DFS Series
SEW-Eurodrive DFS Series, CFM71M, CFM71S, CFM Series, CFM90S Operating Instructions Manual
...
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Drive Technology \ Drive Automation \ System Integration \ Services
DFS/CFM Synchronous Servomotors
Edition 11/2008
Operating Instructions
11354313 / EN
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Contents
Contents
1 General Notes...................................................................................................... 5
1.1 How to use the operating instructions......................................................... 5
1.2 Structure of the safety notes ....................................................................... 5
1.3 Rights to claim under limited warranty ........................................................ 6
1.4 Exclusion of liability..................................................................................... 6
2 Safety Notes ........................................................................................................ 7
2.1 General information .................................................................................... 7
2.2 Target group ............................................................................................... 8
2.3 Designated use ........................................................................................... 8
2.4 Other applicable documentation ................................................................. 9
2.5 Transportation/storage................................................................................ 9
2.6 Installation/assembly................................................................................... 9
2.7 Electrical installation ................................................................................. 10
2.8 Startup/operation ...................................................................................... 10
2.9 Inspection/maintenance ............................................................................ 10
2.10 Disposal .................................................................................................... 10
3 Motor Structure ................................................................................................. 11
3.1 DFS synchronous servomotor – general structure ................................... 11
3.2 CFM synchronous servomotor – general structure................................... 12
3.3 Nameplate, unit designation and serial number........................................ 13
4 Mechanical Installation..................................................................................... 17
4.1 Required tools/resources .......................................................................... 17
4.2 Before you begin....................................................................................... 17
4.3 Preliminary work ....................................................................................... 17
4.4 Installing the motor.................................................................................... 19
4.5 Mounting tolerances.................................................................................. 20
5 Electrical Installation ........................................................................................ 21
5.1 Assembling the connector......................................................................... 21
5.2 Wiring notes .............................................................................................. 21
5.3 Connecting the motor and encoder system using SM../SB..
plug connectors......................................................................................... 22
5.4 Dimensioning the cable cross section....................................................... 23
5.5 Power cables for DFS motors ................................................................... 27
5.6 Power cables for CFM motors .................................................................. 32
5.7 Feedback cable for resolver...................................................................... 41
5.8 Feedback cable for HIPERFACE
5.9 Forced cooling fan cable........................................................................... 56
5.10 Cable specification of motor cables for DFS and CFM motors ................. 58
5.11 Cable specification of feedback cables for DFS and CFM motors............ 62
5.12 Connecting the motor via the terminal box ............................................... 64
5.13 Connecting the BR brake (CFM motor) .................................................... 69
5.14 Connecting the B brake (DFS56 motor).................................................... 80
5.15 Accessory equipment................................................................................ 84
®
encoders............................................ 47
Operating Instructions – DFS/CFM Synchronous Servomotors
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3
Contents
6 Startup................................................................................................................ 90
6.1 Prerequisites for startup............................................................................ 90
7 Malfunctions ...................................................................................................... 91
7.1 Motor malfunctions.................................................................................... 91
7.2 Malfunctions when operated with a servo inverter.................................... 91
7.3 Brake malfunctions .................................................................................. 92
8 Inspection/Maintenance ................................................................................... 93
8.1 Safety notes regarding inspection/maintenance ....................................... 93
8.2 Inspection intervals ................................................................................... 94
8.3 Inspection work for the B brake (DFS)...................................................... 94
8.4 Inspection work for the B brake (CFM) ..................................................... 95
9 Technical Data................................................................................................. 100
9.1 Main technical data of the servomotors .................................................. 100
9.2 Plug connectors ...................................................................................... 105
9.3 Connection with terminal box.................................................................. 105
9.4 Work done, braking torques.................................................................... 106
9.5 Brake coil resistance............................................................................... 106
9.6 BR brake – operating currents ................................................................ 107
10 Appendix.......................................................................................................... 108
10.1 Crimping tools ......................................................................................... 108
10.2 SM11/SB11 power connector assembly (for DFS56 servomotor) .......... 111
10.3 Assembly of SM5./SM6. and SB5./SB6. power connectors.................... 114
10.4 Assembly of signal plug connectors (resolver/HIPERFACE
10.5 Wiring diagrams for DFS/CFM synchronous servomotors...................... 118
10.6 Wiring diagram for CFM motors with power connector ........................... 119
10.7 Wiring diagram for CFM motors with signal connector ........................... 119
10.8 Wiring diagram for CFM motors with terminal box.................................. 121
10.9 Wiring diagram for DFS motors with power connector ........................... 123
10.10 Wiring diagram for DFS motors with signal connector............................ 123
10.11 Wiring diagram for DFS motors with terminal box .................................. 125
10.12 Wiring diagram for VR forced cooling fan ............................................... 127
®
)................ 115
11 Address List .................................................................................................... 128
Index................................................................................................................. 137
4
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Operating Instructions – DFS/CFM Synchronous Servomotors
How to use the operating instructions
1 General Notes
1.1 How to use the operating instructions
The operating instructions are an integral part of the product and contain important information for operation and service. The operating instructions are written for all employees who assemble, install, startup, and service this product.
