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Drehstrommotoren DRS/DRE/DRP / Operating Instructions / 2007-05

1. Gearmotors Industrial Gear Units Drive Electronics Drive Automation Services UNO OS AC Motors DRS DRE DRP Edition 05 2007 O gt E 11606215 EN perating Instructions SEW EURODRIVE Driving the world Contents T General Information aa pa s 5 1 1 Structure of the safety notes 5 1 2 Rights to claim Under warramtby canarias 5 1 3 Exclusion of liability o oooonnnnnniidnn niaccconnnnnccncnnnnncconnnonnnnrrn carr rnnr rara 5 2 Safety NOS nosi pidio 6 2 1 Preliminary Information 6 2 2 Ener helices Gide DEENEN ee 6 2 3 Designated USO ici da 7 2 4 1 TAN e E Me i 7 2 5 TE e EE 7 2 6 Electrical connection sssesseessesertresersstesttttttrnrennstrettttttrnnnnnnnnnn nnne ee nenen 8 KS Ale ee 8 3 Motor DesigO ciooioeiainsic tr EENS 9 3 1 Basic structure of DR71 DR100 ssessensnennnensseessnnrrrrrrnnserssresrrrnrrrnrrn 9 3 2 Basic structure DRIIS eee eeteeeeceaecaeceeeeeeeeeeeteeteeesenaaees 10 3 3 Nameplate unit designation oooooccnnnnnnnnnnnnnniccnononccnncononononnnnnnnnannnnnnnnos 11 4 Mechanical Installation ocoommncnnnnnonnoncccnncnnncnennnnnnnnannnn cnn cnn nn narran nn 12 4 1 Before YOu DegiO cccccioiiionnionid iii idad cda dai 12 4 2 Mechanical Installaton tenne neseerttnnrtnnrnnsrensttrnttnnnnnnsenne 12 5 Electrical Installation adornan d ains 15 5 1 Use wiring dagrams tenn n enn 15 5 2 WINING NOLES e
2. cceeeeeeeeeeeeeees 64 Operating Instructions AC Motors DRS DRE DRP Cc Changing the braking torque BEO5 ceicalen a ees 43 BEJ A een ee 43 BEA20 ho dd cda 43 60 BELL eet eege tege 43 60 BED EE EE e 43 BES td Eed ita 43 Connecting the Motor oconcoccccnnnncccccccnnnancnaninnnns 19 Connection Della A eerie 19 Marimar ti aaa 19 Customer service coococccccnnnconcccccnncnncncnanan o nancnnnnnos 84 D Delta connection 19 74 Design ET EE 9 DRIT 5 aiii 10 DRED iio 9 DREQ iii nani teil 9 DRIU il dci 9 ee EE 9 10 Designated use ccccoiciocccnnncadosnrnnndcrnran atar terrancaenns 7 E ETS nai 27 33 Electrical Connection oooonnncccnnnnncncccnnnnonncininnnnnn 8 Electrical Installation oo nccnnnnnncccnnnnacccccnnnnns 15 EMC tienen an ieee 17 Seele 27 e IS a aia 27 ASTRAL 27 LE KEE 27 ESTA sundae ee 27 ESOS italia eege ed 27 Encoder Connection concccconoccccccconannnnccnnannncnnnnnnnos 27 ESCH uan ida 27 32 ESTO gegen dee A e 27 32 Exclusion of liabilitY 5 Extended Storage cooooccccccnnooccccconnnnncnccnnnnnncnnnnnnnos 13 F Forced Cooling fan V ecien 26 Frequency inverter operation seee 16 G General safety notes 0 eee eeeeceeeeeeeenteeeeeeeenaees 6 Grounding EE 17 11 85 11 86 Index l Improving the grounding 17 Inspecting brake motor DRINI ira aa ie ae a ieai 54 Inspecting the brake motor DRI OO dada 39 DRIT A aa dh eed 39 DREO rae EE EEN 39 DRIO Sn aeta a
3. 15 Install the fan 36 and fan guard 35 Operating Instructions AC Motors DRS DRE DRP 51 52 Inspection and Maintenance Inspection and maintenance for brake motor DR315 7 8 Inspection and maintenance for brake motor DR315 7 8 1 Basic structure of brake motor DR315 1 Motor with brake endshield 22 Hex head bolt 31 Key 32 Circlip 35 Fan guard 36 Fan 37 V ring 47 O ring 53 Releasing lever 55 Closing piece 56 Stud 57 Conical coil spring 58 Setting nut 62 Circlip 64 Setscrew 70 Carrier 57 255 256 58 353595787 71 Key 255 Conical seat 256 Spherical washer 550 Pre assembled brake 900 Screw 901 Gasket Operating Instructions AC Motors DRS DRE DRP Inspection and Maintenance Inspection and maintenance for brake motor DR315 7 8 2 Basic structure of brake BE120 BE122 28 Closing cap 66 49 Pressure plate 67 50 Brake spring 68 52b Brake stationary disc BE122 only 68b 54 Magnet complete 69 60 Stud 3x 69b 61 Hex nut 256 Operating Instructions AC Motors DRS DRE DRP 353594123 Rubber sealing collar 702 Friction disc Setting sleeve 732 Cover disc Brake disc 733 Screw Brake disc BE122 only Annular spring Annular spring BE122 only Brake spring 53 7 Inspection and Maintenance Inspection and maintenance for brake motor DR315 7 8 3 Procedure for inspecting b
4. BE120 BE122 lt 12 mm See the following sections Replacing the brake disk for brake BEO5 BE5 page 41 Replacing the brake disk for brake BE120 BE122 page 58 Brake lining worn down Replace entire brake disk See the following sections Replacing the brake disk for brake BEO5 BE5 page 41 Replacing the brake disk for brake BE120 BE122 page 58 Incorrect braking torque Check the project planning and change the braking torque if needed see section Work done working air gap braking torques 63 by changing the type and number of brake springs See the following sections Changing the braking torque of brake BEO5 BE5 page 43 Changing the braking torque of brake BE120 BE122 page 60 e by selecting a different brake See section Braking torque breakdown page 64 Working air gap so large that setting nuts for the manual release come into contact Set the working air gap See the following sections Setting the working air gap for brake BEO5 BE5 page 40 Setting the working air gap for brake BE120 BE122 page 56 Manual brake release device not set correctly Set the setting nuts for the manual release correctly See the following sections Changing the braking torque of brake BEO5 BE5 page 43 Changing the braking torque of brake BE120 BE122 page 60 Brake locked by manual brake release HF Loosen the setscrew rem
5. Technical Data Resistances 8 4 Resistances 8 4 1 Brake BE05 1 BEZ BE5 BE05 1 BE2 BES Max braking torque 5 40 10 89 20 180 55 490 Nm in 1b Braking power W hp 32 0 043 43 0 058 49 0 066 Inrush current ratio la cllu 4 4 5 7 Rated voltage Vrated BE05 1 BE2 BES Vac Voc Race Rsec Race Rsec Race Rsec 24 23 26 10 0 77 2 35 0 57 1 74 ES 60 57 63 24 4 85 14 8 3 60 11 0 2 20 10 5 120 111 123 48 19 4 59 0 14 4 44 0 8 70 42 0 184 174 193 80 48 5 148 36 0 111 22 0 105 208 194 217 90 61 0 187 45 5 139 27 5 132 230 218 243 96 77 0 125 58 0 174 34 5 166 254 244 273 110 97 0 295 72 0 220 43 5 210 290 274 306 125 122 370 91 275 55 0 265 330 307 343 140 154 470 115 350 69 0 330 360 344 379 160 194 590 144 440 87 0 420 400 380 431 180 245 740 182 550 110 530 460 432 484 200 310 940 230 690 138 660 500 485 542 220 385 1180 290 870 174 830 575 543 600 250 490 1480 365 1100 220 1050 The following illustration shows how to measure resistance with cutoff in the AC circuit RD Race WH o BU RD Rsec WH BU The following illustration shows how to measure resistance with cutoff in the DC and AC circuits RD Raco WH oO BU RP Rgec WH BU BS Acceleration coil RD red TS Coil section WH white Race Acceleration coil resistance at 20 C 68 F Q BU blue Rgec
6. The motor or gearmotor may only be mounted or installed in the specified mounting position on a level vibration proof and torsionally rigid support structure Carefully align the motor and the driven machine to avoid placing any intolerable 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 prevent objects or fluids entering motors in vertical mounting positions protective cowl C Ensure the cooling air supply is unobstructed and that air heated by other apparatus cannot be drawn in again Balance components for subsequent mounting on the shaft with a half key motor shafts are balanced with a half key Condensation drainage holes are plugged with closing plugs These can be opened if you want to drain the condensation but must be closed again as open drain holes render higher enclosures void 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 release 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 Thoroughly clean the sealing surfaces of terminal boxes and terminal box covers prior to reassembly gaskets must be glued in on one side Re
7. mm BE05 BE1 1 5 BE2 BE5 2 8 Put the rubber sealing collar back in place and re install the dismantled parts NOTE The lockable manual brake release type HF is already released if a resistance is encountered when operating the setscrew The self reengaging manual brake release type HR can be operated with normal hand pressure e In 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 NOTE Important after replacing the brake disc the maximum braking torque is reached only after several cycles Operating Instructions AC Motors DRS DRE DRP Inspection and Maintenance Inspection and maintenance for brake motor DR71 DR100 7 6 7 Changing the braking torque of brake BE05 BE5 The braking torque can be altered in stages by changing the type and number of brake springs by changing the complete magnet only possible for BEO5 and BEI by changing the brake from motor size DR90 To find the possible braking torque graduations for each motor refer to the Technical Data section page 63 Changing the brake spring Severe or fatal injuries can occur A DANGER Risk of crushing if the drive starts up unintentionally Isolate the motor and brake from the power supply before starting work safe guardin
8. remove the white conductor from the brake rectifier if it remains connected the internal resistance of the brake rectifier will cause erroneous results 68 Operating Instructions AC Motors DRS DRE DRP Technical Data Brake rectifier combinations 8 5 Brake rectifier combinations 8 5 1 Brake BE05 1 BEZ BE5 The table below shows the standard and optional combinations of brakes and brake rectifiers BE05 BE1 BE2 BE5 E BG 1 5 x x x BG 3 x2 x2 x BGE 1 5 x BGE BGE 3 x2 BS BS 24 x x x BMS 1 5 BMS BMS 3 az BME 1 5 BME BME 3 BMH 1 5 BMH BMH 3 BMK 1 5 BMK BMK 3 BMP 1 5 BMP BMP 3 BMV BMV 5 BSG BSG x BGE 3 SR 11 BGE 3 SR 15 BSR BGE 1 5 SR 11 BGE 1 5 SR 15 BGE 3 UR 11 BUR BGE 1 5 UR 15 X Standard design X Standard design with brake rated voltage of AC 150 500 V X2 Standard design with brake rated voltage of AC 24 42 150 V e Optional Not permitted 8 5 2 Brake BE120 BE122 The table below 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 70 8 6 8 6 1 Motor size DR71 100 M
9. 604 Lubrication ring 606 Greasing nipple 607 Greasing nipple 608 Oil seal flange 609 Hex head bolt 633 End bracket 634 End plate 705 Protective cowl 706 Spacer bolt 707 Hex head bolt 715 Hex nut 716 Washer Operating Instructions AC Motors DRS DRE DRP Motor Design Nameplate unit designation 3 3 Nameplate unit designation 3 3 1 Nameplate Example DRE gearmotor vc gt with brake SEW EURODRIVE C 76646 Bruchsal Germany RF47 DRE90M4BE2 TF Z C 3 1EC60034 01 300123456 0002 06 rpm 1425 88 kw 1 1 S1 Nm 122 G V 230 400 A Y cos p 0 79 V 220 240 A 380 415 Y A 4 45 2 55 Ins Cl 130 B M M1 IP 55 Hz 50 C UBR 220 240 AC Nm 20 BGE1 5 kg 41 0188 229 5 Ch CLPCCVG220 0 651 Made in Germany 3 3 2 Unit designation Example Foot mounted AC motor with brake DRE 90 M4 BE2 Fl TF ES7S 186018187 gt Motor option sinusoidal encoder ES7S Operating Instructions AC Motors DRS DRE DRP Motor option thermal motor protection with thermistor TF IEC foot mounted motor version 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 11 12 Mechanical Installation Before you begin 4 Mechanical Installation NOTE It is imperative that you observe the safety notes in section 2 during installation 4 1 Before you begin The drive
10. 8 8 Lubricant tables 8 8 1 Motor size DR71 100 Motor size DR315 Lubricant table for roller bearings The bearings are 2Z or 2RS closed bearings and cannot be relubricated Ambient temperature Manufacturer Type DIN designation 20 C 4 F Esso Polyrex EM K2P 20 80 C 176 F Motor roller 20 C 68 F Kl ber Barrierta L55 22 KX2U bearings 100 C 212 F 40 C 40 F Kyodo Yushi Multemp SRL K2N 40 60 C 140 F 1 Mineral lubricant mineral based roller bearing grease 2 Synthetic lubricant synthetic based roller bearing grease Series DR315 motors may be equipped with a lubrication device Ambient temperature Manufacturer Type DIN designation 20 C 4 F Esso Polyrex EM K2P 20 Motor roller 80 C 176 F bearings 40 C 40 F SKF GON K2N 40 60 C 140 F 1 Mineral lubricant mineral based roller bearing grease 8 9 Order information for lubricants and anti corrosion agents Lubricants and anti corrosion agents may be obtained directly from SEW EURODRIVE using the following order numbers Use Manufacturer Type Quantity Order number Esso Polyrex EM 400g 09101470 Lubricant for roller 14 1 oz bearings SKF GXN 400g 09101276 14 1 oz Type of lubricant ter Petamo GHY 133 199 04963458 Sealing rings 0 35 oz Anti corrosive and SEW EURODRIVE Noco Fluid 5 5 g 0910
