Siemens SIMOTICS A-1FV5, SIMOTICS A-1PV5 Operating Instructions Manual

SIMOTICS A-1FV5/1PV5

synchronous/induction motors

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SIMOTICS A-1FV5/1PV5 synchronous/induction motors

Operating Instructions

03/2014

610.45002.40

Introduction

1

Safety notes

2

Description

3

Preparing for use

4

Mounting

5

Connection

6

Commissioning

7

Operation

8

Service and maintenance

9

Decommissioning and
disposal

10

Appendix

A

Siemens AG
Industry Sector
Postfach 48 48
90026 NÜRNBERG
GERMANY

Order number: 610.45002.40

Ⓟ

Copyright © Siemens AG 2014.
All rights reserved

Legal information

Warning notice system

DANGER

indicates that death or severe personal injury will result if proper precautions are not taken.

WARNING

indicates that death or severe personal injury may result if proper precautions are not taken.

CAUTION

indicates that minor personal injury can result if proper precautions are not taken.

NOTICE

indicates that property damage can result if proper precautions are not taken.

Qualified Personnel

personnel qualified

Proper use of Siemens products

WARNING

Siemens products may only be used for the applications described in the catalog and in the relevant technical

maintenance are required to ensure that the products operate safely and without any problems. The permissible
ambient conditions must be complied with. The information in the relevant documentation must be observed.

Trademarks

Disclaimer of Liability

This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent
damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert
symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are
graded according to the degree of danger.

If more than one degree of danger is present, the warning notice representing the highest degree of danger will
be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to
property damage.

The product/system described in this documentation may be operated only by
task in accordance with the relevant documentation, in particular its warning notices and safety instructions.
Qualified personnel are those who, based on their training and experience, are capable of identifying risks and
avoiding potential hazards when working with these products/systems.

for the specific

Note the following:

documentation. If products and components from other manufacturers are used, these must be recommended
or approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation and

All names identified by ® are registered trademarks of Siemens AG. The remaining trademarks in this publication
may be trademarks whose use by third parties for their own purposes could violate the rights of the owner.

We have reviewed the contents of this publication to ensure consistency with the hardware and software
described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the
information in this publication is reviewed regularly and any necessary corrections are included in subsequent
editions.

03/2014 Subject to change

Table of contents

1 Introduction ............................................................................................................................................. 7

2 Safety notes ............................................................................................................................................ 9

3 Description ............................................................................................................................................ 15

4 Preparing for use .................................................................................................................................. 23

5 Mounting ............................................................................................................................................... 29

2.1 General safety information ............................................................................................................. 9

2.2 Safety and operating instructions................................................................................................. 10

2.3 Observing the five safety rules ..................................................................................................... 11

2.4 Thermal hazard ............................................................................................................................ 11

2.5 Information about electromagnetic fields ..................................................................................... 12

2.6 Electrostatic sensitive devices (ESD) .......................................................................................... 13

3.1 Application .................................................................................................................................... 15

3.2 Rating plate (type plate) ............................................................................................................... 16

3.3 Technical features ........................................................................................................................ 17

3.4 Design .......................................................................................................................................... 18

3.4.1 Regulations .................................................................................................................................. 18

3.4.2 Types of construction ................................................................................................................... 18

3.4.3 Degree of protection .................................................................................................................... 18

3.4.4 Ambient conditions ....................................................................................................................... 19

3.4.5 Cooling ......................................................................................................................................... 19

3.4.6 Noise emission ............................................................................................................................. 22

4.1 Shipment and packaging ............................................................................................................. 23

4.2 Transport and storage .................................................................................................................. 23

4.2.1 Transport ...................................................................................................................................... 23

4.2.2 Storage ......................................................................................................................................... 26

5.1 Installation .................................................................................................................................... 29

5.2 Fixing ............................................................................................................................................ 30

5.3 Attaching the output elements ..................................................................................................... 31

5.4 Vibration load ............................................................................................................................... 33

SIMOTICS A-1FV5/1PV5 synchronous/induction motors
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Table of contents

6 Connection ........................................................................................................................................... 35

7 Commissioning ..................................................................................................................................... 43

8 Operation .............................................................................................................................................. 49

9 Service and maintenance ...................................................................................................................... 53

10 Decommissioning and disposal ............................................................................................................. 57

A Appendix .............................................................................................................................................. 61

Index .................................................................................................................................................... 65

6.1 Mechanical connection of water cooling system ......................................................................... 35

6.2 Electrical connection ................................................................................................................... 36

6.2.1 Safety information ....................................................................................................................... 36

6.2.2 Cable entry and routing ............................................................................................................... 37

6.2.3 Circuit diagram ............................................................................................................................ 38

6.2.4 Terminal box ............................................................................................................................... 39

6.2.5 Data for electrical connection ...................................................................................................... 40

6.2.6 Signal connection ........................................................................................................................ 41

6.2.7 Connecting the temperature sensor ............................................................................................ 42

6.2.8 Connecting the ground conductor ............................................................................................... 42

6.2.9 Connecting-up a converter .......................................................................................................... 42

7.1 Measures prior to commissioning ............................................................................................... 43

7.2 Performing a trial run ................................................................................................................... 45

7.3 Checking the insulation resistance ............................................................................................. 45

7.4 Switching on the motor ................................................................................................................ 47

7.5 Liquid cooling .............................................................................................................................. 47

8.1 Safety instructions during operation ............................................................................................ 49

8.2 Stoppages ................................................................................................................................... 50

8.3 Shutdown .................................................................................................................................... 50

8.4 Faults ........................................................................................................................................... 50

9.1 Safety information ....................................................................................................................... 53

9.2 Maintenance intervals ................................................................................................................. 55

9.3 General inspection guidelines ..................................................................................................... 56

9.4 Bearing replacement intervals .................................................................................................... 56

10.1 Decommissioning ........................................................................................................................ 57

10.2 Disposal....................................................................................................................................... 57

A.1 List of abbreviations .................................................................................................................... 61

A.2 Siemens Service Center ............................................................................................................. 62

A.3 Declaration of conformity ............................................................................................................ 63

SIMOTICS A-1FV5/1PV5 synchronous/induction motors

6 Operating Instructions, 03/2014, 610.45002.40

1

Note

All data that are generally applicable for the motor also always apply to the generator.

Text format features

Note

A Note is an important item of information about the product, handling of the product
or the relevant section of the document. Notes provide you with help or further
suggestions/ideas.

These operating instructions describe the motor and explain how to handle the motor from
the delivery to the disposal stage.

Before you start using the motor, you must read these operating instructions to ensure safe,
problem-free operation and to maximize the service life.

Siemens strives continually to improve the quality of information provided in these operating
instructions. If you find any mistakes or would like to offer suggestions about how this
document could be improved, please contact the Siemens Service Center.

Always follow the safety instructions and notices in these operating instructions. The warning
notice system is explained on the rear of the inside front.

In addition to the safety-related notices and instructions which you must read, you will find
the text in these operating instructions is formatted in the following way:

1. Handling instructions are always formatted as a numbered list. Always perform the steps

● Lists are formatted as bulletted lists.

in the order given.

– Lists on the second level are hyphenated.

SIMOTICS A-1FV5/1PV5 synchronous/induction motors
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Introduction

SIMOTICS A-1FV5/1PV5 synchronous/induction motors

8 Operating Instructions, 03/2014, 610.45002.40

2

2.1

General safety information

Safety and commissioning information for converter-fed low-voltage three-phase motors

DANGER

qualified, responsible personnel

injury or material damage

national, local and plant/system-specific regulations and requirements

Special versions

construction variants

type

designation and serial number

(in accordance with the Low Voltage Directive 2006/95/EC)

All work associated with transporting, connecting, commissioning, and maintaining the
motors must be carried out by
note IEC 60364).

(DIN EN 50110-1;

Failure to follow proper procedures may result in

The valid
carefully observed.

aspects. If in doubt, you are strongly advised to contact the manufacturer specifying the

carried out by the SIEMENS Service Center.

Vehicles with converter-fed low-voltage three-phase motors must fulfill the protective
requirements of the EMC Directive 2004/108/EC.

The user is responsible for ensuring that installation is carried out properly. The signal and
power cables must be shielded.

The information provided by the converter manufacturer regarding EMC-compliant
installation must be observed.

and

may differ with respect to certain technical

(see rating plate) or arrange for any maintenance work to be

.

must be

SIMOTICS A-1FV5/1PV5 synchronous/induction motors
Operating Instructions, 03/2014, 610.45002.40

9

Safety notes

2.2

Safety and operating instructions

The safe use of electrical machines

WARNING

Rotating or live parts

Qualified personnel

Note
Siemens Service Center

We recommend engaging the support and services of your local Siemens Service Center
for all planning, installation, commissioning, and maintenance work.

2.2 Safety and operating instructions

Rotating or live parts are dangerous.

