AC Motors DRS/DRE/DRP - SEW Eurodrive · 2 Safety Notes Preliminary information 6 Operating Instructions – AC Motors DRS/DRE/DRP 2 Safety Notes The following basic safety notes

Gearmotors \ Industrial Gear Units \ Drive Electronics \ Drive Automation \ Services

AC Motors DRS/DRE/DRP

Operating InstructionsEdition 05/200711606215 / EN

SEW-EURODRIVE – Driving the world

Contents

1 General Information .......................................................................................... 51.1 Structure of the safety notes ..................................................................... 51.2 Rights to claim under warranty.................................................................. 51.3 Exclusion of liability ................................................................................... 5

2 Safety Notes ...................................................................................................... 62.1 Preliminary information ............................................................................. 62.2 General ..................................................................................................... 62.3 Designated use ......................................................................................... 72.4 Transportation ........................................................................................... 72.5 Installation ................................................................................................ 72.6 Electrical connection ................................................................................. 82.7 Operation .................................................................................................. 8

3 Motor Design ..................................................................................................... 93.1 Basic structure of DR71 – DR100............................................................. 93.2 Basic structure DR315 ............................................................................ 103.3 Nameplate, unit designation ................................................................... 11

4 Mechanical Installation................................................................................... 124.1 Before you begin ..................................................................................... 124.2 Mechanical Installation............................................................................ 12

5 Electrical Installation ...................................................................................... 155.1 Use wiring diagrams................................................................................ 155.2 Wiring notes ............................................................................................ 155.3 Special features when operating with a frequency inverter..................... 165.4 Improving the grounding (EMC).............................................................. 175.5 Special features for switching operation ................................................. 185.6 Ambient conditions during operation....................................................... 185.7 Connecting the motor.............................................................................. 195.8 Connecting the brake.............................................................................. 245.9 Accessory equipment.............................................................................. 25

6 Startup.............................................................................................................. 286.1 Prerequisites for startup.......................................................................... 28

7 Inspection and Maintenance .......................................................................... 297.1 Inspection and maintenance intervals..................................................... 297.2 Bearing lubrication ................................................................................. 307.3 Reinforced bearing.................................................................................. 317.4 Preliminary work for motor and brake maintenance................................ 327.5 Inspection and maintenance work on the motor DR71-DR100............... 347.6 Inspection and maintenance for brake motor DR71-DR100 ................... 367.7 Inspection and maintenance work on the motor DR315 ......................... 497.8 Inspection and maintenance for brake motor DR315.............................. 52

Operating Instructions – AC Motors DRS/DRE/DRP
3

4

ontents

8 Technical Data................................................................................................. 638.1 Work done, working air gap, braking torques ......................................... 638.2 Braking torque breakdown ...................................................................... 648.3 Operating currents .................................................................................. 658.4 Resistances ............................................................................................ 678.5 Brake rectifier combinations.................................................................... 698.6 Brake control .......................................................................................... 708.7 Permitted roller bearing types ................................................................. 728.8 Lubricant tables....................................................................................... 738.9 Order information for lubricants and anti-corrosion agents ..................... 73

9 Appendix.......................................................................................................... 749.1 Wiring diagrams ...................................................................................... 74

10 Malfunctions .................................................................................................... 8110.1 Motor malfunctions.................................................................................. 8110.2 Brake malfunctions ................................................................................. 8310.3 Malfunctions when operating with a frequency inverter .......................... 8410.4 Customer service .................................................................................... 84

11 Index................................................................................................................. 85

Address List .................................................................................................... 88

C


1General InformationStructure of the safety notes

1 General Information1.1 Structure of the safety notes

The safety notes in these operating instructions are structured as follows:

1.2 Rights to claim under warrantyAdhering to the operating instructions is a prerequisite for fault-free operation and thefulfillment of any right to claim under warranty. Read the operating instructions beforeyou start working with the unit. Make sure that the operating instructions are available to persons responsible for thesystem and its operation, as well as to persons who work independently on the unit. Youmust also ensure that the documentation is legible.

1.3 Exclusion of liabilityYou must comply with the information contained in these operating instructions toensure safe operation of the electric motors and to achieve the specified product char-acteristics and performance features. SEW-EURODRIVE assumes no liability for injuryto persons or damage to equipment or property resulting from non-observance of theseoperating instructions. In such cases, any liability for defects is excluded.

Symbol SIGNAL WORD

Nature and source of hazardPossible consequence(s) if disregarded.• Measure(s) to avoid the hazard.

Symbol Signal word Meaning Consequences if disregarded

Example:

General hazard

Specific danger,e.g. electric shock

DANGER Imminent danger Severe or fatal injuries

WARNING Possible dangerous situation Severe or fatal injuries

CAUTION Possible dangerous situation Minor injuries

STOP Possible damage to property Damage to the drive system or its environment

NOTE Useful information or tip.Simplifies the handling of the drive system.

5

2 afety Notesreliminary information

6

2 Safety NotesThe following basic safety notes are intended to prevent injury to persons and damageto property. The operator must make sure that the basic safety notes are read andobserved. Make sure that the persons responsible for the plant and its operation, as wellas 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 inthis documentation, please contact SEW-EURODRIVE.

2.1 Preliminary informationThe 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 operatinginstructions.Also consider the supplementary safety notes in the individual sections of these oper-ating instructions.

2.2 GeneralNever install or operate damaged products. In the event of damage, submit a complaintto 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• The national/regional regulations governing safety and the prevention of accidentsRemoving covers without authorization, improper use as well as incorrect installation oroperation may result in severe injuries to persons or damage to machinery.Consult the documentation for additional information.

SP


2Safety NotesDesignated use

2.3 Designated useThe electric motors are intended for industrial systems. Use in potentially explosiveareas 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 Â 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 unitcomply with the nameplate information.

2.4 TransportationImmediately upon receipt, inspect the shipment for any damage that may have occurredduring transportation. If necessary, inform the shipping company immediately. You mayneed 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 ofthese should be used for transportation. In this case, the tension force vector of theslings 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 transportation. Iflow-voltage machines are put into storage, make sure they are kept in a dry, dust-freeand low-vibration (veff Â 0.2 mm/s) environment (bearing standstill damage). Measurethe insulation resistance prior to startup. Dry the winding if values Â 1 kΩ per volt of therated voltage.

2.5 Installation Make sure that the supports are even, the foot and flange mounting is correct and ifthere is direct coupling, align with precision. Resonances between the rotationalfrequency 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 indecoupled status.Only install or remove belt pulleys and couplings using suitable devices (heat up) andcover with a touch guard. Avoid improper belt tension.Make the pipe connections that may eventually be required. Mounting positions withshaft ends pointing upwards should be equipped with a cover to prevent foreign objectsfrom falling into the fan. Ensure that ventilation openings are not obstructed and thatused air, including air from adjacent units, cannot be drawn in again straight away.Observe the notes in the "Mechanical Installation" section.

7

2 afety Noteslectrical connection

8

2.6 Electrical connectionAll work may only be carried out by qualified personnel. During work, the low-voltagemachine must be 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 electromagneticcompatibility. 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 asobserving the wiring diagram.The connection should be a continuous secure electrical connection (no protruding wireends); use the cable end equipment intended for this purpose. Establish a secureprotective earth connection. When the motor is connected, the distances to non-insulated and live parts must not be shorter than the minimum values according toIEC 60664 and national regulations. With low voltage, the distances should be noshorter than the following values, in compliance with IEC 60664:

The terminal box must be free of foreign objects, dirt and humidity. Unused cable entryopenings and the box itself must be closed so that they are dust and water proof. Securekeys for test mode without output elements. When operating low-voltage machines withbrakes, check that the break is functioning correctly before startup. Observe the notes in the "Electrical Installation" section.

2.7 OperationWhenever changes to normal operation occur, such as increased temperatures, noise,vibrations, etc., you should determine the cause and contact the manufacturer, ifrequired. 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.

Rated voltage VN Distance

Â 500 V 3 mm

Â 690 V 5.5 mm

SE


3Motor DesignBasic structure of DR71 – DR100

3 Motor Design

3.1 Basic structure of DR71 – DR100

NOTEThe following illustration shows the general structure. Its only purpose is to facilitate theassignment of components to the spare parts lists. Deviations are possible dependingon the motor size and version.

173332747

[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[30] Oil seal[32] Circlip[35] Fan guard[36] 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

[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

[10]

[11][44] [36]

[32]

[2] [3]

[1]

[111]

[113]

[115][112]

[131]

[156]

[262]

[119]

[129]

[134]

[132]

[123]

[116]

[118]

[117]

[107][106]

[7]

[103][100]

[93]

[9]

[12]

[90]

[109]

[108]

[24]

[16] [41]

[392]

[22]

[13][30]

[35]

[706]

[705]

[707]

[42]

9

3 otor Designasic structure DR315

10

3.2 Basic structure DR315

351998603

[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

[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

[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

[452]

[634]

[633][151]

[117][219]

[123]

[132]

[131]

[119]

[112]

[111]

[113]

[109][108]

[24]

[707]

[706][716]

[715][30]

[25][35][26]

[19][22]

[107]

[106]

[250] [100]

[7]

[9]

[42][17]

[94][90]

[15][16]

[705]

[115][134] [607]

[129]

[118]

[116]

[128][140]

[139]

[454]

[606] [604]

[609]

[11][608]

[105]

[3]

[31]

[21][44]

[43][40] [36]

[32]

[4][1]

[2]

[103]

MB


3Motor DesignNameplate, unit designation

3.3 Nameplate, unit designation3.3.1 NameplateExample: DRE gearmotor with brake

3.3.2 Unit designationExample: Foot-mounted AC motor with brake

186018187

76646 Bruchsal / Germany

RF47 DRE90M4BE2/TF/Z/C

01.300123456.0002.06

1425 / 88 1.1 S1

M1

220..240 AC

CLP CC VG220 0,65 l

230 / 400 / Y

rpm kW

V

UBR 20 BGE1.5 41Nm

16.22i

4.45 / 2.55A

55IP 50Hz

3~IEC60034

kg

Made in Germany

0188 229 5

IM

0,79cos ϕ

V 220..240 / 380..415 Y

Nm 122

Ins.Cl. 130(B)

°C

DRE 90 M4 BE2 /FI /TF /ES7S

Motor option sinusoidal encoder ES7S

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

4 echanical Installationefore you begin

12

4 Mechanical Installation

4.1 Before you beginThe drive may only be installed if:• the specifications on the drive's nameplate and the output voltage of the frequency

inverter match the voltage supply system• the drive is undamaged (no damage caused by transportation or storage)• it is 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.

4.2 Mechanical Installation4.2.1 Preliminary work

Motor shaft ends must be thoroughly cleaned of anti-corrosion agents, contamination orsimilar (use a commercially available solvent). Do not allow the solvent to penetrate thebearings or sealing rings – this could cause material damage.

Motors with reinforced bearings

NOTE

It is imperative that you observe the safety notes in section 2 during installation.

1) Note that you can also limit the temperature range of the gear unit (see gear unit operating instructions).

STOP

The mounting position for installation must correspond to the specifications on the nameplate.

STOP

Motors with a reinforced bearing must not be operated without an overhung load.Otherwise you risk damaging the bearings.

MB


4Mechanical InstallationMechanical Installation

Extended storage of motors

• Note that the service life of the lubricant in the ball bearings is reduced by 10% peryear after the first year of storage.

