cack sai eed eed tede 20
88. productivity With innovative technology that solves tomorrow s problems today With comprehensive With uncompromising knowledge in virtually quality that reduces the every branch of cost and complexity of industry today daily operations A SEW EURODRIVE Driving the world c P With online information and software updates via the Internet available around the clock SEW EURODRIVE GmbH amp 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
89. r low voltage U1 1 w1 3 1 L3 242603147 1 Motor winding 2 Motor terminal board 3 Incoming cables A connection The following figure depicts the connection for high voltage 11 2 U2 V2 w2 w2 U2 v2 PRA U1 V1 w1 lese 242598155 1 Motor winding 2 Motor terminal board 3 Incoming cables Change in direction of rotation Replacing two incoming cables L1 L2 Operating Instructions AC Motors DRS DRE DRP 81 Appendix Wiring diagrams 9 1 2 Motor protection using TF or TH with DR71 100 TF TH The following figures show the connection of the motor protection with TF PTC ther mistor sensors or TH bimetallic thermostats Either a two pole terminal clip or a five pole terminal strip is available for connecting to the trip switch Example TF TH to a two pole terminal strip 2b TF TH b TF TH Example 2 x TF TH to a five pole terminal strip 1a 2 jal 3 Jal amp al 5 la 2a 3a 4a 5a 1 TF TH 1 TF TH 2 TF TH 2 TF TH 2x TF TH with anti condensation heater The following figure shows the connection of the motor protection with 2 TF PTC ther mistor sensors or TH bimetal thermostats and Hx anti condensation heater 82 1a 2a 3a 4a 1 TF TH 1 TF TH 2 TF TH 2 TF TH Oper
90. reville Electro Services Tel 241 7340 11 B P 1889 Fax 241 7340 12 Libreville Great Britain Assembly Normanton SEW EURODRIVE Ltd Tel 44 1924 893 855 Sales Beckbridge Industrial Estate Fax 44 1924 893 702 Service P O Box No 1 http www sew eurodrive co uk GB Normanton West Yorkshire WF6 1QR info sew eurodrive co uk Greece Sales Athen Christ Boznos amp Son S A Tel 30 2 1042 251 34 Service 12 Mavromichali Street Fax 30 2 1042 251 59 P O Box 80136 GR 18545 Piraeus http www boznos gr info boznos gr Hong Kong Assembly Hong Kong SEW EURODRIVE LTD Tel 852 2 7960477 79604654 Sales Unit No 801 806 8th Floor Fax 852 2 7959129 Service Hong Leong Industrial Complex contact sew eurodrive hk No 4 Wang Kwong Road Kowloon Hong Kong Hungary Sales Budapest SEW EURODRIVE Kft Tel 36 1 437 06 58 Service H 1037 Budapest Fax 36 1 437 06 50 Kunigunda u 18 office sew eurodrive hu India Assembly Baroda SEW EURODRIVE India Pvt Ltd Tel 91 265 2831086 Sales Plot No 4 Gidc Fax 91 265 2831087 Service Por Ramangamdi Baroda 391 243 http www seweurodriveindia com Gujarat mdoffice seweurodriveindia com Technical Offices Bangalore SEW EURODRIVE India Private Limited Tel 91 80 22266565 308 Prestige Centre Point Fax 91 80 22266569 7 Edward Road salesbang seweurodriveindia com Bangalore Ireland Sales Dublin Alperton Engineering Ltd Tel 353 1 830 6277 Service 48 Moyle Road Fax 353 1 830 6458 Dublin Industrial Estate info
91. s 5 6 Ambient conditions during operation 5 6 1 Ambient temperature The temperature range of 20 C to 40 C must be ensured unless specified otherwise on the nameplate Motors intended for use in higher or lower ambient temperatures have the appropriate designation on the nameplate 5 6 2 Installation altitude The maximum installation altitude of 1 000 m above sea level must not be exceeded Otherwise power is reduced by the factor f according to the diagram below 1000 2000 3000 4000 m 173325195 The reduced rated power is calculated according to the following formula Pm Py x fy Pn4 Reduced rated power kW Py Rated power kW fy Factor for reduction due to installation altitude 5 6 3 Hazardous radiation Motors must not be subjected to hazardous radiation such as ionizing radiation Con tact SEW EURODRIVE if necessary Operating Instructions AC Motors DRS DRE DRP 19 20 9 7 5 7 1 Electrical Installation Connecting the motor Connecting the motor Connecting the motor via terminal box According to the circuit diagram provided Check cable cross section Arrange terminal links correctly Tighten connections and protective earth Inthe terminal box Check winding connections and tighten them if necessary Layout of the terminal links for A connection Layout of the terminal links for A connection Motor size DR 71 DR 160 Motor size DR 315
92. s included with the motor Do not connect or start up the accessory equipment if the wiring dia gram is missing You can obtain the valid wiring diagrams free of charge from SEW EURODRIVE 5 9 1 TF temperature sensor STOP Do not connect any voltages gt 30 V to the TF temperature sensor The positive temperature coefficient PTC thermistors comply with DIN 44082 Resistance measurement measuring instrument with V lt 2 5 V or lt 1 mA Standard measured values 20 500 Q thermal resistance gt 4 000 O When using the temperature sensor for thermal monitoring the evaluation function must be activated to maintain reliable isolation of the temperature sensor circuit If the tem perature reaches an excessive level the thermal protection function must be effective immediately 5 9 2 TH winding thermostats The thermostats are connected in series and open when the permitted winding temper ature is exceeded They can be connected in the drive monitoring loop ACV DC V Voltage U V 250 60 24 Current cos q 1 0 2 5 1 0 1 6 Current cos q 0 6 1 6 Contact resistance max 1 ohm at DC 5V 1 mA Operating Instructions AC Motors DRS DRE DRP Electrical Installation Accessory equipment 5 9 3 V forced cooling fan Connection in separate terminal box e Max connection cross section 3 x 1 5 mm Cable gland M16 x 1 5
