NORD B1091 User Manual

Intelligent Drivesystems, Worldwide Services

B1091

Operating and Maintenance Instructions

Three-phase Asynchronous Motors – Standard Design Explosion-proof Motors with Type of Protection „e“ Dust Explosion-proof Motors (Zone 21+ Zone 22)

1. General information .............................................................................................................. 3

2. Description .............................................................................................................................. 4

2.1 Range of application ................................................................................................................. 4

3. Information on the designated use of electric motors ...................................................... 4

3.1 Transport, storage .................................................................................................................... 4

3.2 Installation ................................................................................................................................. 5

3.3 Balancing, output components ................................................................................................. 5

3.4 Alignment .................................................................................................................................. 5

3.5 Electrical connection ................................................................................................................. 5

3.6 Checking insulation resistance ................................................................................................. 6

3.7 Commissioning ......................................................................................................................... 6

4. Maintenance and servicing .................................................................................................... 7

5. Motors with ignition protection "increased safety Exe" .................................................... 8

6. Motors for use in Zone 21 and Zone 22 .............................................................................. 11

6.1 General ................................................................................................................................... 11

6.2 Safety information ................................................................................................................... 11

6.3 Commissioning information / Field of application / Extended ambient temperature range ............. 11

6.4 Structure and method of operation ......................................................................................... 12

6.5 Minimum cross section of bonding conductors ...................................................................... 12

6.6 Maintenance ........................................................................................................................... 13

7. Motors for use in Zone 21 and Zone 22 according to EN 60079-0 and IEC 60079 ........ 14

7.1 General ................................................................................................................................... 14

7.1.2 Impact test .............................................................................................................................. 14

7.2 Safety information ................................................................................................................... 14

7.3 Commissioning information / Field of application / Extended ambient temperature range ............. 15

7.3.1 Electrical Connection .............................................................................................................. 16

7.3.2 Cable and wiring glands ......................................................................................................... 16

7.3.3 Permissible ambient temperature range ................................................................................ 17

7.3.4 Painting ................................................................................................................................... 17

7.3.5 IEC-B14 Motors ...................................................................................................................... 17

7.4 Structure and method of operation ......................................................................................... 18

7.5 Minimum cross section of bonding conductors ...................................................................... 18

7.6 Maintenance ........................................................................................................................... 18

Options for motors for use in Zone 22 ............................................................................... 19

8.1 Inverter operation option ......................................................................................................... 19

8.2 External fan option .................................................................................................................. 19

8.3 Return stop option .................................................................................................................. 19

8.4 Brake option............................................................................................................................ 20

9. Spare parts drawing and spare parts list ........................................................................... 21

10. Conformity declarations ...................................................................................................... 22

Contents

Safety and information symbols Please always observe the following safety and information symbols!

Danger!

Risk of fatalities and injury

Danger!

Important information regarding explosion protection

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Notice!

Machine may be damaged

Note!

1. Information

1. General information

These Operating Instructions must be read before you transport, assemble, commission, maintain or repair NORD motors. All persons who are involved with such tasks must observe these Operating Instructions. All safety instructions provided in these Operating Instructions must be strictly observed for reasons of personal protection and protection of property.

Information and instructions provided in the manual supplied, safety and commissioning information and all other manuals must be observed.

This is absolutely essential in order to avoid hazards and damage! Any applicable national, local and system-specific regulations and requirements must also be

observed!

Special designs and design variants may differ with regard to technical details. If any points are not clear, it is urgently recommended that you consult the manufacturer stating the type designation and motor number or have the maintenance work performed by NORD.

Qualified staff are persons who, owing to their training, experience, instruction received, and their knowledge of relevant standards, accident prevention regulations and the appropriate operating conditions, are entitled to perform the activities necessary in order to put the motor into operation.

This also includes knowledge of first aid measures and the local emergency services. It is assumed that the work for transport, assembly, installation, commissioning, maintenance

and repair will be performed by qualified staff. In particular, the following points must be observed:

 Specifications and information about permissible use, assembly, connection, ambient

and operating conditions, which are included in the catalogue, the order documentation and any other product documentation

 The local, system-specific regulations and requirements  Proper use of tools, hoisting equipment and transport equipment  Use of personal safety equipment

For reasons of clarity the Operating Instructions cannot contain all detailed information about possible design variants so that they cannot take into consideration every conceivable case of installation, operation or maintenance.

For this reason these Operating Instructions essentially only contain such instructions as are required for normal use by qualified staff.

To prevent malfunctions it is necessary that the specified maintenance and inspection work is performed by appropriately trained staff.

 The planning guide B1091-1 must be included with the operating instructions when

operated with the inverter.

 The additional operating instructions must be taken into account if an external fan is

present.

 The brake operating instructions must also be taken into account with braking motors.

If, for any reason, the operating instructions or the planning guide are lost, new documentation must be obtained from Getriebebau NORD.

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2. Description

2.1 Field of Application

Use of the motors: The motors may only be used for their intended purpose.

The motors are designed with at least IP 55 protection (for degree of protection see name plate). They may be installed in dusty or damp environments. The necessary degree of protection and any additional precautions required always depend on the operating and environmental conditions. For outdoor installation and vertical designs, e.g. V1 or V5 with the shaft pointing downward, NORD recommends the use of the double fan hood option [RDD]. The motors must be protected against intense sunlight, e.g. by means of a protective shield. The insulation is tropicalised.

