NORD B1092 User Manual
Intelligent Drivesystems, Worldwide Services
GB
B1092
Operating and Assembly Instructions for
1 MA-7 Three-phase Motors for operation with
Frequency Inverters BG 63 - 160
1. General Information................................................................................................................3
2. Description ..............................................................................................................................3
2.1 Field of application....................................................................................................................3
2.2 Cooling .....................................................................................................................................3
3. Information on the correct handling of electric motors .....................................................3
3.1 Transport and storage...............................................................................................................3
3.2 Installation.................................................................................................................................4
3.3 Terminal box .............................................................................................................................4
3.4 Balancing, driving elements......................................................................................................4
3.5 Elekctrical connection ...............................................................................................................4
3.6 Checking the insulation resistance ...........................................................................................5
3.7 ICommissioning.........................................................................................................................5
4. Maintenance ............................................................................................................................6
5. Motors with increased ignition protection, type “e” Ex e 1MA..........................................8
5.1 Additional information for operation with a frequency inverter..................................................9
6. Drawing and list of replacement parts................................................................................11
6.1 Drawing and list of replacement parts.....................................................................................11
6.2 Tightening torques ..................................................................................................................15
6.3 Cross sections which may be connected................................................................................16
6.4 Changing the bearings............................................................................................................16
7. Data Sheets............................................................................................................................17
7.1 BG 63 M..................................................................................................................................17
7.2 BG 71 M..................................................................................................................................20
7.3 BG 80 M..................................................................................................................................23
7.4 BG 90 L ...................................................................................................................................26
7.5 BG 100 L.................................................................................................................................29
7.6 BG 100 L (increased performance).........................................................................................32
7.7 BG 112M.................................................................................................................................35
7.8 BG 132 M................................................................................................................................38
7.9 BG 160 M................................................................................................................................41
7.10 BG 160 L.................................................................................................................................44
8.
Type Plates ............................................................................................................................47
9. Declaration of Conformity....................................................................................................48
10. Addresses..............................................................................................................................49
Contents
Safety and information symbols
Please always observe the following safety and information symbols!
Danger
Danger of death or injury
to persons
Danger
Important information
regarding explosion
protection
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Attention!
Damage to the machine possible
Note!
1. General information
2. Description
1. General information
The applicable national, local and plant-specific regulations and requirements must be
observed.
Technical details may vary for special designs and constructions. In case of doubt it is
urgently recommended that the manufacturer is contacted, giving details of the type and serial
number (No. …. see rating plate), or have the maintenance work carried out by a service
centre.
2.1 Field of Application
Intended use of the motors:
The motors are constructed in protection class IP55 (protection class: see rating plate). They
may be installed in dusty or damp environments. For use outdoors an additional covering is
recommended to avoid the tong-term influence of direct intense sunlight, rain, snow, ice or
dust. If necessary, consultation/technical coordination is advisable.
Ambient temperature: ......... -20°C to +40°C
Installation altitude: .............
In case of differing ambient conditions, these must be indicated on the rating plate. The details
on the rating plate then apply.
2.2 Cooling
1MA motors are self-cooling (with fan).
3. Information on the correct handling of electric motors
3.1 Transport and storage
When transporting the motor, all available lifting lugs must be used.
When transporting sets of machinery (e.g. gearbox, fan, pumps etc.) only use the attached
lifting lugs. Sets of machinery must not be lifted by hanging on the motor lifting lugs.
With long periods of storage the period of use of the bearing grease is reduced. For storage of
longer than 12 months the condition of the grease must be checked. If the check reveals
contamination of the grease (ingress of condensation causes a change in consistency of the
grease) the grease must be replaced.
The roller bearings should be replaced if the time from delivery to commissioning of the motor
exceeds 4 years.
The probable life-span of the bearing system reduces with increasing storage time.
Machined surfaces (flange surfaces, shaft ends, etc.) should be protected with corrosion
protection agents.
If necessary, the insulating resistance of the windings must be checked, see Sect ion 3.6.
≤ 1000 m
All work must be carried out only when the system is in an electrically voltage-free state.
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3.2 Installation
For vertical configuration, all available lifting lugs and if necessary lifting straps (DIN EN 14921:2000) and/or tie-down straps (DIN EN 12195-2:2001) must be used to stabilise the position.
Attachments must not be used as lifting aids.
After installation, screwed-on lifting lugs must be tightened or removed.
For vertical installation with the shaft end pointing downwards, a protective cover for the fan
cover is recommended, to prevent the entry of foreign bodies.
On the other hand, in the case of shaft ends pointing upwards, the ingress of liquids along the
shaft must be prevented.