• You should re-lubricate the lubrication devices on motors that have been in storagefor longer than 5 years before startup. Observe the information on the motor lubricantplate.

• Check whether the motor has absorbed moisture as a result of being stored for a longtime. To do so, measure the insulation resistance (measuring voltage 500 V).

The insulation resistance (see following figure) varies greatly depending on thetemperature. The motor must be dried if the insulation resistance is not adequate.

Drying the motor Heat the motor:• with hot air or • 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

The drying process is finished when the minimum insulation resistance has beenexceeded.In the terminal box check that:• the inside is clean and dry• the connections and fixing parts are free from corrosion• the gasket and sealing surfaces are functioning• the cable glands are sealed; if they are not, clean or replace them

173323019

100

10

1

0,10 20 40 60 80

[˚C ]

[M ]

174065419

Trafo

13

4 echanical Installationechanical Installation

14

4.2.2 Installing the motorThe motor or gearmotor may only be mounted or installed in the specified mountingposition on a level, vibration-proof and torsionally rigid support structure.Carefully align the motor and the driven machine to avoid placing any intolerable strainon 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 verticalmounting positions (protective cowl C).Ensure the cooling air supply is unobstructed and that air heated by other apparatuscannot be drawn in again.Balance components for subsequent mounting on the shaft with a half key (motor shaftsare balanced with a half key).Condensation drainage holes are plugged with closing plugs. These can beopened if you want to drain the condensation but must be closed again, as opendrain holes render higher enclosures void.If using brake motors with manual brake release, screw in either the hand lever (withself-reengaging manual brake release) or the setscrew (with lockable manual brakerelease).

Installation in damp locations or in the open

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 tightenthem well; then coat them again.Seal the cable entry well.Thoroughly clean the sealing surfaces of terminal boxes and terminal box covers priorto reassembly; gaskets must be glued in on one side. Replace 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• ISO j6 at Ø Â 28 mm (1.1 in)• ISO k6 at á Ã 38 mm (1.5 in) to Â 48 mm (1.9 in)• ISO m6 at á Ã 55 mm (2.2 in)• Center hole in accordance with DIN 332,

shape DR.

Centering shoulder tolerance in accordance with EN 50347• ISO j6 at Ø Â 250 mm (9.84 in)• ISO h6 at Ø Ã 300 mm (11.8 in)

MM


5Electrical InstallationUse wiring diagrams

5 Electrical Installation

5.1 Use wiring diagramsConnect the motor only as shown in the wiring diagram(s) included with the motor. Donot connect or start up the motor if the wiring diagram is missing. You can obtainthe valid wiring diagrams free of charge from SEW-EURODRIVE.

5.2 Wiring notesComply with the safety notes during installation.

5.2.1 Protection against interference from brake controlsUnless they are shielded, brake cables must always be routed separately from otherpower cables with phased currents to protect brake controls against interference. Inparticular, power cables with phased currents include:• output cables from frequency inverters and servo controllers, soft startup units and

brake units• supply cables for braking resistors and similar options

5.2.2 Protecting against interference by motor protection devicesTo protect against interference by SEW motor protection devices (temperature sensorsTF, winding thermostats TH):• 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.

NOTE• It is imperative that you observe the safety notes in section 2 during installation.• Use switch contacts in utilization category AC-3 according to EN 60947-4-1 for

switching the motor and the brake.

15

5 lectrical Installationpecial features when operating with a frequency inverter

16

5.3 Special features when operating with a frequency inverterWhen motors are powered by inverters, you must adhere to the relevant wiring notesissued by the inverter manufacturer. You must also observe the operating instructionsfor the frequency inverter.

5.3.1 Motor on SEW inverterSEW-EURODRIVE has tested operation of the motor on SEW frequency inverters. Therequired dielectric strength values of the motors were confirmed and the startup routinesadjusted to the motor data. You can operate the DR motor with any frequency inverterfrom SEW-EURODRIVE. To do this, start up the motor as described in the operatinginstructions for the frequency inverter.

5.3.2 Motor on a non-SEW inverterYou may operate SEW motors on non-SEW frequency inverters if the pulse voltagesindicated in the figure below are not exceeded at the given rise times.

244030091

[1] Permitted pulse voltage for DR standard[2] Permitted pulse voltage according to IEC 60 034-17

600

800

1000

1200

1400

1600

1800

2000

0 0.2 0.4 0.6 0.8 1.0 1.2 1.4

Rise time [µs]

Pe

rmit

ted

pu

lse

vo

lta

ge

U

LL

[V

]

[2]

[1]

NOTEThe diagram applies to motor operation of the motor. If the permitted pulse voltage isexceeded, you must install limiting measures, such as filters, chokes or special motorcables. You should also consult the manufacturer of the frequency inverter.

ES


5Electrical InstallationImproving the grounding (EMC)

5.4 Improving the grounding (EMC)For improved, low-impedance grounding at high frequencies, we recommend using thefollowing connections:

5.4.1 Size DR71...DR100:DIN 7500 M5 x 12 self-tapping screw and 2 serrated lock washers in accordance withDIN 6798.

5.4.2 Size DR315:• 1 x hex head bolt ISO 4017 M12 x 30• 1 x washer ISO 7090• 1 x serrated lock washer DIN 6798

176658571

[1] Use the pre-cast bore at the terminal box (brake motor)[2] Bore in stator housing (á = 4.6 tmax = 11.5)

[2] [1]

370040459

[1] Use the grounding screw at the terminal box

[1]

17

5 lectrical Installationpecial features for switching operation

18

5.5 Special features for switching operationWhen the motors are used in switching operation, it is necessary to exclude possibleinterference of the switchgear using suitable wiring. According to EN 60204 (electricalequipment of machines), motor windings must have interference suppression to protectthe numerical or programmable logic controllers. Since it is primarily switching opera-tions that cause interference, SEW-EURODRIVE recommends installing protectivecircuits on the switching devices.

5.6 Ambient conditions during operation5.6.1 Ambient temperature

Adherence to the temperature range of –20 °C (–4 °F) to +40 °C (104 °F) is imperativeunless specified otherwise on the nameplate. Motors intended for use in higher or lowerambient temperatures will have the respective designation on the nameplate.

5.6.2 Installation altitudeThe maximum installation altitude of 1000 m (3281 ft) above sea level must not beexceeded. Otherwise this causes a power reduction at a factor fH as specified in thefollowing diagram.

The reduction in rated power is calculated according to the following formula:

5.6.3 Hazardous radiationMotors must not be subjected to hazardous radiation (such as ionizing radiation).Contact SEW-EURODRIVE if necessary.

173325195

PRated1 = reduced rated power [kW]PRated = rated power [kW]fH = factor for reduction due to installation altitude

1000 2000 3000 4000 m

0.7

0.8

0.9

1.0

fH

fH= ×PRated1 PRated

ES


5Electrical InstallationConnecting the motor

5.7 Connecting the motor5.7.1 Connecting the motor via terminal boxes

• in accordance with the wiring diagram provided• check cable cross section• arrange terminal links correctly• firmly screw on connections and protective earth conductors• In the terminal box: check winding connections and tighten them if necessary

Arrangement of terminal links with Õ connection

Arrangement of terminal links with Ö connection

Motor size DR71-100: Motor size DR315:

[1] Terminal link[2] Terminal stud[3] Flange nut

[4] Terminal board[5] Customer connection[6] Customer connection with divided connection cable

U1 V1

W1

[1]

[2]

[3]

[4]

[5]

U1

U2

V2

V1

W1

W2

[1]

[2]

[3]

[4]

[5]

U1

U2

V2

V1

W1

W2

[1]

[2]

[3]

[4]

[6]

[6]

NOTEThe terminal box must be free of foreign objects, dirt and humidity. Unused cable entryopenings and the terminal box itself must be closed so they are dust and water proof.

19

5 lectrical Installationonnecting the motor

20

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 themon firmly. Observe the tightening torques specified in the following tables.

The versions in bold print apply to S1 operation for the standard voltages and standardfrequencies according to the data in the catalog. Other versions may have differentconnections, for example different terminal stud diameters and/or a different scope ofdelivery.

Motor size DR71-100

Terminal stud diameter

Tightening torque of hex nut

Connection at customer end

Version Connection type

Scope of delivery

cross section

M4 1.6 Nm (14 in-lb) Â 1.5 mm2 Version 1a Solid wireconductor end sleeve

Pre-assembled terminal links

Â 6 mm2 Version 1b Ring cable lug Pre-assembled terminal links

Â 6 mm2 Version 2 Ring cable lug Small connection accesso-ries enclosed in bag

M5 2.0 Nm (18 in-lb) Â 10 mm2 Version 2 Ring cable lug Small connection accesso-ries enclosed in bag

M6 3.0 Nm (27 in-lb) Â 16 mm2 Version 3 Ring cable lug Small connection accesso-ries enclosed in bag

Motor size DR315

Terminal stud diameter

Tightening torque of hex nut

Connection at customer end

Version Connection type

Scope of delivery

cross section

M12 15.5 Nm (137 in-lb) Â 50 mm2Version 3 Ring cable lug Connection parts

pre-assembledM16 30 Nm (270 in-lb) Â 95 mm2

EC



Version 1

Version 1a: cross section Â 1.5 mm2

a) If the cross section of the external connection is Â 1.5 mm2, it can be installeddirectly below the terminal washer.

b) If the cross section of the external connection is > 1.5 mm2, it must be installedas a cable lug below the terminal washer.

88866955

[1] External connection with cross section Â 1.5 mm2

[2] Terminal stud[3] Flange nut[4] Terminal link[5] Terminal washer[6] Winding connection with Stocko connection terminal

≤ 1.5 mm2

> AWG 16

> 1.5 mm2

[1]

[2][1]

[3]

[5]

[6]

[4]≥ 8 - < 10 mm

21

5 lectrical Installationonnecting the motor

22

Version 1b: Cross section > 1.5 mm2

Version 2

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

[1]

[2] [1]

[3]

[5]

[6]

[4]

> 1.5 mm2

≤ AWG 16

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

[1]

[2]

[3]

[4]

[5]

[6]

[7]

[8]

EC



Version 3

199641099

[1] External connection with ring cable lug, according to DIN 46237 or DIN 46234, for example[2] Terminal stud[3] Top nut[4] Washer[5] Terminal link[6] Bottom nut [7] Winding connection with ring cable lug[8] Serrated lock washer

[5]

[7]

[6]

[2] [1]

[3]

[4]

[8]

23

5 lectrical Installationonnecting the brake

24

5.8 Connecting the brakeThe brake is released electrically. The brake is applied mechanically when the voltageis switched off.

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.

• Check the cable cross sections – braking currents (see Section "TechnicalData")

• 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.

STOP• Comply with the applicable regulations issued by the relevant employer's liability

insurance association for phase failure protection and the associated cycletimes/cycle time modifications.

• Connect the brake according to the wiring diagram provided.• 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 inutilization category AC-3 according to EN 60947-4-1.

EC


5Electrical InstallationAccessory equipment

5.9 Accessory equipmentConnect accessory equipment as shown in the wiring connection diagram(s) providedwith the motor. Do not connect any accessory equipment if the wiring connectiondiagram is missing. You can obtain the valid wiring diagrams free of charge from SEW-EURODRIVE.

