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With the introduction of this documentation, earlier issues of are superseded.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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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

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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 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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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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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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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

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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

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“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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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

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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 limited vibration loads and accelerations after mounting are not to be exceeded
refer to chapter 3.3
In the event of deviations from normal operation –e.g. rise in temperature, noises,
vibration –disable the motor. Identify the cause and, if necessary, contact the
manufacturer.
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 that it is suitable for your machine.
During mounting:
Only mount the motor on the fixing possibilities 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).
Water cooling:
To avoid damaging the housing, only screwed sockets with a cylindrical thread may be
used for the water connections (inlet and outlet).
The coolant pipes should not exert compression-tension forces or torsional strain on
the motor connections.
The connection must be carried out by specially trained personnel. Here, the motor
must be disconnected and de-energized.
When coupling and uncoupling the coolant pipes, make sure that coolant does not
enter into the motor's terminal box.
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).
•oil is not leaking near the A-side thrust bearing.
•the motor is not mounted in the danger zone of other facilities.
•the motor is used for the designated purpose (See Sections 1.2 and 2.4).
observe nameplate details, warning labels and signs.
•anti-corrosive agents are fully removed from the shaft ends.

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When using standard solvents such as Acetone or benzine, the shaft sealing ring must not be
moistened!
•the motor is designed for the ambient conditions and environmental influences on site (see
Section 2.4).
•the compartment in the machine is suitable for the cooling method employed by the electric
motor (see Section 2.6).
The motor must be installed in such a way that the coolant lines can subsequently be
connected.
•there is enough room in the machine for connecting the motor and for inspection and
maintenance work.
For the installation dimensions of the motor and tolerance specifications, please refer to the
technical documentation or your provided dimensional drawing.
•the motor can be mounted and operated with the connection data and fixing possibilities
provided.
The mounting dimensions of the motor and the tolerance details are provided in the technical
documentation.
When mounting the flanges on the motor, make sure that the flange surface rests well and
evenly. The supports and bearing surface must be clean and undamaged. They must be
precisely aligned with the connecting shafts to prevent the bearing, shafts and housing being
exposed to damaging loads through misalignment. When tightening the flange fixing screws,
(min. property class 8.8) make sure that the flange connection is not twisted.
•no liquid can penetrate the upper bearing when installing vertically with the shaft end facing
upwards. Note: Thrust-bearing motors may only be operated horizontally.
•the permitted radial forces in accordance with the operating characteristics in the technical
documentation are not exceeded. If necessary, contact Baumüller. The motor manufacturer
must always be contacted in the case of axial forces.
•the brake (optional) can be released after feeding the operating voltage (audible creaking
sound).
•the rotor rotates smoothly without making a scraping sound.
If the motor is equipped with a brake, the brake should be released previously.
•the design of the motor and encoder cables complies with the details in the technical
documentation.
•the output and input elements are secured. With thrust-bearing and hollow-shaft motors,
sufficient contact protection on the open B-side shaft end during operation must be ensured.
•the complete cooling circuit is leak proof and fully functional and protected against any foreign
objects falling into it.
•
3.3 Vibrations and resistance to vibrations
The vibration response of the entire system at the place of use, caused by output elements, mounting
conditions, alignment and installation as well as by influences of external vibrations, can lead to an
increase in the vibration values at the motor. Under certain circumstances a complete c balancing of
the rotor with the output element becomes necessary.
In order to be able to guarantee perfect function and service life the specified vibration values based
on DIN ISO 10816 must not be exceeded at the specified measuring points of the motor
(refer to figure 1).
Figure 1: Measuring points for vibration measurement

