SEW-Eurodrive DFS Series User manual

14/004/92
T
DFS/DFY Synchronous
Motors
Operating Instructions
Edition 02/2000
0919 9519 / 0200

2
DFS/DFY Synchronous Motors
Safety Notes
Allways follow the warnings and safety instructions contained herein!
A requirement of fault-free operation and any rights to claim under guarantee is that these Instal-
lation and Operating Instructions are followed. Therefore read these Installation and Operating
Instructions carefully before you start working with the unit!
The Installation and Operating Instructions contain important service instructions. They should
therefore be kept in the vicinity of the equipment.
Disposal (please observe current regulations):
Depending on the material they are made of, stator and rotor are to be disposed of in accordance
with the applicable waste disposal regulations for
– steel scrap
– aluminium
– copper
– plastic material
The cable screw fittings used up to this point with
sizes Pg 7 to Pg 48 will be replaced by the new
metric fittings with M 12 x 1.5 to M 63 x 1.5.
We are enclosing the corresponding adapters for
conversion from PG to metric.
Electrical hazard, e. g. during live working.
Mechanical hazard, e. g. when working on hoists.
Important instructions for safe and fault-free operation.
Revisions made in edition
03/98
of the operating instructions “DFY Synchronous Motors with and without
Brake and Accessories“ (order no. 0922 7113) are indicated by a gray line in the margin.
M.. x 1,5
Pg
Pg

Contents
DFS/DFY Synchronous Motors 3
1 Safety Instructions .............................................................................. 4
2 Installation/Assembly .......................................................................... 5
2.1 Before you begin....................................................................................................5
2.2 Preparatory work after an extended period of storage ...........................................5
2.3 Installing the motor ...............................................................................................6
2.3.1 Installation in damp areas or in the open air................................................6
2.4 Tolerances .............................................................................................................6
3 Electrical Connection........................................................................... 7
3.1 EMC-compliant wiring ...........................................................................................7
3.2 Connecting the motor ............................................................................................7
3.2.1 DFS56 motors with terminal boxes .............................................................7
3.2.2 DFY71...DFY112 motors with terminal box..................................................8
3.2.3 Motors with plug connector ........................................................................8
3.3 Connecting the brake .............................................................................................9
3.3.1 DFS 56 .. B ................................................................................................10
3.3.2 DFY 71 - 112 .. B.......................................................................................10
3.4 Connecting the Accessories.................................................................................11
3.4.1 AV1Y absolute angle encoder....................................................................12
4 Startup.......................................................................................... 14
4.1 Before you begin..................................................................................................14
4.2 Startup.................................................................................................................14
5 Inspection/Maintenance ..................................................................... 15
5.1 Inspection and maintenance periods ...................................................................15
5.2 Tools / resources required...................................................................................15
5.3 Inspection/maintenance brake .............................................................................15
5.3.1 DFY 56 .. B brake.......................................................................................15
5.3.2 DFY 71 ... DFY 112 .. B brake ....................................................................16
6 Retrofitting the Brake DFY71...DFY112 ................................................... 19
6.1 Preparing the motor.............................................................................................19
6.2 Preassembly of the brake coil..............................................................................19
6.3 Preassembly of the brake.....................................................................................20
6.4 Mounting the brake to the motor .........................................................................20
6.5 Mounting the manual brake release .....................................................................21
6.6 Electrical connection............................................................................................21
7 Trouble Shooting.............................................................................. 22
7.1 Problems with the motor .....................................................................................22
7.2 Brake problems....................................................................................................23
8 Index of revisions ............................................................................. 24
Appendix ....................................................................................... 25

4
DFY Permanent-Field Synchronous Motors
Safety Instructions1
1 Safety Instructions
Live and moving parts of electrical machines can cause serious or fatal injuries.
Installation, connection, commissioning and maintenance and repair work may only be carried
out by qualified personnel in observance of
• these instructions
• all other project planning documentation, instructions for commissioning as well as wiring dia-
grams relating to the drive
• current national/regional regulations (safety/accident prevention regulations).

