Baumuller DSC Series Guide

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

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LEGAL NOTES ON DOCUMENTATION
Copyright
This documentation may only be copied, as many times as required, by the owner for
internal use. For other purposes, this documentation may not be copied or duplicated either
in whole or in part. Utilization by and provision of the contents to third parties is not
permitted. Names and company logos used in this documentation may be trademarks,
whose use by third parties for their own purposes may infringe the rights of the owner.
Applicability
This documentation is part of the unit/the machine. These Commissioning and Maintenance
Instructions must be available to the operator at all times and be in a readable condition.
If the unit/machine is sold or put into storage, the owner must pass on this documentation
together with the unit/machine. Following the sale of the unit/machine, this original and all
copies are to be passed on to the purchaser. Following disposal or any other form of
termination of utilization, this original and all copies are to be destroyed.
With the introduction of this documentation, corresponding documentation with earlier issue
dates is superseded.
Please note that all data/figures/information represent current data at the time of going to
press. These details are not legally binding for the purposes of dimensioning, computation,
or calculation.
Baumüller Nürnberg GmbH reserves the right to change the technical data and the method
of operation of Baumüller products in the context of the further development of the products.
No liability can be accepted concerning the correctness of this documentation unless
otherwise specified in the General Conditions of Sale and Delivery.
BAUMÜLLER NÜRNBERG GmbH
Motors division
90482 Nürnberg, Germany
www. baumueller.de

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Table of contents
1General safety instructions............................................................................4
1.1Safety...........................................................................................................................................4
1.2Designated purpose.....................................................................................................................5
1.3Prohibition of unauthorized modifications and changes..............................................................6
2Operating conditions ......................................................................................6
2.1Product description......................................................................................................................6
2.2Items supplied..............................................................................................................................6
2.3Nameplate ...................................................................................................................................7
2.4Technical data .............................................................................................................................8
2.5Transport, intermediate storage ..................................................................................................9
2.6Installation conditions, cooling details .......................................................................................10
2.7Balancing, output elements, vibration........................................................................................11
3Mounting........................................................................................................13
3.1Safety instructions .....................................................................................................................13
3.2Installation, fixing .......................................................................................................................13
4Electrical connections ..................................................................................14
5Commissioning, operation...........................................................................15
5.1Safety instructions .....................................................................................................................15
5.2Checks prior to commissioning..................................................................................................16
5.3Commissioning, operation .........................................................................................................16
5.4Malfunctions in operation...........................................................................................................17
6Inspection and maintenance........................................................................18
6.1Inspection ..................................................................................................................................18
6.2Maintenance ..............................................................................................................................19
7Disposal .........................................................................................................19
8Annex 1: pole assignment (main connection and control port) ...............20
8.1Main connection via plug ...........................................................................................................20
8.2Main connection via the terminal box (Standard design acc. to catalogue)..............................20
8.3Main connection via the terminal box (customer specific design acc. to EN 60034; non UL-
approved)...................................................................................................................................21
8.4Main and control connection via combination-mounting-box (customer specific design) .........22
8.5Fan connection ..........................................................................................................................23
8.6Control port: Resolver................................................................................................................23
8.7Control port: SRS / SRM 50 ......................................................................................................24
8.8Control port: SEK / SEL 52........................................................................................................24
8.9Control port: ECN 1313 / EQN 1325 .........................................................................................25
8.10Control port: ECN 1325 / EQN 1337 (M23) (encoder with EnDat 2.2-port from Heidenhain
companies) ................................................................................................................................25
9Appendix 2: water-cooled machines ...........................................................26
9.1Definitions of power ratings for water-cooled machines............................................................26
9.2Motorcooling ..............................................................................................................................26
9.3Instructions for installation .........................................................................................................27
9.4Electrical connections................................................................................................................27
9.5Specifications for required coolant volume flows ......................................................................27
9.6Coolant consistency...................................................................................................................28
9.7Min. coolant temperature against ambient temperature and humidity ......................................28
9.8Malfunctions in operation...........................................................................................................30
9.9Inspection ..................................................................................................................................30