Fatal or severe injuries and substantial material damage can occur if the required covers
are removed or if the machines are not handled, operated, or maintained properly.

Covers must only be removed and the motor operated in accordance with the relevant
regulations. The motor must be maintained on a regular basis.

These operating instructions only contain the information necessary for ensuring that the
motor is operated by properly trained personnel in accordance with its intended purpose.

Those responsible for plant safety must ensure the following:

● The basic planning work for the system and all work relating to transportation, assembly,
installation, commissioning, maintenance and repairs is carried out by qualified personnel
and checked by responsible, suitably skilled personnel.

● The operating instructions and the motor documentation are available at all times.

● The technical data and specifications relating to installation, connection, ambient and

operating conditions are taken into account at all times.

● The system-specific installation and safety regulations are observed.

● Personal protective equipment is used.

● Unqualified persons must not work on or in the vicinity of these motors at any time.

SIMOTICS A-1FV5/1PV5 synchronous/induction motors

10 Operating Instructions, 03/2014, 610.45002.40

Safety notes

2.3

Observing the five safety rules

Five safety rules

2.4

Thermal hazard

CAUTION

Do not touch any hot surfaces!

Only operate the motors in conjunction with effective temperature control.

2.3 Observing the five safety rules

For your personal safety and to prevent material damage when working on the machine,
always observe the safety instructions and the following five safety rules. Apply the five
safety rules in the order stated before starting work at the machine.

1. Disconnect the system.

You must also make sure that the auxiliary circuits are also disconnected.

2. Protect against reconnection.

3. Make sure that the equipment is de-energized.

4. Ground and short-circuit.

5. Cover or enclose adjacent components that are still live.

When work has been completed, remove these measures in reverse order.

The surface temperature of the motors can exceed 65 °C.

Temperature-sensitive components (electric cables, electronic components) must not be
placed on hot surfaces. If the motors overheat, this can destroy the windings/bearings and
the permanent magnet may become demagnetized

SIMOTICS A-1FV5/1PV5 synchronous/induction motors
Operating Instructions, 03/2014, 610.45002.40

11

Safety notes

2.5

Information about electromagnetic fields

Note
Permanent magnets

The rotors of 1FV5 synchronous motors contain permanent magnets with high magnetic flux
densities and strong forces of attraction to ferromagnetic bodies.

Persons with cardiac pacemakers are endangered in the vicinity of a disassembled rotor.

Data stored o

WARNING

Electromagnetic fields

2.5 Information about electromagnetic fields

n electronic data carriers can be destroyed.

Electromagnetic fields are generated when electrical power engineering installations
(e.g. transformers, converters, or motors) are operated.

Electromagnetic fields can interfere with electronic devices, which could cause them to
malfunction. Heart pacemakers can be affected, for example, which could potentially
damage a person's health or even result in death. Steps must be taken, therefore, to
ensure that persons with heart pacemakers cannot enter these areas.

The plant operator is responsible for taking appropriate measures (labels and hazard
warnings) to adequately protect operating personnel and others against any possible risk.

● Observe the relevant nationally applicable health and safety regulations. In Germany,
"electromagnetic fields" are subject to regulations BGV B11 and BGR B11 stipulated by
the German statutory industrial accident insurance institution.

● Display adequate hazard warning notices.

● Place barriers around hazardous areas.

● Take appropriate measures (e.g. shields) to reduce electromagnetic fields at their source.

SIMOTICS A-1FV5/1PV5 synchronous/induction motors

12 Operating Instructions, 03/2014, 610.45002.40

Safety notes

2.6

Electrostatic sensitive devices (ESD)

ESD guidelines

NOTICE

Electrostatic discharge

NOTICE

Use conductive packaging material

2.6 Electrostatic sensitive devices (ESD)

Electronic modules contain components that can be destroyed by electrostatic discharge.

These modules can be easily destroyed by improper handling.

To protect your equipment against damage, follow the instructions given below.

● Never touch electronic modules unless absolutely necessary in the course of

maintenance and repair procedures.

● If the modules have to be touched, the body of the person concerned must be

electrostatically discharged immediately beforehand and be grounded.

● Electronic modules should not come into contact with electrically insulating materials

(e.g. plastic foil, plastic parts, insulating table supports, or clothing made of synthetic
fibers).

● Always place the modules on conductive bases.

● Always store and transport electronic modules or components in conductive packaging

(e.g. metallized plastic or metal containers).

Electronic modules must be stored, transported, and dispatched in conductive
packaging.

Electronic modules that are not correctly stored, transported, or dispatched can be
damaged.

Pack electronic modules in appropriate conductive packaging (e.g. foam rubber or
aluminum foil).

SIMOTICS A-1FV5/1PV5 synchronous/induction motors
Operating Instructions, 03/2014, 610.45002.40

13

Safety notes

(1)

Sitting

(2)

Standing

(3)

Standing/sitting

ESD protective measures

a

= conductive floor

b

= ESD table

c

= ESD footwear

d

= ESD coat

s

= ESD wrist strap

f

= cubicle ground connection

2.6 Electrostatic sensitive devices (ESD)

The necessary ESD protective measures for electrostatically sensitive devices are illustrated
once again in the following drawings:

Figure 2-1 ESD protective measures

SIMOTICS A-1FV5/1PV5 synchronous/induction motors

14 Operating Instructions, 03/2014, 610.45002.40

3

3.1

Application

Proper usage

Mode of operation and design

The motors are designed for installation in electrically driven vehicles. and are characterized
by their high power density, ruggedness, long lifetime, and overall reliability. The three-phase
motors are either closed-loop speed or torque controlled using a converter. The direct
connection to the three-phase line supply is not permissible. It is forbidden to install them in
hazardous areas unless they are explicitly designed for this.

The 1PV5 motors are liquid-cooled squirrel-cage induction motors.

The 1FV5 generators are liquid-cooled synchronous motors with permanent magnet rotors.

Both active parts are equipped with two temperature sensors integrated in the stator winding,
where the second can be used as a reserve.

An encoder system for sensing the speed and direction of rotation is optionally installed in
the NDE bearing shield of the motors.

SIMOTICS A-1FV5/1PV5 synchronous/induction motors
Operating Instructions, 03/2014, 610.45002.40

15

Description

3.2

Rating plate (type plate)

No.

Description

No.

Description

L010

MLFB

L170

Rated power PN (3)

L020

Factory serial number

L180

Unit rated power (3)

L025

Consecutive number

L190

Rated current IN (3)

L040

Options

L210

Rated speed nN (3)

L060

Maximum speed n

L230

Temperature class

L070

Operating mode (1)

L240

Degree of protection

L071

Rated time (1)

L250

Type of construction

L072

Unit rated time (1)

L260

Revision number

L080

Rated power PN (1)

L270

Weight

L090

Rated current IN (1)

L280

Temperature sensor

3.2 Rating plate (type plate)

The rating plate (type plate) shows the technical specifications for the supplied motor.

Figure 3-1 Schematic layout of rating plate

Table 3- 1 Elements on the rating plate

L030 Z: (For options) L200 Unit rated current IN (3)

L050 Rated voltage L220 Rated speed nN (3)

max

SIMOTICS A-1FV5/1PV5 synchronous/induction motors

16 Operating Instructions, 03/2014, 610.45002.40

Description

No.

Description

No.

Description

L100

Rated speed nN (1)

L290

Encoder (encoder)

L110

Operating mode (2)

L300

Optional customer information

L111

Rated time (2)

L310

Cooling method

L112

Unit rated time (2)

L320

Coolant flow

L120

Rated power PN (2)

L330

Unit coolant flow

L130

Rated current IN (2)

L340

Cooling pressure

L140

Rated speed nN(2)

L350

Maximum value

L150

Operating mode (3)

L360

Maximum coolant temperature

L151

Rated time (3)

L370

Unit maximum coolant temperature

L152

Unit rated time (3)

L380

UL mark

3.3

Technical features

1FV5

1PV5

synchronous motor

Magnet material

Rare-earth magnetic material

---

Speed encoder (optional)

Rotor position encoder (RPE)

Toothed-wheel encoder (64 pin)

Insulation of stator winding according to EN 60034–1

Thermal class 180 (H)

Cooling

Liquid cooling

Installation altitude according to EN 60034-1

≤ 2500 m above sea level, otherwise power derating

Degree of protection to EN60034-5

IP65/IP69K (without DE shaft output)

EN 60034-11

(half-key balancing)

in accordance with DIN 42955

Vibration severity grade according to EN 60034-14

Grade A is maintained up to rated speed

Sound pressure level according to DIN EN ISO 1680

75 dB (A) + 3 dB (A) tolerance

12-pin signal connector

3.3 Technical features

Table 3- 2 Technical features

Type of motor Permanent-magnet

Type of construction acc. to EN 60034–7 IM B5

Temperature monitoring in accordance with

DE shaft extension accordance with DIN 748-3 Plain or geared shaft, optional shaft with fitted key and keyway

Radial eccentricity, concentricity and axial eccentricity

Connection Terminal board in the terminal box for power

2 x KTY 84-130 temperature sensor in the stator winding

Tolerance N (normal)

Induction motor

SIMOTICS A-1FV5/1PV5 synchronous/induction motors
Operating Instructions, 03/2014, 610.45002.40

17

Description

3.4

Design

3.4.1

Regulations

Feature

Standard

Rated and operation characteristics

IEC/EN 60034-1

Degree of protection

IEC/EN 60034-5

Cooling

IEC/EN 60034-6

Type of construction

IEC/EN 60034-7

Terminal markings

IEC/EN 60034-8

Noise emission

IEC/EN 60034-9

Temperature monitoring

IEC/EN 60034-11

Vibration severity grades

IEC/EN 60034-14

(1)

The degree of protection and type of construction of the motor are stamped on its rating plate.

