Baumuller DST2 Series Installation instructions

TAM 00695 1
DST2-135 –400 W 10 / 2019
Three-phase synchronous motor, water-cooled English
TAM 00695
DST2-135 –400 W
Three-phase synchronous motor
Water-cooled
Version: 10 / 2019
English
Operating instructions including
the safety instructions

TAM 00695 2
DST2-135 –400 W 10 / 2019
Three-phase synchronous motor, water-cooled English
LEGAL NOTES ON DOCUMENTATION
Copyright
This documentation is only permitted to be copied by the owner for internal use. As many
copies as required may be made. For other purposes, this documentation may not be copied
or duplicated either in whole or in part. Utilisation and provision of the contents to third
parties is not allowed. Names and company logos in this documentation may be trademarks,
which, if used by third parties for their own purposes, may result in infringements of 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.
On the sale/storage of the unit/machine, this documentation must be passed on together
with the unit/machine by the owner. 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 utilisation, this original and all copies are to be destroyed.
With the introduction of this documentation, earlier issues of are superseded.
Please note that the details/figures/information represent current values at the time of
going to press. These details are not legally binding for the purpose dimensioning,
computation and 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 the product information unless
otherwise specified in the General Conditions of Sale and Delivery.
BAUMÜLLER NÜRNBERG GmbH
Motor Division
D-90482 Nürnberg
www.baumueller.com

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DST2-135 –400 W 10 / 2019
Three-phase synchronous motor, water-cooled English
Table of contents
1General Safety Instructions..........................................................................................4
1.1 Safety........................................................................................................................................ 4
1.2 Designated use ......................................................................................................................... 5
1.3 Prohibition of unauthorised modifications and changes ........................................................... 6
2Operating conditions ....................................................................................................6
2.1 Product description ................................................................................................................... 6
2.2 Items supplied........................................................................................................................... 7
2.3 Nameplate................................................................................................................................. 7
2.4 Technical Data .......................................................................................................................... 8
2.5 Transport, intermediate storage................................................................................................ 8
2.6 Installation conditions, cooling details....................................................................................... 9
2.7 Balancing, drive elements and vibration................................................................................. 10
3Mounting......................................................................................................................11
3.1 Safety instructions................................................................................................................... 11
3.2 Installation, fixing..................................................................................................................... 11
3.3 Vibrations and resistance to vibrations................................................................................... 12
3.4 Electrical connections ............................................................................................................. 14
4Commissioning, operation .........................................................................................15
4.1 Safety instructions................................................................................................................... 15
4.2 Checks prior to commissioning............................................................................................... 16
4.3 Commissioning, operation....................................................................................................... 16
4.4 Malfunctions............................................................................................................................ 17
5Inspection and maintenance ......................................................................................18
5.1 Inspection................................................................................................................................ 18
5.2 Maintenance............................................................................................................................ 19
5.3 Re-lubrication (optional).......................................................................................................... 20
6Disposal.......................................................................................................................20
7Appendix 1: pole assignment (main connection and control port) .........................21
7.1 n connection with terminal box................................................................................................ 21
7.2 Control port : Resolver:........................................................................................................... 23
7.3 Control port : SRS / SRM 50................................................................................................... 23
7.4 Control port: ECN 1313 / EQN 1325....................................................................................... 24
8Appendix 2: water-cooled machines..........................................................................25
8.1 Definitions of power ratings for water-cooled machines......................................................... 25
8.2 Motorcooling............................................................................................................................ 25
8.3 Instructions for installation....................................................................................................... 25
8.4 Electrical connections ............................................................................................................. 26
8.5 Specifications for required coolant volume flows.................................................................... 26
8.6 Coolant consistency................................................................................................................ 26
8.7 Min. coolant temperature against ambient temperature and humidity.................................... 27
8.8 Inspection................................................................................................................................ 28
9Appendix 3: information concerning thrust-bearing motors and oil-features........29
9.1 Information on permissible axial forces on thrust-bearing motors.......................................... 29
9.2 Specifications for oil quantities................................................................................................ 29
9.3 Specifications for oil service life.............................................................................................. 29

