SEW EURODRIVE DFS/DFY series synchronous motors

Overview

Name: DFS/DFY Synchronous Motors Operating Instructions

Core purpose: To guide the safe installation, wiring, starting, maintenance, and troubleshooting of DFS/DFY series synchronous motors (with or without brakes), including the brake modification process

Product range:

Model: DFS56 (with terminal box), DFY71/90/112 (with terminal box/plug)

Configuration: No brake, with brake (.. B suffix), with AV1Y absolute encoder/TF/TH thermal protection/VY cooling fan

Key limitations:

Storage environment: dry, dust-free, vibration free, temperature -25~+40 ℃

Operating environment: No harmful media such as oil, acid, gas, etc., humidity ≤ 85% (no condensation)

Installation height: ≤ 1000m, if it exceeds 1000m, the capacity needs to be reduced (ratio not specified)

Safety and Installation Fundamentals

Safety operation requirements

Specific requirements for safety categories

Only professional personnel are authorized to install, wire, start, and maintain the operation qualification

Compliance with regulations must comply with project documents, controller manuals, and national/regional safety regulations

Risk protection: Avoid live working and shaft end impact, and prevent contact with high-temperature surfaces (>65 ℃)

Preparation before installation

Long term storage preprocessing (execution required for overdue storage):

Measure the insulation resistance of the winding (U/V/W to the casing) and measure the voltage at 500V

The insulation resistance must meet the temperature corresponding limit (≥ 1M Ω at 20 ℃, ≥ 0.5M Ω at 40 ℃)

The terminal box/plug needs to be clean and dry, with intact seals and tightened threads

Tool preparation: standard tools, crimping tools, end connectors (DIN 46228 Part 1, E-Cu material), disassembly tools

Installation specifications

Mechanical installation:

Installation surface: horizontal, vibration free, anti torsion rigid support

Axis alignment: Avoid bearing force on the axis, follow the allowable cantilever load and axial thrust

Cleaning requirements: Rust inhibitor should be removed from the shaft end and flange (solvents that corrode bearings are prohibited)

Vertical installation: Motors with VY cooling fans require protective covers to prevent foreign objects/liquids from entering

Installation in special environments (humid/outdoor):

Terminal box cable entry facing downwards

Apply sealant to the sealing joint of the threaded cable and tighten it securely

Clean the sealing surface of the terminal box, bond the gasket on one side, and replace the aging gasket

Repair the anti-corrosion coating if necessary

Electrical connection

Motor wiring

Model wiring method, core wiring points

DFS56 (terminal box) cage clamp connection power: U/V/W/PE; Signal: solver (R1/R2/S1-S4), TF/TH

DFY71-112 (terminal box) terminal block connection power: U/V/W/PE; Signal: solver (R1/R2/S1-S4), TF/TH

Prefabricated cables/custom cables with plugs, power core wires 1-3 (U/V/W), PE (yw/gn color); Signal core wires are defined by pins

Key note: Do not change the motor direction through commutation

Brake connection

Model Power Supply Specification Control Method Cable Requirements

DFS56.. B 24VDC ± 10% direct control 4-core cable, connected according to terminal definition

DFY71-112. B 110/230/400VAC or 24VDC switchgear with BM series rectifiers (BMP/BMH/BME) or BSG control unit 4-core cables, requiring simultaneous disconnection of AC/DC circuits (for elevator applications)

Contactor requirements: AC3 level contactors (EN 60947-4-1) must be used, suitable for DC voltage and high current loads

attachment link

AV1Y absolute encoder:

Connection distance: up to 100m

Adaptive controller: MOVIDYN ® (APA12 interface) MOVIDRIVE ® (DPA11A/DIP11A tab)

Cable requirements: twisted pair shielded cable, with both ends of the shielding layer extensively grounded

TF/TH thermal protection:

TF (PTC Thermistor): Compliant with DIN 44082, normal temperature resistance 20-500 Ω, over temperature>4000 Ω

TH (Embedded Thermostat): series connection, over temperature disconnect, maximum voltage 60VAC/DC

VY cooling fan: 3-core cable, connecting phase, neutral wire PE， Connect the plug pins according to the definition

EMC compliance requirements

Signal cable: The resolver and TF/TH signals use twisted pair shielded cables, with each pair of signals twisted separately

