Trust Bharat Bijlee STS-050-2500-215B-F-K User manual

USER GUIDE
High performance BB servo motor
IFU: Information For Use

COPYRIGHT
ALL RIGHTS RESERVED
This User's Guide ("Guide") along with all its contents is the sole property of Bharat Bijlee Ltd
("BBL"). It is delivered to others on the condition that it shall be used only by the purchaser of
BBL's Servo Motor or his authorized agent who shall follow all operating instructions and
installation guidelines stated therein to ensure correct and accurate installation of the said
Servo Motor. BBL shall not hold any responsibility unless installation of the Servo Motor is
carried out in strict accordance with the instructions laid down in this Guide.
This User Guide may not be copied, reproduced, republished, sold, downloaded and posted,
broadcast or transmitted in any way except with the prior written permission of BBL.
BBL reserves the right to make changes in the Guide and its contents without prior
intimation /notice.
Any dispute arising out of this Notice shall be subject to Indian Laws and to the exclusive
Jurisdiction of the courts in Mumbai, India.

INDEX
1. GENERAL INFORMATION 4
1.1. Synchrotorque Servo Motor 4
1.2. Objective 4
1.3. Checking 4
2. SAFETY INSTRUCTIONS & PRECAUTIONS 5
3. PRODUCT INFORMATION 8
4. MARKING AND IDENTIFICATION DETAILS 9
4.1 Dimensions 10
4.2 Technical specifications 11
4.2.1 Technical specifications STS-050-2500-215B-F-K 11
4.2.2 Technical specifications STS-070-2500-215B-F-K 13
4.2.3 Technical specifications STS--090-2500-215B-F-K 15
5. PRE COMMISSIONING 17
5.1. Cooling fan 17
5.2. Shaft Load precautions 17
5.3. Mounting 17
5.4. Environmental 17
6. ELECTRICAL CONNECTION 18
6.1. Earthing 18
6.2. Connection Diagram 19
7. INSTALLATION 20
7.1. Before starting machine 20
8. TROUBLESHOOTING 21
9. DOS & DON'TS 22
10. WARRANTY 24
11. LIST OF ACCESSORIES 26
12. CERTIFICATION 30

Congratulations!! for buying BBL servo motors.
SynchroTorq® is a Bharat Bijlee's new brand name under which the permanent magnet
synchronous motors are manufactured. For the direct drive segment all the machines at MTM
division are manufactured under this brand.
• Please preserve this User Guide. Store this user guide carefully for future reference.
1.2. Objective
This Guide provides technical information about the characteristics of servo motors, its intended
use, product information. It also includes directions on mounting, installation, troubleshooting
and maintenance.
This Guide should be read by all installation and maintenance teams & all instructions therein be
strictly followed before attempting the Installation.
For further information, suggestion and clarification, please contact Bharat Bijlee,
[e-mail] or visit www.bharatbijlee.com.
1.3. Checking
Please check the rating of the motor after opening the packing and confirm that it is in accordance
with your order.
The packing of the servo motor contains the servo motor, routine test certificate, installation
manual and warranty card.
If you observe product damaged during the transportation, please inform Bharat Bijlee
immediately.
The machines are to be used and operated by the authorized trained persons only.
1. GENERAL INFORMATION
1.1. SynchroTorq® Servo Motor
4

2. BB SERVO MOTOR - GENERAL WIRING, CAUTION,
SAFETY INSTRUCTIONS & PRECAUTIONS
CAUTION
WARNING
5
The instructions given in this manual or any other instructions supplied must always be observed
to avoid danger or damage.
WARNING / CAUTION: This indicates noncompliance with the instructions and can lead to
personal injury and product damage.
The mounting, installation, and maintenance of the SERVO motor, is allowed only to qualified and
trained personnel.
Following the safety at work regulations and general recommendations.
• The machines are not designed for direct connection to the three-phase
system; but are to be operated via an electronic frequency converter. Direct
connection to the system may destroy the motor.
• Strictly follow the installation check points
• Ensure that power & control cables are not damaged, stressed loaded, or
pinched and properly secured to respective motor terminals / connectors.
• Ensure that motor is provided with proper earthing connection
• Ensure that the terminal box is properly closed before powering the motor.
• Do not open the terminal box cover when the motor is powered.
• It is mandatory to provide proper access to the motor for maintenance
purpose.
• Only the voltage specified on nameplate should be applied to corresponding
terminals to prevent unwanted electrical hazards and damage to motor parts.
• During operation, never touch the rotating parts of the servo motor. Doing so
can cause injury.