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13. 12 0 15 0 13 Key lace Acceleration current brief inrush current ly Holding current r m s value in the supply cable to the SEW brake rectifier Ipc Direct current with direct DC voltage supply Vrateqd Rated voltage rated voltage range Operating Instructions AC Motors DRS DRE DRP 65 Technical Data Operating currents 8 3 2 Brake BE120 BE122 The current values ly holding current specified in the tables are r m s values Measure the r m s values using only the appropriate measuring instruments The inrush current acceleration current lacc only flows for a short time max 400 ms when the brake is released You may not use a direct voltage supply is not required BE120 BE122 Max braking torque 1000 8851 2000 17700 Nm in 1b Braking power W hp 250 0 335 250 0 335 Inrush current ratio la cllu 4 9 4 9 Rated voltage Vrated BE120 BE122 Vac Voc re re 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 lace Acceleration current brief inrush current ly Holding current r m s value in the supply cable to the SEW brake rectifier Ipc Direct current with direct DC voltage supply VRated Rated voltage rated voltage range Operating Instructions AC Motors DRS DRE DRP
14. 63 10 Put the rubber sealing collar back in place and re install the dismantled parts Operating Instructions AC Motors DRS DRE DRP 57 58 Inspection and Maintenance Inspection and maintenance for brake motor DR315 7 8 5 Replacing the brake disc for brake BE120 BE122 When fitting a new brake disc thickness lt 12 mm 0 47 in also inspect the other removed parts and if necessary install new ones A DANGER Risk of crushing if the drive starts up unintentionally Severe or fatal injuries can occur Isolate the motor and brake from the power supply before starting work safe guarding them against accidental startup Carefully observe the following operation steps Remove forced cooling fan and incremental encoder if installed See section Preliminary work for motor and brake maintenance page 32 2 Remove the fan guard 35 circlip 32 and fan 36 Loosen the plug connector on the magnet Remove the rubber sealing collar 66 and the manual brake release setting nuts 58 conical seat 255 spherical washer 256 conical coil springs 57 studs 56 releasing lever 53 Unfasten hex nuts 61 carefully remove complete magnet 54 and remove brake springs 50 265 Remove the pressure plate 49 and brake disc 68b and clean the brake compo nents Install a new brake disc Re install the brake components except for the fan and the fan guard
15. 734 Nut 367 Retaining screw 748 Screw 657 Protection cover Removing EH7 Remove the protection cover 657 by unfastening the screws 659 e Separate the encoder from the fan guard by loosening the nut 734 e Unfasten the retaining screw 367 on the encoder and remove the encoder 220 from the shaft Removing AH7 Remove the protection cover 657 by loosening the screws 659 Separate the encoder from the fan guard by loosening the screws 748 e Unfasten the retaining screw 367 on the encoder 220 and remove the encoder 220 from the shaft Re assembly For re assembly please note Apply NOCO fluid to the encoder spigot e Tighten the retaining screw with the following tightening torques Encoder Tightening torque EH7 0 7 Nm 6 in lb AH7 3 0 Nm 27 in Ib Operating Instructions AC Motors DRS DRE DRP 33 7 Inspection and Maintenance Inspection and maintenance work on the motor DR71 DR100 7 5 Inspection and maintenance work on the motor DR71 DR100 7 5 1 Basic structure of DR71 DR100 1 Rotor 2 Circlip 8 Key 7 Flanged endshield 9 Screw plug 10 Circlip 11 Deep groove ball bearing 12 Circlip 13 Machine screw 16 Stator 22 Hex head bolt 24 Eyebolt 30 Oil seal 32 Circlip 35 Fan guard 36 Fan 34 41 Shim washer 42 B side endshield 44 Deep groove ball bearing 90 Base plate 93 Pan head screw 100 He
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17. Coil section resistance at 20 C 68 F Q VRatea Rated voltage rated voltage range NOTE When measuring the resistance of the coil section Rsg or the acceleration coil R Acc remove the white conductor from the brake rectifier if it remains connected the internal resistance of the brake rectifier will cause erroneous results Operating Instructions AC Motors DRS DRE DRP 67 Technical Data Resistances 8 4 2 Brake BE120 BE122 BE120 BE122 ve dach torque 1000 8851 2000 17700 Braking power W hp 250 0 335 250 0 335 Inrush current ratio lacc Iy 4 9 4 9 Rated voltage Vrated BE120 BE122 Vac Voc Race Rsec Race Rsec 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 z 12 0 46 5 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 z 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 The following illustration shows how to measure resistance with BMP 3 1 RD WH BU BS Acceleration coil TS Coil section RD Race WH Rgec BU Race Acceleration coil resistance at 20 C 68 F Q Sec Coil section resistance at 20 C 68 F Q VRatea Rated voltage rated voltage range NOTE When measuring the resistance of the coil section Rgec or the acceleration coil Race
18. I NNO NAO BE5 260 2300 0 25 0 9 1374 0709 1374 0717 I NNA ANAND ANA BE120 520 4600 0 4 1 2 1360 8770 1360 831 2 I ANI BE122 520 4600 0 5 1 2 1360 877 0 1360 831 2 Soo ARAOS I ANI 1 Please note when checking the working air gap Parallelism tolerances on the brake disc may cause deviations of 0 15 mm after a test run Operating Instructions AC Motors DRS DRE DRP Technical Data Braking torque breakdown 8 2 Braking torque breakdown 8 2 1 Motor size DR71 100 Motortype Brake type Braking torque gradation in Nm in Ib 18 25 35 5 0 DR71 BEOS 16 22 31 44 5 0 7 0 10 0 Se 44 62 88 5 18 25 35 5 0 aai ug 22 31 44 5 0 7 0 10 gen Sex 44 62 89 BE2 7 0 10 14 20 62 89 120 180 BE1 5 0 7 0 10 44 62 89 BE2 7 0 10 14 20 Sen 62 89 120 180 BE5 20 28 40 55 180 250 350 490 BE2 7 0 10 14 20 DR100 62 89 120 180 BE5 20 28 40 55 180 250 350 490 8 2 2 Motor size DR315 Motor type Brake type Braking torque gradation in Nm in Ib 400 600 800 1000 BE120 3540 5310 7080 8851 DR315 BE122 800 1200 1600 2000 7080 10620 14160 17700 Operating Instructions
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20. and remove brake from brake endshield Align the cam of the friction disc and mount the brake onto the brake endshield using a screw 900 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 The 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 Technical Data Work done working air gap braking torques 8 Technical Data 8 1 Work done working air gap braking torques Brake type Work done Working air gap Braking torque settings until mainte nance mm Braking Type and number of Order numbers for torque brake springs brake springs 108 J in Ib min max Nm in Ib Normal Blue Normal Blue 5 0 44 2 3 5 31 2 2 5 22 1 8 16 10 89 BE1 120 1060 0 25 0 6 7 0 62 5 0 44 20 180 14 120 10 89 7 0 62 55 490 40 350 28 250 20 180 1000 8851 800 7080 600 5310 400 3540 2000 17700 1600 14160 1200 10620 800 7080 BE05 120 1060 0 25 0 6 0135017 X 1374 137 3 WONA 0135 017 X 1374 137 3 ANI BE2 165 1460 0 25 0 6 1374 0245 1374 052 0
21. are not proceed to step 7 If there is condensation proceed to step 5 If there is gear oil have the motor repaired by a specialist workshop If there is condensation inside the stator With gearmotors remove the motor from the gear unit With motors without a gear unit remove the A flange Remove the rotor 1 Clean the winding dry it and check it electrically see Preliminary work section page 12 Replace the deep groove ball bearings 11 44 with permitted ball bearings See section Permitted roller bearing types page 72 Reseal the shaft A side Replace oil seal 106 B side Replace oil seal 30 Coat the sealing lip with grease Kl ber Petamo GHY 133 Reseal the stator seat Seal the sealing surface with a duroplastic sealing compound operating temper ature 40 C 40 F 180 C 356 F such as Hylomar L Spezial Replace gasket 392 10 Install the motor and accessory equipment Operating Instructions AC Motors DRS DRE DRP 35 7 Inspection and Maintenance Inspection and maintenance for brake motor DR71 DR100 7 6 Inspection and maintenance for brake motor DR71 DR100 7 6 1 Basic structure of brake motor DR71 DR80 1 Motor with brake endshield 22 Hex head bolt 35 Fan guard 36 Fan 49 Pressure plate 50 Brake spring 51 Hand lever 53 Releasing lever 54 Magnet complete 36 95 59 53 56 57 58
22. because the working air gap has to be set first see section Setting the working air gap for brake BE120 BE122 page 56 Operating Instructions AC Motors DRS DRE DRP Inspection and Maintenance Inspection and maintenance for brake motor DR315 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 The 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 e mm BE120 BE122 2 10 Put the rubber sealing collar back in place and re install the dismantled parts NOTE e The lockable manual brake release type HF is already released if a resistance is encountered when operating the setscrew e After replacing the brake disc the maximum braking torque is reached only after several cycles Operating Instructions AC Motors DRS DRE DRP 60 Inspection and Maintenance Inspection and maintenance for brake motor DR315 7 8 6 Changing the braking torque of brake BE120 BE122 The braking torque can be altered in stages Changing the brake spring by changing the type and number of brake springs by changing the brake To find the possible braking torque graduations for each mo
23. from the power supply before starting work safe guarding them against accidental startup Carefully observe the following operation steps Remove the following forced cooling fan and incremental encoder if installed See section Preliminary work for motor and brake maintenance page 32 flange cover or fan guard 35 circlip 62 and fan 36 Sealing ring 95 Screw in studs 56 insert sealing ring 95 and hammer in the parallel pin 59 Use setting nuts to set the floating clearance s between the conical coil springs pressed flat and the setting nuts see the following figure The 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 1 5 BE2 BE5 2 5 Reassemble the removed parts Operating Instructions AC Motors DRS DRE DRP Inspection and Maintenance Inspection and maintenance work on the motor DR315 7 7 Inspection and maintenance work on the motor DR315 7 7 1 Basic structure of the motor DR315 22 1 Rotor 2 Circlip 8 Key 4 Key 7 Flange 9 Screw plug 11 Roller bearing 15 Machine screw 16 Stator 17 Hex nut 19 Machine screw 21 Oil seal flange 22 Hex head bolt 24 Eyebolt 25 Machine screw 26 Sealing washer 30 Oil seal 31 Key 32 C
24. it electrically see Preliminary work section page 12 10 Replace the deep groove ball bearings 11 44 with permitted ball bearings See section Permitted roller bearing types page 72 11 Reseal the shaft A side Replace oil seal 106 B side Replace oil seal 30 Coat the sealing lip with grease Kl ber Petamo GHY 133 12 Reseal the stator seat Seal the sealing surface with a duroplastic sealing compound operating temper ature 40 C 40 F 180 C 356 F such as Hylomar L Spezial Replace gasket 392 13 Install the motor brake and accessory equipment Operating Instructions AC Motors DRS DRE DRP 39 40 Inspection and Maintenance Inspection and maintenance for brake motor DR71 DR100 7 6 5 Setting the working air gap for brake BE05 BE5 A DANGER Risk of crushing if the drive starts up unintentionally Severe or fatal injuries can occur Isolate the motor and brake from the power supply before starting work safe guarding them against accidental startup Carefully observe the following operation steps O a Remove the following Forced cooling fan and incremental encoder if installed see section Preliminary work for motor and brake maintenance page 32 Flange cover or fan guard 21 Push the rubber sealing collar 5 aside release the clip to do this if necessary vacuum up any abraded residue Measure the br
25. on standstill enabled and safeguarded against an accidental restart This also applies to auxiliary circuits e g anti condensation heating Check that the motor is de energized Exceeding the tolerances in EN 60034 1 VDE 0530 part 1 voltage 5 frequency 2 curve shape symmetry increases the heating and influences electromagnetic compatibility Observe nameplate data and the wiring diagram in the terminal box Pay attention to the wiring information and different data on the nameplate as well as observing the wiring diagram The connection should be a continuous secure electrical connection no protruding wire ends use the cable end equipment intended for this purpose Establish a secure protective earth connection When the motor is connected the distances to non insulated and live parts must not be shorter than the minimum values according to IEC 60664 and national regulations With low voltage the distances should be no shorter than the following values in compliance with IEC 60664 Rated voltage Vy Distance lt 500 V 3 mm lt 690 V 5 5 mm The terminal box must be free of foreign objects dirt and humidity Unused cable entry openings and the box itself must be closed so that they are dust and water proof Secure keys for test mode without output elements When operating low voltage machines with brakes check that the break is functioning correctly before startup Observe the notes in th