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1 General safety instructions
1.1 Safety
This electric motor has been constructed in accordance with the relevant safety standards and
underwent an operational safety check before leaving our factory.
To ensure correct commissioning and safe utilization, please read the following:
• These Commissioning and Maintenance Instructions and if applicable the enclosed
supplementary parts
• The enclosed safety and commissioning notes
• The technical documentation that accompanies the product
• The commissioning and safety notes provided by the manufacturer of the converter
• The national, local, and system-specific regulations concerning your finished product
• The technical instruction of TAM 00697 during the use in safety relevant applications
We draw your attention to the following hazards when using the product:
Hazards resulting from • Lifting and transport
• Electrical power
• Moving parts
• Hot surfaces
• EMC interference
• Mechanical overload
• Thermal overload
To avoid damage to persons and property and to minimize residual risks, please read all of the
safety instructions and, in particular, those that are marked with a symbol.
Risk of fatality due to electric shock
Failure to observe can lead to fatal or serious injuries.
Warning about general dangers
Failure to observe can lead to serious injury or damage to property.
Warning about a dangerous situation
Failure to observe can lead to damage to the system or peripheral equipment.
Touching prohibited
Failure to observe can lead to serious injury.
Improper handling prohibited
Failure to observe can lead to serious injury
Warning about a hot surface
Failure to observe can lead to serious injury
Electrostatically sensitive components
Failure to observe can lead to damage to the system or peripheral equipment.

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1.2 Designated purpose
The electric motor must only be used for its designated purpose. In this context, the electric motor
must only be used for the applications described in the technical documentation under strict
observance of all the notes in these Commissioning and Maintenance Instructions.
All assembly, commissioning, maintenance, and operating tasks must be carried out by qualified
personnel only.
Within the context of these safety instructions, qualified personnel refers to persons who are
trained and authorized in the specialized area, who are authorized to set up, assemble,
commission, and operate units, systems, and circuits under application of the applicable safety
standards (EN 50110-1).
Inappropriate conduct can result in serious injury and damage to property.
The electric motor is designed for use in industrial applications and is subject to a number of
standards and directives, including the following:
Standards
EN 60034-1, EN 60034-5, EN 60034-6, EN 60034-7, EN 60034-9, EN 60034-11, EN 60034-14
EN 60204-1
Voltage Directive EC
The electric motors in this series fully comply with the requirements of the Low Voltage Directive
EC (conformity).
EMC Directive EC
The operation of the electric motor in accordance with its designated use must comply with the
safety requirements in the EMC Directive EC. The proper installation (e. g. separation of signal
lines and power cables, screened lines and cables etc.) is the responsibility of the erector of the
installation and the system provider. During converter operation the EMC information of the
converter-, encoder- and brake-manufacturer must be observed.
All national, local, and system-specific regulations must also be observed!
The electric motor is designed for the following ambient conditions:
• Ambient temperature: 0 °C to +40 °C
• Altitude: ≤1000 m above sea level
• Relative humidity: 5 % to 85 %
Please take note of any deviating details specified on the nameplate or in the technical
documentation. The conditions at the place of utilization must correspond to the details on the
rating plate.
Utilization in areas with potentially explosive atmospheres is prohibited unless the
unit is expressly designed for this purpose (refer to additional notes). Furthermore, the
area surrounding the electric motor must be free of inflammable gas mixtures and
hazardous concentrations of dust.
Live and hot motor parts are inflammable and may cause serious injury and damage
to property.
If, in special cases (for utilization in non-industrial applications), more stringent
requirements are in place, e. g., protection against contact with a child's fingers, these
conditions must be met by the customer when installing the system.