TAM 00695 4
DST2-135 –400 W 10 / 2019
Three-phase synchronous motor, water-cooled English
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 utilisation, 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 for use in safety-oriented applications
We draw your attention to the following hazards when using the product:
Hazards resulting from • lifting and transport processes
• electrical current
• moving parts
• hot surfaces
• EMC disturbances
• mechanical overloads
• thermal overload
To avoid damages to persons and property and minimize residual risks, please read all of the
safety instructions and, in particular, those that are marked with a symbol.
Danger to life from electrical current
Non-observance can cause the death or severe injuries.
Warning about general dangers
Non-observance can cause severe injuries or material damage.
Warning about dangerous situation
Non-observance can damage the system and also the vicinity.
Do not touch!
Non-observance can cause severe injuries.
No Inadmissible actions!
Non-observance can cause severe injuries
Warning about hof surfaces
Non-observance can cause severe injuries
Magetic field warning.
Failure to observe can lead to severe injuries or damage to property.
Electrostatically sensitive components
Non-observance can damage the system or the vicinity

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DST2-135 –400 W 10 / 2019
Three-phase synchronous motor, water-cooled English
1.2 Designated use
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 this 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 devices, systems and circuits under application of the applicable safety
standards (in accordance with EN 50110-1).
Inappropriate action can cause serious damage to persons and property.
The electric motor is designed to be used for 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
EU Low Voltage Directive
The electric motors in this series fully comply with the requirements of the Low Voltage Directive
2014/35/EU (conformity).
EU Machinery Directive
Electric motors are components which are intended to be installed in machines as described in
the Machinery Directive. Commissioning is not permitted until such time as the conformity of
the finished product with this directive has been established (refer to EN 60204-1 "Electrical
Equipment of Machines").
EU EMC Directive
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 followed!
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 hazardous areas is prohibited, unless the unit is expressedly designed
for this purpose (refer to additional notes). Furthermore, the area surrounding the
electric motor must be free of inflammable gas mixtures and concentrations of dust.
Live and hot motor parts are inflammable and may cause serious injury and damage
to property.
If, in special cases, greater requirements are placed –for utilization in non-industrial
applications –(e.g. protection against contact with a child’s fingers), these conditions
must be by the customer met when installing the system.

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DST2-135 –400 W 10 / 2019
Three-phase synchronous motor, water-cooled English
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 hazards:
Caution! Highly inflammable!
Temperatures of over 70 °C can build up on the motor surfaces. Touch contact measures
should be implemented if necessary!
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. A thermal sensor should
be used to monitor the temperature.
1.3 Prohibition of unauthorised modifications and changes
For safety reasons, unauthorised modifications and changes to the electric motor are
not permitted. If such modifications / changes are necessary, please contact the
manufacturer.
No safety devices may be dismantled or decommissioned prior to the operation of the
device.
2 Operating conditions
2.1 Product description
Electric motors of the series “DST2…W” are permanently excited, high-pole, three-phase
synchronous motors with rare-earth magnets.
An innovative motor concept with integrated liquid cooling (water-based coolant) ensures a high
torque density at low and medium speeds and a robust and compact design.
The elimination of the fan unit significantly reduces noise emission and provides for a high level of
protection. In connection with the low-maintenance motor design, these motors are ideally suited
for direct drive applications with production machines (e.g. printing presses, extruders, injection
molding machines etc.).
Thrust-bearing motors: Thanks to the integration of an axial thrust bearing turning in oil, very high
return pressures, e.g. such as those that occur in extrusion, can be taken up by the motor shaft.
This makes the low-maintenance motors the best for use as a direct drive for production machines
(e.g. extruders etc.).
Moreover, when operating with a motor-controlled pulse converter, the speed and position of these
compact motors can be optimally controlled. These drives have a high overload capacity and are
therefore ideally suited for applications in mechanical engineering.