26. pulse voltages indicated in the figure below are not exceeded at the given rise times N o o o 1800 4 1600 4 1400 1200 4 1000 4 800 4 Permitted pulse voltage Uu V o o o 0 02 04 06 08 10 12 14 Rise time us 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 of the motor If the permitted pulse voltage is exceeded you must install limiting measures such as filters chokes or special motor cables You should also consult the manufacturer of the frequency inverter Operating Instructions AC Motors DRS DRE DRP Electrical Installation 5 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 DR71 DR100 DIN 7500 M5 x 12 self tapping screw and 2 serrated lock washers in accordance with DIN 6798 2 1 176658571 1 Use the pre cast bore at the terminal box brake motor 2 Bore in stator housing 4 6 tmax 11 5 5 4 2 Size DR315 e 1x hex head bolt ISO 4017 M12 x 30 1x washer ISO 7090 e 1x serrated lock washer DIN 6798 370040459 1 Use the grounding screw at the terminal box Operating Instructions AC Motors DRS DRE DRP 17 5 Electrical Installation Specia
27. relay AC 230 575 V 2 8 BMP 3 1 829 507 7 for cut off in the DC circuit Operating Instructions AC Motors DRS DRE DRP 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 breakdown with regard to motor size and connection technology The different housings have different colors color code to make them easier to distin guish Motor size DR71 100 Holding Part Color Type Function Voltage current Type number code lHmax A Bis One way rectifier AC 150 500 V 1 5 BMS 1 5 825 802 3 Black as with BG AC 42 150 V 3 0 BMS 3 8258031 Brown One way rectifier with AC 150 500 V 1 5 BME 1 5 825 722 1 Red BME electronic switching as with BGE AC 42 150 V 3 0 BME 3 825 723 X Blue One way rectifier with AC 150 500 V 1 5 BMH 1 5 825 818 X Green BMH electronic switching and heating function AC 42 150 V 3 BMH 3 825 819 8 Yellow One way rectifier with AC 150 500 V 1 5 BMP 1 5 8256853 White BMP electronic switching inte grated voltage relay for AC 42 150 V Light cut off in the DC circuit 3 0 BMP 3 826 566 6 gt One way rectifier with AC 150 500 V 1 5 BMK 1 5 826 463 5 Aqua electronic switching BMK 24 Vpc control input and de AC 42 150 V 3 0 BMK 3 8265674 Bright DC circuit Brake control unit with Bmv yg
28. start or starts only with difficulty Motor power designed for delta connection but connected in star Correct the connection from star to delta follow the wiring diagram Motor power designed 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 star connection If the delta inrush current is not too high observe the regulations of the power supplier start up directly in delta Check the project planning and use a larger motor or special 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 malfunctions page 83 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 Repa
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32. 2 screws 25 Remove the setscrew and screw in the remaining screws 25 16 Renew oil seals A side 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 GHY133 B side insert the oil seal 30 and coat the sealing lip with the same grease This condition applies only to gearmotors 17 Align the cam of the friction disc and mount the brake onto the brake endshield using a 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 The 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 19 Install the fan 36 and fan guard 35 20 Install the motor and accessory equipment Operating Instructions AC Motors DRS DRE DRP 55 56 Inspection and Maintenance Inspection and maintenance for brake motor DR315 7 8 4 Setting the working air gap for brake BE120 BE122 A DANGER Risk of crushing if the drive starts up unintentionally Severe or fatal injuries can occur Isolate the motor and brake from the power supply before starting work safe guarding them again
33. 36 62 56 Stud 57 Conical coil spring 58 Setting nut 59 Parallel pin 60 Stud 3x 61 Hex nut 62 Circlip 65 Pressure ring 66 Rubber sealing collar 67 68 70 71 73 95 35 22 174200971 Counter spring Brake disc Carrier Key Stainless steel shim plate Sealing ring 718 Damping plate Operating Instructions AC Motors DRS DRE DRP Inspection and Maintenance Inspection and maintenance for brake motor DR71 DR100 7 6 2 Basic structure of brake motor DR90 DR100 1 Motor with brake endshield 56 Stud 22 Hex head bolt 57 Conical coil spring 85 Fan guard 58 Setting nut 36 Fan 59 Parallel pin 51 Hand lever 62 Circlip 53 Releasing lever 70 Carrier Operating Instructions AC Motors DRS DRE DRP 35 py Pn para El 50 20 56 a 179981963 95 Sealing ring 550 Pre assembled brake 900 Screw 901 Gasket 37 Inspection and Maintenance Inspection and maintenance for brake motor DR71 DR100 7 6 3 Basic structure of brake BE05 BE5 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 disc 54 Magnet complete 67 Counter spring 718 Damping plate 60 Stud 3x 68 Brake disc 61 Hex nut 69 Annular spring Operating Instructions AC Motors DRS DRE DR
34. 7819 lubricant 0 19 oz Operating Instructions AC Motors DRS DRE DRP 73 9 Appendix Wiring diagrams 9 Appendix 9 1 Wiring diagrams NOTE The motor should be connected as shown in the connection wiring diagram or the assignment diagram which are included with the motor Only a selection of the common types of connections are shown in the following section You can obtain the relevant wiring diagrams free of charge from SEW EURODRIVE 9 1 1 Delta and star connection Three phase current motor For all motors with a rotation speed direct on line or L Astartup A connection The following illustration shows the Aconnection for lower voltage 1 Wi ER L1 L2 L3 242603147 1 Motor winding 2 Motor terminal board DI Supply cables A connection The following illustration shows the A connection for high voltage 1 2 U2 v2 w2 w2 U2 v2 KT ar S CD e 9 9 I I l U1 Vi w1 lle ee ae U1 Vi w1 B L1 L2 L3 242598155 1 Motor winding 2 Motor terminal board DI Supply cables Change in direction of rotation Swap connection of 2 supply cables L1 L2 74 Operating Instructions AC Motors DRS DRE DRP Appendix 9 Wiring diagrams 9 1 2 Motor protection using TF or TH with DR71 100 TF TH 2xTF TH with standstill heater The following illustrations show the connection of the motor protection with TF PTC ther mistor sensors or TH bimet
35. AC Motors DRS DRE DRP Technical Data Operating currents 8 3 Operating currents 8 3 1 Brake BE05 1 BE2 BE5 The current values ly holding current specified in the tables are r m s values Measure the r m s values using only the appropriate measuring instruments The inrush current acceleration current lacc only flows for a short time max 160 ms when the brake is released There is no increased inrush current if a BG or BMS brake rectifier is used or if there is a direct DC voltage supply only possible with brakes up to size BE2 BE05 1 BE2 BE5 Max braking torque 5 40 10 89 20 180 55 490 Nm mn Ib Braking power W hp 32 0 043 43 0 058 49 0 066 Inrush current ratio lace ly 4 4 5 7 Rated voltage Vrated BE05 1 BE2 BE5 Vac Voc wi e ot e ancl 24 23 26 10 2 10 2 80 2 75 3 75 60 57 63 24 0 88 1 17 1 57 1 46 1 25 120 111 123 48 0 45 0 58 0 59 0 78 0 64 184 174 193 80 0 29 0 35 0 38 0 47 0 40 208 194 217 90 0 26 0 31 0 34 0 42 0 36 230 218 243 96 0 23 0 29 0 30 0 39 0 33 254 244 273 110 0 20 0 26 0 27 0 34 0 29 290 274 306 125 0 18 0 26 0 24 0 30 0 26 330 307 343 140 0 16 0 20 0 21 0 27 0 23 360 344 379 160 0 14 0 18 0 19 0 24 0 21 400 380 431 180 0 13 0 16 0 17 0 21 0 18 460 432 484 200 0 11 0 14 0 15 0 19 0 16 500 485 542 220 0 10 0 13 0 13 0 17 0 15 575 543 600 250 0 09 0 11 0
36. E5 2 7 Put the rubber sealing collar back in place and re install the dismantled parts NOTE Replace setting nuts 58 and hex nuts 61 if the removal procedure is repeated Operating Instructions AC Motors DRS DRE DRP Inspection and Maintenance Inspection and maintenance for brake motor DR71 DR100 Changing the magnet Severe or fatal injuries can occur A DANGER Risk of crushing if the drive starts up unintentionally Isolate the motor and brake from the power supply before starting work safe guarding them against accidental startup Carefully observe the following operation steps Remove the following forced cooling fan and incremental encoder if installed See section Preliminary work for motor and brake maintenance page 32 flange cover or fan guard 35 circlip 62 and fan 36 Remove the rubber sealing collar 66 and the manual brake release setting nuts 58 conical coil springs 57 studs 56 releasing lever 53 spiral dowel pin 59 Remove the terminal box cover and loosen the brake cable from the rectifier If necessary attach trailing wire to brake cables Unfasten hex nuts 61 remove complete magnet 54 replace brake springs 50 276 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 ga
37. P Inspection and Maintenance 7 Inspection and maintenance for brake motor DR71 DR100 7 6 4 Procedure for inspecting brake motor DR71 DR100 A DANGER Risk of crushing if the drive starts up unintentionally Severe or fatal injuries can occur e Isolate the motor and brake from the power supply before starting work safe guarding them against accidental startup e Carefully observe the following operation steps 1 Remove forced cooling fan and incremental encoder if installed See section Preliminary work for motor and brake maintenance page 32 N Remove fan guard 35 and fan 36 3 Remove machine screws 13 from the flanged endshield 7 and take the B side endshield 42 and stator 16 off the flanged endshield Remove the terminal box cover and unfasten the brake cable from the rectifier Push the brake off the stator and carefully lift it off Pull the stator back by approx 3 4 cm 1 2 in NO PS Visual inspection are there traces of gear oil or condensation inside the stator If there are not proceed to step 10 If there is condensation proceed to step 8 If there is gear oil have the motor repaired by a specialist workshop 8 If there is condensation inside the stator With gearmotors remove the motor from the gear unit With motors without a gear unit remove the A flange Remove the rotor 1 9 Clean the winding dry it and check
38. ake control Example Motor AC 230 400 V Brake AC 230 V 242599819 1 Brake coil 2 SR11 15 current relay Operating Instructions AC Motors DRS DRE DRP 79 80 Appendix Wiring diagrams 9 1 6 BMP3 1 brake control in the terminal box BE120 BE122 brake BMP3 1 brake control Apply voltage to release the brake see nameplate Contact rating of the brake control AC3 in accordance with EN 60947 4 1 Separate supply cables are required for the voltage supply BMP3 1 The following illustration shows the wiring for the BMP3 1 brake rectifier for the AC side shutoff as well as the DC and AC side shutoff BMP3 1 365750411 1 Brake coil Operating Instructions AC Motors DRS DRE DRP Malfunctions ES G Motor malfunctions lt gt 10 Malfunctions 10 1 Motor malfunctions Malfunction Possible cause Remedy Motor does not start up Break in supply cable Check the connections and intermediate terminal points correct if necessary Brake does not release See sec Brake malfunctions page 83 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 protection does not trip Check motor protection control Malfunction in control or in the control process Observe the switching sequence correct if necessary Motor does not