The operating instructions must be accessible and legible. Make sure that persons responsible for the system and its operation, as well as persons who work independently
on the unit, have read through the operating instructions carefully and understood them.
Consult SEW-EURODRIVE if you have any questions or if you require further information.
1.2 Structure of the safety notes
The safety notes in these operating instructions are structured as follows:
Symbol SIGNAL WORD
Nature and source of hazard.
Possible consequence(s) if disregarded.
• Measure(s) to prevent the hazard.
General Notes
1
Symbol Signal word Meaning Consequences if
disregarded
Example:
General danger
Specific danger,
e.g. electric shock
DANGER Imminent danger Severe or fatal injuries
WARNING Possible hazardous situation Severe or fatal injuries
CAUTION Possible hazardous situation Minor injuries
NOTICE Potential damage to property. Damage to the drive system or its environ-
ment
TIP Useful information or tip.
Simplifies handling of the drive
system.
Operating Instructions – DFS/CFM Synchronous Servomotors
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1
General Notes
Rights to claim under limited warranty
1.3 Rights to claim under limited warranty
Adhering to the operating instructions is a prerequisite for fault-free operation and the
fulfillment of any right to claim under warranty. Therefore, read the operating instructions
before you start working with the unit.
1.4 Exclusion of liability
You must comply with the information contained in these operating instructions to ensure safe operation of the electric motors and to achieve the specified product characteristics and performance features. SEW-EURODRIVE does not assume liability for injury to persons or damage to equipment or property resulting from non-observance of
these operating instructions. In such cases, any liability for defects is excluded.
6
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Operating Instructions – DFS/CFM Synchronous Servomotors
2 Safety Notes
The following basic safety notes must be read carefully to prevent injury to persons and
damage to property. The operator must ensure that the basic safety notes are read and
observed. Make sure that persons responsible for the plant and its operation, as well as
persons who work independently on the unit, have read through the operating instructions carefully and understood them. If you are unclear about any of the information in
this documentation, please contact SEW-EURODRIVE.
2.1 General information
DANGER
Servomotors, gearmotors and gear units may have live, uninsulated, and sometimes
moving or rotating parts as well as hot surfaces during operation.
Severe or fatal injuries.
• All work related to transportation, storage, setup/mounting, connection, startup,
maintenance and repair may only be carried out by qualified personnel, in strict
observation of:
– The relevant detailed operating instructions
– Warning and safety signs on the motor/gearmotor All other project planning
documents, operating instructions and wiring diagrams belonging to the drive
– The specific regulations and requirements for the system
– The national/regional regulations governing safety and the prevention of
accidents
• Never install damaged products
• Immediately report any damages to the shipping company
Safety Notes
General information
2
Removing the required protection cover or the housing without authorization, improper
use as well as incorrect installation or operation may result in severe injuries to persons
or damage to property.
Refer to the documentation for additional information.
Operating Instructions – DFS/CFM Synchronous Servomotors
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7
2
2.2 Target group
Safety Notes
Target group
Any mechanical work may only be performed by adequately qualified personnel. Qualified personnel in this context are persons who are familiar with the setup, mechanical
installation, trouble shooting and maintenance for this product. Further, they are qualified as follows:
• Completed apprenticeship in the field of mechanical engineering (e.g. mechanic or
mechatronic technician).
• They are familiar with these operating instructions.
Any electric work may only be performed by adequately qualified personnel. Qualified
electricians in this context are persons who are familiar with the electronic installation,
startup, trouble shooting and maintenance for this product. Further, they are qualified as
follows:
• Completed apprenticeship in the field of electrical engineering (e.g. electric or
mechatronic technician).
• They are familiar with these operating instructions.
Any activities regarding transportation, storage, operation, and disposal must be carried
out by persons who have been instructed appropriately.
2.3 Designated use
The designated use refers to the procedure specified in the operating instructions.
DFS/CMP synchronous servomotors are drive motors designed for use in industrial and
commercial systems. Motor utilization other than that specified (refer to nameplate) and
areas of application other than industrial and commercial systems can only be used after
consultation with SEW-EURODRIVE.
The DFS/CFM synchronous servomotors meet the requirements stipulated in the low
voltage guideline 2006/95/EC. Do not take the unit into operation until you have established that the end product complies with the Machinery Directive 98/37/EC.
You must observe the technical data and information on the connection requirements
as provided on the nameplate and in the documentation.