Installation altitude: Ambient temperature: -20°C...+40°C. With standard motors, a greater ambient temperature range is permitted from -20°C...+60°C. The rated power must however be reduced to 82% of the catalogue value. If the maximum value of the ambient temperature is between +40°C and +60°C, the power consumption can be inversely interpolated linearly between 100% and 82%. The motor connection cables and the cable inlet glands must be suitable for temperatures  90°C.

3. Information

 1,000 m

3. Information on the correct handling of electric motors

All work must only be carried out with the power to the system switched off.

3.1 Transport, storage

 For transport, use all the hoisting lugs fitted to the motor!  The hoisting lugs are designed for the weight of the motor; do not attach any

additional loads!

 Only use the hoisting lugs and pins provided when transporting machine sets (e.g.

gear unit attachments) !

 Machine sets must not be hoisted by attaching to individual machines!

To prevent damage to the motor, the motor must always be lifted with suitable hoisting equipment. Under favourable conditions the roller bearings should be replaced if the time between delivery and motor commissioning (storage in dry, dust-free and vibration-free rooms) is more than 4 years. Under unfavourable conditions this time is reduced considerably. It may be necessary to treat unprotected, machine surfaces (flanging surface, shaft end, etc.) with corrosion inhibitor. If necessary, check the insulation resistance of the winding, see section 3.6. Changes in normal operation (higher power consumption, higher temperatures or higher vibrations, unusual noises or smells, response from the monitoring system, etc.) indicate that operation is impaired. To avoid personal injury and damage to property, the maintenance staff responsible must be informed about the change immediately.

In case of doubt switch off the motor without delay, as soon as the status of the system permits.

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3. Information

3.2 Installation

 After installation, screwed-on lifting lugs must be tightened or removed.  Smooth running: Precise alignment of the coupling and a well-balanced drive element

(coupling, belt pulleys, fans, etc.) are prerequisites for quiet, low vibration operation.

 Complete balancing of the motor with the drive elements may be necessary.  The upper section of the terminal box and the terminal box position can be rotated by

4 x 90 degrees.

 IEC-B14 motors:

All four fixing screws must be screwed into the flanged bearing cover, even if they are not required! The fixing screw threads must be inserted with a sealant, e.g. Loctite 242. The maximum depth for screwing into in the bearing cover is 2 x d.

 The motor must be inspected for damage before installation and commissioning.

A damaged motor must not be commissioned.

 Rotating shafts and unused shaft ends must be safely protected against contact.

Unused parallel keys must be secured against being thrown out.

3.3 Balancing, drive elements

Fitting and removal of output assemblies (coupling, pulleys, gears, etc.) must be performed with a suitable device. As standard, the rotors are balanced with half key balancing. When

fitting output elements to the motor shaft observe the appropriate type of balancing! The output elements must be balanced in accordance with DIN ISO 1940!

Take the general precautions necessary for providing the output elements with touch guards. If a motor is put into operation without an output element, secure the parallel key to prevent it from being thrown out. This also applies if a second shaft end is fitted. Alternatively, remove the parallel key.

3.4 Alignment

Especially in case of direct coupling, align the shafts of the motor and the driven machine both axially and radially. Inaccurate alignment can lead to bearing damage, excessive vibrations and shaft breakage.

3.5 Electrical connection

Feed the connecting leads into the terminal box with cable glands. The terminal box must be sealed so that it is dust-tight and water-tight. The mains voltage and frequency must conform to the data on the rating plate. ± 5% voltage deviations or ± 2% frequency deviations are permissible without any reduction in performance. The connections and arrangement of the terminal board jumpers must conform to the circuit diagram provided in the terminal box.

Connect the protective earth lead to the protective earth terminal. Provide the ends of the connecting leads with cable lugs or curved ring eyes and connect them to the terminal board. This also applies to the protective earth connection and the external bonding lead.

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Refer to the table below for the tightening torques of the screw connections of electric terminals and the terminal board connections (apart from terminal strips):

3. Information

Tightening torque (Nm) 0.6 – 1.2 1.8 – 2.5 2.7 – 4.0 5.5 – 8.0

If the machine has an standstill heater, it must not be switched on during operation.

3.6 Checking the insulation resistance

Before putting the motor into operation for the first time, after a lengthy period of storage or standstill (approx. 6 months), the insulation resistance of the winding must be determined. During and immediately after the measurements, the terminals carry dangerous voltages and must not be touched.

Insulation resistance

The insulation resistance of new, cleaned, repaired windings against the housing and against one another is >200 MΩ.

Measurement

In the case of windings up to an operating voltage of 400 V the insulation resistance against the housing must be measured with a DC voltage of 500 V. At operating voltages up to 725 V measure with a DC voltage of 1000 V. For this the temperature of the windings should be 25°C ± 15°C.

Checking

In the case of a new, cleaned winding or a repaired motor which has been stored or shut down for any lengthy period, if the insulation resistance of the winding against the housing is less than 50 MΩ, the cause may be moisture. The windings must then be dried. After a lengthy period of operation the insulation resistance may reduce. As long as the measured value does not fall below the critical insulation resistance of < 50 MΩ, the motor may continue to be operated. If the value falls below the critical level, the cause must be established and if necessary, the windings or winding sections must be repaired, cleaned or dried.

Tightening torques for terminal board connections

Thread diameter M4 M5 M6 M8

3.7 Commissioning Note: Electromagnetic compatibility

Production of interference: In case of large torque differences (e.g. when driving a piston

compressor) a non-sine wave motor current is induced, whose harmonics can cause an impermissible effect on the mains and therefore impermissible production of interference. With supply by frequency inverters, various strengths of interference are produced according to the design of the frequency inverter (type, interference suppression, manufacturer). The EMC information of the inverter manufacturer must be observed. If the manufacturer recommends the use of a screened motor supply lead, screening will be most effective if it is electrically connected to a large area of the metal terminal box of the motor (with EMC cable gland made of metal). In the case of motors with built-in sensors (e.g. PTC thermistors) interference voltages due to the inverter can occur in the sensor line.