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DST2-135 –400 W 10 / 2019
Three-phase synchronous motor, water-cooled English
2.2 Items supplied
The delivery is put together on an order-related basis.
•The carrier must immediately be notified of any damage caused during transport.
•On delivery, please check that the ratings and motor type 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, commisioning must not take place until the error has been rectified by a
specialist.
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. The nameplate must be
legible at all times. Never remove the nameplate from your motor.
Figure 1: Nameplate
1 →
Motor type / designation
2 →
Rated current
3 →
Rated frequency
4 →
Power factor
5 →
2D Code
6 →
Motor number
7 →
Motor operating mode
8 →
Thermal class
9 →
Motor protection class
10 →
Balance quality
11 →
Article number
12 →
Rated voltage
13 →
Rated speed
14 →
Rated power
15 →
Standards and approvals

TAM 00695 8
DST2-135 –400 W 10 / 2019
Three-phase synchronous motor, water-cooled English
2.4 Technical Data
The technical data you can find in the technical product list DST2-135 - 400 W- or online at:
www.baumueller.com under Download and Technical documentation. If necessary, you can
request the corresponding documentation
Storage Class 1K2/1M1 according to DIN EN 60721-3-1:1995
Transport Class 2K2/2M1 according to DIN EN 60721-3-2:1995
Note:
To avoid frost damage, cooling water should be removed at ambient temperatures < 3 °C!
Bearing Rolling bearings with permanent grease lubrication
(optional: re-lubrication)
Thrust-bearing Axial spherical roller bearing with oil lubrication
Calculated bearing life Lh 10 = 20000 h (guideline value)
Caution!
If the electric motor supplied is not a standard type according to the technical list or if special
contractual arrangements have been made, there may be differences in the information
contained in these Commissioning and Maintenance Instructions. If this is so, 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 lifting tackle must be used, e. g. belt webbing and loop belts. If provided,
the lifting lugs of 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.
Series “DST2-..VA..” electric motors have the following weights in the overall length classes:
DST2-135
KO to YO
DST2-200
KO to XY
DST2-260
KO to XO
DST2-315
KO to ZA
DST2-400
KO to XY
approx.100 kg to
approx.185 kg
approx. 200 kg to
approx. 470 kg
approx. 370 kg to
approx. 860 kg
approx. 450 kg to
approx. 1,250 kg
approx. 2100 kg to
approx. 3600 kg
Table 1: Weights of DST2-.. VA-motors

TAM 00695 9
DST2-135 –400 W 10 / 2019
Three-phase synchronous motor, water-cooled English
“DST2-..DG..” with thrust bearings have the following weights in the overall length classes:
DST2-135
KO to YO
DST2-200
KO to XY
DST2-260
KO to XO
DST2-315
KO to ZA
DST2-400
KO to XY
approx.130 kg to
approx. 215 kg
approx. 280 kg to
approx. 550 kg
approx. 520 kg to
approx. 1050 kg
approx. 720 kg to
approx. 1500 kg
approx. 2200 kg to
approx. 3800 kg
Table 2: Weights of DST2-.. DG-motors
Please refer to your delivery documentation for the exact weight specifications.
Note on thrust-bearing motors:
The motor must only be transported horizontally and standing on its feet, or else the oil filler plug
with the air hole (see Appendix 3 –Fig. 8 on the bearing end plate, side A, must be replaced with
a solid screw plug (M20x1.5).
The motor shaft and the connection surfaces must be protected against corrosion. The motor must
only be transported with a shaft protection cover; damage to the motor shaft must be avoided.
Intermediate storage:
If a motor is not to be commissioned immediately after delivery, it should be stored inside a building
in am inside room which is dry, dust-free and free of significant vibration (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 guarantee periods start from the date of delivery. We therefore 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 8 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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DST2-135 –400 W 10 / 2019
Three-phase synchronous motor, water-cooled English
2.7 Balancing, drive elements and vibration
The shaft and bearing must not be exposed to knocks.
No axial forces are permitted when mounting or dismounting the output elements.
The generally required measures to prevent contact with the output elements must be
observed.
If the motor is commissioned without the output element, the featherkey must be
secured to ensure that it is not thrown out.
Balancing:
With the standard version, the rotors are dynamically balanced as per EN 60034-14
ISO 8821 / ISO 1940 using a half key; does not apply for thrust-bearing motors.
NOTE: Observe the type of balancing as identified on the shaft end face:
H = Balancing with half key Standard version
F = Balancing with full key Special version
Output elements:
When mounting the output element, note the appropriate 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.
•Warm up output elements if necessary before mounting (max. admissible transient
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 (in accordance with DIN 748) 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 3 must not be exceeded.
thread
tightening torque
in Nm
M5
2,2
M8
10,0
M10
19,0
M12
33,0
Table 3: Tightening torque for safety screw S of a belt pulley
appropriate measures for securing screw must be applied
S