The following applications are prohibited unless the unit is explicitly designed for such
use:
• Use in potentially explosive atmospheres
• Use in areas exposed to harmful oils, acids, gases, vapors, dust, radiation, etc.
8
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Operating Instructions – DFS/CFM Synchronous Servomotors
2.4 Other applicable documentation
The following publications and documents have to be observed as well:
• "SPIROPLAN
• "Low Backlash Geared Servomotors (BSF.., PSF..)" catalog
• Operating instructions of the inverter for motors powered by inverters
• Corresponding wiring diagrams
®
W Gear Units, R..7, F..7, K..7, S..7 Series" operating instructions
2.5 Transportation/storage
Follow the instructions on transportation, storage and proper handling.
Immediately upon receipt, inspect the shipment for any damage that may have occurred
during transportation. Inform the shipping company immediately in the event of damage.
If you notice any transport damage, do not startup the motor, consult the
SEW-EURODRIVE Service.
Remove securing devices used for transportation prior to startup.
Safety Notes
Other applicable documentation
2
Tighten installed transportation eyebolts. They are designed to only carry the weight of
the motor/gearmotor; do not attach any additional loads.
The installed lifting eyebolts comply with DIN 580. The loads and regulations specified
in this standard must always be observed. If the gearmotor has 2 suspension eye lugs
or lifting eyebolts, then you should also use both suspension eye lugs for attaching
transport ropes. In this case, the tension force vector of the slings must not exceed a 45°
angle according to DIN 580.
Store the servomotor in a dry, dust-free environment if it is not to be installed straight
away.
2.6 Installation/assembly
Comply with the instructions in section 4, "Mechanical Installation" and section 5, "Electrical Installation".
The units must be installed and cooled according to the regulations and specifications
in the corresponding documentation.
Protect the synchronous servomotors from excessive strain. Ensure that components
are not deformed, particularly during transportation and handling.
The following applications are prohibited unless the unit is explicitly designed for such
use:
• Use in potentially explosive atmospheres
• Use in areas exposed to harmful oils, acids, gases, vapors, dust, radiation, etc.
Operating Instructions – DFS/CFM Synchronous Servomotors
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9
2
Safety Notes
Electrical installation
2.7 Electrical installation
Perform electrical installation according to the respective applicable laws, regulations
and standards (e.g. cable cross sections, fusing, protective conductor connection). For
any additional information, refer to the applicable documentation.
Observe the wiring information and differing data on the nameplate.
Observe the notes in sec. 5, "Electrical Installation".
2.8 Startup/operation
Whenever changes to normal operation occur, such as increased temperatures, noise,
vibrations, determine the cause and consult the manufacturer.
Observe the notes in section 6, "Startup".
2.9 Inspection/maintenance
2.10 Disposal
Observe the notes in section 8, "Inspection/Maintenance".
This product consists of:
•Iron
•Aluminum
• Copper
• Plastic
• Electronic components
Dispose the individual components in accordance with the material structure and
the regulations in force.
10
Operating Instructions – DFS/CFM Synchronous Servomotors
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DFS synchronous servomotor – general structure
3 Motor Structure
TIP
The following illustrations are intended to explain the general structure. They are to
facilitate the assignment of components to the spare parts list. Deviations are possible
depending on the motor size and version!
3.1 DFS synchronous servomotor – general structure
Motor Structure
3
[316] [321] [1] [10][7] [11] [304]
[1] Rotor [304] Housing cover
[7] Flanged endshield [305] Resolver
[10] Retaining ring [313] Locking plate
[11] Grooved ball bearing [314] Pin contact power/brake
[16] Stator [316] Power connector, complete
[42] B-side endshield [318] Flange socket complete
[44] Grooved ball bearing [319] Pin contact signal
[106] Oil seal without key [321] Signal connector, complete
[220] Absolute encoder [550] Complete brake
[313]
[314]
[318]
[319]
[305][42][44][550][16][106]
AS1H / ES1H
[220]
[304]
413859723
Operating Instructions – DFS/CFM Synchronous Servomotors
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3
Motor Structure
CFM synchronous servomotor – general structure
3.2 CFM synchronous servomotor – general structure
[313]
[316]
[317]
[105]
[11]
[106]
[7]
[1]
[16]
[44]
[42]
[312]
[550]
[660]
[737]
[321]
[327]
[304]
[318]
[305]
413861259
[1] Rotor [312] Connector housing
[7] Flanged endshield [313] Locking plate
[11] Grooved ball bearing [316] Power connector, complete
[16] Stator [317] Socket contact
[42] B-side endshield [318] Flange socket complete
[44] Grooved ball bearing [321] Signal connector, complete
[105] Shim washer [327] Cover
[106] Oil seal [550] Complete brake
[304] Housing cover [660] Release lever
[305] Resolver [737] Encoder housing
12
Operating Instructions – DFS/CFM Synchronous Servomotors
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Nameplate, unit designation and serial number
3.3 Nameplate, unit designation and serial number
3.3.1 Nameplate
Example: CFM 71M /BR /TF /RH1M synchronous brake motor
76646 Bruchsal/Germany
Typ
CFM71M/BR/TF/RH1L/SB50
Nr.