Smooth running: Precise alignment of the clutch and a well-balanced drive element (clutch,
pulleys, fan …) are prerequisites for smooth vibration-free running.
Complete balancing of the motor and the drive elements may be necessary.
3.3 Terminal box
Tightening torques for the screws of the terminal box: See Fig. 4.2.
3.4 Balancing, drive elements
3. Notes
The fitting and removal of drive elements (clutch, pulley, gear wheel,…) must be performed
with suitable equipment (see Fig.7).
As standard, the rotor is balanced with half parallel key.
When fitting the drive element, pay attention to the type of balancing!
The balancing condition is stated on the end face of the shaft or the type plate (H = half, F =
full parallel key balancing, N = balancing without parallel key).
The drive elements must be balanced according to ISO 1940:2003.
For balancing with half parallel key, the protruding visible portion of the parallel key T
be machined off (see Fig. 8).
The generally necessary measures for protection against touching the drive elements must be
observed.
3.5 Electrical connection
All work must only be carried out by qualified technicians on stationary low-voltage machines
which have been switched off and secured against switching on again. This also applies to the
auxiliary power circuits.
The terminal box must be sealed against dust and water.
The mains voltage and frequency must conform to the data on the rating plate. A voltage
deviation of ± 5% and/or a frequency deviation of ± 2% are permissible. The connection and
configuration of the jumpers must be performed according to the circuit diagram in the
terminal box. Connect the bonding conductor to this terminal
For connection terminals with terminal bridges (e.g. according to DIN 46282) the conductors
must be arranged so that approximately the same terminal heights result on both sides of the
bar. This type of connection therefore requires that individual conductors are bent to a Ushape or a fork terminal must be connected (see Fig. 5) This also applies to the bonding
connector and the external green/yellow earthing conductor.
.
must
p
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3. Notes
For tightening torques of screw connections of the electrical connections and terminal board
connections (except for the terminal bar) see Fig. 4.
3.6 Checking the insulation resistance
Prior to the initial commissioning of the motor after a long period of storage or standstill
(approx. 6 months) the insulation resistance of the windings must be checked.
During and immediately after the measurements, the terminals have voltages which can be
dangerous, and must not be touched.
Insulation resistance
The minimum insulation resistance of new, cleaned or repaired windings against earth
is 10 MΩ.
Initially, the critical insulation resistance R
multiplying the measured voltage U
R
= 0.69 kV x 0.5 MΩ /kV =0.345 MΩ
krit
, e.g. 0.69 kV AC, with the constant factor (0.5 MΩ /kV):
N
is calculated. The calculation is made by
krit
Measurement:
The minimum insulation resistance of the winding against earth is measured with 500 V DC.
The temperature of the windings should be 25°C ± 15°C.
The critical insulation resistance must be measured with the windings at operating
temperature using 500 V DC.
Testing:
If for new or cleaned windings or repaired motors, which have been stored or not used for
long periods, the minimum insulation resistance of the winding against earth is less than 10
MΩ, this may be caused by moisture. The windings must then be dried.
After long periods of operation the minimum insulation resistance may fall to the critical
insulation resistance. As long as the measured value does not fall below the calculated value
for the critical insulation resistance, operation of the motor may continue. If this value is fallen
below, the motor must be switched off immediately. The cause of this must be established
and if necessary the windings or parts of the windings must be repaired, cleaned or
dried.
3.7 Commissioning
NOTE: Electromagnetic compatibility
Production of interference: Great differences of torque (e.g. when driving a piston
compressor) induce a non-sine wave motor current, 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 a shielded motor supply
cable is recommended, the shielding is most effective if a large area is electrically connected
to the metal terminal box of the motor (with metal screw connectors). With motors with
integrated sensors (e.g. thermistors) interference voltages due to the inverter may be
produced in the sensor cables.
Interference immunity: For motors with integrated sensors (e.g. thermistors) the operator
must ensure adequate immunity to interference by the selection of a suitable sensor cable
(possibly with screening, with connection as for the motor supply cable) and evaluation
device.
When operating motors with inverters at higher speeds than the nominal speed, the
mechanical limiting speed (Safe operating speed IEC 60034-1) must be observed (max. 3000
1
/
).
min
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Safety measures
Before starting any work on the motor or the device, but especially before opening the covers
of active components, the motor must be isolated according to regulations. In addition to the
main power circuits, any additional or auxiliary circuits must be taken into account.
The usual "5 Safety Rules" e.g. according to EN 50110-1 (DIN VDE 0105) are:
• Isolate,
• S ecure against switching on,
• Check for no voltage,
• Earth and short circuit,
• Cover or fence off neighbouring live components.