Note

Make sure that your end product is in compliance with all of the applicable legislation!
You
and requirements.

3.4.2

Types of construction

3.4.3

Degree of protection

3.4 Design

The motors comply with the following regulations according to IEC 60034-x/EN 60034-x:

Table 3- 3 Regulations that have been applied

(1)

(1)

The three-phase motors comply with the relevant sections of EN 60034 and EN 60204-1.
Three-phase motors comply with Low-Voltage Directive 2006/95/EC. Standard motors
comply with the UL regulations. "UR" is stamped on the rating plate of these motors.

must take into account the applicable national, local, and system-specific regulations

The motor has type construction IM B5.

The motors have degree of protection IP65/IP69K. In order to guarantee the degree of
protection, the drive end flange must be suitably implemented.

SIMOTICS A-1FV5/1PV5 synchronous/induction motors

18 Operating Instructions, 03/2014, 610.45002.40

Description

3.4.4

Ambient conditions

3.4.5

Cooling

Water cooling

Coolant

Water/anti-freeze mixture, 50/50 %

Female thread in the bearing shield Pg 13.5 /8 deep

Lower values will result in a derating

Max. pressure at inlet

max. 2.5 bar

< 0.4 bar for minimum cooling water flow with 1FV516

at T

<60 °C; T

> -40 °C

temperature, without derating

higher values will result in derating

3.4 Design

The motors are designed for ambient temperatures from -40 °C to +70 °C and installation
altitudes up to 2500 m above sea level. In the case of different ambient conditions, contact
the manufacturer.

The motor can only be operated in a closed coolant circuit with a cooling unit. The motor is
connected to the cooling circuit using two hose connections with an outer diameter of 18 mm
at the NDE bearing shield of the motor. On motors with angled hose connections, after
loosening the locknuts they can be adjusted in both directions (preferred direction clockwise;
max. 1 revolution). After adjusting the position, the coolant connections must be fixed by
tightening the union nuts.

The inlet and outlet connections can be selected as required.

Table 3- 4 Technical data of the water cooling

Cooling water connection Hose connection with an outer diameter of 18

Cooling water flow 16 l/min

Pressure loss between inlet and
outlet

Min. cooling water inlet temperature T

Maximum cooling water inlet

< 0.2 bar for minimum cooling water flow with
1PV513/1FV513

> T

cool

ambient

≤ 55 °C,

ambient

– 5 K

coolmin

As coolant, only a water/anti-freeze mixture in a ratio of 50 % / 50 % is permissible. Glycol is
recommended as antifreeze. When you select a different anti-freeze, a minimum steady­state temperature of -40 °C must be observed. Different anti-freeze agents should not be
mixed.

A filter (100 µm) must be installed in the inlet pipe to protect the motor against pollution.
Additional protection for the motor must be provided by means of a pressure relief valve
installed downstream from the filter.

If a throttle is needed to restrict the flow, it is best to install it downstream of the motor. It is
not permissible to install the throttle directly in front of the inlet because the effects of
cavitation may damage the motor.

SIMOTICS A-1FV5/1PV5 synchronous/induction motors
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19

Description

Contents and chemical composition

Value

pH value

6 … 8

Sulfate ions

< 50 ppm

Dissolved solids

< 340 ppm

Total hardness

< 170 ppm

Electrical conductivity

< 500 μS/cm

Size of any particles in the coolant

< 100 µm

Note
Storing or transporting the motor

The cooling circuit must be emptied when storing the motor, for longer periods when the
motor is out of service and when the motor is being transported.

3.4 Design

Figure 3-2 Pressure losses as a result of volumetric flow

Coolant temperatures below the ambient temperature lead to increased condensation of
water. The difference between the coolant inlet temperature and ambient temperature should
therefore not exceed maximum 5 Kelvin. If the motor is out of operation for a prolonged
period of time, coolant inflow must additionally be interrupted.

The values specified for the cooling water (refer to the following table) correspond to the
requirements of closed cooling circuits. Not all of the specified concentrations will occur in
the cooling water at the same time.

Table 3- 5 Water specifications for the coolant

Chloride ions < 40 ppm

Nitrate ions < 50 ppm

SIMOTICS A-1FV5/1PV5 synchronous/induction motors

20 Operating Instructions, 03/2014, 610.45002.40

Description

Materials used in the cooling circuit

Materials and components in the cooling circuit

Material

Used as

Description

Zinc breaks down the glycol-based inhibitors.

fittings

units).

window recommended.

separator for stainless heat sink.

Chapter "Coolant definition".

well as Antifrogen N.

materials (mixed installation)

fittings

fittings and hoses

DEMITTEL; from PE/EPD, supplied from Telle).

fittings

Pipe - hose

the Telle company.

3.4 Design

The materials used in the cooling circuit must the coordinated with the materials in the motor
(aluminum alloy) and hose connection (nickel plated brass).

The following table lists a wide variety of materials and components which may or may not
be used in a cooling circuit.

Table 3- 6 Materials and components of a cooling circuit

Zinc Pipes, valves and

fittings

Brass Pipes, valves and

Copper Pipes, valves and

fittings

Common steel (e.g. St37) Pipes Permissible in closed circuits and semi-open circuits with

Cast steel, cast iron Pipes, motors Closed circuit and use of strainers and flushback filters. Fe

High-alloy steel, Group 1 (V2A) Pipes, valves and

fittings

High-alloy steel, Group 2 (V4A) Pipes, valves and

fittings

ABS (AcrylnitrileButadieneStyrene) Pipes, valves and

fittings

Installation comprising different

Pipes, valves and

Use is not permitted. Non-ferrous metals chips can lead to pitting
corrosion in galvanized pipes.

Can be used in closed circuits.

Can be used only in closed circuits in which the heat sink and
copper component are separated (e.g. connection hose of the

inhibitors or Antifrogen N, check for oxide formation, inspection

Can be used for drinking or municipal water with a chloride
content up to <250 ppm, suitable according to definition in

Can be used for drinking or municipal water with a chloride
content up to <500 ppm, suitable according to definition in
Chapter "Coolant definition".

Suitable according to the definition in Chapter "Coolant
definition". Suitable for mixing with inhibitor and/or biocide as

Use is not permitted.

PVC Pipes, valves,

Hoses Reduce the use of hoses to a minimum (device connection).

Gaskets Pipes, valves and

Hose connections Transition

SIMOTICS A-1FV5/1PV5 synchronous/induction motors
Operating Instructions, 03/2014, 610.45002.40

Use is not permitted.

Must not be used as the main pipe for the whole system.
Recommendation: EPDM hoses with an electrical resistance

9

> 10

Ω (e.g. Semperflex FKD supplied from Semperit or

Use of Viton, AFM34, EPDM is recommended.

Secure with clips conforming to EN14420, available, e.g. from

21

Description

3.4.6

Noise emission

3.4 Design

The following recommendation applies in order to achieve an optimum motor heatsink
(enclosure) lifetime:

● Engineer a closed cooling circuit with cooling unit manufactured out of stainless steel that
dissipates the heat through a water-water heat exchanger.

● All other components such as cooling circuit cables and fittings manufactured out of ABS,
stainless steel or general construction steel.

In operation, in the speed range extending from 0 up to rated speed, 1PV5 and 1FV5 motors
can reach the following measuring surface sound pressure level Lp(A) according to
ISO 1680:

● 75 dB(A) + 3 dB tolerance

SIMOTICS A-1FV5/1PV5 synchronous/induction motors

22 Operating Instructions, 03/2014, 610.45002.40

4

4.1

Shipment and packaging

Checking the delivery for completeness

4.2

Transport and storage

4.2.1

Transport

WARNING

Hazards during lifting and transportation!

The drive systems are assembled on an individual basis. Upon receipt of the delivery, check
immediately whether the items delivered are in accordance with the accompanying
documents. Siemens will not accept any claims relating to items missing from the delivery
and which are submitted at a later date.

