» Operating and maintenance
guidelines
EMK-motors
Table of contents
Operating and maintenance guidelines
EMK motors
Operating and maintenance guidelines EMK motors 3
Spare Parts 5
Lubrication periods 6
Measures 7
Operating and maintenance guidelines spring-operated brake 9
Operating and maintenance guidelines
EMK motors
» EMK motors distinguish themselves...
The electrical connection and maintenance of an elec-
tric drive may only be carried out by qualified electrical
personnel, who are conversant with the relevant regu-
lations. Similarly, the applicable accident prevention
regulations are to be adhered to.
Every EMZ motor is dispatched only after the specifi-
cations on the order have been checked, and a trial run
had been carried out. Until installed, the motor is to be
stored dry and in the same way as the mounting positi-
on. For longer stocked motors the insulated resistance
of every phase has to be measured to ground. It has to
be greater than 0,5 MΩ. For trouble free functioning,
proper installation and operation is essential.
Installation
The motor is to be installed according to its mounting
position and on an even and vibration-free base. The
shaft extensions up to 50 mm 0 have tolerances con-
forming to ISO k6 and above to ISO m6. Before fitting,
the rust inhibitor must be removed from the shaft end,
however, care must be exercised to ensure that no sol-
vent penetrates into the bearing. The motor shaft end
has been provided with a centre and a tapped hole, ac-
cording to the DIN specification 332 type D, which can
be used to pull on the transmission elements without
exerting harmful forces on the motor bearings.
Hammer blows and jolts are to be avoided at all times!
So as not to load the motor shaft excessively, the motor
and the driven machine are to be carefully aligned.
Important for installations in wet internal conditions
or outdoors.
Please note that trouble free operation can only be en-
sured if all the measures set out below are carried out.
The motor terminal box is to be fitted so that the cable
entries are directed downwards.
Use suitable conduit screw fittings for the cable being
used and if necessary use reducing nipples.
Conduit screw fittings and plugs are to be coated with
sealing compound, tightened up securely and recoated.
Cable intakes are also to be made completely water-
tight.
The sealing surfaces of terminal boxes and termi¬nal
box covers are to be properly cleaned before reassem-
bly.
Size
M12 x 1,5 1,5 8
M16 x 1,5 3,0 10
M20 x 1,5 6,0 12
M25 x 1,5 8,0 12
M32 x 1,5 10,0 18
M40 x 1,5 13,0 18
M50 x 1,5 15,0 20
M63 x 1,5 16,0 20
M72 x 1,5 - 28
M80 x 1,5 - 40
Plastic Metal
Torques (Nm)
Gaskets are to be glued down on one face. Brittle gas-
kets are to be replaced!
When reassembling after maintenance work, etc. the
end shield centring spigots are also to be coated with
sealing compound.
The corrosion protection consists of a number of paint
coatings. Depending on environmental conditions the
paint coating must be renewed on a regular basis or
wherever necessary.
EMK Operating and maintenance guidelines 3
The stated rated motor power applies for a maximum
40 °C ambient temperature and installation altitude up
to 1000 m (3330 feet) above sea level. For higher am-
bient temperatures or installation at greater heights
the power rating is reduced accordingly. (Refer to DIN
57530).
The unimpeded access of ventilating cooling air must
be ensured.
Condensate water drain holes (only on customer‘s re-
quest) are plugged with plastic plugs that can be ope-
ned as required. Open condensate water drain holes are
not permitted because then the IP44 resp. IP55 is lost!
Electrical connection
The motor is connected in accordance with the data
shown on the nameplate and per the accompanying
circuit diagram. Ensure that the terminal links are cor-
rectly placed and all connections, including the protec-
tive earth conductor, are screwed tightly.
To protect the motor from being overloaded, appropri-
ate protective devices must be provided. Fuses do not
give this protection. For motors with high starting fre-
quencies the conventional motor protection is insuffici-
ent; and it is advisable to purchase these motors with
thermistors imbedded in the windings and to monitor
them with an external tripping relay. In this manner the
motors are fully protected against practical all possible
overloads.
Maintenance
For motors up to and including size 132 it is sufficient
to keep the cooling passages cleaned and to check the
bearings. These motors have bearings with service life
lubrication. If the motor is being overhauled the bea-
rings are to be replaced. Motors larger than size 160 are
provided with a lubricator. In addition to keeping the
regularly and relubricated with a grease pump accor-
ding to the schedule below.
Relevant for greasing interval and grease quantity are
the grease labels fitted on the motor.