DFS/DFY Synchronous Motors
5
Installation/Assembly 2
2 Installation/Assembly
2.1 Before you begin
If you do not install the motor straightaway, store it in a dry, dust and vibration-free room at
–25 ... + 40 °C.
The drive must only be assembled if:
• The entries on the motor nameplate match the project planning documentation.
• The drive is undamaged (no damage caused by carriage or storage).
• It is certain that the following requirements are met:
Standard design No oil, acids, gases, vapors, radiation, etc.
Permissible humidity: 85 %. No condensation!
Permissible without derating are:
– Coolant temperature between – 25 °C and + 40 °C1
– Installation height max. 1000 meters above sea level
Special design For deviating ambient and/or operating conditions the
design must be in accordance with the project planning
documentation.
Tools / resources required
• Standard tools
• Fitting tool if necessary
• If end ferrules are used: crimping tool and end ferrules (without insulating sleeve, DIN 46228,
Part 1, material E-Cu)
if necessary:
• Crimping tool (for connector)
• Removal tool
2.2 Preparatory work after an extended period of storage
Check whether the motor has absorbed any
moisture during the extended period of storage.
For this purpose the insulation resistance of the
motor winding (U, V, W to housing) must be
measured (measuring-circuit voltage 500 V) .
Note:
The insulation resistance is very much depen-
dent on the temperature.
If the insulation resistance is insufficient, the
motor must be dried by skilled personnel.
00056AXX
Fig. 1: Minimum insulation resistance
End drying process when the limit shown in Fig. 1 is exceeded.
1. If the AGY absolute encoder is used in the standard version, the coolant temperature is limited to 0 ... + 40 °C.
Please note that the temperature range of the gear unit may be restricted too (see Installation and Operating
Instructions of the gear unit).
.

6
DFS/DFY Synchronous Motors
2 Installation/Assembly
Check the terminal box/connector to ensure that:
– the inside is clean and dry
– connection and mounting components are free of corrosion
– joint seals are in order
– screwed cable glands are tight.
if not, clean or replace them.
2.3 Installing the motor
The motor or geared motor may be only be mounted or installed in the specified mounting position
on a level, vibration-free and torsionally rigid support structure.
• Thoroughly remove anti-corrosion agents from the shaft ends and flange (use a standard
solvent). Do not allow the solvent to penetrate the bearings and oil seals - this could cause
material damage.
• Carefully align the motor and the driven machine to avoid placing any unacceptable strain on the
motor shafts (observe permissible overhung loads and axial thrusts).
• Avoid thrusts and blows on the shaft ends.
• Protect motors in a vertical mounting position with a VY forced cooling fan with a suitable
cover against the ingress of foreign matter and liquid!
• Ensure an unobstructed cooling air supply.
• Balance components for subsequent mounting on the shaft without key.
• The surface temperature of the motor may exceed 65 °C when in operation. Therefore
appropriate measures must be taken to safeguard against accidental contact.
2.3.1 Installation in damp areas or in the open air
• Mount the terminal box so that the cable entries point downwards if possible.
• Use suitable screwed cable glands for the supply lead (use reducing adapters if necessary).
• Coat the threads of screwed cable glands and sealing plugs with sealing compound and tighten
them well, then coat them again.
• Seal the cable entries well.
• Clean the sealing faces of terminal boxes and their covers well before reassembly; gaskets must
be cemented in on one side. Replace brittle gaskets.
• Restore the anticorrosive coating if necessary.
• Check the type of enclosure.
2.4 Tolerances
→“Servo Geared Motors” catalog, Sec. “Notes on Dimension Sheets”
Shaft ends Flanges
Diametric tolerances
– ISO k6 for ≤50 mm
– ISO m6 for > 50 mm
(Centring hole to DIN 332, shape DR.. . Use centring hole for mounting transmission
elements to prevent damage to the anti-friction bearings.)
Centring shoulder
tolerance
– ISO j6 for ≤230 mm
– ISO h6 for > 230 mm