5.9.1 Temperature sensor TF

The positive temperature coefficient (PTC) temperature sensors comply with DIN 44082.Resistance measurement (measuring instrument with V Â 2.5 V or I < 1 mA):• Standard measured values: 20...500 Ê, thermal resistance > 4000 Ê When using the temperature sensor for thermal monitoring, the evaluation function mustbe activated to maintain reliable insulation of the temperature sensor circuit. If thetemperature reaches an excessive level, the thermal protection function must bebrought into effect immediately.

5.9.2 Winding thermostats THThe thermostats are connected in series and open when the permitted winding temper-ature is exceeded. They can be switched in the drive monitoring circuit.

STOP

The temperature sensor TF may not be subjected to voltages > 30 V.

AC V DC V

Voltage U [V] 250 60 24

Current (cos φ = 1.0) [A] 2.5 1.0 1.6

Current (cos φ = 0.6) [A] 1.6

Contact resistance max. 1 Ohm at DC 5 V / 1 mA

25

5 lectrical Installationccessory equipment

26

5.9.3 Forced cooling fan V• Connection in separate terminal box• Max. connection cross section 3 x 1.5 mm2

• Cable gland M16 × 1.5

Operating mode / connection Frequency in Hz Voltage V

1 ~ AC ( Ö ) 50 230 – 277

1 ~ AC ( Ö ) 60 230 – 277

3 ~ AC Õ 50 346 – 500

3 ~ AC Õ 60 346 – 575

3 ~ AC Ö 50 200 – 290

3 ~ AC Ö 60 200 – 330

NOTE

For information on how to connect the forced cooling fan V, refer to the wiring diagram.

EA


5Electrical InstallationAccessory equipment

5.9.4 Overview of encoders Refer to the wiring connection diagrams on information on how to connect incrementalencoders:

5.9.5 Encoder connectionWhen connecting encoders to inverters, always follow the operating instructions for therelevant inverter.• Maximum cable length (inverter – encoder):

– 100 m (328 ft) with a capacitance per unit length Â 120 nF/km (193 nF/mile)• Core cross section: 0.20 ... 0.5 mm2

• Use a shielded cable with twisted pair cores and apply shield over a large surfacearea at both ends:– to the 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 distanceof at least 200 mm (7.87 in).

Encoder SEW motor Encoder type 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 DC 7..12 V Hiperface single-turn 68 170 xx 061)

AS7H DR71-100 Encoder Shaft-centered DC 7..12 V Hiperface multi-turn 68 170 xx 061)

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 Â 10 g À 100 m/s2 (3937.008 in/s2)

(10 Hz ... 2 kHz)• Shock resistance Â 100 g À 1000 m/s2 for the DR71-100• Shock resistance Â 200 g À 2000 m/s2 (78740.157 in/s2) for the DR315

27

6 tartuprerequisites for startup

28

6 Startup6.1 Prerequisites for startup

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:• 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.

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).

STOPOn brake motors with a self-reengaging manual brake release, the hand lever must beremoved after startup. A bracket is provided for storing the lever on the outside of themotor.

SP

00

I


7Inspection and MaintenanceInspection and maintenance intervals

7 Inspection and Maintenance

7.1 Inspection and maintenance intervals

DANGER

Risk of crushing if the hoist falls. Severe or fatal injuries can occur.• Secure or lower hoist drives (danger of falling)• 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.

CAUTION

The surfaces on the drive can be very high during operation. Danger of burns.• Let motor cool down before beginning work.

Unit / unit part Time interval Procedure?

BE brake

• If used as a working brake:at least every 3000 hours of opera-tion1)

• If used as a holding brake:every 2 to 4 years, depending on operating conditions1)

1) the periods of wear are affected by many factors and may be short. The machine designer must calculatethe required inspection/maintenance intervals individually in accordance with the project planning docu-ments (e.g. "Project Planning for Drives").

Inspect the brake• measure 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 operation2)

2) For the DR315 with lubrication device, observe the short re-lubrication intervals in the "Bearing lubricationDR315" section.

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

29

7 spection and Maintenanceearing lubrication

30

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 DR315Series 315 motors may be equipped with a lubrication device. The following figureshows the positions of the lubrication devices.

In normal operating conditions and 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 isused instead, which is also a mineral polyurea-based grease.

Relubrication You can purchase the lubricants in 400 g cartridges from SEW-EURODRIVE. For orderinformation, refer to the section, "Lubricant tables for roller bearings of SEW motors"(page 73).

Grease the motor bearings in accordance with the information on the lubricant plate. Theused grease collects inside the motor and after every 6-8 re-greasings, this should beremoved during an inspection. Each time you re-lubricate, ensure that the bearing istwo-thirds full.After relubricating the motors, you should startup slowly, if possible, so that the greaseis distributed evenly.

375353099

[1] Lubrication device in type A in accordance with DIN 71412

[1]

NOTEOnly mix lubricants of the same thickness type, the same base oil and the same consis-tency (NLGI class).

InB


7Inspection and MaintenanceReinforced bearing

Relubrication interval

Relubrication interval for bearings• if the ambient temperature is –20 °C (–4 °F) to 40 °C (104 °F),• at a 4-pole speed,• and with a normal load, are assigned using the table below. At greater speeds, higher loads or higher ambienttemperatures, the relubrication intervals are shorter.

7.3 Reinforced bearing

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).

Horizontal mounting position Vertical mounting position

Motor type Duration Quantity Duration Quantity

DR315 /NS 5000 h 50 g 3000 h 70 g

DR315 /ERF /NS 3000 h 50 g 2000 h 70 g

STOPIn the /ERF (reinforced bearing) option, cylindrical roller bearings are installed on theA side. These must not be operated without an overhung load, otherwise you riskdamaging the bearings.

31

7 spection and Maintenancereliminary work for motor and brake maintenance

32

7.4 Preliminary work for motor and brake maintenance

7.4.1 Removing the incremental encoder from the DR71-100.The following figure shows how to remove an encoder using the ES7. incrementalencoder as example.

Removing ES7. • Remove the protection cover [361].• Unfasten the expansion anchor by unscrewing the screws [733] from the cover grid.• 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.• Unfasten the expansion anchor by unscrewing the screws [733] from the cover grid.• 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.• Tighten the central retaining screw [367] with a tightening torque of 2.9 Nm (26 in-lb).• Tighten the screw [733] in the expansion anchor with a tightening torque of max.

1.0 Nm (8.9 in-lb).

DANGER

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.• Safeguard against accidental startup.

179980299

[1] Rotor[220] Connection cover[361] Protection cover

[367] Retaining screw[733] Screws

[1]

[733] [367] [220]

[361]

InP


7Inspection and MaintenancePreliminary work for motor and brake maintenance

7.4.2 Removing the incremental encoder from the DR315The following figure shows how to remove the incremental encoder on the DR315.

Removing EH7. • Remove the protection cover [657] by unfastening the screws [659].• Separate the encoder from the fan guard by loosening the nut [734].• 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].• 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.• Tighten the retaining screw with the following tightening torques:

407629451

[35] Fan guard[220] Encoder[367] Retaining screw[657] Protection cover

[659] Screw[734] Nut[748] Screw

[657][220]

[220]

[734]

[748]

[35]

EH7.

AH7.

[659][367]

[367]

Encoder Tightening torque

EH7. 0.7 Nm (6 in-lb)

AH7. 3.0 Nm (27 in-lb)

33

7 spection and Maintenancespection and maintenance work on the motor DR71-DR100

34

7.5 Inspection and maintenance work on the motor DR71-DR1007.5.1 Basic structure of DR71-DR100

173332747

[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[30] Oil seal[32] Circlip[35] Fan guard[36] 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

[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

[10]

[11][44] [36]

[32]

[2] [3]

[1]

[111]

[113]

[115][112]

[131]

[156]

[262]

[119]

[129]

[134]

[132]

[123]

[116]

[118]

[117]

[107][106]

[7]

[103][100]

[93]

[9]

[12]

[90]

[109]

[108]

[24]

[16] [41]

[392]

[22]

[13][30]

[35]

[706]

[705]

[707]

[42]

InIn


7Inspection and MaintenanceInspection and maintenance work on the motor DR71-DR100

7.5.2 Procedure for inspecting motor DR71-DR100

1. Remove forced cooling fan and incremental encoder (if installed). See section "Preliminary work for motor and brake maintenance" (page 32).

2. Remove fan guard [35] and fan [36].3. Remove the machine screws [13] from the flanged endshield [7] and the B-side

endshield [42] and the stator [16] from the flanged endshield.4. Visual inspection: are there traces of gear oil or condensation inside the stator?

– If there 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

5. 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]

6. Clean the winding, dry it and check it electrically see "Preliminary work" section(page 12).

7. Replace the deep groove ball bearings [11] [44] with permitted ball bearings.See section "Permitted roller bearing types" (page 72).

8. Reseal the shaft:– A-side: Replace oil seal [106]– B-side: Replace oil seal [30]

Coat the sealing lip with grease (Klüber Petamo GHY 133). 9. 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.

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.

35

7 spection and Maintenancespection and maintenance for brake motor DR71-DR100

36

7.6 Inspection and maintenance for brake motor DR71-DR1007.6.1 Basic structure of brake motor DR71, DR80

174200971

[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

[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] Counter spring[68] Brake disc[70] Carrier[71] Key[73] Stainless steel shim plate[95] Sealing ring[718] Damping plate

170 73 68 49 718 66

50 54 95 59 53 56 57 58 36 62 35 22

60

6567

61

71

51

InIn


7Inspection and MaintenanceInspection and maintenance for brake motor DR71-DR100

7.6.2 Basic structure of brake motor DR90, DR100

179981963

[1] Motor with brake endshield[22] Hex head bolt[35] Fan guard[36] Fan[51] Hand lever[53] Releasing lever

[56] Stud[57] Conical coil spring[58] Setting nut[59] Parallel pin[62] Circlip[70] Carrier

[95] Sealing ring[550] Pre-assembled brake[900] Screw[901] Gasket

[1] [71]

[70][62]

[900]

BE5

BE2

BE1

[550][95]

[59][53]

[51][57]

[58][56]

[36][62] [22]

[35 ]

[901]

37


38

7.6.3 Basic structure of brake BE05-BE5

174202635

[49] Pressure plate[50] Brake spring (standard)[54] Magnet, complete[60] Stud 3x[61] Hex nut

[65] Pressure ring[66] Rubber sealing collar[67] Counter spring[68] Brake disc[69] Annular spring

[276] Brake spring (blue)[702] Friction disc[718] Damping plate

67 65 50/276718 5449 6068702 666169

InIn



7.6.4 Procedure for inspecting brake motor DR71-DR100

1. Remove forced cooling fan and incremental encoder (if installed).See section "Preliminary work for motor and brake maintenance" (page 32).

2. 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.4. Remove the terminal box cover and unfasten the brake cable from the rectifier.5. Push the brake off the stator and carefully lift it off.6. Pull the stator back by approx. 3 – 4 cm (1 – 2 in).7. 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 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 (Klüber 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.

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.

39


40

7.6.5 Setting the working air gap for brake BE05-BE5

1. 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]

2. Push the rubber sealing collar [5] aside,– release the clip to do this, if necessary– vacuum up any abraded residue

3. Measure the brake disc [68]:– if the brake disc Â 9 mm, (on motors up to DR100), replace the brake disc.

See section "Replacing the brake disc for brake BE05-BE5" (page 41). 4. 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]

5. Tighten the hex nuts [61]:6. Tighten the setting sleeves

– until the working air gap is set correctly; see "Technical Data" section (page 63).7. Put the rubber sealing collar back in place and re-install the dismantled parts.