01.1234567890.0001.07
M
Motor
0
n
N
U
Sys
Bremse
Getriebe
M
i
a pk
:1
Nm
6,5
r/min
3000
V
400
V
230
IM
B5
Nm
I
max
Iso.Kl.
Nm
14
n
a pk
I
0
A
4,3
17,2
Permanentmagnet
A
155 (F)
Gleichrichter
/
n
BME
e pk
Motor Structure
3 IEC60034
IP
65
˚C
-20...+40
r/min
13,0
kg
3
0199 081 0.13
3.3.2 DFS/CFM unit designations
Synchronous servomotors
DS... Motor for mounting to size 56 gear units
DFS... Size 56 in flange-mounted version
CM... Motor for mounting to gear units of sizes 71/90/112
CFM... Sizes 71/90/112 in flange-mounted version
Standard equipment for synchronous servomotors
/SM.0 Motor plug connector (socket on motor end only)
/SB.0 Plug connector motor + brake (socket on motor end only)
/RH1M Resolver
/RH1L Resolver for brake motors
/TF Thermistor (PTC resistor)
/KTY Temperature sensor
Umrichterbetrieb
Made in Germany
685748747
Operating Instructions – DFS/CFM Synchronous Servomotors
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3
Motor Structure
Nameplate, unit designation and serial number
Synchronous servomotor options
/B Size 56 disk brake
/BR Size 71/90/112 disk brake
/HR . . manual brake release with automatic re-engaging function sizes 71/90/112
/SM.. Motor plug connector with code number for size and connection cross section
SB.. Plug connector for motor + brake with code number for size and connection cross section
®
/ES1H HIPERFACE
/AS1H HIPERFACE
/AV1H HIPERFACE
/AV1Y Multi-turn SSI encoder, solid shaft, size 56
/AK0H Multi-turn SSI encoder, solid shaft, size 56
/EK0H HIPERFACE
/VR Forced cooling fan
/KK Terminal box
/KK5 Terminal box for radial encoder
/KK6 Terminal box for axial encoder
single-turn encoder, spreadshaft, size 56/71/90/112
®
multi-turn encoder, spreadshaft, size 56/71/90/112
®
multi-turn encoder, solid shaft, size 56/71/90/112
®
single-turn encoder, spread shaft, size 56
3.3.3 Sample unit designation: DFS synchronous brake motor
DFS 56L /B /TF /RH1M /SM11
Plug connector (motor option)
Resolver as standard equipment
TF thermistor as standard equipment
Brake (motor option)
Size 56L
Flange-mounted motor DFS series
14
Operating Instructions – DFS/CFM Synchronous Servomotors
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Nameplate, unit designation and serial number
3.3.4 Sample unit designation: CFM synchronous brake motor
CFM 112S /BR /TF /AS1H /SB50
3.3.5 Scope of delivery for SEW-EURODRIVE motors
The scope of delivery for SEW-EURODRIVE servomotors includes for standard mo-
tors:
Motor Structure
Plug connector as standard
Motor option HIPERFACE® multi-turn
encoder
TF thermistor as standard equipment
Brake (motor option)
Size 112S
Flange-mounted motor CFM series
3
Delivery with order confirmation
Delivery with drive 1 x Motor according to order confirmation
Pre-fabricated cable 1 x Bag with loose parts including conductor end sleeves and cable lugs for connection to
Forced cooling fan 1 x Power connector
Plug connector 1 x Encoder connector (radial or axial)
1 x Operating instructions in the language of the corresponding country, if requested. When ordering
several servo gear units, the customer can reduce the number of operating instructions.
1 x Safety notes for startup, if requested
1 x Spare parts list if requested
SEW-EURODRIVE inverters.
1 x Power socket
4 x Hex head screw
4 x Square nut
10 x Crimp socket contacts for encoder connector for core cross sections of 0.25 mm2 to 0.5 mm2.