DFS/DFY Synchronous Motors
7
Electrical Connection 3
3 Electrical Connection
Carefully read and follow the Safety Instructions in Section 1.
3.1 EMC-compliant wiring
EMC-compliant wiring: →Installation and Operating Instructions of the servo controller (e.g.
MOVIDYN®
).
Make sure that
• the cabling is in accordance with the applicable regulations (see nameplate for rated current
data)
• the signals leads are twisted pairs with a common shield (one pair each for reference, sine,
cosine signals and TF PTC thermistors / TH thermostat)
• brake cables must be run separately from power cables or alternatively power cables must
be shielded to avoid any electromagnetic interference with the brake
3.2 Connecting the motor
Strictly follow the Installation and Operating Instructions of the servo controller!
3.2.1 DFS56 motors with terminal boxes
• Connect the motor in accordance with the
wiring diagram:
Connect motor power cable to the terminal
block using cage clamps (Fig. 2):
Note:
Connect resolver signal leads and the thermal
motor protection (TF) to terminal block (Fig. 3):
U phase U
V phase V
W phase W
yPE
It is not possible to reverse the direction
of rotation by changing over the phases.
02907AXX
Fig. 2: DFS56 terminal box connection
1R1 Reference
2R2
3S1 Cosine
4S3
5S2 Sine
6S4
7+ Brake
8-
9TH/TF Thermal motor
protection
10
Tighten all connections. 02908AXX
Fig. 3: DFS terminal strip terminal block
VWU
y
12345678910
1
3
5
9
2
4
6
10
78

8
DFS/DFY Synchronous Motors
3 Electrical Connection
3.2.2 DFY71...DFY112 motors with terminal box
• Connect motor according to wiring diagram:
Motor power supply lines are located on the
board (Fig. 4).
Note:
Signal leads from resolver and thermal motor
protection (TH/TF) on terminal strip (Fig. 5):
3.2.3 Motors with plug connector
The diagrams show the connector pin assignment for the cable on the connecting side (rear).
Prefabricated cables are available from SEW for connection with plug connectors. The marking
(core no. or core colour ) of these cables is given in the tables below.
If you fabricate the cables yourself: The assembly of the plug connectors SM21...SM41 is
explained in the appendix.
DFY 56 / DFY 56 ... B
U phase U
V phase V
W phase W
yPE
It is not possible to reverse the direction
of rotation by changing over the phases.
00063BXX
Fig. 4: DFY 71 ... DFY112 terminal box connection
1R1 Referenz
2R2
3S1 Cosinus
4S3
5S2 Sinus
6S4
9TH/TF Motorschutz
10
Tighten all connections. 00064AXX
Fig. 5: DFY71 ... DFY112 terminal strip terminal box
Connector
pin Connection Core
1PhaseU1
3PhaseW2
4PhaseV3
yPE yw/gn
CBrake+5
DBrake–6 00066BXX
Fig. 6: DFY56 power and brake plug connector
12345678910
W
V
U
12345678910
1
3
5
9
2
4
6
10
43
1
C
D
ABV
PE
U
-
+
W

DFS/DFY Synchronous Motors
9
Electrical Connection 3
DFY 71, 90, 112
00065BXX
Fig. 7: DFY 71, 90, 112 power connector
Resolver / TF/TH
00067CXX
Fig. 8: Resolver connection
The power connector (in DFY 56 .. B motors also the brake connector) and the resolver/thermal
motor protection connection (TH/TF, in DFY 56 only TF) must be wired by the customer. Prefabri-
cated cables of any length are available from SEW.
• The socket contacts are implemented as crimp contacts (exception: motor connection with
SM46 and the resolver connection in DFY 56 motors is by way of solder contacts). Only use
suitable crimping tools for crimping.
• Strip insulation of lead wires over length A (see Table 1 of the Appendix).
• Remove incorrectly assembled socket contacts with suitable removal tools only.
Secure connector with coupling ring.
3.3 Connecting the brake
The brake is released electrically. Braking is by mechanical means after the voltage has been
removed.
Important:
Observe the applicable regulations of the respective Employers' Liability Insurance Association
on phase failure protection and the associated wiring circuits/modifications to wiring circuits.
Note:
Check the cross-section of the cables - brake currents see Appendix, Table 3.
Connector
pin Connection Core
1PhaseU1
2PhaseV2
3PhaseW3
yPE yw/gn
Connector
pin Connection Core
1R1
Reference pink
2 R2 grey
3S1
Cosine red
4S3 blue
5S2
Sine yellow
6 S4 green
9TH/TF Motor
protection
white
10 brown
2
43
1
U
PE
V
W
5
2
4
6
3
1U
PE
V
W
DFY 90
DFY 112 S / DFY 112 M
DFY 71
DFY 112 ML / DFY 112 L
3456
9
10
11
12
1
2
6S4
5 S2
4 S3
3 S1
2 R2
1 R1
9
10
7
8
TH/TF