39. ake disc 68 ifthe brake disc lt 9 mm on motors up to DR100 replace the brake disc See section Replacing the brake disc for brake BEO5 BE5 page 41 Measure the working air gap A see following figure use a feeler gauge and measure at three points offset by 120 between the pressure plate 49 and damping plate 718 Tighten the hex nuts 61 Tighten the setting sleeves until the working air gap is set correctly see Technical Data section page 63 Put the rubber sealing collar back in place and re install the dismantled parts 179978635 Operating Instructions AC Motors DRS DRE DRP Inspection and Maintenance Inspection and maintenance for brake motor DR71 DR100 7 6 6 Replacing the brake disc for brake BE05 BE5 When fitting a new brake disc thickness lt 9 mm also inspect the other removed parts and if necessary install new ones A DANGER Risk of crushing if the drive starts up unintentionally Severe or fatal injuries can occur Isolate the motor and brake from the power supply before starting work safe guarding them against accidental startup Carefully observe the following operation steps NOTE The brake for motor sizes DR 71 80 cannot be removed from the motor because the BE brake is directly installed on the brake endshield of the motor With motor sizes DR 90 100 you can remove the brakes when changing the brake disc as the BE brake is pre as
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41. allic 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 1b 2b TF TH TF TH Example 2xTF TH to a five pole terminal strip Gi 2 3 8 la 2a 3a 4a 18 TF TH 18 TF TH 20 TFITH 274 TF TH The following illustration shows the connection of the motor protection with 2 TF PTC thermistor sensors or TH bimetallic thermostats and Hx standstill heater la 2a 3a 4a 18 TF TH 18 TF TH 20d TF TH 2d TF TH Operating Instructions AC Motors DRS DRE DRP 75 76 Appendix Wiring diagrams 9 1 3 Motor protection using TF or TH with DR315 TF TH The following illustrations show the connection of the motor protection with TF PTC ther mistor sensors or TH bimetallic thermostats Depending on the version an x pole terminal strip is available for connecting to the trip switch Example TF TH to terminal strip 1 TF 1 TF 1 TH 1 TH Example 2xTF TH to terminal strip 1 TF 2 TF 2 TF 1 TH 2 TH 2 TH Operating Instructions AC Motors DRS DRE DRP Appendix 9 Wiring diagrams 9 1 4 BGE BG BSG BUR brake control Brake BE BGE BG BSG BUR brake cont
42. anger e g electric shock STOP Possible damage to property Damage to the drive system or its environment HQ NOTE Useful information or tip Simplifies the handling of the drive system 1 2 Rights to claim under warranty Adhering to the operating instructions is a prerequisite for fault free operation and the fulfillment of any right to claim under warranty Read the operating instructions before you start working with the unit Make sure that the operating instructions are available to persons responsible for the system and its operation as well as to persons who work independently 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 ensure safe operation of the electric motors and to achieve the specified product char acteristics and performance features SEW EURODRIVE assumes no liability for injury 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 are intended 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 the per
43. cal coil springs pressed flat and the setting nuts see the following figure The 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 9 Put the rubber sealing collar back in place and re install the dismantled parts NOTE Replace setting nuts 58 and hex nuts 61 if the removal procedure is repeated Operating Instructions AC Motors DRS DRE DRP 62 Inspection and Maintenance Inspection and maintenance for brake motor DR315 Replacing the brake on DR315 STOP The mounting position for installation should correspond to the specifications on the nameplate make sure that the intended mounting position is permitted Risk of crushing if the drive starts up unintentionally Severe or fatal injuries can occur Isolate the motor and brake from the power supply before starting work safe guarding them against accidental startup Carefully observe the following operation steps ao A O N Remove forced cooling fan and incremental encoder if installed See section Preliminary work for motor and brake maintenance page 32 Remove the flange cover or fan guard 35 circlip 32 and fan 36 Unfasten brake connector Unfasten screws 900
44. connection is gt 1 5 mn it must be installed as a cable lug below the terminal washer Version 1a cross section lt 1 5 mm 1 gt 8 lt 10mm lt 1 5 mm2 gt AWG 16 88866955 1 External connection with cross section lt 1 5 mm 2 Terminal stud 8 Flange nut 4 Terminal link 5 Terminal washer 6 Winding connection with Stocko connection terminal Operating Instructions AC Motors DRS DRE DRP 21 Electrical Installation Connecting the motor Version 1b Cross section gt 1 5 mm 1 88864779 1 External connection with ring cable lug according to DIN 46237 or DIN 46234 for example 2 Terminal stud 3 Flange nut 4 Terminal link 5 Terminal washer 6 Winding connection with Stocko connection terminal Version 2 1 2 3 4 185439371 1 Terminal stud 2 Lock washer 3 Terminal washer 4 Winding connection 5 Top nut 6 Washer 7 External connection with ring cable lug according to DIN 46237 or DIN 46234 for example 8 Bottom nut Operating Instructions AC Motors DRS DRE DRP Electrical Installation Connecting the motor Version 3 199641099 1 External connection with ring cable lug according to DIN 46237 or DIN 46234 for example 2 Terminal stud 8 Top nut 4 Washer 5 Terminal link 6 Bottom nut 7 Winding connection with ring cable lug 8 Serrated lock washer O
45. ct SEW EURODRIVE if necessary 18 Operating Instructions AC Motors DRS DRE DRP Electrical Installation 5 Connecting the motor 5 7 Connecting the motor 5 7 1 Connecting the motor via terminal boxes e in accordance with the wiring diagram provided e check cable cross section e arrange terminal links correctly e firmly screw on connections and protective earth conductors Inthe terminal box check winding connections and tighten them if necessary Arrangement of terminal links with connection Arrangement of terminal links with A connection Motor size DR71 100 Motor size DR315 1 Terminal link 4 Terminal board 2 Terminal stud 5 Customer connection 3 Flange nut 6 Customer connection with divided 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 19 20 Electrical Installation Connecting the motor 5 7 2 Motor connection terminal board The motors are supplied and connected differently depending on the electrical design Arrange the cables and terminal links as shown in the wiring diagram and screw them on firmly Observe the tightening torques specified in the following tables Motor size DR71 100 Terminal
46. d at an ambient temperature between 20 C 4 F to 40 C 104 F SEW EURODRIVE uses a mineral high performance high tempera ture grease for lubrication a polyurea based lubricant produced by ESSO Polyrex EM K2P 20 DIN51825 For motors in the low temperature range up to 40 C 40 F the SKF GXN grease is used instead which is also a mineral polyurea based grease You can purchase the lubricants in 400 g cartridges from SEW EURODRIVE For order information refer to the section Lubricant tables for roller bearings of SEW motors page 73 NOTE Only mix lubricants of the same thickness type the same base oil and the same consis tency NLGI class Grease the motor bearings in accordance with the information on the lubricant plate The used grease collects inside the motor and after every 6 8 re greasings this should be removed during an inspection Each time you re lubricate ensure that the bearing is two thirds full After relubricating the motors you should startup slowly if possible so that the grease is distributed evenly Operating Instructions AC Motors DRS DRE DRP Inspection and Maintenance Reinforced bearing Relubrication interval Relubrication interval for bearings e if the ambient temperature is 20 C 4 F to 40 C 104 F ata 4 pole speed e and with a normal load are assigned using the table below At greater speeds higher loads or higher ambie
47. d lubrication ring 604 into the bearing bore of the 50 flange 7 Hang the rotor 1 onto the B side thread and guide into the flange 7 Fasten the oil seal flange 608 to the flange 7 using the hex head bolts 609 Operating Instructions AC Motors DRS DRE DRP Inspection and Maintenance Inspection and maintenance work on the motor DR315 11 Mount the stator 16 Reseal the stator seat seal the sealing surface with a duroplastic sealing compound operating temperature 40 C 40 F 180 C 356 F such as Hylomar L Spezial Important Protect the winding overhead 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 Before mounting 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 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 14 Renew oil seals A side 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 side insert the oil seal 30 and coat the sealing lip with the same grease
48. d sel Zeta EE 39 Inspecting the motor RE LEE 35 DIN iii A A 50 DRIT TEE 35 DREO critica ari 35 ROO e do e 35 Inspection vincia ici add deidad 29 Inspection and Maintenance ococccccccccnnnnicncncnnnos 29 Inspection and maintenance intervals 29 Inspection intervals ooooccnocccncnnnnnnccccnccnconnoncnnnon 29 Installati0N 7 14 Electrical eege ee 15 MU ET 12 Installation tolerances 14 L Lubricant table 0 cceeeeeeeeeeeceeceeeeeeeeeteteeenenes 73 M Maintenance cieie aiaia aha eiaa aaa aa 29 Maintenance intervals ooocicccccnnnnnccnncccconcnnccnnno 29 Malfunctions 81 Malfunctions when operating with a frequency inverter aasssseessseserrrresrrrrieeseennresrenns 84 Mechanical Installation ooooooooonnnnnnnnnnnonnnncnnnns 12 Motor Connection aE 19 DING EE 13 Extended storage sssrin 13 ISE 14 Motor connection terminal board 0000 20 Motor Design coidar i ia a a iea 9 DRIOO ainia 9 DORA A e a EE 10 DRIT airada labios 9 DR AER 9 DRIO iia ade ta 9 Motor malfunctions oooooocnccnconoccccnccnnnnncnicananannnos 81 Motor protection cecceeeeeeeteeteeseees 75 76 Ts dano edad cane 75 76 TH pis eel oe aA 75 76 Motor protection device oooocociiccnniccccccccccccnnno 15 N Nameplate c cccccceceeeeeeeeeseeeeensneeeeeeeeeeess 11 O Operation with frequency inverter 2 005 16 P Preliminary work for motor and bra
49. e Electrical Installation section Whenever changes to normal operation occur such as increased temperatures noise vibrations etc you should determine the cause and contact the manufacturer if required Never deactivate protection devices 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 structure of DR71 DR100 3 Motor Design NOTE The following illustration shows the general structure lts only purpose is to facilitate the assignment of components to the spare parts lists Deviations are possible depending on the motor size and version 3 1 Basic structure of DR71 DR100 44 36 1 Rotor 2 Circlip 3 Key 7 Flanged endshield 9 Screw plug 10 Circlip 11 Deep groove ball bearing 12 Circlip 13 Machine screw 16 Stator 22 Hex head bolt 24 Eyebolt 80 Oil seal 82 Circlip 85 Fan guard 86 Fan 41 Shim washer 42 B side endshield 44 Deep groove ball bearing 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 b
50. e 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 11 2006 95 EURODRIVE EURODRIVE EURODRIVE SEW EURODRIVE Driving the world Gearmotors Industrial Gear Units Drive Electronics Drive Automation 1 Services How were driving the world With people who think fast and With a worldwide With drives and controls develop the service network that is that automatically future with you always close at hand improve your productivity a A With a global presence With innovative that offers responsive
51. emove the protection cover 361 e Unfasten the expansion anchor by unscrewing the screws 733 from the cover grid e Unscrew the central retaining screw 367 by about two to three turns and unfasten the spread shaft cone by tapping lightly on the head of the screw Remove the incremental encoder from the bore of the rotor 1 Removing AS7 Remove the protection cover 361 Unscrew the connection cover 220 and remove it Do not disconnect the encoder connection cable e Unfasten the expansion anchor by unscrewing the screws 733 from the cover grid e Unscrew the central retaining screw 367 by about two to three turns and unfasten the spread shaft cone by tapping lightly on the head of the screw Remove the incremental encoder from the bore of the rotor 1 Re assembly For re assembly please note Apply NOCO fluid to the encoder spigot e Tighten the central retaining screw 367 with a tightening torque of 2 9 Nm 26 in Ib e Tighten the screw 733 in the expansion anchor with a tightening torque of max 1 0 Nm 8 9 in 1b 32 Operating Instructions AC Motors DRS DRE DRP Inspection and Maintenance 7 Preliminary work for motor and brake maintenance 7 4 2 Removing the incremental encoder from the DR315 The following figure shows how to remove the incremental encoder on the DR315 85 734 367 220 659 657 748 367 220 407629451 35 Fan guard 659 Screw 220 Encoder