DANGER



179978635

A

InIn



7.6.6 Replacing the brake disc for brake BE05-BE5When fitting a new brake disc (thickness Â 9 mm), also inspect the other removed partsand, if necessary, install new ones.

1. 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]

2. 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]3. Unfasten hex nuts [61], carefully pull off the brake coil body [54] (brake cable) and

remove the brake springs [50].4. Remove the damping plate [718], pressure plate [49] and brake disc [68], and clean

the brake components.5. Install a new brake disc.6. Re-install the brake components,

– except for the fan and the fan guard, because the working air gap has to be setfirst see section "Setting the working air gap for brake BE05-BE5" (page 40).

DANGER



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-assembled on the motor's brake endshield on top of afriction disc.

41


42

7. With manual brake release: use setting nuts to set the floating clearance "s" betweenthe 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 upas the brake lining wears. Otherwise, reliable braking is not guaranteed.

8. Put the rubber sealing collar back in place and re-install the dismantled parts.

177241867

Brake Floating clearance "s" [mm]

BE05; BE1 1.5

BE2; BE5 2

s

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.• In brake motors with self-reengaging manual brake release, the manual brake

release lever must be removed after startup/maintenance. A bracket is provided forstoring the lever on the outside of the motor.

NOTEImportant: after replacing the brake disc, the maximum braking torque is reached onlyafter several cycles.

InIn



7.6.7 Changing the braking torque of brake BE05-BE5The braking torque can be altered in stages, • by changing the type and number of brake springs• by changing the complete magnet (only possible for BE05 and BE1)• by changing the brake (from motor size DR90)To find the possible braking torque graduations for each motor, refer to the "TechnicalData" section (page 63).

Changing the brake spring




dowel pin [59]3. Unfasten hex nuts [61] and pull off the brake coil body [54]

– By approx. 50 mm (2.0 in) (watch the brake cable)4. Change or add brake springs [50/276]

– Position the brake springs symmetrically5. Re-install the brake components,


DANGER



43


44

6. With manual brake release: use setting nuts to set the floating clearance "s" betweenthe 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 upas the brake lining wears. Otherwise, reliable braking is not guaranteed.


177241867


BE05; BE1 1.5

BE2; BE5 2

s

NOTE

Replace setting nuts [58] and hex nuts [61] if the removal procedure is repeated.

InIn



Changing the magnet




dowel pin [59]3. Remove the terminal box cover and loosen the brake cable from the rectifier. If

necessary, attach trailing wire to brake cables.4. Unfasten hex nuts [61], remove complete magnet [54], replace brake springs

[50/276]. 5. Re-install the brake components,




DANGER



177241867


BE05; BE1 1.5

BE2; BE5 2

s

45


46

Replacing the brake on DR71 and DR80



2. Remove the terminal box cover and loosen the brake cable from the rectifier. Ifnecessary, attach trailing wire to brake cables.

3. Loosen machine screws [13] and remove brake endshield with brake from stator. 4. Guide the brake cable into the terminal box. 5. Align the cam of the brake endshield.

Notes for BE05 and BE1 installed on the DR80: You can only turn the brakeagainst the shaft as long as the brake is not making contact with the carrier. Turningthe brake on the shaft can destroy the brake disc of the brake. Turning the wholebrake, 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 upas the brake lining wears. Otherwise, reliable braking is not guaranteed.

DANGER



177241867


BE05; BE1 1.5

BE2 2

s

InIn



Replacing the brake on DR90 and DR100



2. Remove the terminal box cover and loosen the brake cable from the rectifier. Ifnecessary, attach trailing wire to brake cables.

3. Unfasten screws [900] and remove brake from brake endshield.4. Pay attention to the alignment of the gasket [901]. 5. Guide the brake cable into the terminal box. 6. Align the cam of the friction disc.

Note for BE1: You can only turn the brake against the shaft as long as the brake isnot making contact with the carrier. Turning the brake on the shaft can destroy thebrake disc of the brake. Turning the whole brake, including the shaft, is permitted.

7. Mount oil seal [95]. 8. With manual brake release: use setting nuts to set the floating clearance "s" between


DANGER



177241867


BE1 1.5

BE2; BE5 2

s

47


48

7.6.8 Retrofitting the manual brake release HR/HF



2. Sealing ring [95].3. Screw in studs [56], insert sealing ring [95], and hammer in the parallel pin [59]. 4. 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 upas the brake lining wears. Otherwise, reliable braking is not guaranteed.

5. Reassemble the removed parts.

DANGER



177241867


BE05; BE1 1.5

BE2; BE5 2

s

InIn


7Inspection and MaintenanceInspection and maintenance work on the motor DR315

7.7 Inspection and maintenance work on the motor DR3157.7.1 Basic structure of the motor DR315

351998603

[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

[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

[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

[452]

[634]

[633][151]

[117][219]

[123]

[132]

[131]

[119]

[112]

[111]

[113]

[109][108]

[24]

[707]

[706][716]

[715][30]

[25][35][26]

[19][22]

[107]

[106]

[250] [100]

[7]

[9]

[42][17]

[94][90]

[15][16]

[705]

[115][134] [607]

[129]

[118]

[116]

[128][140]

[139]

[454]

[606] [604]

[609]

[11][608]

[105]

[3]

[31]

[21][44]

[43][40] [36]

[32]

[4][1]

[2]

[103]

49

7 spection and Maintenancespection and maintenance work on the motor DR315

50

7.7.2 Procedure for inspecting motor DR315

1. Remove forced cooling 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].3. Unfasten machine screws [25] and [19] and remove B-side endshield [42]. 4. 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].5. 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.6. 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

7. If there is condensation inside the stator:Clean the winding, dry it and check it electrically see "Preliminary work" section(page 12).

8. 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 beforeinstalling the bearings.

9. Starting on the A-side, mount the motor vertically.10.Place the cup springs [105] and lubrication ring [604] into the bearing bore of the

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].

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.

InIn


7Inspection and MaintenanceInspection 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 machinescrews [19] and hex nuts [17]. Lift the oil seal flange [21] with the setscrew, andfasten 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 fullwith grease (Klüber Petamo GHY133).

– B-side: insert the oil seal [30], and coat the sealing lip with the same grease. 15.Install the fan [36] and fan guard [35].

51

7 spection and Maintenancespection and maintenance for brake motor DR315

52

7.8 Inspection and maintenance for brake motor DR3157.8.1 Basic structure of brake motor DR315

353595787

[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

[71] Key[255] Conical seat[256] Spherical washer [550] Pre-assembled brake[900] Screw[901] Gasket

[1]

[71][31]

[70][62]

[900][550]

[37][47][53]

[64][56]

[36][32]

[22]

[255] [256] [58][57]

BE120

BE122

[35][55]

InIn


7Inspection and MaintenanceInspection and maintenance for brake motor DR315

7.8.2 Basic structure of brake BE120-BE122

353594123

[28][49][50][52b][54][60] [61]

Closing capPressure plateBrake springBrake stationary disc (BE122 only)Magnet, completeStud 3xHex nut

[66] [67] [68] [68b][69] [69b][256]

Rubber sealing collarSetting sleeveBrake discBrake disc (BE122 only)Annular springAnnular spring (BE122 only)Brake spring

[702][732][733]

Friction discCover discScrew

[702]

[69]

[69b][68b]

[68]

[67][49]

[50/265]

[28]

[52b]

[60]

[54]

[61]

[66]

[733]

[732]

53


54

7.8.3 Procedure for inspecting brake motor DR315

1. Remove forced cooling fan and incremental encoder (if installed)See section "Preliminary work for motor and brake maintenance" (page 32).

2. Remove fan guard [35] and fan [36]3. Unfasten brake connector4. Loosen screws [900] and remove pre-assembled brake [550] from brake endshield.5. Unfasten machine screws [25] and [19] and remove B-side endshield [42]. 6. 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].7. 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.8. 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

9. 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 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 beforeinstalling 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

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].

DANGER



InIn



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 using2 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 (KlüberPetamo GHY133).

– B-side: insert the oil seal [30], and coat the sealing lip with the same grease. Thiscondition applies only to gearmotors

17.Align the cam of the friction disc, and mount the brake onto the brake endshield usinga screw [900].

18.With manual brake release: use setting nuts to set the floating clearance "s" betweenthe 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 upas the brake lining wears. Otherwise, reliable braking is not guaranteed.

19.Install the fan [36] and fan guard [35].20.Install the motor and accessory equipment.

353592459


BE120; BE122 2

S

55


56

7.8.4 Setting the working air gap for brake BE120-BE122

1. Remove forced cooling fan and incremental encoder (if installed)See section "Preliminary work for motor and brake maintenance" (page 32)

2. Remove fan guard [35] and fan [36]3. Push the rubber sealing collar [66] aside,

– release the clip to do this, if necessary– vacuum up any abraded residue

4. Measure the brake disc [68, 68b]:Replace the brake disc if the brake disc Â 12 mm (0.47 in). See section "Replacing the brake disc for brake BE120-BE122" (page 58)

5. Unfasten the setting sleeve [67] by turning it towards the endshield6. Measure the working air gap A (see following figure)

(use a feeler gauge and measure at three points offset by 120°):

DANGER



A

InIn



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:

9. Tighten the setting sleeves – towards the magnet– until the working air gap is set correctly; see "Technical Data" section (page 63)

10.Put the rubber sealing collar back in place and re-install the dismantled parts.

Mounting position X in [mm]M4 10.0M2 10.5

[49][52b][68][68b][900]

Pressure plateBrake stationary disc (BE122 only)Brake discBrake disc (BE122 only)Hex nut

XX

M4 M2

[49]

[52b]

[900]

[68b]

[68]

57


58

7.8.5 Replacing the brake disc for brake BE120-BE122When fitting a new brake disc (thickness Â 12 mm (0.47 in)), also inspect the otherremoved parts and, if necessary, install new ones.


2. Remove the fan guard [35], circlip [32] and fan [36]3. Loosen the plug connector on the magnet4. 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]

5. Unfasten hex nuts [61], carefully remove complete magnet [54] and remove brakesprings [50/265].

6. Remove the pressure plate [49] and brake disc [68b], and clean the brake compo-nents.

7. Install a new brake disc.8. Re-install the brake components,


DANGER



InIn




10.Put the rubber sealing collar back in place and re-install the dismantled parts.

353592459


BE120; BE122 2

S

NOTE• The lockable manual brake release (type HF) is already released if a resistance is

encountered when operating the setscrew.• After replacing the brake disc, the maximum braking torque is reached only after

several cycles.

59


60

7.8.6 Changing the braking torque of brake BE120-BE122The braking torque can be altered in stages, • by changing the type and number of brake springs• by changing the brake To find the possible braking torque graduations for each motor, refer to the "TechnicalData" section (page 63).

Changing the brake spring


2. Remove the flange cover or fan guard [35], circlip [32] and fan [36].3. Unfasten the plug connector on the magnet [54] and protect it from getting dirty 4. 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]

5. Unfasten hex nuts [61] and pull off the magnet [54]– by approx. 50 mm (2.0 in)

6. Change or add brake springs [50/265]– Position the brake springs symmetrically

7. Re-install the brake components,– except for the fan and the fan guard, because the working air gap has to be set

first see section "Setting the working air gap for brake BE120-BE122" (page 56).