93. section of the external connection is gt 1 5 mm it must be installed as cable lug under the terminal washer Type 1a Cross section lt 1 5 mm gt 8 lt 10 mm lt 1 5 mm2 gt AWG 16 88866955 1 External connection with cross section lt 1 5 mm 2 Terminal stud 3 Hexagon nut with flange 4 Terminal link 5 Terminal washer 6 Winding connection with Stocko connection terminal 22 Operating Instructions AC Motors DRS DRE DRP Electrical Installation Connecting the motor Type 1b Cross section gt 1 5 mm Type 2 1 A gt 1 5 mm2 lt AWG 16 1 External connection with ring cable lug for example according to DIN 46237 or DIN 46234 2 Terminal stud 3 Hexagon nut with flange 4 Terminal link 5 Terminal washer 6 Winding connection with Stocko connection terminal 185439371 1 Terminal stud 2 Lock washer 3 Terminal washer 4 Winding connection 5 Upper nut 6 Washer 7 External connection with ring cable lug for example according to DIN 46237 or DIN 46234 8 Lower nut Operating Instructions AC Motors DRS DRE DRP 88864779 23 24 Type 3 Electrical Installation Connecting the motor 199641099 1 External connection with ring cable lug for example according to DIN 4637 or DIN 46234 2 Terminal stud 3 Upper nut 4 Washer 5 Terminal link 6 Lower nut 7 Winding connection with ring
94. shing if the drive starts up unintentionally Severe or fatal injuries Isolate the motor and brake from the power supply before starting work safeguarding them against unintentional power up Strictly observe the following instructions N OO 5 Oo Remove the following Forced cooling fan and incremental encoder if installed See sec Preliminary work for motor and brake maintenance page 33 Flange cover or fan guard 35 circlip 32 62 and fan 36 Remove the terminal box cover and loosen the brake cable from the rectifier If nec essary attach trailing wire to brake cables Loosen machine screws 13 remove brake endshield with brake from stator Insert brake cable into the terminal box Align the cam of the brake endshield Install seal 95 With manual brake release Use setting nuts to set the floating clearance s between the conical coil springs pressed flat and the setting nuts see the following figure This floating clearance s is necessary so that the pressure plate can move up as the brake lining wears Otherwise reliable braking is not guaranteed 177241867 Brake Floating clearance s mm BE05 BE1 BE2 1 5 BE5 BE11 BE20 2 Operating Instructions AC Motors DRS DRE DRP 51 7 Inspection Maintenance Inspection and maintenance for DR71 DR100 brake motors Changing the brake of DR 90 to DR 160 A DANGER Risk o
95. t unit part Time interval What to do Brake BE If used as a working brake At least every 3 000 hours of opera tion If used as a holding brake Every 2 to 4 years depending on operating conditions 1 Inspect the brake Measure brake disc thickness Brake disc lining Measure and set working air gap Pressure plate Carrier gearing Pressure rings Vacuum up the abraded matter Inspect the switch elements and change if necessary e g in case of burn out Motor Every 10 000 hours of operation Inspect the motor Check anti friction bearings and replace if necessary Replace the oil seal Clean cooling air passages Drive Varies depending on external factors Repair or renew surface anticorrosion coating 1 The amount of wear is affected by many factors and the service life may be short The machine designer must calculate the required inspection maintenance intervals individually in accordance with the project planning documents e g Project Planning for Drives 2 Forthe DR 315 with relubrication device please note the shortened relubrication periods in sec Bearing lubrication DR 315 Operating Instructions AC Motors DRS DRE DRP Inspection Maintenance Bearing lubrication 7 2 Bearing lubrication 7 2 1 Bearing lubrication of DR 71 DR 160 The motor bearings are equipped with lifetime lubrication as standard 7 2 2 Bearing lubrica
96. th O ring 15 Hex head bolt 106 Oil seal 137 Bolt 16 Stator 107 Oil flinger ring 153 Terminal strip complete 17 Hexagonal nut 108 Nameplate 156 Information sign 19 Machine screw 109 Grooved pin 390 O ring 22 Hex head bolt 111 Seal for bottom part 705 Protection canopy 24 Lifting eyebolt 112 Terminal box lower part 706 Spacer 30 Sealing ring 113 Bolt 707 Hex head bolt 31 Key 115 Terminal board 715 Hex head screw 32 Circlip 117 Hex head bolt 35 Fan guard 118 Lock washer Operating Instructions AC Motors DRS DRE DRP Inspection Maintenance Inspection and maintenance work on the motor DR71 DR100 7 5 3 Inspection steps for DR 71 DR 160 motors A DANGER Risk of crushing if the drive starts up unintentionally Severe or fatal injuries Disconnect the motor from the power supply before starting work and protect it against unintentional re start Strictly observe the following instructions Remove forced cooling fan and incremental encoder if installed See sec Preliminary work for motor and brake maintenance page 33 2 Remove fan guard 35 and fan 36 3 Remove stator Size DR 71 DR 132 Remove machine screws 13 from flanged endshield 7 and B side endshield 42 Remove stator 16 from flanged endshield 7 Size DR 160 Loosen hex head screw 19 and remove B side endshield 42 Loosen hex head screw 15 and remove