Interference immunity: In the case of motors with built-in sensors (e.g. PTC thermistors) the user must ensure adequate interference immunity by selecting a suitable sensor signal cable (possibly with screening and connection as with the motor supply cable) and the evaluation device. Prior to commissioning always observe the information and instructions in the operating manuals for inverters as well as all other instructions. After installing the motors, check them to make sure that they are operating correctly! In the case of brake motors also check that the brake operates correctly.

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4. Maintenance, Servicing

Safety measures

Always isolate the motor electrically according to the regulations before commencing any work on the motor or device, especially before opening covers of live components. In addition to the main power circuits, any additional or auxiliary circuits must be taken into account.

The standard "5 safety rules", e.g. according to DIN VDE 0105, are:

 Disconnect  Prevent the equipment from being switched on again  Check that there is no voltage present  Earth and short-circuit  Cover any adjacent live components or prevent access with barriers

These measures may only be removed when the maintenance work is complete and the motor has been completely assembled. Inspect the motors properly at regular intervals. The valid national standards and regulations must be observed. In particular look for any physical damage, ensure that cooling passages are free, listen for any unusual noises, and ensure that electrical connections are made in a proper manner. With the exception of standardised, commercial or equivalent parts, only genuine spare parts may be used!

NOTE: If motors are provided with closed condensation ports, they must be opened from time to time so that any accumulated condensation can drain off. Condensation ports are always positioned at the lowest point of the motor. When installing the motor ensure that the condensation holes are at the bottom.

Changing bearings, grease packing

Under normal operating conditions and with the motor installed horizontally, depending on coolant temperature and motor speed the period for changing bearings in operating hours [h] on IEC motors with coupling drive is as follows:

up to 1800 rpm up to 3,600 rpm

25°C 40°C

approx. 40000 h approx. 20000 h approx. 20000 h approx. 10000 h

In the case of direct gearbox attachment or under special operating conditions, e.g. vertical motor, substantial vibrations or shock loads, frequent reversing, etc. the operating hours stated above will be reduced considerably. The motor must be subjected to a general overhaul every 5 years!

General overhaul

For this the motor must be dismantled. The following work must be carried out:

 All components of the motor must be cleaned  All components of the motor must be examined for damage  All damaged components must be replaced  All roller bearings must be replaced  All seals and shaft sealing rings must be replaced

The general overhaul must be performed in a specialised workshop with appropriate equipment and by qualified staff. We urgently recommend that the general overhaul is carried out by NORD Service.

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5. Motors with ignition protection

The following supplementary or the following specific information applies for these motors.

The motors are suitable for use in Zone 1 and conform to equipment group II, category 2G, and may be used at an ambient temperature between -20°C and +40°C.

Type supplement: 2G e.g.: 80 L/4 2G TF

class "increased safety Exe"

The marking is If the motor is attached to a gear unit, the EX labelling of the gear unit must also be observed!

Explosive gas mixtures or concentrations of dust in conjunction with hot, live and moving parts on electrical machinery can cause severe or fatal injuries. The increased hazard in explosiv e areas calls for partic ularly careful comp liance with the gener al safety and commissioning instructions. The staff responsible must be trained regarding correct use of motors in explosive areas. Explosion-protected electrical machines comply with the standards in series EN 60034 (VDE 0530) as well as EN 60079-0:2009 and EN 60079-7:2007. The degree of explosion risk determines the zone classification. DIN EN 60079, Part 10, provides information on this. The user is responsible for the zone classification. It is prohibited to use motors which are not certified for explosive areas in explosive areas.

Cable glands must be approved for explosive atmospheres. Openings which are not used must be closed off with approved blind plugs. When connecting installation lines, the connections to the motor terminals and the earth lead must be bent into a U-shape under the respective terminals so that the terminal clamps and studs are subjected to uniform loading and are not deformed under any circumstances. Alternatively, the connections can be made with a cable lug. The use of aluminium connecting cables is not permissible. All motors with the protection class Ex e are supplied with certified cable glands. Cables with a circular cross-section must be used with the cable glands which are supplied. The clamping nuts of the cable gland must be tightened to the torque specified in the following table.

When connecting, always ensure that the permissible clearance distances of 10 mm and the permissible creepage distances of 12 mm between live components and components with the housing potential or between individual live components are observed. Before the terminal box is closed, ensure that all the nuts on the terminals and the screw on the protective earth terminal are tight. The terminal box seals and the seals on the cable gland must be fitted properly and must not be damaged in any way. If the shaft end is at the top, e.g. versions IMV3 or IMV6, and the motor has Exe protection, the user/installer must fit a cover which prevents foreign bodies from falling into the motor fan cover (see DIN EN 60079-0). This must not obstruct the fan from cooling the motor. If the shaft end is at the bottom, e.g. versions IMV1 or IMV5, the motors are generally provided with a protective shield on the fan cover. A handwheel at the second shaft end is not permitted. The motors are designed for continuous operation and normal, non-recurring start-ups in which no substantial start-up heat develops. Section A in EN 60034-1 (VDE 0530 Part 1) - voltage ± 5%, frequency ± 2%, characteristic, mains symmetry - must be complied w ith, so that the development of heat remains within the limits permitted. Any major deviations from the rated values can cause an impermissible increase in the development of heat in the motor. The motor temperature class stated on the type plate must at least conform to the temperature class of any combustible gas that may occur.