1 x SM50 mating connector for motor power cable
4 x Crimp socket contacts for power connection for core cross sections of 1.5, 2.5, 4, 6 or 10 mm
2
Operating Instructions – DFS/CFM Synchronous Servomotors
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3
Motor Structure
Nameplate, unit designation and serial number
The scope of delivery for SEW-EURODRIVE servomotors includes for brakemotors:
Delivery with order confirmation
Delivery with drive 1 x Motor according to order confirmation
Pre-fabricated cable 1 x Bag with loose parts including conductor end sleeves and cable lugs for connection to
Brake 1 x AC-operated BME brake rectifier for DIN rail mounting, or alternatively:
Forced cooling fan 1 x Power connector
Plug connector 1 x Encoder connector (radial or axial)
1 x Operating instructions in the language of the corresponding country, if requested. When ordering
several servo gear units, the customer can reduce the number of operating instructions.
1 x Safety notes for startup, if requested
1 x Spare parts list if requested
SEW-EURODRIVE inverters
- BMP, BMH or BMK brake rectifier
- BSG brake control unit at a voltage of DC 24 V
1 x Manual release lever if brake with manual release was ordered
1 x Power socket
4 x Hex head screw
4 x Square nut
4 x Mounting bracket
10 x Crimp socket contacts for encoder connector for core cross sections of 0.25 mm2 to 0.5 mm
1 x SB50 mating connector for motor power and brake cable
4 x Crimp socket contacts for power connection for core cross sections of 1.5, 2.5, 4, 6 or 10 mm
3 x Crimp socket contacts for brake connection for core cross sections of 1 mm2 or 1.5 mm
2
2
2
3.3.6 Example: Serial number
01. 301234568. 0001. 03
Final two digits of the year of manufacture
Unit serial number (4 digits)
Order number (10 digits)
Sales organization
16
Operating Instructions – DFS/CFM Synchronous Servomotors
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4 Mechanical Installation
4.1 Required tools/resources
• Standard tools
• Mounting device
• Operation with conductor end sleeves: Crimping tool and conductor end sleeves
• Crimping tool for plug connectors
• Removal tool
4.2 Before you begin
The drive may only be installed if
• The specifications on the drive's nameplate and/or the output voltage of the
frequency inverter match the voltage supply system
• The drive is undamaged (no damage caused by transportation or storage).
Mechanical Installation
Required tools/resources
4
• You are certain that the following requirements have been fulfilled:
– Ambient temperature between –20 °C and +40 °C
– No oil, acid, gas, vapors, radiation, etc.
– Installation altitude max. 1000 m above sea level
– Special designs: Drive configured in accordance with the ambient conditions
4.3 Preliminary work
Motor shaft ends must be thoroughly cleaned of anti-corrosion agents, contamination or
similar (use a commercially available solvent). Make sure that the solvent does not come
into contact with the bearing or sealing rings as it may damage the material.
NOTICE
The bearing and the sealing rings can be damaged if exposed to solvents.
Potential damage to property.
• Protect the bearing and sealing rings from exposure to solvents.
4.3.1 Installation after extended storage
• Note that the service life of the lubricant in the ball bearings is reduced by 10% per
year after the first year of storage.
• Check whether the motor has absorbed moisture as a result of being stored for a long
time. Measure the insulation resistance for this purpose (measuring voltage
DC 500 V).
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4
Mechanical Installation
Preliminary work
The insulation resistance (see following figure) varies greatly depending on the temperature. The motor must be dried if the insulation resistance is not adequate.
The following figure shows the insulation resistance depending on the temperature.
[MΩ]
100
4.3.2 Drying the motor
TIP
Insulation resistance too low:
→ Servomotor has absorbed moisture
Measure:
• Use hot air to heat up the motor.
• Open the motor compartment enough for moisture to escape from the inside.
Next check whether:
• The wiring space is dry and clean.
• The connections and fastening parts are free from corrosion.
• The joint seal is functioning.
• The cable glands are tight, otherwise clean or replace them.
10
0,1
[1]
1
0
20
40
60
80
[°C]
413914507
18
Operating Instructions – DFS/CFM Synchronous Servomotors
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4.4 Installing the motor
NOTICE
Improper mounting may result in damages to the motor.
Potential damage to property.
• Only install the motor in the specified mounting position on a level, vibration-free,
and torsionally rigid support structure.
• Align the motor and the driven machine carefully to avoid placing any unacceptable
strain on the output shafts.
• Observe permitted overhung and axial loads → "Low Backlash Servo Gearmotors
(BSF.., PSF..)" catalog.
• Do not butt or hammer the shaft end.
NOTICE
Vertical designs with VR forced-cooling fan can get damaged by foreign objects or
moisture.
Potential damage to property.
• Protect vertical designs with VR forced-cooling fan with corresponding covers.
Mechanical Installation
Installing the motor
4
If a forced cooling fan is used, ensure there is sufficient clearance around the unit to
allow for adequate cooling. Make sure that the unit does not suck in hot outgoing air from
other units.
Components with a keyway to be mounted belatedly on the shaft must be balanced
using a half key. Motor shafts may be balanced with a half key (vibration level "N" to
EN/IEC 600 34). You must not operate the motor without a key.