DANGER



InIn





353592459


BE120; BE122 2

S

NOTE

Replace setting nuts [58] and hex nuts [61] if the removal procedure is repeated.

61


62

Replacing the brake on DR315


2. Remove the flange cover or fan guard [35], circlip [32] and fan [36]3. Unfasten brake connector4. Unfasten screws [900] and remove brake from brake endshield.5. Align the cam of the friction disc, and mount the brake onto the brake endshield using

a screw [900]. 6. With manual brake release: use setting nuts to set the floating clearance "s" between


STOP

The mounting position for installation should correspond to the specifications on thenameplate; make sure that the intended mounting position is permitted.

DANGER



353592459


BE120; BE122 2

S

InIn


8Technical DataWork done, working air gap, braking torques

8 Technical Data8.1 Work done, working air gap, braking torques

Brake type Work done until mainte-

nance

Working air gap Braking torque settings

[mm] Braking torque

Type and number of brake springs

Order numbers for brake springs

[106 J] ([in-lb]) min.1)

1) Please note when checking the working air gap: Parallelism tolerances on the brake disc may cause deviations of ±0.15 mm after atest run.

max. [Nm] ([in-lb]) Normal Blue Normal Blue

BE05 120 (1060) 0.25 0.6

5.0 (44)3.5 (31) 2.5 (22) 1.8 (16)

22––

4263

0135 017 X 1374 137 3

BE1 120 (1060) 0.25 0.610 (89) 7.0 (62) 5.0 (44)

642

–24

0135 017 X 1374 137 3

BE2 165 (1460) 0.25 0.6

20 (180) 14 (120) 10 (89) 7.0 (62)

622–

–424

1374 024 5 1374 052 0

BE5 260 (2300) 0.25 0.9

55 (490) 40 (350) 28 (250) 20 (180)

422–

2424

1374 070 9 1374 071 7

BE120 520 (4600) 0.4 1.2

1000 (8851) 800 (7080) 600 (5310) 400 (3540)

8644

–24–

1360 877 0 1360 831 2

BE122 520 (4600) 0.5 1.2

2000 (17700) 1600 (14160) 1200 (10620) 800 (7080)

8644

–24–

1360 877 0 1360 831 2


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8 echnical Dataraking torque breakdown

64

8.2 Braking torque breakdown8.2.1 Motor size DR71-100

8.2.2 Motor size DR315

Motor type Brake type Braking torque gradation in Nm ([in-lb])

DR71BE05 1.8

(16)2.5 (22)

3.5 (31)

5.0 (44)

BE1 5.0 (44)

7.0 (62)

10.0 (88.5)

DR80

BE05 1.8 (16)

2.5 (22)

3.5 (31)

5.0 (44)

BE1 5.0 (44)

7.0 (62)

10 (89)

BE2 7.0 (62)

10 (89)

14 (120)

20 (180)

DR90

BE1 5.0 (44)

7.0 (62)

10 (89)

BE2 7.0 (62)

10 (89)

14 (120)

20 (180)

BE5 20 (180)

28 (250)

40 (350)

55 (490)

DR100

BE2 7.0 (62)

10 (89)

14 (120)

20 (180)

BE5 20 (180)

28 (250)

40 (350)

55 (490)

Motor type Brake type Braking torque gradation in Nm ([in-lb])

DR315BE120 400

(3540)600

(5310)800

(7080)1000

(8851)

BE122 800 (7080)

1200 (10620)

1600 (14160)

2000 (17700)

TB

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8Technical DataOperating currents

8.3 Operating currents8.3.1 Brake BE05/1, BE2, BE5

The current values IH (holding current) specified in the tables are r.m.s. values. Measurethe r.m.s. values using only the appropriate measuring instruments. The inrush current(acceleration current) IAcc only flows for a short time (max. 160 ms) when the brake isreleased. There is no increased inrush current if a BG or BMS brake rectifier is used orif there is a direct DC voltage supply – only possible with brakes up to size BE2.

Key

BE05/1 BE2 BE5

Max. braking torque[Nm] ([in lb])

5 (40)/10 (89) 20 (180) 55 (490)

Braking power [W] ([hp]) 32 (0.043) 43 (0.058) 49 (0.066)

Inrush current ratio IAcc/IH 4 4 5.7

Rated voltage VRated BE05/1 BE2 BE5

IH[AAC]

IDC[ADC]

IH[AAC]

IDC[ADC]

IH[AAC]VAC VDC

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 0.12 0.15 0.13

IAcc Acceleration current – brief inrush current

IH Holding current r.m.s. value in the supply cable to the SEW brake rectifier

IDC Direct current with direct DC voltage supply

VRated Rated voltage (rated voltage range)


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8 echnical Dataperating currents

66

8.3.2 Brake BE120, BE122The current values IH (holding current) specified in the tables are r.m.s. values. Measurethe r.m.s. values using only the appropriate measuring instruments. The inrush current(acceleration current) IAcc only flows for a short time (max. 400 ms) when the brake isreleased. You may not use a direct voltage supply is not required.

Key

BE120 BE122

Max. braking torque [Nm] ([in lb])

1000 (8851) 2000 (17700)

Braking power [W] ([hp]) 250 (0.335) 250 (0.335)

Inrush current ratio IAcc/IH 4.9 4.9

Rated voltage VRated BE120 BE122

IH[AAC]

IH[AAC]VAC VDC

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

IAcc Acceleration current – brief inrush current

IH Holding current r.m.s. value in the supply cable to the SEW brake rectifier

IDC Direct current with direct DC voltage supply

VRated Rated voltage (rated voltage range)

TO

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8Technical DataResistances

8.4 Resistances8.4.1 Brake BE05/1, BE2, BE5

BE05/1 BE2 BE5

Max. braking torque[Nm] ([in lb])

5 (40) /10 (89) 20 (180) 55 (490)

Braking power [W] ([hp]) 32 (0.043) 43 (0.058) 49 (0.066)

Inrush current ratio IAcc/IH 4 4 5.7

Rated voltage VRated BE05/1 BE2 BE5

RAcc RSec RAcc RSec RAcc RSecVAC VDC

24 (23-26) 10 0.77 2.35 0.57 1.74 – –

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.

The following illustration shows how to measure resistance with cutoff in the DC and AC circuits.

BS Acceleration coilTS Coil sectionRAcc Acceleration coil resistance at 20 °C (68 °F) [Ê]RSec Coil section resistance at 20 °C (68 °F) [Ê]VRated Rated voltage (rated voltage range)

RD redWH whiteBU blue

WH

RD

BU

RAcc

RD

WH

BURSec

WH

RD

BU

RAcc

RD

WH

BURSec

NOTEWhen measuring the resistance of the coil section (RSec) or the acceleration coil (RAcc),remove the white conductor from the brake rectifier; if it remains connected, the internalresistance of the brake rectifier will cause erroneous results.


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8 echnical Dataesistances

68

8.4.2 Brake BE120, BE122

BE120 BE122

Max. braking torque [Nm] ([in lb]) 1000 (8851) 2000 (17700)

Braking power [W] ([hp]) 250 (0.335) 250 (0.335)

Inrush current ratio IAcc/IH 4.9 4.9

Rated voltage VRated BE120 BE122

RAcc RSec RAcc RSecVAC VDC

230 (218-243) – 7.6 29.5 7.6 29.5

254 (244-273) – 9.5 37.0 9.5 37.0

290 (274-306) – 12.0 46.5 12.0 46.5

360 (344-379) – 19.1 74.0 19.1 74.0

400 (380-431) – 24.0 93.0 24.0 93.0

460 (432-484) – 30.0 117.0 30.0 117.0

500 (485-542) – 38.0 147.0 38.0 147.0

575 (543-600) – 48.0 185.0 48.0 185.0

The following illustration shows how to measure resistance with BMP 3.1.

BS Acceleration coilTS Coil sectionRAcc Acceleration coil resistance at 20 °C (68 °F) [Ê]RSec Coil section resistance at 20 °C (68 °F) [Ê]VRated Rated voltage (rated voltage range)

WHRD BU

RAcc

RD

WH

BURSec

NOTEWhen measuring the resistance of the coil section (RSec) or the acceleration coil (RAcc),remove the white conductor from the brake rectifier; if it remains connected, the internalresistance of the brake rectifier will cause erroneous results.

TR

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8Technical DataBrake rectifier combinations

8.5 Brake rectifier combinations8.5.1 Brake BE05/1, BE2, BE5

The table below shows the standard and optional combinations of brakes and brakerectifiers.

8.5.2 Brake BE120, BE122The table below shows the standard and optional combinations of brakes and brakerectifiers.

BE05 BE1 BE2 BE5

BGBG 1.5 X1 X1 X1 –

BG 3 X2 X2 X2 –

BGEBGE 1.5 • • • X1

BGE 3 • • • X2

BS BS 24 X X X –

BMSBMS 1.5 • • • –

BMS 3 • • • –

BMEBME 1.5 • • • •

BME 3 • • • •

BMHBMH 1.5 • • • •

BMH 3 • • • •

BMKBMK 1.5 • • • •

BMK 3 • • • •

BMPBMP 1.5 • • • •

BMP 3 • • • •

BMV BMV 5 • • • •

BSG BSG • • • X

BSR

BGE 3 + SR 11 • • • •

BGE 3 + SR 15 • • • •

BGE 1.5 + SR 11 • • • •

BGE 1.5 + SR 15 • • • •

BURBGE 3 + UR 11 • • • •

BGE 1.5 + UR 15 • • • •

X Standard designX1 Standard design with brake rated voltage of AC 150 – 500 VX2 Standard design with brake rated voltage of AC 24/42 – 150 V• Optional– Not permitted

BE120 BE122

BMP 3.1 X X


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8 echnical Datarake control

70

8.6 Brake control 8.6.1 Motor wiring compartment

The following table lists the technical data of brake control systems for installation in themotor wiring compartment and the breakdown in regard to motor size and connectiontechnology. The different housings have different colors (= color code) to make themeasier to distinguish.

Motor size DR71-100

Motor size DR315

Type Function VoltageHolding current

IHmax [A]Type Part

numberColor code

BG One-way rectifierAC 150...500 V 1.5 BG 1.5 825 384 6 Black

AC 24...500 V 3.0 BG 3 825 386 2 Brown

BGE One-way rectifier with electronic switching

AC 150...500 V 1.5 BGE 1.5 825 385 4 Red

AC 42...150 V 3.0 BGE 3 825 387 0 Blue

BSROne-way rectifier +

current relay for cut-off in the DC circuit

AC 150...500 V1.0 BGE 1.5 + SR 11 825 385 4

826 761 8

1.0 BGE 1.5 + SR 15 825 385 4 826 762 6

AC 42...150 V1.0 BGE 3 + SR11 825 387 0

826 761 8

1.0 BGE 3 + SR15 825 387 0 826 762 6

BUROne-way rectifier +

voltage relay for cut-off in the DC circuit

AC 150...500 V 1.0 BGE 1.5 + UR 15 825 385 4 826 759 6

AC 42...150 V 1.0 BGE 3 + UR 11 825 387 0 826 758 8

BS Varistor protection circuit DC 24 V 5.0 BS24 826 763 4 Aqua

BSG Electronic switching DC 24 V 5.0 BSG 825 459 1 White


IHmax [A]Type Part

numberColor code

BMP

One-way rectifier with electronic switching,

integrated voltage relay for cut-off in the

DC circuit.

