Baumuller DSC Series Guide

TAM 00682 1
DSC 045-100 07 / 2012
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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Three-phase synchronous motor English
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dates is superseded.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.