52. ength inverter encoder 100 m 328 ft with a capacitance per unit length lt 120 nF km 193 nF mile Core cross section 0 20 0 5 mm Use a shielded cable with twisted pair cores and apply shield over a large surface area at both ends tothe connection cover of the encoder in the cable gland or in the encoder plug to the 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 7 87 in Operating Instructions AC Motors DRS DRE DRP 27 6 28 C xD Startup Prerequisites for startup 6 Startup 6 1 Prerequisites for startup NOTE It is essential to comply with Safety notes in section 2 page 6 during installation In case of problems refer to the Malfunctions section page 81 6 1 1 Before startup make sure that the drive is undamaged and not blocked the measures stipulated in section Preliminary work page 12 are performed after extended storage period 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 the rated motor current and that there are no other sources of danger present 6 1 2 During startup make sure that
53. etting the working air gap for brake BE120 BE122 page 56 If the brake disk is too thin replace the brake disk BE05 BE5 lt 9 mm BE120 BE122 lt 12 mm See the following sections Replacing the brake disk for brake BE05 BE5 page 41 Replacing the brake disk for brake BE120 BE122 page 58 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 specialist workshop Check switchgear replace if needed Rectifier defective Replace rectifier and brake coil it may be more economical to replace the complete brake Brake does not brake Working air gap not correct Measure and set working air gap See the following sections Setting the working air gap for brake BEO5 BE5 page 40 Setting the working air gap for brake BE120 BE122 page 56 If the brake disk is too thin replace the brake disk BE05 BE5 lt 9 mm
54. g them against accidental startup Carefully observe the following operation steps Remove the following forced cooling fan and incremental encoder if installed See section Preliminary work for motor and brake maintenance page 32 flange cover or fan guard 35 circlip 62 and fan 36 Remove the rubber sealing collar 66 and the manual brake release setting nuts 58 conical coil springs 57 studs 56 releasing lever 53 spiral dowel pin 59 Unfasten hex nuts 61 and pull off the brake coil body 54 By approx 50 mm 2 0 in watch the brake cable Change or add brake springs 50 276 Position the 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 for brake BEO5 BE5 page 40 Operating Instructions AC Motors DRS DRE DRP 43 44 Inspection and Maintenance Inspection and maintenance for brake motor DR71 DR100 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 The 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 1 5 BE2 B
55. he motor s Note that the service life of the lubricant in the ball bearings is reduced by 10 per year after the first year of storage e You should re lubricate the lubrication devices on motors that have been in storage for longer than 5 years before startup Observe the information on the motor lubricant plate Check whether the motor has absorbed moisture as a result of being stored for a long time To do so measure the insulation resistance 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 MA 0 20 40 60 80 c 173323019 Heat the motor e with hot air or e using an isolation transformer connect the windings in series see following figure auxiliary AC voltage supply max 10 of the rated voltage with max 20 of the rated current Trafo 174065419 The drying process is finished when the minimum insulation resistance has been exceeded In the terminal box check that e the inside is clean and dry the connections and fixing parts are free from corrosion the gasket and sealing surfaces are functioning e the cable glands are sealed if they are not clean or replace them Operating Instructions AC Motors DRS DRE DRP 13 14 Mechanical Installation Mechanical Installation 4 2 2 Installing the motor Installation in damp locations or in the open
56. ia bever fastbg net Cameroon Sales Douala Electro Services Tel 237 4322 99 Rue Drouot Akwa Fax 237 4277 03 B P 2024 Douala Canada Assembly Toronto SEW EURODRIVE CO OF CANADA LTD Tel 1 905 791 1553 Sales 210 Walker Drive Fax 1 905 791 2999 Service Bramalea Ontario L6T3W1 http www sew eurodrive ca reynolds sew eurodrive ca Vancouver SEW EURODRIVE CO OF CANADA LTD Tel 1 604 946 5535 7188 Honeyman Street Fax 1 604 946 2513 Delta B C V4G 1 E2 b wake sew eurodrive ca Montreal SEW EURODRIVE CO OF CANADA LTD Tel 1 514 367 1124 2555 Rue Leger Street Fax 1 514 367 3677 LaSalle Quebec H8N 2V9 a peluso 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 www sew eurodrive cl LAMPA RCH Santiago de Chile P O Box Casilla 23 Correo Quilicura Santiago Chile ventas sew eurodrive cl 11 2006 89 1 Address List P O Box 80136 GR 18545 Piraeus China Production Tianjin SEW EURODRIVE Tianjin Co Ltd Tel 86 22 25322612 Assembly No 46 7th 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 51
57. icana Km 37 5 sewar sew eurodrive com ar 11 2006 Address List 1 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 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 caron vector 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 Sof
58. ii dat a ee aed 15 5 3 Special features when operating with a frequency inverter 16 5 4 Improving the grounding EMC 17 5 5 Special features for switching operation ssssssesersnnssnssrerrerrrrrnrennerene 18 5 6 Ambient conditions during operation 18 5 7 Connecting the moior eee ee eeeeeee eee tene eee eeeeeeeeeeeteeeeettineeeeeeeee 19 5 8 Connecting the brake coordinare i i eiaa 24 5 9 Accessory et EE 25 A essen ac cektcece dentdevansa A EEEEEENENER ENEE 28 6 1 Prerequisites for startup 28 7 Inspection and Maintenance 2 ccecceeeeeeeeeeeeeeeeneeeeeeeeeeeeeseeseeesseeneeeees 29 7 1 Inspection and maintenance intervals neensseeeeeesrrerrnnneeersresrrenr rnea 29 7 2 Bearing lubrication iiuna r ra 30 1 3 Reinforced Dearing enstinn rea digita 31 7 4 Preliminary work for motor and brake maintenance 32 7 5 Inspection and maintenance work on the motor DR71 DR100 34 7 6 Inspection and maintenance for brake motor DR71 DR100 36 7 7 Inspection and maintenance work on the motor DR315 sssssssensenneeee 49 7 8 Inspection and maintenance for brake motor DR31D 52 Operating Instructions AC Motors DRS DRE DRP Contents 8 Technical Data iii tad dao cid 63 8 1 Work done working air gap braking torques oooonoonccccnnnnnncccccnnannccccnnn 63 8 2 Braking torque breakdown ooooooocccconnnooccccconoonccncconnonnncnnnnnnnnncnnnnnnnncncnn
59. ing fan and incremental encoder if installed See section Preliminary work for motor and brake maintenance page 32 With gearmotors Remove the motor from the gear unit 2 Remove fan guard 35 and fan 36 9 Unfasten machine screws 25 and 19 and remove B side endshield 42 Unfasten machine screws 15 from the flange 7 and remove the complete rotor 1 together with the flange With gearmotors pull off the oil flinger 107 Loosen screws 609 and separate the rotor from the flange 7 Before disassembly protect the oil seal seat against damage using adhesive tape or a protective sleeve Visual inspection are there traces of gear oil or condensation inside the stator If there are not proceed to step 8 If there is condensation continue with 7 If there is gear oil have the motor repaired by a specialist workshop If there is condensation inside the stator Clean the winding dry it and check it electrically see Preliminary work section page 12 Replace the roller bearings 11 44 with permitted roller bearing types See section Permitted roller bearing types page 72 Fill the bearing with grease until it is two thirds full See section Bearing lubrication DR315 page 30 Important place the oil seal flange 608 and 21 onto the rotor shaft before installing the bearings Starting on the A side mount the motor vertically 10 Place the cup springs 105 an
60. ir 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 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 Operating Instructions AC Motors DRS DRE DRP 10 81 10 82 ER ANS lt Malfunctions SC Motor malfunctions Malfunction Possible cause Remedy 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 passages 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 Supply voltage deviates from the rated mo
61. irclip 35 Fan guard 36 Fan 40 Circlip 42 B side endshield 43 Supporting ring 44 Roller bearing 90 Foot mounting 94 Machine screw 100 Hex nut 103 Stud 105 Cup spring 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 bolt 123 Hex head bolt 128 Serrated lock washer 129 Screw plug 131 Gasket for cover Operating Instructions AC Motors DRS DRE DRP 132 Terminal box cover 134 Screw plug 139 Hex head bolt 140 Washer 151 Machine screw 219 Hex nut 250 Oil seal 452 Terminal strip 454 Top hat rail 604 Lubrication ring 606 Greasing nipple 607 Greasing nipple 608 Oil seal flange 609 Hex head bolt 633 End bracket 634 End plate 705 Protective cowl 706 Spacer bolt 707 Hex head bolt 715 Hex nut 716 Washer 351998603 49 7 Inspection and Maintenance Inspection and maintenance work on the motor DR315 7 7 2 Procedure for inspecting motor DR315 A DANGER Risk of crushing if the drive starts up unintentionally Severe or fatal injuries can occur Disconnect the motor from the power supply before starting work and safeguard against accidental startup Carefully observe the following operation steps Remove forced cool
62. ke ET Te 32 R Reinforced bearing n 12 31 Relubrication ooooocoonnonoccccconccnncnnccnccnnonnnnrononncnnnno 30 Relubrication intervals sseseeseeeeeeeeeees 31 Removing the encoder seses 32 33 Te Ke A eae 33 PASTE EE 32 EELS easel toh ete de 33 ESTEE EE 32 ESTA eege 32 Removing the incremental encoder 32 33 BIT Ye EE 33 ASTM AS E A e 32 EHTS lari oia es 33 EST DEE 32 ESO ua idolos tie idee 32 Replacing the brake disc Een 41 LTE NEE 41 BE N20 uni dai GE 58 BELL tios daa anes A 58 LTE 41 LTE 41 Retrofitting the manual brake release HR HF 48 Right to claim under warranty oocoinncccioncccnnonccnnno 5 Roller bearing types ooonnnccccnnnnocccnnnncncnnnnnnnnnnnns 72 S Safiy Notes teron cod 6 Designated USE cooiccccnnnoccccccnnannncncnnnnnnnccnnnnns 7 Electrical connection n se 8 General asaos lisis 6 a Ee NET 7 Operation A 8 Transportaiion 7 Operating Instructions AC Motors DRS DRE DRP Index Setting the working air gap D nee ohne teen ee 40 BETA AAA AS 40 BELLO AR As 56 BE122 concern AAA 56 BEE A 40 BEN Atle hae a Ad 40 Special features for switching operation 18 Star CONNECHON 2 203 206 5083 edd 19 74 Stanu p MEET 28 Switching operation ooonnccccnnnncccccnnnnonccininannnncnnnns 18 T Reuler Te EE 63 Temperature sensor TF 2 0 eceeceeeeeeeeeeees 25 ME 25 75 76 O 25 75 76 RTE Lel le EE 7 Operating Inst
63. l features for switching operation 5 5 Special features for switching operation When the motors are used in switching operation it is necessary to exclude possible interference of the switchgear using suitable wiring According to EN 60204 electrical equipment of machines motor windings must have interference suppression to protect the numerical or programmable logic controllers Since it is primarily switching opera tions that cause interference SEW EURODRIVE recommends installing protective circuits on the switching devices 5 6 Ambient conditions during operation 5 6 1 Ambient temperature Adherence to the temperature range of 20 C 4 F to 40 C 104 F is imperative unless specified otherwise on the nameplate Motors intended for use in higher or lower ambient temperatures will have the respective designation on the nameplate 5 6 2 Installation altitude The maximum installation altitude of 1000 m 3281 ft above sea level must not be exceeded Otherwise this causes a power reduction at a factor f4 as specified in the following diagram 1000 2000 3000 4000 m 173325195 The reduction in rated power is calculated according to the following formula Pratedt Pratea X fH Prated1 reduced rated power kW PRatea rated power kW H factor for reduction due to installation altitude 5 6 3 Hazardous radiation Motors must not be subjected to hazardous radiation such as ionizing radiation Conta