● Report any apparent transport damage to the delivery agent immediately.

● Report any apparent defects/missing components to the appropriate Siemens office

immediately.

These safety instructions are part of the scope of supply; keep them in a location where they
can be easily accessed.

The additional rating plate supplied separately with the consignment should be used for
indication of the motor data in the vicinity of the motor.

The rating plate is located in the terminal box.

Use suitable load bearing equipment when transporting and installing the motor. Make sure
that all of the available eyebolts are used during transportation. Country-specific regulations
must be observed.

If the motor is not to be commissioned immediately following delivery, it must be stored in a
dry, dust-free room that is not susceptible to vibration (see "Storage").

Devices and tools that are badly designed, unsuitable, or damaged can result in personal
injury and/or material damage.

Lifting devices, industrial trucks, and load bearing equipment must comply with require­ments. Pay attention to the lifting capacity of the hoisting gear. Do not attach any additional
loads. To hoist the motor, use suitable cable-guidance or spreading equipment (particularly
if the motor is equipped with built-on assemblies). The weight of the motor is specified on
the rating plate.

SIMOTICS A-1FV5/1PV5 synchronous/induction motors
Operating Instructions, 03/2014, 610.45002.40

23

Preparing for use

WARNING

Transporting and lifting the motor by means of the lifting eyebolts

NOTICE

Transporting and lifting the motor using a cross beam

4.2 Transport and storage

Only lift the motor using the lifting eyebolts on the bearing end shields.

Lifting eyebolts must not be attached to the shaft extension.

Never lift the motor by the Sensor Module or the cooling water pipe system. The motor can
fall down. This can result in death or serious injury as well as damage or total loss of the
motor.

When lifting and transporting the motors using the eyebolts supplied (acc. to DIN 580),
you must use a cross beam!

The following should be noted:

• The ring bolt must be screwed in completely and secured by hand (approx. 8 Nm).
Do not overtighten.

• Do not remove the plain pressboard washer and do not use warped or damaged ring
bolts.

• Loads that run transverse to the ring plane are not permitted.

Figure 4-1 Lifting and transporting the motor with a cross beam (example)

SIMOTICS A-1FV5/1PV5 synchronous/induction motors

24 Operating Instructions, 03/2014, 610.45002.40

Preparing for use

Transporting a motor that has already been in operation

4.2 Transport and storage

Figure 4-2 Arrangement of the lifting eyebolts for 1PV513x/1FV513x

Figure 4-3 Location of the lifting eyebolts for the 1FV516x

If you want to transport a motor that has already been in operation, proceed as follows:

1. Allow the motor to cool down.

2. Remove the connections provided by the customer.

3. Empty the motor of any cooling water and purge it carefully with air.

4. Close and seal all openings on the terminal box and housing.

5. Always transport and lift the motor by the lifting eyebolts on the bearing end shields.

SIMOTICS A-1FV5/1PV5 synchronous/induction motors
Operating Instructions, 03/2014, 610.45002.40

25

Preparing for use

4.2.2

Storage

NOTICE

Seizure damage to bearings

Storing indoors

Protection against humidity

4.2 Transport and storage

The motors can be stored for up to 2 years in a dry, dust-free room that is not susceptible to
vibration (v

< 0.2 mm/s) without the specified storage time being reduced.

rms

If the motors are stored incorrectly, bearing seizure damage can occur (e.g. brinelling) as a
result of vibration.

● Apply a preservation agent (e.g. Tectyl) to bare, external components (e.g. shaft
extensions) if this has not already been carried out in the factory.

● Store the motor in an area that fulfills the following requirements:

– Dry, dust-free, frost-free and vibration-free The relative air humidity should be less

than 60 % and the temperature should not drop below -15 °C in accordance with
EN 60034-1.

– Well ventilated

– Offers protection against extreme weather conditions

– The air in the storage area must not contain any harmful gases.

● Protect the motor against shocks and humidity.

● Make sure that motor is covered properly.

● Avoid contact corrosion. You are advised to rotate the shaft extension manually every

three months.

If a dry storage area is not available, the following measures must be taken:

● Wrap the motor in humidity-absorbent material and then wrap it in film so that it is air
tight.

● Include several bags of desiccant in the seal-tight packaging. Check the desiccant and
replace as required.

● Place a humidity meter in the seal-tight packaging to indicate the level of air humidity
inside it.

● Inspect the motor on a regular basis.

SIMOTICS A-1FV5/1PV5 synchronous/induction motors

26 Operating Instructions, 03/2014, 610.45002.40

Preparing for use

Long-term storage

Protecting the cooling-water system

4.2 Transport and storage

If you intend to place the motor in storage for longer than six months, you must check its
condition every six months.

● Check the motor for any damage.

● Carry out any necessary maintenance work.

● Document all preservation measures taken so that they can be reversed before the

machines are recommissioned.

● Make sure that storage area is air-conditioned.

When delivered, the cooling system is not filled with coolant.

When you place the motor in storage after use, drain the cooling water ducts and purge them
with air so that they are completely empty.

SIMOTICS A-1FV5/1PV5 synchronous/induction motors
Operating Instructions, 03/2014, 610.45002.40

27

Preparing for use

4.2 Transport and storage

SIMOTICS A-1FV5/1PV5 synchronous/induction motors

28 Operating Instructions, 03/2014, 610.45002.40

5

5.1

Installation

NOTICE

Temperature-sensitive parts

NOTICE

Shaft end

Note

Observe the technical data on the motor enclosure rating plates.

The following must be taken into account when the motors are installed

1PV513x/1FV513x

1FV516x

Radial force

1100 N

1800 N

Axial force (both directions)

700 N

1100 N

Some parts of the motor enclosure can reach temperatures that exceed 100 °C.
Temperature-sensitive components, e.g. cables etc., can be damaged if they come into
direct contact with the motor enclosure.

When locating temperature-sensitive components, ensure that they do not come into
contact with the motor enclosure.

When installing the motor, ensure that the end of the shaft is protected against blows and
pressure.

● Observe the data on the rating plate, as well as the warning and information plates on the

motor.

● The permissible cantilever and axial forces at the shaft end of the motors may not be

exceeded.

Table 5- 1 Permissible forces at the motor

● Check that they match the conditions (temperature, installation altitude) at the installation

location.

● Ensure that the end of the shaft is completely free of any anti-corrosion protection (use a

commercially available solvent).

● Ensure that the flange is in even contact with the mounting surface. When tightening the

fixing screws avoid any uneven stressing. Observe the tightening torques for the fixing
screws of the motor flange (see Fixing (Page 30) Table 5.2).

SIMOTICS A-1FV5/1PV5 synchronous/induction motors
Operating Instructions, 03/2014, 610.45002.40

29

Mounting

5.2

Fixing

Mounting using the motor flange (flange mounting)

Note

When the motor is flange
specific natural mounting frequencies. In operation, this can result in excessive vibration.

To counter this, additional support can be provided at the NDE.

Ensur

Note

At the DE, only use screws with washer.

When mounting on an unsprung mass, always support at the NDE.

5.2 Fixing

● Rotate the drive elements by hand. If you hear any grinding noise, rectify the cause or
contact the manufacturer.

● Eyebolts that have been screwed in must either be tightened or removed after installation.

● The motors are to be installed in such a way that the coolant can freely flow in and out

unimpeded.

● Only remove all protective caps immediately before installing the respective parts.

To ensure smooth, vibration-free operation, the motor must be precisely aligned and the
components to be mounted on the shaft end correctly balanced.

-mounted, this creates a system that is capable of oscillation with

e that the motor is not subject to excessive tension.

SIMOTICS A-1FV5/1PV5 synchronous/induction motors

30 Operating Instructions, 03/2014, 610.45002.40

Mounting

①

Thread for NDE support

Tightening torques

Motor

Screw

Tightening torque

±10 % [Nm]

Property class of the

screws

DE

M 12

85

8,8

NDE

M12 (screw-in depth, 25...30 mm)

85

8.8

DE

M 16

190

10.9

NDE

M12 (screw-in depth, 18...20 mm)

85

8.8

Alignment accuracy for coupling output

5.3

Attaching the output elements

Note

Do not subject the motor's shaft and bearings to impact. Do not exceed permissible
cantilever and radial forces.

5.3 Attaching the output elements

Figure 5-1 Motor support at the NDE

Table 5- 2 Tightening torques

1PV513x/
1FV513x

1FV516x

The maximum permissible concentricity deviation of the shafts of the motor and the driven
machine is 0.05 mm in the diameter.

SIMOTICS A-1FV5/1PV5 synchronous/induction motors
Operating Instructions, 03/2014, 610.45002.40

31

Mounting

Balancing

Note

Note the designation of the balancing type on the shaft end face. Plain or toothed shaft ends
are not marked.

Pushing on the output elements

WARNING

Shock-hazard protection for output elements

5.3 Attaching the output elements

The motors are balanced so that when they are shipped, they correspond to vibration
severity grade A in accordance with EN60034-14 over the complete speed range.