Please pay attention that the regreasing device may
not be filled for the first greasing interval.
For this, the double grease quantity has to be used.
As soon as the maximum number of relubrications is
exceeded, the old grease must be removed from the
grease chambers and bearings, after which these must
be cleaned thoroughly. Next the inner chambers and
the bearings must be provided with new grease. The
outer chambers may not be filled with grease.
The type of grease to be used for lubricating the be-
arings can be found on the relubrication plate of the
motor.
WARNING:
When motor is exploited in extremely conditions, i.e.:
» dustiness > 800mg/m3
» relative humidity > 80%
» aggressive in air
it is necessary to decrease minimum two times period
between consecutive inspections.
Drain-hole
EMK-motors are equipped with a drain-hole (originally
closed) which has to be opened during service regularly.
cooling passages clean the bearing should be checked
4 Technical amendments reserved, errors excepted
Spare Parts
» When requiring spares please quote the serial number and data shown on the
nameplate together with part numbers and description.
Motor malfunctions
Faults Cause Remedy
Motor overheated (can only
be determined by measurement)
Motor does not start Fuse burnt out. Replace the fuse.
Motor does not start or starts
with difficulty
Motor does not start when
connected in star, however,
starts in delta
Motor hums and takes excessive current
Fuses blow or motor
protec-tion switch trips
immediately
Wrong direction of rotation Motor incorrectly connected. Interchange any two of the incoming mains phases.
For winding faults
Motor connected in delta instead of in star as intended. Correct the wiring connection.
Mains voltage deviates from the rated motor voltage by more than 5 %. Too
high voltage is particularly detrimental for multi-pole motors, since such
motors have a ,,no-load” current approximately equal to the full load current
Overload at normal mains voltage. Current excessive. Speed too low.
Motor capability exceeded (S1 to S8, DIN 57 530). The motor e.g. becomes
overheated due to excessive starting frequency. Here it is not sufficient simply
to use a larger motor since in all probability the same conditions would still
Supply cable has loose contact (temporary single phasing!) Fuse burnt out. Correctly secure the loose contact. Replace the fuse.
Voltage or frequency of electrical supply deviates considerably from required
even when operating on normal current.
Volume of cooling air inadequate, air ducts clogged up. Ensure the unimpeded access and discharge of cooling air.
Cooling air is preheated. Arrange for cool air supply.
arise.
Motor protection switch has tripped. Check protection switch for correct setting and adjust.
Motor contactor inoperative. Control fault. Check contactor operation and control and rectify.
Designed for delta connection but connected in star. Connect motor correctly.
rated value during starting conditions.
Torque insufficient from the connection in star.
Contact fault on the star/delta starter. Rectify star ter fault.
Fault in windings.
Rotor grazing.
Short circuit on the line or motor. Remove short circuit.
Short circuit to motor frame of between the windings turns. Fault to be remedied by a qualified electrical engineer.
Motor incorrectly wired up. Correct the connections.
Arrange for the correct mains voltage to be applied.
Install larger motor (determine the frame size by measuring
Adapt to the duty-cycle rating necessary for the operating con-
ditions. It is preferable under these circumstances to consult
a qualified electrical engineer to determine the correct size of
motor required in order that the motor may be adapted to suit
If delta current is not excessive then reconnect for DIRECT-ONLINE starting, otherwise a larger size of motor or motor having
Motor must be examined and repaired by an electrical service
Motor must be examined and repaired by an electrical service
The motor MUST be repaired at an electrical service centre.
the power).
the actual mode of operation.
Improve mains supply conditions.
special windings will be required.
centre.
centre.