64. may only be installed if e the specifications on the drive s nameplate and the output voltage of the frequency inverter match the voltage supply system e the drive is undamaged no damage caused by transportation or storage e itis certain that the following requirements have been fulfilled ambient temperature between 20 C 4 0 F and 40 C 104 F 1 no oil acid gas vapors radiation etc installation altitude max 1000 m 3281 ft above sea level note the limitations for encoders special versions drive configured in accordance with the ambient conditions STOP The mounting position for installation must correspond to the specifications on the nameplate 4 2 Mechanical Installation 4 2 1 Preliminary work Motors with reinforced bearings 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 sealing rings this could cause material damage STOP Motors with a reinforced bearing must not be operated without an overhung load Otherwise you risk damaging the bearings 1 Note that you can also limit the temperature range of the gear unit see gear unit operating instructions Operating Instructions AC Motors DRS DRE DRP Mechanical Installation 4 Mechanical Installation Extended storage of motors Drying t
65. nns 64 8 3 Operating CUrreNts ooccconininninonnnnccci cane 65 9 4 RESISTANCES iii di 67 8 5 Brake rectifier combinations canario 69 8 6 Brake COTO erran Ae E E Ae laicos 70 8 7 Permitted roller bearing types ooococoinnonccccnnnncccccccnnnoncnccnonannnccnnnnnnnccncnanns 72 8 8 Lubricant tables inicial dada da bd dad 73 8 9 Order information for lubricants and anti corrosion agents 73 CR TN E O E naa da eaea aAa aapa 74 HI Wing diagramas me isrisorieemiiaai A i AE ER 74 ELIT E 81 10 1 Motor malneton enee a T T 81 10 2 Brake malfunctions saenisisicrisidi iei ant rii ie ei 83 10 3 Malfunctions when operating with a frequency Imverter 84 10 4 Customer SOriCe annie anien ii e EAEAN SNEEN 84 DTI DOK iii T T N 85 Address RT EE 88 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 structured as follows A SIGNAL WORD Nature and source of hazard Possible consequence s if disregarded e Measure s to avoid the hazard o o lt lt 3 gt g y 2 2 Signal word Meaning Consequences if disregarded Example gt DANGER Imminent danger Severe or fatal injuries WARNING Possible dangerous situation Severe or fatal injuries General hazard A CAUTION Possible dangerous situation Minor injuries Specific d
66. nsportation If low voltage machines are put into storage make sure they are kept in a dry dust free and low vibration Veg 0 2 mm s environment bearing standstill damage Measure the insulation resistance prior to startup Dry the winding if values lt 1 KQ per volt of the rated voltage Installation Make sure that the supports are even the foot and flange mounting is correct and if there is direct coupling align with precision Resonances between the rotational frequency and the double network frequency caused by the structure are to be avoided Turn the rotor manually and listen for unusual noises Check the direction of rotation in decoupled status Only install or remove belt pulleys and couplings using suitable devices heat up and cover with a touch guard Avoid improper belt tension Make the pipe connections that may eventually be required Mounting positions with shaft ends pointing upwards should be equipped with a cover to prevent foreign objects from falling into the fan Ensure that ventilation openings are not obstructed and that used air including air from adjacent units cannot be drawn in again straight away Observe the notes in the Mechanical Installation section 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
67. nt temperatures the relubrication intervals are shorter Horizontal mounting position Vertical mounting position Motor type Duration Quantity Duration Quantity DR315 INS 5000 h 50g 3000 h 70g DR315 ERF NS 3000 h 50g 2000 h 70g 7 3 Reinforced bearing STOP In the ERF reinforced bearing option cylindrical roller bearings are installed on the A side These must not be operated without an overhung load otherwise you risk damaging the bearings The reinforced bearing is only offered with the NS relubrication option so as to facili tate optimal lubrication of the bearing For bearing lubrication refer to the notes in the Bearing lubrication DR315 section page 30 Operating Instructions AC Motors DRS DRE DRP 31 7 Inspection and Maintenance Preliminary work for motor and brake maintenance 7 4 Preliminary work for motor and brake maintenance Risk of crushing if the drive starts up unintentionally Severe or fatal injuries can occur Before starting work isolate the motor and brake from the power supply e Safeguard against accidental startup 7 4 1 Removing the incremental encoder from the DR71 100 The following figure shows how to remove an encoder using the ES7 incremental encoder as example 179980299 1 Rotor 367 Retaining screw 220 Connection cover 733 Screws 361 Protection cover Removing ES7 R
68. nts include output cables from frequency inverters and servo controllers soft startup units and brake units e supply cables for braking resistors and similar options 5 2 2 Protecting against interference by motor protection devices To protect against interference by SEW motor protection devices temperature sensors TF winding thermostats TH e 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 Operating Instructions AC Motors DRS DRE DRP 15 Electrical Installation Special features when operating with a frequency inverter 5 3 Special features when operating with a frequency inverter When motors are powered by inverters you must adhere to the relevant wiring notes issued by the inverter manufacturer You must also 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 dielectric 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 this start up the motor as described in the operating instructions for the frequency inverter 5 3 2 Motor on a non SEW inverter You may operate SEW motors on non SEW frequency inverters if the
69. olt 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 Protective cowl 706 Spacer 707 Pan head screw 10 Motor Design Basic structure DR315 3 2 Basic structure DR315 1 Rotor 2 Circlip 3 Key 4 Key 7 Flange 9 Screw plug 11 Roller bearing 15 Machine screw 16 Stator 17 Hex nut 19 Machine screw 21 Oil seal flange 22 Hex head bolt 24 Eyebolt 25 Machine screw 26 Sealing washer 30 Oil seal 31 Key 32 Circlip 35 Fan guard 36 Fan 40 Circlip 42 B side endshield 9 1608 l ae 04 250 100 43 Supporting ring 44 Roller bearing 90 Foot mounting 94 Machine screw 100 Hex nut 103 Stud 105 Cup spring 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 bolt 123 Hex head bolt 128 Serrated lock washer 129 Screw plug 131 Gasket for cover 351998603 132 Terminal box cover 134 Screw plug 139 Hex head bolt 140 Washer 151 Machine screw 219 Hex nut 250 Oil seal 452 Terminal strip 454 Top hat rail
70. otor size DR315 Technical Data Brake control Brake control Motor wiring compartment The following table lists the technical data of brake control systems for installation in the motor wiring compartment and the breakdown in regard to motor size and connection technology The different housings have different colors color code to make them easier to distinguish Holding Type Function Voltage current Type Fart color number code lHmax A AC 150 500 V 1 5 BG 1 5 825 3846 Black BG One way rectifier AC 24 500 V 3 0 BG 3 825 386 2 Brown BGE One way rectifier with AC 150 500 V 1 5 BGE 1 5 825 385 4 Red electronic switching AC 42 150 V 3 0 BGE 3 825 3870 Blue 825 385 4 1 0 BGE 1 5 SR 11 826 761 8 AC 150 500 V Boba One way rectifier 1 0 BGE 1 5 SR 15 956 769 6 BSR current relay for cut off in soe cer the DC circuit 1 0 BGE 3 SR11 826 761 8 AC 42 150 V ESOO 1 0 BGE 3 SR15 826 762 6 825 385 4 One way rectifier AC 150 500 V 1 0 BGE 1 5 UR 15 826 759 6 BUR voltage relay for cut off in SOTO the DC circuit AC 42 150 V 1 0 BGE 3 UR 11 826 758 8 BS Varistor protection circuit DC 24 V 5 0 BS24 8267634 Aqua BSG Electronic switching DC 24 V 5 0 BSG 8254591 White Holding Type Function Voltage current Type hart Golor number code lHmax A One way rectifier with electronic switching BMP integrated voltage
71. ove if needed Operating Instructions AC Motors DRS DRE DRP 10 83 10 SCH Ed Malfunctions SC Malfunctions when operating with a frequency inverter Malfunction Possible cause Remedy Brake is applied with time lag Brake is switched only on AC voltage side 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 Check the project planning replace the brake disk if needed carrier caused by jolting startup See the following sections Replacing the brake disk for brake BEO5 BE5 page 41 Replacing the brake disk for brake BE120 BE122 page 58 Have a specialist workshop replace the carrier Pulsating torques due to incorrectly set Check correct setting of frequency inverter according to its frequency inverter operating instructions correct if needed 10 3 Malfunctions when operating with a frequency inverter The symptoms described in section Motor malfunctions may also occur when the motor is operated with a frequency inverter Please refer to the frequency inverter oper ating instructions for the significance of the problems which occur and to find information about rectifying the problems 10 4 Customer service 84 Please have the following information available if you require customer service assis
72. p for brake BEO5 BE5 page 40 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 The 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 1 5 BE2 BE5 2 7 Put the rubber sealing collar back in place and re install the dismantled parts Operating Instructions AC Motors DRS DRE DRP 45 Replacing the brake on DR71 and DR80 Inspection and Maintenance Inspection and maintenance for brake motor DR71 DR100 A DANGER Severe or fatal injuries can occur Risk of crushing if the drive starts up unintentionally Isolate the motor and brake from the power supply before starting work safe guarding them against accidental startup Carefully observe the following operation steps Remove the following forced cooling fan and incremental encoder if installed See section Preliminary work for motor and brake maintenance page 32 flange cover or fan guard 35 circlip 62 and fan 36 Remove the terminal box cover and loosen the brake cable from the rectifier If necessary attach trailing wire to brake cables Loosen machine screws 13 and remove brake endshield with brake from stato
73. perating Instructions AC Motors DRS DRE DRP 23 24 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 e Comply with the applicable regulations issued by the relevant employer s liability insurance association for phase failure protection and the associated cycle times cycle time modifications e Connect the brake according to the wiring diagram provided e In 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 according to EN 60947 4 1 5 8 1 Connecting the brake control The DC disc brake is powered by a brake control with protection circuit This is accom modated in the terminal box IS lower part or must be installed in the control cabinet e Check the cable cross sections braking currents see Section Technical Data Connect the brake control according to the wiring diagram provided For motors in thermal class 180 H install the brake rectifier in the control cabinet Operating Instructions AC Motors DRS DRE DRP Electrical Installation Accessory equipment 5 9 Accessory equipment Connect accessory equipment as shown in the wiring connection diagram s provided with the motor Do not connect any accessor
74. place brittle gaskets Restore the anticorrosive coating if necessary Check the enclosure 4 2 3 Installation tolerances Shaft end Flanges Diameter tolerance according to EN 50347 Centering shoulder tolerance in accordance e ISO j6 at Y lt 28 mm 1 1 in with EN 50347 e ISOk6 at Y gt 38 mm 1 5 in to lt 48 mm 1 9 in ISO j6 at lt 250 mm 9 84 in e ISO m6 at Y gt 55 mm 2 2 in e ISO h6 at Y gt 300 mm 11 8 in Center hole in accordance with DIN 332 shape DR Operating Instructions AC Motors DRS DRE DRP Electrical Installation 5 Use wiring diagrams 5 Electrical Installation NOTE e Itis imperative that you observe the safety notes in section 2 during installation e Use switch contacts in utilization category AC 3 according to EN 60947 4 1 for switching the motor and the brake 5 1 Use 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 installation 5 2 1 Protection against interference from brake controls Unless they are shielded brake cables must always be routed separately from other power cables with phased currents to protect brake controls against interference In particular power cables with phased curre