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The specified maximum radial and axial vibration values must be adhered to at the same time. They
apply to substructures which can be described as elastic. An elastic substructure is present if the
lowest natural frequency of the overall system (machine and base) in the measuring direction is at
least 25% below the essential excitation frequency. All of the other substructures can be described as
rigid. In case of rigid substructures, the manufacturer must be consulted.
Maximum radial vibration load:
Peak vibration acceleration 1 g > 250 Hz
Peak vibration displacement ≤ 0.16 mm < 6,3 Hz
Effect. vibration speed ≤ 4.5 mm/s 6.3 Hz –250 Hz
Figure 2: Permitted radial vibration load
Maximum axial vibration load:
Peak vibration acceleration 0.225 g > 55 Hz
Peak vibration displacement ≤ 0.16 mm < 6.3 Hz
Effect. vibration speed ≤ 4.5 mm/s 6.3 Hz –55 Hz
Additional vibration resistance:
Vibration acceleration 3 g radial and 1g axial 10 Hz to 55 Hz
The specified vibrations are additionally endured by the motor. However, the service life of wear parts
(such as bearings) can be reduced.
Shock load:
If there are increased vibration loads in the form of shocks, measurements on the installed machine
are necessary.
Based on this, constructive revisions and evaluations are carried out with the company Baumüller.
To evaluate the vibration speed, the measuring equipment shall meet the requirements of ISO 2954.
The vibration acceleration shall be evaluated in the time range in the frequency band from 10 Hz to 2
kHz.
If significant vibration excitations above 2 kHz are to be expected, such as meshing frequencies, the
measuring range must be adapted accordingly. The permissible maximum values thereby do not
change.

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3.4 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 (also auxiliary circuits).
Work may only be carried out once the machine 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 terminals when the rotor is turning.
Regulations for working in electrical plants must be adhered to!
Attention! The safety regulations for work in electrotechnical plants in accordance with
EN 50110-1 (DIN VDE 0105-100) must be observed:
- Disconnect the system
- Secure against unintentional restarting
- Verify safe isolation from 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 screening connections
(when using screened cables) must be permanently secure!
Never touch the contacts of the encoder or thermal sensor with your hands or with
tools that are electrostatically charged. The encoder and the thermal sensor are
electrostatically sensitive components.
Electrical installation:
•The supplier of the system is responsible for the correct electrical installation.
•The motor data on the nameplate must be observed.
•Connection cables and plug connections must be checked for any occurring voltages and
current intensity and must be suitable for the method of installation employed.
•The motor and the modules (brake, encoder etc.) must be connected in accordance with the
details in the wiring diagrams (comp. enclosed wiring diagrams / Appendix 1).
•Screened power and encoder cables must be used to protect against electromagnetic EMC
interference from motor cables and their effect on the encoder and control system. Please
refer to the EMC notes provided by the supplier of the converter.
•To enhance operational safety, we recommend that the ready-made connection cables from
Baumüller be used.
•Prior to connection, the female connectors, connectors and terminal box must be checked for
damage, corrosion, dirt and dampness.
•Ensure the connections are made correctly and are tight. Seals and sealing faces on the
connectors and the terminal boxes maintain the type of protection.
Note! Also in the interests of safeguarding the degree of protection, the rotatable junction
boxes should not be turned in their direction of connection more than 5 times altogether.
•Connectors and terminal box connections must not be exposed to mechanical stress. If
necessary, provide strain, shearing, twist and antikink relief.

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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. Appendix 1 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.
4 Commissioning, operation
4.1 Safety instructions
Working on the electric motor:
Work must not be carried out on the electric motor until the motor had come to a
standstill and is de-energized. All connections, such as screw connections, that were
loosened 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 Manitenance
Instructions.
Attention: If the optional holding brake is fitted, it must not be used to secure
anything while working on the motor (e. g. for retaining loads)!
Danger to life through electrical shock:
Make sure that the motor is disconnected and de-energized.
Never disconnect the motor connections while in operation.
Only connect measuring device when motor is disconnected from power supply and
de-energized.
Only commence work on the motor connections when you are sure that the motor is
de-energized and that there is no electric potential.
When in operation, electric potential can be found at the motor terminals/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 commissioned without first mounting the 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..
Danger on contact:
Make sure that the electric motor has come to a standstill and is secured against
accidental restarting before you touch it.
Only touch the drive shaft when it is de-energised and the motor has come to a
standstill. Otherwise, danger through rotating rotor.
Danger of burns! Never touch the motor housing when motor is running at rated
load. Surface temperatures can rise up to 70 °C.