AC 230...575 V 2.8 BMP 3.1 829 507 7

TB

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8Technical DataBrake contro

8.6.2 Control cabinetThe following tables list the technical data of brake control systems for installation in thecontrol 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

Motor size DR315


IHmax [A]Type

Part number Color

code

BMS One-way rectifier as with BG

AC 150...500 V 1.5 BMS 1.5 825 802 3 Black

AC 42...150 V 3.0 BMS 3 825 803 1 Brown

BMEOne-way rectifier with electronic switching as

with BGE

AC 150...500 V 1.5 BME 1.5 825 722 1 Red

AC 42...150 V 3.0 BME 3 825 723 X Blue

BMHOne-way rectifier with

electronic switching and heating function

AC 150...500 V 1.5 BMH 1.5 825 818 X Green

AC 42...150 V 3 BMH 3 825 819 8 Yellow

BMPOne-way rectifier with

electronic switching, inte-grated voltage relay for cut-off in the DC circuit

AC 150...500 V 1.5 BMP 1.5 825 685 3 White

AC 42...150 V 3.0 BMP 3 826 566 6 Light blue

BMK


24 VDC control input and separation in the

DC circuit

AC 150...500 V 1.5 BMK 1.5 826 463 5 Aqua

AC 42...150 V 3.0 BMK 3 826 567 4 Bright red

BMVBrake control unit with electronic switching,

24 VDC control input and fast cut-off

DC 24 V 5.0 BMV 5 1 300 006 3 White


IHmax [A]Type

Part number Color

code

BMP


integrated voltage relay for cut-off in the

DC circuit.

AC 230...575 V 2.8 BMP 3.1 829 507 7


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n

71

8 echnical Dataermitted roller bearing types

72

8.7 Permitted roller bearing types8.7.1 Roller bearing types for motor size DR71-100

8.7.2 Roller bearing types for motor size DR315

Motor with reinforced bearings

Motor typeA-side (drive) bearing B-side (non drive) bearing

IEC motor Gearmotor Three-phase current motor

Brake motor

DR71 6204-2Z-J-C3 6303-2Z-J-C3 6203-2Z-J-C3 6203-2RS-J-C3DR80 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

Motor type A-side (drive) bearing B-side (non drive) bearingIEC motor Gearmotor IEC motor Gearmotor

DR315K

6319-J-C36319-J-C3

6319-J-C36319-J-C3

DR315SDR315M

6322-J-C3 6322-J-C3DR315L

Motor type A-side (drive) bearing B-side (non drive) bearingIEC motor Gearmotor

DR315K

NU319E 6319-J-C36319-J-C3

DR315SDR315M

6322-J-C3DR315L

TP

Pi

fkVA

Hz

n


8Technical DataLubricant tables

8.8 Lubricant tables8.8.1 Lubricant table for roller bearingsMotor size DR71-100

The bearings are 2Z or 2RS closed bearings and cannot be relubricated.

Motor size DR315

Series DR315 motors may be equipped with a lubrication device.

8.9 Order information for lubricants and anti-corrosion agentsLubricants and anti-corrosion agents may be obtained directly from SEW-EURODRIVEusing the following order numbers.

Ambient temperature Manufacturer Type DIN designation

Motor roller bearings

–20 °C (–4 °F) ... 80 °C (176 °F)

Esso Polyrex EM1)

1) Mineral lubricant (= mineral-based roller bearing grease)

K2P-20

+20 °C (68 °F) ... 100 °C (212 °F)

Klüber Barrierta L55/22)

2) Synthetic lubricant (= synthetic-based roller bearing grease)

KX2U

–40 °C (–40 °F) ... 60 °C (140 °F)

Kyodo Yushi Multemp SRL2) K2N-40

Ambient temperature Manufacturer Type DIN designation

Motor roller bearings

–20 °C (–4 °F) ... 80 °C (176 °F)

Esso Polyrex EM1)

1) Mineral lubricant (= mineral-based roller bearing grease)

K2P-20

–40 °C (–40 °F) ... 60 °C (140 °F)

SKF GXN1) K2N-40

Use Manufacturer Type Quantity Order number

Lubricant for roller bearings

Esso Polyrex EM 400 g (14.1 oz)

09101470

SKF GXN 400 g (14.1 oz)

09101276

Type of lubricant Sealing rings Klüber Petamo GHY 133 10 g

(0.35 oz) 04963458

Anti-corrosive and lubricant SEW-EURODRIVE Noco Fluid® 5.5 g

(0.19 oz) 09107819


Pi

fkVA

Hz

n

73

9 ppendixiring diagrams

74

9 Appendix9.1 Wiring diagrams

9.1.1 Delta and star connectionThree-phase current motor For all motors with a rotation speed, direct-on-line or Õ- Östartup.

Ö connection The following illustration shows the Öconnection for lower voltage.

Õ connection The following illustration shows the Õ connection for high voltage.

Change in direction of rotation: Swap connection of 2 supply cables (L1 – L2).

NOTEThe motor should be connected as shown in the connection wiring diagram or theassignment diagram, which are included with the motor. Only a selection of thecommon types of connections are shown in the following section. You can obtain therelevant wiring diagrams free of charge from SEW-EURODRIVE.

242603147

[1] Motor winding [2] Motor terminal board[3] Supply cables

V1U1 W1

[1]

V2U2 W2W2 U2

V1U1

V2

W1

L2L1 L3

[2]

[3]

242598155

[1] Motor winding [2] Motor terminal board[3] Supply cables

V1U1 W1

[1]

V2U2 W2 W2 U2 V2

[2]

[3]W1V1U1

L3L2L1

AW


9AppendixWiring diagrams

9.1.2 Motor protection using TF or TH with DR71-100

TF/TH The following illustrations show the connection of the motor protection with TF PTC ther-mistor sensors or TH bimetallic thermostats. Either a two-pole terminal clip or a five-pole terminal strip is available for connecting tothe trip switch.Example: TF/TH to a two-pole terminal strip.

Example: 2xTF/TH to a five-pole terminal strip.

2xTF/TH / with standstill heater

The following illustration shows the connection of the motor protection with 2 TF PTCthermistor sensors or TH bimetallic thermostats and Hx standstill heater.

1b 2b

TF/TH TF/TH

1a 2a 3a 4a 5a

1st TF/TH 1st TF/TH 2nd TF/TH 2nd TF/TH –

1b

2b

1b 2b

Hx Hx

1a 2a 3a 4a 5a

1st TF/TH 1st TF/TH 2nd TF/TH 2nd TF/TH –

1b

2b

75


76

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 tripswitch.Example: TF/TH to terminal strip

Example: 2xTF/TH to terminal strip

1.TF/ 1.TF/1.TH 1.TH



AW



9.1.4 BGE, BG, BSG, BUR brake controlBrake BEBGE, BG, BSG, BUR brake control;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 theAC-side shut-off as well as the DC and AC-side shutoff.

242604811

[1] Brake coil

AC

RD BUWH

UAC

[1]

BGE

BG

1 2 3 4 5

AC

DC

RD

BU

WH

[1]

UAC

BGE

BG

1 2 3 4 5

77


78

BSG control unit The following illustration shows the DC 24 V connection of the BSG control unit

BUR brake control

The following illustration shows the wiring for the BUR brake control

242606475

[1] Brake coil

RD BUWH

[1]

24VDC

- +

BSG

1 2 3 4 5

STOP

Connection to motor terminal board not permitted.

242608139

[1] Brake coil[2] UR11/UR15 voltage relay

UR 11 (42 – 150 V) = BNUR 15 (150 – 500 V) = BK

[4]

BN

/ B

K

U ~(V )AC

RD

BU

WH[1]

[3] [3]

BN

/ B

K

RD BU

[2]

BGE

BG

1 2 3 4 5

AW



9.1.5 BSR brake controlBE brake BSR brake controlBrake voltage = Phase voltageThe white connecting leads are the ends of a converter loop and, depending on themotor connection, must be connected to the motor terminal block instead of the Ö or Õbridge.

Factory: Õ The following illustration shows the factory wiring for the BSR brake controlExample: Motor: AC 230/400 V Brake: AC 230 V

242599819

[1] Brake coil[2] SR11/15 current relay

W2 U2

V1U1

V2

W1

L2L1 L3

[1]RD BU

BGE

BG

1 2 3 4 5

WH WH

RD

BU

WH

[2]

W2 U2 V2

W1V1U1

L3L2L1

[1]RD BU

BGE

BG

1 2 3 4 5

WHWH

RD

BU

WH

[2]

79


80

9.1.6 BMP3.1 brake control in the terminal boxBE120, BE122 brakeBMP3.1 brake controlApply 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-sideshutoff as well as the DC and AC-side shutoff.

365750411

[1] Brake coil

AC

1 2 3

13 14 15

BMP3.1

ACU

RD BUWH

[1]

AC

DC 1 2 3

13 14 15

BMP3.1

ACU

RD BUWH

[1]

AW


10MalfunctionsMotor malfunctions

10 Malfunctions10.1 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 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 withcable 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 withSEW-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 Send motor to specialist workshop for repair

Rotor rubbing

Fuses blow or motor protec-tion trips immediately

Short circuit in the motor supply cable Repair short circuit

Supply cables connected incorrectly Correct the wiring, observe the wiring diagram

Short circuit in motor Send motor to specialist workshop for repair

Ground fault on motor

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

81

10 alfunctionsotor malfunctions

82

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 motor 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


MM


10MalfunctionsBrake malfunctions

10.2 Brake malfunctions


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)– "Setting the working air gap for brake BE120-BE122" (page 56)If the brake disk is too thin, replace the brake disk (BE05-BE5 < 9 mm / BE120-BE122 < 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 > 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 BE05-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 < 9 mm / BE120-BE122 < 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)

Brake lining worn down. Replace entire brake disk. See the following sections:– "Replacing the brake disk for brake BE05-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 BE05-BE5" (page 43)– "Changing the braking torque of brake BE120-BE122" (page 60)

• by selecting a different brakeSee 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 BE05-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 correctlySee the following sections:– "Changing the braking torque of brake BE05-BE5" (page 43)– "Changing the braking torque of brake BE120-BE122" (page 60)

Brake locked by manual brake release HF Loosen the setscrew, remove if needed

83

10 alfunctionsalfunctions when operating with a frequency inverter

84

10.3 Malfunctions when operating with a frequency inverter

10.4 Customer service

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 carrier caused by jolting startup

Check the project planning, replace the brake disk if neededSee the following sections:– "Replacing the brake disk for brake BE05-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 frequency inverter

Check correct setting of frequency inverter according to its operating instructions, correct if needed


The symptoms described in section "Motor malfunctions" may also occur when themotor 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 informationabout rectifying the problems.