10
DFS/DFY Synchronous Motors
3 Electrical Connection
Note:
In view of the DC voltage to be switched and the high current load either special brake contac-
tors or AC contactors with contacts in duty class AC3 to EN 60 947-4-1 must be used.
3.3.1 DFS 56 .. B
In DFS 56 .. B brake motors the brake is controlled directly with 24 VDC (24 V ± 10 %).
3.3.2 DFY 71 - 112 .. B
BM.. brake rectifiers or the BSG brake control unit are installed in the switch cabinet. The brake is
connected with a 4-core cable.
1) Brake coil
2) For brake release apply voltage specified on nameplate. Switch contacts according to application class AC3
meeting EN 60 947-4-1.
BMH: For brake release and heating in standstill apply voltage specified on nameplate.
K12 off = heating mode
Contact rating of terminals 1 and 4 on BMH: AC11, terimnal 3: AC3 meeting EN 60 947-4-1.
3) Brake cable
4) Right-angle connector 185 871 8
BME brake rectifier BMH brake rectifier BMP brake rectifier
Switch-off in AC and DC circuit s
Fast brake reaction
Switch-off in AC and DC circuits
Fast brake reaction
Switch-off in AC and DC circuits
Fast brake reaction
BME brake rectifier BMH brake rectifier BSG brake control unit
Switch-off in AC circuit
Standard brake reaction
Switch-off in AC circuit
Standard brake reaction
For 24 VDC connection
BME
1
2
3
PE
3)
4)
2)
1
2
3
4
13
14 15
UAC PE
1)
BMH
1
2
3
PE
3)
1)
4)
2)
1
2
3
4
13
14 15
UAC PE
K12
BMP
1
2
3
PE
3)
1)
4)
2)
1
2
3
4
13
14 15
UAC PE
BME
1
2
3
PE
3)
1)
4)
2)
1
2
3
4
13
14 15
UAC PE
BMH
1
2
3
PE
3)
1)
4)
2)
1
2
3
4
13
14 15
UAC PE
K12
1
2
3
PE
3)
1 2 3 4 5
4)
BSG
PE
+
-
24 VDC
1)

DFS/DFY Synchronous Motors
11
Electrical Connection 3
The connector for brake connection to
the brake control unit is to be wired by
the customer.
Note:
Secure connector with central screw. Do not undo while energized!
3.4 Connecting the Accessories
Connect the accessories supplied in accordance with the wiring diagrams enclosed.
TF PTC thermistors
The PTC thermistors conform to DIN 44082.
Resistance check (instrument with measuring-circuit voltage V ≤7.5 V or I < 1 mA).
Measurements:
standard 20 ... 500 Ω, thermal resistance > 4000 Ω.
TH embedded thermostats
The thermostats are connected in series and open when the permissible winding temperature is
exceeded.
VY forced cooling fan
Connect the VY forced cooling fan in
accordance with the wiring diagram:
Connector
Pin Core
11
22
33
yPE (yw/gn) 00069AXX
Fig. 9: Wiring diagram for the brake
TH data AC DC
Max. voltage 60 VAC 1)
1) 250 VAC is permissible for terminal box versions.
60 VDC 24 VDC
Current (p.f. = 1.0) 2.5 AAC 1.0 ADC 1.6 ADC
Current (p.f. = 0.6) 1.6 AAC
Connector
pin Connection Core
1Phase1
2 Neutral
conductor
2
yPE yw/gn 00070AXX
Fig. 10: Forced cooling fan connection (top view)
3
3
2
2
1
1
2
1