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Three-phase synchronous motor, water-cooled English
4.2 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 fixed. All screwed connections are correctly tightened.
Unused connection threads in the end shield have to be closed.
•The motor is not leaking oil; oil is not exiting from the leak hole (compare to App. 3 –Fig.1).
•All the appropriate safety devices (mechanical, thermal and electrical) are mounted.
•The motor connections have been carried out correctly.
•The protective conductor system is correct and its functionality has been checked.
•The lines and cables do not come into contact with the motor surface.
•The drive does not block (release brake, if applicable).
•Emergency OFF functions have been checked.
•The coolant pipes have been properly corrected and the functionality of the cooling circuit has
been tested.
4.3 Commissioning, operation
Note on brake function (if present):
The brake is designed as a holding brake with an emergency stop function.
(power failure and emergency stop)
It must not be used as a working brake.
Commisioning must be carried out exclusively by qualified personnel
Please refer absolutely to the commisioning instructions for the converter and the cooling system.
Checks during commissioning
•Release brake, if applicable.
•Has the functionality of all motor modules such as the brake, encoder, cooling system been
checked and are the utilization conditions being adhered to?
•Have all electrical connections been carried out and fixed as required by the regulations (Refer
to wiring diagrams / Appendix 1 or enclosed wiring diagrams)?
•Have all protection measures that eliminate the possibility of contact with live parts, hot
surfaces, rotating and moving parts been observed and are these measures fully functional?
•Have all output elements been mounted and set in accordance with the manufacturer's
instructions?
•Are measures in place to ensure that the max. permitted speed nmax of the motor cannot be
exceeded. The max. permitted speed nmax is the highest permitted operating speed for short-
time duty?
•The maximum permissible axial force (compare to Appendix 3) is not exceeded
Checks during operation
•Watch out for unusual noises.
•If scraping, scratching or grinding noises occur, stop the motor immediately and locate the
cause.
•Check the motor surface and connection cables for dirt, e. g. layers of dust, oil deposits,
dampness and leaks etc.
•Check the maintenance intervals.

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Three-phase synchronous motor, water-cooled English
4.4 Malfunctions
Safety instructions:
Troubleshooting and error recovery may only be carried out by qualified personnel.
Do not disconnect any of the safety devices –even during test operations
Only disconnect coolant pipes when depressurized
Only disconnect and connect electrical connection cables when in de-energized and
protected condition
Observe the 5 safety rules for “Disconnecting” (comp. Section 3.4).
Beware of hot surfaces!
In the event of a malfunction
•refer to the operating instructions of the machine/system
•refer to the operating instructions for the converter
•If necessary, contact the manufacturer of the motor or converter
Have the following parameters 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 possible causes can be helpful in the fault correction process:
Fault
Cause
Recovery
Motor does not start
No controller enable
Controller error, encoder error
Brake doe not release
Brake defect
No power supply
Rotating field
Activate controller enable
Read out error list at
converter or controller, rectify
error
Check connections and power
supply
Repair by manufacturer
Check connections and power
supply
Check phase sequence, if
necessary, replace
connecting cables
Uneven running
Insufficient screening on
connecting cables
Controller parameters too high
Check screening connection
and grounding
Optimise controller
parameters
Vibrations
Coupling element or work
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
Repair by motor manufacturer
Repair by motor manufacturer

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Three-phase synchronous motor, water-cooled English
Fault
Cause
Recovery
Temperature rise in motor
Motor temperature monitoring
unit responds
Drive overloaded
Brake does not release fully -
scraping brake
Water cooling not active.
Coolant supply inadequate
- filter urgently requires
cleaning
- deposits in cooling channels
- disturbances in external
cooling system
Check motor load and
compare with nameplate
Repair by motor manufacturer
Check and, if necessary,
switch on
Check water circuit
- check and, if ecessary,clean
- check and, if ecessary,clean
- follow system suppier's
instructions
Excess pressure in cooling
system
Coolant impure
Cooling channels blocked
Disturbances in the external
cooling system
Filter coolant
Check and, if necessary, clean
Follow system suppier's
instructions
Current consumption too high,
motor torque too low
Indexing angle incorrect
Check indexing angle and
adjust if necessary
Oil leak on A-side shaft
extension or leak hole
(Appendix 3)
Shaft sealing ring damaged or
worn
Repairs carried out by motor
manufacturer
Table 4: Malfunctions
5 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 de-energized, depressurised and has cooled. All connections, such as
screw connections, that were loosened must be tightened again after the inspection
or maintenance work.
When carrying out work on the motor, please observe the technical instructions and
notes in the respective Sections in these Commissioning and Manitenance
Instructions.
When carrying out maintenance work, observe all safety instructions which also apply
for the commissioning of the motor (comp. Section 4.1).
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)!
5.1 Inspection
Depending on the pollution severity on site, cleaning will have to be carried out regularly to
guarantee the continuous dissipation of heat loss. The flow rate and the pressure ratio of the
cooling system must be checked.
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. When the permissible wear limits have been reached, the
brake must be replaced (see Section 5.2).