Please have the following information available if you require customer service assistance:• Nameplate data (complete)• Type and extent of the problem• Time the problem occurred and any accompanying circumstances• Assumed cause

MM


11Index

11 IndexAAccessory equipment ..........................................25AH7Y ........................................................... 27, 33Ambient conditions

Ambient temperature ....................................18Hazardous radiation .....................................18Installation altitude ........................................18

AS7H ........................................................... 27, 32

BBE05 ...................................................................38BE1 .....................................................................38BE120 .................................................................53BE122 .................................................................53BE2 .....................................................................38BE5 .....................................................................38Bearing lubrication ..............................................30Brake

BE05 .............................................................38BE1 ...............................................................38BE120 ...........................................................53BE122 ...........................................................53BE2 ...............................................................38BE5 ...............................................................38Braking torque breakdown ...........................64Braking torques ............................................63Operating currents ........................................65Resistances ..................................................67Work done ....................................................63Working air gap ............................................63

Brake connection ................................................24Brake control ..........................................15, 24, 70

BG ................................................................77BGE ..............................................................77BMP3.1 .........................................................80BSG ..............................................................77BSR ..............................................................79BUR ..............................................................77Control cabinet .............................................71Motor wiring compartment ............................70

Brake malfunctions .............................................83Brake rectifier combinations ................................69Braking torque breakdown ..................................64

CChanging the braking torque

BE05 ............................................................ 43BE1 .............................................................. 43BE120 ....................................................43, 60BE122 ....................................................43, 60BE2 .............................................................. 43BE5 .............................................................. 43

Connecting the motor ......................................... 19Connection

Delta ............................................................ 19Star .............................................................. 19

Customer service ............................................... 84

DDelta connection ..........................................19, 74Design

DR100 ........................................................... 9DR315 ......................................................... 10DR71 ............................................................. 9DR80 ............................................................. 9DR90 ............................................................. 9Motor ....................................................... 9, 10

Designated use .................................................... 7

EEH7S ............................................................ 27, 33Electrical connection ............................................ 8Electrical Installation .......................................... 15EMC ................................................................... 17Encoder .............................................................. 27

AH7Y ........................................................... 27AS7H ........................................................... 27EH7S ........................................................... 27ES7H ........................................................... 27ES7S ........................................................... 27

Encoder connection ........................................... 27ES7H ............................................................ 27, 32ES7S ............................................................ 27, 32Exclusion of liability .............................................. 5Extended storage ............................................... 13

FForced cooling fan V .......................................... 26Frequency inverter operation ............................. 16

GGeneral safety notes ............................................ 6Grounding .......................................................... 17

85

11

86

dex

IImproving the grounding .....................................17Inspecting brake motor

DR315 ..........................................................54Inspecting the brake motor

DR100 ..........................................................39DR71 ............................................................39DR80 ............................................................39DR90 ............................................................39

Inspecting the motorDR100 ..........................................................35DR315 ..........................................................50DR71 ............................................................35DR80 ............................................................35DR90 ............................................................35

Inspection ...........................................................29Inspection and Maintenance ...............................29Inspection and maintenance intervals .................29Inspection intervals .............................................29Installation ...................................................... 7, 14

Electrical .......................................................15Mechanical ...................................................12

Installation tolerances .........................................14

LLubricant table ....................................................73

MMaintenance .......................................................29Maintenance intervals .........................................29Malfunctions ........................................................81Malfunctions when operating with a frequency inverter ...............................................84Mechanical Installation ........................................12Motor

Connection ...................................................19Drying ...........................................................13Extended storage .........................................13Installation ....................................................14

Motor connection terminal board ........................20Motor Design .........................................................9

DR100 ............................................................9DR315 ..........................................................10DR71 ..............................................................9DR80 ..............................................................9DR90 ..............................................................9

Motor malfunctions ..............................................81

Motor protection ...........................................75, 76TF ..........................................................75, 76TH ..........................................................75, 76

Motor protection device ...................................... 15

NNameplate .......................................................... 11

OOperation with frequency inverter ...................... 16

PPreliminary work for motor and brake maintenance ...................................................... 32

RReinforced bearing .......................................12, 31Relubrication ...................................................... 30Relubrication intervals ........................................ 31Removing the encoder .................................32, 33

AH7Y ........................................................... 33AS7H ........................................................... 32EH7S ........................................................... 33ES7H ........................................................... 32ES7S ........................................................... 32

Removing the incremental encoder .............32, 33AH7Y ........................................................... 33AS7H ........................................................... 32EH7S ........................................................... 33ES7H ........................................................... 32ES7S ........................................................... 32

Replacing the brake discBE05 ............................................................ 41BE1 .............................................................. 41BE120 .......................................................... 58BE122 .......................................................... 58BE2 .............................................................. 41BE5 .............................................................. 41

Retrofitting the manual brake release HR/HF .... 48Right to claim under warranty .............................. 5Roller bearing types ........................................... 72

SSafety Notes ........................................................ 6

Designated use .............................................. 7Electrical connection ...................................... 8General .......................................................... 6Installation ..................................................... 7Operation ....................................................... 8Transportation ............................................... 7

In


11Index

Setting the working air gapBE05 .............................................................40BE1 ...............................................................40BE120 ...........................................................56BE122 ...........................................................56BE2 ...............................................................40BE5 ...............................................................40

Special features for switching operation .............18Star connection ............................................ 19, 74Startup ................................................................28Switching operation .............................................18

TTechnical data .....................................................63Temperature sensor TF ......................................25TF ..........................................................25, 75, 76TH ..........................................................25, 75, 76Transportation .......................................................7

UUnit designation ................................................. 11

VV ......................................................................... 26

WWinding thermostats TH .................................... 25Wiring diagram

BMP3.1 ........................................................ 80Wiring diagrams ................................................. 74

BG ............................................................... 77BGE ............................................................. 77BSG ............................................................. 78BSR ............................................................. 79BUR ............................................................. 78Delta connection .......................................... 74Star connection ............................................ 74TF ..........................................................75, 76TH ..........................................................75, 76

87

Address List

88

Address ListGermany

HeadquartersProductionSales

Bruchsal SEW-EURODRIVE GmbH & Co KGErnst-Blickle-Straße 42 D-76646 BruchsalP.O. BoxPostfach 3023 • D-76642 Bruchsal

Tel. +49 7251 75-0Fax +49 7251 75-1970http://[email protected]

Service Competence Center

CentralGear units / Motors

SEW-EURODRIVE GmbH & Co KGErnst-Blickle-Straße 1 D-76676 Graben-Neudorf

Tel. +49 7251 75-1710Fax +49 7251 [email protected]

CentralElectronics

SEW-EURODRIVE GmbH & Co KGErnst-Blickle-Straße 42 D-76646 Bruchsal


North SEW-EURODRIVE GmbH & Co KGAlte Ricklinger Straße 40-42 D-30823 Garbsen (near Hannover)


East SEW-EURODRIVE GmbH & Co KGDänkritzer Weg 1D-08393 Meerane (near Zwickau)


South SEW-EURODRIVE GmbH & Co KGDomagkstraße 5D-85551 Kirchheim (near München)


West SEW-EURODRIVE GmbH & Co KGSiemensstraße 1D-40764 Langenfeld (near Düsseldorf)


Drive Service Hotline / 24 Hour Service +49 180 5 SEWHELP+49 180 5 7394357

Additional addresses for service in Germany provided on request!

France

ProductionSalesService

Haguenau SEW-USOCOME 48-54, route de Soufflenheim B. P. 20185F-67506 Haguenau Cedex

Tel. +33 3 88 73 67 00 Fax +33 3 88 73 66 00http://[email protected]

AssemblySalesService

Bordeaux SEW-USOCOME Parc d'activités de Magellan62, avenue de Magellan - B. P. 182F-33607 Pessac Cedex

Tel. +33 5 57 26 39 00Fax +33 5 57 26 39 09

Lyon SEW-USOCOME Parc d'Affaires RooseveltRue Jacques TatiF-69120 Vaulx en Velin

Tel. +33 4 72 15 37 00Fax +33 4 72 15 37 15

Paris SEW-USOCOME Zone industrielle 2, rue Denis Papin F-77390 Verneuil I'Etang

Tel. +33 1 64 42 40 80Fax +33 1 64 42 40 88

Additional addresses for service in France provided on request!

Algeria

Sales Alger Réducom 16, rue des Frères ZaghnounBellevue El-Harrach16200 Alger

Tel. +213 21 8222-84Fax +213 21 8222-84

Argentina


Buenos Aires SEW EURODRIVE ARGENTINA S.A.Centro Industrial Garin, Lote 35Ruta Panamericana Km 37,51619 Garin


11/2006

Address List

Australia


Melbourne SEW-EURODRIVE PTY. LTD.27 Beverage DriveTullamarine, Victoria 3043


Sydney SEW-EURODRIVE PTY. LTD.9, Sleigh Place, Wetherill Park New South Wales, 2164


Townsville SEW-EURODRIVE PTY. LTD.12 Leyland StreetGarbutt, QLD 4814

Tel. +61 7 4779 4333Fax +61 7 4779 [email protected]

Austria


Wien SEW-EURODRIVE Ges.m.b.H. Richard-Strauss-Strasse 24A-1230 Wien

Tel. +43 1 617 55 00-0Fax +43 1 617 55 00-30http://[email protected]

Belgium


Brüssel SEW Caron-Vector S.A.Avenue Eiffel 5B-1300 Wavre


Brazil

ProductionSalesService

Sao Paulo SEW-EURODRIVE Brasil Ltda.Avenida Amâncio Gaiolli, 50Caixa Postal: 201-07111-970Guarulhos/SP - Cep.: 07251-250


Additional addresses for service in Brazil provided on request!

Bulgaria

Sales Sofia BEVER-DRIVE GmbHBogdanovetz Str.1BG-1606 Sofia

Tel. +359 2 9151160Fax +359 2 [email protected]

Cameroon

Sales Douala Electro-ServicesRue Drouot AkwaB.P. 2024Douala

Tel. +237 4322-99Fax +237 4277-03

Canada


Toronto SEW-EURODRIVE CO. OF CANADA LTD. 210 Walker Drive Bramalea, Ontario L6T3W1


Vancouver SEW-EURODRIVE CO. OF CANADA LTD.7188 Honeyman Street Delta. B.C. V4G 1 E2


Montreal SEW-EURODRIVE CO. OF CANADA LTD.2555 Rue Leger Street LaSalle, Quebec H8N 2V9


Additional addresses for service in Canada provided on request!

Chile


Santiago de Chile

SEW-EURODRIVE CHILE LTDA.Las Encinas 1295Parque Industrial Valle GrandeLAMPARCH-Santiago de ChileP.O. BoxCasilla 23 Correo Quilicura - Santiago - Chile


11/2006 89

Address List

90

China

ProductionAssemblySalesService

Tianjin SEW-EURODRIVE (Tianjin) Co., Ltd.No. 46, 7th Avenue, TEDA Tianjin 300457

Tel. +86 22 25322612Fax +86 22 [email protected]://www.sew-eurodrive.com.cn


Suzhou SEW-EURODRIVE (Suzhou) Co., Ltd.333, Suhong Middle RoadSuzhou Industrial ParkJiangsu Province, 215021P. R. China


Additional addresses for service in China provided on request!