6
WARNING
CAUTION
• Transport the products correctly according to their weights mentioned in
nameplate/catelogue.
• Lifting plates provided by the manufacturer must be used to lift and transport
the servo motor only.
• Do not lift/ carry the servo motor by the cables, shaft or terminal box.
• Do not put heavy objects on servo motor.
• Do not install or operate the servo motor which has been damaged or has any
parts missing
• Do not block the air intake/exhaust port of the servo motor having cooling
fan.
• Do not drop or strike servo motor.
• Never hit the servo motor or shaft, especially when coupling the servo motor
to the load. The encoder/resolver may become defective.
• Ensure that no temperature sensitive external parts / objects are in contact
with the motor body as the motor body temperature rises during the motor
operation. Protection against accidental contact should be provided, if
required.
• Ensure that the power & control connections to the motor are proper to
prevent over heating due to loose connections.
• Before powering the motor, ensure that the drive parameters are properly
programmed as per motor details. Improper settings may cause undesired
operation / malfunction.
CAUTION

7
WARNING
CAUTION
• Always store the servo motor indoors in a clean and dry place.
• If the insulation resistance of the winding decreases, reexamine the storage
method.
• Though the servo motor is rust-proofed before shipment using paint or rust
prevention , rust may be produced depending on the storage conditions or
storage period.
• If the servo motor is to be stored for longer than six months, apply rust
prevention oil especially to the machined surfaces of the shaft, etc.
• If the motor is stored for extended period, ensure to turn the motor shaft
rotates freely using hand, before using the motor.
• When the motor has been stored for an extended period of time, consult BBL.
• Do not dismantle the servo motor without consulting BBL.
• The motor and the accessories are to be used as per its intended use as
mentioned in the user guide, IFU document.

8
3.1. Name Plate
The name plate is sticked on the machine, It includes some necessary
parameters for setting frequency inverter. Please refer the parameters for
frequency inverter setting.
For Example:
3. PRODUCT INFORMATION
3.2. Nomenclature
STS XX-XXXX-XXXX- X- X
Rated Speed
Rated Torque
SynchroTorq® Servo motor
Connector: K: Connector
O: Glands
Cooling method: F: Forced cooling
Mounng PCD in mm: B: Flange mounted
C: Foot mounted
Nomenclature for Servo Motors
SynchroTorq Servo®Rated
Torque
Rated
Speed
Mounng PCD
B-Flange Mounted
C-Foot Mounted
Fan Forced
cooling
F-IC
Connector
K-With connectors
O-No connectors
STS 090 112B/C2500 F K
e.g. STS-090-2500-112B-F-K

No. of phases It is a single phase or three phase system provided on
name plate.
Performance STD Available on name plate
Degree of protection Available on name plate
Method of cooling Available on name plate
Thermal Class Available on name plate
Rated output Available on name plate
Rated Voltage Available on name plate
Rated Frequency Available on name plate
Open circuit voltage –
Rated current Available on name plate
Rated Speed Available on name plate
Permissible overspeed 20% more than rated speed
Rated power Factor 0.9
Rated ambient temperature 45⁰ C
4. MARKING AND IDENTIFICATION DETAILS
1
Details
Sr.
No. Marking
2
3
Min ambient temperature -10 ⁰C
Altitude 1000m
Total mass of the machine Mentioned on name plate
Direction of rotation Machine operates on both CW and CCW directions
Connecting instructions Provided inside the T box cover
Starting requirements Provided in IFU
Manufacturer’s name or mark Provided on name plate
Serial no. or identification mark Serial no of the machine provided on the name plate.
Year of manufacturing First two leers indicate year of manufacture
Manufacturer’s machine code Available on name plate
9
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24

4.1 Dimensions
STS-050-2500-215B-F-K 563 69
603 78STS-070-2500-215B-F-K
638 87
673 97STS-115-2500-215B-F-K
Model L (mm) CG (mm) Wt. (kg)
STS-090-2500-215B-F-K
179
199
216
233
10
4C.G.
124.5
4 NOS, 14 THRU Ø
EQ. SPACED ON PCD 215
80±0.5
Ø180
CONNECTOR
FOR FAN
POWER SUPPLY
CONNECTOR
RESOLVER+KTY
17 PIN CONNECTOR
H
105
210
210
Ø38
L
300
300
310
310
H (mm)