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Motor design with rare-earth magnets:
Please be aware of the following risks in the vicinity of a retracted or exposed rotor with
a strong magnetic field:
•People with electronic or metallic implants (e. g. cardiac pacemakers, hearing aids,
plates or pins) are at risk, if the distance between the implant and the magnetic
pole is less than 0.5 m.
•Due to the strong attraction forces exerted on ferromagnetic parts there is a risk of:
oCrushinginjuries
oDamage to measuring and assembly tools, credit cards, watches etc.
oContamination of the rotor assembly due to attracting metal debris or powder.
Thermal hazard:
Caution, risk of burns!
The surface temperatures on the motors may 70° C. If necessary, fit guards!
Temperature-sensitive parts, e.g., normal cables or electronic components, must not be
placed on or fixed to the hot surfaces.
Thermal overloading can destroy the winding and the bearing and lead to the
demagnetization of the rare-earth magnets. A thermal sensor should be used to monitor
the temperature.
1.3 Prohibition of unauthorized modifications and changes
For safety reasons, unauthorized modifications and changes to the electric motor are
not permitted. If such modifications/changes are necessary, please contact the motor
manufacturer.
No safety devices may be dismantled or decommissioned when operating the electric
motor.
2 Operating conditions
2.1 Product description
With its new DSC 45-100 series, Baumüller is making the torque motor servo-ready.
In developing this series, the focus was on improving ratings in order to achieve a higher torque
density while also drastically reducing the volume of the unit. The typical servo speed range of up
to 4,000 rpm is, however, still covered. The new DSCs are up to 30 % more compact than
conventional servo motors.
The motors of the DSC 45-100 series feature a smooth housing surface to protect against soiling.
These motors are particularly easy to mount and offer a high protection type.
2.2 Items supplied
The delivery is put together on an order-specific basis.
• The carrier must be notified immediately of any damage caused during transport.
• On delivery, please check that the ratings and type of the motor supplied correspond with the
order data. In the event of apparent defects or incomplete delivery, the appropriate Baumüller
office or the Baumüller head office in Nuremberg should be notified immediately.
In both of the above cases, commissioning must not take place until the error has been rectified by
a specialist.

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2.3 Nameplate
The nameplate is used to identify each electric motor. The unique motor number is clearly shown
on each nameplate and is essential for internal tracking procedures. It must be possible to read the
nameplate at all times. Never remove the nameplate from your motor.
Figure 1: Nameplate
1 →Motor number
2 →Standards and approbation
3 →Motor type / designation
4 →Motor protection class
5 →Heat category (class of insulation
VDE)
6 →Motor is powered with converter
7 →(optional) Supply voltage of the
brakes DC
8 →Motor type: 3-phase motor
9 →Permitted ambient temperature
10 →Rated frequency
11 →Isolation system UL
12 →Motor operating type
13 →Rated voltage UN
14 →Standstill torque Mo
15 →Standstill current lo
16 →Rated speed nN
17 →Rated output PN
18 →Article number
19 →Kind of balancing (only for motor
size 45 and 56)

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2.4 Technical data
Built class (EN 60034-7) IM B5 installation position horizontal
IM V1 installation position vertical, shaft end
downwards
IM V3 installation position vertical, shaft end
upwards
Note: On installation positions IM V3 in connection with protective class IP 64, the shaft
gland must be protected against ingress of water and dirt.
Safety class (EN 60034-5) with consideration of the shaft gland
IP 64 Standard: without shaft seal ring
IP 65 Option: with shaft seal ring
without the consideration of the shaft gland
IP 67 for self-cooling versions (IC 410 and
IC3W7); not for motors with terminal box
IP 65 for surface cooled versions (IC 416)
IP 65 for model with terminal box
Caution: The listed safety classes are only met when the plug connection is completely
installed (main and control connection) and fully closed terminal box.
Cooling process (EN 60034-6) IC 410 Standard:
completely enclosed motor design self-cooling
without fan
IC 416 Option: from shaft height 56
completely enclosed motor
surface cooled with fan
air flow direction from NDE to DE
IC 3W7 Option from shaft height 71
completely enclosed motor
water cooled
Cooling circuit connections towards NDE
(non-drive end)
Electrical connections (refer to annex1) via angled (3 x 90°) rotating built-in boxes
Caution:In the event of idling currents I0> 36 A the mains connection is via terminal boxes
Main connection 8-pole standard: U V W + temperature sensor
Option: brake
Control connection 12-pole standard: Resolver
12 / 17-pole Option: absolute encoder
Option: Encoder + thermal sensor
12-pole Option: Hiperface-port
17-pole Option: Endat 2.1
9-pole Option: Endat 2.2
fan (optional) 6-pole
Thermal motor protection (EN 60034-11) temperature sensor KTY84 in the stator winding
Winding insulation (EN 60034-1) Heat category F (Δθ = 105 K)
Ambient temperature 0 °C... +40 °C (standard)
Altitude of site (EN 60034-1) ≤1.000 m above sea level (standard)