The motors are fitted with a key; this means that they are dynamically balanced with half a
key. The balancing type is marked on the DE shaft end with "H" (half key).

● Make sure that the balancing method of the output element is correct! The output
elements must be balanced to balance quality grade G2.5 to ISO 1940. Rotary forces that
exceed this are not permissible. Please note that rotary forces can also occur with
coupling output.

● If the output element is shorter than the feather key with balancing method "H", the
section of the feather key that protrudes from the shaft contour and output element must
be removed to maintain the balance quality.

● Fit/remove the output elements only by means of suitable equipment:

– Use the threaded hole in the shaft extension (front).

– If necessary, heat up the output element.

– When removing output elements, use a washer to maintain the centering in the shaft

extension.

The general shock-hazard protection measures for output elements must be
observed.

Figure 5-2 Fitting/removing output elements; A = intermediate washer (for maintaining the

centering in the shaft extension)

SIMOTICS A-1FV5/1PV5 synchronous/induction motors

32 Operating Instructions, 03/2014, 610.45002.40

Mounting

Motor without output element

WARNING

The feather key can fall out

See also

5.4

Vibration load

Description

Vibration values

Vibration velocity v

according to ISO 10816

Max. 4.5 mm/s

Vibration acceleration a

peak

axial 1)

25 m/s2

Vibration acceleration a

radial 1)

50 m/s2

1) The measurement locations should be selected in accordance with ISO 10816-1 Paragraph 3.2.

5.4 Vibration load

The featherkeys are only secured during transport to prevent them from falling out. If a
motor is not equipped with an output element, the feather key may fall out during operation.

Death or serious injury can result.

At the shaft extension, secure the fitted key without output element so that it cannot be
flung out and for balance type "H" shorten it by approximately half.

Installation (Page 29)

The on-site system vibration characteristics depend on factors such as the output elements,
assembly conditions, alignment, installation, and external vibrations and can increase the
level of vibration on the motor.

Under certain circumstances, the rotor may have to be balanced completely with the output
element.

To ensure problem-free operation and a long service life, the vibration values specified to
ISO 10816 must not be exceeded at the defined measuring points on the motor.

Table 5- 3 Vibration values

rms

peak

SIMOTICS A-1FV5/1PV5 synchronous/induction motors
Operating Instructions, 03/2014, 610.45002.40

33

Mounting

Note
Continuous operation within the natural frequency

Continuous operation within the natural frequencies of the mounted system should be
avoided. Generally, this results in permissible vibration values being exceeded, resulting in
damage to the system. To reduce vibration, flanged
the NDE.

5.4 Vibration load

Figure 5-3 Vibration values at the measurement locations

The vibration acceleration must be evaluated in a frequency band of 10 to 2000 Hz.
The maximum peak value in the time range is to be considered.

To measure the vibration velocity, the measuring equipment must fulfill the requirements of
ISO 2954.

-mounted motors can be supported at

SIMOTICS A-1FV5/1PV5 synchronous/induction motors

34 Operating Instructions, 03/2014, 610.45002.40

6

6.1

Mechanical connection of water cooling system

See also

The inlet and outlet holes for the cooling water supply are located on the NDE in the bearing
shield.

1. Make sure that the cooling water fulfills the required cooling water specification, see the

chapter titled "Cooling".

2. Make sure that the appropriate volume of cooling water is available, see the rating plate

(type plate).

3. Attach the cooling water pipes to the cooling water connections. You can connect the inlet

and outlet as required.

4. Ensure that the maximum permissible operating pressure does not exceed 2.5 bar.

5. Ensure that the cooling water connections and the cooling water pipes are not subject to

continuous forces.

Adjusting the outlet direction of the cooling water connection:

1. Remove the union nut from the adjusting bracket

2. Rotate the adjusting bracket to the required output direction

3. Manually fix the adjusting bracket

4. Tighten the union nut to 32 Nm using a torque wrench

Cooling (Page 19)

SIMOTICS A-1FV5/1PV5 synchronous/induction motors
Operating Instructions, 03/2014, 610.45002.40

35

Connection

6.2

Electrical connection

6.2.1

Safety information

DANGER

Risk of electric shock

DANGER

Motor damage warning

NOTICE

Electrostatically sensitive devices

6.2 Electrical connection

For synchronous motors, hazardous voltages are present at the motor terminals when the
rotors are rotating.

Only qualified personnel may perform work on the motor. The motor must be stationary,
isolated from the line supply and locked out so that it can be accidentally switched on.
This also applies to auxiliary circuits.

Converters and connectors must only be installed by properly trained personnel.
Regulations regarding work carried out in electrical installations must be observed.

The motor will be destroyed if it is directly connected to the three-phase line supply.

Only operate the motors with the appropriately engineered converters! Ensure the correct
phase sequence is used!

The motor contains electrostatic sensitive devices. Touching signal connections with
electrostatically charged hands or tools can result in malfunctions.

Note the ESD protection measures.

Safety rules for working on electrical installations in accordance with EN 50110-1:

● Disconnect the system.

● Protect against reconnection.

● Make sure that the equipment is de-energized.

● Ground and short-circuit.

● Cover or enclose adjacent components that are still live.

SIMOTICS A-1FV5/1PV5 synchronous/induction motors

36 Operating Instructions, 03/2014, 610.45002.40

Connection

6.2.2

Cable entry and routing

Thread ∅

M6

M8

M10

Tightening torque [Nm]

4 ± 10 %

8 ± 10 %

13 ± 10 %

6.2 Electrical connection

● When selecting the required connecting cables, make sure that you take into account the

rated current and plant-specific conditions, such as ambient temperature, routing type,
etc. according to IEC / EN 60364-5-52 and IEC / EN 60204-1.

● Use EMC cable glands for permanently installed cable entries.

● Use shielded cables whose shields are conductively connected to a large area of the

terminal box of the motor using EMC cable glands. Make sure that the cable shields are
properly connected.

● Arrange the exposed connecting cables in the terminal box so that the PE conductor has

an excess length and the insulation of the cable conductors cannot be damaged.

● Only remove insulation from the cable ends so that the insulation reaches up to the cable

lug, terminal, or wire end ferrule.

● Adapt the size of the cable lugs or end sleeves in line with the dimensions of the terminal

board connections and the cross-section of the power cable (use parallel connecting
cables, if necessary).

● Make sure that the inside of the terminal box or connector is clean and free of cable

cuttings and moisture.

● Tighten all of the screws for the electrical connections (terminal board connections, with

the exception of the terminal strips) to the specified torque:

Table 6- 1 Tightening torques at the terminal board

● When connecting or changing internal connection cables, always observe the minimum

air clearance of 5.5 mm.

● Avoid protruding cable ends.

● Seal unused cable entries and screw in sealing elements so that they are secure and

airtight.

● Check seals and sealing surfaces of the terminal box or connector to ensure that the

degree of protection is maintained.

● Take measures to ensure that connecting cables cannot rotate, are not subject to strain

and pushing force and also provide anti-kink protection. It is not permissible to subject the
connector, the connecting bolts and cable glands to continuous force.

● The coding slot for the plug-in connections must be aligned when inserted into the socket

connector. The union nut must be tightened by hand up to the endstop.

● Plug in or remove the connector only when the system is de-energized.

SIMOTICS A-1FV5/1PV5 synchronous/induction motors
Operating Instructions, 03/2014, 610.45002.40

● The PE must be connected.

● The cable lugs of the power connections must extend directly to the cable lugs of the

motor winding connections. (see the diagram, "Attaching the cable lugs").

● It is not permissible to mark the cable connections using paint.

37

Connection

6.2.3

Circuit diagram

Note
Cable outlet direction

If the direction of the cable outlet is not changed correctly, this can damage the connecting
cables. The direction of the cable outlet must not be changed as this invalidates warranty
claims.

6.2 Electrical connection

The circuit diagram contains information about the connection, connecting the motor winding
and signal lines.

Figure 6-1 Circuit diagram_1FV5 (without position encoder, contacts 1 ... 5 not assigned)

SIMOTICS A-1FV5/1PV5 synchronous/induction motors

38 Operating Instructions, 03/2014, 610.45002.40

Figure 6-2 Circuit diagram_1PV5 (without encoder, contacts 1 ... 5 not assigned)

Connection

6.2.4

Terminal box

①

Ground conductor connection, M8

6.2 Electrical connection

● The motor connection depends on the desired direction of rotation, and is carried out as

follows:

– Clockwise direction of rotation when viewing the shaft extension:

Phase U1 connected to L1, V1 to L2 and W1 to L3

Signal Ua1 is received before Ua2.

– Counter clockwise direction of rotation when viewing the shaft extension:

Phase U1 connected to L3, V1 to L2 and W1 to L1

Signal Ua2 is received before Ua1

● Terminal assignment in the terminal box should be implemented as shown in the

following diagrams "Terminal box 1PV51xx/ 1FV51xx".