11
4.2 Technical Specifications
4.2.1 Technical specification for servo motor STS-050-2500-215B-F-K
SPECIFICATIONS
Model STS-050-2500-215B-F-K
Rated RPM 2500
Rated Nm 50
Rated kW 13.08
Rated Amp. 27
Vrms (rated operang voltage) 360
Kt (torque constant) 1.85
Vs/1000 (back EMF constant) 128
Max Nm 105
RPM at max torque 2500
Amp. At max torque 62
Rated Specificaon
Overload Specificaon
Max RPM 3200
Nm at max RPM 40
Over speed Specificaon
Sha Dia in mm 38
PCD in mm 215
-
Inera 10 ³ kgm² 11.39
Mechanical Specificaon
Other Features
Insulaon Class H
Temp Rise
160°C
KTY Qty 1 no's
Fan Single phase 230 V
Resolver 2 Pole, 1024 PPR
Connector Yes (Fan, Resolver, Power Supply, KTY, PTC)
Weight 73 kg
IP 54
Mounng Type Flange type, 4 mm Spigot
Color BLACK RAL 9017
Ambient temp 45 °C
Sha Key less sha, 80 mm Extension
PTC Tripping
110 K

• Torque Speed Curve:
12
Mo
S1 Mn
S3 40%
S3 10%
Maximum torque
Voltage limited
zone
0
20
40
60
80
100
120
140
160
0 500 1000 1500 2000 2500 3000 3200
Torque (Nm)
Speed (r/min)
STS-050-2500-215B-F-K
Nn
Notes:
1. Mo is standstill torque & Mn is the rated torque at rated speed Nn
2. S1 duty, S3 40% & S3 10% duty temp rise = 110 K
3. In peak condition that is max torque, motor can withstand for 15 to 20 sec,
but also need to consider bear time of drive.
• Basic requirements for safe & proper operation :
1. Proper earthing at min. two points should be given to the motor.
2. Proper air ventilation needs to be provided to avoid overheating of motor.
3. All other standard procedures and practices to be followed.

13
4.2.2 Technical specification for servo motor STS-070-2500-215B-F-K
SPECIFICATIONS
Model STS-070-2500-215B-F-K
Rated RPM 2500
Rated Nm 70
Rated kW 18.32
Rated Amp. 39
Vrms (rated operang voltage) 370
Kt (torque constant) 1.79
Vs/1000 (back EMF constant) 122
Max Nm 165
RPM at max torque 2500
Amp. At max torque 94
Rated Specificaon
Overload Specificaon
Max RPM 3200
Nm at max RPM 54
Over speed Specificaon
Sha Dia in mm 38
PCD in mm 215
-
Inera 10 ³ kgm² 14.21
Mechanical Specificaon
Other Features
Insulaon Class H
Temp Rise
160°C
KTY Qty 1 no's
Fan Single phase 230 V
Resolver 2 Pole, 1024 PPR
Connector Yes (Fan, Resolver, Power Supply, KTY, PTC)
Weight 78 kg
IP 54
Mounng Type Flange type, 4 mm Spigot
Color BLACK RAL 9017
Ambient temp 45 °C
Sha Key less sha, 80 mm Extension
PTC Tripping
110 K

• Torque Speed Curve:
14
STS-070-2500-215B-F-K
Mo S1
Nn
Mn
S3 40%
S3 10%
Maximum torque
Voltage limited
zone
0
50
100
150
200
250
0 500 1000 1500 2000 2500 3000 3200
Torque (Nm)
Speed (r/min)
Notes:
4. Mo is standsll torque & Mn is the rated torque at rated speed Nn
5. S1 duty, S3 40% & S3 10% duty temp rise = 110 K
6. In peak condion that is max torque, motor can withstand for 15 to 20 sec, but
also need to consider bear me of drive.
• Basic requirements for safe & proper operaon :
4. Proper earthing at min. two points should be given to the motor.
5. Proper air venlaon needs to be provided to avoid overheang of motor.
6. All other standard procedures and pracces to be followed.

15
4.2.3 Technical specification for servo motor STS-090-2500-215B-F-K
SPECIFICATIONS
Model STS-090-2500-215B-F-K
Rated RPM 2500
Rated Nm 90
Rated kW 23.55
Rated Amp. 50
Vrms (rated operang voltage) 360
Kt (torque constant) 1.8
Vs/1000 (back EMF constant) 122
Max Nm 208
RPM at max torque 2500
Amp. At max torque 118
Rated Specificaon
Overload Specificaon
Max RPM 3200
Nm at max RPM 58
Over speed Specificaon
Sha Dia in mm 38
PCD in mm 215
-
Inera 10 ³ kgm² 16.6
Mechanical Specificaon
Other Features
Insulaon Class H
Temp Rise
160°C
KTY Qty 1 no's
Fan Single phase 230 V
Resolver 2 Pole, 1024 PPR
Connector Yes (Fan, Resolver, Power Supply, KTY, PTC)
Weight 90 kg
IP 54
Mounng Type Flange type, 4 mm Spigot
Color BLACK RAL 9017
Ambient temp 45 °C
Sha Key less sha, 80 mm Extension
PTC Tripping
110 K