12
DFS/DFY Synchronous Motors
3 Electrical Connection
3.4.1 AV1Y absolute angle encoder
The AV1Y absolute angle encoder is supplied with encoder and connected cable (3 ft./1 m) inclu-
ding pin coupling as well as the required mating connector with socket contacts. SEW also offers a
pre-fabricated cable to serve as an extension for the connection to the MOVIDRIVE®
drive inverter
as well as the MOVIDYN®
servo controller.
01940CXX
Fig. 11: Connection of AV1Y to MOVIDYN
®
servo controller
1941CXX
Fig. 12: Connection AV1Y to MOVIDRIVE
®
drive inverter with DPA11A
1942CXX
Fig. 13: Connection AV1Y to MOVIDRIVE
®
mit DIP11A drive inverter
3
4
56
9
10
11
12
13
14 15
16
17
1
2
7
8
8
9
14
17
10
7
PK
GY
YE
GN
BN
WH
T+
T-
D+
D-
GND
US
max. 100 m (330 ft)
32
33
34
35
38
39
APA12
X11:
yy
AV1Y
T+
T-
D+
D-
GND
US
max. 100 m (330 ft)
32
33
34
35
38
39
DPA11A
X50:
y
y
3
4
56
9
10
11
12
13
14 15
16
17
1
2
7
8
8
9
14
17
10
7
AV1Y PK
GY
YE
GN
BN
WH
T+
T-
D+
D-
GND
US
max. 100 m (330 ft)
y
3
8
1
6
5
9
(N.C.) 2
(N.C.) 4
(N.C.) 7
1
5
6
9
DIP11A
X62:
y
3
4
56
9
10
11
12
13
14 15
16
17
1
2
7
8
8
9
14
17
10
7
AV1Y PK
GY
YE
GN
BN
WH

DFS/DFY Synchronous Motors
13
Electrical Connection 3
• Twisted pair cable with shield connected at both ends over as large an area as possible.
• Clip on with strain relief clamps (over as large an area as possible).
• The socket contacts are implemented as crimp contacts. Use only suitable crimping tools for
crimping.
• Strip insulation off lead wires over length A (see Appendix, Table 1). Pull shrink sleeve over
connections.
• Remove incorrectly mounted socket contacts with suitable removal tools only.
• Secure plug connector with coupling ring.
Pin Connection Core
10 GND supply contact separation from housing BN
7V
S+ 13 ... 15 ... 24 VDC, polarized WH
14 Data+ data output, serial high = “1” (positive logic) BK
17 Data– high = “0” VT
8 Pulse+ Takt, Stromschleife 7 mA in direction pulse+ = “1” PK
9 Pulse– 7 mA in direction pulse– = “0” GY

14
DFS/DFY Synchronous Motors
4 Startup
4 Startup
Carefully read and follow the Safety Instructions on page 4.
4.1 Before you begin
Before startup ensure that
• all connections have been made correctly and the connectors have been secured against coming
loose.
• all motor protection features are active during startup.
• the drive is not blocked.
• no other sources of danger are present.
• the drive is not damaged (no damage caused by carriage/storage)
• in the event of extended periods of carriage/transportation →Sec. 2.2
4.2 Startup
• Follow the Installation and Operating Instructions of the servo controller (e.g. MOVIDRIVE®).
• Use software support where available (e.g.MOVITOOLS, MD_SCOPE).

DFS/DFY Synchronous Motors
15
Inspection/Maintenance 5
5 Inspection/Maintenance
Isolate the drive from the supply before you start any maintenance work and safeguard the
drive against unintentional power-up. Do not undo connectors while the drive is energized.
Only use original spare parts in accordance with the valid parts list.
5.1 Inspection and maintenance periods
The service life of a part is influenced by many factors and differs for the various parts. Inspection
and maintenance periods must therefore be determined individually in accordance with the project
planning documentation. Carry out regular visual inspections of the drive.
The bearings should only be changed by SEW-trained personnel since the resolver must be re-set
each time the motor has been disassembled.
5.2 Tools / resources required
• Standard tools
• Tools for mounting the encoder
(EW 1 setting tool by Stegmann, art. no. 81B 001 003 001)
• Stud to DIN 938:
DFY 71: M5×45
DFY 90: M6×60
DFY 112: M8×70
5.3 Inspection/maintenance brake
5.3.1 DFY 56 .. B brake
The brake of the DFY 56 motor does not require any maintenance work.