0102 II 2G Ex e IIC T3 Gb with details of the temperature class.

Cable gland

M20x1.5 6 M25x1.5 8 M32x1.5 12 M40x1.5 16

Clamping nut

tightening torque [Nm]

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5. Motors with ignition protection class "increased safety Exe"

Each machine must be protected against impermissible development of heat by means of a currentdependent delayed protection switch tested for operation by an approved facility, with phase-failure protection compliant with VDE 0660 or an equivalent system in all phases. The protective system must be set to the rated current. If windings are connected in a delta circuit the trips must be connected in series with the winding phases and set to 0.58 times the rated current. If such a configuration is not possible, additional precautions are necessary (e.g. thermal machine protection). If the rotor jams, the protective system must shut down within the t temperature class.

Electric machines for heavy-duty starting (ramp time > 1.7 x t monitoring system in accordance with the provisions of the EC prototype test certificate. Thermal machine protection by means of direct thermal monitoring of the winding with PTC thermistor temperature sensor is permissible if this is documented and stated on the name plate.

Do not connect any voltage higher than 30V to the PTC thermistor temperature sensor! If the only protection is a PTC thermistor temperature sensor, a performance-tested, PTC tripping device certified by a designated body must be used. The PTC tripping device must be provided with the following marks with regard to the degree of protection:

II (2) G The following standards and regulations must be observed for the installation of electrical systems

in explosion hazard areas: DIN EN 60079-14 (VDE 0165-1), the Technical Regulations for Operational Safety (TRBS), the industrial safety regulations and the explosion protection regulations (Ex-RL). Other regulations must also be observed, if applicable. For all countries the appropriate national regulations must be observed.

Operation in conjunction with an inverter must be explicitly certified. The separate manufacturer's information must be observed. For Exe protection the motor, inverter and protective systems must be identified as belonging together and the permissible operating data must be defined on the joint EC prototype test certificate. The levels of voltage peaks generated by the inverter may be unfavourably influenced by the connecting cable installed between the inverter and the electric machine. In the system comprising the inverter, the cable and the electric motor, the maximum value for voltage peaks at the connecting terminals on the machine must not exceed the figure specified in the separate manufacturer's instructions. In addition, the EMC Directive must also be observed.

Repairs must be performed by NORD or accepted by an officially recognised expert. The work must be identified by means of an additional repair plate. With the exception of standardised, commercial and equivalent parts, only genuine spare parts must be used (see spare parts list): this particularly applies to seals and connecting parts. In the case of motors with closed condensation holes the threads of the plugs must be recoated with Loctite 242 or Loxeal 82-21 after condensation has been drained off. After this, the plugs must be reinserted immediately. The electrical connections must be checked at regular interval s. The connection terminals, protective earth terminal and equipotential bonding terminal must be inspected to make sure they are firm. When doing so, check to make sure that the cable entry, cable gland and terminal box seals are in good condition.

All work on electric machines must be performed with the machine vertical and with all terminals disconnected from the mains.

The motor must be removed for measurement of the installation resistance. The measurement must not be performed in the explosion hazard area. As soon as measurement has been completed, discharge the connecting terminals again by shorting them in order to prevent any spark discharges occurring in the explosive area.

-time specified for the respective

-time) must be protected by a start-up

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5. Motors with ignition protection

Painting: The motors are supplied with a maximum paint thickness of 0.2 mm in order to prevent electrostatic charging. In case of repainting, the total thickness of the paint layer, including the original painting, must not exceed 0.2 mm.

Type plate for NORD Exe motors according to EN 60079

class "increased safety Exe"

Explanation of the standard details on the type plate

EN 60034 (H), (A)/ EN 60079

(Please note the Declaration of Conformity)

Voltage range A according to EN 60034-1

Half key balancing according to EN 60034-14

Product standard

Standard series used for explosion protection

1 Data Matrix Code 9 Operating mode 17 Explosion protection labelling 2 Code number of the designated

body 3 Number of phases 11 Nominal frequency 19 tE- time 4 Type designation 12 Nominal voltage 20 Note: TMS with statement of the tA time only

5 Order number / motor number 13 Permissible voltage range 21 Notice ! Observe operating instruction

6 Year of manufacture: 14 Data sheet number 22 Nominal power 7 Temperature class 15 Power factor 23 Nominal current 8 Housing protection type 16 Speed 24 Individual serial number

10 Details of standards 18 Start-up current/nominal current

with PTC tripping device according to

DIN 44082

B1091.

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6. Motors for use in

Zone 21 and Zone 22

6.1 General information

The following information applies additionally or particularly for category 2D and 3D motors! According to their labelling, the motors are suitable for use in Zone 21 (category 2D) or Zone 22 – non-conduc-

tive dusts (category 3D) .

Type suffix: Zone 21: 2D e.g.: 80 L/4 2D TF Zone 22: 3D e.g.: 80 L/4 3D TF

The labelling is as follows:

* the details of the surface temperature may deviate from 125°C and may be obtained from the type plate If the motor is attached to a gear unit, the EX labelling of the gear unit must also be observed!

6.2 Safety information

The increased danger in areas with combustible dust requires that the general safety and commissioning instructions are strictly complied with. Explosive concentrations of dust may cause explosions if ignited by hot or sparking objects. Such explosions may cause serious or fatal injuries to persons or severe material damage. It is absolutely essential that the persons responsible for the use these motors and frequency inverters in explosion hazard areas are trained in their correct use.