Colombia


Bogotá SEW-EURODRIVE COLOMBIA LTDA. Calle 22 No. 132-60Bodega 6, Manzana BSantafé de Bogotá


Croatia

SalesService

Zagreb KOMPEKS d. o. o.PIT Erdödy 4 IIHR 10 000 Zagreb


Czech Republic

Sales Praha SEW-EURODRIVE CZ S.R.O.Business Centrum Praha Lužná 591CZ-16000 Praha 6 - Vokovice

Tel. +420 220121234Fax +420 220121237http://[email protected]

Denmark


Kopenhagen SEW-EURODRIVEA/SGeminivej 28-30, P.O. Box 100DK-2670 Greve


Estonia

Sales Tallin ALAS-KUUL ASMustamäe tee 24EE-10620 Tallin

Tel. +372 6593230Fax +372 [email protected]

Finland


Lahti SEW-EURODRIVE OYVesimäentie 4FIN-15860 Hollola 2

Tel. +358 201 589-300Fax +358 3 [email protected]://www.sew-eurodrive.fi

Gabon

Sales Libreville Electro-ServicesB.P. 1889Libreville

Tel. +241 7340-11Fax +241 7340-12

Great Britain


Normanton SEW-EURODRIVE Ltd.Beckbridge Industrial Estate P.O. Box No.1GB-Normanton, West- Yorkshire WF6 1QR


Greece

SalesService

Athen Christ. Boznos & Son S.A.12, Mavromichali StreetP.O. Box 80136, GR-18545 Piraeus

Tel. +30 2 1042 251-34 Fax +30 2 1042 251-59http://[email protected]

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Address List

Hong Kong


Hong Kong SEW-EURODRIVE LTD.Unit No. 801-806, 8th FloorHong Leong Industrial ComplexNo. 4, Wang Kwong Road Kowloon, Hong Kong

Tel. +852 2 7960477 + 79604654Fax +852 2 [email protected]

Hungary

SalesService

Budapest SEW-EURODRIVE Kft.H-1037 BudapestKunigunda u. 18

Tel. +36 1 437 06-58Fax +36 1 437 [email protected]

India


Baroda SEW-EURODRIVE India Pvt. Ltd.Plot No. 4, GidcPor Ramangamdi • Baroda - 391 243Gujarat

Tel. +91 265 2831086Fax +91 265 2831087http://[email protected]

Technical Offices Bangalore SEW-EURODRIVE India Private Limited308, Prestige Centre Point7, Edward RoadBangalore


Ireland

SalesService

Dublin Alperton Engineering Ltd. 48 Moyle RoadDublin Industrial EstateGlasnevin, Dublin 11

Tel. +353 1 830-6277Fax +353 1 830-6458

Israel

Sales Tel-Aviv Liraz Handasa Ltd. Ahofer Str 34B / 22858858 Holon


Italy


Milano SEW-EURODRIVE di R. Blickle & Co.s.a.s.Via Bernini,14 I-20020 Solaro (Milano)

Tel. +39 02 96 9801Fax +39 02 96 799781http://[email protected]

Ivory Coast

Sales Abidjan SICASte industrielle et commerciale pour l'Afrique165, Bld de MarseilleB.P. 2323, Abidjan 08

Tel. +225 2579-44Fax +225 2584-36

Japan


Iwata SEW-EURODRIVE JAPAN CO., LTD 250-1, Shimoman-no,IwataShizuoka 438-0818


Korea


Ansan-City SEW-EURODRIVE KOREA CO., LTD. B 601-4, Banweol Industrial Estate Unit 1048-4, Shingil-DongAnsan 425-120


Latvia

Sales Riga SIA Alas-KuulKatlakalna 11CLV-1073 Riga


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Lebanon

Sales Beirut Gabriel Acar & Fils sarlB. P. 80484Bourj Hammoud, Beirut

Tel. +961 1 4947-86 +961 1 4982-72+961 3 2745-39Fax +961 1 4949-71 [email protected]

Lithuania

Sales Alytus UAB IrsevaNaujoji 19LT-62175 Alytus

Tel. +370 315 79204Fax +370 315 [email protected]://www.sew-eurodrive.lt

Luxembourg


Brüssel CARON-VECTOR S.A.Avenue Eiffel 5B-1300 Wavre


Malaysia


Johore SEW-EURODRIVE SDN BHD No. 95, Jalan Seroja 39, Taman Johor Jaya81000 Johor Bahru, JohorWest Malaysia


Mexico


Queretaro SEW-EURODRIVE MEXIKO SA DE CVSEM-981118-M93Tequisquiapan No. 102Parque Industrail QueretaroC.P. 76220Queretaro, Mexico


Morocco

Sales Casablanca Afit5, rue Emir AbdelkaderMA 20300 Casablanca

Tel. +212 22618372Fax +212 [email protected]

Netherlands


Rotterdam VECTOR Aandrijftechniek B.V. Industrieweg 175 NL-3044 AS RotterdamPostbus 10085NL-3004 AB Rotterdam


New Zealand


Auckland SEW-EURODRIVE NEW ZEALAND LTD. P.O. Box 58-428 82 Greenmount driveEast Tamaki Auckland


Christchurch SEW-EURODRIVE NEW ZEALAND LTD. 10 Settlers Crescent, FerrymeadChristchurch


Norway


Moss SEW-EURODRIVE A/SSolgaard skog 71N-1599 Moss


Peru


Lima SEW DEL PERU MOTORES REDUCTORES S.A.C.Los Calderos, 120-124Urbanizacion Industrial Vulcano, ATE, Lima


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Address List

Poland


Lodz SEW-EURODRIVE Polska Sp.z.o.o.ul. Techniczna 5 PL-92-518 Lodz


Portugal


Coimbra SEW-EURODRIVE, LDA. Apartado 15 P-3050-901 Mealhada


Romania

SalesService

Bucuresti Sialco Trading SRL str. Madrid nr.4 011785 Bucuresti

Tel. +40 21 230-1328Fax +40 21 230-7170 [email protected]

Russia


St. Petersburg ZAO SEW-EURODRIVE P.O. Box 36 195220 St. Petersburg Russia

Tel. +7 812 3332522 +7 812 5357142Fax +7 812 3332523http://[email protected]

Senegal

Sales Dakar SENEMECA Mécanique GénéraleKm 8, Route de Rufisque B.P. 3251, Dakar


Serbia and Montenegro

Sales Beograd DIPAR d.o.o.Ustanicka 128aPC Košum, IV floorSCG-11000 Beograd

Tel. +381 11 347 3244 / +381 11 288 0393Fax +381 11 347 [email protected]

Singapore


Singapore SEW-EURODRIVE PTE. LTD. No 9, Tuas Drive 2 Jurong Industrial Estate Singapore 638644


Slovakia

Sales Bratislava SEW-Eurodrive SK s.r.o.Rybnicna 40SK-83107 Bratislava


Zilina SEW-Eurodrive SK s.r.o.ul. Vojtecha Spanyola 33SK-010 01 Zilina


Banská Bystrica SEW-Eurodrive SK s.r.o.Rudlovská cesta 85SK-97411 Banská Bystrica


Slovenia

SalesService

Celje Pakman - Pogonska Tehnika d.o.o.UI. XIV. divizije 14SLO - 3000 Celje

Tel. +386 3 490 83-20Fax +386 3 490 [email protected]

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South Africa


Johannesburg SEW-EURODRIVE (PROPRIETARY) LIMITEDEurodrive House Cnr. Adcock Ingram and Aerodrome RoadsAeroton Ext. 2Johannesburg 2013P.O.Box 90004Bertsham 2013


Capetown SEW-EURODRIVE (PROPRIETARY) LIMITED Rainbow ParkCnr. Racecourse & Omuramba RoadMontague GardensCape TownP.O.Box 36556Chempet 7442 Cape Town

Tel. +27 21 552-9820Fax +27 21 552-9830Telex 576 [email protected]

Durban SEW-EURODRIVE (PROPRIETARY) LIMITED2 Monaceo PlacePinetownDurbanP.O. Box 10433, Ashwood 3605


Spain


Bilbao SEW-EURODRIVE ESPAÑA, S.L. Parque Tecnológico, Edificio, 302E-48170 Zamudio (Vizcaya)

Tel. +34 9 4431 84-70Fax +34 9 4431 84-71http://[email protected]

Sweden


Jönköping SEW-EURODRIVE ABGnejsvägen 6-8S-55303 JönköpingBox 3100 S-55003 Jönköping


Switzerland


Basel Alfred lmhof A.G.Jurastrasse 10 CH-4142 Münchenstein bei Basel


Thailand


Chon Buri SEW-EURODRIVE (Thailand) Ltd.Bangpakong Industrial Park 2700/456, Moo.7, Tambol DonhuarohMuang DistrictChon Buri 20000


Tunisia

Sales Tunis T. M.S. Technic Marketing Service7, rue Ibn EI Heithem Z.I. SMMT2014 Mégrine Erriadh

Tel. +216 1 4340-64 + 1 4320-29Fax +216 1 [email protected]

Turkey


Istanbul SEW-EURODRIVE Hareket Sistemleri San. ve Tic. Ltd. Sti. Bagdat Cad. Koruma Cikmazi No. 3 TR-34846 Maltepe ISTANBUL

Tel. +90 216 4419163 / 164 3838014/15Fax +90 216 [email protected]

Ukraine

SalesService

Dnepropetrovsk SEW-EURODRIVEStr. Rabochaja 23-B, Office 40949008 Dnepropetrovsk


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Address List

USA

ProductionAssemblySalesService

Greenville SEW-EURODRIVE INC. 1295 Old Spartanburg Highway P.O. Box 518Lyman, S.C. 29365

Tel. +1 864 439-7537Fax Sales +1 864 439-7830Fax Manuf. +1 864 439-9948Fax Ass. +1 864 439-0566Telex 805 550 http://[email protected]


San Francisco SEW-EURODRIVE INC. 30599 San Antonio St.Hayward, California 94544-7101


Philadelphia/PA SEW-EURODRIVE INC. Pureland Ind. Complex 2107 High Hill Road, P.O. Box 481Bridgeport, New Jersey 08014


Dayton SEW-EURODRIVE INC.2001 West Main Street Troy, Ohio 45373


Dallas SEW-EURODRIVE INC.3950 Platinum Way Dallas, Texas 75237


Additional addresses for service in the USA provided on request!

Venezuela


Valencia SEW-EURODRIVE Venezuela S.A.Av. Norte Sur No. 3, Galpon 84-319Zona Industrial Municipal NorteValencia, Estado Carabobo

Tel. +58 241 832-9804Fax +58 241 838-6275http://[email protected]@cantv.net

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SEW-EURODRIVE – Driving the world

www.sew-eurodrive.com

How we’re driving the world

With people whothink fast anddevelop thefuture with you.

With a worldwide service network that isalways close at hand.

With drives and controlsthat automaticallyimprove your productivity.

With comprehensiveknowledge in virtuallyevery branch ofindustry today.

With uncompromisingquality that reduces thecost and complexity ofdaily operations.

With a global presencethat offers responsive and reliable solutions. Anywhere.

With innovativetechnology that solvestomorrow’s problemstoday.

With online informationand software updates,via the Internet, availablearound the clock.

Gearmotors \ Industrial Gear Units \ Drive Electronics \ Drive Automation \ Services

SEW-EURODRIVEDriving the world

SEW-EURODRIVE GmbH & Co KGP.O. Box 3023 · D-76642 Bruchsal / GermanyPhone +49 7251 75-0 · Fax +49 7251 [email protected]

AC Motors DRS/DRE/DRP - SEW Eurodrive · 2 Safety Notes Preliminary information 6 Operating Instructions – AC Motors DRS/DRE/DRP 2 Safety Notes The following basic safety notes

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