16
DFS/DFY Synchronous Motors
5 Inspection/Maintenance
5.3.2 DFY 71 ... DFY 112 .. B brake
02912AXX
Fig. 14: Cutaway view of the DFY 71... 112 brake motor
Checking the working air gap
To check the working air gap, measure the travel of the pressure plate when the brake is released
(permissible range: 0.25...0.8 mm).
In brakes with manual brake release:
– Measure the travel on a stud (15) of the releasing yoke.
In brakes without manual brake release:
– Remove plug (23).
– Screw stud (Sec. 5.2) into pressure plate.
(not too deep, since you might damage coating).
– Measure travel.
– Remove stud and replace plug.
02914AXX
Fig. 15: Detail of Fig. 14
1 Brake end shield
2 Brake disc complete
3 Intermediate ring
4 Pressure plate
5 Circlip/snap ring
6 Parallel pin
7 Brake spring
8 Brake coil, complete
9 Manual release lever
10 Releasing yoke
11 Brake coil body
12 Compressing spring
13 Disc
14 Look nut
15 Stud
16 Closing cap
17 Connector
18 Cheese head screw
19 Circlip/snap ring
20 O-ring
21 Key
22 Carrier
12345678
9
10
11
12
13
14
15
16
171819202122
23

DFS/DFY Synchronous Motors
17
Inspection/Maintenance 5
Replacing the brake disc
1. Remove connector (17) and flat gasket.
2. In brakes with manual brake release: Remove
the manual release lever. In brakes without
manual brake release: Remove plugs (23)
from holes.
3. Pull pressure plate (4) on to brake springs
using two auxiliary mounting screws and
washers. Use studs as per Sec. 5.2. Other
screws could damage or even destroy the
brake disc.
4. Unscrew coil body (11) incl. O-ring (20).
5. Pull off brake disc (2).
6. Remove abraded material.
8. Screw on coil body (11) incl. O- Ring (20). Remove
auxiliary mounting screws.
9. Remount manual brake release or closing plug.
Reposition gasket and connector and secure with
central screw.
Mounting the manual brake release: The clearance
between the disc (13) and the releasing yoke (10)
must be 2 mm to ensure correct functioning of the
brake.
Changing the holding torque
1. to 4. see Sec. “Replacing the brake disc”.
5. Remove abraded material.
6. Loosen pressure plate (4). Insert new brake springs in accordance with Table 4 in the Appen-
dix.
Arrange symmetrically.
7. Pull pressure plate on to brake springs again, using the auxiliary mounting screws.
8. and 9. see Sec. “Replacing the brake disc”.
7. Slide on new brake disc.
Be careful not to soil the brake disc with
grease or oil.
02915AEN
Fig. 16 : Detail of Fig. 14
02913AXX
Fig. 17: Detail of Fig. 14
11
4
7
Washers
Auxiliary
mounting screws
10
13
2

18
DFS/DFY Synchronous Motors
5 Inspection/Maintenance
Brake motors with AV1Y absolute encoder
The encoder must be removed prior to carrying out any maintenance work on the brakes of DFY
motors:
1. Open and remove central screw of the right-angle connector (5).
2. Loosen bolts (11) and turn spring washer (10) to the outside before you remove encoder (12)
with coupling half (9).
Caution: Coupling is a two-piece plug-in connector!
3. Remove protective caps (6, only with DFY71) and flange retaining bolts (3) through the
assembly hole (the bolts are on the outside with DFY90 and DFY112). , using an 8mm span-
ner. Then undo the screw counterclockwise using a 4mm hexagon socket spanner. This will
release the expanding shaft, and undo the connection with the coupling (10). For this step the
EW1 setting tool by Stegmann can be used (Art. No. 81B 001 003 001).
4. Loosen intermediate flange (8) and center screw on right-angle connector (5) and remove
plug.
5. Loosen coupling clamping screw (9) and carefully remove coupling from motor shaft.
6. You may now carry out the brake maintenance work (see Sec. 5.3.2).
Reassemble in reverse order (ensure true running of tacho shaft (max. 0.05 mm)):
Coupling may not display any axial tension in stretched condition.
02910AXX
Fig. 18: DFY/B AV1Y brake motor
1 Screw plug
2 Coil body
3 Flange retaining
screw
4 Plug connector brake
5 Center screw right-angle
connector
6 Protective caps
7 Plug connector brake
8 Encoder flange
9 Coupling
10 Spring washers
11 Bolts
12 Encoder
13 Rubber seal (DFY112)
1234
789 1213
56
10 11

