NORD B1091 User Manual
Intelligent Drivesystems, Worldwide Services
GB
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.
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.
E
-time specified for the respective
E
-time) must be protected by a start-up
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