These measures may only be removed when the maintenance work is complete and the
motor has been completely assembled.
NOTE: If the motors are designed with closed condensation outlets, these must be opened
occasionally in order to allow any accumulated condensation to drain off. Condensation
outlets must always be located at the lowest point of the motor.
Changing bearings, grease packing
Bearing replacement period [h] under normal operating conditions, with horizontal installation
of the motor, cooling medium temperature or motor speed:
up to 1800 min-1 approx. 40000 h
up to 3000 min-1 approx. 20000 h
NOTE: The permissible axial and transverse forces must not be ex ceeded.
Independent of the hours of operation of a motor which is in use, the roller bearing should be
replaced approximately every 3 years due to the reduction of lubrication.
Under special operating conditions, e.g. vertical motor installation, heavy loads due to
vibration and shock, or operation with frequent reversing, the operating hours stated above
are significantly reduced.
The motors have groove ball bearings with cover plates (2ZC3 design). The material of the
plates should be temperature resistant from -30°C to +150°C, e.g. polyacrylic rubber (ACM).
Grease types for standard machines: UNIREX N3 (ESSO); Substitute greases must comply
with
DIN 51825-K3N:2004.
Special greases are indicated on the rating plate or on an additional plate.
Dismantle the motor to the necessary extent. Remove the roller bearing using suitable
equipment (see Fig. 6). Clean any contamination from the bearing seats.
Uniformly heat the roller bearings to approx. 80-100°C and fit. Hard blows (e.g. with a
hammer) must be avoided.
Any warn sealing elements (e.g. shaft seals) must also be renewed. If shaft sealing rings
without springs are installed, the replacement component must also be installed without
springs.
Centring edge seal
When assembling the motor, the bright fitting surfaces between the motor housing and the
bearing covers must be sealed with a suitable non-hardening sealing compound, e.g. Fluid-D.
Tightening torques for the screws on the bearing covers: see Fig. 4.2.
Regreasing device
For motors with regreasing devices, the details on the lubrication plate or the rating plate must
be observed. Regreasing should be performed with the motor running.
4. Maintenance
40°C
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4. Maintenance
General overhaul
A general overhaul of the motor must be carried out every 5 years.
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
• Measure the insulation resistance
• Check the stationary voltage according to EN 60034-1
The general overhaul must be carried out by qualified personnel in a specialist workshop with
appropriate equipment. We strongly recommend that the general overhaul is carried out by
NORD-Service.
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5. Motors with increased ignition
protection, type "e" Ex e
5. Motors with increased ignition protection, type "e" Ex e 1MA
Identification: CE 0102 II G Ex e lI T3
Attention
Repairs must be carried out in or by authorised workshops. Repairs must be documented on
the motor (e.g. additional plate).
The increased hazard in areas endangered by explosions or fire damp requires particularly careful
observation of the general safety and start-up information.
Replacement parts - Only original replacement parts (see replacement parts list) may be used: this
particularly applies to seals and connection components. Exceptions are standard equivalent
commercially available components (e.g. roller bearings).
Explosion-protected electrical machines comply with standards:
EN 60034-1:2004 and all relevant parts, as well as EN 60079-0:2004, EN60079-7:2003.
They may only be used in explosion hazard areas according to the conditions stipulated by
the responsible supervisory authorities. They are responsible for the determination of the
explosion hazard (allocation of zones).
If the certification is supplemented with an "X" the special conditions in the EU prototype
certification must be observed.
The cable entries must be approved for explosion hazard areas and secured against
spontaneous loosening. Unused openings must be closed with approved stoppers. For the
assembly of the cable entries the instructions in the instruction manual of the cable entry
manufacturer must be observed. The number of threaded holes, the thread sizes and the type
of thread are given in Table 1. Special entries are indicated.
For vertical installation of the motor with the end of the shaft facing upwards or downwards,
e.g. types IMV3, IMV6, IMV19, for 1MA motors a cover must be arranged so that foreign
bodies cannot enter into the motor fan cover. Cooling of the motor must not be obstructed by
the cover. If nothing is stated to the contrary in the EU prototype certification or on the rating
plate with regard to type of operation and tolerances, electrical machines are designed for
continuous operation and normal infrequent starts, in which there is not significant start-up
warming.
The motors may only be used for the type of operation stated on the rating plate.
Range A in EN 60034-1:2004 - voltage ± 5%, frequency ± 2%, curve shape, symmetrical
mains - must be complied with in order that warming remains within the permissible limits.