75. r 4 Guide the brake cable into the terminal box Align the cam of the brake endshield Notes for BE05 and BEI installed on the DR80 You can only turn the brake against the shaft as long as the brake is not making contact with the carrier Turning the brake on the shaft can destroy the brake disc of the brake Turning the whole brake including the shaft is permitted 6 Mount oil seal 95 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 The 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 1 5 BE2 2 Operating Instructions AC Motors DRS DRE DRP Inspection and Maintenance Inspection and maintenance for brake motor DR71 DR100 Replacing the brake on DR9O and DR100 Severe or fatal injuries can occur A DANGER Risk of crushing if the drive starts up unintentionally Isolate the motor and brake from the power supply before starting work safe guarding them against accidental startup Carefully observe the following operation steps oon Bb 0 Remove the following forced cooling fan and incremental encoder if installed See section Preliminary work for motor and brake main
76. r additional information Operating Instructions AC Motors DRS DRE DRP Safety Notes Designated use 2 3 2 4 2 5 Designated use The electric motors are intended for industrial systems Use in potentially explosive areas is prohibited unless measures are expressly taken to make it possible Air cooled versions are designed for ambient temperatures of 20 C 4 F to 40 C 104 F and installation altitudes lt 1000 m 3281 ft above sea level Note that informa tion on the nameplate may differ It is essential that the operating conditions for the unit comply with the nameplate information Transportation Immediately upon receipt inspect the shipment for any damage that may have occurred during transportation If necessary inform the shipping company immediately You may need to preclude startup Tighten the eyebolts securely They are only intended for the weight of the motor gear motor do not attach any additional loads The built in lifting eyebolts comply with DIN 580 Always observe the loads and regula tions listed in this standard If the gearmotor is equipped with two eyebolts then both of these 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 when necessary Remove any trans portation fixings prior to startup Reattach these in the case of further tra
77. rake motor DR315 Severe or fatal injuries can occur A DANGER Risk of crushing if the drive starts up unintentionally Isolate the motor and brake from the power supply before starting work safe guarding them against accidental startup Carefully observe the following operation steps Oak o HM Remove forced cooling fan and incremental encoder if installed See section Preliminary work for motor and brake maintenance page 32 Remove fan guard 35 and fan 36 Unfasten brake connector Loosen screws 900 and remove pre assembled brake 550 from brake endshield Unfasten machine screws 25 and 19 and remove B side endshield 42 Unfasten machine screws 15 from the flange 7 and remove the complete rotor 1 together with the flange With gearmotors pull off the oil flinger 107 Loosen screws 609 and separate the rotor from the flange 7 Before disassembly protect the oil seal seat from damage using adhesive tape or a protective sleeve Visual inspection are there traces of gear oil or condensation inside the stator If there are not proceed to step 8 If there is condensation continue with 7 If there is gear oil have the motor repaired by a specialist workshop If there is condensation inside the stator Clean the winding dry it and check it electrically see Preliminary work section page 32 10 Replace the roller bearings 11 44 with permi
78. requency in Hz Voltage V 1 AC A 50 230 277 1 AC A 60 230 277 3 AC A 50 346 500 3 AC A 60 346 575 3 AC A 50 200 290 3 AC A 60 200 330 NOTE For information on how to connect the forced cooling fan V refer to the wiring diagram Operating Instructions AC Motors DRS DRE DRP Electrical Installation Accessory equipment 5 9 4 Overview of encoders Refer to the wiring connection diagrams on information on how to connect incremental encoders Encoder SEW motor GE Mounting type Power supply Signal Wiring diagram ES7S DR71 100 Encoder Shaft centered DC 7 30 V 1 Vss sin cos 68 169 xx 061 ES7H DR71 100 Encoder Shaft centered DC7 12V Hiperface single turn 68 170 xx 06 AS7H DR71 100 Encoder Shaft centered DC 7 12 V Hiperface multi turn 68 170 xx 06 EH7S DR315 Encoder Shaft centered DC 10 30 V 1 Vss sin cos 08 259 xx 071 AH7Y DR315 Encoder Shaft centered DC 9 30 V TTL SSI RS 422 08 259 xx 071 1 xx placeholder for the wiring diagram version NOTE Maximum oscillation load for encoder lt 10 g 100 m s 3937 008 in s 10 Hz 2 kHz Shock resistance lt 100 g 1000 m s for the DR71 100 Shock resistance lt 200 g 2000 m s 78740 157 in s for the DR315 5 9 5 Encoder connection When connecting encoders to inverters always follow the operating instructions for the relevant inverter e Maximum cable l
79. rol Apply voltage to release the brake See nameplate Contact rating of the brake control AC3 in accordance with 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 illustration shows the wiring for BG and BGE brake rectifiers for the AC side shut off as well as the DC and AC side shutoff E AC AC 242604811 1 Brake coil Operating Instructions AC Motors DRS DRE DRP 17 9 Appendix Wiring diagrams BSG control unit The following illustration shows the DC 24 V connection of the BSG control unit 24V Dc 242606475 1 Brake coil BUR brake control STOP Connection to motor terminal board not permitted The following illustration shows the wiring for the BUR brake control 242608139 1 Brake coil 2 UR11 UR15 voltage relay UR 11 42 150 V BN UR 15 150 500 V BK 78 Operating Instructions AC Motors DRS DRE DRP Appendix 9 Wiring diagrams 9 1 5 BSR brake control BE brake BSR brake control 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 A The following illustration shows the factory wiring for the BSR br
80. ructions AC Motors DRS DRE DRP U Unit designation 2 0 eee eeeeees 11 V EE 26 Ww Winding thermostats TH seeen 25 Wiring diagram BMP EE 80 Wiring diagraMS 0 0 0 eee cette ee eeeeeeees 74 BG renee sas rias 77 BGE attire ria alo 77 BS E Aessen iii 78 BOR te ethan attr coto 79 BUR e ee ia teen eee Ae 78 Delta connechon seiere a 74 Star connection seenen 74 LP agit ohare ae eee 75 76 TEE 75 76 11 87 O Address List 1 Address List 1619 Garin Germany Headquarters Bruchsal SEW EURODRIVE GmbH 8 Co KG Tel 49 7251 75 0 Production Ernst Blickle Strafe 42 Fax 49 7251 75 1970 Sales D 76646 Bruchsal http www sew eurodrive de P O Box sew sew eurodrive de Postfach 3023 D 76642 Bruchsal Service Central SEW EURODRIVE GmbH amp Co KG Tel 49 7251 75 1710 Competence Center Gear units Ernst Blickle StraRe 1 Fax 49 7251 75 1711 Motors D 76676 Graben Neudorf sc mitte gm sew eurodrive de Central SEW EURODRIVE GmbH amp Co KG Tel 49 7251 75 1780 Electronics Ernst Blickle StraRe 42 Fax 49 7251 75 1769 D 76646 Bruchsal sc mitte e 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 Dankritzer Weg 1 Fax 49 3764 7606 30 D 08393 Meerane near Zwickau
81. sembled on the motor s brake endshield on top of a friction disc Remove the following forced cooling fan and incremental encoder if installed See section Preliminary work for motor and brake maintenance page 32 flange cover or fan guard 35 circlip 62 and fan 36 Remove the rubber sealing collar 66 and the manual brake release setting nuts 58 conical coil springs 57 studs 56 releasing lever 53 spiral dowel pin 59 Unfasten hex nuts 61 carefully pull off the brake coil body 54 brake cable and remove the brake springs 50 Remove the damping plate 718 pressure plate 49 and brake disc 68 and clean the brake components Install a new brake disc 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 for brake BEO5 BE5 page 40 Operating Instructions AC Motors DRS DRE DRP 41 42 Inspection and Maintenance Inspection and maintenance for brake motor DR71 DR100 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 following figure The 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
82. slectonic switching DC 24 V 5 0 BMV5 13000063 White 24 Vpc control input and fast cut off Motor size DR315 Holding Part Color Type Function Voltage current Type number code lHmax A One way rectifier with electronic switching BMP integrated voltage relay AC 230 575 V 2 8 BMP 3 1 829 507 7 for cut off in the DC circuit Operating Instructions AC Motors DRS DRE DRP 71 72 Technical Data Permitted roller bearing types 8 7 Permitted roller bearing types 8 7 1 Roller bearing types for motor size DR71 100 A side drive bearing B side non drive bearing Motor type IEC motor Gearmotor Three phase Brake motor current motor DR71 6204 2Z J C3 6303 2Z J C3 6203 2Z J C3 6203 2RS J C3 DR80 6205 2Z J C3 6304 2Z J C3 6304 2Z J C3 6304 2RS J C3 DR90 DR100 6306 2Z J C3 6205 2Z J C3 6205 2RS J C3 8 7 2 Roller bearing types for motor size DR315 Motor tins A side drive bearing B side non drive bearing yP IEC motor Gearmotor IEC motor Gearmotor GE 6319 J C3 6319 J C3 DR315M 6319 J C3 6319 J C3 DR315L 6322 J C3 6322 J C3 Motor with reinforced naan A side drive bearing B side non drive bearing bearings DS IEC motor Gearmotor AER 6319 J C3 NU319E 6319 J C3 DR315M 6322 J C3 DR315L Operating Instructions AC Motors DRS DRE DRP Technical Data Lubricant tables
83. sons responsible for the plant and its operation as well as those who work independently on the unit have read through the operating instruc tions carefully and understood them If you are unclear about any of the information in this documentation please contact SEW EURODRIVE Preliminary information General The following safety notes relate primarily to the use of motors If using gearmotors please also refer to the safety notes for gear units in the corresponding operating instructions Also consider the supplementary safety notes in the individual sections of these oper ating instructions Never install or operate damaged products In the event of damage submit a complaint to the shipping company immediately Low voltage machines have dangerous live and rotating parts as well as hot surfaces All work related to transportation storage setup mounting connection startup mainte nance and repair may only be carried out by qualified personnel in strict observation of 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 e 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 fo
84. st accidental startup Carefully observe the following operation steps Remove forced cooling fan and incremental encoder if installed See section Preliminary work for motor and brake maintenance page 32 Remove fan guard 35 and fan 36 Push the rubber sealing collar 66 aside release the clip to do this if necessary vacuum up any abraded residue Measure the brake disc 68 68b Replace the brake disc if the brake disc lt 12 mm 0 47 in See section Replacing the brake disc for brake BE120 BE122 page 58 Unfasten the setting sleeve 67 by turning it towards the endshield Measure the working air gap A see following figure use a feeler gauge and measure at three points offset by 120 Operating Instructions AC Motors DRS DRE DRP Inspection and Maintenance 7 Inspection and maintenance for brake motor DR315 7 Tighten the hex nuts 61 8 If you are mounting the BE122 in a vertical position set the 3 springs on the brake stationary disc to the following measurement Mounting position X in mm M4 10 0 M2 10 5 M4 M2 gt Y 49 68b 52b R 68 l 900 xX 49 Pressure plate 52b Brake stationary disc BE122 only 68 Brake disc 68b Brake disc BE122 only 900 Hex nut 9 Tighten the setting sleeves towards the magnet until the working air gap is set correctly see Technical Data section page