● Use cable lugs to DIN 46234.

● Screw the cover of the terminal box back on (tightening torque, 5 Nm).

Figure 6-3 Terminal box, 1PV513x/1FV513x

SIMOTICS A-1FV5/1PV5 synchronous/induction motors
Operating Instructions, 03/2014, 610.45002.40

39

Connection

①

Ground conductor connection, M8

6.2.5

Data for electrical connection

Terminal box

Cable entry
(power)

Cable entry
(external signals)

Max. external
cable diameter 1)

Number of main
terminals

Cross-section per
terminal, max.

Grounding: 1 x M8

1) Dependent on the cable gland design

6.2 Electrical connection

Figure 6-4 1FV516x terminal box

Figure 6-5 Attaching cable lugs

Table 6- 2 1PV513x/1FV513x motors

Integrated in the
motor

SIMOTICS A-1FV5/1PV5 synchronous/induction motors

3 x PG16 1 x M23 15 mm Phases: 3 x M6

1 x 35 mm2

40 Operating Instructions, 03/2014, 610.45002.40

Connection

Terminal box

Cable entry
(power)

Cable entry
(external signals)

Max. external
cable diameter 1)

Number of main
terminals

Cross-section per
terminal, max.

Grounding: 1 x M8

1) Dependent on the cable gland design

6.2.6

Signal connection

Pin

1PV5

1FV5

1PV5
without
encoder

1FV5
without
position
encoder

Connector

1

Signal Ua2

Signal T

Not assigned

2

Signal Ua1

Signal S

Not assigned

3

Not assigned

Signal R

Not assigned

4

Power supply

Not assigned

5

Grounding

Not assigned

6

- - -

-

7

- - -

- 8 - - -

-

9

KTY 84 + 1R1

10

KTY 84 -1R2/ -2R2

Note

•

•

•

6.2 Electrical connection

Table 6- 3 1FV516x motors

Gk420 3 x M32 x 1.5 1 x M23 27 mm Phases: 3 x M10

For the motors, the speed encoder and temperature sensor are connected using a 12-pin
connector, which is installed in the terminal box. Contact is established through the contact
pins. If the motors do not have an encoder, then only the temperature sensor signals are
assigned in the connector, as shown in the following table.

Table 6- 4 Signal connection, view of connector pins

1 x 70 mm2

11 KTY 84 +2R1
12 -

A suitable socket connector can be used to rotate the angle plug. Make sure that the

Removal, installation and adjustment of sensors only according to the corresponding

Only remove the protective cap from the angle connector immediately before inserting the

SIMOTICS A-1FV5/1PV5 synchronous/induction motors
Operating Instructions, 03/2014, 610.45002.40

socket connector is completely screwed on to avoid damaging the pin contacts.

instructions.

mating connector.

41

Connection

6.2.7

Connecting the temperature sensor

6.2.8

Connecting the ground conductor

See also

6.2.9

Connecting-up a converter

Selecting and connecting the cables

6.2 Electrical connection

The temperature sensor is connected to the signal connector together with the speed
encoder signal.

The grounding conductor connection is located on the enclosure (see Fig. 6-3 and Fig. 6-4).
The grounding conductor connection must be in full compliance with the installation
regulation, e.g. according to IEC / EN 60204-1.

Terminal box (Page 39)

Use shielded connection cables to connect the motor to a converter. The cable shielding,
made up of many strands, must have a high electrical conductivity. Braided shields made of
copper or aluminum are well suited.

The shield must be connected at both ends to the motor and the converter; unshielded cable
ends must be kept as short as possible.

To ensure that high-frequency currents are effectively discharged, establish the shield
connection through the largest possible area, as 360° contact at the converter and at the
motor, e.g. using EMC glands at the cable entry points.

SIMOTICS A-1FV5/1PV5 synchronous/induction motors

42 Operating Instructions, 03/2014, 610.45002.40

7

7.1

Measures prior to commissioning

Note

This list below does not claim to be complete. It may be necessary to perform additional
checks and tests in accordance with the specific, on

CAUTION

Thermal hazard: hot surfaces

Mechanical connection

Before commissioning the system, check that it is properly installed and connected. The
drive system must be commissioned as described in the operating instructions for the
converter/inverter.

-site situation.

The surface temperature of the motors can exceed 65 °C.

Do not touch hot surfaces.

If necessary, implement shock-hazard protection measures.

Temperature-sensitive parts (electric cables, electronic components) must not be placed on
hot surfaces.

The following conditions must be fulfilled and suitable for the operating conditions:

● All touch protection measures for moving and live parts must have been applied.

● The motor has been assembled and aligned properly.

● The rotor must be able to be manually rotated or using suitable equipment without coming

into contact with the stator.

● The operating conditions correspond to the data specified on the rating plate.

● All fixing screws, connecting elements, and electrical connections must be tightened and

properly implemented.

● The output elements have the proper setting conditions according to type, for example.

– Couplings are aligned and balanced.

– The belt tension is properly adjusted if a belt drive is used.

– Gear tooth flank play and gear tooth tip play as well as radial play are properly

adjusted if a gearwheel drive is used.

SIMOTICS A-1FV5/1PV5 synchronous/induction motors
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43

Commissioning

Note

If changes occur with respect to normal operation (e.g. increased temperatures, noise
or oscillation), if in doubt, switch off the motor. Determine the cause and if necessary
consult the manufacturer. Even in test operation, never disable protective functi
devices.

Electrical connection

CAUTION

Monitoring equipment

Liquid cooling

Note
Venting

The

7.1 Measures prior to commissioning

ons or

● The motor is connected so that it rotates in the direction specified.

● The minimum insulation resistance values are maintained.

● The grounding and equipotential bonding connections have been established correctly.

● The indicated speed limit n

● Appropriately configured control and speed monitoring functions ensure that the motor

cannot exceed the permissible speeds specified on the rating plate.

● The temperature sensors for the motor monitoring devices have been correctly connected
and are fully functional.

If liquid cooling is used, the coolant supply must be connected and ready for operation. The
coolant circulation (flow rate, temperature) complies with requirements.

is not exceeded during operation on a converter.

max

If the speed n

is exceeded, this can damage the bearings, short-circuiting rings, press

max

fits, etc. To ensure that the motor does not run at excessive speeds, the controller must
configured accordingly or speed monitoring must be activated in the drive system.

cooling circuit must be vented before commissioning.

SIMOTICS A-1FV5/1PV5 synchronous/induction motors

44 Operating Instructions, 03/2014, 610.45002.40

Commissioning

Roller bearings

Note
Unfavorable conditions

If the motor was stored under unfavorable conditions, the bearings need to be replaced after
approx. 18 months.

7.2

Performing a trial run

WARNING

Danger from rotating rotor

7.3

Checking the insulation resistance

WARNING

WARNING

Danger! High voltage

7.2 Performing a trial run

If the motor has been stored under favorable conditions (i.e. in a dry, dust-free room that is
not susceptible to vibration) for more than three years, the bearings must be replaced.

Implement shock-hazard protection measures for output elements. Take suitable measures
to ensure that feather keys (if used) cannot fall out.

After long storage or shutdown periods, the insulation resistance of the windings must be
measured to ground with direct voltage.

Work on power installations must only be carried out by specialists. Before measuring the
insulation resistance, read the manual for the insulation resistance meter you are going to
use.

During and immediately after the measurement, hazardous voltage levels may be present.
Touching live components can be result in death or serious injury.

Never touch the terminals when measuring or immediately after the measurement.

Check the connected supply feeder cables to ensure that the line supply voltage cannot be
connected.

SIMOTICS A-1FV5/1PV5 synchronous/induction motors
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45

Commissioning

Limits

Rated voltage UN < 2 kV

Measurement voltage

1000 V (minimum, 100 V)

windings

time

Note
Cleaning and/or drying the windings when reaching critical insulation resistance

If the critical insulation resistance is less than or equal to this value, the windings must be
dried or, if the fan is removed, cleaned thoroughly and dried.

Note that the in
windings. The insulation resistance can only be evaluated accurately when measured on
a winding that has been cooled down to room temperature (approx. 20 to 30

Note
Measured value close to critical value

If the measured value is close to the critical value, the insulation resistance should be
subsequently checked at suitably regular intervals.

Values apply for measurement at a winding temperature of 25 °C.

7.3 Checking the insulation resistance

● Always measure the insulation resistance of the winding to the motor enclosure when the
winding temperature is between 20 and 30 °C.

● When performing the measurement, wait until the final resistance value is reached
(this takes approx. one minute).