EMK Operating and maintenance guidelines 5
Lubrication periods
bearing h/3000 rpm h/1500 rpm h/1000 rpm h/750 rpm quantity (g)
6309 5200 9500 11700 12800 20
6311 3500 7400 9400 10700 25
6312 2600 5900 7800 8800 25
6313 2500 5700 7700 8900 30
6314 1800 4800 6600 7600 30
6315 1400 3900 5400 6400 30
6316 1600 4500 6300 7500 40
6317 1200 3700 5400 6500 40
6319 1000 3300 5100 6200 50
6320 820 3300 5100 6400 60
6322 580 2800 4600 5800 70
6324 440 2300 4000 5200 80
NU309 2800 7000 9500 11000 20
NU311 1600 5100 7400 8800 25
NU312 1300 4000 5900 7300 25
NU313 1000 3800 5700 7200 30
NU314 810 3000 4800 6000 30
NU315 500 2400 3900 5000 30
NU316 480 2700 4500 4800 40
NU317 430 2200 3700 4900 40
NU319 330 1800 3300 4600 50
NU320 240 1600 3300 4600 60
NU322 120 1300 2800 4100 70
NU324 110 1100 2300 3600 80
Motortype : KAE
BG AS BS BG AS BS
56 6201-2RZ 6201-2RZ 160 6309/NU309 6309
63 6201-2RZ 6201-2RZ 180 6311/NU311 6311
71 6202-2RZ 6202-2RZ 200 6312/NU312 6312
80 6204-2RZ 6204-2RZ 225 (2) 6312/NU312 6312
90 6205-2RZ 6205-2RZ 225 (4-8) 6313/NU313 6312
100 6206-2RZ 6206-2RZ 250 (2) 6313/NU313 6313
112 6306-2RZ 6306-2RZ 250 (4-8) 6314/NU314 6313
132 6308-2RZ 6308-2RZ 280 (2) 6314/NU314 6314
280 (2-4) 6317/NU317 6314
Motortype: KOI Motortype: KZI
BG AS BS BG AS BS
315 (2) 6317/NU317 6317 315 (2) 6317/NU317 6317
315 (4-8) 6319/NU319 6319 315 (4-8) 6319/NU319 6319
355 (2) 6317/NU317 6317 355 (2) 6319/NU319 6319
355 (4-8) 6322/NU322 6320 355 (4-8) 6322/NU322 6322
4
-all bearings: C3 bearing play
6 Technical amendments reserved, errors excepted
Measures
» For prolonged storage and before commissioning of low-voltage motors
Motive
In many cases, low-voltage motors are stored for lon-
ger periods of time before assembly and commissio-
ning, sometimes for several years.
In order to prevent premature damage, our customers
must be informed about this topic and, if necessary,
also about the following measures:
» Storage
When storing the motors, the supplied operating inst-
ructions must always be followed:
» Storage room
The motors must be stored in a dry, ventilated, dust-
free, and vibration-free room. Further, the storage
temperature should not be below -15°C (according to
EN60034-1) and the relative humidity should be below
60%.
If this is guaranteed, no special protective packaging
is required.
In all other cases, special packaging with plastic bags
and humidity indicators and a regular inspection will
be necessary.
EA regular inspection of the corrosion coating and, if
necessary, a renewal is necessary.
» Rotor holding device
The rotor holding device serves as a protection of the
bearings during transport and / or in the case of non-
vibration-free mounting (danger of brinelling). If a
rotor retaining device has been mounted on the drive
end of the shaft (DE shaft end) by the factory (e.g. for
designs with roller bearings), this must not be remo-
ved.
If the disassembly of the rotor retaining device is un-
avoidable (e.g. during inspections, tests, etc.), it must
be reattached before dispatch or during further sto-
rage. This also applies in particular to motors in which
a coupling half must be mounted on the DE shaft end.
The coupling half must be removed again after the ad-
justment, the rotor holding device must be reassem-
bled and the coupling half must be supplied or stored
separately.
» Condensation water
If condensation drain holes are present on the motor,
any condensation water must be drained off by remo-
ving the plugs.
» Anti-rust
All exposed, outer components (e.g. shaft end, flanges,
feet) have a protective coating for 6 months storage
under dry conditions.
In order to secure a longer storage period, all accessib-
le bare parts must be provided with a long-term corro-
sion protection coating (e.g. Tectyl 506), provided this
has not already been applied by the factory.
Commissioning
The operating instructions of the EMK motor as well
as the safety information „Warnings“ which are sup-
plied with each motor or can be downloaded from the
Internet must be observed entirely.
» Bearings / Lubrication
The rolling bearings must be relubricated if the time
between delivery and commissioning is more than 2
years.
EMK Operating and maintenance guidelines 7
a) Shaft height 56 to 132 (closed bearings)
If the time from delivery to commissioning of the en-
gines is
» under proper conditions (storage in dry, dust-free
and vibration-free rooms) more than 4 years
» more than 2 years under unfavourable conditions
the bearings must be replaced.
b) Shaft height 160 to 355
If the time from delivery to commissioning of the en-
gines is
» under proper conditions (storage in dry, dust-free
and vibration-free rooms) more than 4 years
» more than 2 years under unfavourable conditions
the bearings must be relubricated.
Minimum insulation resistance for new, cleaned or
repaired windings (at 25°C) 10 MOhm
Critical specific insulation resistance after long opera-
tion time at 25ºC winding temperature 0,5 MOhm/kV
The critical value of the insulation resistance is calcu-
lated by multiplying the nominal voltage (in kV) by the
given specific critical insulation resistance (0.5 MOhm
/ kV).