85. stud Tightening torque of Connection at Version Connection Scope of delivery diameter hex nut customer end type cross section M4 1 6 Nm 14 in Ib lt 1 5 mm Version la Solid wire Pre assembled terminal conductor end links sleeve lt 6 mm Version 1b Ring cable lug Pre assembled terminal links lt 6 mm Version 2 Ring cable lug Small connection accesso ries enclosed in bag M5 2 0 Nm 18 in lb lt 10 mm Version 2 Ring cable lug Small connection accesso ries enclosed in bag M6 3 0 Nm 27 in lb lt 16 mm Version 3 Ring cable lug Small connection accesso ries enclosed in bag Motor size DR315 Terminal stud Tightening torque of Connection at Version Connection Scope of delivery diameter hex nut customer end type cross section M12 15 5 Nm 137 in Ib lt 50 mm Connection parts 7 Version 3 Ring cable lug bled M16 30 Nm 270 in Ib lt 95 mm pre assemble The versions in bold print apply to S1 operation for the standard voltages and standard frequencies according to the data in the catalog Other versions may have different connections for example different terminal stud diameters and or a different scope of delivery Operating Instructions AC Motors DRS DRE DRP Electrical Installation 5 Connecting the motor Version 1 a If the cross section of the external connection is lt 1 5 mm it can be installed directly below the terminal washer b Ifthe cross section of the external
86. tance e Nameplate data complete Type and extent of the problem Time the problem occurred and any accompanying circumstances e Assumed cause Operating Instructions AC Motors DRS DRE DRP Index 11 Index A Accessory equipment coocococcoccccccccccccnnnnnannoncnnccnnnns 25 ATV at dd a 27 33 Ambient conditions Ambient temperature cococicoccccnnnnnnccicccanannnnnns 18 Hazardous radiation n 18 Installation altitude oooonnnnnnnnnnnnininccccocno 18 EE 27 32 B BED e A clado 38 BE do ent dl da ls co 38 BEN20 uti addict 53 BETZA uta dada 53 BE ta ee 38 BE eer 38 Bearing lubrication 30 Brake BEOS sitos icono ile EE 38 BET hiaedechs sgaddsghewedentees tack 38 BELLO iii A A EN 53 BELL e EE 53 LTE 38 BE eege eeh ee 38 Braking torque breakdown nsss 64 Braking tOrQUeS nre e e e G ns 63 Operating currents aececi 65 RESISTANCES eiiis eit 67 Work done oooocicoccccconcncccncnnnnanono cnn nnnnnnnnnnnnnns 63 Working air DAD rrr a AE ET E 63 Brake connection ooocccccccccicononnoncnnnnnnnnnnnnnnnnnnnnnos 24 Brake control ccccccccccncccncnnncnnnnncncnnno 15 24 70 EE 77 BEE TT 77 E WEE 80 BSG ii A nei ae 77 BR A Ee 79 BOR ee tege ee ee eege EE 77 Control Cabinet ioioccccncnniccnnanancannnnncnncnnnnnnnns 71 Motor wiring compartment s e 70 Brake malfunctions cccceeeeeeeeeeeseeeteeaeees 83 Brake rectifier combinations sssssssnneeneneeeeeeeeee 69 Braking torque breakdown
87. technology that solves and reliable solutions tomorrow s problems Anywhere today gt a gt lt With comprehensive With uncompromising knowledge in virtually quality that reduces the every branch of cost and complexity of industry today daily operations e aN we D G Ss L SEW EURODRIVE Driving the world z J p With online information and software updates via the Internet available around the clock ay 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
88. tenance page 32 flange cover or fan guard 35 circlip 62 and fan 36 Remove the terminal box cover and loosen the brake cable from the rectifier If necessary attach trailing wire to brake cables Unfasten screws 900 and remove brake from brake endshield Pay attention to the alignment of the gasket 901 Guide the brake cable into the terminal box Align the cam of the friction disc Note for BE1 You can only turn the brake against the shaft as long as the brake is not making contact with the carrier Turning the brake on the shaft can destroy the brake disc of the brake Turning the whole brake including the shaft is permitted 7 Mount oil 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 The 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 BE1 1 5 BE2 BE5 2 Operating Instructions AC Motors DRS DRE DRP 47 Inspection and Maintenance Inspection and maintenance for brake motor DR71 DR100 7 6 8 Retrofitting the manual brake release HR HF Severe or fatal injuries can occur A DANGER Risk of crushing if the drive starts up unintentionally Isolate the motor and brake
89. the brake disc thick ness brake disc lining measure and set working air gap pressure plate carrier gearing pressure rings vacuum up any abraded residue inspect the switch contacts and change if necessary e g in case of burn out Motor Every 10 000 hours of operation Inspect the motor check roller bearings and change if necessary change the oil seal clean the cooling air passages Drive Varies depends on external influences Touch up or renew the surfaces anticorrosion coating 1 the periods of wear are affected by many factors and may be short The machine designer must calculate the required inspection maintenance intervals individually in accordance with the project planning docu ments e g Project Planning for Drives 2 For the DR315 with lubrication device observe the short re lubrication intervals in the Bearing lubrication DR315 section Operating Instructions AC Motors DRS DRE DRP Inspection and Maintenance Bearing lubrication 7 2 Bearing lubrication 7 2 1 Bearing lubrication DR71 100 The motor bearings generally come with lubrication for life 7 2 2 Bearing lubrication DR315 Relubrication Series 315 motors may be equipped with a lubrication device The following figure shows the positions of the lubrication devices 375353099 1 Lubrication device in type A in accordance with DIN 71412 In normal operating conditions an
90. the motor is running correctly no overload no speed fluctuation no loud noises etc and the correct braking torque is set according to the specific application see Tech nical Data page 63 section STOP On brake motors with a self reengaging manual brake release the hand 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 Inspection and Maintenance Inspection and maintenance intervals 7 Inspection and Maintenance A DANGER Risk of crushing if the hoist falls Severe or fatal injuries can occur Secure or lower hoist drives danger of falling e Isolate the motor and brake from the power supply before starting work safe guarding them against accidental startup Only use genuine spare parts in accordance with the valid parts list Always install a new brake control at the same time as replacing the brake coil A CAUTION Danger of burns Let motor cool down before beginning work The surfaces on the drive can be very high during operation 7 1 Inspection and maintenance intervals Unit unit part Time interval Procedure BE brake If used as a working brake at least every 3000 hours of opera tion If used as a holding brake every 2 to 4 years depending on operating conditions Inspect the brake measure
91. tor refer to the Technical Data section page 63 A DANGER Severe or fatal injuries can occur Risk of crushing if the drive starts up unintentionally Isolate the motor and brake from the power supply before starting work safe guarding them against accidental startup Carefully observe the following operation steps Remove forced cooling fan and incremental encoder if installed See section Preliminary work for motor and brake maintenance page 32 2 Remove the flange cover or fan guard 35 circlip 32 and fan 36 Unfasten the plug connector on the magnet 54 and protect it from getting dirty Remove the rubber sealing collar 66 and the manual brake release setting nuts 58 conical seat 255 spherical washer 256 conical coil springs 57 setscrews 56 releasing lever 53 Unfasten hex nuts 61 and pull off the magnet 54 by approx 50 mm 2 0 in Change or add brake springs 50 265 Position the 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 for brake BE120 BE122 page 56 Operating Instructions AC Motors DRS DRE DRP Inspection and Maintenance Inspection and maintenance for brake motor DR315 8 With manual brake release use setting nuts to set the floating clearance s between the coni
92. tor voltage by more than 5 range A 10 range B Adjust motor to supply voltage Rated operation type S1 to S10 DIN 57530 exceeded e g through excessive startup frequency Adjust rated operation type of motor to required operating conditions if necessary call in a specialist to determine correct drive Excessively loud Ball bearing compressed dirty or damaged Re align motor and the driven machine inspect ball bearing see sec Permitted ball bearing types and replace if necessary 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 the cooling air passages Operating Instructions AC Motors DRS DRE DRP Malfunctions G 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 nameplate Brake control unit failed Install a new brake control check resistances and insulation of the brake coils see Resistances section for resistance values 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 sections Setting the working air gap for brake BE05 BE5 page 40 S
93. tted roller bearing types See section Permitted roller bearing types page 72 Fill the bearing with grease until it is two thirds full See section Bearing lubrication DR315 page 30 Important place the oil seal flange 608 and 21 onto the rotor shaft before installing the bearings 11 Starting on the A side mount the motor vertically 12 Place the cup springs 105 and lubrication ring 604 into the bearing bore of the 54 flange 7 Hang the rotor 1 onto the B side thread and guide into the flange 7 Fasten the oil seal flange 608 to the flange 7 using the hex head bolts 609 Operating Instructions AC Motors DRS DRE DRP Inspection and Maintenance Inspection and maintenance for brake motor DR315 13 Mount the stator 16 Reseal the stator seat seal the sealing surface with a duroplastic sealing compound operating temperature 40 C 40 F 180 C 356 F such as Hylomar L Spezial Important Protect the winding overhead from damage Screw in the stator 16 and flange 7 with screws 15 14 Before mounting the brake endshield screw in the M8 setscrew approximately 200 mm 7 87 in into the oil seal flange 21 15 Before mounting 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
94. ve 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 caron vector be 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 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 Industrail 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 richard miekisiak 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 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
95. x 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 36 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 Protective cowl 706 Spacer 707 Pan head screw Operating Instructions AC Motors DRS DRE DRP Inspection and Maintenance Inspection and maintenance work on the motor DR71 DR100 7 5 2 Procedure for inspecting motor DR71 DR100 A DANGER Risk of crushing if the drive starts up unintentionally Severe or fatal injuries can occur Disconnect the motor from the power supply before starting work and safeguard against accidental startup Carefully observe the following operation steps Remove forced cooling fan and incremental encoder if installed See section Preliminary work for motor and brake maintenance page 32 Remove fan guard 35 and fan 36 Remove the machine screws 13 from the flanged endshield 7 and the B side endshield 42 and the stator 16 from the flanged endshield Visual inspection are there traces of gear oil or condensation inside the stator If there
96. y equipment if the wiring connection diagram is missing You can obtain the valid wiring diagrams free of charge from SEW EURODRIVE 5 9 1 Temperature sensor TF STOP The temperature sensor TF may not be subjected to voltages gt 30 V The positive temperature coefficient PTC temperature sensors comply with DIN 44082 Resistance measurement measuring instrument with V lt 2 5 V or lt 1 mA e Standard measured values 20 500 Q thermal resistance gt 4000 Q When using the temperature sensor for thermal monitoring the evaluation function must be activated to maintain reliable insulation of the temperature sensor circuit If the temperature reaches an excessive level the thermal protection function must be brought into effect immediately 5 9 2 Winding thermostats TH The thermostats are connected in series and open when the permitted winding temper ature is exceeded They can be switched in the drive monitoring circuit ACV DC V Voltage U V 250 60 24 Current cos q 1 0 A 2 5 1 0 1 6 Current cos 0 6 A 1 6 Contact resistance max 1 Ohm at DC 5V 1 mA Operating Instructions AC Motors DRS DRE DRP 26 Electrical Installation Accessory equipment 5 9 3 Forced cooling fan V e Connection in separate terminal box Max connection cross section 3 x 1 5 mm e Cable gland M16 x 1 5 Operating mode connection F

Drehstrommotoren DRS/DRE/DRP / Operating Instructions / 2007-05

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