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Three-phase synchronous motor, water-cooled English
If equipped with the optional shaft sealing ring, this must be checked regularly to ensure that it is
functioning correctly (leaks).
Note on thrust-bearing motors: An inspection hole for leak oil from the thrust-bearing housing is
located on the bottom of the A-side bearing end plate near the feet (see Appendix 3 –Fig. 1). If
oil exits here, the shaft sealing rings of both sealing points must be replaced.
5.2 Maintenance
Depending on the operating conditions, (e. g. mode, temperature, speed and load), the service life
of the bearings and sealing elements can differ greatly.
Maintenance work (except for oil changes) must be carried out by Baumüller or a specialist
company commissioned by Baumüller.
In the case of troublefree operation, we generally recommend the following maintenance
procedures:
•replacement of the bearings after 20000 running hours (The bearings are designed for a
calculated service life of 20000 running hours)
•In case of hollow-shaft motors: replacement of the encoder, encoder-bearing and toothed
belt after 20000 running hours.
In the case of thrust-bearing motors, we generally recommend the following maintenance
guidelines:
•First oil change after about 5000 operating hours. All subsequent oil change after 10000
operating hours. Oil lubrication (sump) with high-performance synthetic gear oil –
"Klübersynth GH6-320” (Klüber Lubrication) or "Omala S4 WE 320"(Shell) or „Degol GS 320“
(ARAL).
•A change of shaft sealing, in case of presence, must be implemented when leakage occurs.
Note on oil changes:
Do not begin draining the oil until the motor is secured and the housing parts have cooled down to
room temperature!
For quicker emptying, unscrew the filler and drain plugs.
(compare to Appendix 3 –Fig. 8).
Fill the thrust-bearing housing with the appropriate oil; the motor should be horizontal when doing
so. The required oil level is reached when the oil drips out of the opened oil level screw (overflow
principle).
For the approximate oil quantity, please refer to Appendix 3.
If an optional brake is fitted, it is essential that it is replaced when its wear limits are reached.
Caution!
The specifications of the technical instructions TAM 00697 must be followed during
maintenance and servicing on motors which are used for safety-oriented applications.

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Three-phase synchronous motor, water-cooled English
5.3 Re-lubrication (optional)
Attention: Re-lubrication only with grease outlet open.
Prior to re-lubrication it is imperative that the covers be removed from the grease outlet opening.
Re-grease bearing with re-lubrication device only when the motor is running.
After re-lubrication, 2 - 4 hours of motor operation is necessary (the old bearing grease is ejected
from the grease outlet opening by the rotation of the bearing), the cover is then to be refitted to the
grease outlet opening.
The theoretical bearing service life as well as the specified motor protection type can only be
maintained if the grease outlet opening is sealed with the cover supplied during operation.
Re-lubrication intervals and grease quantities can be found on the sign on the motor.
6 Disposal
The motor must be disposed off in accordance with the national and local regulations within the
framework of the normal recycling process.
Attention: The rotors of the DST motors have rare-earth magnets with high magnetic energy
densities. See also the note in Section 1.2.
The encoder electronics (if provided) must be disposed of in the proper manner as electronic
scrap.
Before you open the thrust-bearing motor, the oil for thrust-bearing lubrication must be drained via
the locking screw (Appendix 3 –Fig. 8).
The oil is to be disposed of separately as mineral oil.