97. tion of the DR 315 Relubrication Motors of size 315 can be equipped with a relubrication device The following figure shows the location of the relubrication devices 375353099 1 Relubrication device in form A to DIN 71412 For normal operating conditions and an ambient temperature from 20 C to 40 C SEW EURODRIVE uses a mineral high performance grease on poly urea basis ESSO Polyrex EM K2P 20 DIN51825 for the first grease filling For motors in the low temperature range down to 40 C SKF GXN grease is used an other mineral grease on poly urea basis The grease can be ordered in 400 g cartridges as individual part from SEW EURO DRIVE For order details refer to sec Lubricant tables for anti friction bearings of SEW motors page 80 NOTE Only mix greases of the same thickening agent same oil stock and same consistency NLGI class Grease the motor bearings according to the information on the lubrication plate of the motor The used grease accumulates in the inside of the motor It should be removed after 6 8 relubrication cycles within the context of an inspection When replacing the grease in the bearings make sure that the bearing is filled two thirds roughly After relubrication start up the motors slowly if possible to distribute the grease evenly Operating Instructions AC Motors DRS DRE DRP 32 Relubrication period Inspection Maintenance Reinforced bearing T
98. tor 7 8 6 Changing the braking torque of BE120 BE120 brakes The braking torque can be changed in steps Changing the brake spring By the type and number of brake springs By changing the brake For the possible braking torque steps please refer to sec Technical Data page 68 A DANGER Risk of crushing if the drive starts up unintentionally Severe or fatal injuries Isolate the motor and brake from the power supply before starting work safeguarding them against unintentional power up Strictly observe the following instructions Remove forced cooling fan and incremental encoder if installed See sec Preliminary work for motor and brake maintenance page 33 2 Remove flange cover or fan guard 35 circlip 32 and fan 36 3 Remove plug connector from the magnet 54 and protect against dirt 4 Remove the rubber sealing collar 66 and the manual brake release Setting nuts 58 ball cup 255 concave washer 256 conical coil springs 57 studs 56 release lever 53 Loosen hex nuts 61 pull off the magnet 54 By approx 50 mm Change or add brake springs 50 265 Arrange brake springs symmetrically Re install the brake components Except for the fan and the fan guard because the working air gap has to be set first see section Setting the working air gap of the BE120 BE122 brakes page 61 Operating Instructions AC Motors DRS DRE DRP 6
99. ull off the magnet 54 and take out the brake springs 50 265 6 Remove pressure plate 49 and brake disk 68b Clean brake components T Install a new brake disk 8 Re install the brake components Except for the fan and the fan guard because the working air gap has to be set first see section Setting the working air gap of the BE120 BE122 brakes page 61 Operating Instructions AC Motors DRS DRE DRP 63 7 Inspection Maintenance Inspection and maintenance for DR315 brake motor 9 With manual brake release Use setting nuts to set the floating clearance s between the conical coil springs pressed flat and the setting nuts see the following figure This floating clearance s is necessary so that the pressure plate can move up as the brake lining wears Otherwise reliable braking is not guaranteed 353592459 Brake Floating clearance s mm BE120 BE122 2 10 Install the rubber sealing collar back in place and re install the dismantled parts NOTES several cycles The lockable manual brake release type HF is already released if resistance is encountered when operating the grub screw After replacing the brake disc the maximum braking torque is reached only after 64 Operating Instructions AC Motors DRS DRE DRP Inspection Maintenance 7 Inspection and maintenance for DR315 brake mo