Larger deviations from the rated values can cause a permissible warming of the electrical
machine and must be stated on the rating plate.
The temperature class of the motor stated on the rating plate must conform with the
temperature class of any escaping inflammable gases.
In addition, the safety device must be adjusted to the rated current. A triggering device
certified according to RL94/9/EU must be used.
Thermal protection of the machine by means of direct temperature monitoring of the windings
is permissible, if this is certified and stated on the rating plate.
An earthing tab is cast onto the housing for the connection of the external bonding cable. The
thread sizes for the screws of this external bonding cable are stated in Table 2.
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5. Motors with increased ignition
protection, type "e" Ex e
In the case of external sources of heat or cold, no additional measures are necessary if the
temperatures of the attached components do not exceed the permissible temperatures listed
in Table 3. The values in Table 3 apply for an ambient temperature of -20°C to +40°C with
self-ventilation. Special applications with external sources of heat and cold must be examined
by means of type testing with regard to the effect on the maximum surface and operating
temperatures and suitable measures taken if necessary.
For the installation of electrical equipment in explosion hazard areas in Germany, attention is
drawn to DIN EN 60079-14:2003 and the "Betriebssicherheitverordnung" [Operating Safety
Regulations]! In foreign countries the appropriate national regulations must be observed.
Operation with an inverter must be explicitly certified. The separate manufacturer's information
must be observed.
5.1 Additional information for operation with a frequency inverter
In addition to this information, the operating instructions of the frequency inverter and if
necessary the operating instructions of the gear unit and any other operating instructions must
be observed. Failure to observe these can cause material damage and personal injury.
Series 1 MA7 motors are produced in the ignition protection type "Increased Safety" and are
suitable for operation with a frequency inverter. The suitability can be identified by the
statement of the maximum frequency (e.g. f
Individual acceptance by a designated testing facility is not necessary.
It is essential that the supplied data sheet for the EU prototype certification (see
Section 7.) is complied with. This includes important information for operation and
commissioning.
Ex e motors suitable for use with frequency inverters are equipped with a triple PTC.
This must be evaluated by a certified triggering device with protection type labelling Ex II (2)
G.
The joint operation of several motors on one frequency inverter is not permissible.
Connecting cables must be dimensioned for a continuous thermal load of at least 80°C.
In addition, the frequency inverter used must be equipped with a speed-dependent current
limitation (Precision of measurement of effective current: 5%).
The current limitation is set to the maximum permissible nominal current of the
frequency inverter. A limitation of the output current of the frequency inverter to double the
rated current of the motor must be ensured.
Observation of the rev/f characteristic and the permissible torque depending on the
frequency is essential.
Voltage drops due to the use of long supply cables and/or sine wave filters between the
motor and the frequency inverter must be taken into account. The maximum
permissible length of cable is 30m. The frequency inverter also causes a drop in
voltage.
The motor terminal voltage can be influenced by increasing the input voltage of the frequency
inverter.
Voltages in excess of 1556 V (peak values) must not occur at the motor terminals.
Unfavourable cable lengths and short switching times of the frequency inverter can
cause impermissible overvoltages. The occurrence of such overvoltages must
be ruled out before starting up.
100 Hz) on the type plate.
max
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5. Motors with increased ignition
protection, type "e" Ex e
Shaft height Thread size Number
63 – 90 M16x1.5
M25x1.5
100 – 132 M32x1.5 4
160 M40x1.5 4
Table 1: Thread sizes in terminal box
Shaft height Thread of screw for bonding cable
63 – 90 M4
100 – 112 M5
132 – 160 M6
1
1
Table 2: Bonding cable screw threads
Number of pairs of poles 4-pole
Maximum shaft temperature 75°C
Maximum flange temperature 75°C
Table 3: Maximum permissible heat and cold sources
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replacement parts
6.1 List and drawings of replacement parts
Replacement parts which can be supplied ex works
Item no. Designation
1.00 AS bearing
.40 Bearing cover
.43 Shaft seal
.58 Spring washer
.60 Roller bearing
.61 Spring strip for bearing cover hub (not always present)
3.00 Rotor, complete
.88 Parallel key for fan
4.00 Stator, complete
.07 Housing foot, right
.08 Housing foot, left
.18 Rating plate
.19 Screw
.20 Cover
.30 Contact bracket
.31 Earthing bracket
5.00 Terminal box, complete
.03 Seal
.04 Seal
.10 Terminal board, complete
.11 Terminal bar
.44 Terminal box, upper section
.70 Retaining clip
.71 Retaining clip
.83 Seal
.84 Terminal box cover
.85 Seal
.90 Terminal box upper section, rotatable 4x90 degrees, complete (for retrofitting)
.92 Terminal box cover
.93 Seal
.95 Terminal box, upper section
.98 Seal
.99 Adapter plate
6.00 BS bearing
.10 Roller bearing
.11 Spring strip for bearing cover hub (not always present)
.20 Bearing cover
.23 Shaft sealing ring
7.00 Ventilation, complete
.04 Fan
6. Drawing and list of
.40 Fan hood
Fitting and removal tools for roller bearings, fan and drive elements can not be supplied!