The table below specifies the measuring circuit voltage as well as the limit values for the
minimum insulation resistance and the critical insulation resistance with a rated motor
voltage of U

Table 7- 1 Stator winding insulation resistance at 25 °C

< 2 kV:

N

Minimum insulation resistance for new, cleaned or repaired

Critical specific insulation resistance after a long operating

10 MΩ

0.5 MΩ/kV

Note the following:

● Dry, new windings have an insulation resistance of between 100 and 2000 MΩ
(sometimes higher).

An insulation resistance value close to the minimum value could be due to moisture
and/or dirt accumulation.

● The insulation resistance of the motor winding can drop during the course of its service
life can drop due to ambient and operational influences. The critical insulation resistance
for a temperature of 25 °C on the winding can be calculated by multiplying the rated
voltage (kV) by the specific critical resistance value (0.5 MΩ/kV);

Example: Critical resistance for a rated voltage (V

) of 0.6 kV:

N

0.6 kV x 0.5 MΩ/kV = 0.3 MΩ

sulation resistance of dried, clean windings is lower than that of warm

SIMOTICS A-1FV5/1PV5 synchronous/induction motors

46 Operating Instructions, 03/2014, 610.45002.40

°C).

Commissioning

7.4

Switching on the motor

NOTICE

Operation noise or abnormal noises

CAUTION

Note the maximum rotational speed

7.5

Liquid cooling

NOTICE

WARNING

Risk of burning from hot steam

7.4 Switching on the motor

Before you switch on the motor, ensure that the parameters of the frequency converter have
been assigned correctly.

The motor can be damaged by improper handling during transport, storage, or setup. If a
damaged motor is operated, this can damage the winding or bearings and could even
destroy the system.

If the motor is not running smoothly or is emitting abnormal noises, shut the motor down
and try to determine the cause of the fault as it runs down.

The maximum rotational speed n

is the highest permissible operating speed.

max

The maximum speed is specified on the rating plate.

If the speed n

is exceeded, this can damage the bearings, short-circuiting rings, press

max

fits, etc. To ensure that the motor does not run at excessive speeds, the controller must
configured accordingly or speed monitoring must be activated in the drive system.

The motor must always be connected to the cooling water supply when in operation.

If the cooling water supply fails or the motor is operated for a short time without cooling
water, this can cause it to overheat. This can result in material damage or destroy the motor
completely.

Never operate the motor without the cooling water supply. Monitor the permissible water
inlet temperatures.

When cooling water enters the hot motor, this immediately generates hot steam that
escapes under high pressure. The cooling water system can burst. This can result in death,
serious injury or material damage.

Do not connect the cooling water supply until the motor has cooled down.

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Commissioning

7.5 Liquid cooling

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8

8.1

Safety instructions during operation

WARNING

Do not remove covers when motor is running

WARNING

Faults during operation

CAUTION

Danger of burns

Rotating or live parts are dangerous. Death, serious injury, or material damage can result if
the required covers are removed.

All covers that prevent operators from coming into contact with active or rotating parts,
ensure compliance with the required degree of protection, or ensure proper air guidance
and, in turn, effective cooling must not be opened/removed during operation.

Deviations from normal operation (e.g. increased power consumption, temperatures or
vibrations, unusual noises or odors, tripping of monitoring devices, etc.) indicate that the
machine is not functioning properly. This can cause faults that can result in eventual or
immediate death, serious injury, or material damage.

Inform maintenance personnel immediately. If in doubt, shut down the motor immediately,
taking into account the plant-specific safety regulations.

The temperature of certain parts of the motor can exceed 65 °C. Physical contact with the
machine could cause serious burns.

Check the temperature of the parts before touching them and take appropriate protective
measures if necessary.

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Operation

8.2

Stoppages

Measures for operational motors during stoppages

Note
Damage due to improper storage

The motor can be damaged if it is not stored properly.

If the motor is out of service for extended periods of time, implement suitable anti
corrosion, preservation, and drying measures.

W
recommended in "Commissioning".

8.3

Shutdown

Measures during shutdown

8.4

Faults

Note
Damage to the machine caused by faults

Correct the cause of the fault as specified in the remedial measures section. Repair any
damage to the machine/motor that might have occurred.

Note

When operating the motor with a converter, refer also to the operating instructions of the
frequency converter if electrical faults occur.

8.2 Stoppages

● If the motor is out of service for extended periods of time, run it at regular intervals
(roughly once a month) or at least spin the rotor.

● Refer to the section "Energizing" before restarting the motor.

-

hen restarting the motor after a long shutdown period, carry out the measures

● When switching off the motor, refer to the operating instructions for the converter.

● Switch off the cooling water supply if the standstill period is expected to be lengthy.

If there are deviations from normal operation or if faults occur, initially proceed according to
the following list. In this regard, observe the relevant chapters in the documentation
associated with the components of the complete drive system.

Even in test operation, never disable protective functions or devices.

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Operation

Fault

Cause of fault (see key table)

Motor does not start up

A B E

Motor starts up slowly

A C E F

Rumbling noise during startup

C E F

Rumbling noise during operation

A C E F

operation

Overheating with load

A C G H I

winding sections

Uneven running

J K

Grinding sound, running noise

L

Radial vibrations

M N O P R

Axial vibrations

O Q R

Water is escaping

S

No.

Cause of fault

Remedial measures

A

Overload

Reduce load

cable

frequency too low

Check the settings on the frequency converter, perform automatic motor
identification

E

Stator winding incorrectly connected

Check winding connections

circuit in stator winding

Measure the winding resistances and insulation resistances, repair after
consultation with manufacturer

off

Water connection / pipes defective

Locate leaks and seal as necessary, or consult the manufacturer

Cooling water flow rate too low

Increase cooling water flow rate

Inlet temperature too high

Set correct inlet temperature

in and out unimpeded

foreign bodies

unimpeded

Fan motor does not start up

Make sure that the fan motor works properly

encoder cable

K

Excessive drive controller gain

Adjust the controller

8.4 Faults

Table 8- 1 Possible faults

Overheating during no-load

Overheating of individual

D G H I

E F

Table 8- 2 Key to causes of faults and remedial measures

B Interruption of a phase in the supply

C Interruption of a phase in the supply after

Check frequency converter and supply cables

Check frequency converter and supply cables

switching on

D Converter output voltage too high,

F Winding short circuit or phase short

G Cooling water not connected / switched

Check cooling water connection / switch on cooling water

H

I Heat dissipation impeded by deposits Clean the surface of the drives and ensure that the cooling air can flow

Cooling air inlet/outlet is blocked by

J Insufficient shielding for motor and/or

SIMOTICS A-1FV5/1PV5 synchronous/induction motors
Operating Instructions, 03/2014, 610.45002.40

Remove the block and ensure that the cooling air can flow in and out

Check the shielding and grounding

51

Operation

No.

Cause of fault

Remedial measures

Rotating parts are grinding

Determine cause and adjust parts

Foreign bodies within the motor

Send to manufacturer for repair

Bearing damage

Send to manufacturer for repair

M

Rotor not balanced

Decouple rotor and rebalance

N

Rotor out of true, shaft bent

Consult the manufacturer

O

Poor alignment

Align motor unit, check coupling

P

Coupled machine not balanced

Re-balance coupled motor

Q

Shocks from coupled machine

Check coupled motor

R

Imbalance originating from gearing

Adjust/repair gearing

defective

8.4 Faults

L

S Cooling water pipe / water connection

If the fault still cannot be resolved after applying the measures specified above, please
contact the manufacturer or the Siemens Service Center.

Locate leaks and seal as necessary, or consult the manufacturer

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9

9.1

Safety information

DANGER

Risk of electric shock from touching live parts

WARNING

Danger of burns

If you are unclear about anything, consult the manufacturer, specifying the motor type and
serial number, or arrange for the maintenance work to be carried out by one of the Siemens
Service Centers.

For synchronous motors, hazardous voltages are present at the motor terminals when the
rotors are rotating.

Live electrical parts are dangerous. Touching these parts will result in an electric shock,

which in turn causes death or serious injury.

Before starting work on the machines, make sure that the plant or system has been
disconnected in a manner that is compliant with the appropriate specifications and
regulations. In addition to the main currents, make sure that supplementary and auxiliary
circuits, particularly in heating devices, are also disconnected.

Note all the information provided in "Safety information and application information" in these
operating instructions and ensure that only persons who have the necessary know-how are
entrusted to carry out work on power installations.

Some parts of the enclosure of electrical machines can reach temperatures in excess
of 65 °C.

Touching components when the machine is in operation can cause severe burns.

Do not touch frame parts while the machine is in operation or immediately after machine
operation. Allow frame parts to cool off before starting any work.

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Service and maintenance

Safety regulations

Other safety-related measures

NOTICE

Personal protective equipment when using chemical cleaning agents

CAUTION

Personal protective measures when working with compressed air

Qualified personnel

9.1 Safety information

Before starting maintenance work, always observe the five safety rules.