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19
4
Mechanical Installation
Mounting tolerances
4.4.1 Installation in damp locations or in the open
• Try to arrange the motor and encoder connection so that the connector cables do not
point upwards.
• Coat the threads of the cable glands and filler plugs with sealing compound and
tighten them properly. Then coat them again.
• Clean the sealing surfaces of the connector (motor and/or encoder connection)
before reassembly.
• Replace any brittle seals.
• If necessary, restore the anticorrosive paint coat.
• Check that the degree of protection is maintained.
4.5 Mounting tolerances
Shaft end Flanges
Diameter tolerance according to EN 50347
•ISO k6
• Center bore in accordance with DIN 332, shape
DR..
Centering shoulder tolerance in accordance with
EN 50347
•ISO j6
20
Operating Instructions – DFS/CFM Synchronous Servomotors
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5 Electrical Installation
DANGER
Risk of injury due to electric shock.
Severe or fatal injuries.
• It is essential to comply with the safety notes in section 2 during installation.
• Use switch contacts in utilization category AC-3 to EN 60947-4-1 for connecting
the motor and the brake.
• When motors are powered from inverters, you must adhere to the wiring
instructions issued by the inverter manufacturer.
• Observe the operating instructions for the servo inverter.
5.1 Assembling the connector
NOTICE
If the connector is tightened when it is installed in the wrong position, the insulator could
slip, causing irreparable damage.
Potential damage to property.
Note the following when plugging in the power and signal connectors:
• Check that the connector is installed in the correct position.
• Check that the detent on the connector is positioned correctly.
• Make sure that the connector lock can be turned without having to apply too much
force.
Electrical Installation
Assembling the connector
5
5.2 Wiring notes
5.2.1 Protection against interference by brake controllers
Do not route unshielded brake cables alongside switched-mode power cables, since
brake controllers may cause interference.
Switched-mode power cables include in particular:
• Output cables from frequency inverters and servo inverters, converters, soft start
units and brake units
• Supply cables to braking resistors and similar.
5.2.2 Thermal motor protection
Install the connecting lead of the TF/KTY separately from other power cables, maintaining a distance of at least 200 mm. Collective installation is only permitted if either the
TF / KTY cable or the power cable is shielded.
Operating Instructions – DFS/CFM Synchronous Servomotors
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21
5
Electrical Installation
Connecting the motor and encoder system using SM../SB.. plug connectors
5.3 Connecting the motor and encoder system using SM../SB.. plug connectors
The DFS/CFM motors are supplied with the SM../SB.. plug connector system. In the
basic version, SEW-EURODRIVE delivers DFS/CFM motors with a flange socket on the
motor end and without mating connector. The encoder system is connected using a separate 12-pin round plug connector. The standard encoder cable entry is axial for the DFS
motor and radial for the CFM motor.
5.3.1 Cable cross section
Make sure that the type of cable complies with the applicable regulations. The rated currents are specified on the nameplate. The cable cross sections that can be used are
listed in the following table.
Typ e Cable type Cable cross section
[mm2] [AWG]
SM11/SM51/SM61
SM52/SM62 4 x 2.5 mm
SM54/SM64 4 x 4 mm
SM56/SM66 4 x 6 mm
SM59/SM69 4 x 10 mm
SB11
SB51/SB61 4 x 1.5 mm
SB52/SB62 4 x 2.5 mm
SB54/SB64 4 x 4 mm
SB56/SB66 4 x 6 mm
SB59/SB69 4 x 10 mm
Motor cable
Brakemotor cable
4 x 1.5 mm
4 x 1.5 mm
2
2
2
2
2
2
+ 2 x 1 mm
2
+ 3 x 1 mm
2
+ 3 x 1 mm
2
+ 3 x 1 mm
2
+ 3 x 1.5 mm
2
+ 3 x 1.5 mm
2
AWG 16
AWG 14
AWG 12
AWG 10
AWG 8
2
AWG 16 + AWG 18
2
AWG 16 + AWG 18
2
AWG 14 + AWG 18
AWG 12 + AWG 18
2
AWG 10 + AWG 16
2
AWG8 + AWG16
5.3.2 Prefabricated cables
Pre-fabricated cables are available from SEW-EURODRIVE to connect the SM../SB..
plug connector system. The core designation and contact assignment are listed in the
following tables.
Observe the following when you assemble the cables yourself:
• Section 10 describes the assembly of the SM1./SB1., SM5./SM6., SB5./SB6 power
connectors and the signal connector.
• The socket contacts for the motor connection are designed as crimp contacts. Only
use suitable tools for crimping.
• Strip the insulation of the leads according to section 10.
• Use suitable removal tools to remove incorrectly installed socket contacts.