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Rolling-contact bearings with long-term
grease lubrication: Standard: Ball bearing
Option (from shaft height 56): Roller bearing (DE-side)
Calculated bearing use duration 20.000 h (guide value)
Strength of vibration (EN 60034-14) standard: level A
on request: level B (only for ball bearings)
True running (DIN 42955) Standard: N
on request: R (reduced)
Shake proof (EN 60068-2-6) radial: 3 g (10 Hz to 100 Hz)
axial: 0.5 g (10 Hz to 100 Hz)
Holding brake Option
Rotation speed list value indicator Standard: 2-pole resolver
(high-quality version upon request)
Option: absolute encoder with Hiperface-port
Option: absolute encoder with EnDat-port
For further technical data, refer to our technical product list online at: www.baumueller.com under
Download and Technical documentation. If necessary, you can request the corresponding
documentation.
Attention!
If the electric motor supplied is not a standard type as per the technical list or if special contractual
arrangements have been made, there may technical differences to the information contained in these
Commissioning and Maintenance Instructions. In this case, request the relevant technical
supplements.
2.5 Transport, intermediate storage
Water-cooled motors:
To avoid frost damage it must be ensured that there is no coolant in the motor during
the transport or intermediate storage at ambient temperatures < 3 °C.
Transport:
The permitted environmental conditions which affect the motor during the transport
must be taken from DIN EN 60721-3-2 (class 2K2/2M1). Contrary to the DIN, a
reduced temperature range of – 15 °C to + 60 °C is permitted.
Suitable load suspension material must be used, e. g. belt webbing, loop belts, etc. If
provided, the lifting lugs on the motor can be used for lifting.
The terminal boxes and motor connectors must not be used for securing the motor for
transport or as lifting eyes.
The regulations of the respective countries must be adhered to during transport. Lifting
devices and transport and lifting tackle must comply with the relevant regulations.

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For information on weight of the single motors, please refer to the technical documentation that
accompanies the product.
The motor shaft and the connection surfaces must be protected against corrosion. The motor may
only be transported with a shaft protection cover; damage to the motor shaft must be avoided.
Bearing safety (applies only for motors with cylinder roller bearings)
On motors with cylinder roller bearings, the runner must be blocked at the end of the
shaft in order to prevent damage during transit.
The transport safety must be reused for further transports.
If this lock can no longer be used due to mounting of a drive element, other suitable
means must be employed for axial fixing of the rotor for transport
Intermediate storage:
If a motor is not to be commissioned immediately after delivery, it should be stored inside a building
in a dry, dust-free, and low-vibration room (Vrms ≤0.2 mm/s).
The electric motors should be stored at as uniform a temperature as possible, not outside of the
temperature range -15 to +60 °C, for no more than two years. Elevated storage temperatures
within the framework of the working temperature accelerate the rate at which seals and bearing
grease deteriorate and therefore have a negative impact on the service life even before the unit
has been commissioned. Direct exposure to incident solar radiation, UV light and ozone also lead
to an ageing of the gaskets and must be avoided!
Please note that the warranty periods commence from the date of delivery. For this reason, we
recommend that storage periods be kept to a minimum.
Should nevertheless a longer storage be necessary, the environmental conditions acc. to DIN
EN 60721-3-1 (class 1K2/1M1) have to be observed. Contrary to the DIN, an expanded
temperature range of – 15 °C to + 60 °C is permitted.
2.6 Installation conditions, cooling details
For motors with water-cooling please take Section 9 into account in addition.
Surroundings:
The motor can be installed in roofed rooms in dusty or damp environment and under normal
climatic conditions.
Unless alternative arrangements have been made, the motor is designed by default for the
following climatic conditions:
•Ambient temperature 0 °C to 40 °C
•Installation height ≤1000 m above sea level
•Relative humidity 5 % to 85 %
All other allowed application conditions have to correspond to DIN EN 60721-3-3 (class 3K3/3Z12).
It is absolutely imperative to comply with these climatic conditions when installing the unit.
Aggressive, corrosive, abrasive and plastic-dissolving solutions should be kept well away from the
motor and the air that is used to cool it.
Consultation with the motor manufacturer is essential in the case of installation outdoors.