1. Disconnect the system.

2. Protect against reconnection.

3. Make sure that the equipment is de-energized.

4. Ground and short-circuit.

5. Cover or enclose adjacent components that are still live.

These measures described above must not be reversed until the maintenance work has
been completed and the motor fully assembly again.

Chemical cleaning agents can be caustic or emit dangerous fumes.

If these come into contact with skin or if you inhale the fumes, this can cause injuries
(e.g. chemical burns on the skin or respiratory passages, or skin irritation).

During cleaning, make sure that appropriate methods of extracting fumes are in place and
that you wear the appropriate protective gear (e.g. gloves, goggles, face masks).

If using chemical cleaning agents, observe the instructions and any warnings provided in
the relevant safety data sheet. Chemical cleaning agents must be suitable for use with the
machine's components, particularly where plastic components are concerned.

When you clean using compressed air, this can stir up dust, metal chips, or cleaning
agents, Personal injury will result.

When cleaning using compressed air, make sure you use suitable extraction equipment
and wear protective equipment (safety goggles, protective suit, etc.).

This machine must be commissioned and operated by qualified personnel only. For the
purpose of the safety information in these Operating Instructions, a "qualified person" is
someone who is authorized to energize, ground, and tag equipment, systems, and circuits in
accordance with established safety procedures.

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Service and maintenance

Safety notes

WARNING

Rotating or live parts

WARNING

Transportation in accordance with proper procedures

9.2

Maintenance intervals

General

Note
Inspection if there are faults or unusual conditions

Unusual condi
three
the machine.

If there are faults or unusual conditions such as overload or short circuit
inspect the motor.

Measures, inspection/maintenance intervals

9.2 Maintenance intervals

Rotating or live parts are dangerous. Death, serious injury, or material damage can result if
the required covers are removed or if the device is not operated properly.

Before starting work on the motor and, in particular, before opening the covers of live parts,
make sure that the motor or system is properly isolated.

Only transport the motor in accordance with the transport guidelines. Death, serious injury,
or material damage can result if the motor is not transported properly.

Whenever you have to transport the motor, follow the instructions provided in the section
"Transport and storage".

Within the scope of the bearing change intervals, the motors are maintenance-free within the
specified usage time.

Careful and regular maintenance, inspections, and overhauls are essential for detecting and
eliminating faults in good time before they can cause any damage.

tions or faults that represent electrical or mechanical overstressing of the

-phase motor, such as overload, short circuit, etc. can cause consequential damage to

Operating conditions and characteristics can vary widely. For this reason, only general
maintenance intervals can be specified here.

etc. immediately

● Maintenance intervals should, therefore, be scheduled to suit the local conditions, such

as pollution/dirt, switching frequency, load, etc.

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Service and maintenance

9.3

General inspection guidelines

NOTICE

9.4

Bearing replacement intervals

9.3 General inspection guidelines

When inspecting a motor, you do not generally need to dismantle it. The motor only be
dismantled if the bearings need to be replaced.

While the motor is running, check that:

● The smooth running characteristics and machine running noise have not deteriorated.

● The cooling water system is not leaking.

Once the machine has been shut down, check that:

● All the fixing bolts/screws for the mechanical and electrical connections have been
securely tightened.

If you identify any problems during the inspection, rectify them immediately. Otherwise
the machine may be damaged.

The bearings are subject to wear and must be replaced after a defined number of operating
hours. For average load levels, the bearings must be replaced after approx. 20,000 h,
however, at the latest after 5 calendar years. The address for service & support is provided
in the Appendix under Siemens Service Center.

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10

10.1

Decommissioning

WARNING

Machine parts can fall

10.2

Disposal

Disassembly of the machine must be carried out and/or supervised by qualified personnel
with appropriate expert knowledge.

1. Contact a certified waste disposal organization in your vicinity. Clarify what is expected in

terms of the quality of dismantling the machine and provision of the components.

2. Follow the five safety rules.

3. Disconnect all electrical connections.

4. Remove all liquids such as oil, water, …

5. Remove all cables.

6. Release the motor mounting.

7. Transport the machine to a suitable location for disassembly.

Dismantle the machine using the general machine-typical procedures.

The machine is made up of heavy parts. These parts can fall during dismantling. This can
result in death, serious injury or material damage.

Secure the machine parts being dismantled to prevent them falling.

The motors must be disposed of in accordance with domestic and local regulations as part of
the standard recycling process or they can be returned to the manufacturer.

The encoder electronics must be properly disposed of as electronic waste.

Protecting the environment and preserving its resources are corporate goals of the highest
priority for us. Our worldwide environmental management system to ISO 14001 ensures
compliance with legislation and sets high standards in this regard. Environmentally friendly
design, technical safety and health protection are always firm goals even at the product
development stage.

SIMOTICS A-1FV5/1PV5 synchronous/induction motors
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Recommendations for the environmentally friendly disposal of the machine and its
components are given below. Be sure to comply with local disposal regulations.

57

Decommissioning and disposal

Components

Process materials and chemicals

Insulating materials

Disposing of permanent magnets

10.2 Disposal

Sort the components for recycling according to whether they are:

● Electronics waste, e.g., sensor electronics

● Iron to be recycled

● Aluminum

● Non-ferrous metal, e.g., motor windings

● Insulating materials

Sort the process materials and chemicals for recycling according to whether they are:

● Oil

Dispose of the spent oil as special waste in accordance with the spent oil ordinance.

● Grease

● Solvents

● Cleaner solvent

● Paint residues

Do not mix solvents, cleaner solvents and paint residues.

Electrical insulation materials are mainly used in the stator. Some supplementary
components are made of similar materials and must, therefore, be handled in the same
manner. The insulating materials in question are used on the following items of equipment:

● Various insulators, which are used in terminals boxes

● Voltage and current transformers

● Electric cables

● Instrument wiring

● Surge arrester

● Capacitors

Permanent magnets must be demagnetized prior to disposal. This helps avoid potential
hazards caused by permanent magnets during and after disposal. Permanent magnets are
heated to demagnetize them.

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58 Operating Instructions, 03/2014, 610.45002.40

Decommissioning and disposal

NOTICE

Removing the rotor

10.2 Disposal

Permanent magnets can be demagnetized in one of the following ways:

● Arrange for the entire machine to be subject to thermal treatment by a specialist disposal

company.

● Return the machine to the manufacturer who can then remove and demagnetize the rotor

and/or permanent magnets. Rotors that are still installed and have not been
demagnetized must not be transported.

It is only permissible that the manufacturer removes a permanent magnet rotor. Contact the
Siemens Service Center (Page 62) if necessary.

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Decommissioning and disposal

10.2 Disposal

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A

A.1

List of abbreviations

Abbreviation

Meaning

ABS

Acrylonitrile-butadiene-styrene

BGR

Rules of the German Trade Association

BGV

Regulations of the German Trade Association

DE

Drive end

Standard)

EC

European Community

ESD

Electrostatically sensitive devices

EMC

Electromagnetic compatibility

EN

Euro-Norm

EPDM

Ethylene-propylene-diene-rubber

H

Halfkey balancing

IEC

International Electrotechnical Commission

IM

Type of construction

IP

International Protection

ISO

International Organization for Standardization

LG

Position encoder

NDE

Non-drive end

NN

Normal zero

PVC

Polyvinyl chloride

RPE

Rotor position encoder

UL

Underwriters Laboratories

DIN Deutsche Industrie Norm (German Industry

KTY Temperature sensor

MLFB Machine-readable product code

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61

Appendix

A.2

Siemens Service Center

A.2 Siemens Service Center

If you have any questions relating to repair or spare parts, please contact your local Siemens
office.

For more information, go to the Internet address:
http://www.siemens.com/automation/service&support .

There, you can find Siemens contacts worldwide for information about specific technologies.

Wherever possible, you will find a local contact partner for:

● Technical support

● Spare parts/repairs

● Service

● Training

● Sales

● Technical support/engineering

You start by selecting

● a country

● a product or

● a sector

Once the remaining criteria have been laid down, the required contact will be shown along
with the associated area of expertise.

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Appendix

A.3

Declaration of conformity

A.3 Declaration of conformity

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Appendix
A.3 Declaration of conformity

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A

C

D

E

F

I

M

O

R

S

T

V

Ambient conditions, 19

Circuit diagram, 38
Commissioning, 43
Connection

Electrical, 36
Mechanical, 35

Connection of the liquid cooling, 35

Declaration of conformity, 63
Degree of protection, 18

Electrical connection, 36
ESD guidelines, 13

Faults, 50
Flange mounting, 30

Rating plate, 16
Regulations, 18

Safety information, 9
Shutdown, 50
Siemens Service Center, 62
Storage, 26

Terminal box, 39
Tightening torques

Electrical connections, 37
Transportation, 23
Types of construction, 18

Vibration load, 33
Vibration values, 33

Inspection and maintenance, 53

Maintenance intervals, 55
Mounting the motor, 30

Output elements, 32

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