• Install the insulator in the signal connectors on the motor end at "zero" degree (center
position). Observe this coding on the cable end.
• Cable relief according to EN 61984 and EN 60529 is influenced by the tightening
torque of the screw. The tightening torque must be matched to the cable.
22
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Dimensioning the cable cross section
5.4 Dimensioning the cable cross section
5.4.1 Cable dimensioning according to EN 60402
The following figure shows the minimum required cable cross section depending on
cable length l [m] and current I [A].
150
130
110
100
90
70
50
2,5 mm²
1,5 mm²
6 mm²
4 mm²
10 mm²
Electrical Installation
25 mm²
16 mm²
5
30
010 2030405060708090100
Hybrid cables with cross sections of 1.5 mm
dered from SEW-EURODRIVE.
I [A]
576701195
2
(AWG 16) to 10 mm2 (AWG 8) can be or-
Operating Instructions – DFS/CFM Synchronous Servomotors
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5
5.4.2 Cable load table
Electrical Installation
Dimensioning the cable cross section
Cable load through current I in [A] according to EN 60204-1 table 5, ambient temperature 40 °C.
Triple-core, plas-
Cable cross section
[mm2] [AWG] [A] [A] [A]
1,5 AWG 16 12,2 15,2 16,1
2,5 AWG 14 16,5 21,0 22
4 AWG 12 23 28,0 30
6 AWG 10 29 36,0 37
10 AWG 8 40 50,0 52
16 AWG 6 53 66,0 70
25 AWG 4 67 84,0 88
35 AWG 2 83 104,0 114
tic-sheathed cable
in
Duct or cable
Triple-core, plastic-
sheathed cable on
top of each other on
wall
Triple-core, plastic-
sheathed cable
next to each other,
horizontal
These data are merely recommended values and are no substitute for the detailed
project planning of the cables depending on the concrete application considering the
applicable regulations.
Observe the voltage drop that occurs along the cable in particular with the DC 24 V
brake coil when dimensioning the cross sections for the brake cable. The accelerator
current is decisive for the calculation.
24
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Dimensioning the cable cross section
5.4.3 Assignment of servomotor and cable cross section
Electrical Installation
5
Rated speed nN [rpm] Motor
CFM71S 5 2.2 51 / 61 3.95 51 / 61
CFM71M 6.5 3 51 / 61 5.3 51 / 61
CFM71L 9.5 4.2 51 / 61 7.4 52 / 62
CFM90S 11 4.9 51 / 61 8.7 52 / 62
2000
3000
4500
6000
1) For UL application only with terminal box
CFM90M 14.5 6.9 51 / 61 12.1 54 / 64
CFM90L 21 9.9 51 / 61 17.1 56 / 66
CFM112S 23.5 10 51 / 61 18.0 56 / 66
CFM112M 31 13.5 52 / 62 24.5 59 / 69
CFM112L 45 20 54 / 64 35.5 59 / 69
CFM112H 68 30.5 59 / 69 – –
DFS56M 1 1.65111.6511
DFS56L 22.4112.411
DFS56H 42.811 – –
CFM71S 5 3.3 51 / 61 5.9 51 / 61
CFM71M 6.5 4.3 51 / 61 7.6 52 / 62
CFM71L 9.5 6.2 51 / 61 11.1 54 / 64
CFM90S 11 7.3 51 / 61 12.7 54 / 64
CFM90M 14.5 10.1 51 / 61 17.4 56 / 66
CFM90L 21 14.4 52 / 62 25.5 59 / 69
CFM112S 23.5 15 52 / 62 27 59 / 69
CFM112M 31 20.5 54 / 64 35 59 / 69
CFM112L 45 30 59 / 69 48 –
CFM112H 68 43 – – –
DFS56M 11.6511 – –
DFS56L 22.411 – –
DFS56H 4411––
CFM71S 5 4.9 51 / 61 8.5 52 / 62
CFM71M 6.5 6.6 51 / 61 11.3 54 / 64
CFM71L 9.5 9.6 51 / 61 17.1 56 / 66
CFM90S 11 11.1 51 / 61 18.9 56 / 66
CFM90M 14.5 14.7 52 / 62 26 59 / 69
CFM90L 21 21.6 54 / 64 39 59 / 69
CFM112S 23.5 22.5 54 / 64 38.5 59 / 69
CFM112M 31 30 56 / 66 54 –
CFM112L 45 46 59 / 69
CFM112H 68 66 – – –
DFS56M 11.6511 – –
DFS56L 22.7511 – –
DFS56H 45.311 – –
CFM71S 5 6.5 51 / 61 11.6 54 / 64
CFM71M 6.5 8.6 51 / 61 14.1 54 / 64
CFM71L 9.5 12.5 52 / 62 21.5 59 / 69
CFM90S 11 14.5 52 / 62 23.5 59 / 69
CFM90M 14.5 19.8 54 / 64 37 59 / 69
CFM90L 21 29.5 56 / 66 51 –
M
[Nm]
0
400 V 230 V
I
0
[A] [A]
SM
SB
I
1)
––
0
SM
SB
1)
1)
1)
1)
The suggested cross sections for 230 V are sufficient for NFPA 79 and UL 508
(without 1). Further DFS/230 V motor variants are available on request
Operating Instructions – DFS/CFM Synchronous Servomotors
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5
Electrical Installation
Dimensioning the cable cross section
TIP
The assignments of SM/SB plug connectors are not binding. Given the dynamic properties in the system, other cross sections can also be implemented.