Example:
critical insulation resistance for =690V:
0,69 kV x 0,5 MOhm/kV = 0,345 MOhm
Only identical or compatible greases may be used for
relubrication!
» Insulation resistance
The insulation resistance of the windings to ground
must be measured before commissioning of the mo-
tors. If the minimum values specified by the manufac-
turer are not observed, the motor windings must be
dried.
The following conditions apply to the measurement:
The insulation resistance of the winding is measured
with a DC voltage of 500V to ground. Here, the measu-
ring voltage is applied until the reading values main-
tain stable. The specified minimum values must be
reached during the measurement:
8 Technical amendments reserved, errors excepted
Instruction manual
» Spring-operated brake EMK-KHF 3-Phase-Induction-motors
General Description
» Application
DThe spring-operated DC-energized disc brakes are
used for the EMK three-phase AC motors of the KHF
series in frame sizes 80 - 132. The brake must not be
operated in potentially explosive or aggressive atmos-
pheres. Ambient temperature: -20°C to + 40°C
» Design and mode of operation
The brake is a single-disc brake with two friction
surfaces. In the de-energized state, more preloading
springs are used to generate the braking torque due to frictional locking. The brake is released electromagneti-
cally.
Fig: Brake assembly
During the braking process, the brake disc is pressed against the counter friction surface by the compression
springs. In the braked state, there is an air gap between the magnetic part and the armature plate. By activating
the coil of the magnet part, the armature plate is pressed against the spring force to the magnet part and the
brake is released. In addition, the brake can be released mechanically by pulling the release lever in the direction
of the fan cover.
» Operation
» Electrical wiring
The connection of the brake motor must in accordance with the circuit in the motor terminal box. The AC voltage
for the excitation winding of the brake must be connected to the two free terminals (~) of the rectifier.
Fig. Brake circuit
EMK Operating and maintenance guidelines 9
Instruction manual
» Spring-operated brake EMK-KHF 3-Phase-Induction-motors
Operating conditions
The EMK-KHF series motors can be used under the fol-
lowing conditions:
Frequency / voltage:
3AC50Hz, 230VD/400VY, 3AC60Hz, 460VY
Ambient temperature: -20 - + 40°C
-20 - + 40°C
Installation altitude:
<= 1.000 m above sea level
Relative humidity
<= 85%
The environment should be free of acidic and alkaline
gases, which may interfere with the insulation could
damage the wiring.
Maintenance
The motor should be checked and cleaned regularly.
The intake port of the fan cover should be cleaned of
dirt to ensure proper cooling. The motors have perma-
nently lubricated, maintenance-free bearings.
The brake disc should have a minimum thickness of
1mm. If the minimum thickness is not reached, the
brake disc should be replaced.
The electromagnetic brake should be cleaned regular-
ly and made dust-free.
Adjustment of the brake should only be carried out by
qualified personnel.
To adjust the air gap, tighten the three adjustment
screws evenly.
The friction surface of the brake must be free of oil
and grease.
10
Technical Data
» Operating values of the brake
IEC frame size air gap (mm)) stat. brake torque (Nm) max. air gap (mm)
80 0.3-0.8 7 1.0 <0.20 <0.50
90 0.3-0.8 15 1.0 <0.20 <0.50
100 0.3-0.8 30 1.0 <0.20 <0.50
112 0.3-0.8 40 1.0 <0.25 <0.60
132 0.4-0.9 80 1.2 <0.25 <0.60
brake release time (s) %
fast slow
» Dimensions of the brake
Figure: KHF 80-132
IEC frame
Brake type d1 d2 d3 d4 d5 d6 d L1 L2 L3 L h1 h2 h b
size
80 DLTZ3-08 117 105 92 65 3xM5 10 20 54,3 31 3 20 124 71 21,6 6 0,3
90 DLTZ3-15 127 114 97 65 3xM6 10 24,8 60 36 3 25 126 73 28,1 8 0,4
100 DLTZ3-30 147 133 116 80 3xM6 10 29,5 60 36 3 30 134 83 32,8 8 0,4
112 DLTZ3-40 166 150 130 90 3xM8 12 29,5 62 39 3 30 162 96 32,8 8 0,5
132 DLTZ3-80 187 170 150 104 3xM8 12 39,5 75,2 48 3 30 175 105 42,8 12 0,5
EMK Operating and maintenance guidelines 11
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