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Air cooling:
Please also see Section 2.4 and the technical documentation that accompanies the product.
Cooling method IC 410 – Self-cooling without a fan.
Cooling method IC 416 – Surface cooling with a fan.
The following must be observed:
•The installation conditions must not impair thermal convection and radiation.
•The cooling air used for forced ventilation must be able to flow in freely and the hot air must be
able to flow out freely. The hot exhaust air must not be sucked back in.
•A clearance of at least 100 mm must be observed in relation to neighboring machine parts.
•If installed in very dirty locations, the housing surface and airways must be cleaned regularly.
flange connection:
By connecting the motor to the mounting surface, a part of the motor loss performance is lead
away via the flange.
The dimensions of the mounting surface based on their axis height are listed in the following table
1. This information provides minimum values for the safe heat dissipation via the motor flange
surfaces.
Axis height Steel plate, width x height x thickness in mm Mounting surface in m
2
45 250 x 250 x 10 0.06
56 – 100 450 x 400 x 30 0.18
Table 1: Mounting surfaces
The heat dissipation conditions approve on larger mounting surfaces. An insulated mounting of the
motors is not permitted.
2.7 Balancing, output elements, vibration
Do not subject the shaft or bearings to impacts.
On mounting and dismounting output elements, it is not permitted for any axial forces
to be applied to the motor.
The generally applicable measures for the protection of output elements against
physical contact are to be followed.
If a motor without output elements is commissioned, measures must be put in place to
ensure the key is not flung out.
Balancing
On an ideal design with fitted key, the runners are dynamically balanced with half fitted keys.
(acc. to EN 60034-14 / ISO 8821 / ISO 1940)
NOTE: Observe the type of balancing as identified on the shaft end face and on the
nameplate:
H = Balancing with half key (standard design)
F = Balancing with full key (special design)
N = Balancing without key (special design)

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Output elements:
On mounting the output element, pay attention to the related type of balancing. The output
elements must themselves be balanced in accordance with ISO 1940.
Suitable jigs are always to be used for fitting or removing output elements (e.g., clutch disk,
gear, pulley).
• Use the threaded hole in the end of the shaft.
• When pulling, use intermediate washers to provide the shaft with mechanical protection.
• When hoisting heat up the drive elements if required (max. permissible temperature at shaft
end 150°C).
Attention!
• On shaft versions without a key, the output elements are to be fastened to the output shaft
with the aid of suitable clamping sets.
• On shaft versions with a key, it must be ensured that the output elements rest on the shaft
shoulder. Note: The chamfer or radius on the output element and the shaft radius on the
shoulder must be matched.
• Is the tapped hole in the end of the shaft used for axial securing of output elements (e. g. belt
pulley), the maximum tightening torque acc. to following table 2 must not be exceeded.
thread tightening torque
in Nm
M5 2,2
M8 10,0
M10 19,0
M12 33,0
Table 2: Tightening torque for safety screw S of a belt pulley
appropriate measures for securing screw must be applied
Vibration:
The site vibration response of the system, which is determined by the output elements,
the mounting conditions, the alignment, the installation, and the effects of external
vibrations, may cause the vibration values at the motor to increase.
In the interest of reliable motor operation and a long bearing service life, the permitted
vibration values in accordance with EN 60034-14 should not be exceeded. Under
certain circumstances, the rotor may need to be fully balanced with the output element
(in accordance with ISO 1940).
The vibration value after assembly must not exceed the permitted rates of acceleration
(see Sect. 2.4 Technical data).
In case of deviations from the normal operation - e. g. increased temperatures, noise,
vibration - disable the motor. Identify the cause and, if necessary, contact the
manufacturer.
S