• Torque Speed Curve:
16
STS-090-2500-215B-F-K
Mo S1
Nn
Mn
S3 40%
S3 10%
Maximum torque
Voltage limited
zone
0
50
100
150
200
250
300
0 500 1000 1500 2000 2500 3000 3200
Torque (Nm)
Speed (r/min)
Notes:
1. Mo is standsll torque & Mn is the rated torque at rated speed Nn
2. S1 duty, S3 40% & S3 10% duty temp rise = 110 K
3. In peak condion that is max torque, motor can withstand for 15 to 20 sec, but
also need to consider bear me of drive.
• Basic requirements for safe & proper operaon:
7. Proper earthing at min. two points should be given to the motor.
8. Proper air venlaon needs to be provided to avoid overheang of motor.
9. All other standard procedures and pracces to be followed.

17
5.1. Cooling fan
Please note the motor is fan cooled. Please maintain minimum distances between the motor's
suction face and wall as well on the motor top as shown in below figure.
5. PRE COMMISSIONING
MINIMUM DISTANCE
FROM TOP
100mm
MINIMUM DISTANCE
FROM WALL
100mm
Figure 2
5.2. Shaft Load precautions
The servo motor shaft is not meant to take impact load. Please don't hammer the shaft while
assembling or dismantling the coupling else it will damage the resolver or disturb the resolver
setting.
DO NOT HAMMER
ON MOTOR SHAFT
5.3. Mounting
Servo motor is to be flange mounted as shown in the Figure 2
5.4. Environmental
• The ambient temperature must be within -10°C and +45°C
• Maximum permissible humidity is 85%.(No moisture condensation)
• Do not operate the motor in an explosive atmosphere.
• Be aware of the protection class specified on the motor name plate.
• The deviation of the supply voltage fluctuation and rating does not exceed +7%.
• Transportation should be done with proper packing and as per BBL packing box.
• Storage should in dust free and safe environmental conditions.
• Adequate ventilation and lighting arrangement are to be provided by the client.
• Any scrapping / Disposal has to be done as per the standard international practice.
Figure 3

6. ELECTRICAL CONNECTION
18
6.1. Earthing
For safety reason, it is very important that the motor should have properly earthing. Voltage
between Earth and Neutral should be less than 3 Volts at standstill as well as during running. BBL
servo motor unit contains two earthing points as shown in below images. Use the earthing bolts
provided on the machine. Any one of these can be used for motor body protective earthing.
Ensure that the shielding of the cable & 4th Core of the cable is
connected to earth at motor as well as controller end.
WARNING

6.2. Connecon Diagram
19
CONNECTION DETAILS
T-BOX
DRIVING END
NON DRIVING END
SUPPLY (U)
SUPPLY (V)
SUPPLY (W)
EARTHING
EARTHING
LIVE (L) NEUTRAL (N)
POWER SUPPLY
CONNECTOR
1
2
3
FAN CONNECTOR
A
B
C
D
RESOLVER & KTY
CONNECTIONS
1
2 3 4 5
6 7 8 9 10
11 13 14
15 16 17
12
Pin
No. Colour
1N.A. Shield
7 RED Sin -
8BLACK Sin +
3 YELLOW Cos +
4BLUE Cos +
12 RED-WHITE Ref -
13 YELLOW-WHITE Ref +
10 YELLOW (KTY) K +
14 GREEN (KTY) K -
Signal
4

20
7.1. Before starting machine
Before starting the machine, go through the following checklist:
7. INSTALLATION
Sr. No YES NO
Check list Recommended
1
2
3
4
5
6
7
8
9
10
Machine Mounng Bolts
Check Input Voltage to Drive
Winding Insulaon Resistance
Terminal Connecon
Power Cable and Resolver Cable
Earthing at 2 points to
Gearless Machine Unit
Shield of power cable is connected to
Earth at Motor end, as well as at the
Controller end.
Thermistor / KTY connected with drive
Fan connected to supply
Tighten
390 Volt A.C. to 415 Volt A.C.
< 3 Volt
≥ 2 M-ohm
Not loose
(All Connecons proper)
Routed separately minimum
100mm clearance
Connected
Connected
Connected
Connected
Check Machine Earthing during
standsll & Running