DFS/DFY Synchronous Motors
19
Retrofitting the Brake
DFY71...DFY112 6
6 Retrofitting the Brake DFY71...DFY112
Check the received parts for completeness.
6.1 Preparing the motor
Part references: (213/19) means part 213 in Fig. 19
– Remove the cheese head screws (213/19) holding down the housing cover.
– Remove the housing cover (304/19).
– Remove circlip/snap ring (62/19) from free second shaft end.
– Pull off bush (308/19) from shaft, using a suitable pull-off device.
Be careful not to damage the shaft seat and the resolver fitted behind!
– The key (71/19) remains where it is.
– Heat the brake carrier (70/20) and pull on to the shaft on the non-drive end.
– Fit new circlip/snap ring (62/20).
–Allow the carrier to cool down (warm to the touch).
00207BXX
Fig. 19: DFY motor without brake
6.2 Preassembly of the brake coil
– Insert the O-ring (281/20) in the groove provided on the plug connection of the brake coil (286/
20).
– Screw the terminal link (295/20) to the brake coil through either hole, using one of the two
cheese head screws (310/20) and lock washers (294/20) (there is a thread provided for this at
the rear of the plug connection).
Do not tighten yet!
107 105 11 3 1 71 44 43 40 305308 62
9
7 103 101 100 16 289 42 13 304 213
307 306 301
305
2
106
319
108 109 392

20
DFS/DFY Synchronous Motors
6Retrofitting the Brake
DFY71...DFY112
00208CXX
Fig. 20: DFY motor with brake
6.3 Preassembly of the brake
– Insert the preassembled brake coil (see. 6.2) in the coil body (54/20) and lock it axially with the
circlip/snap ring (285/20).
Take care not to damage the O-ring!
– Screw the brake coil to the coil body through the second opening on the terminal link using the
second cheese head screw and lock washer.
– The protective ground connection is provided by screwing the terminal link to the brake coil.
– Push the two parallel pins (300/20) into the hole provided in the coil body.
– The pins are pushed in deep enough if they do not project from the pressure plate (49/20).
– Insert the brake springs (265/20) symmetrically into the holes provided over the perimeter of
the coil body, depending on the required brake torque (see Table 4).
– Screw one auxiliary mounting nut each on the two cheese head screws (56/20).
– Position the pressure plate (49/20) on the parallel pins and screw the two cheese head screws
into the pressure plate through the holes in the coil body (provided for the manual brake
release).
– Screw in so that no threads project from the pressure plate.
– Pull pressure plate on to the coil body by tightening the nut.
– Place the O-ring on the coil body.
6.4 Mounting the brake to the motor
– Place clip (69/20) with open side facing front in gearing of carrier (70/20).
– Slide brake disc (68/20) on carrier (70/20) (hub facing front).
– Position one half of the brake disc on the carrier and then push on to the carrier completely,
turning it slightly (hold motor shaft in place).
– The intermediate ring (299/20) is ribbed on three sides, the fourth is flat. The non-drive end
bearing end shield is designed in a similar way. Position the O-ring (392/20) on the non-drive
end bearing end shield. Position the intermediate ring on the centring fit of the non-drive end
bearing end shield and align.
– Position the O-ring (393/20) and then position the preassembled coil body with the pressure
plate on to the intermediate ring (flat sides facing each other) and screw down loosely with the
aid of the four cheese head screws (213/20).
Do not tighten screws yet!
107 105 11 3 1 71 44 4340 305 70 62
9
7103 101 100 16 289 42 13 299 47
307 306 285 305
54281
286 53
51
303
301
302
58
57
56
265 300
28
213
2
106
4968
31 108 109 295 310 294
392 393