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3 Mounting
3.1 Safety instructions
Before mounting:
Never mount or commission a damaged electric motor.
Never install the electric motor in a damaged machine.
Before mounting the electric motor, make sure it is suitable for your machine.
During mounting:
Only mount the motor using the fastening features provided.
The motor should not be exposed to knocks, e. g., with a hammer, or shocks when
mounting.
Make sure that all covers and safety devices are mounted. All safety devices must
comply with the latest regulations (e g. EN 60204).
Air cooling:
Protective guards have to be fitted to the air inlets and outlets, if there is a risk of foreign
bodies falling into the fan during operation.
3.2 Installation, fixing
Prior to and during mounting, check that
• The motor is not damaged (e. g., the shaft sealing ring must not have sustained any damage
at all from sharp or pointed objects).
• The motor is not mounted in the danger zone of other equipment.
• The motor is used for the designated purpose (see Sect. 1.2, Sect. 2.4).
(Observe nameplate details, warning labels, and signs.)
• Anti-corrosion agents have been fully removed from the shaft ends.
If a common solvent such as acetone or a cleaning solvent is used, it must not be allowed to
wet the shaft sealing ring.
• The motor is designed for the ambient conditions and environmental influences on site (see
Sect 2.4).
• The compartment in the machine is suitable for the cooling method employed for the electric
motor.
The motor is to be installed in such a way that heat can be adequately dissipated via the
housing surface and via the motor flange surface (refer to Sect. 2.6)
• The motor can be mounted and operated with the fastening features and connection data
provided.
The mounting dimensions of the motor and the tolerance details are provided in the technical
documentation that accompanies the product. When mounting the flanges on the motor, make
sure that the flange surface rests well and evenly. The supports and bearing surfaces must be
clean and undamaged. They must be precisely aligned with the connecting shafts to prevent
the bearings, shafts, and housing being exposed to damaging loads through misalignment
throughout the entire system. When tightening the flange fixing screws (min. property class
8.8), make sure that the flange connection is not distorted.
• No liquid can penetrate the upper bearing when installing vertically with the shaft end facing
upwards.
• The permitted radial forces according to the operating characteristics in the technical
documentation that accompanies the product are not exceeded (if necessary, contact
Baumüller for clarification).
The motor manufacturer must always be contacted if axial forces occur.
• The brake (optional) can be ventilated after the operational voltage has been applied (audible
operating noise).

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• The rotor rotates smoothly without a scraping sound.
On motors with a brake fitted, release the brake beforehand.
• the design of the motor and encoder cables – and of the fan cable (if available), complies with
the details in the technical documentation that accompanies the product.
• The output and input elements are secured.
• the complete cooling circuit is leak proof and fully functional and protected against any foreign
objects falling into it.
4 Electrical connections
Important notes:
All work must be carried out by specially trained personnel.
Work must only be carried out when the system has been de-energized and secured
against unintentional restarting (including auxiliary circuits).
Work must only be carried out once the motor has come to a standstill.
In the case of three-phase synchronous motors with permanent-magnet excitation, a
voltage of > 60 V can occur at the motor contacts when the rotor is turning.
Regulations for working in electrical plants must be observed!
Attention! The safety regulations for work in electrotechnical systems must be observed
according to EN 50110-1:
• Isolate
• Secure against unintentional restarting
• Verify safe isolation from the supply
• Earth and short
• Safeguard or cover adjacent live parts
The electric motor must be operated via a correspondingly designed converter. A
direct connection to the three-phase mains can destroy the motor.
Ensure that the phase sequence and the pin assignment are correct!
Electrical connections, protective conductor connections, and screen connections
(when using screened cables) must be permanently secure!
Never touch the contacts of the encoder or thermal sensors with your hands or with
tools that are electrostatically charged. The encoder and the thermal sensors are
electrostatically sensitive components.
Electrical installation:
• The person setting up the system is responsible for correct electrical installation.
• The motor data on the nameplate must be observed.
• Connection cables and connectors must be correctly rated for the voltages and currents and
must be suitable for the method of installation employed.
• The motor and its modules (brake, encoder, fan, etc.) must be connected in accordance with
the details in the wiring diagrams (see enclosed wiring diagrams and Section 8).
• Screened power and encoder cables must be used to protect against electromagnetic EMC
interference from motor cables and their effects on the encoder and control systems. Please
refer to the EMC notes provided by the supplier of the converter.
• In the interest of ensuring operational safety, we recommend that you use connecting cables
assembled by Baumüller (see Technical Product List).
• Before connection, the plugs, sockets and the terminal boxes must be checked for damage,
corrosion, dirt and dampness.