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6. Drawing and list of
Standard components to be obtained commercially according to dimensions, materials and surfaces.
4.05 (see Fig. 3) DIN EN ISO 70897090
(DIN 125)
4.10
4.39
5.78
7.12 DIN 471
6.02 DIN 472
4.04 (see Fig. 3) DIN 580
1.49
4.11
4.39
5.19
5.49
5.79
5.89
5.91
5.94
6.29
7.49
3.38 DIN 6885
5.52
5.53
5.96
1.60
6.10
DIN 128
DIN EN ISO 4762
(DIN 912)
DIN EN ISO 4017
(DIN 933)
DIN EN ISO 4014
(DIN 931)
DIN EN ISO 7045
(DIN 7985)
DIN EN 50262
DIN 625 Bearing type
replacement parts
Replacement parts are to be ordered via the Sales departments of the particular producers.
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replacement parts
6. Drawing and list of
For aluminium bearing covers (1.40 AH 90) a spring strip (1.61) is inserted in the hub
(hook the bead into the groove).
certified screw connection (5.1)
Fig. 2 BG63…90L
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6. Drawing and list of
replacement parts
For aluminium bearing covers (1.40/6.20) a spring strip (1.61/6.11) is inserted in the hub
(hook the bead into the groove).
certified screw connection (5.1)
Fig. 2 BG 100…160L
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replacement parts
e.g. outlet for cables and wires - at bottom
Fig. 3, BD 100…160L, version with lateral configuration of upper section of terminal box (rotatable 4x90
degrees)
6. Drawing and list of
6.2 Tightening torques
Tightening torques for terminal board connections
Thread diameter M4 M5 M6 M8 M10 M12 M16
Tightening torque (Nm) min. 0.8 1.8 2.7 5.5 9.0 14.0 27.0
Tightening torque (Nm) max. 1.2 2.5 4.0 8.0 13.0 20.0 40.0
Fig. 4, Tightening torques of screw connections of the electrical connections and terminal board connections
(except for the terminal bar)
Nm min. Nm max. Nm min. Nm max.
M12x1.5 4 5
M16x1.5 5 7.5
M25x1.5 6 9
M32x1.5
M40x1.5
Fig 4.1, Tightening torques for cable connectors made from metal (*) and plastic 9**) for direct attachment to
motor. For other connectors (e.g. reducers) the corresponding torques according to the table should be used.
Tightening torque (Nm) max. 3 5 9 24 42 70 165 340
8 12 4 6
Thread diameter M4 M5 M6 M8 M10 M12 M16 M20
Tightening torque (Nm) min. 2 3.5
(*) (**)
2
Tightening torques on terminal box
6
3
16 28 46 110 225
O-ring thickness
mm
2
Fig. 4.2, tightening torques for screws on the electrical terminal box, on bearing covers and on screw
connectors for bonding cables
The above values apply unless other values are stated.
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6. Drawing and list of
6.3 Cross sections which may be connected
2
…25 mm
For connection with
a DIN fork terminal,
the fork terminal
must be angled
downwards.
Fig. 5, cross sections which may be connected according to the size of terminal (may be reduced due to the
size of the cable entries)
6.4 Changing the bearings
…10 mm2 …25 mm2 …10 mm2 …25 mm2
Connection of a
single conductor
with retaining clip.
replacement parts
Connection of two
conductors of
approximately the
same diameter with
retaining clip.
Connection of a
single conductor
under the external
earthing bracket.
For connection with
DIN fork terminal
under the external
earthing bracket.
Fig. 6, Intermediate plate (protection of centring in the end of the shaft)
Fig. 7, fitting and removal of drive elements (intermediate plate to protect the centring at the end of the shaft)
When fitting drive elements (clutch, gear wheel, pulley etc.) use the thread in the end of the shaft and as far
as possible heat the drive elements as necessary. Use suitable equipment for removal. When fitting or
removing, no blows (e.g. with a hammer or similar) or radial or axial forces in excess of those permissible
according to the catalogue may be transferred to the motor bearing via the end of the shaft.
Fig. 8, balancing with half parallel key
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