6.3 Commissioning information / Field of application

If the motors are intended for inverter operation, this must be specified when ordering. The motors must be protected against overheating with suitable monitoring equipment! Dust deposits must not exceed 5 mm! The motors are designed for the voltage and frequency range A in EN 60034 Part 1.

Motors for use in Zone 21 and Zone 22, with labelling TF may be thermally monitored via the built-in PTC thermistor temperature sensor in combination with a suitable triggering device as the sole protection. Electrical equipment for use in areas with combustible dust complies with the standards EN 50281-1-1, EN 60034 and EN 50014. The level of the explosion hazard is determined by the categorisation of the zone. The operator/employer is responsible for categorisation of the zones (Directive 1999/92/EC).

If the certification is supplemented by an X, the special conditions in the EC type examination certificate must be complied with. The use of standard motors which are not certified for explosion hazard areas in explosion hazard areas is prohibited. In Zone 21, the cable glands must be authorised for Ex areas (protection class minimum IP 66) and must be secured against accidental loosening. Unused apertures must be sealed with approved plugs (minimum protection class IP 66).

For Zone 22, the cable glands must at least correspond to the protection type specified on the type plate. Unused openings must be closed with plugs, which at least correspond to the protection class of the motor. The motor must not be opened in hazardous atmospheres for connection of the electrical cables or for any other work. The voltage must always be switched off and secured against being switched on again before opening the motor!

II 2 D T 125°C for category 2 (Zone 21)*

0102

II 3 D T 125°C for category 3 (Zone 22 non-conductive dust)*

Certification number: BVS 04 ATEX E 037

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6. Motors for use in

If the motor is supplied with a certified cable gland, the clamping nuts of the cable gland must be tightened to the torque specified in the following table.

The permissible ambient temperature range for all motors is -20°C...+40°C. An extended ambient temperature range of -20°C...+60°C is permissible with motors for operation in Zones 21 and 22. However, this does not apply with the option brake and external fan! The rated power must be reduced to 72% of the catalogue value. If the maximum value of the ambient temperature is between +40°C and +60°C, the value of the power consumption can be inversely interpolated linearly between 100% and 72%. In this case thermal protection of the motor by means of a thermistor sensor is mandatory. The motor connection cables and the cable glands must be suitable for temperatures  90°C.

IEC-B14 Motors

Zone 21 and Zone 22

Cable gland

M20x1.5 6 M25x1.5 8 M32x1.5 12 M40x1.5 16

Clamping nut

tightening torque [Nm]

The B14 flanged bearing cover must be covered with a protective foil which must be removed before the motor is fastened in place. Even if they are not required, all four fixing screws must be screwed into the flanged bearing cover! The fixing screw threads must be inserted with a sealant, e.g. Loctite 242. The maximum depth for screwing into the bearing cover is 2 x d.

If the shaft end faces upwards, e.g. versions IMV3, IMV6, a cover must be positioned on the motor by the operator/installer to prevent foreign bodies from falling into the motor fan cover (see DIN EN 50 280-1-1). This must not obstruct the fan from cooling the motor. If the shaft ends face down, e.g. versions IMV1, IMV5, motors for Zone 21 are generally equipped with a protective shield on the fan cover. A handwheel at the second shaft end is not permitted. Unless other operating modes and tolerances are specified in the test certificate or type plate, electrical machinery is designed for continuous operation and normal infrequent start-ups where no significant start-up heating occurs. The motors may only be used for the operating mode specified on the type plat e.

The installation instructions must be strictly observed.

6.4 Structure and method of use

The motors are self-cooling. Rotary shaft seals are fitted both on the drive side (DS) and on the ventilation side (VS). Motors for Zone 21 and Zone 22 have metal fans. The motors are produced with protection class IP55, optionally protection class IP 66, (Zone 22 – non-conducting dust) or IP66 (Zone 21). Under normal operating conditions, the surface temperature does not exceed the surface temperature stated on the type plate.

6.5 Minimum cross section of bonding conductors

Cross-section of the phase conductor in

installation S in mm

S ≤ 16

16 < S ≤ 35

S > 35

When connecting a lead to the external earth, the minimum cross-section must be 4 mm2.

Minimum cross-section of the associated

earth lead S P in mm2

0.5 S

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6. Motors for use in

Zone 21 and Zone 22

6.6 Maintenance

The voltage must always be switched off and secured against being switched on again before opening the motor! Notice ! Higher temperatures than the maximum permitted surface temperature of the housing may be present inside the motor. The motor must therefore never be opened in dust explosion hazard atmospheres! The motors must be regularly checked and tested for functional safety! The applicable national standards and regulations must be complied with!

Impermissibly thick dust deposits > 5 mm must not be allowed to build up! If functional safety cannot be ensured, the motor may not be operated! When the ball bearings are replaced, the rotary shaft seals must also be replaced. FKM rotary shaft seals as specified by Getriebebau NORD must be used. Ensure that they are fitted correctly! The rotary shaft seals must be lubricated on the external rings and on the seal lips. If an explosion protected gear is flanged dust-tight to the motor, an NBR rotary shaft seal may be used on the drive side of the motor if the gear oil temperature does not exceed 85°C. Only original parts may be used as spare parts with the exception of standardised, commercially available and equivalent parts. This also applies in particular to seals and connection components. Parts for terminal boxes or spare parts for external earthing must be ordered according to the spare parts list in the operating instructions. The functionality of seals, rotary shaft seals and cable glands must be regularly checked! Maintenance of dust protection for the motors is of paramount importance for explosion prote ction..