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• In order to ensure the appropriate type of protection is provided, make sure that the screwed
connections, gaskets, and sealing surfaces of the connectors are seated correctly and are
tight.
Note! Also, to maintain the safety class, the rotating connecting boxes should not be modified
by more than 5 times in the connecting direction by turning.
• Connectors must not be exposed to mechanical stress. If necessary, provide strain, shearing,
twist, and anti-kink relief
In case of connection using a terminal box it is to be ensured
•the insulation is not over stripped, i. e. that the insulation extends right up to the cable lugs or
terminals. The ends of the cables must not protrude.
• the cable lugs that are used are suitable for the dimensions and cross-sections of the
terminals and cables.
• the screwed electrical connections are tightened in accordance with the specified tightening
torque (comp. Section 8.3 table 5).
• the protection type is maintained.
Note: All lead-ins that are not used must be closed off with the sealing caps. The sealing
elements must be fully functional and undamaged when closing the terminal box.
5 Commissioning, operation
5.1 Safety instructions
Working on the electric motor:
Work must not be carried out on the electric motor until the motor has come to a
standstill, is electrically isolated, and has cooled down. All connections, such as screw
connections, that were loosened when working on the motor must be tightened again
prior to commissioning.
When carrying out work on the motor, please observe the technical instructions and
notes in the respective sections in these Commissioning and Maintenance
Instructions.
Attention: if the optional holding brake is fitted, this brake must not perform a safety
function during work on the motor (e. g., retaining loads)!
Risk of fatality due to electric shock:
Make sure that the motor is disconnected and electrically isolated.
Never disconnect the motor connections during operation.
Only connect measuring instruments when the motor is disconnected from the power
supply and electrically isolated.
Only commence work on the motor connections when you are sure the motor is
electrically isolated and there is no potential.
When in operation, electric potential can be found at the motor contacts and at the
motor windings. Never touch these modules/elements while the motor is in operation.
Installing and uninstalling safety devices:
The electric motor must not be operated without installed safety devices.
The motor must be put out of operation when installing and dismantling components
and systems which are provided for monitoring the motor for safe operation

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Danger on physical contact:
Make sure that the electric motor has come to a standstill and is secured against
unintentional restarting before you touch it.
Only touch the output shaft when it is electrically isolated and the motor has come to a
standstill. Otherwise there is a risk due to the rotating rotor.
Danger of burns! Never touch the motor housing when the motor is running at rated
load. The surface temperatures on the motors may exceed 70 °C
5.2 Checks prior to commissioning
• The drive is undamaged and is not located within the danger zone of other equipment.
• The motor is correctly aligned and fastened. All screwed connections are correctly tightened.
• All the appropriate safety devices (mechanical, thermal, and electrical) are mounted.
• The motor connections have been made correctly.
• The cables are not in contact with the surface of the motor.
• The protective conductor system is correct and its functionality has been checked.
• The drive is not blocked (release brake, if present).
• Emergency stop functions have been checked.
• Fan is connected properly and its function has been checked.
5.3 Commissioning, operation
Note on brake function (if present):
The brake is designed as a holding brake with an emergency stop function.
(power failure, emergency stop)
It must not be used as a working brake.
Commissioning must be carried out exclusively by qualified personnel.
Please refer to the commissioning instructions for the converter.
Checks during commissioning:
• Release the brake, if necessary.
• Has the functionality of all motor modules such as the brake, encoder, fan, etc., been checked
and are the conditions of use met?
• Have all electrical connections been made correctly and tightened (observe wiring diagrams,
see Section 8 and respectively the enclosed wiring diagrams)?
• Have all protection measures that eliminate the possibility of contact with live parts, hot
surfaces, and rotating and moving parts and modules been observed and are these measures
fully functional?
• Have all output elements been mounted and adjusted in accordance with the manufacturer's
instructions?
• Are measures in place to ensure that the maximum permitted speed nmax of the motor cannot
be exceeded? The maximum permitted speed nmax is the highest permitted operating speed
for short-time duty.
Checks during operation:
• Listen out for unusual noises.
• If scraping, scratching, grinding, or other similar noises occur, stop the drive immediately and
locate the cause.

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• Check the motor surface and connection cables for dirt, e. g., layers of dust, oil deposits,
dampness, etc.
• Check the maintenance intervals.
• Check air inlet and outlet ports for fouling.
5.4 Malfunctions in operation
Safety instructions:
Troubleshooting and rectification must only be performed by qualified personnel.
Do not disconnect any of the safety devices – even during test runs.
Only disconnect and connect connection cables when they are electrically isolated and
secured.
Observe the 5 safety rules for "Isolation" (see Sect. 4).
Beware of hot surfaces!
In case of malfunctions in operation always
• Refer to the operating instructions for the machine/system.
• Refer to the operating instructions for the converter.
• If necessary, contact the manufacturer of the motor or converter.
Have the following information ready:
• nameplate data
• type and scope of malfunction
• circumstances leading up to the malfuntion
• application data (torque cycle, speed and forces over time; ambient conditions)
The following selection of possible causes can be helpful in the fault rectification process:
Malfunction Cause Remedy
Motor does not start No controller enable
Controller fault, encoder fault
Brake does not release
Faulty brake
No power supply
Rotating field
Activate controller enable
Read out fault list at converter
or controller; rectify fault
Check control, connections,
and power supply
Repairs carried out by
manufacturer
Check connections and power
supply
Check phase sequence. If
necessary, replace the
connection cables
Uneven running Insufficient screening on
connecting cables
Controller parameters too high
Check screening connection
and grounding
Optimize controller
parameters