Cable separation: Separate the brake cable from the power cable for wiring, or shield the power cable

Shielded connection: The shielding layer is grounded at both ends to ensure large-area contact

Start up and maintenance

startup process

Starting premise:

All connections are correct and secure, and the plugs are anti loose

The motor protection function (TF/TH, overcurrent) has been activated

The drive system has no jamming or safety hazards

Insulation inspection has been completed after long-term transportation/storage

Start operation:

Follow the accompanying servo controller (MOVIDYN) ®/ MOVIDRIVE ®） Instruction Manual

Suggest using software tools (MOVITOOLS, MD_SCOPE) to assist with startup

maintenance

Maintenance cycle: There is no fixed cycle, it needs to be formulated according to the application scenario, and regular visual inspections are required

Brake maintenance (DFY71-112. B):

Maintain project requirements/steps

During the inspection and release of the working air gap, the pressure plate stroke is 0.25-0.8mm, which can be measured using screws or disassembled plugs

Brake disc replacement: 1. Remove the plug and gasket; 2. Use auxiliary screws to pull back the pressure plate; 3. Disassemble the coil body; 4. Replace the brake disc (to avoid oil contamination); 5. Reinstall and tighten

Adjust the braking torque and replace the brake spring as needed after disassembly (symmetrical installation), refer to Appendix Table 4

Encoder maintenance:

Before disassembling the brake, it is necessary to remove the AV1Y encoder to avoid damaging the coupler

Ensure that the coupler has no axial tension and the shaft runout is ≤ 0.05mm during reassembly

Bearing replacement: Only SEW trained personnel can operate (requires recalibration of the resolver)

Brake modification (DFY71-112 without brake → with brake)

Core steps:

Motor preparation: Remove the end cover, retaining spring, and shaft sleeve, heat up the brake bracket and install it

Pre installation of brake coil: Install O-ring, terminal link, insert coil body and lock

Brake pre installation: Install parallel pins, brake springs (according to torque requirements), and pressure plates

Motor installation: Install the retaining spring, brake disc, intermediate ring, and tighten the coil body

Manual release installation: Install the release yoke and lever, adjust the gap by 2mm

Electrical connection: Connect according to section 3.3 and test the braking action

Troubleshooting

Common motor faults

Possible causes and solutions for the fault phenomenon

Unable to initiate circuit breakage, fuse failure, controller malfunction/wiring error. Check and repair the circuit; Replace the fuse; Check the controller and wiring

Difficulty in starting the controller due to incorrect settings, overload and reconfiguration of the controller; Check the load and reduce it

Steering error controller control error check controller setting value, swap setting value circuit

Reduce load due to motor overheating, overload, insufficient cooling, and high ambient temperature; Clean the cooling channel/install a cooling fan; Reduce the ambient temperature

Damaged bearings with abnormal noise, unbalanced rotating parts, and re centering; Check the driven equipment; replace the bearing

Common brake malfunctions

Possible causes and solutions for the fault phenomenon

Unable to release voltage error, control unit malfunction, air gap out of tolerance, coil short circuit, apply nameplate specified voltage; Replace the control unit; Adjust the air gap/replace the brake disc; Replace the brake

The braking delay is changed from only cutting off the AC circuit to cutting off both the AC and DC circuits simultaneously

Abnormal braking torque, incorrect spring selection, brake disc wear, replacement of springs as required; Replace the brake disc

Brake noise causing gear wear and incorrect controller settings due to startup impact. Check the drive configuration; Re optimize controller parameters

Key technical data

Core parameters of brake system

Motor model Maximum braking torque (Nm) Minimum braking torque (Nm) Coil resistance (24VDC, Ω)

DFS56M/B – 2.5 59

DFY71S/B 6 3 3.6

DFY90S/B 20 12 2.5

DFY112L/B 90 35 1.8

Cable specifications

Connecting object, core wire section, cable outer diameter (mm), stripping length (mm)

Motor power (DFY71) 4 × 1.5mm ² 13.5 7 ± 0.5

Resolver signal 4 × 2 × 0.22~0.56mm ² -5 ± 1

AV1Y encoder 3 × 2 × 0.24~1mm ² 8 4