Maintenance must be performed by qualified personnel in a specialist workshop with suitable equipment. We urgently recommend that the general overhaul is carried out by NORD Service.

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7. Motors for use in Zone 21 and Zone 22

according to EN 60079-0 and IEC 60079

NOTICE! Section 7 of these operating instructions applies as a supplement for explosion protected electric motors for Zone 21 and Zone 22 according to EN 60079 and IEC 60079. Please disregard Section 6 for these motors.

7.1 General information

The following information applies additionally or especially to motors for Zone 21 and Zone 22! Motors which comply with EN 60079 and IEC 60079 are suitable according to their labelling for use in Zone

21 or Zone 22 - non-conductive dust.

Type suffix according to Zone 21: 2D e.g.:……….. ........................... 80 L/4 2D TF

EN 60079 : Zone 22: 3D e.g: ......................................... 80 L/4 3D TF

Type suffix according to Zone 21: EPL Db e.g:……………………….80 L/4 IDB TF IEC 60079: Zone 22: EPL Dc e.g.:………………………80L/4 IDC TF

Labelling according to

EN 60079 and

(Zone 21)*

94/9 EC

Labelling according to IEC 60079

Ex tb IIIC T125°C Db for Category 2 *

Ex tc IIIB T125°C Dc for Category 3

* the details of the surface temperature may deviate from 125°C and can be obtained from the type plate If the motor is attached to a gear unit, the EX labelling of the gear unit must also be observed!

II 2 D Ex tb IIIC T125°C Db for Category 2

0102

II 3 D Ex tc IIIB T125°C Dc for Category 3

(Zone 22, non-conducting dust)*

(non-conducting dust)*

7.1.2 Impact test

According to 26.4.2 of EN 60079-0:2009 and IEC 60079-0:2007 motors for Category 2D and 3D are subjected to an impact test with 4J.

7.2 Safety information

It is absolutely essential that the persons responsible for the use these motors and frequency inverters in explosion hazard areas are trained in their correct use.

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7. Motors for use in Zone 21 and Zone 22 according to EN 60079-0 and IEC 60079

7.3 Commissioning information / Field of application

If the motors are intended for inverter operation, this must be specified when ordering. The motors must be protected against overheating with suitable monitoring equipment! The thickness of dust deposits must not exceed 5 mm! The motors are designed for the voltage and frequency range B of EN 60034 Part 1. Exception: Size 132MA/4 2D, 132MA/4 3D, 132LH/4 2D and 132LH/4 3D motors comply with voltage and frequency range A. Motors for use in Zone 21 and Zone 22, with labelling TF may be thermally monitored via the built-in PTC thermistor temperature sensor in combination with a suitable triggering device as the sole protection. Electrical equipment for use in areas with inflammable dust comply with the standards DIN EN 60079-0, IEC 60079-0, EN 60079-31, IEC 60079-31, as well as DIN EN 60034 and IEC 60034. The valid version of the standard can be obtained from the EC Declaration of Conformity or the IECEx CoC. The degree of explosion hazard determines the zone categorisation. The operator / employer is responsible for the assignment of zones (in Europe: RL 1999/92/EC) If the certification is supplemented with an "X" the special conditions in the EC prototype certification, the IECEX CoC and/or the relevant documentation must be observed. The use of standard motors which are not certified for explosion hazard areas in explosion hazard areas is p ro hibited.

The terminal box cover seal must be captively fastened to the terminal box cover. Please only use an original seal when replacing the seal. If the terminal box is opened during installation, maintenance, repair, troubleshooting or overhaul, the terminal box cover must be re-fitted after the work is complete. There must be no dirt on the surface of the seal or the sealing surface of the terminal box frame. The screws for the terminal box cover must be tightened with a torque according to the following table.

Tightening torques for terminal box cover screws

Thread Tightening torque [Nm]

M4 0.8 to 1.2 M5 1.2 to 1.8 M6 1.5 to 2.5 M8 3.0 to 5.0

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7. Motors for use in Zone 21 and Zone 22 according to EN 60079-0 and IEC 60079

7.3.1 Electrical Connection

The electrical connections of the terminal board are protected against twisting. The voltage supply to the terminal board must be made by means of suitable ring terminals. The ring terminals are installed between the two brass washers below the lock washer. The nuts must be tightened with a torque according to the table below. The contact pressure is permanently maintained by means of the specified torque and the lock washer. In addition, twisting of the ring terminals of the voltage supply is prevented. The connection elements are corrosion-proof.

Torques for electrical terminal board connections

Nominal thread diameter Tightening torque [Nm]

M1.6 0.09-0.12

M3 0.35-0.5 M4 0.8-1.2 M5 1.8-2.5 M6 2.7-4.0

M8 5.5-8,0 M10 9.0-13.0 M12 16.0-20.0 M16 36.0-40.0

Electrical connection:

Brass nut Lock washer Brass washer Brass washer

Brass nut

Brass washer

Ring terminal

Brass washer Brass thread with collar

Mechanical protection against twisting

7.3.2 Cable and wiring glands

In Zone 21, the cable glands must be approved for Ex areas (protection class minimum IP 66) and must be secured against accidental loosening. Unused apertures must be sealed with approved plugs (minimum protection class IP 66). For Zone 22, the cable glands must at least correspond to the protection type specified on the name plate. Unused openings must be closed with plugs, which as a minimum correspond to the protection class of the motor and the requirements of EN 60079-0 and IEC 60079-0. The cable glands and blank plugs must be suitable for a temperature of at least 80°C.