26
Operating Instructions – DFS/CFM Synchronous Servomotors
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Electrical Installation
Power cables for DFS motors
5.5 Power cables for DFS motors
5.5.1 Structure of the motor cables and brakemotor cables for DFS motors
The following figure shows the structure of the motor cables and brakemotor cables:.
5
[1]
[2]
X
[3]
[4]
Connector: Intercontec BSTA 078
[1]
SEW-EURODRIVE logo printed on cable
[2]
Nameplate
[3]
Cable length ≤ 10 m: Tolerance +200 mm
[4]
Cable length ≥ 10 m: Tolerance +2%
Permitted line length according to the technical documents.
Prefabricated cable end for inverter
[5]
Required loose parts are supplied with the cable.
Shielding 20 mm, pulled back approximately + 5 mm
[6]
[5]
[6]
500 ±5
413916043
Motor side The motor cables on the motor side consist of an 8-pin plug connector and socket con-
tacts.
The shield is connected in the connector housing according to EMC requirements. All
plug connectors seal the plug on the cable end with a lamellar seal and ensure cable
relief according to EN 61884.
Inverter side The individual cable cores of the motor and brakemotor cables are exposed and the
shield is prepared for connection in the control cabinet. The cable for the inverter end
has yet to be assembled. The loose parts required are supplied with the cable in a separate bag.
Loose parts The following loose parts are supplied in accordance with the core cross sections for
connection to the power terminals on the inverter:
Bag no. Content
2
1
4 x conductor end sleeves 1.5 mm
4 x M6 U-shaped cable lugs 1.5 mm
, insulated
2
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5
Electrical Installation
Power cables for DFS motors
5.5.2 Motor cable for DFS motors
DFS motor cable
X
DFS motor cable types
413917579
Plug connector type Number of cores and cable cross
SM11 4 × 1.5 mm
SM11 4 × 1.5 mm
DFS motor cable – pin assignment
Plug connector
View X
BSTA 078
0198 6740
8-pole with
socket contacts
W1
PE
2
V1
U1
section
2
(AWG 16) Fixed installation 0590 4544
2
(AWG 16) Cable carrier
Pin Cable core color Assigned Extra
1 (BK) Black U Bag of loose
2 (GN/YE) Green/yellow PE
3 (BK) Black W
4 (BK) Black V
D
3
C
4
B
A
1
Installation Part number
installation
0590 6245
parts
DFS motor cable – alternative plug connector
Plug connectors for power supply with socket contacts (complete).
Plug connector type Number of cores and cable
SM11 4 × 1.5 mm
28
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cross section
2
Operating Instructions – DFS/CFM Synchronous Servomotors
(AWG 16)
Installation
Fixed installation /
cable carrier installa-
tion
Part number
0198 6740
5.5.3 DFS motor cable – extension cable
Y
Extension cable for DFS motor cable:
X
DFS motor cable – types of extension cables
Electrical Installation
Power cables for DFS motors
5
413920651
Plug connector type Number of cores and cable cross
section
2
SM11 4 × 1.5 mm
(AWG 16)
DFS motor extension cable – pin assignment
Plug connector
View X
BSTA 078
0198 6740
8-pin with socket contacts
Pin Cable core color Assigned Pin Plug connector
(BK/WH)
1
Black with
white lettering
U, V, W
2
(GR/YE)
Green/yellow
3(BK/WH)
4V4
Black with
white lettering
U, V, W
Extension cable for DFS motor cable – alternative plug connector
Plug connector with pins (complete) for motor extension cable.
Installation Part number
Cable carrier
installation
1333 2457
View Y
BKUA 199
U1
PE 2
W3
1333 2430
8-pin with pin contacts
D
3
C
4
2
B
1
A
W/3
PE
V/2
U/1
Plug connector type Number of cores and cable cross
section
2
SM11 4 × 1.5 mm
(AWG 16)
Installation
Fixed installation /
cable carrier installa-
tion
Part number
1333 2430
Operating Instructions – DFS/CFM Synchronous Servomotors
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