100. unit is used must comply with all specifications on the nameplate Inspect the shipment for any damage that may have occurred in transit as soon as you receive the delivery Inform the shipping company immediately You may need to pre clude startup Tighten the eyebolts They are only rated for the weight of the motor gearmotor do not attach any additional loads The installed lifting eyebolts are in accordance with DIN 580 The loads and regulations specified in that document must always be observed If the gearmotor is equipped with two suspension eye lugs or lifting eyebolts then both of the suspension eye lugs should be used for transportation In this case the tension force vector of the slings must not exceed a 45 angle according to DIN 580 Use suitable sufficiently rated handling equipment if necessary Remove any transpor tation restraints prior to startup Re use for any further transports When storing low volt age machines make sure to keep it in a dry dust free environment with minimum vibra tion Ver 0 2 mm s damage to stalled bearings Measure the insulation resistance before startup Dry the winding if values lt 1 k per volt of the rated voltage Make sure the feet and flanges are safely fixed and rest positively on their entire surface Check the exact alignment with direct coupling Avoid resonance of the base with the rotational frequency and double mains frequency Turn the rotor by hand and listen for un
101. usual grinding noises Check the direction of rotation with the machine uncoupled Use only suitable tools to mount or pull off belt pulleys or couplings heat and cover with a protection against accidental contact Avoid unadmissible tension of the belts Provide necessary pipe connections if required For vertical shaft up designs suitable protection must be provided at the mounting end so that no foreign matter can enter the ventilation holes Such protection must however not affect the cooling and air leaving the motor or adjacent groups must not be drawn in again Observe the notes in sec Mechanical Installation Operating Instructions AC Motors DRS DRE DRP 2 6 2 7 Safety Notes Electrical connection Electrical connection Operation All work may only be carried out by qualified personnel During work the low voltage machine must be at standstill in enabled condition and safeguarded against uninten tional restart This also applies to auxiliary power circuits e g anti condensation heat ing Ensure that the unit is de energized Exceeding the tolerances in EN 60034 1 VDE 0530 part1 voltage 5 frequency 2 curve shape symmetry increases the temperature and influences electromag netic compatibility Observe nameplate data and the wiring diagram in the terminal box Note the wiring information and deviating data on the nameplate and the wiring diagram The supply cables must be
102. y for BE122 Magnet complete Stud 3x Hexagonal nut 66 67 68 68b 69 69b 256 353594123 Rubber sealing collar 702 Friction disc Setting sleeve 732 Cover disc Brake disc 733 Bolt Brake disk only BE122 Circular spring Circular spring only BE122 Brake spring Operating Instructions AC Motors DRS DRE DRP Inspection Maintenance Inspection and maintenance for DR315 brake motor 7 8 3 Inspection steps DR 315 brakemotor A DANGER Risk of crushing if the drive starts up unintentionally Severe or fatal injuries Isolate the motor and brake from the power supply before starting work safeguarding them against unintentional power up Strictly observe the following instructions Remove forced cooling fan and incremental encoder if installed See sec Preliminary work for motor and brake maintenance page 33 2 Remove fan guard 35 and fan 36 3 Loosen brake connector 4 Loosen the bolts 900 and remove the pre assembled brake from the brake end shield 5 Loosen hex head screws 25 and 19 and remove B side endshield 42 6 Remove machine screws 15 from the flange 7 Remove rotor 1 completely to gether with the flange For gearmotors remove oil flinger 107 Loosen screws 609 and remove rotor from the flange 7 Before disassembly pro tect oil seal seat against damage e g with tape or a protective sleeve Visual inspection
103. y on the unit You must also ensure that the documentation is legible 1 3 Exclusion of liability You must comply with the information contained in these operating instructions to en sure safe operation of the electric motors and to achieve the specified product charac teristics and performance requirements SEW EURODRIVE assumes no liability for in jury to persons or damage to equipment or property resulting from non observance of these operating instructions In such cases any liability for defects is excluded Operating Instructions AC Motors DRS DRE DRP 2 2 1 2 2 Safety Notes Preliminary information Safety Notes The following basic safety notes must be read carefully to prevent injury to persons and damage to property The operator must make sure that the basic safety notes are read and observed Make sure that persons responsible for the plant and its operation as well as persons who work independently on the unit have read through the operating instructions carefully and understood them If you are unclear about any of the informa tion in this documentation please contact SEW EURODRIVE Preliminary information The following safety notes are concerned with the use of motors If using gearmotors please also refer to the safety notes for gear units in the corresponding operating in structions Also consider the supplementary safety notes in the individual sections of these operat ing instructions Ge

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