The motor must not be opened under hazardous atmospheres for connection of the electrical cables or for any other work. The voltage must always be switched off and secured against being switched on again before opening the motor!

The motors are equipped with cable glands according to the following overview.

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7. Motors for use in Zone 21 and Zone 22 according to EN 60079-0 and IEC 60079

Assignment of Cable Glands to Motor Size

Cable glands for standard motors Cable glands for brake motors

Type Number Thread Number Thread Number Thread Type Number Thread Number Thread Number Thread 63 2 M20x1.5 63 4 M20x1.5 2 M12x1.5 71 2 M20x1.5 71 4 M20x1.5 2 M12x1.5 80 2 M25x1.5 80 4 M25x1.5 2 M12x1.5 90 2 M25x1.5 90 4 M25x1.5 2 M12x1.5 100 2 M32x1.5 100 4 M32x1.5 2 M12x1.5 112 2 M32x1.5 112 4 M32x1.5 2 M12x1.5 132 2 M32x1.5 132 4 M32x1.5 2 M12x1.5 2 M16x1.5

160/ 180/..X 2 M40x1.5 2 M12x1.5 2 M16x1.5 180/ 200/..X 2 M40x1.5 2 M12x1.5 2 M16x1.5

200 2 M40x1.5 2 M12x1.5 2 M16x1.5 200 2 M40x1.5 2 M12x1.5 2 M16x1.5

If the motor is supplied with a certified cable gland, the clamping nuts of the cable gland must be tightened to the torque specified in the following table.

Cable gland

Clamping nut

tightening torque [Nm]

M20x1.5 6 M25x1.5 8 M32x1.5 12 M40x1.5 16

160/ 180/..X 2 M40x1.5 2 M12x1.5 2 M16x1.5 180/ 200/..X 2 M40x1.5 2 M12x1.5 2 M16x1.5

Cable gland

7.3.3 Permissible Ambient Temperature Range

The permissible ambient temperature range for all motors is -20°C...+40°C. A greater ambient temperature range of -20°C...+60°C is permissible with motors for operation in Zones 21 and 22. However, this does not apply for the option brake and external fan! The rated power must however be reduced to 72% of the catalogue value. If the maximum ambient temperature is between +40°C and +60°C, the power output should be inversely linearly interpolated between 100% and 72%. In this case thermal protection of the motor by means of a thermistor sensor is mandatory. The motor connection cables and the cable glands must be suitable for temperatures of at least 80°C.

7.3.4 Painting

Motors for Zone 21 and Zone 22 are provided with suitable painting ex-works. Subsequent painting may only be carried out after consultation with Getriebebau NORD or with a workshop which is approved for the repair of explosion protected motors. Compliance with the valid standards and regulations is mandatory.

7.3.5 IEC-B14 Motors

The B14 flanged bearing cover must be covered with a protective foil which must be removed before the motor is fastened in place. Even if they are not required, All four fixing screws must be screwed into the flanged bearing cover! The fixing screw threads must be inserted with a sealant, e.g. Loctite 242. The maximum depth for screwing into the bearing cover is 2 x d.

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7. Motors for use in Zone 21 and Zone 22 according to EN 60079-0 and IEC 60079

If the end of the shaft faces upwards, e.g. version IMV3, IMV6, a cover must be provided by the operator / installer, which prevents foreign bodies from falling into the fan cover of the motor (see DIN EN 60079-0, Item 17, or IEC 60079). This must not obstruct the fan from cooling the motor. If the end of the shaft faces downwards, e.g. versions IMV1, IMV5, motors for Zone 21 and Zone 22 are provided with a protective cover on the fan cover. A handwheel on the second end of the shaft is not permitted for versions with the "shaft end downwards".

Unless otherwise specified for operating modes and tolerances in the test certificate, the power rating plate or in IECEx CoC, electrical machinery is designed for continuous operation and normal infrequent start-ups where insignificant start-up heating occurs. The motors may only be used for the operating mode specified on the type plate.

The installation instructions must be strictly observed.

7.4 Structure and method of use

The motors are self-cooling. Rotary shaft seals are fitted both on the drive side (DS) and on the ventilation side (VS). Motors for Zone 21 and Zone 22 have metal fans. Motors with brakes for Zone 22 (Category 3D, non-conducting dust) have a special plastic fan. The motors are produced with protection class IP55, optionally protection class IP 66, (Zone 22 - non-conductive dust, EPL Dc) or IP66 (Zone 21, EPL Db). Under normal operating conditions, the surface temperature does not exceed the surface temperature stated on the type plate.

7.5 Minimum cross section of bonding conductors

Cross-section of phase conductor

of the installation S in mm

S ≤ 16

16 < S ≤ 35

S > 35

When connecting a lead to the external earth, the minimum cross-section must be 4 mm2.

7.6 Maintenance

The voltage must always be switched off and secured against being switched on again before opening the motor! Notice ! Higher temperatures than the maximum permitted surface temperature of the housing may be present inside the motor. The motor must therefore never be opened in hazardous dust atmospheres! The motors must be checked and tested regularly for functional safety! The applicable national standards and regulations must be complied with!