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Malfunction Cause Remedy
Vibrations Coupling element or driven
machine poorly balanced
Inadequate alignment of the
drive train
Fixing screws loose
Rebalance
Realign machine set
Check and tighten screwed
connections
Running noises Foreign matter in motor
Damaged bearing
Repairs carried out by motor
manufacturer
Repairs carried out by motor
manufacturer
Temperature rise in the motor
Motor temperature monitoring
unit trips
Drive overload
Motor surface/air ducts soiled
Cramped installation
conditions
Brake does not release
sufficiently: grinding brake
Check motor load and
compare with nameplate
Clean motor surface/air ducts
Check motor has been
mounted in accordance with
Sect. 2.6 and 3
Repairs carried out by motor
manufacturer
Current consumption too high,
motor torque too low
Indexing angle incorrect Check indexing angle and
adjust if necessary
Table 3: Malfunctions
6 Inspection and maintenance
Working on the electric motor:
Work must not be carried out on the electric motor until the motor has come to a
standstill, is electrically isolated, and has cooled down. All connections, such as screw
connections, that were loosened when working on the motor must be tightened again
after the inspection and maintenance work.
When carrying out work on the motor, please observe the technical instructions and
notes in the respective sections in these Commissioning and Maintenance
Instructions.
When carrying out maintenance work, observe all safety instructions which also apply
to the commissioning of the motor (see Sect. 5.1).
Attention: if the optional holding brake is fitted, this brake must not perform a safety
function during work on the motor (e. g. retaining loads)!
6.1 Inspection
Depending on the severity of soiling on site, cleaning will have to be carried out regularly to
guarantee the continuous adequate dissipation of heat.
If an optional brake is fitted, wear limits are specified (e. g., maximum permissible operating air
gap, maximum number of emergency braking operations). The actual degree of wear on the brake
must be checked at regular intervals. If the permissible wear limits are reached, the brake must be
replaced (see Sect. 6.2).
If an optional shaft sealing ring is used, it must be checked at regular intervals to ensure it is
functioning correctly (leakage).

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6.2 Maintenance
The service life of the bearings and sealing elements can differ greatly depending on the operating
conditions (e.g., operating mode, temperature, speed, and load).
In the case of trouble-free operation, we generally recommend the following maintenance
procedures:
• Replacement of the bearings after 20.000 running hours (the bearings are designed for a
calculated service life of 20.000 running hours)
• Replacement of the shaft sealing ring after approximately 5.000 running hours, if present and
if no leaks have been detected during previous inspections
If an optional brake is fitted, it is essential that it is replaced when its wear limits are reached.
Maintenance work must be carried out by Baumüller or a specialist company commissioned by
Baumüller.
Caution!
It is imperative, on motors that are used for safety related applications, to heed the technical
instructions of TAM 00697 during service and maintenance work.
7 Disposal
The motor must be disposed of in accordance with the relevant national and local regulations within
the framework of the normal recycling process.
The encoder electronics (if provided) must be disposed of in the proper manner as electronic scrap.

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8 Annex 1: pole assignment (main connection and control port)
8.1 Main connection via plug
The standstill current I0 of the motor determines the connector size of the built-in box.
Size 1: I0to 20 A; Size 1.5: I0to 36 A
Figure 2: Main connection with thermal sensor and brake
Note: If the thermal sensor is routed via the encoder channel, signals K+ and K- are
omitted from the wiring diagrams above.
8.2 Main connection via the terminal box (Standard design acc. to catalogue)
Use during standstill current I0 > 36 A.
Figure 3: pole assignment with thermal sensor and brake
Table 4 shows the cable leads of the terminal boxes and the main connector pin assignment
together with the permissible torque specification.
On the connections for the cable leads we recommend the use of EMC connectors.