Impermissibly thick dust deposits > 5 mm must not be allowed to accumulate! If functional safety cannot be ensured, the motor may not be operated! When the ball bearings are replaced, the rotary shaft seals must also be replaced. FKM rotary shaft seals as specified by Getriebebau NORD must be used. Ensure that they are fitted correctly! The rotary shaft seals must be lubricated on the external rings and on the seal lips. If an explosion protected gear unit is flanged dust-tight to the motor, an NBR rotary shaft seal can be used on the drive side of the motor if the gear oil temperature does not exceed 85°C. Only original parts may be used as spare parts with the exception of standardised, commercially available and equivalent parts. This also applies in particular to seals and connection components. Parts for terminal boxes or spare parts for external earthing must be ordered according to the spare parts list in the operating instructions. The functionality of seals, rotary shaft seals and cable glands must be regularly checked! Maintenance of the dust protection is of paramount importance for explosion protection. Maintenance must only be performed in a specialist workshop by qualified personnel. We urgently recommend that the general overhaul is carried out by NORD Service.

Minimum cross-section of the associated

earth lead S P in mm2

0.5 S

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8. Options for motors for use in Zone 22

8.1 Inverter operation option

ATEX NORD motors for Zone 22 are suitable for inverter operation due to the design of their insulation system. Because of the variable speed range, temperature monitoring with PTC resistors or temperature monitors is necessary. For safe planning and use, the engineering guideline for the operating and assembly instruction B1091-1 must be observed. The engineering guideline provides information about the necessary requirements for inverter operation and about the permitted speed ranges.

8.2 External fan option

Motors with the additional labelling F (e.g. 80S/4 3D F) are equipped with an external fan and must be monitored via the integrated temperature sensor.

Notice! The motor may only be operated together with the external fan! A failure of the external fan can lead to the motor overheating and therefore endanger property and/or persons. Observe the operating instructions for the external fan!

The power supply for the external fan is provided independently via the external fan terminal box. The external fan power supply must be identical to the voltage rating given on the type plate. The external fan must be protected against overheating with suitable monitoring equipment! The IP protection classes of the external fan and motor may be different. The lower IP protection class applies to the drive unit. The cable glands must at least correspond to the protection type specified on the type plate. Unused openings must be closed with plugs, which at least correspond to the protection class of the motor. External fans and motors for use in explosion hazard areas have Ex labelling according to Directive 94/9 EC. This labelling must be present on the external fan and on the motor. If the labelling of the external fan and the motor differ, the lowest designated explosion protection applies to the entire drive. The maximum specified temperature stated in the surface temperature data for the individual components applies for the entire drive unit. In this context, it may be necessary to take into account any gear units that may be present. Contact Getriebebau NORD if there are any doubts. If any component in the entire drive does not have an Ex designation, then the entire drive may not be operated in an Ex area.

8.3 Return stop option

Motors with the additional labelling RLS (e.g. 80S/4 3D RLS) are equipped with a return stop. Motors with return stops have an arrow marking the direction of rotation on the fan cover. The arrow points in the direction of rotation of the motor. When connecting the motor and during motor control, it must be ensured that the motor can only operate in the correct direction of rotation, e.g. by means of a rotary field test. Switching the motor to the blocked rotation direction, i.e. incorrect rotation direction, can lead to damage.

Return stops operate without wear from a speed of approx. 800 rpm Return stops must not be operated at speeds under 800 rpm to prevent impermissible heating and rapid wear of the return stop. This must be taken into account for motors with a frequency of 50 Hz and poles ≥ 8, and for motors with frequency inverters.

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8. Options for motors for

8.4 Brake option

Motors with the additional labelling BRE (e.g. 80S/4 3D BRE 10) are equipped with a brake and must be monitored via the integrated temperature sensor. If the temperature sensor of one of the components (motor or brake) is triggered, the entire drive must be safely shut down. The motor and brake PTC's must be connected in series. The brake may be used as a holding brake with up to 4 activations per hour. An optional manual release (with a lockable manual release lever) may only be used if no explosive atmosphere is present. Notice!

Observe the operating instructions for the brake!

The DC voltage supply for the brake must be implemented via a rectifier located in the motor terminal box or via a directly supplied voltage. The brake voltage shown on the type plate must be complied with. The power supply lines must not be laid in the same cable together with the temperature sensor circuit. The brake functionality must be checked before start-up. There should be no rubbing noises, as this could lead to impermissible excessive heating.

use in Zone 22

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9. Spare parts drawing and

spare parts list

Item No. Description Item No. Description 00 Rotor with shaft 902 A bearing cover

902.1 Bolt

902.2 Hexagonal nut 904 Radial packing ring 905 A bearing 906 Ball bearing shim 907 Terminal box frame

907.1 Chassis connection terminal wire clamp

907.2 Cheese head screw 908 Terminal box cover

908.1 Cylindrical bolt 909 Terminal box frame seal 910 Terminal box cover seal 911 Terminal board

911.1 Cylindrical bolt

911.5 Spring lock washer 912 Mini-terminal

912.1 Cheese head screw 913 Spacer

913.1 Cylindrical bolt

913.2 Spring lock washer 916 Stator with winding

916.1 Equipotential bonding terminal

916.2 Hollow dowel pin

918 Parallel key 924 Screw-on foot (Size 100-132)

924.1 Hexagon head bolt

924.2 Spring lock washer

924.3 Hexagonal nut 929 B bearing 932 B-bearing cover

932.1 Cylindrical bolt

932.2 Hexagonal nut 933 Radial packing ring 939 Fan 940 Fan cover

940.1 Cheese head screw

940.2 Countersink screw B3 941 Parallel key 942 947 Circlip 948 Circlip 952 Clamping bush 953 Cable gland 955 Blind plug 956 Blind plug 980 Protective shield 988 Sealing ring 989 Type plate

989.1 Cheese head screw

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